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Ultimate FAQ Guide To Melt Blown
The phrase “melt blown” comes to mind when you think of face masks made of non-woven fabrics or filters capable of blocking viruses transmitted through aerosols and droplets.
Melt Blown Non-Woven Fabric
It is the computer-controlled melt-blown process that produces these minute non-woven fibers that prevent infectious airborne aerosol particles less than 1 microns from infecting humans.
Global demand for meltblown non-woven face masks, anti-bacterial wipes, medical garments, gauze, and under-pads has made a significant impact on this industry.
Read on for our ultimate FAQ guide to melt blown to find out everything that you need to know.
- What Is Melt Blown Extrusion?
- What Desirable Properties Does The Melt Blown Process Impart Into Non-Woven Filters?
- How Does The Melt Blown Extrusion Process Produce Non-Woven Fabric?
- How Do You Make Disposable Medical Masks Out Of Melt Blown Non-Woven Fabric?
- Where Are Melt Blown Filters Used?
- What Are The Advantages of Melt Blown Fabrics?
What Is Melt Blown Extrusion?
The process of making non-woven fabrics or sheets from polymers of polypropylene and other such plastic materials is known as melt blown extrusion.
In cotton fabrics, the cotton yarn is first produced and then knitted into fabrics.
However, in the case of non-woven fabrics, fibers are not weaved together.
Instead, fibers of molten polymers combine mechanically, chemically, or thermally to form web-like fabrics.
What Desirable Properties Does The Melt Blown Process Impart Into Non-Woven Filters?
Melt Blown Properties
The melt blown process imparts several desirable properties into non-woven filters including:
- Bacterial barrier
- Liquid repellency
- Flame retardancy
How Does The Melt Blown Extrusion Process Produce Non-Woven Fabric?
Melt Blown Extrusion Process
You can use the melt-blown fabric extruder machinery to produce non-woven fabric from thermoplastic resin.
There are several components to this machine including the raw material feeding system, extruder assembly, metering gear pump, die assembly, collector, and winder unit.
· Raw Material (Feed) System
The feed in the form of pellets of a thermoplastic resin are gravity fed from the resin bag at the top to the extruder hopper.
The feed can be raw materials in the form of polymers of polypropylene (PP), polybutylene terephthalate (PBT), elastic polypropylene (EPP), polycarbonate (PC), thermoplastic polyurethane (TPU), and polyamide (PA).
· Conditions That Influence Melt Blown Characteristics
There are several process variables that affect the characteristics of melt-blown fabrics.
These variables are controlled at the input stage and by making changes to the operating conditions.
- Molecular weight and other material characteristics of the polymer used in the extrusion (For example, PP polymers will differ from TPU polymers)
- Distance between the collector screen and nosepiece
- Temperatures set for the extrusion process
- Number of die nosepiece orifices, their sizes, and geometries
- Speed at which the collector works
- Temperature and velocity of the hot air stream
· Melt Blown Extrusion Process
Once the feed is transferred from the resin feed system into the extruder assembly, the heated barrel contained in this assembly carries the feedforward with the help of a screw impeller.
You will find that the feed begins to melt when it comes in touch with the barrel’s heated walls at the feed, transition, and metering zones of the screw impeller.
As soon as the feed enters the feed zone at the entry point to the barrel, the set high temperature begins to melt the feed.
This feed is homogenized into a compressed fluid mass as it moves forward along the narrowing transition zone.
The completely melted and homogenous polymer mass enters the metering zone.
Here, it undergoes preset pressure conditions, is screened for impurities, and then discharged into the melt blown die assembly.
· Metering Gear Pump
The molten polymer output reaches a temperature of 250 ̊C to 300 ̊C as it enters the metering gear pump at the right pressure.
It is here that process variations in pressure, temperature, and viscosity of the molten polymer output are adjusted to positively displace constant volumes.
There are two counter-rotating, intermeshed gears inside the metering gear pump that meet the suctioned molten mass outputted from the pump and feed it into the die assembly.
· Melt Blown Feed Distribution
The air manifolds, feed distribution unit, and die nosepiece are three components inside the die assembly that distribute the feed.
While most machines use the coat-hanger distribution method to distribute an even flow of polymers, some use the tampered or untampered T-type feed distribution method.
You will find that the die nosepiece is instrumental in creating the melt blown output uniformly within the distribution system.
A fixed number of orifices are made on the tapered and hollow wide metal part of the die nosepiece.
The molten polymer mix is extruded through these orifices to create the desired melt-blown fabric.
Compressed air inside air manifolds goes through an electric furnace and heating exchanger to reach a temperature of 230 ̊C to 360 ̊C.
It reaches a velocity of 0.5 to 0.8 times the speed of sound, allowing the air manifolds to force high-velocity heated air on to the extruded fibers.
· Melt Blown Extruded Non-Woven Collector Unit
Microfibers measuring 0.1 microns to 15 microns are blown in semi-molten state over a collector screen, as high-velocity air separates the extruded polymer mix pushed out of the die nosepiece.
The ambient air begins to cool down and solidify the melt blown web of microfibers formed over the collector screen with the help of a vacuum pump found on the inner side of this screen.
You can make adjustments to the distance between the collector and die nosepiece and also the collector speed to ensure specific densities of the web fabric are established to suit a specific application.
· Winding Melt Blown Non-Woven Fabrics
A cardboard core within the winder unit winds this cooled bonded fabric that is then used as filtering material in a wide range of applications including the manufacture of surgical and medical masks.
Additional bonding processes such as thermal bonding is done to increase the material strength of melt-blown non-woven fabric.
You can watch this video to find out how to make melt blown fabric.
How Do You Make Disposable Medical Masks Out Of Melt Blown Non-Woven Fabric?
Melt Blown Non-Woven Face Mask Making Machine
You will find that the typical disposable face mask consists of three layers of non-woven material.
The inner layer absorbs saliva and tiny liquid particles coughed out by the user.
Made of waterproof material, the outer layer blocks all kinds of transmitted or absorbed liquids from passing through.
Melt blown non-woven fabric made of polypropylene forms the vital middle layer.
This layer is reinforced with electrostatic properties to trap tiny moisture particles that may escape through the inner layer.
· Melt Blown Non-Woven Face Mask Making Process
The melt blown face mask manufacturing process is completely automized.
1. The first step you need to do is to combine the three layers of non-woven fabric.
Melt-blown fabrics are supported separately.
The machine pulls the different non-woven fabrics from their supports and forms the multi-layered mask fabric.
2. The nose clip is then inserted and stitched into the fabric over the bridge of the nose. This allows the user to enforce a closer seal over the face.
3. The folding section of the machine generates pleats or folds over the multi-layered face mask.
4. The three-layer material is cut and stitched to form small, medium, and large-sized masks.
5. Adhesive is applied to ear loops and pasted on the face mask.
A thermal press dries the ear loop over the face mask.
Ultrasonic welding is another way of bonding the ear loop with the face mask.
6. The finished face masks are then sterilized with ethylene oxide to remove traces of microbial contamination.
7. You next dry it for seven days until the ethylene oxide dissipates completely.
You can watch this video to find out more about the mask making process.
Where Are Melt Blown Filters Used?
Melt Blown Non-Woven Uses
Melt blown non-woven fabrics are used in different kinds of applications including:
· Melt Blown HEPA Filters
Melt Blown HEPA Filters
Melt blown high efficiency particulate air (HEPA) filters are capable of removing 99.97% of particles in the air that are less than 0.3 microns in size.
Designed for air filters, these melt-blown HEPA filters are widely used in the pharmaceutical, computer-chip manufacture, nuclear power, and aerospace sectors.
You can remove different types of microscopic airborne particles including dust, allergens, pollen, and mold spores.
PM2.5 polluted particles from vehicular pollution, fossil fuel and chemical emissions can cause serious health problems in they reach the alveoli in our lungs.
These melt blown HEPA filters can remove particulate matter (PM) 10 matter that have diameters less than 10 microns, and PM2.5 matter that have diameters less than 2.5 microns as well.
· Melt Blown Filtering Facepiece (FFP) Masks
Melt blown FFP masks are half masks that cover the nose, mouth, and chin and prevent infectious pollutants or agents in the form of solid particles, aerosols, and droplets from entering the respiratory system.
The EN149 standard has categorized these masks into the FFP1, FFP2, and FFP3 class of respirators based on their filtering efficiencies.
o Melt Blown FFP1 Mask
Melt-Blown FFP1 Mask
The melt blown filter FFP1 mask offers the least protection as per EN149 standards and usually has a yellow elastic band on the mask.
FFP1 masks meet the EN149 maximum filter penetration requirements of 20%, both for the sodium chloride test at 95 l/min and paraffin oil test at 95 l/minute.
Filter penetration averages just 0.5% with the analytical reagent (AR), mass spectrometry (MS), and thermal compartment (TC) detection methods during the sodium chloride test and nearly 0.43% during the paraffin oil test.
The FFP1 mask has a cloth facepiece and melt blown filter offering protection from dust particles, liquid and solid aerosols, and particulate matter that cause lung diseases like COPD and lung cancer.
It may have an exhalation valve near the nose that makes it easier for you to breathe. This filter condenses the air inside the mask and prevents it from entering the filter.
You will find the abbreviations “R” (reusable) and “NR” (non-reusable) mandatorily printed on these FFP1 masks to indicate whether they can be used for more than one day or must be disposed of the same day.
The abbreviation “D” indicates the FFP1 mask has passed the Dolomite test for breathing resistance.
“V” indicates it has an exhalation valve.
“DV” indicates the mask passes the Dolomite test for breathing resistance and has the exhalation valve.
You will find that there is an aerosol filtration percentage of 80% and a maximum 22% leakage rate between the mask and face.
The melt-blown filter FFP1 face mask offers protection against hazardous substances with maximum concentrations of 4X Occupational Exposure Limit (OEL) and 4X Assumed Protection Factor (ASF).
These FFP1 masks are basically used by surface miners, construction workers, farmers, and textile workers.
o Melt Blown FFP2 Mask
Melt-Blown FFP2 Mask
Offering high protection from dust, pollutants, bacteria, and especially viruses, the melt blown FFP2 mask uses high-quality melt-blown fabrics for maximum levels of protection and security.
Similar in construction and appearance to the FFP1 mask, the FFP2 mask is used for protection against aerosols and minute dusts released from stone, concrete, wood, cement, steel, glass, varnish, welding electrodes, grain dust allergies, spray paint, mineral fibers, vehicle exhaust fumes, bacteria, and mold.
Meeting international standards including CE 2163, EN149:2001+A1:2009, melt blown FFP2 masks are extensively used in hospitals, clinics, dental offices, surface mining, and construction safety equipment, farming and textile protective gear.
Your melt blown FFP2 masks must also pass the Dolomite test for clogging. The abbreviation “D” is mentioned on the mask.
This PPE component can also be used in protective overalls and eye-protection devices.
FFP2 masks fulfill maximum filter penetration requirements of 6%, both for the paraffin oil test at 95 l/minute and sodium chloride test at 95 l/minute.
Maximum filter penetration requirements remain the same as FFP1.
FFP2 masks separate 94% of airborne particles and allow less than 8% leakage rates between the face and mask.
Melt-blown filter FFP2 face masks offer protection against hazardous substances with maximum concentrations of 12X Occupational Exposure Limit (OEL) and 10X Assumed Protection Factor (ASF).
FFP2 masks are often reinforced with special coatings to be more effective during viral pandemics like the coronavirus COVID-19.
o Melt Blown FFP3 Mask
Melt Blown FFP3 Mask
Customized with the latest innovations, melt blown FFP3 masks are especially designed to prevent the spread of viruses that spread universally like the Covid-19 pandemic.
These are perfectly designed melt blown non-woven masks that are often backed by 100% guarantees from professional FFP mask producers.
Similar in construction to FFP1 and FFP2 masks, these melt blown FFP3 masks meets ASTM F2100-07, CE, and FDA standards.
FFP3 masks meet maximum filter penetration requirements of 1%, both for the paraffin oil at 95 l/minute and sodium chloride at 95 l/minute tests.
Maximum filter penetration requirements remain the same as FFP1 and FFP2.
FFP3 masks filter out 99% of all airborne particles and are designed to allow just 2% leakage rates between the mask and face.
The melt-blown filter FFP3 face mask protects against hazardous substances with maximum concentrations of 50X Occupational Exposure Limit (OEL) and 20X Assumed Protection Factor (ASF).
It has the abbreviation “D” mentioned on the mask to indicate it has passed the Dolomite test for clogging.
FFP3 masks are the best PPEs to protect you from very fine dusts, aqueous mists, fibers, oil-based mists, and infections arising from viral attacks like the coronavirus COVID-19 pandemic.
You can watch this video on the best masks to protect you against diseases.
· Melt Blown Surgical Face Mask
Melt-Blown Surgical Face Mask
Constructed with polypropylene non-woven material, the melt blown surgical face mask is not just used by medical professionals in hospital settings but also by healthcare workers exposed to disease-causing droplets or biological aerosols.
You can get surgical face masks with three or four layers and one or two layers of non-woven filtering materials capable of blocking germs, bacteria, and viruses larger than 1 micron in size.
They fit loosely over the mouth and nose without a seal.
They are generally made for different levels of ASTM approvals.
1. Level 1: Melt blown masks are approved for 80mmHg fluid resistance capabilities and are used for basic surgical and medical procedures.
These masks are constructed for minimum risk conditions where you are not exposed to disease-carrying sprays, fluids, and aerosols.
2. Level 2: The fluid resistance is 120mmHg at this level. The level 2 melt blown masks offer protection against aerosols, sprays, and fluids to some extent.
3. Level 3: Fluid resistance is at the highest at 160mmHg. These level 3 melt-blown masks offer maximum protection against sprays, aerosols, and fluid penetration.
Melt-blown surgical face masks meet OSHA, NIOSH, and FDA standards. Professional surgical mask makers follow established standard practices and fulfill government approval processes.
Surgical face masks are checked for bacterial filtration efficiency (BFE) by shooting aerosol droplets infected with staphylococcus aureus bacteria towards these masks at 28.3 liters per minute.
The non-woven filters along with other layers must not lose shape in order to pass the breathable resistance test.
Also, polystyrene microsphere aerosols are sprayed at the surgical face mask to ensure the melt-blown filters block minute particulates.
· Antiviral Melt Blown Face Mask
Antiviral Melt Blown Face Mask
Using melt-blown filter with substrates designed to eliminate viruses and bacteria on contact, the antiviral melt blown face mask is manufactured with customized techniques.
Tiny particles are prevented from entering the respiratory system by the non-active outer layer.
This surface material is made of special melt-blown non-woven fibers that are reinforced with excellent particulate filters that allow you to breathe easily.
The middle layer consists of non-woven active materials capable of trapping and killing dangerous viruses and bacteria.
The inner layer consists of fluid-resistant melt blown soft material that is gentle to the skin.
The antiviral melt blown face mask has the capability to counter SARS, Influenza A, Bird Flu, pneumonia, common cold, and other viral infections.
Expert antiviral face mask manufacturers offer custom antiviral masks that can negate the effects of airborne microbes as well.
Based on your OEM/ODM orders, antiviral melt-blown face masks meet CE, FDA, BFE99 and ISO requirements.
· Active Carbon Melt Blown Face Mask
Active Carbon Melt Blown Face Mask
One of the most effective disposable face masks in the market, the active carbon melt blown face mask can help you effectively filter out 99.9% of bacteria and viruses.
This melt-blown mask is made up of three layers of non-woven fabric with an active carbon component added to protect you from dust, bacteria, germs, pollen, and dangerous viruses.
You can use this mask in different kinds of environments, as the face mask is waterproof as well.
· Melt Blown Air-Purifying Respirator
Melt Blown Air-Purifying Respirator
The air-purifying respirator is different from the surgical face mask, as it forms a seal around the nose and mouth to prevent airborne viruses and bacteria from penetrating the mask.
These are usually disposable respirators based on N-Series (N95, N99, and N100), R-Series (R95), and P-Series (P95 & P100) classifications.
These melt blown air-purifying respirators are validated and certified by world-recognized health agencies like the CDC.
Bacterial filtration efficiency (BFE) is the standard to measure filtration capacities of air-purifying respirators that use melt-blown filters.
o Melt Blown N95/N99/N100 Respiratory Mask
Melt-Blown N95 Respiratory Mask
Available as the medical N95, KN95, and N95 among other categories and controlled by OSHA and NIOSH regulations, melt-blown N95 respiratory masks are used by medical professionals in hospital settings and health workers outside hospital settings.
When properly fitted over your face, these n95 masks can block 95% of tiny (0.3 micron) airborne particles but is not resistant to oil.
They are essentially used for protection against spraying body fluids, microorganisms, particulate matter, and to take care of people suffering from dangerous viral diseases like coronavirus COVID-19.
The N99 and N100 respiratory masks differ only in the way they block airborne particles.
The N99 blocks 99%, while the N100 blocks 100% of all airborne particles.
Each and every respiratory mask must have markings of the manufacturer’s business name and approval number, model number, lot number, NIOSH logo, and the melt blown non-woven filter efficiency level.
KN95 respirator masks are certified for a total inward leakage (TIL) mean rating of ≤ 8 percent.
They maintain inhalation resistance of around 350 Pa at maximum pressure drop and exhalation resistance of around 250 Pa at maximum pressure drop.
You can get a n95 respirator mask meeting the ≤ 1% CO2 clearance requirement from reliable suppliers.
o Melt Blown R95 Respiratory Mask
Melt Blown R95 Respiratory Mask
Certified for 8 hours of usage, the melt blown R95 respiratory mask is resistant to solid and liquid aerosol particulates containing oil.
These are the least preferred respiratory masks because of their short usage span.
o Melt Blown P95/P100 Respiratory Mask
Melt Blown P95 Respiratory Mask
The melt blown P95/P100 masks are quite similar to the R95 series in that they can protect you against liquid and solid aerosol particulates that contain oil.
They are certified by NIOSH for 40 hours or 30 days of usage making these masks cost-effective respiratory mask solutions for oil-based applications that generate massive amounts of airborne impurities.
o Reusable Melt Blown Respiratory Mask
Reusable Melt Blown Respiratory Mask
Reusable melt-blown respiratory masks are available as half and full masks.
These masks have melt-blown filters and pre-filters; gas, vapor, and particulate layers to protect you from dangerous gas and vapor exposure and airborne particulate matter.
For example, you can use the reusable respirator to protect yourself from vapors of acetone and particulate matter in the form of airborne formaldehyde.
The number of melt blown filters, gas and vapor layers may vary depending on the application and level of protection you need.
You can watch this video that shows you how to sterilize your reusable mask.
· Disposable Melt Blown Disinfectant Wipes
Disposable Melt Blown Disinfectant Wipes
Made from environmentally friendly materials, disposable melt blown disinfectant wipes are the new-generation wipes made of premium melt-blown materials.
This breathable and flexible melt blown disinfectant wipe is of the lightweight non-burning variety that decomposes easily, is non-toxic, recyclable, and non-irritating on the skin.
Ultrafine non-woven fibers less than 2 microns in size are used to make these disposable melt blown disinfectant wipes.
You can get these wipes in 17.5 cm widths and varied lengths from 10 meters to 100 meters.
These wipes weigh around 25 g and are used as custom DIY face cover filters, surface cleaners, and for personal care.
· Spunbond Meltblown Spunbond (SMS)
Spunbond Meltblown Spunbond (SMS)
Popularly known as SMS, spunbond meltblown spunbond is basically a fabric made of three layers.
On the top, you will find a layer of spunbond polypropylene, in the middle comes the meltblown polypropylene layer, and finally another spunbond polypropylene layer at the bottom.
There are two ways SMS is made.
- The first method simply laminates webs made of spunbond and meltblown together.
- The other method is to use the multi-denier spinning technique to combine spunbond and meltblown materials together into a single nonwoven web.
Prebonding ensures these webs pass smoothly through the calendar-rolling process and are thermally bonded together.
SMS fabrics are popular, as the excellent barrier and wicking properties of meltblown filters are combined with the excellent strength and durability of spunbond materials.
This make SMS not just strong but also increases its capability to block fluids and particles.
SMS materials are extensively used as gas and liquid filters, cartridge filters, and in surgical face masks.
Innovative manufacturers use its insulation properties in dishwashers and other products.
The basic SMS material can be coated with additional oil, blood, and alcohol repellents to increase its use in the manufacture of sterilization wraps, female sanitary napkins, nappies, surgical drapes and gowns, incontinence products, and disposable patient sheets.
You can watch this video to find out how to compare SMS and melt blown fabrics to find out the difference between them.
· Melt Blown Medical Fabrics
Melt Blown Medical Fabrics
From surgical gowns to surgical drapes, melt blown medical fabrics can be used as filter materials that are disposable or can be cleaned and sterilized for recuse.
You will find that these are economical and eco-friendly fabric solutions for the medical industry that reduce the risk of infection from disease-carrying microbes.
Cutting-edge nanotechnology procedures allow manufacturers to produce fibrillated and split fibers that form the extremely fine strands needed in melt-blown medical fabrics.
New filtration and barrier technologies are able to modify melt-blown fibers to increase their capabilities to filter out bacteria and viruses.
Some of the other medical applications include isolation gowns, medical packaging, surgical covers, caps, and surgical scrub suits.
· Melt Blown Air Filtration Media
Melt Blown Air Filtration Media
Designed for low pressure loss, the melt blown air filtration media undergoes electret treatment to increase its filtering efficiency.
The melt-blown process is used to produce fibers of different diameters and pore sizes to meet custom air-filtering media requirements.
Several enhancements like lightweight fabrics and increased collection yields are added to comply with your specific air-filtering application.
Melt blown air filtration media are used in building air conditioners, vacuum cleaners, and air-cleaning systems.
· Melt Blown Drip Coffee Filters
Melt Blown Drip Coffee Filters
Multilayered dry-laid non-woven materials extruded by modern machines yield melt blown drip coffee filters capable of sustaining high water and air permeability levels.
These machines can control conformity standards and the density of melt-blown filters to fulfill custom requirements.
Structured with ultrafine 5 micron polypropylene meltblown materials, these drip coffee filters have stable filtration efficiencies across a wider temperature range.
Melt blown filter media specifications are customized to prevent loss of material.
What Are The Advantages of Melt Blown Fabrics?
- You will find that these fabrics are available in different colors for use in custom applications.
- Melt-blown machines are capable of making melt blown fabrics that are 160 cm in width, as they are useful in multiple applications.
- You can control air permeability quite accurately.
- The melt blown process allows in-line measurement control.
- Added coatings reinforce these melt-blown fabrics for hydrophobicity, UV stability, and they also demonstrate higher air permeability and bacteria filtration efficiencies.
- Melt-blown filters can be static-charged to filter out sub-micron particulates.
- Productivity rates are very high in the solvent-free melt blown operation.
- You can get melt-blown fibers with diameters less than 37 nm that are soft on the skin.
- These fabrics are cost-effective filter solutions, as there are no intermediate processes like yarn formation and spinning involved.
- As these filters are used mostly in disposable face masks, you get better filter protection than face masks made of cotton, polyester, and other woven materials.
- 4-ply melt blown masks designed for children can filter out 99 percent fluid penetration.
Melt blown fabrics are in great demand, especially in the face mask filter segment, as they can be sanitized and are easy to stitch.