05.31.17
INDEX17 was the largest ever, according to its organizers, nonwovens association EDANA and OrgExpo. Held April 4-7 at Palexpo in Geneva, Switzerland, the event featured 666 exhibitors who attracted 12,758 visitors, making it a true “global meeting point” for the nonwovens industry.
“With more exhibitors and visitors than ever, INDEX truly stands as the flagship exhibition of the nonwovens industry and a vital business development tool for industry players of all sizes,” says Martin Rapp of Glatfelter and chairman of EDANA.
Those in attendance could engage with a larger portion of the industry than ever before and avail of a wide variety of presentations, demonstrations and tutorials. Additionally, the sector seminars on transportation, medical and geotextile nonwoven products were popular throughout the exhibition, with several editions offering standing room only.
“Our industry has evolved to a great extent,” says Pierre Wiertz, general manager of EDANA. “Nonwovens and related materials are increasingly used in the automotive, filtration and construction sectors for example, illustrating how the sector offers innovative solutions for a wide range of purposes. This evolution was also reflected in the makeup of the visitors to this year’s show, with a wider range than ever before. The products and services they saw throughout the exhibition provide a snapshot of how our industry is developing—and it is a privilege to witness this first-hand and know that the success of our sector is in safe hands. Looking ahead to INDEX20, we are reminded of how both resilient and innovative the nonwovens industry really is.”
EDANA announced at INDEX that INDEX 2020 will again be held at PalExpo March 31,-April 3, 2020. EDANA’s board chose the Geneva location after considering proposals seeking to host the event in a total of six European cities.
“In general, outstanding ideas were brought forward, with valid proposals to take INDEX20 to another high after the resounding successes of the 2014 edition and INDEX17, which is already now confirmed as the largest ever nonwovens exhibition.EDANA has chosen Palexpo because we trust the new Palexpo team to ensure continuity, innovation and competence” says Pieter Meijer, director of sales, McAirlaid’s and chairman of EDANA’s Exhibition Advisory Board.
Reifenhäuser Launches New Technology
Reifenhäuser launched its next generation Reicofil spunmelt technology at INDEX. The German technology provider announced it was commercializing Reicofil 5 technology, more than 15 years after introducing its Reicofil 4 line technology and more than three decades after first developing Reicofil technology for the nonwovens industry.
Markus Müller, sales director at Reicofil says: “Venturing into the market with a new technology after 15 successful years is always an exciting moment. For me personally the launch of RF5 is especially exciting because we are making a big step forward with the new performance data and the new and fascinating possibilities that arise from digitalization. RF5 enables our customers to produce nonwovens on the next quality and productivity level. And the best is: even customers with existing Reicofil lines will have the possibility to benefit from some of the new advantages. We are developing amazing upgrades for RF3 and RF4 lines.“
One of the highlights of RF5 is the significant reduction of failures within nonwovens. When running standard raw materials, hard pieces will be reduced by up to 90% in comparison to RF4 technology. By this Reicofil provides a solution for one of the major issues of contamination that exists in the industry. Producers running an RF4 line will be able to make use of this advantage by upgrading the line to RF4.5.
RF5 Technology also fulfills the market demand for finer and finer filaments: the technology can produce up to 20% smaller fiber diameters. Thereby titers lower than one denier are producible for the first time. Compared to the RF4s technology the same titers can be achieved with higher outputs or finer titers are feasible with the same outputs, but can provide for better uniformity, strength and softness.
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n terms of productivity the RF5 technology also raises the bar significantly: the output increases by up to 35%—to up to 270 kg/h per meter beam width for spunbond and to up to 70 kg/h per meter beam for meltblown. So, producers can run their lines at maximum speeds even for higher grammages.
The meltblown technology benefits from the increased output by a much wider process window, which raises the flexibility. Producers can decide now depending on their requirements whether to use the maximum output capacity and increase productivity by up to 35% or to produce 20% higher meltblown quality at the present throughput levels.
Looking at the line speed the new RF5 technology reaches the new peak value of 1200 meter per minute. As this value is the actual speed on the conveyor belt and not, as before, the speed at the winder, it can be fully utilized in production. Effectively producers can run their lines 30% faster than they could on RF4 lines.
When it comes to energy efficiency Reicofil lives up to its own claim of reducing the specific energy consumption with every new line generation. For the production of composite nonwovens RF5 saves up to 15% compared to RF4.
To further optimize the uptime, which had already reached a very high level with RF4 technology, Reicofil took another close look at maintenance time: Quench chambers and secondary air gaps can now be cleaned much faster. The result is decreased downtimes and increased productivity. In addition many of the new digital solutions have a positive effect on the uptime.
Jens Mager, responsible for digitalization at Reicofil, says: “With digitalization we strengthen all the existing advantages of the Reicofil technology such as quality, productivity and reliability. In the future our lines will become an expert on themselves and will guide customers much more than today through the production process. Our solution will help customers to avoid both process failures and human mistakes, it will help to identify and exploit unused potential, to raise reproducibility and to find the best possible machine set-up for high quality and productivity.”
Reicofil developed solutions for more intuitive operation, continuous process and quality monitoring, predictive maintenance, and detection of anomalies. For example, the line will provide its operators with productivity analyses, predict when a wear part is going to fail, warn the operator of drip formation before it occurs, and provide information to help solve the problem.
Jens Mager adds: “First solutions with great customer benefits are already developed. But digitalization still has huge potentials for innovation that we want to exploit together with our customers. We can react to individual requirements and problems now. That is a huge advantage of digitalization.”
Also at INDEX, Reicofil announced the Turkish nonwovens producer Gulsan had committed to purchased a new Reicofil 5 line with an annual capacity of 35,000 tons. The new line will be built in Turkey.
GDM Shows Off Machinery Upgrades
At INDEX, GDM promoted its complete product portfolio of baby diapers, adult open, lady and light incontinence lines, turnkey packaging solutions and its Option Zero program. With specific reference to medium-high speed manufacturing machines, GDM offers effective solutions responding to its customers’ needs in terms of flexibility and production performance.
Machines of note include the B8-W Grey, a GDM baby open diaper line that helps customers face production challenges through innovative Zero Time technologies, minimizing size change and raw materials setting adjustment time according to manufacturers’ specific needs.
Based on magnetic floating principles, GDM’s patented innovation “Linear Motion technology” is employed providing full chassis width regulation, eliminating hardware replacement and set-up. Within the Rear Wings application, thanks to its joined actions with the dynamic shaping unit, it is possible to produce up to four open baby diaper product sizes with no mechanical components replacement.
For the most flexible solution GDM has also developed E-cams that, installed on the final accelerator of Rear Wings application, manage the final pitch adjustment, minimize machine setting time without any mechanical regulation.
Meanwhile, B10-W Red is GDM’s best in class performance baby open diaper line, producing up to 1000 ppm with high efficiency and reliability results. Its new development handling extra thin cores allow an optimized product absorption thanks to the high core integrity. The machine is targeted for companies looking for market expansion thanks to its high productivity. A5-MR Red is designed to manufacture adult open products with rectangular panels that, thanks to the Zero Waste design, allow to minimize material waste and unitary product cost. Real panel lamination with elastic materials ensures product wearability and increased consumer’s comfort. GDM’s A5 technology ensures high product quality level and process control at a speed up to 500 ppm.
GDM also introduced an extended range of technological and product innovations, particularly focusing on discreet material application and gentle material handling, training pants evolution and waist band on topsheet at INDEX.
Berry Changes Name
Berry Plastics Group, Inc. used INDEX as a platform to announce its new name, Berry Global Group, Inc., which became effective April 13, 2017.
“Our business has transformed significantly since our name became Berry Plastics in 1983,” explains Tom Salmon, Berry’s chief executive officer. “Berry has evolved from one manufacturing facility in Evansville, Indiana, to over 130 facilities throughout the world. And our business has grown from less than $25 million in annual revenue in 1983 to now over $7 billion, reflecting the AEP acquisition.
“By changing our name to Berry Global we are portraying a more balanced view of who we are to our customers, our investors, and ourselves.”
Salmon adds, “Two critical components of Berry’s culture are continuous improvement and innovation. As such, we are ‘Always Advancing’ to improve the way we work and to improve the products and services we provide.
“If you look across all of our products, they have one element in common – they protect. They protect what people eat, drink, and use every day … they protect healthcare professionals and their patients … and they protect buildings, transportation, pipelines, and other infrastructure.”
Berry’s mission also encompasses advancing its facilities’ safety practices to protect its employees; advancing sustainability efforts to protect the environment; and, advancing the Company’s business strategies to protect the investments of its shareholders.
With the name change and new mission, the Company has also adopted a new logo and Values. The logo was developed with the company’s values in mind.
“Our Values serve as the cornerstone of Berry. The icon in the logo illustrates those four Values – Partnership, Excellence, Growth, and Safety,” says Salmon.
He adds, “These are exciting times and today is yet another milestone in Berry’s history. Our new branding not only references our legacy businesses and the strong foundation that they created, but also allows us to share the aspirations we have for the bright future that is before us.”
Rando, Ramina Form Alliance
At INDEX, machinery and equipment suppliers Rando Machine Corporation and Ramina officially announced a strategic alliance that will allow them to supply turnkey production lines to the nonwovens industry.
Rando, based in Macedon, NY, will supply airlaid web formation, fiber preparation, shredding/refiberizing machinery while Ramina, based in Grantorto, Italy, will provide ovens, calenders, winders, slitters, packaging and laminating lines.
“We have found that our product offerings are very complementary,” says Rando president and CEO Michael Flaherty. “Ramina offers great solutions for bonding and winding equipment for our fiber preparation and formation lines that require thermal bonding and other finishing equipment.”
Meanwhile, through this strategic alliance, Ramina is able to add Rando’s strong and proven airlaid brand with unique capabilities to its business opportunities.
“We are looking forward to this alliance to increase our presence in the U.S. market with a partner who has very strong technical capabilities across multiple, global industries,” says Graziano Ramina, CEO of Ramina.
The companies have already developed a history of working together on several successful line installations and expect this alliance to expand these efforts globally.
“Our alliance allows both Rando and Ramina to offer customers one single source,” Flaherty adds. “We know each other’s machinery and have learned how to integrate both lines efficiently. Through our experience together, we have established clear standards and processes that ensure our customers a smooth installation and commissioning experience.” Customers will be able to test both Rando and Ramina’s combined capabilities as Ramina’s thermobonding oven and winding equipment will be installed at Rando’s New York Research, Development and Technical Center this fall, allowing customers the opportunity to run trials and develop products on a complete line.
Fameccanica Unveils Developments at INDEX
Fameccanica Group is a leader in the development of machinery for manufacturing hygiene products, delivering custom solutions and anticipating needs in respect of sustainable development. The company presented its latest technologies at INDEX17.
Innovision Machine is a Fameccanica diaper machine concept based on FA-X P10, with excellent performance levels and high quality products for end users. “Innovision” is the name of an internal Fameccanica contest, based on selecting innovative ideas submitted by its employers. The project started in 2009 and every year the best ideas are awarded. The features of the machine provide new solutions for raw materials and innovative combinations of ultrasonic and thermo-bonding technologies. Together they contribute to reducing the environmental impacts and allow cost saving of €1.5 million ($1.6 million) per year, estimated for each baby diaper machine FA-X P10 - 1000 ppm. The seven features are:
Also at INDEX, Fameccanica discussed new improvements found in FA-X P10X, the new high speed baby pant machine. These include a cross-direction process which incorporates MHR ultrasonic multi-up side sealing. Thanks to the flexible manufacturing, now it is possible to switch elastic threads and side elastics films on the same machine. About the performance: the guaranteed production speed is 900 ppm or 350 m/min.
Meanwhile, Easylife is the new, original suite expressly created by Fameccanica and Microsoft to manage a complex plant in a very easy way. Control, security and saving are the main features of “The Simplicity Maker.” It combines cutting-edge applied manufacturing technology with the latest in digital innovation, creating a “company collaboration network” that facilitates the management of factories and manufacturing plants through the collection, exchange, distribution and use of ordered information, guaranteeing a significant advantage both in performance optimization and economic terms, allowing easy non-stop monitoring production plant performance every time, everywhere.
Automatic Cuff Defect System at Joa Booth
Curt G. Joa, Inc. recently received a patent for its automatic cuff defect correction system, the latest addition to its family of waste minimization technology.
First developed in 2007, Joa’s waste minimization technologies are rooted in TRIZ methodology, or the theory of inventive problem solving. These proprietary Joa technologies allow manufacturers to increase efficiency and reduce waste.
“The development of our waste stream management technologies has been a continuous effort over the last decade,” says Curt G. Joa, Inc. president Gene Kiela II. “We filed our first patent in this field in 2007. Since then, our continuous improvement initiatives allow us to claim that our machine platforms have the lowest ramp-up cost of any available hygiene converting equipment in the world.”
Joa’s newest waste minimization technology identifies, prevents and corrects defects in the cuff section of the product construction, including cuff folding and elastics. This responsive technology enables correction without stopping the machine, preventing rejected products associated with shut down and ramp up.
Joa’s waste minimization technologies also include:
At INDEX Jacob Holm launched SoftFlush Fast, its latest brand of dispersible substrate material for the flushable wipes market. SoftFlush Fast, which is made using proprietary technology on Jacob-Holm’s latest U.S.-based line in Candler, NC, offers the same dispersibility as premium toilet paper and the strength of a wet wipe. “SoftFlush Fast has really pushed the frontiers of what this new line can do and sets a new standard in flushability that to my knowledge has never before been met,” says CEO Martin Mikkelsen.
Also at INDEX, Jacob Holm was for the first time showcasing its new corporate identity to signify the completion of two major growth steps and further strengthen the position of its strong brand portfolio including Sontara, SoftFlush, Softlite and Softesse. With its new branding, the company is launching a new tag line “Magic meets Fabric.”
Between 2014 and today, Jacob Holm has successfully completed two major growth steps—the construction of its dispersible proprietary technology in North Carolina and the integration of the acquired division of DuPont – Sontara.
New Finishing Treatment from Omnova
Omnova Solutions launched the new Softwick SF20 finishing treatment at INDEX17. The new silicone-free finishing treatment enables producers of nonwovens substrates and makers of finished goods in hygiene, wipes and medical applications to achieve higher levels of comfort and improved fluid management.
“Softwick SF20 finishing treatment is a timely answer for a range of nonwovens trends including thinner, more discrete disposable undergarments, more absorbent and softer food service wipes, and added functionality and comfort in medical applications,” says Pablo León Escobar, global marketing director, Omnova Solutions. “By delivering advanced functionality without using silicone, fluoropolymers, or APEs, it also meets the market desire for more environmentally-preferred solutions.”
In addition to the new Softwick SF20 finishing treatment, Omnova will showcase its full portfolio of binders and finishing treatments for nonwovens, including Genflo, Sunbond, Sequapel, and Omnapel polymers, which enable a range of functional and aesthetic nonwovens properties for high-performance applications in global automotive, hygiene and wipes, filtration, and building material markets.
Spuntech Has New Ideas for Spunlace
Traditionally, spunlace is one or two blends of fibers formed into a continuous fabric, but Spuntech, a global leader in hydroentangled spunlace nonwovens, is now offering a new-three layer innovation in Geneva.
Produced through a proprietary integration of different carding technologies, Spuntech’s unique new TriLayer web can consist of a scrubby top layer, an absorbent inner layer and a smooth hydrophobic bottom. Applications for TriLayer include hygiene, beauty care, medical, baby, household and industrial fabrics. TriLayer fabric weights range from 50 to 300gsm and can blend natural and synthetic materials into 12 unique variations allowing the different fiber mixes to create distinct fabric layers.
Spuntech has also developed a range of sustainable offerings including nonwovens producted from recycled, recyclable, biodegradable and compostable sources. Spuntech’s production process is chemical-free using only purified water that has been recycled within its state of the art environmentally friendly and energy efficient facilities.
Odor Management Solutions on Display
Henkel showcased its odor management solutions at INDEX. The odor of a product or packaging significantly shapes the perception of its quality and wellness attributes. And, as consumers have become ever more sensitive to odor issues in hygiene products, the hygiene industry is quickly seeking components and solutions to address this market need. When it comes to adhesives, Henkel has developed specific approaches and a dedicated portfolio of products for odor management.
As a leading supplier of adhesives to the international hygiene industry, Henkel is emphasizing its focus on enhancing the consumer experience in health, wellness and comfort of hygiene products. The field of odor in hygiene products, in particular, is covered extensively.
Henkel’s Personal Hygiene team has commercialized a new technology unique to the hygiene industry, providing significant improvement for reducing the malodor in the finished product. This is key for shaping the consumer’s perception of the quality and wellness of the finished hygiene product. Henkel discussed a range of products that reduce the typical odors experienced in each region of the world: Technomelt DM COOL 110 ON, Technomelt DM COOL 1106 UV ON, Technomelt DM 757 ON, Technomelt DM 234 ON and Technomelt DF 695 ON.
In addition, Henkel has developed several new products using specific raw materials that significantly neutralize the experienced malodor during manufacturing, while maintaining the excellent bonding performance required by consumers in the final product. An example for one of these products is Technomelt DM 2420, specifically developed for construction applications in the hygiene industry. “Besides delivering a fully sprayable polyolefin technology with an outstanding cost-in-use proposition, Technomelt DM 2420 is also characterized by its ability to manage overall odor,” Jeff Shope, global vice president, Personal Hygiene Marketing, explains. “By trusting in the products capability to address odor, consumers can have more assurance in their hygiene product – boosting their confidence and providing additional freedom in their everyday lives.”
With Technomelt DM 4500, Henkel has developed yet another product that reduces malodor and provides the best possible comfort and fit at the same time. “Based on a proprietary polymer, Technomelt DM 4500 delivers an excellent spray pattern with all applicators. It helps improve process speed and has exceptional thermal stability,” Shope says.
New SAP Generation
Evonik launched a new generation of superabsorbents at INDEX.
With FAVORmax, Evonik has developed its next generation of superabsorbents with unique properties to make baby diapers and incontinence products even more absorbent and reliable. With the new superabsorbents from Evonik, hygiene product manufacturers can further improve the performance of their products to meet even better the requirements of diverse customer groups.
Just a few grams of the new FAVORmax high-performance superabsorbent materials ensure fast absorption of large amounts of fluids and lasting dryness. This is made possible through a finely balanced combination of the superabsorbents’ key performance parameters, which are adapted to the specific design of the absorbent core. As a result of the optimal interaction with other components of the hygiene product, its performance is improved even more.
FAVORmax 1000 has been designed for use in ultra-thin diapers. Thanks to the unique profile of the perfectly aligned parameters, the new superabsorbent has improved the fluid dynamics within the absorbent core and has reduced the risk of leakage. This is achieved through greater fluid retention while retaining constant absorption under pressure, combined with permeability and higher absorption speed.
For use in absorbent cores with a high percentage of fluff pulp, the superabsorbents of the FAVORmax 2000 product family feature high absorption capacity even when under pressure, high retention and absorption speed. When used in incontinence products, the material ensures that large quantities of fluids are absorbed quickly and securely.
Bostik Presented Smart@work Technology
Adhesives supplier Bostik used interactive display stations at INDEX to showcase its Smart@work adhesive technology and expertise.
Fit, absorption, softness and odor are key dynamics to manufacturers of disposable hygiene products and Bostik demonstrated how adhesive products and process expertise can help disposable hygiene producers create better products more efficiently.
Suominen Introduces New Substrate
Suominen has launched Genesis Pro All Purpose, a brand-new nonwoven substrate for general purpose professional wiping. The development of Genesis Pro leverages Suominen’s wetlaid heritage and builds on the company’s new investments in wetlaid production technology.
Suominen claims Genesis Pro All Purpose is the strongest professional wipes material on the market, both wet and dry. It has the highest thickness, unbeatable absorption capacity and also the fastest absorption. Genesis Pro All Purpose in lighter weights outperforms its heavier competitors in key performance areas.
“This is not a typical nonwoven product but a typical Suominen product since it was engineered with the end-user in mind,” says Eileen Calder, product manager for Workplace applications at Suominen. “That is why Genesis Pro All Purpose delivers results with speed and ease in everyday cleaning tasks that are critical to business performance. The professional employees may just focus on getting the job done, confident that the wipes do not let them down, nor in light neither heavy-duty tasks.”
Genesis Pro All Purpose is available in a range of basis weights. Even in its lightest form, AP5000, Genesis Pro is the strongest material available which, thanks to its unmatched absorbency speed, makes it perfect for mopping up spills, cleaning down surfaces and keeping workspaces hazard-free. For the toughest tasks Genesis Pro AP8000 offers protection for the end-user when dealing with metal shavings, as well as oil, grease and cleaning solvents. It is the thickest nonwoven material for professional wipes, even when wet, making it a superior replacement for shop towels and rags.
Genesis Pro All Purpose is available globally and is part of the Suominen@work nonwoven product offering.
ITW Dynatec Offers Adhesive Application Innovations
ITW Dynatec, a global leader of adhesive application solutions for industries such as disposable hygiene products, automotives, packaging and other strategic business segments, showcased its DynaControl V6 Modular Control Platform, Ultra Link High Performance Applicator Platform and Velocity Metered Applicator Platform at INDEX. Brand owners, converters and manufacturers alike can experience these newest adhesive application innovations from ITW Dynatec and learn about their unique advantages and benefits.
These new equipment offerings demonstrate ITW Dynatec’s progressive approach to exploring new ideas and new business models to lead the market with original concepts and true added value. When combined with ITW Dynatec’s uncompromising dedication to its customers, they generate client partnerships that achieve substantial advantages over competitors through innovative technologies and the highest quality solutions.
Dynacontrol V6 is Dynatec’s next generation modular control platform, delivering greater productivity and reducing waste while lowering total cost of ownership by as much as 50%. The new DynaControl V6 is fully compatible with DynaControl V5, making it easy to migrate. The new software offers a variety of options to minimize productivity. The platform features simplified operator training and maintenance and uses the same spare parts as all other Dynatec units.
Meanwhile, the Ultra Linkplatform is the latest in a series of hotmelt adhesive and fluid applicators from ITW Dynatec and is designed to provide the highest level of pattern accuracy.
H.B. Fuller Meets Soft Trend
H.B. Fuller, a leading global adhesives provider with more than 40 years of technology leadership in the hygiene market, has met this global “soft” trend with two innovative solutions. Full-Care 5188, a high performance constructive adhesive, and Full-Care 8008, a premium performance elastic attachment adhesive, both have been tailor-made for more difficult substrates like super soft nonwovens. Both products, which offer low odor and light color, were on display at INDEX.
Kirstin Hedin, Global Marketing Director, Hygiene, H.B. Fuller, comments, “We tirelessly pursue answers and innovative ways to solve customer challenges. We wanted to create adhesive solutions that offered customers a seamless balance of super softness and excellent bonding properties. Full-Care 5188 and Full-Care 8008 achieve this balance.”
Full-Care 5188 and Full-Care 8008 offer proven superior performance on difficult substrates, such as super soft nonwovens, compared to standard adhesives. In terms of elastic, Full-Care 8008 provides best in class creep resistance.
Hedin concludes, “Our innovative products that continue to emerge in the market give customers the capacity and assurance to bring differential innovation to the disposable diaper and fem-care market.”
Beaulieu to Offer Meralux Fibers
Beaulieu Fibres International, a polyolefin fiber supplier, unveiled a pioneering new fiber-platform at INDEX as well as detailed insights into the future-focused hygiene products arising from its on-going investment in innovation and manufacturing capabilities.
Beginning in May, Meralux fibers will be added to the Meraklon product portfolio. First test results show that nonwovens made with the new Meralux fiber combinations have a higher loft/bulk. Meralux’s coverage is unique and provides nonwovens with a very closed surface, without containing additives like TiO2. With the higher loft and unique coverage, softness will be provided by the choice of raw materials. Equipped with all these features, Meralux allows basis weight reductions without losing performance.
In line with the further diversification of its products, Beaulieu Fibres International is set to produce short cut fibers for hygiene applications as of summer 2017. These will be available in cut lengths of 3-24mm in polypropylene (PP) mono and bico. To add to its new products for 2017, the Meraklon portfolio will expand further with the launch of new polyester (PET) core bico fibers. They will come on stream with Meraklon’s new state-of-the-art, long line at the company’s site in Terni, Italy. The €30 million investment to extend production capacity is currently underway and is scheduled to commence operations during this year.
Petra Bohle-Stricker, global sales director of hygiene, Beaulieu Fibres International, comments: “Beaulieu Fibres International is continuing to strengthen its position as a global supplier for polyolefin fibers. Investment in fibers production is an important driver for ensuring we meet future challenges and customers’ needs. In the four years since Meraklon’s takeover, Beaulieu Fibres International has successfully adapted it to the level required to be a leading market player. We have broadened the portfolio significantly to better serve the future market needs and are continually innovating to ensure we go the extra mile for the nonwovens industry.”
Innovations in Wipes on Display at Sandler’s Booth
At INDEX, Sandler presented several innovations for the wipes market. sawatex classy silk and sawatex lace-o-paque add a certain something to cosmetics applications and baby care applications while sawatex classy silk features excellent cleaning efficiency and above all an extraordinarily silky touch, rendering every use into a wellness-treatment. sawatex lace-o-paque offers softness and high bulk, providing gentle care for little explorers. The new embossing design “square” captures the attention of another market segment: Small squares render the substrate bulkier and increase its surface—for even better results in cleaning applications. With a “double action“ substrate for cleaning wipes, Sandler gets to grips with stubborn dirt. The multi-layer nonwoven features a coarser side for efficient cleaning and a smooth side for gentle polishing and grooming the cleaned surface.
All of these nonwoven substrates receive their particular properties from the special fiber blends used. Selected raw materials bring about not only excellent functionality, but also enable a reduction of the basis weights—for less raw material usage. Embossed motifs for visual individualization of wipes are also more detailed.
Sandler’s range of nonwovens for disinfection wipes now encompasses an additional highlight: Colored product variants in various pastel shades enable a visual differentiation of various application areas.
“Stretch your limits“—is the motto with Sandler’s collection for elastic applications. Manufacturers are provided with an assembly kit of materials featuring different degrees of elongation to choose the ideal nonwoven for their respective use. From “basic stretch“ to “premium stretch plus“ it holds the right product for everyone. These nonwovens support an optimum fit, thus increasing wearing comfort.
Comfort is also the watchword when it comes to innovations for topsheets: A new design for these materials visually provides a sense of lightness in daily hygiene: Subtle butterflies make this product a veritable eye-catcher.
A new “canyon” structure for topsheet materials combines visual differentiation and optimized functionality: This special surface renders the topsheet bulkier and even softer; increases stability, and simultaneously supports fluid handling.
Sandler’s new nonwovens for intake layers take this function one step further. They quickly transport fluid away from the body and efficiently distribute it onto the entire surface, for optimal utilization of the core’s storage capacity. The nonwovens also function as an interim storage layer, preventing rewet and protecting the skin. Sandler designs these nonwovens in line with one’s product requirements: Softness and flexibility can be individually adjusted; embossing designs provide visual highlights.
TWE Offers Amphibia
TWE Group showcased its three-layer nonwoven material Amphibia at INDEX. This special structure significantly reduces the size of the core in hygiene products in terms of both weight and volume. This helps create, for example, much thinner baby diapers, incontinence articles and fem care products.
According to TWE, this patented technology has revolutionized the world of disposable products. Unlike most hygiene products that feature a mix of pulp and superabsorbent materials with an acquisition and distribution layer, Amphibia combines an ADL with the absorbing all-in-one core. This results in improved distribution as well as better performance of absorbing time and distribution of the liquid.
Packaging Innovation from Amotek
At INDEX, Amotek presented a packaging machine that packages various nonwoven products in film bags. The Amotek R 168 is suitable for feminine hygiene products, diapers, cotton pads and other products and can even be used for multipacks, depending on the pack size.
The packages can be supplied with holes, reinforcements, handle areas, zippers and other features. Different bag shapes can also be managed. The machine produces on its own, the bags from a folded film, and offers the option to produce bags from a foil roll. The machine is easy to operate and can reach speeds up to 50 packages per minute.
Also on display will be the Amotek IS81, which was developed specifically for diaper packages. The servo-controlled system works with a patented Sierem stacker. The diapers are taken from the converters with an inline rate of up to 800 pieces per minute and packaged at a rate of up to 55 film bags per minute. The system can also be enhanced through the addition of various modules. These include the ability to produce packages with small counts or to load diapers manually into the packaging process.
Dow Launches New Meltblown fibers
The Dow Packaging and Specialty Plastics business of The Dow Chemical Company will present its brand new Aspun MB Meltblown Fiber Resins and Pouchug sensory packaging technology at INDEX. These technolgoies provide converters and brand owners unparalleled choices for improved comfort and softness in nonwoven applications.
Aspun MB Meltblown fiber resins address the difficult challenges of increasing softness and comfort while maintaining strength, durability, and processing efficiency in fabrics such as bico-SMS nonwovens. As a result, this new, patent-pending family of polyethylene (PE) resins produced using Insite Technology from Dow is an ideal solution for nonwovens in hygiene, medical and filtration products.
“The quest for softer, more cloth-like nonwoven materials is a key driver in the ongoing development of health and hygiene products that combine comfortable fit, outstanding performance, and efficient processing,” comments Greg Bunker, senior global marketing director. “With Aspun MB Meltblown Fiber Resins we are offering customers and brand owners something really different, an exclusive option for softer nonwovens.”
In nonwoven packaging applications, Pouchug sensory packaging technology enables the replacement of the external layer of a laminate with a soft, cloth-like nonwoven substrate to elevate packaging to a new level. It was developed using Dow’s Pack Studio capabilities.
In other news, Dow has announced the addition of a new Hills Inc. fiber line at the Pack Studios facility in Freeport, TX. By enabling close collaboration between converters, material science professionals from Dow, and equipment specialists from Hills, this state-of-the-art fiber line allows Dow customers to screen new solutions and prove concept of work with a set of tools that will help continue innovating fiber solutions for hygiene, filtration, and other nonwoven applications.
“With more exhibitors and visitors than ever, INDEX truly stands as the flagship exhibition of the nonwovens industry and a vital business development tool for industry players of all sizes,” says Martin Rapp of Glatfelter and chairman of EDANA.
Those in attendance could engage with a larger portion of the industry than ever before and avail of a wide variety of presentations, demonstrations and tutorials. Additionally, the sector seminars on transportation, medical and geotextile nonwoven products were popular throughout the exhibition, with several editions offering standing room only.
“Our industry has evolved to a great extent,” says Pierre Wiertz, general manager of EDANA. “Nonwovens and related materials are increasingly used in the automotive, filtration and construction sectors for example, illustrating how the sector offers innovative solutions for a wide range of purposes. This evolution was also reflected in the makeup of the visitors to this year’s show, with a wider range than ever before. The products and services they saw throughout the exhibition provide a snapshot of how our industry is developing—and it is a privilege to witness this first-hand and know that the success of our sector is in safe hands. Looking ahead to INDEX20, we are reminded of how both resilient and innovative the nonwovens industry really is.”
EDANA announced at INDEX that INDEX 2020 will again be held at PalExpo March 31,-April 3, 2020. EDANA’s board chose the Geneva location after considering proposals seeking to host the event in a total of six European cities.
“In general, outstanding ideas were brought forward, with valid proposals to take INDEX20 to another high after the resounding successes of the 2014 edition and INDEX17, which is already now confirmed as the largest ever nonwovens exhibition.EDANA has chosen Palexpo because we trust the new Palexpo team to ensure continuity, innovation and competence” says Pieter Meijer, director of sales, McAirlaid’s and chairman of EDANA’s Exhibition Advisory Board.
Reifenhäuser Launches New Technology
Reifenhäuser launched its next generation Reicofil spunmelt technology at INDEX. The German technology provider announced it was commercializing Reicofil 5 technology, more than 15 years after introducing its Reicofil 4 line technology and more than three decades after first developing Reicofil technology for the nonwovens industry.
Markus Müller, sales director at Reicofil says: “Venturing into the market with a new technology after 15 successful years is always an exciting moment. For me personally the launch of RF5 is especially exciting because we are making a big step forward with the new performance data and the new and fascinating possibilities that arise from digitalization. RF5 enables our customers to produce nonwovens on the next quality and productivity level. And the best is: even customers with existing Reicofil lines will have the possibility to benefit from some of the new advantages. We are developing amazing upgrades for RF3 and RF4 lines.“
One of the highlights of RF5 is the significant reduction of failures within nonwovens. When running standard raw materials, hard pieces will be reduced by up to 90% in comparison to RF4 technology. By this Reicofil provides a solution for one of the major issues of contamination that exists in the industry. Producers running an RF4 line will be able to make use of this advantage by upgrading the line to RF4.5.
RF5 Technology also fulfills the market demand for finer and finer filaments: the technology can produce up to 20% smaller fiber diameters. Thereby titers lower than one denier are producible for the first time. Compared to the RF4s technology the same titers can be achieved with higher outputs or finer titers are feasible with the same outputs, but can provide for better uniformity, strength and softness.
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n terms of productivity the RF5 technology also raises the bar significantly: the output increases by up to 35%—to up to 270 kg/h per meter beam width for spunbond and to up to 70 kg/h per meter beam for meltblown. So, producers can run their lines at maximum speeds even for higher grammages.
The meltblown technology benefits from the increased output by a much wider process window, which raises the flexibility. Producers can decide now depending on their requirements whether to use the maximum output capacity and increase productivity by up to 35% or to produce 20% higher meltblown quality at the present throughput levels.
Looking at the line speed the new RF5 technology reaches the new peak value of 1200 meter per minute. As this value is the actual speed on the conveyor belt and not, as before, the speed at the winder, it can be fully utilized in production. Effectively producers can run their lines 30% faster than they could on RF4 lines.
When it comes to energy efficiency Reicofil lives up to its own claim of reducing the specific energy consumption with every new line generation. For the production of composite nonwovens RF5 saves up to 15% compared to RF4.
To further optimize the uptime, which had already reached a very high level with RF4 technology, Reicofil took another close look at maintenance time: Quench chambers and secondary air gaps can now be cleaned much faster. The result is decreased downtimes and increased productivity. In addition many of the new digital solutions have a positive effect on the uptime.
Jens Mager, responsible for digitalization at Reicofil, says: “With digitalization we strengthen all the existing advantages of the Reicofil technology such as quality, productivity and reliability. In the future our lines will become an expert on themselves and will guide customers much more than today through the production process. Our solution will help customers to avoid both process failures and human mistakes, it will help to identify and exploit unused potential, to raise reproducibility and to find the best possible machine set-up for high quality and productivity.”
Reicofil developed solutions for more intuitive operation, continuous process and quality monitoring, predictive maintenance, and detection of anomalies. For example, the line will provide its operators with productivity analyses, predict when a wear part is going to fail, warn the operator of drip formation before it occurs, and provide information to help solve the problem.
Jens Mager adds: “First solutions with great customer benefits are already developed. But digitalization still has huge potentials for innovation that we want to exploit together with our customers. We can react to individual requirements and problems now. That is a huge advantage of digitalization.”
Also at INDEX, Reicofil announced the Turkish nonwovens producer Gulsan had committed to purchased a new Reicofil 5 line with an annual capacity of 35,000 tons. The new line will be built in Turkey.
GDM Shows Off Machinery Upgrades
At INDEX, GDM promoted its complete product portfolio of baby diapers, adult open, lady and light incontinence lines, turnkey packaging solutions and its Option Zero program. With specific reference to medium-high speed manufacturing machines, GDM offers effective solutions responding to its customers’ needs in terms of flexibility and production performance.
Machines of note include the B8-W Grey, a GDM baby open diaper line that helps customers face production challenges through innovative Zero Time technologies, minimizing size change and raw materials setting adjustment time according to manufacturers’ specific needs.
Based on magnetic floating principles, GDM’s patented innovation “Linear Motion technology” is employed providing full chassis width regulation, eliminating hardware replacement and set-up. Within the Rear Wings application, thanks to its joined actions with the dynamic shaping unit, it is possible to produce up to four open baby diaper product sizes with no mechanical components replacement.
For the most flexible solution GDM has also developed E-cams that, installed on the final accelerator of Rear Wings application, manage the final pitch adjustment, minimize machine setting time without any mechanical regulation.
Meanwhile, B10-W Red is GDM’s best in class performance baby open diaper line, producing up to 1000 ppm with high efficiency and reliability results. Its new development handling extra thin cores allow an optimized product absorption thanks to the high core integrity. The machine is targeted for companies looking for market expansion thanks to its high productivity. A5-MR Red is designed to manufacture adult open products with rectangular panels that, thanks to the Zero Waste design, allow to minimize material waste and unitary product cost. Real panel lamination with elastic materials ensures product wearability and increased consumer’s comfort. GDM’s A5 technology ensures high product quality level and process control at a speed up to 500 ppm.
GDM also introduced an extended range of technological and product innovations, particularly focusing on discreet material application and gentle material handling, training pants evolution and waist band on topsheet at INDEX.
Berry Changes Name
Berry Plastics Group, Inc. used INDEX as a platform to announce its new name, Berry Global Group, Inc., which became effective April 13, 2017.
“Our business has transformed significantly since our name became Berry Plastics in 1983,” explains Tom Salmon, Berry’s chief executive officer. “Berry has evolved from one manufacturing facility in Evansville, Indiana, to over 130 facilities throughout the world. And our business has grown from less than $25 million in annual revenue in 1983 to now over $7 billion, reflecting the AEP acquisition.
“By changing our name to Berry Global we are portraying a more balanced view of who we are to our customers, our investors, and ourselves.”
Salmon adds, “Two critical components of Berry’s culture are continuous improvement and innovation. As such, we are ‘Always Advancing’ to improve the way we work and to improve the products and services we provide.
“If you look across all of our products, they have one element in common – they protect. They protect what people eat, drink, and use every day … they protect healthcare professionals and their patients … and they protect buildings, transportation, pipelines, and other infrastructure.”
Berry’s mission also encompasses advancing its facilities’ safety practices to protect its employees; advancing sustainability efforts to protect the environment; and, advancing the Company’s business strategies to protect the investments of its shareholders.
With the name change and new mission, the Company has also adopted a new logo and Values. The logo was developed with the company’s values in mind.
“Our Values serve as the cornerstone of Berry. The icon in the logo illustrates those four Values – Partnership, Excellence, Growth, and Safety,” says Salmon.
He adds, “These are exciting times and today is yet another milestone in Berry’s history. Our new branding not only references our legacy businesses and the strong foundation that they created, but also allows us to share the aspirations we have for the bright future that is before us.”
Rando, Ramina Form Alliance
At INDEX, machinery and equipment suppliers Rando Machine Corporation and Ramina officially announced a strategic alliance that will allow them to supply turnkey production lines to the nonwovens industry.
Rando, based in Macedon, NY, will supply airlaid web formation, fiber preparation, shredding/refiberizing machinery while Ramina, based in Grantorto, Italy, will provide ovens, calenders, winders, slitters, packaging and laminating lines.
“We have found that our product offerings are very complementary,” says Rando president and CEO Michael Flaherty. “Ramina offers great solutions for bonding and winding equipment for our fiber preparation and formation lines that require thermal bonding and other finishing equipment.”
Meanwhile, through this strategic alliance, Ramina is able to add Rando’s strong and proven airlaid brand with unique capabilities to its business opportunities.
“We are looking forward to this alliance to increase our presence in the U.S. market with a partner who has very strong technical capabilities across multiple, global industries,” says Graziano Ramina, CEO of Ramina.
The companies have already developed a history of working together on several successful line installations and expect this alliance to expand these efforts globally.
“Our alliance allows both Rando and Ramina to offer customers one single source,” Flaherty adds. “We know each other’s machinery and have learned how to integrate both lines efficiently. Through our experience together, we have established clear standards and processes that ensure our customers a smooth installation and commissioning experience.” Customers will be able to test both Rando and Ramina’s combined capabilities as Ramina’s thermobonding oven and winding equipment will be installed at Rando’s New York Research, Development and Technical Center this fall, allowing customers the opportunity to run trials and develop products on a complete line.
Fameccanica Unveils Developments at INDEX
Fameccanica Group is a leader in the development of machinery for manufacturing hygiene products, delivering custom solutions and anticipating needs in respect of sustainable development. The company presented its latest technologies at INDEX17.
Innovision Machine is a Fameccanica diaper machine concept based on FA-X P10, with excellent performance levels and high quality products for end users. “Innovision” is the name of an internal Fameccanica contest, based on selecting innovative ideas submitted by its employers. The project started in 2009 and every year the best ideas are awarded. The features of the machine provide new solutions for raw materials and innovative combinations of ultrasonic and thermo-bonding technologies. Together they contribute to reducing the environmental impacts and allow cost saving of €1.5 million ($1.6 million) per year, estimated for each baby diaper machine FA-X P10 - 1000 ppm. The seven features are:
- Glueless Cuffs: The thermosealing cuff elastics application replaces the standard version with glue. This is a new process solution based on a thermo-mechanical bonding system to fix cuff elastics between two layers of nonwoven in intermittent mode. In terms of tension-elongation, the Glueless solution offers the same results as standard application with glue.
- Fameccanica Lamination System (FLS) with integrated tape: The in-line application of tape between two FLS nonwoven layers, replaces the standard FLS version, achieving a stronger bonding of the tape inside the back ear. The results are: raw material saving, more breathability, more resilience: the same elasticity performances for different cycles of use, no contamination with glue.
- Glueless frontal tape: The in-line creation of frontal tape on nonwoven backsheet with ultrasonic bonding replaces the standard version with glue. Fameccanica Glueless frontal tape structure is the combination between the nonwoven backsheet and a nonwoven acting as a loop through ultrasonic sealing. The results are: raw material saving, more softness, pattern customization, no contamination with glue.
- Intermittent SAP & X-THRUE Core Control System: The targeted SAP application on the absorbent core replaces the standard homogeneous distribution. The X-THRUE controls SAP presence and its position in the core, and returns the signal to machine PLC to ensure an accurate application. Main uses and advantages are: on line monitoring of the pad quality; retrofit control and dosing accuracy; easy integration with standard industrial logic components.
- Glueless Leg Elastics and Narrow Poly: The Thermosealing System for the application of leg elastics replaces the standard process with glue. Leg elastics are fixed between two layers of nonwoven in intermittent mode. This solution is combined with the reduction in the width of poly backsheet. In terms of tension-elongation, the Glueless solution offers the same results as standard application with glue.
- Glueless ADL: The Ultrasonic System for ADL application replaces the standard process with glue. ADL lamination on topsheet with ultrasonic sealing, gives a better appearance to the topsheet, which becomes softer and nicer. The new solution offers the same or even improved performances in terms of acquisition time and wetback, if compared with the standard product version.
- Fluffless Core: The Innovative Thin Core replaces the standard SAP & fluff core. Fameccanica fluffless core solution is a version with SAP entrapped inside the ADL. The main outcomes: excellent results in terms of acquisition time; new SAP immobilization; breakthrough integrity.
Also at INDEX, Fameccanica discussed new improvements found in FA-X P10X, the new high speed baby pant machine. These include a cross-direction process which incorporates MHR ultrasonic multi-up side sealing. Thanks to the flexible manufacturing, now it is possible to switch elastic threads and side elastics films on the same machine. About the performance: the guaranteed production speed is 900 ppm or 350 m/min.
Meanwhile, Easylife is the new, original suite expressly created by Fameccanica and Microsoft to manage a complex plant in a very easy way. Control, security and saving are the main features of “The Simplicity Maker.” It combines cutting-edge applied manufacturing technology with the latest in digital innovation, creating a “company collaboration network” that facilitates the management of factories and manufacturing plants through the collection, exchange, distribution and use of ordered information, guaranteeing a significant advantage both in performance optimization and economic terms, allowing easy non-stop monitoring production plant performance every time, everywhere.
Automatic Cuff Defect System at Joa Booth
Curt G. Joa, Inc. recently received a patent for its automatic cuff defect correction system, the latest addition to its family of waste minimization technology.
First developed in 2007, Joa’s waste minimization technologies are rooted in TRIZ methodology, or the theory of inventive problem solving. These proprietary Joa technologies allow manufacturers to increase efficiency and reduce waste.
“The development of our waste stream management technologies has been a continuous effort over the last decade,” says Curt G. Joa, Inc. president Gene Kiela II. “We filed our first patent in this field in 2007. Since then, our continuous improvement initiatives allow us to claim that our machine platforms have the lowest ramp-up cost of any available hygiene converting equipment in the world.”
Joa’s newest waste minimization technology identifies, prevents and corrects defects in the cuff section of the product construction, including cuff folding and elastics. This responsive technology enables correction without stopping the machine, preventing rejected products associated with shut down and ramp up.
Joa’s waste minimization technologies also include:
- Individually rejecting spliced materials before combined to form an end product
- ADL Inversion correction
- Stretch material auto rethread
- Low-cost ramp-up waste, through process stream management
At INDEX Jacob Holm launched SoftFlush Fast, its latest brand of dispersible substrate material for the flushable wipes market. SoftFlush Fast, which is made using proprietary technology on Jacob-Holm’s latest U.S.-based line in Candler, NC, offers the same dispersibility as premium toilet paper and the strength of a wet wipe. “SoftFlush Fast has really pushed the frontiers of what this new line can do and sets a new standard in flushability that to my knowledge has never before been met,” says CEO Martin Mikkelsen.
Also at INDEX, Jacob Holm was for the first time showcasing its new corporate identity to signify the completion of two major growth steps and further strengthen the position of its strong brand portfolio including Sontara, SoftFlush, Softlite and Softesse. With its new branding, the company is launching a new tag line “Magic meets Fabric.”
Between 2014 and today, Jacob Holm has successfully completed two major growth steps—the construction of its dispersible proprietary technology in North Carolina and the integration of the acquired division of DuPont – Sontara.
New Finishing Treatment from Omnova
Omnova Solutions launched the new Softwick SF20 finishing treatment at INDEX17. The new silicone-free finishing treatment enables producers of nonwovens substrates and makers of finished goods in hygiene, wipes and medical applications to achieve higher levels of comfort and improved fluid management.
“Softwick SF20 finishing treatment is a timely answer for a range of nonwovens trends including thinner, more discrete disposable undergarments, more absorbent and softer food service wipes, and added functionality and comfort in medical applications,” says Pablo León Escobar, global marketing director, Omnova Solutions. “By delivering advanced functionality without using silicone, fluoropolymers, or APEs, it also meets the market desire for more environmentally-preferred solutions.”
In addition to the new Softwick SF20 finishing treatment, Omnova will showcase its full portfolio of binders and finishing treatments for nonwovens, including Genflo, Sunbond, Sequapel, and Omnapel polymers, which enable a range of functional and aesthetic nonwovens properties for high-performance applications in global automotive, hygiene and wipes, filtration, and building material markets.
Spuntech Has New Ideas for Spunlace
Traditionally, spunlace is one or two blends of fibers formed into a continuous fabric, but Spuntech, a global leader in hydroentangled spunlace nonwovens, is now offering a new-three layer innovation in Geneva.
Produced through a proprietary integration of different carding technologies, Spuntech’s unique new TriLayer web can consist of a scrubby top layer, an absorbent inner layer and a smooth hydrophobic bottom. Applications for TriLayer include hygiene, beauty care, medical, baby, household and industrial fabrics. TriLayer fabric weights range from 50 to 300gsm and can blend natural and synthetic materials into 12 unique variations allowing the different fiber mixes to create distinct fabric layers.
Spuntech has also developed a range of sustainable offerings including nonwovens producted from recycled, recyclable, biodegradable and compostable sources. Spuntech’s production process is chemical-free using only purified water that has been recycled within its state of the art environmentally friendly and energy efficient facilities.
Odor Management Solutions on Display
Henkel showcased its odor management solutions at INDEX. The odor of a product or packaging significantly shapes the perception of its quality and wellness attributes. And, as consumers have become ever more sensitive to odor issues in hygiene products, the hygiene industry is quickly seeking components and solutions to address this market need. When it comes to adhesives, Henkel has developed specific approaches and a dedicated portfolio of products for odor management.
As a leading supplier of adhesives to the international hygiene industry, Henkel is emphasizing its focus on enhancing the consumer experience in health, wellness and comfort of hygiene products. The field of odor in hygiene products, in particular, is covered extensively.
Henkel’s Personal Hygiene team has commercialized a new technology unique to the hygiene industry, providing significant improvement for reducing the malodor in the finished product. This is key for shaping the consumer’s perception of the quality and wellness of the finished hygiene product. Henkel discussed a range of products that reduce the typical odors experienced in each region of the world: Technomelt DM COOL 110 ON, Technomelt DM COOL 1106 UV ON, Technomelt DM 757 ON, Technomelt DM 234 ON and Technomelt DF 695 ON.
In addition, Henkel has developed several new products using specific raw materials that significantly neutralize the experienced malodor during manufacturing, while maintaining the excellent bonding performance required by consumers in the final product. An example for one of these products is Technomelt DM 2420, specifically developed for construction applications in the hygiene industry. “Besides delivering a fully sprayable polyolefin technology with an outstanding cost-in-use proposition, Technomelt DM 2420 is also characterized by its ability to manage overall odor,” Jeff Shope, global vice president, Personal Hygiene Marketing, explains. “By trusting in the products capability to address odor, consumers can have more assurance in their hygiene product – boosting their confidence and providing additional freedom in their everyday lives.”
With Technomelt DM 4500, Henkel has developed yet another product that reduces malodor and provides the best possible comfort and fit at the same time. “Based on a proprietary polymer, Technomelt DM 4500 delivers an excellent spray pattern with all applicators. It helps improve process speed and has exceptional thermal stability,” Shope says.
New SAP Generation
Evonik launched a new generation of superabsorbents at INDEX.
With FAVORmax, Evonik has developed its next generation of superabsorbents with unique properties to make baby diapers and incontinence products even more absorbent and reliable. With the new superabsorbents from Evonik, hygiene product manufacturers can further improve the performance of their products to meet even better the requirements of diverse customer groups.
Just a few grams of the new FAVORmax high-performance superabsorbent materials ensure fast absorption of large amounts of fluids and lasting dryness. This is made possible through a finely balanced combination of the superabsorbents’ key performance parameters, which are adapted to the specific design of the absorbent core. As a result of the optimal interaction with other components of the hygiene product, its performance is improved even more.
FAVORmax 1000 has been designed for use in ultra-thin diapers. Thanks to the unique profile of the perfectly aligned parameters, the new superabsorbent has improved the fluid dynamics within the absorbent core and has reduced the risk of leakage. This is achieved through greater fluid retention while retaining constant absorption under pressure, combined with permeability and higher absorption speed.
For use in absorbent cores with a high percentage of fluff pulp, the superabsorbents of the FAVORmax 2000 product family feature high absorption capacity even when under pressure, high retention and absorption speed. When used in incontinence products, the material ensures that large quantities of fluids are absorbed quickly and securely.
Bostik Presented Smart@work Technology
Adhesives supplier Bostik used interactive display stations at INDEX to showcase its Smart@work adhesive technology and expertise.
Fit, absorption, softness and odor are key dynamics to manufacturers of disposable hygiene products and Bostik demonstrated how adhesive products and process expertise can help disposable hygiene producers create better products more efficiently.
Suominen Introduces New Substrate
Suominen has launched Genesis Pro All Purpose, a brand-new nonwoven substrate for general purpose professional wiping. The development of Genesis Pro leverages Suominen’s wetlaid heritage and builds on the company’s new investments in wetlaid production technology.
Suominen claims Genesis Pro All Purpose is the strongest professional wipes material on the market, both wet and dry. It has the highest thickness, unbeatable absorption capacity and also the fastest absorption. Genesis Pro All Purpose in lighter weights outperforms its heavier competitors in key performance areas.
“This is not a typical nonwoven product but a typical Suominen product since it was engineered with the end-user in mind,” says Eileen Calder, product manager for Workplace applications at Suominen. “That is why Genesis Pro All Purpose delivers results with speed and ease in everyday cleaning tasks that are critical to business performance. The professional employees may just focus on getting the job done, confident that the wipes do not let them down, nor in light neither heavy-duty tasks.”
Genesis Pro All Purpose is available in a range of basis weights. Even in its lightest form, AP5000, Genesis Pro is the strongest material available which, thanks to its unmatched absorbency speed, makes it perfect for mopping up spills, cleaning down surfaces and keeping workspaces hazard-free. For the toughest tasks Genesis Pro AP8000 offers protection for the end-user when dealing with metal shavings, as well as oil, grease and cleaning solvents. It is the thickest nonwoven material for professional wipes, even when wet, making it a superior replacement for shop towels and rags.
Genesis Pro All Purpose is available globally and is part of the Suominen@work nonwoven product offering.
ITW Dynatec Offers Adhesive Application Innovations
ITW Dynatec, a global leader of adhesive application solutions for industries such as disposable hygiene products, automotives, packaging and other strategic business segments, showcased its DynaControl V6 Modular Control Platform, Ultra Link High Performance Applicator Platform and Velocity Metered Applicator Platform at INDEX. Brand owners, converters and manufacturers alike can experience these newest adhesive application innovations from ITW Dynatec and learn about their unique advantages and benefits.
These new equipment offerings demonstrate ITW Dynatec’s progressive approach to exploring new ideas and new business models to lead the market with original concepts and true added value. When combined with ITW Dynatec’s uncompromising dedication to its customers, they generate client partnerships that achieve substantial advantages over competitors through innovative technologies and the highest quality solutions.
Dynacontrol V6 is Dynatec’s next generation modular control platform, delivering greater productivity and reducing waste while lowering total cost of ownership by as much as 50%. The new DynaControl V6 is fully compatible with DynaControl V5, making it easy to migrate. The new software offers a variety of options to minimize productivity. The platform features simplified operator training and maintenance and uses the same spare parts as all other Dynatec units.
Meanwhile, the Ultra Linkplatform is the latest in a series of hotmelt adhesive and fluid applicators from ITW Dynatec and is designed to provide the highest level of pattern accuracy.
H.B. Fuller Meets Soft Trend
H.B. Fuller, a leading global adhesives provider with more than 40 years of technology leadership in the hygiene market, has met this global “soft” trend with two innovative solutions. Full-Care 5188, a high performance constructive adhesive, and Full-Care 8008, a premium performance elastic attachment adhesive, both have been tailor-made for more difficult substrates like super soft nonwovens. Both products, which offer low odor and light color, were on display at INDEX.
Kirstin Hedin, Global Marketing Director, Hygiene, H.B. Fuller, comments, “We tirelessly pursue answers and innovative ways to solve customer challenges. We wanted to create adhesive solutions that offered customers a seamless balance of super softness and excellent bonding properties. Full-Care 5188 and Full-Care 8008 achieve this balance.”
Full-Care 5188 and Full-Care 8008 offer proven superior performance on difficult substrates, such as super soft nonwovens, compared to standard adhesives. In terms of elastic, Full-Care 8008 provides best in class creep resistance.
Hedin concludes, “Our innovative products that continue to emerge in the market give customers the capacity and assurance to bring differential innovation to the disposable diaper and fem-care market.”
Beaulieu to Offer Meralux Fibers
Beaulieu Fibres International, a polyolefin fiber supplier, unveiled a pioneering new fiber-platform at INDEX as well as detailed insights into the future-focused hygiene products arising from its on-going investment in innovation and manufacturing capabilities.
Beginning in May, Meralux fibers will be added to the Meraklon product portfolio. First test results show that nonwovens made with the new Meralux fiber combinations have a higher loft/bulk. Meralux’s coverage is unique and provides nonwovens with a very closed surface, without containing additives like TiO2. With the higher loft and unique coverage, softness will be provided by the choice of raw materials. Equipped with all these features, Meralux allows basis weight reductions without losing performance.
In line with the further diversification of its products, Beaulieu Fibres International is set to produce short cut fibers for hygiene applications as of summer 2017. These will be available in cut lengths of 3-24mm in polypropylene (PP) mono and bico. To add to its new products for 2017, the Meraklon portfolio will expand further with the launch of new polyester (PET) core bico fibers. They will come on stream with Meraklon’s new state-of-the-art, long line at the company’s site in Terni, Italy. The €30 million investment to extend production capacity is currently underway and is scheduled to commence operations during this year.
Petra Bohle-Stricker, global sales director of hygiene, Beaulieu Fibres International, comments: “Beaulieu Fibres International is continuing to strengthen its position as a global supplier for polyolefin fibers. Investment in fibers production is an important driver for ensuring we meet future challenges and customers’ needs. In the four years since Meraklon’s takeover, Beaulieu Fibres International has successfully adapted it to the level required to be a leading market player. We have broadened the portfolio significantly to better serve the future market needs and are continually innovating to ensure we go the extra mile for the nonwovens industry.”
Innovations in Wipes on Display at Sandler’s Booth
At INDEX, Sandler presented several innovations for the wipes market. sawatex classy silk and sawatex lace-o-paque add a certain something to cosmetics applications and baby care applications while sawatex classy silk features excellent cleaning efficiency and above all an extraordinarily silky touch, rendering every use into a wellness-treatment. sawatex lace-o-paque offers softness and high bulk, providing gentle care for little explorers. The new embossing design “square” captures the attention of another market segment: Small squares render the substrate bulkier and increase its surface—for even better results in cleaning applications. With a “double action“ substrate for cleaning wipes, Sandler gets to grips with stubborn dirt. The multi-layer nonwoven features a coarser side for efficient cleaning and a smooth side for gentle polishing and grooming the cleaned surface.
All of these nonwoven substrates receive their particular properties from the special fiber blends used. Selected raw materials bring about not only excellent functionality, but also enable a reduction of the basis weights—for less raw material usage. Embossed motifs for visual individualization of wipes are also more detailed.
Sandler’s range of nonwovens for disinfection wipes now encompasses an additional highlight: Colored product variants in various pastel shades enable a visual differentiation of various application areas.
“Stretch your limits“—is the motto with Sandler’s collection for elastic applications. Manufacturers are provided with an assembly kit of materials featuring different degrees of elongation to choose the ideal nonwoven for their respective use. From “basic stretch“ to “premium stretch plus“ it holds the right product for everyone. These nonwovens support an optimum fit, thus increasing wearing comfort.
Comfort is also the watchword when it comes to innovations for topsheets: A new design for these materials visually provides a sense of lightness in daily hygiene: Subtle butterflies make this product a veritable eye-catcher.
A new “canyon” structure for topsheet materials combines visual differentiation and optimized functionality: This special surface renders the topsheet bulkier and even softer; increases stability, and simultaneously supports fluid handling.
Sandler’s new nonwovens for intake layers take this function one step further. They quickly transport fluid away from the body and efficiently distribute it onto the entire surface, for optimal utilization of the core’s storage capacity. The nonwovens also function as an interim storage layer, preventing rewet and protecting the skin. Sandler designs these nonwovens in line with one’s product requirements: Softness and flexibility can be individually adjusted; embossing designs provide visual highlights.
TWE Offers Amphibia
TWE Group showcased its three-layer nonwoven material Amphibia at INDEX. This special structure significantly reduces the size of the core in hygiene products in terms of both weight and volume. This helps create, for example, much thinner baby diapers, incontinence articles and fem care products.
According to TWE, this patented technology has revolutionized the world of disposable products. Unlike most hygiene products that feature a mix of pulp and superabsorbent materials with an acquisition and distribution layer, Amphibia combines an ADL with the absorbing all-in-one core. This results in improved distribution as well as better performance of absorbing time and distribution of the liquid.
Packaging Innovation from Amotek
At INDEX, Amotek presented a packaging machine that packages various nonwoven products in film bags. The Amotek R 168 is suitable for feminine hygiene products, diapers, cotton pads and other products and can even be used for multipacks, depending on the pack size.
The packages can be supplied with holes, reinforcements, handle areas, zippers and other features. Different bag shapes can also be managed. The machine produces on its own, the bags from a folded film, and offers the option to produce bags from a foil roll. The machine is easy to operate and can reach speeds up to 50 packages per minute.
Also on display will be the Amotek IS81, which was developed specifically for diaper packages. The servo-controlled system works with a patented Sierem stacker. The diapers are taken from the converters with an inline rate of up to 800 pieces per minute and packaged at a rate of up to 55 film bags per minute. The system can also be enhanced through the addition of various modules. These include the ability to produce packages with small counts or to load diapers manually into the packaging process.
Dow Launches New Meltblown fibers
The Dow Packaging and Specialty Plastics business of The Dow Chemical Company will present its brand new Aspun MB Meltblown Fiber Resins and Pouchug sensory packaging technology at INDEX. These technolgoies provide converters and brand owners unparalleled choices for improved comfort and softness in nonwoven applications.
Aspun MB Meltblown fiber resins address the difficult challenges of increasing softness and comfort while maintaining strength, durability, and processing efficiency in fabrics such as bico-SMS nonwovens. As a result, this new, patent-pending family of polyethylene (PE) resins produced using Insite Technology from Dow is an ideal solution for nonwovens in hygiene, medical and filtration products.
“The quest for softer, more cloth-like nonwoven materials is a key driver in the ongoing development of health and hygiene products that combine comfortable fit, outstanding performance, and efficient processing,” comments Greg Bunker, senior global marketing director. “With Aspun MB Meltblown Fiber Resins we are offering customers and brand owners something really different, an exclusive option for softer nonwovens.”
In nonwoven packaging applications, Pouchug sensory packaging technology enables the replacement of the external layer of a laminate with a soft, cloth-like nonwoven substrate to elevate packaging to a new level. It was developed using Dow’s Pack Studio capabilities.
In other news, Dow has announced the addition of a new Hills Inc. fiber line at the Pack Studios facility in Freeport, TX. By enabling close collaboration between converters, material science professionals from Dow, and equipment specialists from Hills, this state-of-the-art fiber line allows Dow customers to screen new solutions and prove concept of work with a set of tools that will help continue innovating fiber solutions for hygiene, filtration, and other nonwoven applications.
