Fibre Extrusion Technology (FET) is unveiling the FET-500 Series of gel spinning systems in a move set to transform the research and development of UHMWPE (ultra-high molecular weight polyethylene) fibres.

Based in Leeds, UK, FET has established a strong reputation in medical fibre extrusion technology, designing and delivering high-performance equipment for a wide range of precursor medical products. Its expertise includes the development of bespoke extrusion systems for both resorbable and non-absorbable sutures, supporting small-scale, adaptable production and enabling rapid new product development.

In recent years, demand has grown for more advanced R&D in UHMWPE fibres, which are highly valued across many industries for their exceptional properties. However, traditional production methods are complex and geared towards the large-scale manufacture of existing fibre grades, creating a rigid supply chain that has limited innovation in this promising field.

The FET-500 gel spinning systems have been developed to precisely address this gap. They introduce a flexible and consistent process capable of producing high-quality fibres using less than 100 grams of polymer, while eliminating the need for the harsh processing chemicals historically associated with gel spinning. This breakthrough is made possible by using supercritical carbon dioxide as a green solvent in a patent-pending process, unlocking new levels of flexibility for both laboratory and pilot-scale production.

Gel spinning begins with extrusion, but the subsequent washing and drawing stages are critical in defining the performance characteristics of the finished yarn. A key example of the system’s advantages is in the washing process, where FET’s patent-pending technology uses supercritical carbon dioxide to extract carrier oil without resorting to toxic chemicals such as hexane or DCM. CO2 is an environmentally friendly, inexpensive and abundant solvent that is far safer to work with, efficiently dissolving carrier oils without affecting the integrity of the polymer yarn.

This approach brings significant operational cost benefits. The use of CO2 instead of traditional solvents results in a dramatic reduction in solvent consumption, alongside comprehensive oil recovery and recycling. Importantly, the process generates zero solvent waste, unlike conventional hexane-based methods. The washing system itself is compact and highly efficient, featuring recipe-controlled plug-and-play technology that can be scaled and adjusted to suit customer requirements. Carrier oil is recovered and fed back into the extrusion process and the overall factory footprint can be reduced by as much as 80% compared with hexane systems.

Central to the success of the FET-500 is FET’s Fibre Development Centre in Leeds. Having development and manufacturing facilities side by side enables the company to offer customers a reliable route to de-risk projects, develop processes, and demonstrate a system’s capabilities in practice. A complete FET-500 demonstration line is available on site, allowing both existing and prospective customers to see the system in operation from start to finish. FET also supports product development and parameter optimisation through R&D trials, providing the knowledge and confidence needed to transfer new products smoothly onto full-scale production lines.

www.fetuk.com