Hills Lab Services
Production-grade lab trials for fiber innovation.
Advanced pilot and research-scale spinning lines that mirror full-scale production environments.
Hills Inc.'s in-house laboratory is equipped with advanced pilot and research-scale spinning lines that mirror full-scale production environments. These systems allow our engineers and partners to develop, test, and refine polymer extrusion technologies with unmatched precision and repeatability.
From filament, spunbond, and meltblown, each Hills lab machine is built with the same engineering integrity as our commercial systems. These lines enable fiber and process development, polymer screening, cross-section design, and performance testing under controlled conditions, providing data and prototypes that bridge research to production.
In-House Lab Lines
Production-ready testing at research scale.
Filament Line
BRD
The BRD Filament Line supports bi- and tri-component fiber spinning for continuous filament, POY, FDY, and BCF applications. Featuring Hills Temperature Separation Technology, it allows total thermal separation of polymers until they enter the spin pack, enabling side-by-side, sheath-core, islands-in-the-sea, segmented pie, and many more cross-sections and filament counts.
Capable of winding speeds of up to 4,500 m/min for POY and draw rolls to 4,000 m/min, the BRD line is ideal for evaluating polymer compatibility, fiber morphology, and process optimization across PET, PA, PP, and other specialty melt-spinnable materials.
Key Capabilities
- Bi- and tri-component filament spinning
- UOY, POY, FDY, and BCF yarns
- Cross-flow and water quench systems
- Kiss roll or metered finish application
- Integrated Wonderware PLC control with data logging
Meltblown Line
BRD-3
The BRD-3 Meltblown Line enables bicomponent and nanofiber web formation using precision extrusion. Multiple extruder systems are available depending on capacity requirements, with high-temperature capabilities available on the 1-1/2 inch extruder unit.
With interchangeable dies up to 0.5 m wide and hole counts up to 100 HPI, this line produces meltblown webs suitable for filtration, insulation, and specialty applications. Advanced features include multi-zone temperature control, vacuum web forming, and integrated calendaring for point-bonded or smooth finishes.
Key Capabilities
- Meltblown and bicomponent meltblown web formation
- Nanofiber meltblown capability for PP, PET, PA6, PBT, and PLA
- 0.5 m web width with A. Celli auto-doff winder
- Variable capacity using different extruder units
- Full process data logging and SEM analysis
Spunbond Line
HLRD-2
The HLRD-2 Spunbond Line is a 0.5 m pilot system designed for bicomponent nonwoven research. Equipped with variable spin-head height, dual extruders, and a slot-style aspirator, it can produce webs with hole counts up to 5,000 holes/m and basis weights from 10 to 250 g/m2.
This flexible system supports side-by-side, sheath-core, segmented pie, and islands-in-the-sea configurations and includes integrated quenching, forming, calendaring, and winding.
Key Capabilities
- 0.5 m bi-component spunbond web production
- Adjustable spin and forming distances
- Point-bond and smooth calender options up to 250 C
- Real-time data logging and digital reporting
Research and Development Line
LBRD and LBRD-3
The LBRD-3 Line represents Hills latest generation of internal R&D equipment, designed as both a sales demonstration and engineering test platform. It supports multiple configurations, including filament, spunbond, and meltblown trials, with throughput up to 2-3/4 inch extruders and precision Siemens-based HMI control.
Serving as a prototype platform, it allows validation of new designs, accessories, and polymer developments before commercial implementation.
Key Capabilities
- High-temperature operation up to 450 C
- Corrosion resistant materials for LBRD
- Configurable for meltblown, spunbond, and filament modes
- Integrated cooling system and ambient-air quench for LBRD-3
- Live trending and automatic data logging for process evaluation
Collaborative Development and Testing
Refine processes before full-scale production.
Hills' in-house laboratory provides customers with the opportunity to conduct fiber trials, polymer testing, and proof-of-concept studies using production-grade technology. Our experienced lab engineers collaborate directly with partners to refine processes, evaluate new materials, and develop the next generation of multi-component fiber systems.
- Fiber and process development
- Polymer screening
- Cross-section design
- Performance testing under controlled conditions
Lab Trials
Interested in Conducting a Trial or R&D Collaboration?
Our in-house laboratory is open to customers and research partners looking to explore new materials or validate processes. Contact Hills to schedule a trial, discuss your objectives, and experience firsthand the precision and flexibility of Hills engineering.