A.Celli Nonwovens is known as the world leader in its core business of master roll winders, slitter-rewinders and roll handling and packaging technology for the nonwovens industry. The company can report that considerable advances have been made with its newly developed printing technology. The printing technology has been developed to offer the highest quality of printing onto different kinds of substrates including nonwovens, PP/PE film and tissue with a wide range of basis weights. This technology enhances the process chain offering roll goods producers the possibility to add aesthetic benefits to their products to empower their brands with high definition designs and images. The technology offered by A.Celli enables multi-color printing using UV, water-based and solvent-based techniques. A.Celli Nonwovens’ printing technology is currently available at its Italian headquarters in Lucca, Tuscany for customers to carry out dedicated printing tests with their products and designs. The machine available offers both UV and water-based technology.
The company has also developed a new in-line slitting winder, Nexus. Nexus represents the top of the range in in-line slitting to produce high quality slit reels. It features an innovative cross cutting system to minimize scrap during doffing. It is best for spunlace, lamination lines, special multilayered webs and low throughput spunlaid applications.
A.Celli Nonwovens recently applied its expertise of winding and slitting nonwovens to develop innovative spooling technology, for which it has one commercial reference to date. Its spooling machinery is currently capable of continuous production speeds of 600 m/min guaranteeing maximum flexibility and higher throughput due to its non-stop doffing capability. It is capable of being customized to the specific requirements of the web being processed.
Airlaid Nonwovens Systems
Airlaid Nonwovens Systems offers interim project management for the design and installation of complete airlaid machinery in order to minimize the total investment for its customers. An interim project manager can be hired from Airlaid Nonwovens Systems in order to manage an airlaid production machine project for customers who are interested in investing in this technology and business. In this way, the customer has access to airlaid technology, complete drawings, specifications and direct purchasing of equipment from a network of machine and technology subcontractors. By hiring an interim project manager, the customer can minimize the investment and still be able to build a state-of-the-art airlaid machine including production support. Airlaid Nonwovens Systems interim project managers have more than 25 years of experience in production of all airlaid grades, process and machine analysis including pre-engineering, facility design and final engineering, full project management experience worldwide, and commissioning of the airlaid line including training programs.
Amotek offers the automatic bagging machine PB167 for the compression and multiple bagging of baby diapers, adult diapers or underpads into polyethylene premade bags on wicket. PB167 with “full-servo” technology is suitable to pack in single and double rows of product compositions even if high compression is required. At the same time, guaranteeing a high output speed for small packages with low compression. This flexibility makes the PB167 suitable for easy connection with virtually any production line currently existing on the market.
High tech solutions and accurate manufacturing details make the PB167 reliable and functional with a gentle products’ handling during the bagging process. The new design of the precompression area, main compression plates and the full servo driven technology that guarantees excellent access to the machine, reduces the time required for format size changes and offers a cost savings of 40% for parts when compared with older generation machines.
To achieve even shorter installation and start up time, and to increase production efficiency and product quality, Amotek also offers the PB167 in integrated systems including a stacker and bagger with single control panel for easy operation.
The machine frame is a sturdy modular design, with welded self-supported tubular steel frame on adjustable height supporting feet. Complete front and back protective guards allow easy access to the machine. The PB167 is an integrated precompression module that features servo driven compression plates motioned by a toothed belt and with a compression force of 1000 N. It is a pneumatically driven system designed to stop and align the products released from the stacker, a “robot pusher” unit with dual servo drives that transfer products into the feeding area of the bagger.
System supplier Andritz combines the expertise of three leaders in the nonwovens industry with long-standing and successful traditions: Asselin-Thibeau, Küsters and Perfojet. The innovative technologies of these companies complement one another ideally in process solutions for a great variety of applications. The key competences lie in wetlaid, spunlace, needlepunch, spunbond, spunjet, air-through bonding, chemical bonding and finishing technologies.
Andritz offers spunlace production lines with unequalled energy efficiency ratio and a wide range of solutions answering producers’ needs. neXline spunlace unites carding system, hydroentanglement, dewatering, through-air dryer, hydro and thermo embossing for highest production performance. Andritz offers a new design of complete spunlace line dedicated to the growing markets: neXline spunlace aXcess. This line concept is based on tried and tested technology from the mature markets. Indeed, the fast growing spunlace market in several areas like China, Russia and India has led Andritz to introduce this new line configuration fitted out with one card in-line, Varioweb with 3 doffers, combined with the well-known Jetlace Avantage hydroentanglement unit and the dryer Perfodry Avantage. This sophisticated line layout will allow spunlace manufacturers to produce state-of-the-art spunlace fabrics from 30 to 100 gsm with productivity up to 8500 tons a year– an attractive investment that pays. As further option, the neXaqua dewatering system helps to save energy in the production of standard wipes.
Wetlace, a line concept that integrates Andritz wetlaid and hydroentanglement technologies, is an ideal process for the production of flushable wipes from 100% natural and/or renewable fibers without chemical binders. Furthermore, recycling of the waste is an important source for raw material savings. Andritz developed an innovative solution to recover the edge trim of the fabrics at the winder. Due to this system, nonwovens producers can recycle up to 10% of the raw material and reenter the fibers into the production process. In the wetlaid technology, when using pulp fibers, even 100% of the edge trim can be recovered and re-entered into the stock preparation process.
One major achievement in the needlepunch technology is the ProDyn system that generates raw material savings up to 5% or even more, regardless of the fiber characteristics, the bonding system, and the fabric weight. ProDyn allows for optimum control of the weight distribution at the formation of nonwovens webs. The ProDyn system automatically adjusts the CD fiber weight according to the programed weight of the finished fabric.
neXline finish is for the medical market and allows Andritz to provide finishing solutions for spunbond nonwovens from just one source. Hydrophobic, alcohol-repellent, air-permeable, antic-static and breathable are the required properties for use in medical applications. Close cooperation with renowned manufacturers and chemicals suppliers ensures excellent process performance. The Andritz offline finishing technology includes unwinding, impregnating, dosing, drying, curing and winding / slitting.
With a wide range of products and services, Andritz provides full line and individual solutions for almost all nonwovens segments as well as rebuilds and modernization strategies, including in-house automation solutions. Andritz technologies allow a fast, reliable, and profitable return on investment.
Argus Fire Control
Argus Fire Control of Charlotte, NC, has launched its new high speed Metal and Spark Diverter System. The Argus AD-50eC THS-TT offers the nonwovens industry the fastest and most reliable metal detection and diversion system available in the market. Occupying only 2.7 meters (10 feet) of duct space, the AD-50eC operates in 50 milliseconds to remove all ferrous and non-ferrous metal contamination from production lines to protect cards and card clothing from any damage. The AD-50eC is also equipment with the reliable Argus 343 Infrared Spark Detection system to detect and suppress any spark created by production machinery. The AD-50eC is available now worldwide, and can be installed and serviced by the many Argus Fire Control technical teams positioned in key markets around the world.
Aurizon Ultrasonics designs, manufactures and services high-power ultrasonic systems for a variety of nonwoven, hygiene/ personal care, medical, and textile applications. Pioneers of high speed Rotary Ultrasonic bonding and/or cutting technology, Aurizon has several different rotary platforms that can be customized to provide solutions for a variety of applications where high speed, precision, non-contact processing is required.
One of Aurizon’s newest technology developments has been to design and build a platform to demonstrate high speed cross web processing. Available in 20kHz, 30kHz, or 40 kHz options, the Rotary Cross Sealer (RCS) platform can be customized to offer continuous or intermittent motion bonding for many nonwoven-based processes.
Aurizon uses a structured process that includes an initial consultation to identify and understand the application challenge. Then its assesses the technical requirements of the system and design the equipment and process necessary to deliver a solution that offers precise, measurable results. Its “capabilities-based” approach and experience in applying our technology to unique processes allows us to be creative without the constraint of having to use an “off the shelf” product or solution. And our customized approach relies on developing a close working relationship with our customer to make sure that the integration of our technology into a larger process is seamless and supported through scale up and commercialization.
Autefa Solutions Germany GmbH
With the Automatic Needle Exchanger Autefa Solutions offers an efficient and profitable unit for exchanging needles, which should be an integrated part of every service workshop. Autefa Solutions is well known for nonwovens turnkey lines and individual machines such as cards, crosslappers and needle looms.
As a service machine for every needle loom the automatic needle exchanger is suited for every service workshop. According to customer requirements the needling of the needle boards has to be simple, safe and efficient, in order to avoid long downtimes and to extend the service life of the needle boards.
“With the Automatic Needle Exchanger we offer a perfect service machine,” says Stefan Schlichter, managing director. “The machine is efficient and equipped with an adapted software system, so that reproducibility and safety at every needle exchange are most important. The Automatic Needle Exchanger can be universally used for all practicable applications required from our customers and does not only cover inserting needles into new needle boards. It is about time that the hammer as the main tool disappears from the needle workshop.”
The features of the Automatic Needle Exchanger (www.cu4motion.com) are: Fully automatic process of needle exchange; universal application for all needle boards and needles; exchange of even single needles and needle segments; exchange of different needle designs, needle types and needle densities even in one board.
Now and in the future the Automatic Needle Exchanger exchanges each needle pattern. It is important that there is no restriction on certain needle patterns. A gentle treatment of the needle boards enables an extension of the service life of the needle boards, as they will not be damaged any more when worn or broken needles are exchanged. The Automatic Needle Exchanger is capable of detecting also damaged and broken needles as well as contaminations by fiber dust.
Since the actual operation of exchanging needles is happening without the direct involvement of personnel and an entirely encapsulated environment the system is offering an extreme high safety level.
For Autefa Solutions the Automatic Needle Exchanger represents a further building block in the concept of a modern tool management, which focuses on efficiency as well as flexibility.
For the Needle Loom Stylus the innovative i-Point system creates customized needle patterns with regard to technology by preventing surface markings in the nowovens. The i-Point system and the Automatic Needle Exchanger are innovative elements of a preventive maintenance concept and the interface for optimization of the needle pattern.
Bekaert Carding Solutions
Three years ago Bekaert Carding Solutions successfully introduced SiroLock and high performing doffer/worker wire which features a substantially horizontal step undercut on the tooth front. This horizontal step enables the ‘locking’ of fibers, which results in superior fiber taking and holding capabilities and enhanced carding power almost independent from roller speed. Many implementations, especially in the area of high speed carding for spunlace applications (direct nonwovens manufacturing), have proven the high added value of this product.
Based on this buildup of experience in advance fiber control, Bekaert Carding Solutions is now further broadening its product portfolio of worker/doffer wires with EvoStep. This new wire is featured with an evolutionary step undercut on the tooth front with greater aggressiveness than the angle of the overhang part below the tip. Compared to conventional wires, this type of step provides better fiber control that is initiated by a locally increased friction at the undercut. Therefore this makes this doffer/worker wire very suitable for medium speed carding typically used in indirect manufacturing of nonwovens (crosslapping and needlepunch).
The delicately designed undercut step in EvoStep brings the following benefits: Increase the fiber taking and holding capability or the carding power; improved fiber control; increase of the transfer ratio; and further benefits include a lower risk of fiber recycling, loading and melting.
Due to the horizontal undercut step design on the tooth front, SiroLock “locks” the fibers with the geometric constraint instead of with the friction between tooth front and fibers, while EvoStep retains fibers with the locally increase friction on the delicately slanted evolutionary step aiming at the “fit for use” aggressiveness and correspondingly optimum fiber retaining capabilities. As a result, although SiroLock offers superior fiber taking and holding capabilities and the highest carding power, the extension of our product portfolio with EvoStep enables our customers to find the optimal solution for their specific nonwoven applications. Carding speeds (linear roller speeds) as a function of bonding technology, fiber types and fiber range are taken into account to determine the optimal solution.
Card Clothing & Services, Inc. (CCS)
Card Clothing & Services, Inc. (CCS) is a U.S. manufacturer of fiber processing equipment, which includes blending, opening, carding, cross lapping and electrical control systems. CCS equipment is built from the ground up with top quality components in its automated Huntley, IL, fabrication facility. The equipment is electrically wired and test ran before it is disassembled and prepared for shipment. A few of our latest features include direct drives on all feed hoppers. This allows the user to adjust the feed hopper setting while in production.
CCS is currently manufacturing a complete nonwovens line that will include the latest technology in electrical controls. The control system includes recipe management, auto start/stop, alarming, motion detection safeties, displays motor condition, remote access and much more. The company is able to monitor the nonwoven line remotely from anywhere in the world that has internet service.
In addition to capital equipment, CCS manufactures carding machine cylinders and fine opener rollers. The metallic card cylinder reclothing operation is able to wind rollers up to 3.5 meters in width depending on diameter. A typical CCS fine opener can be covered with metallic wire, aluminum pinned lags or large teeth depending on the desired amount of fiber opening.
CCS designs and manufactures a standard line of fiber processing equipment; we offer many different features that allow the end user to customize the equipment to suit the application. Please visit our web site link below to better understand the full range of products that CCS offers.
Wenzhou Chaolong Textile Machinery Co., Ltd. is one of the leading spunbond production equipment manufacturers in China. More than 150 of its production lines have been sold, while its claims a 50% market share in China where it also says the first large rectangular spinneret polypropylene spunbond production line, the first large rectangular spinneret polyester spunbond production line and the first SMS production line are from Wenzhou Chaolong Textile Machinery Co., Ltd.
Spunbond production line—SS/SSS, standard effective width is from 1600mm to 3200mm. Machine speed is from 200-400m/min. We can offer on-line hydrophilic treatment machine.SMS Composites production line—SMS/SMMS/SSMMS, standard effective width is from 1600 to 3200, Machine speed is from 250 to 450m/min. C.L company’s special two web-formers design makes the machine hydrostatic pressure much higher than normal design machine.
PET spunbond production line, standard effective width is from 2400 to 3200mm. Machine speed is from 10-80m/min, actual running power consumption less than 2200kw/T. You can produce PLA spunbond nonwoven fabric products on this machine, which C.L company has our own right patents.
Bicomponent spunbond production line S/C PE/PET & PE/PP composite structure, S/C proportion is from 50:50 to 30:70, machine standard effective width is from 1600mm to 3200mm.
Wenzhou Chaolong Textile Machinery Co., Ltd. manufactures series of spunbond, meltblown, composites complete sets of nonwoven machines, combining installation, commissioning and after-sales service.
Coast Controls is the exclusive manufacturer of a simplified and unique All-Air Automatic Web Guiding System used in various roll-to-roll, web converting industries worldwide.
Materials that require guiding include all types of paper, various plastic films, label stock, cloth, etc. Guiding installations have been made on many different web processing lines such as printing presses, laminators, coating machines, slitters, plastic film extruders, plastic and paper bag machines, multi-wall tubers, envelope machines, packaging machines, etc.
Coast guiding systems are used in many different industries such as: nonwovens, extruded plastic film, paper & plastic bags, envelope manufacturing, tire and rubber manufacturing, flexographic printing, flexible packaging, label & narrow web manufacturing, coating & laminating, die cutting, slitting, metalized film, pharmaceutical & medical packaging, food packaging, etc. In addition, many Original Equipment Manufacturers (OEM’s) incorporate Coast systems on machines they build as well.
The Coast system is extremely simple and is based on a proportional All-Air Servo Controller which operates entirely on low-pressure plant air, normally around 6 psi. The Servo Controller is used in conjunction with an Air-Flow sensor, Air Cylinder and a properly designed and applied intermediate or unwind guide to accurately align the moving web of material.
In addition to simplicity, the All-Air system has many significant advantages including ease of installation and dependability as well as guiding results not being affected by production dust. Also the system is intrinsically explosion-proof and does not require any electricity, motors, electronics or hydraulics. The system has an unprecedented 10-year warranty and is virtually maintenance free. In addition, all guiding applications are guaranteed to the customer’s complete satisfaction.
To adapt a design that is perfect for your application, Coast utilizes SolidWorks 3D Software which can be converted to just about any format so the customer can simply place the 3D model of the guiding equipment or idler rolls right into their design which saves time and money.
Although it carries standard guiding systems to fit most machines in the converting industry, we will modify our designs to adapt to your machine so the installation of a new Coast guide is just like replacing the original equipment and Coast will do this at no extra charge to you.
CTC International has introduced its Power Splice Automatic Butt Splicer. The splicer is suitable for splicing a variety of materials used in the nonwovens industry where light tension coupled with a need for a Butt Splice is a requirement. The Heavy-duty cantilevered unwind design features integral roll lifting and can hold two full 40-inc diameter rolls, allowing new roll prep at any time in the splice sequence. The horizontal web accumulator is positioned on top of the splicer, allowing for a smaller footprint than competitive splicers which accommodates rolls this size. Unit features vector driven unwind spindles as standard, with servo drives optional. Driving the unwind spindles offers several benefits including keeping the machine footprint small, the ability to unwind very delicate materials, and no brakes to wear and need replacement. Automatic “Gapless” Butt Splicing with two pieces of tape for maximum security is standard. Both splice tapes are applied to the web when stopped, reducing chances of a missed splice. The splicer can also be prepped to make a one-sided splice, with the tape always on the same side, without turreting the unwind rolls. The splicer will be offered to accommodate a variety of web widths, line speeds and other process requirements.
As worldwide leading manufacturer for industrial slitting technology, Dienes sets once again a new standard with the innovative DS 6 in the field of knife holders. The DS 6 is the culmination of 100 years experience of the company Dienes and know-how from more than 500,000 produced knife holders. Whether it is with manual or semi-automatic operation, the DS 6 impresses with its extremely high stability with very small cutting width from 30 mm and speed of up to 2000 m/min. Adding to this is the worldwide unique cutting pressure positioning, its high longevity, as well as its comprehensive compatibility.
Due to the Dienes honeycomb structure and the long guide bodies, the compact and light design of the DS 6 is extremely sturdy. This means the user can expect highest accuracy even for small cutting widths, and additionally benefits from an increased durability. Furthermore, the DS 6 with its high variability is suited to many sophisticated fields of application, like the processing of paper, foil, non-woven material and non-ferrous metal foil. Our unique patented cutting pressure positioning prevents the stick-slip effect with the balanced pressure distribution on the knives.
The fact that our new knife holder is trendsetting on the market is also demonstrated by the other product features of the DS 6. For example, it has an integrated patented adjusting slide, which enables precise and reproducible positioning of the holder towards the bottom knife. The setting of the shear angles is possible in two ways: Conventionally with a plate on the retainer as well as from the front with the Dienes angle supports. The quick-change heads ensure a simplified, time-saving and above all safe removal during maintenance and knife exchange – the knife head and the integrated 360° guard can be completely removed and inserted as one unit.
Furthermore, this unit can be used in both directions, so that the knife holder is suitable for all feed-ins or can be quickly repositioned. In addition, the knife holder has a forced sequence control for the cutting pressure positioning. Alternatively, however, supply via two separate compressed air circuits for individual adjustment of vertical and horizontal stroke can be selected, so that the cutting pressure can be set even more accurately and reproducibly.
Operation of the DS 6 is intuitive, comfortable and wholly flexible by being usable from all sides. Its design is vibration absorbing and it has comprehensive rust and dust protection for maximum sturdiness. Furthermore it is compatible with almost all existing slitting systems and is thus ideally suited to easily update existing machines and make them futureproof.
The DS 6 knife holders are available as version M with manual depth adjustment as well as version S with semi-automatic design. The innovative depth adjustment of the DS 6-S provides particular comfort, as it is done step-by-step via a display, which has an integrated teach-in phase. The user thus benefits from even higher accuracy and traceability. At the same time, operating errors are minimized.
DiloGroup is the premier builder and supplier of complete nonwovens lines for staple fiber nonwoven production. Each line is specifically engineered to customer needs. Recent machine concepts from the DiloGroup companies DiloTemafa, DiloSpinnbau and DiloMachines focus on improving operation efficiency, web quality and uniformity with positive effects on all staple fiber bonding processes. All these elements are part of the “Dilo – Isomation Process” and aim at an even web mass for reduced fiber consumption as raw material is the biggest cost factor in textile production.
One machine contributing to this process is the dosing opener DON manufactured by DiloTemafa, which includes a fine opening stage. It delivers the fibrous material continuously and homogeneously to the card feeder.
Another step to improve evenness is the card feeder MultiFeed designed by DiloSpinnbau which is available in working widths up to 5 meters. This machine using the “Twinflow” infeed system offers a capacity of over 400 kg/hour/m of working width when processing 1.7 dtex fiber. It thus represents a state-of-the-art feeding solution for direct cards. The use of a “Twinflow” infeed applies the doubling effect for a more homogeneous flock mass flow.
The Spinnbau MultiCard provides high production availability due to its easy and fast accessibility for cleaning and maintenance work. It handles the full range of fiber fineness and length with a web speed potential of up to 200 m/min and thus represents an economic solution for cross-laid nonwoven production.
Dilo crosslappers provide infeed speeds up to ca. 200 m/min (HL series) and over 160 m/min (DL series). The DL series may be equipped with the Webguide from DiloMachines, which also provides web homogeneity at high speeds and therefore results in significant fiber savings. DiloMachines offers a complete range of vertical and horizontal crosslappers, which ensure high layering precision based on excellent web control up to working widths of 16 meters.
The sales program of DiloMachines includes the complete range of needlelooms, from single board needling on one side to two boards from each side, plus structuring and patterning specialty looms. Endless felt tubes can be needled and also wide working width belts for papermachine clothing applications. The further development of needlelooms continues. Elliptical and circular needlebeam movements are used to control drafts in the needling zone and to provide high speed felt production especially in the low weight range.
All these machines together result in a better felt quality, increased homogeneity saving fibers.
Dover Flexo Electronics
Dover Flexo Electronics has introduced the EasyView Tension Indicator, the compact, low-cost, easy-to-use tension measurement device for nonwovens converters, finishers and anyone who uses a web-fed process. Units measure roughly 3 ½” x 3” x 4”—small enough to fit in your hand. While this unit is pint-sized, operators appreciate the large, high-visibility LED readout on the digital version.
An EasyView Indicator amplifies the web tension signal from tension transducers in a machine’s web path, displays the tension on an analog or digital meter, and provides an isolated 0-to-10 VDC tension signal output, for use if desired, to a PLC, drive or controller.
Quik-Cal is a time-saving technology used to zero and calibrate EasyView output to the tension transducers. With Quik-Cal, the operator pushes a zero button then a calibrate button for one second each to set the output ‘zero’ and ‘span’ settings; this eliminates the need to turn potentiometers. Because settings are stored digitally, device output is inherently stable and drift-free over time and temperature variations.
FeltLOOM is a patented design, engineered for ultimate user-control. For lab testing, it opens the world to “what if” testing. It allows small amounts to be tested quickly. The results are consistent high-quality fabric created exactly to user requirements, every single time. It is built from precision quality parts, industrial-duty, sealed gear motors, and is equipped with operator-friendly controls.
There are four models: 36-, 48-, 60-, and 66-inch. All models are equipped with a double motor and offer control of variable roller speed and needle speed with the ability to match the machine to the fiber. Strategically spaced to allow users to stop the fabric from moving forward and giving the appropriate slippage at any point in the process prevents “pleating.” Dual motors give users the ability to vary the density of the needle punches, depending on their fibers and situation. The roller motor allows users to control the finish on their felt. Variable speed rollers and needles can be independently controlled allowing the fabric to move through at a defined rate from 0% to 100%.
Forward and reverse directions provides the capability to move the fabric back and forth, felt a piece, then turn it around and run it back through with the most control possible enabling texturing, density, etc. Needle density amounts to eight rows per each six-inch needle board segment, 96 needles per segment or .15 meters per segment on all models. This gives maximum needle penetration and maximum punches per inch. Needles also are varied in position and do not line up in straight lines, preventing a “corduroy” effect and creating consistently strong, stable felt.
Knurled 1.5-inch rollers provide the surface and grip needed for both ends of the process as fiber is pushed through the machine and as felt is pulled out of the other side. The table height of all models is the height of a typical counter to work best for most users and prevent fatigue and is built on rollers making the FeltLOOM easy to move around. Needles can be removed and replaced either one at a time or a whole needle board can be replaced at once. The front and back of the machine is equipped with a clear window, enabling users to see the needles moving so they can identify any bent or broken needles while felting is in process. Independent 6-inch needle board segments provide the capability to compare different needle patterns side by side.
Formfiber Denmark ApS
Formfiber Denmark’s patented SPIKE AirCarding Forming Equipment delivers innovative airlaid nonwoven technology, designed to efficiently form carding length or shorter fibrous raw materials. If your mat product application requires heavy basis weight mats of up to 10,000 gsm, SPIKE AirCarding is the best forming technology available. SPIKE AirCarding substantially reduces the amount of bonding fiber required for thermal bonded mat formulations, delivers consistently good mat formation, and excels at forming dissimilar fiber lengths for multi-fiber mat formulations, when applied to the commercial manufacture of both high and low density mat products. If your application requires a low-basis weight web of 10 gsm or more, SPIKE AirCarding is the best forming technology available. SPIKE AirCarding formers are being applied to applications with production line speeds of up to 600 mpm for low basis weight webs, deliver consistently good formation with short fiber lengths, and superior productivity when compared to competitive forming technologies.
Current Formfiber projects are being designed and fabricated for products formulated with fluff pulp for absorbent product applications, natural fiber formulations for mat products used in thermo-forming applications, reclaimed textile fibers for thermal insulation applications, and reclaimed tire cord fiber for acoustical insulation applications. SPIKE AirCarding Forming Technology will efficiently form a wide variety of raw materials and do so with a fiber mixture containing dissimilar raw material lengths.
Formfiber SPIKE AirCarding Technology offers the following commercial manufacturing advantages: 1) substantial forming capacities of up to 1000 kg per hour per meter width of Former; 2) forming air consumption will be less than 50% of competitive forming technologies specifications; 3) will form natural or synthetic fibers with lengths from one to 102 mm (4.0”); 4) will form and then thermal bond mat products with a finished mat thickness of 400 mm (15.75”) or less; 5) forming zone widths of 600 to 5000 mm (24” to 197”) are commercially available; 6) new Formfiber corporate facilities in Denmark offer test plant facilities for our client’s product and process development projects; and 7) a new semi-commercial 600 mm SPIKE AirCarding production line is available for Formfiber client’s market, research, and product development initiatives.
The Formfiber team is ready to be of service to your company, by completing a Test Plant Forming Evaluation, with a mat product formulation of your choice. This forming evaluation will confirm and illustrate the manufacturing advantages of SPIKE AirCarding technology when applied to your product or plant business development projects.
Hansa Industrie-Mixer GmbH & Co. KG (Stuhr, Germany) and RF Systems Srl (Solagna, Italy) have debuted new technology for foaming and drying processes.
The Hansa Foamliner foam applicator and RF Systems Foamdryer radio-frequency dryer are specifically engineered and designed for cost-effective infusion and drying of foamed reactive resins or binders. Together, the Foamliner’s precise foam impregnation and the Foamdryer’s economical and uniform moisture removal provide significant cost savings over traditional methods of foaming and drying.
Hansa Industrie-Mixer GmbH & Co. KG has launched Foamliner, which provides ultimate precision in foam impregnation and systematic penetration of a substrate, for example, natural fiber mats using foamed reactive resins or binders. It has remarkably easy handling for cleaning, individual adjustment of the tape width or, via the attached foam generator, change of recipe.
The Foamliner can be matched with a Hansa Compact-Mix or Pico-Mix. Varying Compact-Mix models can handle most production requirements in the areas of carpeting, synthetic leather, flock, mattresses, black-out blinds, filter mats, fabric wallpaper, doors, artificial turf or clothing. The Compact-Mix is used for coating, tufting, gluing and even duplex coating and the continuous mechanical aeration ensures a constant aerated product flow in consistent density and quality.
The Pico-Mix is a fully automatic laboratory foam generator that provides reproducible results for product requirements such as aeration level, product density, throughput, etc. It also features a temperature-controlled mixing head with double mechanical seal, a PLC control with touch panel and a newly developed, seal-less eccentric screw pump with a double-walled, temperature-controlled reservoir.
Hastem Transportbaender GmbH has developed a new segment-conveyor system “SC25” in which the segments are clicked together. This design meets the requirements for a completely closed surface without slots and hinges. The polygon effect is minimized because the conveyor runs nearly circular on the pulleys. The drive with pulleys forces the conveyor to a straight run and expensive control devices are avoided. The interlocking individual segments can be replaced if they are worn or damaged. A simple shortening or lengthening of the conveyor is another advantage.
Herrmann Ultrasonics provides customized solutions for bonding, slitting, cutting and embossing applications of nonwoven, film and textile materials. The new generation of the Herrmann ultrasonic bonding modules enables high-speed-production at constant quality without the use of adhesive and consumables. It allows for stable processes even at variable speeds. Further advantages: the ultrasonic process is immediately available without preheating and without cooling down. The laminated materials provide a pleasant softness and improve the quality of the final product.
Herrmann’s continuous ultrasonic bonding technology provides significant advantages for high-speed processing of nonwovens, composite materials, paper and films, especially for your application. There are many applications in the hygiene and medical field, i.e. filter products and elastic laminates, where roll goods need to be bonded at respective speeds.
The technical improvement inside the Ultraspin module is the newly designed bearing sleeve technology (versus the alternative diaphragm system). In can be combined with the field proven and patented Microgap control, which is used with a static sonotrode. The close-loop Microgap control allows it to bond materials with consistent quality while ensuring there is no contact with the anvil.
The new sleeve technology withstands high bonding forces. A precise parallel adjustment is given with no more vibration of the sleeve/bearing assembly. The rigid design allows for high-speed continuous and intermittent application. The Ultraspin ultrasonic bonding module consists of a rotating sonotrode, new double bearing sleeve technology, bearings and specially designed 35 kHz Converter. Typical applications include cuff welding, front and back ear attachment, acquisition layer, tape construction, side seam, textile applications and other bonding applications.
Hills, Inc. offers the most advanced nanofiber and multicomponent fiber extrusion equipment to produce meltblown fabrics, spunbond fabrics, staple fibers and continuous filaments. Hills’ core technology is its patented “printed circuit board” method of manufacturing precision polymer flow passages to extrude complex fiber cross sections containing two or more polymers. Recent Hills innovations for nonwovens include the following:
• Hills spunbond machines use its proprietary bicomponent extrusion technology to make microfiber and nanofiber spunbond webs via splittable pie and islands-in-the-sea fibers, as well as more traditional bico and homopolymer webs. Hills’ high-speed slot aspirator is especially suited to high-performance polymer applications such as primary carpet backing, roofing membrane substrate, artificial leather substrate, and filtration media. The flexibility of this equipment makes many of these applications possible on the same machine.
• Hills meltblown machines employ unique die technology to make a variety of high-value products for filtration applications, breathable barriers, and other high-value uses. Webs with low and sub-micron fibers are particularly useful in HEPA filter media and in minimizing the weight of meltblown filter media needed. Average fiber sizes from under 250nm to 10+ microns in diameter, including bicomponent fibers, are produced using a variety of polymers. Hills’ dies are designed for high polymer pressure, hole count up to 100+hpi, and unlimited capillary L/D, which allows custom designs to precisely fit the customer’s polymer and product needs.
The same nanofiber and multicomponent production technology offered in Hills spunbond machinery is also available in Hills staple fiber and continuous filament yarn machines. Splittable/dividable multicomponent fibers can easily be made and split into nanofibers at the high production rates of simple homopolymer processes, and more traditional fibers such as sheath/core and homopolymer are also readily produced.
In addition to production equipment, Hills laboratory and pilot extrusion machines for all of the above processes are offered, and are present in many private and government R&D centers around the world. For example, Hills recently completed the commissioning of several new nonwovens lines at CETI (the European Centre for Innovative Textiles) in the Lille region of northern France. The research facility includes half-meter bicomponent spunbond and meltblown lines as well as tri-component FDY filament and staple crimp cut lines (see www.ceti.com for further information). Customers may also utilize laboratory machines at the Hills facility in Florida, and at other institutions worldwide, to support their product development work.
Ibis offers the “G-3” Filter System. If you are forming a soft absorbent pad, the Ibis filter systems will help provide constant air volume and vacuum to your forming section so you can form a consistent pad. When exceptionally clean air is required for recirculation within the production area and/or exhausted to the local atmosphere, Ibis has developed the G-3 Concept that offers a high level of filtration efficiency while addressing the issues associated with OSHA, CE, ATEX, FM, NFPA and other safety and environmental directives. The G-3 is based on the design principle of “Capture & Contain” eliminating the use of compressed air cleaning, residual dust, and any/all electrical components or other possible sparking components in the air stream. The Ibis “Clean Floor Design” may eliminate the need for explosion venting of the drum filter. Ibis filter systems have always and will continue to offer the option to return this recovered fiber to your production line saving you up to half of 1% of your annual expense of fluff pulp and SAP for that production line.
Investkonsult Sweden is family-owned and Sweden-based Company operating worldwide. Since 1976 we have gone from traders of conventional second hand textile machinery to professional consultants and brokers of machinery serving the producers of nonwovens roll-goods and disposable hygiene products.
As consultants we assist existing producers as well as start-ups, we provide objective valuations, line and set-up guidance, brokering, sales and more. We value building and maintaining close relationships with our customers, always with a high degree of discretion and confidentiality. Our clients include most of the nonwoven and personal care producers worldwide, our network of contacts within these industries is extensive and continuously growing, thus we are able to match buyer and seller within a short time frame. Since we are focusing on the nonwoven and disposable hygiene sectors only we have gathered a broad as well as deep knowledge regarding technical developments and market trends in these sectors. Our Unique matchmaking capabilities make us your first choice when it comes to brokering and consultancy.
Investkonsult have for a long time had our eyes on the growing markets and during the last years we have had a strong focus on the Indian market, where we have sold several nonwoven lines in recent years. We believe in a continuous strong growth for nonwoven and disposable hygiene production in India and in 2013 we have established a JV in Indore called Jajoo Hygiene Pvt. Ltd for production of underpads together with our Indian partner. We believe that the demand for nonwoven and disposable hygiene products will continue to grow in India and as a result, the need for domestic production in these sectors will increase. By starting our own production in India, we want to show that there is a large untapped market for second-hand nonwoven and disposable hygiene equipment.
ISRA VISION is the world’s leading supplier of fully automated 100% high-speed in-line inspection systems for quality control of technical surfaces, such as nonwovens, plastic film, print, flexible packaging or paper. The systems are used to detect defects, improve processes and increase yield.
ISRA surface inspection technology is based upon standard proprietary modules that are scalable and configurable for a variety of applications. These include the latest color and monochrome line scan cameras, image processing hardware with the highest available speeds, and advanced algorithms for classification and image analysis. The system provides the user with a simple data display to optimize converting while monitoring and improving the production process. The result is a user-friendly tool that provides fast payback by improving yield and reducing customer returns and complaints.
With thousands of installations worldwide, ISRA VISION provides the most advanced and customized web inspection systems delivering reliable and comprehensive information of all relevant surface defects such as holes, eyebrows, contaminations, thin areas, thick areas, oil stains, insects, colored contaminations, hard fibers, fiber bundles, fiber stretching, drops, calendar defects and more across the various production steps. As a global enterprise, ISRA VISION guarantees its customers excellence in every aspect: from consulting, service, training and confidentiality to complete solutions and worldwide support. A business relationship with ISRA translates into improved yields, reduced costs and increased profits and meets tomorrow’s customer requirements today.
Kansan Machinery Co. is recognized as a leading complete system supplier for wet wipe industry with the capability of manufacturing not only wet wipe converting machines but also wet wipe packaging and lid applicator machines. Since 1998, it has been devising, designing, manufacturing and installing more than 500 projects worldwide. Research and Development is the crucial part of culture and success of Kansan since the establishment and it continues developing tomorrow’s technologies and solutions for wet wipes industry by combining its unique capabilities with innovative ideas.
New Market Penetrations. Owing to great number of demands from the market, Kansan is already fully booked for 2013 and its turnover will be doubled in comparison with 2012. Moreover, Kansan is about to close the first quarter of 2014 by penetrating new markets as Italy, Peru, Mexico, United Kingdom and South Africa.
New Design Interfold/Non-Interfold Machine. Kansan exhibited new design interfold/non-interfold machine with 800 cuts/minute capacity for the first time at IDEA13 Show, Miami. During the 3-day show numerous meetings were made in Kansan’s booth with potential & existing customers and new orders from U.S.A. and Latin America were already taken.
New Design Rotary Type Ultrasonic Welded Gloves Machine. Kansan has completed new design “Rotary Type Ultrasonic Welded Gloves Machine” which enables its customers to produce different types of gloves which are actually emerging in the countries in where old age population is remarkably growing.
Menges Roller makes large industrial rollers for the nonwovens industry. We make industrial rollers up to 30-feet long and 48-inches in diameter and some weigh more than 10 tons. In addition to making these heavy-duty rollers, we can also cover them in rubber, silicone or urethane-based coatings. Most people don’t understand the important role that rollers play in a nonwovens plant. Our rollers are used in almost every phase, from initial rolling and stretching of materials to laminating and layering, adhesive and coating application processes, general material handling and manipulation, and so on. The one thing about rollers for the nonwovens industry is they just keep getting bigger as production lines get wider. Currently Menges is working on a rather large roller for a nonwovens manufacturer (see photo). This roller is in the final fabrication stage, and will be covered in rubber. The overall length of this roller is 20 feet, and the roller face is approximately 17 feet x 20 inches. The roller will be covered in a very soft (20 durometer, shore A) urethane. Menges is fabricating and covering rollers like this more and more often. Rollers like this are becoming increasingly popular in the nonwovens industry.
Mondon Converting & Winding solutions offers turnkey process from unwinding to palletizing solutions in nonwovens market. Mondon has supplied converting machineries for 30 years. Initial realizations fitted with special applications. Nowadays, Mondon disposes of one the largest range of machinery for nonwoven market to answer in unwinding, slitting, rewinding, spooling and laminating, all offered in semi or fully automatic lines. These converting solutions are enlarged with packing and palletizing solutions both into plastic film or carton boxes. Mondon is definitely your answer from unwinding to palletizing.
During all these years, Mondon developed a strong expertise in unwinding/winding performances. Tension control and transition modes are key factors in the management of the webs.
Mondon offers machineries for all varieties of nonwovens. Conscious of each nonwoven exigencies, dedicated expertise allows determining the best equipment to answer to specific needs. From hygiene to agriculture, solutions are different but always satisfying specifications and mechanical parameters of the product.
Mondon’s team is focused on customer’s satisfaction by offering equipment easy to operate and maintain. Makers of slitting, rewinding/spooling, coating and laminating equipment, Mondon’s customer base is made up of both large global companies and medium sized in need of automated machinery which can provide high productivity, ergonomics and quality products.
Mondon recently introduced its last state-of-the-art turret winder for nonwovens. Dedicated to delicate product, this winder can be installed at the outlet of manufacturing line where high productivity or non-stop process is required. Due to a center-surface rewinding technology, low grammage products can be rewound with accurate tension control. It is equipped with shear cutting knives in order to perform edge trim or multi cut in the width of the product. This winder includes assistance for unloading where operators never handle shafts. It is available in several widths and bobbin diameters. Equipped with VPN network distance control, diagnostic and support can be operated directly from technical center.
This winder is based on our usual strong design includes latest technologies in tension control, speed management and safety. Control touch screens include overall view of the machine with parameter adjustment access and simulator.
During its growth, Mondon has expanded by using automated machinery that can provide both performance and cost savings. The company continues to regularly invest in research, modernization and rationalization of its solutions. Mondon provides the converting modules with its inputs and outputs inside a turnkey project.
It combines solutions such as reel handling, loading and conveying before unwinding, then converting and rewinding/spooling and, finally, packing and palletizing. Customers find an answer to a global project with only one supplier for all the line.
Contact us though our sales team made of competent engineers, each having a background in converting over 15 years minimum.
Nippon Filcon has developed a new Spinbelt for high-speed spunbond lines, which has proven its performance under 940 m/min machine speed producing 8 gsm SSS, SMS and bicomponent web. Smoothest web release, easiest drop cleaning, and dust resistant design will assure you the minimum defects and highest productivity of your high-speed spunbond web production.
Nordson introduced a number of new products this year supporting its OptiBond portfolio of variation management solutions designed to optimize material delivery and dispensing. Implementing variation management programs helps disposable hygiene manufacturers improve production efficiency, decrease maintenance and enhance product quality. The Nordson variation management methodology is Measure, Understand and Improve.
OptiBond solutions address two primary causes of production inconsistency, machine direction and cross-web variation. The first step, accurate measurement, allows understanding of flow across the entire machine speed range, even during the demanding ramp-up phase. Then, solutions can be implemented to control flow. Nordson’s broad range of OptiBond solutions includes: passive or active metering; point-of-application or intermediate system component; and melter-integrated or standalone control.
The new TruFlow meter is a simple, positive-displacement meter that accurately measures actual material flow rates during all production phases. The versatile meter operates across a broad flow range, 10-500 cc’s per minute, as well as a wide spectrum of material viscosities and temperatures.
TruFlow meters are adaptable to most production environments. This meter can be added to existing production lines or included with new systems to provide accurate measurement of material flow. TruFlow meters can be also be linked directly to a parent machine PLC if desired.
Just-announced Concert series flow controllers enable monitoring and control of material flow during all phases of production. Concert flow controllers measure actual material delivery, compare it to the production requirement and continuously adjust melter pump output in real-time. This closed-loop control vastly improves accuracy of material delivery especially during production start.
These flow controllers use Nordson’s intuitive, color touch screen Optix interface to simplify set-up and operation. Optix screens show real-time system status as well as support data logging and graphing to improve operational control. Local language support and on-screen help facilitate operator training.
Recently-released VersaBlue Plus melters introduce optional melter-integrated flow monitoring and control for up to four channels to the existing full-feature set that VersaBlue melters have delivered for more than a decade. Integrated closed-loop control continuously measures and compares material flow rate to the application’s flow requirement, automatically adjusting material delivery in real-time to minimize the difference between the requirement and actual flow rates.
Integrating flow control simplifies installation and provides ease-of-use through the melter’s touch screen interface. The VersaBlue melter’s intuitive, easy-to-use graphical touch display simplifies set-up and operation, and provides system status for various melter functions. Basic graphing and data reporting of flow control are also available on the melter display, or more detailed information can be exported to a laptop or via field bus.
These new products join established products such as AltaBlue Touch melters and TruFlow applicators, dividers and monitors to fortify Nordson’s OptiBond portfolio of variation management solutions, helping disposable hygiene manufacturers reduce material cost and waste.
Omega Engineered Technologies
Omega Engineered Technologies LLC has been repairing needleboards since 2000. What started out as a small business of reneedling boards for local customers has developed into a company that is a resource for needleboard repair. Omega continues to reneedle boards and prides itself on quick turn a rounds. This is especially important when a company suffers a devastating crash. Removing and installing 50,000 needles over a weekend is not uncommon. We also developed the technology for recovering boards, whether they are covered with plastic or urethane. Do not throw away boards simply because the covering is shot. We can recover the boards at an attractive price. If you are having trouble getting boards in and out of the loom, we can straighten the boards also. Omega also provides training and advice for improving your needleboard repair department. If a company does not employ full time needle repair employees, their needling department may be operating at low efficiency. We have developed tools and techniques over the years that we will gladly pass on to our customers. Omega services customers through the USA through its sales representative, the Louis P Batson Company.
RotoMetrics and Mitsubishi Materials have recently partnered to offer Tungsten Carbide rotary cutting dies, These premium quality cutting tools offer superior durability for applications including diapers, sanitary napkins, bandages and stock labels.
Mitsubishi Materials is a major world manufacturer of Tungsten Carbide cutting tools, excelling in the manufacturing process control of the raw material (powder) to final product. This high level of control ensures consistent performance from the die’s first run and throughout the lifetime of the tool. These Tungsten Carbide dies are inspected in all facets from grain size uniformity to the geometry of the blade edge down to a micron tolerance.
The Rotometrics-Mitsubishi Materials secret is in the controlled selection of Tungsten Carbide for each application. The rotary die cutter is equipped with Mitsubishi GM30 Carbide, a proprietary grade which offers a hardness of 90 HRA and a sub-grain size. Together, these result in allowing for a sharper blade edge with superior wear resistance. The anvil is made of Mitsubishi GC30 Carbide which has a larger grain size and a hardness of 88 HRA, manufactured for shock absorption and the right amount of flexibility to guide the blade edge in every cut. The combination of carbides in this application, equate to synchronized tool life, with even wear between the rotary die and the anvil.
RotoMetrics and Mitsubishi Materials also offer unique and patented die stations which work seamlessly with the Tungsten Carbide dies to deliver the best possible converting opportunities. The RigiCube Die Stations are built to absorb backlash and efficiently optimize the capabilities of Tungsten Carbide. The die station design also ensures consistent blade contact throughout the life of the Rotary Die Cutter.
Ryeco offers its Defect Marking System for nonwoven applications. This system places marks on a web at a position relative to a defect or process upset. Certain defects in a web will cause problems in subsequent processes. For quality purposes, these defects must be identified and removed prior to shipping to customers. Ryeco’s Defect Marker places a colored or invisible mark on the web at the machine direction location of the defect. The system can be used manually by machine operators, interfaces with any Web Inspection System, and can be triggered automatically with any process control equipment. Marked defects warn downstream operators to take preventative actions to avoid downtime and ensure that your customers receive only your best product.
Marking defects on a continuous web can be accomplished in a variety of ways depending on the application. Defects can be marked along the edge of the web or in any cross-web position with any number of independent or simultaneous markers. Marks can be as long as the actual defect or as short as 0.5 milliseconds, continuous or dashed, or confined to a discrete area such as an individual label. Marks can also be made in a variety of dye colors including invisible (UV-fluorescing) and on nearly any material. In cases where there is significant web wander or the web width changes periodically, the marker can be actuated to automatically compensate for these changes in width and will track the web edge as it moves.
Marking the web for defects can be initiated several different ways. Machine operators may manually make marks for process upsets or any other observed defects that may occur during production. With the use of a Web Inspection System or process control equipment, defects can be marked automatically as they are identified.
Once marked, defects can be appropriately addressed during downstream processes. Defect positions can now be found visually by operators or automatically with detection devices such as a RYECO Mark Detection System. Appropriate actions can be taken to prevent process upsets, increase process efficiency, or ensure that necessary defects are removed from the final product.
Sandvik Hard Materials
In the continuous effort to stay closer to its customers and serve them locally, Sandvik has opened in 2013 its South American maintenance center for the resharpening of carbide rotary cutters, the regrinding of anvils and the maintenance of frames. The maintenance center is located in the Brazilian factory of Sandvik, in Sao Paulo. Same resharpening procedures as in all Sandvik facilities are a guarantee of quality and performance. Local product specialists and customer service will assist to provide the best service. The Sandvik South American maintenance center is adding to the North American, European and Asian ones.
Today increasing converting line speeds and global efficiency targets require not only to have good quality tools but also the needed service to get the best out of the rotary cutting solution. In this perspective, Sandvik has developed several services aimed to reduce the time to run, to shorten the learning curve and to get the highest benefits out of the equipment. Available services are: three-dimensional design and modelling; operators’ training; advanced engineering training; interactive users’ manuals for quicker learning and part identification; start-up assistance; Sandvik and non-Sandvik cutting unit audit for continuous improvement; vibration measurements, FFT and FRF analysis, FEM modelling, to optimize total unit lifetime; raw material cutting and porosity characterization; airflow and pump characteristics calculations; and many others, depending on customer request.
Sandvik is a leading company in the rotary cutting solutions for the hygiene market. The high quality of its products, combined to the engineering service, customer assistance and global/local service, make it easy to find the right solution for the customer needs.
Located near Pescara in Italy, Sani-Group is celebrating 14 years of excellence in supplying the disposable goods industries worldwide. Sani-Group offers its Cellulose mill, for disc or hammer mills 10”, 20” or other customized mills upon request; Drum forming, for core processors; RDC, for rotary die cutters & embossers; SANIMAC, for machines & prototypes; and Sanipro, for industry services & spare parts division, for Ultra-violet sterilizers division.
Recently the company has developed a multi-purpose drop sealer starseal, ideal for promotional & an Obese side panel machine for adult diapers. Recently, Sanimac has concentrated its efforts on the development of new forming technology, combining the best expertise, the latest technology & know-how of our specialised sister companies, as Cellulose mill with new features like cellulose roll unwinders, diverters, flow systems and as usual double infeed for splicing, temperature control, carbide teeth rotor of different thickness; drum forming for high finishing definition and accuracy thanks to the use of new materials and a new technology of forming chamber with multi-channels system; and RDC with new pad transfer with double core compressor and conveyors.
For the future, the company has in progress the construction of an economic underpad machine, the construction of a prototype machine for a new disposable product and the development of a new recycling system for cellulose and sap.
Spoolex Company is organized in different departments to better respond to the web converting industry different needs. The Machinery department designs, manufactures and sells its well-known Calemard slitters/rewinders and spooling lines. The Ultrasonics department and its Decoup+ brand, is the specialist of ultrasonic continuous cutting and sealing solutions. Then the Industrial rollers department manufactures and sales under Roll Concept, the well-known Alveotube technical rollers and winding cores.
The Calemard brand is the world leader solutions manufacturer for spooling efficiently sensitive nonwovens for diaper and femcare productions. In 1998, based on its 10 year experience and around 70 slitting and spooling lines installed in various industries, Calemard presented its first spooling line dedicated to the ADL (Acquisition & Distribution Layer) producers. Today, with more than 150 spooling heads delivered worldwide, the Calemard brand is now recognized as a leader in providing proven and efficient solutions for spooling sensitive nonwovens.
The Pegase spooling line has been developed to produce jumbo rolls. The spooling technology has been engineered to respond to the baby diapers and femcare producers to maximize their productivity on their production lines with the use of high capacity spools of very sensitive material. These jumbo spools hold 12-40 km of material which means at least a strip 10 times longer than slit pancakes/reels and high savings for diaper and femcare producers: less diaper to reject, less manpower for material handling, higher productivity.
Calemard self-traverse technology guarantees to produce at high speed (600 m/min) spools of a strip with no stress, no tension, no elongation and no twist. Our spooling lines use state of the art technical solutions: accurate web regulation tension, very precise web guiding and strip conveying, double shaft unwinder for mother rolls loading down time, ergonomic ultrasonic splicing unit, and various options for production quality improvement (metal detector, strip width measurement, data collection, dust collection, fast cutter positioning). The company also now propose also options for productivity improvement and specially a new spool automatic unloading system. This Calemard engineered new solution allows to increase by 28% the productivity (should be adjusted for each specific factory organization), to ease significantly handling operations and to reduce drastically costs.
In addition, Calemard range of wide slitter-rewinders offers at the same time state of the art technologies, a high reliability and versatility, combined with easy handling. Calemard equipment processes various kinds of wide web into narrow strips to produce compact rolls with optimised product lengths.
Through the Decoup+ brand, the company also offers in the nonwoven field, ultrasonic splicing benches. The proven and accurate technology produces unequalled quality joins, without any color fading nor burns. Ergonomic and compact, these benches are available either for narrow webs as a module to be fitted on a machine, or for wide webs as a bench to be fitted on line. Spoolex is certified ISO 9001, ISO 14001 and OHSAS 18001.
Tectex - Automatec
Tectex - Automatec presents Phoenix-Tec. This is a new generation of needle punching machines with a lot of innovations against previous ranges. One of these is the elliptical system of needlebeams. This movement can accompany the fiber reducing the stretching of final product and less stressing needles. This technology was already developed many years but only perfected in last months. During this time the company has introduced many modifications to get a high performance to its machines. In addition, TecTex – Automatec has entered in a new business with his complete lines for Mineral Fiber. We are the first in the world that can offer complete line. Our business is in strong expansion, for this reason we decided to enter in this high quality production with our 50 years of needle looms history.
Tectex Needle Boards (TTNB)
TTNB is a new company born three years ago. The mother company decided to open this new business for needle boards, stripper plates and bad plates for all needle loom brands. At present we are the bigger worldwide company that make only this products, with 6 automatic mill machines for working all kind of boards and plates. Recently TTNB has bought a new measurement device we call KOBRA. This devise is patented by biggest scientific company in the world. KOBRA is an important investment for our higher precision on our finished product with a very (nearly zero) error and an instant 3D draw on computer. Moreover this is a portable device that it gives as possibility of measurement in all world.
Teknoweb Srl has developed Arvell, an innovative technology enabling converters to produce their own wet wipes substrates. The company was founded in Italy in 2004 by Piero Mandotti and Fabio Zampollo, who based their experience on a deep knowledge of the highly competitive disposable diaper market. They have been able to bring a revolutionary approach to the category through the introduction of their “trouble-free” production line concept.
Research and development are part of daily life at Teknoweb. The impetus for innovation comes both from customers, with the individual challenges they raise, and from Teknoweb’s desire to lead and inspire the market with new ideas.
In 2013 Teknoweb announced its entry into a new segment of the wipes business value chain: a breakthrough technology for producing a new wet wipes substrate, Arvell.
Arvell is an innovative material, based on proprietary technology, and is composed of a polypropylene filament combined with natural or artificial absorbent fibers. The Arvell technology has been designed to enable intimate blending of the two types of fibers, which are then assembled into a web by thermocalendering technology. The resulting web shows unsurpassed performance in terms of absorption as well as mechanical characteristics.
This revolutionary development has been possible thanks to the solid process and material knowledge available inside the Teknoweb organization. This capability grew through recent investments in R&D resources with the vision of becoming the Standard of Excellence in the area of process and material in the disposable segment. Arvell is far simpler when compared to conventional technology used for producing wipes substrates and gives the converter control of the entire production process from raw material through finished product.
Arvell is a completely “dry process,” not requiring the use of hydroentanglement for bonding/integrity and also not needing an oven to remove water, as is typical for other wipes substrates. These features make this material extremely appealing from the sustainability point of view, as desired by disposables producers and others. Interestingly, in addition to providing breakthrough performance and flexibility, thanks to the simplified manufacturing process, this material has a price target of 30% less than technologies such as spunlace.
For the Arvell development, Teknoweb has recently received the “Premio dei Premi”, a reward assigned by Confindustria, the Italian organization representing more than 142,000 enterprises and sponsored by the Italian Presidency of the Council of Ministers. The reward is assigned to nine companies presenting the best innovation.
Thanks to Arvell, Teknoweb will continue to lead the wipes market via ultimate converting technology.
This innovation enables customers to always respond to the ever-shifting market trends, open opportunities in new market and product segments, simplify the production process and save money and energy.
Texnology is a 15-year old company near Venice, Italy that emerged out of a nonwoven producing company. Texnology manufactures needle looms, web drafters, profiling systems, turnkey lines and is a world leader in high speed cross lapper systems. Their latest development is the groundbreaking new needle loom technology Ellittica. The new Texnology needle loom is a complete reinvention of needling and was presented for the first time in North America at the IDEA 2013 show in Miami Beach in April. With the new generation of Texnology Ellittica needle looms, Texnology has completed the range of machines for the production of technical nonwoven fabrics.
The Ellittica needle loom is a new internationally patented system capable of operating as a vertical or elliptical loom, steplessly adjustable. This makes it the only needle loom in the world with this feature, without sliding rods, rocker arms, opposite connection rods or linkages! In the new needle loom, the connecting rods join and merge in a single gear shaft connected to only one motor. Therefore, the needle board movement is not only vertical but also horizontal.
Elliptical needling has clear advantages. On conventional needling, at every punch, the material is stopped. In order to pull the web through the needle loom, you need to draft it. With the new Ellittica needle loom, it is possible to needle without draft. The speed of the web material in the needling zone is increased by the needles pushing and pulling the web forward. This is a revolution for needling light materials, airlaid products, or any kind of products with low tensile features.
Due to the elliptical movement, products weighing as low as 25 grams (0.9 oz.) per square meter can be successfully needled, as well as high loft products of higher weights at various process speeds. Hence, the customer is able to manufacture finished products for any budget and performance required.
The Texnology technology center is located near Venice, Italy and is available for trials with the customer’s material and a personal demonstration of this revolutionary technology.
Texnology’s representative in the U.S. is Zimmer America Corporation in Spartanburg, South Carolina. Zimmer America’s nonwoven division is a sales and service supplier of nonwoven machinery for the North American market. With the integration of ATM into Zimmer America in 2009, Zimmer’s expertise in the nonwoven industry dates back for more than 30 years and includes modern, highly developed equipment made to meet the highest customer expectations in technology and safety.
The available equipment ranges from fiber bale opening, weigh blending, feeding, carding and webdrafting to crosslapping, thermobonding and various types of needle looms. Zimmer’s European partners are known for their state of the art equipment.
Zimmer’s partner Bematic manufactures nonwoven equipment, including blending, opening and mixing machines, carding machines and dynamic air lay as well as web forming machinery.
Tokuden has added a cooling function to Induction Heated Jacket Roll. By incorporating a mist-generation device in a conventional Induction Heated Jacket Roll, it is possible to rapidly lower the surface temperature of the roll. In cases where processing and operating conditions differ throughout a day, shortening the time lost between varying the conditions improves productivity. In addition, when production stops at the end of a shift, overall business efficiency is improved.
From a signal through the thermocouple embedded in the roll surface, mist volume and power to the induction coil are automatically controlled; whenever there is an external heat input, the roll surface temperature is precisely maintained. In fine film processing operations where slight variations in heating and cooling are called for, this characteristic contributes to improving the quality of the product.
Based on mist cooling, quick temperature descents in a conventional IHJR are achieved. The cooling-down period from a roll surface temperature of 200° to 100° has been shortened by about 75%. Various small lots can be produced more efficiently by decreasing the time lost, thereby improving equipment utilization rates.
Mist cooling, in addition to the independent uniform temperature effect of the Jacket Roll, maintains the roll surface temperature even more precisely. In the fine film processing of resins and so on, when the roll is heated by contact with a web of higher temperature, the external heat input can be controlled with mild cooling by the mist, and in conjunction with the electromagnetic induction heating of the induction coil, the setpoint temperature is precisely maintained.
Because it is a Jacket Roll that doesn’t use any energy source besides electricity, both energy conservation and a clean working environment are offered. Moreover, maintenance is simpler than with the heating-cooling rolls that flood the roll with liquids. With no large peripheral equipment required, initial costs and running costs are low, leading to overall excellent cost performance.
Headquartered in Youngsville, NC, Xerium is a global manufacturer of forming belts, aprons, fabrics, SMART Rolls, and bowed rolls for nonwovens manufacturers.
Xerium’s on-going commitments to continuous improvement and innovative new products are focused on helping our customers further reduce operating costs, improve product quality, and get greater value from their assets. With our innovative products, manufacturers are able to run their machines longer and faster with less maintenance, fewer interruptions, and reduced energy consumption even in the most demanding applications.
Huycon (patent pending) Belt Technology. Specifically designed to produce top quality webs, from robust industrial, to highly critical medical and hygiene applications. The range for spunlaid technology is completed by designs for carding and airlaid lines. Also available with V2 seam technology for rapid seaming and marking freeness.
Huybond Fabric Technology. Engineered for the most demanding hydroentangled and spunlaced applications, Huybond fabrics deliver superior performance with excellent contamination resistance, high fiber support, web uniformity, and excellent mechanical stability.
Huycoil Assembled Fabric Technology. This high performance spiral fabric technology is ideal for machines producing airlaid, as well as certain long-term nonwovens producers where elevated temperatures are used. Huycoil fabrics are manufactured from a variety of polymers to match machine requirements including; high molecular weight polyester,
SMART Technology. Embedded sensors in roll covers provide real-time nip profile data across the machine width as well as nip-width in the machine direction. SMART Rolls can also simultaneously measure nip profiles in multiple adjacent nips.
VARI-BOW Advanced Roll Technology. Bowed roll technology from Stowe and Mount Hope provides precise control of materials produced in web or sheet form. Vari-bow is ideal for machines where different weights, grades and types of materials are produced.
Machinery & Equipment Review
Major suppliers of nonwovens machinery offer new technological developments.
By Compiled by Nonwovens Industry staff
Published August 7, 2013