08.05.19
Themed ‘Innovating the World of Textiles’, the 18th edition of ITMA concluded successfully in Barcelona, Spain, at the end of June.
The global textile and garment manufacturing industry converged at ITMA 2019, chalking up new records for the exhibition, which has been held every four years since 1951. It featured many exciting new product launches and innovative technologies and products, including those that leverage the Internet of Things, by 1717 exhibitors from 45 countries.
CEMATEX, the European Committee of Textile Machinery Manufacturers, and owner of ITMA and ITMA Asia, reported that the industry support from visitors and exhibitors was tremendous, resulting in record-breaking number of exhibitors since its inception.
Fritz P. Mayer, president of CEMATEX, says, “The digital transformation of the textile and garment manufacturing value chain and sustainability concerns of the industry have driven up visitor interests in ITMA 2019. We had a strong turnout, despite trade tensions and poor business sentiments. Many of our exhibitors were pleasantly surprised with the large number of serious buyers attending the exhibition.”
ITMA 2019 attracted visitorship of over 105,000 from 137 countries. The top five countries where visitors came from were Spain (11%), Italy (10%), India (8%), Turkey and Germany (7%). They were followed by France, United States, Portugal, Brazil, Pakistan, China and the United Kingdom.
In addition, a number of ITMA and co-located events drew over 1000 delegates. Among the events were the ITMA-EDANA Nonwovens Forum, Textile Colourant and Chemical Leaders Forum, Better Cotton Initiative Seminar, European Digital Textile Conference, Tex-Summit Global, Planet Textiles, SAC & ZDHC Manufacturer Forum and Texmeeting by TEXFOR.
The next ITMA will be held in Fiera Milano, Milan, Italy, from June 8-14, 2023.
The following is a look at what some companies exhibited in Barcelona.
Andritz Showed Off Nonwovens Solutions
International technology Group Andritz presented its innovative nonwovens production and textile solutions at ITMA.
The presentation of a complete velours needleloom at Andritz’s booth was one of the highlights at the show. In combination with Augmented Reality (AR) content, the needleloom provides a detailed insight into the functionality of this key technology.
Andritz also introduced its latest needling technology for producing veloured felts, mainly for applications in the automotive industry. The long-lasting brush design combined with a needleloom for high production capacities ensure reduced production costs and a high return on investment for customers. With this full-size needleloom exhibit, realistic presentations were provided at many points of the machine using AR technology. Andritz enjoys high market confidence with its needlepunch systems and needlelooms as the core process technologies, especially in the segment for needleloom devices manufactured according to special customer requirements.
Andritz also showed the next generation of its cross-laying technology, the ProWin system. ProWin is a further development of ProDyn and ProWid, which have achieved a high level of acceptance on the market with around 200 systems installed. This technology improves the current weight-profiling options and increases the actual production capacity.
Archroma Launches New Products
Archroma launched at the recent ITMA exhibition its new Lurapret N5396 & N5392 liq, a water-based ultra-low VOC polyurethane (PU) polymer coating technology.
The innovation was developed in compliance with “The Archroma Way: safe, efficient, enhanced, it’s our nature”. The approach finds its origin in Archroma’s deep belief that it is possible to make the textile industry sustainable, economically and ecologically.
Coatings are used in the textile industry to achieve features such as waterproofness, flexibility, durability and UV resistance. With the growing demand for safer and more ecological products, water-based PU coatings are progressively prevailing as the preferred coating technology.
Lurapret N5396 & N5392 liq have been developed to provide textile manufacturers with an additional water-based option that delivers high performance to the coated fabrics of demanding applications, such as indoor and outdoor textiles, nonwovens and papers.
Initially developed for the chemical bonding and coating for backpack and other industrial products, Lurapret N5396 & N5392 liq also improve the mechanical properties of the treated material such as their tensile strength and scratch resistance.
The new products will be the core of Archroma’s Safe Seats system. The system, which combines Lurapret N5392 & N5396 liq with Archroma’s halogen-free Pekoflam STC p flame retardant, allows to create a halogen-free flame retardant coating system for synthetic leather upholstery.
Using Lurapret N5396 & N5392 liq together with Archroma’s Nuva N2155 & N4547 soil protection and release finishes, enables customers to achieve highest standards in water-repellence and waterproofness.
Lurapret N5396 & N5392 liq can be applied by impregnation, coating (paste or foam), and spray, and are compliant with the ZDHC and bluesign requirements.
Autefa Showcased Hydroentanglement Technology
At ITMA, Autefa Solutions Nonwovens Technology was focused on innovations in main process steps from web forming, web bonding and web finishing. Under the headline “Industry 4.0” customers gained an approach for the entire nonwoven production system covering all aspects of improving the performance of a production line during lifetime.
With the new hydroentanglement machine V-Jet FUTURA and the Square Drum Dryer SQ-V, Autefa Solutions has developed an advanced and unique technology with special focus on reducing energy consumption. Besides high energy efficiency, the new Hydroentanglement Machine V-Jet FUTURA offers highest throughputs, easy maintenance and long lasting V-Jet-technology components.
The new module based Airlay FUTURA K12 concept provides tailor-made line solutions. For customers looking for best web quality or highest productivity, Airlay FUTURA K 12 is available with different inlet, forming and delivery modules. Synthetic or natural fibers, heavy or low weight, bulky or dense, the Airlay FUTURA concept offers the right modules for a line upgrade. The Airlay FUTURA modules are mounted on high precision guiding lines. This easy and quick opening of the machine stands for fast cleaning, easy maintenance, easy inspection and extended access to all parts of the machine.
Autefa Solutions Service 4.0 covers all aspects of improving the performance of a production line during lifetime.
Beaulieu Announces New Pilot Line
At ITMA, Beaulieu Engineered Product’s announced a new, fully operational pilot line supporting R&D projects for industrial and hygiene applications. It will also support the development of innovative fibers for new markets and applications. Beaulieu Fibres International’s (BFI) pilot line answers increasing customer demand for co-developments. It is extremely flexible and can replicate any type of staple fiber spinning technology, using different type of polymers and additives, and different type of cross sections.
New high tenacity staple fibers capacity will be available from the end of 2019 at BFI’s Italian plant. BFI’s high tenacity fibers HT8 offer unique high tensile strength without compromising on elongation. The fibers provide opportunities to reduce geotextile system cost by maximizing machine efficiency and ensure desired performance at reduced weight - up to 15% compared with standard geotextile fibers.
New PET-core BICO staple fibers will bring loft to hygiene products. The fibers are available in a dtex range from 1,3-6,7dtex/40mm in both polymer-configurations PP/PET (Polypropylene / Polyethylene terephthalate) and PE/PET (Polyethylene / Polyethylene terephthalate). The specific use of PET in the core improves the resilience/loft of the nonwoven. The use of PE in the sheath provides softness as required in topsheets, for example, while the configuration with PP in the sheath answers the requirements for ultrasonic bonding. Fibers come in an antimony (Sb)-free version, as required by the latest hygiene safety regulations.
BFI’s new and unique polyolefin staple fiber UltraBond eliminates the need for latex or other chemical binders to consolidate nonwovens, contributing to a fully recyclable system. The award-winning innovation opens up a new path to create 100% PP needlepunched fabrics which meet the same performance requirements while reducing the end-of-life environmental impact. CO2 emissions are reduced by 35% over the full production process during fabrics’ production.
Following its pioneering introduction in mid-2018, Beaulieu Yarns is seeing interest increase in 2019 in its drop-in alternative for carpet manufacturers. EqoBalance yarns support the global goal of strong, immediate CO2 emission reduction, allowing a reduction of up to 75% of CO2 eq/kg compared to Beaulieu Yarns’ fossil-based products.
These Green Product Award winning yarns deliver the same quality and performance as the fossil-based equivalents, and enable carpet manufacturers to contribute to a sustainable future through less use of fossil resources and reduced greenhouse gas emissions. Beaulieu Yarns’ EqoBalance is the very first yarn certified by TÜV Süd as meeting the new REDcert standard on the “use of sustainable biomass for material purposes in the chemical industry.”
Brückner Highlighted Industry 4.0 Solutions
For 70 years, Brückner has been the worldwide partner for all companies which are drying, coating and finishing web-shaped materials: whether clothing fabrics, nonwovens, carpet, glass or coatings - the variety of materials to be processed has never been limited.
Today, it is no longer just a question of machines, but rather of automation and control systems. The topic of digitization and Industry 4.0 opens up completely new possibilities for increasing productivity, reducing the use of resources and improving quality. In addition, an increasing shortage of skilled workers can be addressed by more intelligent software.
Brückner has invested, developed and implemented a lot in this area in recent years:
Brückner has something new to offer in the field of multi-layer stenters. Multi-layer stenters are mostly used where little space is available. They are suitable for finishing woven or dimensionally stable knitted fabric, nonwovens, needlefelt, technical textiles or for the wool industry.
With the new Brückner POWER-FRAME VNE multi-layer stenter, only one machine operator is required, as the entry and the exit are on the same machine side. This applies both to the version with two and with six fabric passages.
The new VNE machine concept offers the highest possible power density on a small floor space or a long air flow section in a very confined space. The dryer itself is equipped with Brückner’s patented split-flow air circulation system and the alternating arrangement in each half compartment additionally ensures optimum and uniform air circulation and thermal treatment of the fabric.
Another advantage is the completely lubricant-free fabric transport chain of the multi-layer stenter, because in this version there is absolutely no oil in the dryer interior.
DiloGroup Showcased Complete Line
ITMA 2019 in Barcelona was a total success for DiloGroup. More than 6000 interested parties and customers from more than 80 countries visited the Dilo booth, which with a space of 1150 m2 was the largest booth in the nonwovens machinery sector.
The idea to again show a complete production line with fiber was met with great approval and appreciation. DiloGroup with its focus on complete production lines for the nonwovens industry, wanted to show the complete systems engineering and include the corresponding innovations and inventions. With customer requirements in mind, it can now pursue specific future development work and include these innovations in its standard portfolio. Interest in the new developments was evident, and visitors felt the enthusiasm of 50 DiloGroup employees at the exhibition.
In the technological order, starting with fiber preparation, the components for opening and blending from DiloTemafa attracted great interest. The special highlights of the improved bale opener series “Baltromix Pro” were shown by the design features for the operating assistance with the I4.0 components “Bale Timer”, cleaning control, better accessibility for maintenance and the “DI-LOWATT” system for energy savings in fiber transport. The proven carding willow for further opening and preblending was equipped with modified workers and separate drives to create the prerequisites for a good fine opening.
Another specialty is the fine opening stage installed over the material box of the new card feeder FRS-P where a high dosing accuracy is achieved in cross and longitudinal direction. A very even flock mat was a clear eye-catcher. Consequently, the high web quality at the VectorQuadroCard exit was a result of the high quality of synchronized fiber opening and web forming components which form a technological unit.
The revised HyperLayer NT for the presentation of the latest state-of-the-art highspeed precision layering technique showed new standards, which play an important role especially in hydroentanglement lines. In this application, it is important to achieve layering speeds up to 190 m/minute using sophisticated viscose fibers and a layering width of about 4 m while at the same time showing high layering precision in cross and longitudinal direction.
The FutureLine study “3D-Lofter” met with the greatest interest and broad approval. In this study individual web forming units can deposit fiber masses on freely programmable spots in longitudinal and cross direction thus saving overall fiber mass in applications such as deep moulded parts for the automotive interior. This ability reduces costs in production and operation. This was not the only convincing application, the prospect of a more even flock mat for direct cards and the aerodynamic web forming known as “IsoFeed” concept are further opportunities. The structuring of flat needlefelt floor coverings, which may be further processed with the DI-LOUR and DI-LOOP technology, may be another approach for this application, and a great potential is evident.
The high stitch distribution uniformity achieved by the new needle pattern “6000 X” in conjunction with the new Hyperpunch kinematics is able to reduce investment costs for numerous needlefelt production lines and to increase surface quality.
Finally and importantly, the visiting experts were able to meet “smart industry” in numerous examples on the Dilo booth where more transparency and control of the production process and the operating conditions can be realized with the aid of software, internet and Cloud. The time is here to offer operator guiding and assisting elements with new line configurations to more easily achieve production management.
Gneuss Offers PET Recycling Technology
Gneuss highlighted its innovative PET recycling process for the use of industrial and post-consumer waste in direct spinning.
The Gneuss Recycling Technology enables the processing of high-volume, industrial PET waste from fiber, nonwoven or film production, and from contaminated post-consumer bottle flakes. The recycling technology is based on the Gneuss Processing Unit (GPU) with MRS extruder, rotary filtration system and online viscometer with intelligent viscosity monitoring and control, optional combined with Gneuss’ JUMP reactor.
The first important processing stage, melt decontamination, takes place in the GPU. With its excellent devolatilization capacity, the MRS extruder can process PET waste with high residual moisture levels and/or contamination (such as spin finish oils) without the need for any pre-treatment of the waste. In the Multi Rotation Drum, multiple satellite screws produce a large melt surface and surface exchange rate, so that an optimum devolatilization and decontamination result can be achieved with conventional water ring vacuum pumps. All volatile impurities such as water and / or spinning oils are safely removed eliminating disturbances in the spinning process.
Solid impurities are subsequently filtered out by the melt filter. Rotary Filtration Systems operate continuously, process constant and automatically, and guarantee a particle-free melt thanks to finest filter elements with filter fineness down to below 20 µm.
With the Online Viscometer VIS, the melt viscosity is measured in real time and directly adjusted. Depending on the recycling process, the viscosity is specifically reduced by means of ethylene glycol injection or in a further step specifically increased in the IV boost system JUMP.
Subsequently, the polymer melt is merged with the main, virgin polymer melt flow either upstream or downstream of the finisher.
With this recycling technology, combining an MRS extruder with the optional JUMP reactor, industrial and post-consumer waste can be turned into a high-quality and directly usable melt in a very short time. Thanks to the enormous line flexibility, different PET qualities can be produced.
This recycling concept, which received an award for innovative performance last year, has convinced one of China’s largest fiber producers. The recycling concept for processing fiber waste into pellets will be implemented by the Chinese manufacturer before the end of this year. Then an MRS130 will process up to 900 kg/h of fiber waste (staple fiber and POY) into melt. All the spin finish oil and water and other volatiles will be taken out in the high efficient degassing section. There is a possibility for injecting additives into the MRS as well, so there is an optional adding of color (TiO2, carbon black …) as well as of other reactive additives. After the devolatilization in the MRS all solid particles will be filtered out by a RSFgenius175 equipped with 20 micron screens. The purified melt will be fed via a startup valve into the reactor for the IV lift. Alternatively, in this line set-up, there is an option to feed the melt directly (before the reactor) to a pelletizer to produce pellets with a lower IV.
Kelheim Showcased Specialty Fibers
After a large fire in October 2018, the long-established Bavarian fiber manufacturer Kelheim Fibres is currently rebuilding the heart of its viscose fiber production. In the process, the focus lies on modern state-of-the-art equipment and particularly on resource-saving and environmentally friendly production technology.
Kelheim’s viscose specialty fibers consist of 100% cellulose, a renewable raw material, and are therefore completely biodegradable. These fibers offer an eco-friendly alternative to mineral-oil-based fibers, in particular for end products - like many nonwovens or hygiene applications - intended for convenient one-time use.
Kelheim’s specialty fibers for this area include Galaxy, a viscose fiber for tampon production, as well as short cut fibers that have been specifically designed for processing in modern wetlaid plants. These fibers enable the manufacturing of completely plastic-free and even flushable wipes from 100% cellulose.
In textiles, too, consumers value natural materials. Kelheim’s range of specialty fibers for textile applications comprises spun-dyed fibers, as well as the renowned brand names Viloft and Viseta:
In yarns, the flat fiber Viloft creates small air pockets, that make the textile highly breathable and comfortable – an ideal fiber for warm, close-to-the-skin feel-good clothes.
Viseta is 50% finer than silk and gives clothes a flowing drape and a soft and naturally luxurious touch.
Spoolex Brands Exhibited
Spoolex has, through its worldwide-recognized brands Calemard, Decoup+ and Roll Concept, real expertise in slitting, rewinding/spooling, ultrasonic splicing and technical rollers.
Calemard, is the converting machinery division of Spoolex Group. Present since 1955 in a wide range of markets, Calemard has focused its activities on highly technical cutting applications. Always based on three modules (unwinding, slitting, winding), Calemard equipment is multi-purpose and can convert thick or thin materials into pads or spools of wide or narrow strips. Its technical and process expertise have allowed it to develop and equip machines with sensitive web tension control and guiding systems, to manage, depending on the product to be converted, high, low and even extremely low tension on the same machine. The result is compact rolls with consistent tension, clean and straight edges for easy use on the downstream product manufacturing process. In addition to its standard range of slitter-rewinders, with 40 Jumbo spooling lines in operation worldwide, the widest high speed spooling line for ADL in the world (mother roll width up to 1.5 m) and a fully automated Pegase 3 Spooling Cell and the top speed Pegase 4, Spoolex Group confirms the world leading position of its Calemard machinery brand in providing customized spooling solution for demanding productions with tension sensitive materials.
Decoup+, meanwhile, is a specialist in ultrasonic cutting and welding. Ultrasonic technology offers various advantages, especially in sun protection, clothing, ribbons, technical textile or packaging industries. This technology performs clean and soft edges, without fraying, overthickness, burning or yellowing, but also strong and regular weldings without any additional material such as glue, staples, rivet, etc. Ultrasonic can be used on any synthetic fabrics (with minimum synthetic fiber content), technical textiles, nonwovens, thermoplastics…in a word, on any “thermofusible product” (which melts under heat effect). Quick and aesthetic, ultrasonic technology allows a direct use of the final product. Present since 1975 on the market with a complete range of cutting and welding devices, Decoup+ has gained strong position worldwide. Compact and ergonomic, these devices can be used for any step of the production process: from looms, to stenter-frames or finishing operation machine, and of course, final make-up operations. The solutions developed by Decoup+ are part of an industrial range of ultrasonic equipment; they are proven solutions with different powers and are specifically adapted to continuous operations. These solutions are proposed as modular units to be mounted on existing lines, as adapted benches or as handheld units.
Roll Concept is the industrial rollers division of the group. For almost 30 years, it has designed and manufactured the well-known Alveotube product line used as industrial rollers, cylinders and winding cores/mandrels. Specially engineered to improve process performance and increase line speed on web handling and converting industry, its lightweight precision rollers and winding cores ensure to users easy installation, easy handling and durability. Indeed, it takes advantage of Calemard’s integrated engineering department. Roll Concept’s engineering team, used to design and to understand converting needs, is therefor able to develop the right roller: improving profiles and proposing the best coating and assembly to fully adapt the roller to specific application. Then, because they are made from an aluminum alveolar structure, its rollers are light and strong and represent the best compromise on the market between bending resistance and low inertia. Compared to an aluminum tube, Alveotube profile allows manufacturing rollers with reduced production costs and with lower inertia. As a result, its rollers provide the reduction of electrical power consumption when accelerating and a reduced load torque for idler rollers. Even more light than the Alveotube, Roll Concept designed a new carbon roll based on a patented solution.
TECHNOplants Highlighted Machinery Range
TECHNOplants is one of the fastest-growing suppliers of nonwovens machinery, serving the main nonwoven sectors with machines and turn-key plants of its own design and manufacture.
At ITMA Barcelona 2019, TECHNOplants presented its range of lines for the automotive, furniture and geosynthetics sectors.
Its MULTIline system for denim shoddy web formation, developed to meet the most stringent automotive requirements, guarantees a first-rate coefficient weight variation (CV) of less than 2% in both machine and cross-machine direction.
Automotive is also served by integrating its MULTIline Airlay system with a two-step powder distribution system for shoddy and glass fiber nonwovens, which combines an excellent distribution tolerance and an intimate mix of fiber and powder. A complete recirculation and suction system allows the recovery of all the bonding powder, without leakage.
TECHNOplants’ Airlay MULTIline can also manage synthetic fibers, coconut, kenaf and all shoddy fibers in a range from 80 gsm to 10,000 gsm.
The airlay MULTIline is available in seven different configurations to allow the maximum production flexibility; this allows TECHNOplants to meet also the strictest low-budget projects.
Its range of three thermal bonding ovens covers any kind of thermal bonding process and are designed for heavy duty, high thermal efficiency applications, thanks to heat recovery systems and an easy-maintenance design, which allows operators to open both sides of the machine to let them clean from both sides.
Its well-known automatic and semi-automatic end of lines complete TECHNOplants’ machinery range: in-line and off-line slitting, cross cutting and winders for light and heavy weights, soft and stiff materials, stacking machines for pads, packaging and palletizing solutions.
Texnology Showed Complete Needlepunch Line
Exhibiting a complete production line at ITMA 2019 in Barcelona was a great success for Texnology.
A complete needlepunching line - Blending and Carding by Bematic, Profiling Unit, Crosslapping, Webdrafting, Elliptical Needling machine, Scanning System and End of line (Winding system) - was showed on a floor space of 1000 m² and put into operation in only 15 days.
The fiber was processed during the demonstration time and the reliability of the machines was proved during the seven days of the show.
This line was the most complete ever showed at ITMA and attracted a large number of visitors from all over the world because of the machines’ efficiency, the product quality and the unique design that impressed those coming into the booth.
Texnology used this opportunity to show its technologies in the field of the nonwoven machineries.
Stirovelo is the new Texnology profiling unit. It is fed by the card at constant speed and density and in output it generates variable density at constant speed. This unit maintains the characteristics of the web before crosslapping and increases its speed.
The Bucefalo Speciale Crosslapper (3 x 5,5 mt lapping width) is characterized by high web infeed speeds and guarantees homogeneity of the web, the highest layering precision and elimination of any bottleneck.
The batt drafter is an important prerequisite for needling. Texnology batt drafter has five trio groups and it is made up of wired cylinders at progressive speed. This technology increases the line productivity of light products and reduces the drafts.
Ellittica is Texnology elliptical needlepunching machine. This machine has an extreme needle density (4000 n/lin.m.) and guarantees a reduction of the fiber transport per stroke. This means high resistance and best surface quality.
This line was designed for the production of different nonwovens in various application areas such as coverings, automotive linings, carpeting. Furthermore, we offer installations for the production of disposables, which are used in cosmetics, medicine, hygiene.
ITMA 2019 was also the forum to present the latest development by Texnology: Acqualoom. This machine has been designed for spunlace nonwovens. Acqualoom can reach every working width in accordance with the final product. In line with product and material, compaction and dewatering as well as the number and position of water beams are freely selectable to meet the customer’s individual product and material requirements. Acqualoom also allows efficient web bonding with a short bonding path.
Texnology has delivered several complete production lines to the nonwovens industry and has the know-how to design the best installation for the final product in accordance with the customer’s needs.
Truetzschler Offers Technologies for Sustainable Nonwovens
At ITMA, Truetzschler Group presented intelligent machine technologies, digital solutions and installations for sustainable nonwovens.
Cost pressure, personnel bottlenecks and fluctuating raw material qualities: These are some of the most pressing challenges in spinning preparation. At the same time, spinning preparation is decisive for the yarn’s quality. In order to meet these requirements, Truetzschler counts on state-of-the-art sensor technology and digital integration – and opens up a new chapter in carding technology: The new intelligent card TC 19i automatically and continuously optimizes the carding gap whose setting has a critical influence on quality and performance. With a precision not achievable by humans, the intelligent card permanently realizes even the narrowest carding gap setting of 3/1000 inch.
“This allows us to measurably improve our customers’ raw material utilization and productivity while achieving consistently high quality,” says Dr. Dirk Burger, CEO of the Truetzschler Group.
In addition, new cloud-based digital monitoring and management systems provide yarn manufacturers with transparency over all processes in the spinning mill. The My Wires app, for example, provides information on the status of clothings and service intervals and helps with the planning of reorders. Competent service for re-clothing can be provided immediately by Truetzschler Card Clothing (TCC).
“With the smart networking of machines as well as production and maintenance, we support customers in simplifying their entire spinning process,” explains Dr. Christof Soest, CTO. “This is why our digital platforms work not only for Truetzschler technology.”
The latest innovation in the blowroom offers more economy and quality as well: The Portal Bale Opener BO-P, with widths of 2900 mm or 3500 mm, allows significantly more bales to be placed side by side and processes them in parallel using two opening rolls. Thus, it results in significantly better blending and higher productions of up to 3,000 kg/h.
As a complete supplier for spinning preparation, Truetzschler is also breaking new ground in draw frames, the quality filters in the spinning mill. The autoleveller draw frame TD 10 automatically adjusts the perfect break draft for optimum sliver quality and realizes significant cost savings due to its compact design and energy-efficient suction system. Like the TC 19i and the BO-P, the TD 10 provides the operator-friendly T-LED remote display, which visualizes important machine and production information in a simple way.
Truetzschler Nonwovens also presented sustainable concepts tailored to individual customer needs. The focus is on technologies for the production of biodegradable light-weight webs from renewable raw materials. In addition to proven solutions for carded, spunlaced nonwovens made of 100% cotton or 100% viscose, Truetzschler Nonwovens has developed an alternative technology in cooperation with Voith: In a wet-on-wet process, the web is formed from cellulose-based short fibers suspended in water and then bonded by means of hydroentanglement. The sustainable, high-quality wipes and cleaning cloths that result from this process can be completely degraded by microorganisms in the environment after usage by the consumer.
The Man-Made Fibers division presented the new four-end BCF machine MO40, which is based on the proven M40 concept. The symmetrical design in combination with the lamellaless HPc texturing results in maximum yarn and bobbin qualities. As each spinning position produces four BCF ends simultaneously, the machine achieves high productivity at moderate speeds, which ensures a stable process. “Higher, faster, further is not always the solution,” emphasizes Dr. Lassad Nasri, CTO at Truetzschler Man-Made-Fibers, “as with the entire Truetzschler Group, individual customer requirements always have priority for us. We support our customers with complete installation concepts, services and know-how - from the product idea to new business models.”
In addition to the highlights from the Spinning, Nonwovens and Man-Made Fibers business units, the Truetzschler Group showcased the comprehensive services and high-performance clothings for cards and roller cards from TCC on 1400 m2. TCC completes its portfolio of special flat clothings with the MT 52, which demonstrates outstanding stability, particularly at high card productions in ring and rotor spinning. In addition, TCC has developed the new PRECISETOP flat clothing, which is essential for the intelligent self-optimization of the carding gap in the TC 19i. Thanks to the close cooperation between machine developers and clothing specialists at Truetzschler, customers benefit from tailor-made and compatible solutions along the entire value chain.
WEKO Presented Latest Systems
WEKO-Fluid-Application systems (WFA) are known for low add moisture management and softener solutions in textile industry. In technical textiles and nonwovens, WEKO apply diverse functions to surfaces with encapsulated ProTec system to create a safe working environment by using harmful substances.
The worldwide textile production is suffering from immense cost pressure and is driven by using high volumes of fresh water, energy and chemicals with comparatively slow production speeds. WEKO together with its partners Lilienweiss Textile Services, Textilchemie Dr. Petry and Archroma developed new processing concepts creating sustainable, cost-efficient dyeing and finishing processes.
Benefits for denim yarn dyeing include non-stop change over (topping); no tailing; raised product fastness; wide variety of colors and effects achievable; reduced reddish (indigo / sulfur dyeing); less number of dye bathes needed; stable and precise production; no generation of dye bath waste; reduction of energy costs thanks to short drying times and economical use of the application medium.
WEKO-NEO could be placed on any section of a slasher dyeing range. It means in the pre-treatment or preparation area, dyeing, wash off or after-treatment area. Also the number or applicators is unlimited. Use it for topping, bottoming, Color-DENIM, Black-DENIM, fixation, hydrogen peroxide or others.
Meanwhile, benefits in textile finishing include up to 80% reduced pick-up; no material contact (no stress); up to 50% less drying energy; raising line speed also on heavy textiles up to 270%; saving up to 70% water and waste; one or both side application; adjustable penetration level.
WEKO-NEO could be installed on the stenter frame entrance or exit. A wide range of applications could be done, for example fixation, resin and flat finish, luster or brilliance, grip modification, softener, tinting and over-dying.
The global textile and garment manufacturing industry converged at ITMA 2019, chalking up new records for the exhibition, which has been held every four years since 1951. It featured many exciting new product launches and innovative technologies and products, including those that leverage the Internet of Things, by 1717 exhibitors from 45 countries.
CEMATEX, the European Committee of Textile Machinery Manufacturers, and owner of ITMA and ITMA Asia, reported that the industry support from visitors and exhibitors was tremendous, resulting in record-breaking number of exhibitors since its inception.
Fritz P. Mayer, president of CEMATEX, says, “The digital transformation of the textile and garment manufacturing value chain and sustainability concerns of the industry have driven up visitor interests in ITMA 2019. We had a strong turnout, despite trade tensions and poor business sentiments. Many of our exhibitors were pleasantly surprised with the large number of serious buyers attending the exhibition.”
ITMA 2019 attracted visitorship of over 105,000 from 137 countries. The top five countries where visitors came from were Spain (11%), Italy (10%), India (8%), Turkey and Germany (7%). They were followed by France, United States, Portugal, Brazil, Pakistan, China and the United Kingdom.
In addition, a number of ITMA and co-located events drew over 1000 delegates. Among the events were the ITMA-EDANA Nonwovens Forum, Textile Colourant and Chemical Leaders Forum, Better Cotton Initiative Seminar, European Digital Textile Conference, Tex-Summit Global, Planet Textiles, SAC & ZDHC Manufacturer Forum and Texmeeting by TEXFOR.
The next ITMA will be held in Fiera Milano, Milan, Italy, from June 8-14, 2023.
The following is a look at what some companies exhibited in Barcelona.
Andritz Showed Off Nonwovens Solutions
International technology Group Andritz presented its innovative nonwovens production and textile solutions at ITMA.
The presentation of a complete velours needleloom at Andritz’s booth was one of the highlights at the show. In combination with Augmented Reality (AR) content, the needleloom provides a detailed insight into the functionality of this key technology.
Andritz also introduced its latest needling technology for producing veloured felts, mainly for applications in the automotive industry. The long-lasting brush design combined with a needleloom for high production capacities ensure reduced production costs and a high return on investment for customers. With this full-size needleloom exhibit, realistic presentations were provided at many points of the machine using AR technology. Andritz enjoys high market confidence with its needlepunch systems and needlelooms as the core process technologies, especially in the segment for needleloom devices manufactured according to special customer requirements.
Andritz also showed the next generation of its cross-laying technology, the ProWin system. ProWin is a further development of ProDyn and ProWid, which have achieved a high level of acceptance on the market with around 200 systems installed. This technology improves the current weight-profiling options and increases the actual production capacity.
Archroma Launches New Products
Archroma launched at the recent ITMA exhibition its new Lurapret N5396 & N5392 liq, a water-based ultra-low VOC polyurethane (PU) polymer coating technology.
The innovation was developed in compliance with “The Archroma Way: safe, efficient, enhanced, it’s our nature”. The approach finds its origin in Archroma’s deep belief that it is possible to make the textile industry sustainable, economically and ecologically.
Coatings are used in the textile industry to achieve features such as waterproofness, flexibility, durability and UV resistance. With the growing demand for safer and more ecological products, water-based PU coatings are progressively prevailing as the preferred coating technology.
Lurapret N5396 & N5392 liq have been developed to provide textile manufacturers with an additional water-based option that delivers high performance to the coated fabrics of demanding applications, such as indoor and outdoor textiles, nonwovens and papers.
Initially developed for the chemical bonding and coating for backpack and other industrial products, Lurapret N5396 & N5392 liq also improve the mechanical properties of the treated material such as their tensile strength and scratch resistance.
The new products will be the core of Archroma’s Safe Seats system. The system, which combines Lurapret N5392 & N5396 liq with Archroma’s halogen-free Pekoflam STC p flame retardant, allows to create a halogen-free flame retardant coating system for synthetic leather upholstery.
Using Lurapret N5396 & N5392 liq together with Archroma’s Nuva N2155 & N4547 soil protection and release finishes, enables customers to achieve highest standards in water-repellence and waterproofness.
Lurapret N5396 & N5392 liq can be applied by impregnation, coating (paste or foam), and spray, and are compliant with the ZDHC and bluesign requirements.
Autefa Showcased Hydroentanglement Technology
At ITMA, Autefa Solutions Nonwovens Technology was focused on innovations in main process steps from web forming, web bonding and web finishing. Under the headline “Industry 4.0” customers gained an approach for the entire nonwoven production system covering all aspects of improving the performance of a production line during lifetime.
With the new hydroentanglement machine V-Jet FUTURA and the Square Drum Dryer SQ-V, Autefa Solutions has developed an advanced and unique technology with special focus on reducing energy consumption. Besides high energy efficiency, the new Hydroentanglement Machine V-Jet FUTURA offers highest throughputs, easy maintenance and long lasting V-Jet-technology components.
The new module based Airlay FUTURA K12 concept provides tailor-made line solutions. For customers looking for best web quality or highest productivity, Airlay FUTURA K 12 is available with different inlet, forming and delivery modules. Synthetic or natural fibers, heavy or low weight, bulky or dense, the Airlay FUTURA concept offers the right modules for a line upgrade. The Airlay FUTURA modules are mounted on high precision guiding lines. This easy and quick opening of the machine stands for fast cleaning, easy maintenance, easy inspection and extended access to all parts of the machine.
Autefa Solutions Service 4.0 covers all aspects of improving the performance of a production line during lifetime.
Beaulieu Announces New Pilot Line
At ITMA, Beaulieu Engineered Product’s announced a new, fully operational pilot line supporting R&D projects for industrial and hygiene applications. It will also support the development of innovative fibers for new markets and applications. Beaulieu Fibres International’s (BFI) pilot line answers increasing customer demand for co-developments. It is extremely flexible and can replicate any type of staple fiber spinning technology, using different type of polymers and additives, and different type of cross sections.
New high tenacity staple fibers capacity will be available from the end of 2019 at BFI’s Italian plant. BFI’s high tenacity fibers HT8 offer unique high tensile strength without compromising on elongation. The fibers provide opportunities to reduce geotextile system cost by maximizing machine efficiency and ensure desired performance at reduced weight - up to 15% compared with standard geotextile fibers.
New PET-core BICO staple fibers will bring loft to hygiene products. The fibers are available in a dtex range from 1,3-6,7dtex/40mm in both polymer-configurations PP/PET (Polypropylene / Polyethylene terephthalate) and PE/PET (Polyethylene / Polyethylene terephthalate). The specific use of PET in the core improves the resilience/loft of the nonwoven. The use of PE in the sheath provides softness as required in topsheets, for example, while the configuration with PP in the sheath answers the requirements for ultrasonic bonding. Fibers come in an antimony (Sb)-free version, as required by the latest hygiene safety regulations.
BFI’s new and unique polyolefin staple fiber UltraBond eliminates the need for latex or other chemical binders to consolidate nonwovens, contributing to a fully recyclable system. The award-winning innovation opens up a new path to create 100% PP needlepunched fabrics which meet the same performance requirements while reducing the end-of-life environmental impact. CO2 emissions are reduced by 35% over the full production process during fabrics’ production.
Following its pioneering introduction in mid-2018, Beaulieu Yarns is seeing interest increase in 2019 in its drop-in alternative for carpet manufacturers. EqoBalance yarns support the global goal of strong, immediate CO2 emission reduction, allowing a reduction of up to 75% of CO2 eq/kg compared to Beaulieu Yarns’ fossil-based products.
These Green Product Award winning yarns deliver the same quality and performance as the fossil-based equivalents, and enable carpet manufacturers to contribute to a sustainable future through less use of fossil resources and reduced greenhouse gas emissions. Beaulieu Yarns’ EqoBalance is the very first yarn certified by TÜV Süd as meeting the new REDcert standard on the “use of sustainable biomass for material purposes in the chemical industry.”
Brückner Highlighted Industry 4.0 Solutions
For 70 years, Brückner has been the worldwide partner for all companies which are drying, coating and finishing web-shaped materials: whether clothing fabrics, nonwovens, carpet, glass or coatings - the variety of materials to be processed has never been limited.
Today, it is no longer just a question of machines, but rather of automation and control systems. The topic of digitization and Industry 4.0 opens up completely new possibilities for increasing productivity, reducing the use of resources and improving quality. In addition, an increasing shortage of skilled workers can be addressed by more intelligent software.
Brückner has invested, developed and implemented a lot in this area in recent years:
- Intelligent assistance systems monitor the machine settings in the background and provide the machine operator with information on how to run the system even more productively and consuming less resources. Studies have shown that optimizing production parameters can increase production speed by up to 40% and/or reduce energy consumption by up to 30%.
- A newly developed simulation tool helps to optimize existing recipes. The many machine parameters to be set have been reduced to the essentials and can in future be calculated automatically on the basis of the textile key data.
- For the service, there is a new maintenance tool that proactively gives the machine operator or maintenance department service instructions that can be tracked in a logbook. In future, a newly developed online service platform will support customers with all service inquiries. The technicians communicate directly with the customer via video conferencing - partly with augmented reality. Documents such as circuit diagrams or maintenance manuals can be viewed and explained together and spare parts can be ordered directly. For regular maintenance processes, photo or video illustrations can be stored in local language. Technically caused downtimes can be significantly reduced by these new systems. This increases system availability and thus productivity.
- The exchange of machine data with higher-level control station or ERP systems is easily possible with OPC-UA. This allows to rationalize processes in the textile factory and to monitor the quality.
Brückner has something new to offer in the field of multi-layer stenters. Multi-layer stenters are mostly used where little space is available. They are suitable for finishing woven or dimensionally stable knitted fabric, nonwovens, needlefelt, technical textiles or for the wool industry.
With the new Brückner POWER-FRAME VNE multi-layer stenter, only one machine operator is required, as the entry and the exit are on the same machine side. This applies both to the version with two and with six fabric passages.
The new VNE machine concept offers the highest possible power density on a small floor space or a long air flow section in a very confined space. The dryer itself is equipped with Brückner’s patented split-flow air circulation system and the alternating arrangement in each half compartment additionally ensures optimum and uniform air circulation and thermal treatment of the fabric.
Another advantage is the completely lubricant-free fabric transport chain of the multi-layer stenter, because in this version there is absolutely no oil in the dryer interior.
DiloGroup Showcased Complete Line
ITMA 2019 in Barcelona was a total success for DiloGroup. More than 6000 interested parties and customers from more than 80 countries visited the Dilo booth, which with a space of 1150 m2 was the largest booth in the nonwovens machinery sector.
The idea to again show a complete production line with fiber was met with great approval and appreciation. DiloGroup with its focus on complete production lines for the nonwovens industry, wanted to show the complete systems engineering and include the corresponding innovations and inventions. With customer requirements in mind, it can now pursue specific future development work and include these innovations in its standard portfolio. Interest in the new developments was evident, and visitors felt the enthusiasm of 50 DiloGroup employees at the exhibition.
In the technological order, starting with fiber preparation, the components for opening and blending from DiloTemafa attracted great interest. The special highlights of the improved bale opener series “Baltromix Pro” were shown by the design features for the operating assistance with the I4.0 components “Bale Timer”, cleaning control, better accessibility for maintenance and the “DI-LOWATT” system for energy savings in fiber transport. The proven carding willow for further opening and preblending was equipped with modified workers and separate drives to create the prerequisites for a good fine opening.
Another specialty is the fine opening stage installed over the material box of the new card feeder FRS-P where a high dosing accuracy is achieved in cross and longitudinal direction. A very even flock mat was a clear eye-catcher. Consequently, the high web quality at the VectorQuadroCard exit was a result of the high quality of synchronized fiber opening and web forming components which form a technological unit.
The revised HyperLayer NT for the presentation of the latest state-of-the-art highspeed precision layering technique showed new standards, which play an important role especially in hydroentanglement lines. In this application, it is important to achieve layering speeds up to 190 m/minute using sophisticated viscose fibers and a layering width of about 4 m while at the same time showing high layering precision in cross and longitudinal direction.
The FutureLine study “3D-Lofter” met with the greatest interest and broad approval. In this study individual web forming units can deposit fiber masses on freely programmable spots in longitudinal and cross direction thus saving overall fiber mass in applications such as deep moulded parts for the automotive interior. This ability reduces costs in production and operation. This was not the only convincing application, the prospect of a more even flock mat for direct cards and the aerodynamic web forming known as “IsoFeed” concept are further opportunities. The structuring of flat needlefelt floor coverings, which may be further processed with the DI-LOUR and DI-LOOP technology, may be another approach for this application, and a great potential is evident.
The high stitch distribution uniformity achieved by the new needle pattern “6000 X” in conjunction with the new Hyperpunch kinematics is able to reduce investment costs for numerous needlefelt production lines and to increase surface quality.
Finally and importantly, the visiting experts were able to meet “smart industry” in numerous examples on the Dilo booth where more transparency and control of the production process and the operating conditions can be realized with the aid of software, internet and Cloud. The time is here to offer operator guiding and assisting elements with new line configurations to more easily achieve production management.
Gneuss Offers PET Recycling Technology
Gneuss highlighted its innovative PET recycling process for the use of industrial and post-consumer waste in direct spinning.
The Gneuss Recycling Technology enables the processing of high-volume, industrial PET waste from fiber, nonwoven or film production, and from contaminated post-consumer bottle flakes. The recycling technology is based on the Gneuss Processing Unit (GPU) with MRS extruder, rotary filtration system and online viscometer with intelligent viscosity monitoring and control, optional combined with Gneuss’ JUMP reactor.
The first important processing stage, melt decontamination, takes place in the GPU. With its excellent devolatilization capacity, the MRS extruder can process PET waste with high residual moisture levels and/or contamination (such as spin finish oils) without the need for any pre-treatment of the waste. In the Multi Rotation Drum, multiple satellite screws produce a large melt surface and surface exchange rate, so that an optimum devolatilization and decontamination result can be achieved with conventional water ring vacuum pumps. All volatile impurities such as water and / or spinning oils are safely removed eliminating disturbances in the spinning process.
Solid impurities are subsequently filtered out by the melt filter. Rotary Filtration Systems operate continuously, process constant and automatically, and guarantee a particle-free melt thanks to finest filter elements with filter fineness down to below 20 µm.
With the Online Viscometer VIS, the melt viscosity is measured in real time and directly adjusted. Depending on the recycling process, the viscosity is specifically reduced by means of ethylene glycol injection or in a further step specifically increased in the IV boost system JUMP.
Subsequently, the polymer melt is merged with the main, virgin polymer melt flow either upstream or downstream of the finisher.
With this recycling technology, combining an MRS extruder with the optional JUMP reactor, industrial and post-consumer waste can be turned into a high-quality and directly usable melt in a very short time. Thanks to the enormous line flexibility, different PET qualities can be produced.
This recycling concept, which received an award for innovative performance last year, has convinced one of China’s largest fiber producers. The recycling concept for processing fiber waste into pellets will be implemented by the Chinese manufacturer before the end of this year. Then an MRS130 will process up to 900 kg/h of fiber waste (staple fiber and POY) into melt. All the spin finish oil and water and other volatiles will be taken out in the high efficient degassing section. There is a possibility for injecting additives into the MRS as well, so there is an optional adding of color (TiO2, carbon black …) as well as of other reactive additives. After the devolatilization in the MRS all solid particles will be filtered out by a RSFgenius175 equipped with 20 micron screens. The purified melt will be fed via a startup valve into the reactor for the IV lift. Alternatively, in this line set-up, there is an option to feed the melt directly (before the reactor) to a pelletizer to produce pellets with a lower IV.
Kelheim Showcased Specialty Fibers
After a large fire in October 2018, the long-established Bavarian fiber manufacturer Kelheim Fibres is currently rebuilding the heart of its viscose fiber production. In the process, the focus lies on modern state-of-the-art equipment and particularly on resource-saving and environmentally friendly production technology.
Kelheim’s viscose specialty fibers consist of 100% cellulose, a renewable raw material, and are therefore completely biodegradable. These fibers offer an eco-friendly alternative to mineral-oil-based fibers, in particular for end products - like many nonwovens or hygiene applications - intended for convenient one-time use.
Kelheim’s specialty fibers for this area include Galaxy, a viscose fiber for tampon production, as well as short cut fibers that have been specifically designed for processing in modern wetlaid plants. These fibers enable the manufacturing of completely plastic-free and even flushable wipes from 100% cellulose.
In textiles, too, consumers value natural materials. Kelheim’s range of specialty fibers for textile applications comprises spun-dyed fibers, as well as the renowned brand names Viloft and Viseta:
In yarns, the flat fiber Viloft creates small air pockets, that make the textile highly breathable and comfortable – an ideal fiber for warm, close-to-the-skin feel-good clothes.
Viseta is 50% finer than silk and gives clothes a flowing drape and a soft and naturally luxurious touch.
Spoolex Brands Exhibited
Spoolex has, through its worldwide-recognized brands Calemard, Decoup+ and Roll Concept, real expertise in slitting, rewinding/spooling, ultrasonic splicing and technical rollers.
Calemard, is the converting machinery division of Spoolex Group. Present since 1955 in a wide range of markets, Calemard has focused its activities on highly technical cutting applications. Always based on three modules (unwinding, slitting, winding), Calemard equipment is multi-purpose and can convert thick or thin materials into pads or spools of wide or narrow strips. Its technical and process expertise have allowed it to develop and equip machines with sensitive web tension control and guiding systems, to manage, depending on the product to be converted, high, low and even extremely low tension on the same machine. The result is compact rolls with consistent tension, clean and straight edges for easy use on the downstream product manufacturing process. In addition to its standard range of slitter-rewinders, with 40 Jumbo spooling lines in operation worldwide, the widest high speed spooling line for ADL in the world (mother roll width up to 1.5 m) and a fully automated Pegase 3 Spooling Cell and the top speed Pegase 4, Spoolex Group confirms the world leading position of its Calemard machinery brand in providing customized spooling solution for demanding productions with tension sensitive materials.
Decoup+, meanwhile, is a specialist in ultrasonic cutting and welding. Ultrasonic technology offers various advantages, especially in sun protection, clothing, ribbons, technical textile or packaging industries. This technology performs clean and soft edges, without fraying, overthickness, burning or yellowing, but also strong and regular weldings without any additional material such as glue, staples, rivet, etc. Ultrasonic can be used on any synthetic fabrics (with minimum synthetic fiber content), technical textiles, nonwovens, thermoplastics…in a word, on any “thermofusible product” (which melts under heat effect). Quick and aesthetic, ultrasonic technology allows a direct use of the final product. Present since 1975 on the market with a complete range of cutting and welding devices, Decoup+ has gained strong position worldwide. Compact and ergonomic, these devices can be used for any step of the production process: from looms, to stenter-frames or finishing operation machine, and of course, final make-up operations. The solutions developed by Decoup+ are part of an industrial range of ultrasonic equipment; they are proven solutions with different powers and are specifically adapted to continuous operations. These solutions are proposed as modular units to be mounted on existing lines, as adapted benches or as handheld units.
Roll Concept is the industrial rollers division of the group. For almost 30 years, it has designed and manufactured the well-known Alveotube product line used as industrial rollers, cylinders and winding cores/mandrels. Specially engineered to improve process performance and increase line speed on web handling and converting industry, its lightweight precision rollers and winding cores ensure to users easy installation, easy handling and durability. Indeed, it takes advantage of Calemard’s integrated engineering department. Roll Concept’s engineering team, used to design and to understand converting needs, is therefor able to develop the right roller: improving profiles and proposing the best coating and assembly to fully adapt the roller to specific application. Then, because they are made from an aluminum alveolar structure, its rollers are light and strong and represent the best compromise on the market between bending resistance and low inertia. Compared to an aluminum tube, Alveotube profile allows manufacturing rollers with reduced production costs and with lower inertia. As a result, its rollers provide the reduction of electrical power consumption when accelerating and a reduced load torque for idler rollers. Even more light than the Alveotube, Roll Concept designed a new carbon roll based on a patented solution.
TECHNOplants Highlighted Machinery Range
TECHNOplants is one of the fastest-growing suppliers of nonwovens machinery, serving the main nonwoven sectors with machines and turn-key plants of its own design and manufacture.
At ITMA Barcelona 2019, TECHNOplants presented its range of lines for the automotive, furniture and geosynthetics sectors.
Its MULTIline system for denim shoddy web formation, developed to meet the most stringent automotive requirements, guarantees a first-rate coefficient weight variation (CV) of less than 2% in both machine and cross-machine direction.
Automotive is also served by integrating its MULTIline Airlay system with a two-step powder distribution system for shoddy and glass fiber nonwovens, which combines an excellent distribution tolerance and an intimate mix of fiber and powder. A complete recirculation and suction system allows the recovery of all the bonding powder, without leakage.
TECHNOplants’ Airlay MULTIline can also manage synthetic fibers, coconut, kenaf and all shoddy fibers in a range from 80 gsm to 10,000 gsm.
The airlay MULTIline is available in seven different configurations to allow the maximum production flexibility; this allows TECHNOplants to meet also the strictest low-budget projects.
Its range of three thermal bonding ovens covers any kind of thermal bonding process and are designed for heavy duty, high thermal efficiency applications, thanks to heat recovery systems and an easy-maintenance design, which allows operators to open both sides of the machine to let them clean from both sides.
Its well-known automatic and semi-automatic end of lines complete TECHNOplants’ machinery range: in-line and off-line slitting, cross cutting and winders for light and heavy weights, soft and stiff materials, stacking machines for pads, packaging and palletizing solutions.
Texnology Showed Complete Needlepunch Line
Exhibiting a complete production line at ITMA 2019 in Barcelona was a great success for Texnology.
A complete needlepunching line - Blending and Carding by Bematic, Profiling Unit, Crosslapping, Webdrafting, Elliptical Needling machine, Scanning System and End of line (Winding system) - was showed on a floor space of 1000 m² and put into operation in only 15 days.
The fiber was processed during the demonstration time and the reliability of the machines was proved during the seven days of the show.
This line was the most complete ever showed at ITMA and attracted a large number of visitors from all over the world because of the machines’ efficiency, the product quality and the unique design that impressed those coming into the booth.
Texnology used this opportunity to show its technologies in the field of the nonwoven machineries.
Stirovelo is the new Texnology profiling unit. It is fed by the card at constant speed and density and in output it generates variable density at constant speed. This unit maintains the characteristics of the web before crosslapping and increases its speed.
The Bucefalo Speciale Crosslapper (3 x 5,5 mt lapping width) is characterized by high web infeed speeds and guarantees homogeneity of the web, the highest layering precision and elimination of any bottleneck.
The batt drafter is an important prerequisite for needling. Texnology batt drafter has five trio groups and it is made up of wired cylinders at progressive speed. This technology increases the line productivity of light products and reduces the drafts.
Ellittica is Texnology elliptical needlepunching machine. This machine has an extreme needle density (4000 n/lin.m.) and guarantees a reduction of the fiber transport per stroke. This means high resistance and best surface quality.
This line was designed for the production of different nonwovens in various application areas such as coverings, automotive linings, carpeting. Furthermore, we offer installations for the production of disposables, which are used in cosmetics, medicine, hygiene.
ITMA 2019 was also the forum to present the latest development by Texnology: Acqualoom. This machine has been designed for spunlace nonwovens. Acqualoom can reach every working width in accordance with the final product. In line with product and material, compaction and dewatering as well as the number and position of water beams are freely selectable to meet the customer’s individual product and material requirements. Acqualoom also allows efficient web bonding with a short bonding path.
Texnology has delivered several complete production lines to the nonwovens industry and has the know-how to design the best installation for the final product in accordance with the customer’s needs.
Truetzschler Offers Technologies for Sustainable Nonwovens
At ITMA, Truetzschler Group presented intelligent machine technologies, digital solutions and installations for sustainable nonwovens.
Cost pressure, personnel bottlenecks and fluctuating raw material qualities: These are some of the most pressing challenges in spinning preparation. At the same time, spinning preparation is decisive for the yarn’s quality. In order to meet these requirements, Truetzschler counts on state-of-the-art sensor technology and digital integration – and opens up a new chapter in carding technology: The new intelligent card TC 19i automatically and continuously optimizes the carding gap whose setting has a critical influence on quality and performance. With a precision not achievable by humans, the intelligent card permanently realizes even the narrowest carding gap setting of 3/1000 inch.
“This allows us to measurably improve our customers’ raw material utilization and productivity while achieving consistently high quality,” says Dr. Dirk Burger, CEO of the Truetzschler Group.
In addition, new cloud-based digital monitoring and management systems provide yarn manufacturers with transparency over all processes in the spinning mill. The My Wires app, for example, provides information on the status of clothings and service intervals and helps with the planning of reorders. Competent service for re-clothing can be provided immediately by Truetzschler Card Clothing (TCC).
“With the smart networking of machines as well as production and maintenance, we support customers in simplifying their entire spinning process,” explains Dr. Christof Soest, CTO. “This is why our digital platforms work not only for Truetzschler technology.”
The latest innovation in the blowroom offers more economy and quality as well: The Portal Bale Opener BO-P, with widths of 2900 mm or 3500 mm, allows significantly more bales to be placed side by side and processes them in parallel using two opening rolls. Thus, it results in significantly better blending and higher productions of up to 3,000 kg/h.
As a complete supplier for spinning preparation, Truetzschler is also breaking new ground in draw frames, the quality filters in the spinning mill. The autoleveller draw frame TD 10 automatically adjusts the perfect break draft for optimum sliver quality and realizes significant cost savings due to its compact design and energy-efficient suction system. Like the TC 19i and the BO-P, the TD 10 provides the operator-friendly T-LED remote display, which visualizes important machine and production information in a simple way.
Truetzschler Nonwovens also presented sustainable concepts tailored to individual customer needs. The focus is on technologies for the production of biodegradable light-weight webs from renewable raw materials. In addition to proven solutions for carded, spunlaced nonwovens made of 100% cotton or 100% viscose, Truetzschler Nonwovens has developed an alternative technology in cooperation with Voith: In a wet-on-wet process, the web is formed from cellulose-based short fibers suspended in water and then bonded by means of hydroentanglement. The sustainable, high-quality wipes and cleaning cloths that result from this process can be completely degraded by microorganisms in the environment after usage by the consumer.
The Man-Made Fibers division presented the new four-end BCF machine MO40, which is based on the proven M40 concept. The symmetrical design in combination with the lamellaless HPc texturing results in maximum yarn and bobbin qualities. As each spinning position produces four BCF ends simultaneously, the machine achieves high productivity at moderate speeds, which ensures a stable process. “Higher, faster, further is not always the solution,” emphasizes Dr. Lassad Nasri, CTO at Truetzschler Man-Made-Fibers, “as with the entire Truetzschler Group, individual customer requirements always have priority for us. We support our customers with complete installation concepts, services and know-how - from the product idea to new business models.”
In addition to the highlights from the Spinning, Nonwovens and Man-Made Fibers business units, the Truetzschler Group showcased the comprehensive services and high-performance clothings for cards and roller cards from TCC on 1400 m2. TCC completes its portfolio of special flat clothings with the MT 52, which demonstrates outstanding stability, particularly at high card productions in ring and rotor spinning. In addition, TCC has developed the new PRECISETOP flat clothing, which is essential for the intelligent self-optimization of the carding gap in the TC 19i. Thanks to the close cooperation between machine developers and clothing specialists at Truetzschler, customers benefit from tailor-made and compatible solutions along the entire value chain.
WEKO Presented Latest Systems
WEKO-Fluid-Application systems (WFA) are known for low add moisture management and softener solutions in textile industry. In technical textiles and nonwovens, WEKO apply diverse functions to surfaces with encapsulated ProTec system to create a safe working environment by using harmful substances.
The worldwide textile production is suffering from immense cost pressure and is driven by using high volumes of fresh water, energy and chemicals with comparatively slow production speeds. WEKO together with its partners Lilienweiss Textile Services, Textilchemie Dr. Petry and Archroma developed new processing concepts creating sustainable, cost-efficient dyeing and finishing processes.
Benefits for denim yarn dyeing include non-stop change over (topping); no tailing; raised product fastness; wide variety of colors and effects achievable; reduced reddish (indigo / sulfur dyeing); less number of dye bathes needed; stable and precise production; no generation of dye bath waste; reduction of energy costs thanks to short drying times and economical use of the application medium.
WEKO-NEO could be placed on any section of a slasher dyeing range. It means in the pre-treatment or preparation area, dyeing, wash off or after-treatment area. Also the number or applicators is unlimited. Use it for topping, bottoming, Color-DENIM, Black-DENIM, fixation, hydrogen peroxide or others.
Meanwhile, benefits in textile finishing include up to 80% reduced pick-up; no material contact (no stress); up to 50% less drying energy; raising line speed also on heavy textiles up to 270%; saving up to 70% water and waste; one or both side application; adjustable penetration level.
WEKO-NEO could be installed on the stenter frame entrance or exit. A wide range of applications could be done, for example fixation, resin and flat finish, luster or brilliance, grip modification, softener, tinting and over-dying.
