In recent years, very low cost melt-spinning equipment has been developed and is offered today in Asia for a price that is 20% of that of a dry/wet plant of equivalent production capacity. This new process attracted many newcomers into the spandex production field. In addition, recent developments brought more adequate TPU polymers and the introduction of pre-polymer into the melt stream of TPU to improve the elastic characteristics of the produced yarns. All these developments have further pushed this process forward. Still there are drawbacks in producing melt-spun spandex. Among them are the short lifetime of spinneret, repeated cleanings of manifold; non-uniformity of the yarn that causes a zebra effect in the end product; recovery of less than 90% and a high (300%) modulus; a low melting point and the limited range of deniers that can be economically produced. In spite of these drawbacks, melt-spun spandex production facilities continue to
The low melting point of melt-spun spandex depends solely on the raw materials used. This issue is best solved by the raw materials suppliers, as it is up to them to alter the mix of materials used in their production of TPU to arrive at higher yarn melting point. One leading supplier is already delivering a higher melting point raw material and a second major supplier is developing an improved raw material having a higher melting point as well.
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