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What is the production process of composite spun fibers

source：www.kingcharmgroup.com | Release time：2026-08-24

Composite spun fibers are two different polymers that are independently processed and merged in a composite spinneret assembly. They are extruded from the same spinneret hole to form a single two-component fiber, which is divided into raw material pretreatment → melt extrusion → composite spinning forming → cooling and oiling → stretching → post-processing (curling, heat setting, cutting) → finished product. Short fibers (ES fibers) are most commonly used in production.
Complete process
1. Raw material pretreatment (pre crystallization, drying)
Two types of polymer slices are processed separately to remove moisture and prevent high-temperature hydrolysis; Strictly control the moisture content.
Example: ES fiber, PP (core), PE (skin) are dried separately; Polyester products need to be pre crystallized and then dried.
2. Twin screw independent melt extrusion
Two independent screw extruders are used to heat and melt two types of raw materials, and filter impurities separately; The flow ratio of the melt is precisely controlled by a metering pump to ensure the stability of the skin core/parallel component ratio.
3. Composite spinning component spray forming (core process)
Two streams of melt are separately fed into a specialized composite spinning component, where a special flow channel is used to distribute the melt. The melt converges at the entrance of the spinning hole and is extruded to form a primary filament with a design cross-section of skin core, parallel, sea island, and split.
Key: Two types of melts converge inside the component and do not mix before extrusion.
4. Cooling and solidification
The extruded high-temperature melt flows fine, is cooled by side blowing/ring blowing, and solidifies into primary composite fibers.
5. Apply oil
Apply spinning oil on the surface of the fiber bundle to reduce friction, eliminate static electricity, and facilitate subsequent stretching processing.
6. Stretching and stretching
Multi stage thermal drawing of newborn fibers to stretch the orientation of macromolecules, enhance fiber strength, and reduce elongation; The shrinkage characteristics of different components are retained here (the parallel type generates curling by the difference in shrinkage).
7. Curling processing (short fibers)
By using a curling machine, the fibers are physically curled to enhance the fluffy and gripping force; Long filament products can skip this process.
8. Heat setting
Hot air heat setting eliminates internal stress, stabilizes fiber size, and reduces later shrinkage.
9. Cut off
Cut into short fibers of the specified length according to usage requirements (ES fibers are commonly 38-51mm); The filament process directly winds it into a silk cake.
10. Packaged finished products
Inspect, package and store.
Additional processing for island type composite fibers: alkali dissolution is required to dissolve the "marine" to obtain ultrafine fibers; Splitting type requires mechanical external force to achieve fiber opening.

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