Abstract: A method for producing a non-woven polymeric fabric web, such as a spunbond web, having filaments of 0.1 to 5 denier with equivalent production rates is provided. A plurality of continuous polymeric filaments is extruded from an extruder and attenuated by a drawing unit that includes a longitudinal elongated slot strategically positioned at an optimum distance very close to the spinneret. A web forming table is positioned below the drawing unit for collecting the filaments and forming the filaments into a non-woven fabric web. At startup, nominal throughput and air pressure is used. Gradually, throughput is greatly increased by simultaneously increasing air pressure while reducing the distance between the spinneret and the drawing unit. Coordinating the adjustment of the throughput with air pressure and distance reduction of the spinneret and the drawing unit produces the finest filaments at equivalent production or the same filament size at the highest production rate and lowest cost.

Abstract: A process for producing a non-woven polymeric fabric web, such as a spunbond web, having filaments of 0.1 to 5 denier with equivalent production rates. A plurality of continuous polymeric filaments is extruded from an extruder and attenuated by a drawing unit that includes a longitudinal elongated slot strategically positioned at an optimum distance very close to the spinneret. A web forming table is positioned below the drawing unit for collecting the filaments and forming the filaments into a non-woven fabric web. At startup, throughput is nominal, air pressure is below 20 psig, and the spinneret is positioned more than 100 cm away from the drawing unit. Gradually, throughput is greatly increased by simultaneously increasing air pressure while reducing the distance between the spinneret and the drawing unit.

Abstract: An apparatus, process and product by process for producing a non-woven polymeric fabric web, such as a spunbond web, having filaments of 0.1 to 3.0 denier with equivalent production rates. The apparatus includes a polymer filament extruder and a melt spinning device with a spinneret having multiple spaced orifices for extruding a plurality of continuous polymeric filaments, a drawing unit that includes a longitudinal elongated slot strategically positioned at a predetermined distance below the spinneret to produce the desired filament diameter, a nozzle for providing an air supply strategically within a drawing unit slot for creating turbulence, and a web forming unit positioned below the slot for collecting the filaments and forming the filaments into a non-woven fabric web. The apparatus may also include a water spray unit positioned adjacent to and surrounding the spinneret for cooling the filaments to prevent premature sticking together of the filaments and enhancing the production rate.