Nonwovens Staff05.03.22
Approximately 5000 participants engaged in face-to-face business meetings with global leaders in nonwovens and engineered materials at IDEA 2022 in Miami Beach, FL, co-located with the second FiltXPO, North American’s only exhibition and conference dedicated exclusively to filtration and separation. Both events were successfully held March 29-31 at the Miami Beach Convention Center.
Organized by INDA, IDEA also featured five essential nonwovens training classes; market presentations from China, Asia, Europe, North America and South America; industry recognitions with the IDEA Achievement Awards and the IDEA Lifetime Achievement Awards; and a welcome reception celebration.
Also, organized by INDA, FiltXPO featured five panels of global leaders in filtration and separation for the first-ever “Summit for Global Change,” discussing societal challenges such as indoor air quality, environmental sustainability, pandemic readiness, clean water, and filtration standards. The event also featured a 1.5-day filter media training course, and sessions highlighting filter media market trends and filtration industry statistics.
Exhibitors and attendees noted the welcome return to meeting face-to-face among industry senior leaders participating in the three-day event.
“While most professionals have now become accustomed to the greater flexibility working from home provides, and conducting Zoom or Team meetings, there’s no substitute to meeting face-to-face and in person,” INDA president Dave Rousse says. “The event attracted a high level of participation among key decision makers despite lingering travel restrictions, which is a testimonial to the show’s importance within the international nonwovens and engineered materials industry.”
A highlight of IDEA was the announcement of the IDEA Achievement Awards by INDA, in partnership with Nonwovens Industry magazine. Moderated by Rousse and Karen McIntyre, editor, Nonwovens Industry, the awards recognize the leading introductions in equipment, raw materials, short-life, long-life and nonwovens products, and sustainability, since the previous IDEA Exposition in 2019.
In addition, INDA presented the IDEA 2022 Lifetime Achievement Award to Val Hollingsworth, board chair and CEO of Hollingsworth & Vose, and Nonwovens Industry presented the IDEA Entrepreneur Achievement Award to Doug Brown, president of Biax-Fiberfilm/5K Fibres at the event.
The following awards were presented on March 30:
IDEA Equipment Achievement Award: Elastic Thread Anchoring (ETA) Sonotrode, Herrmann Ultrasonics, Inc.
This easy-to-use closed-loop feedback manufacturing solution, where the fixation of the elastic threads is accomplished with ultrasonic energy, offers a wide process window, without the need for adhesives or tool changeovers, at processing speeds above 2000 ft./min.
IDEA Raw Material Achievement Award: ODOGard, Rem Brands, Inc.
A revolutionary advancement in odor elimination using molecular bonding to malodors. Malodors are permanently attached to the ODOGard molecule, changing them permanently into non-odorous molecules.
IDEA Short-Life Product Achievement Award: LifeSavers Wipes, LifeSavers LLC
LifeSavers Wipes are personal hygiene wipes that change color if they detect abnormal health indicators in urine. A diabetic wipe is the launch product that will change color if there are abnormal levels of glucose in the urine. This innovative product assists with personal hygiene, acts as an early warning system, and serves as an instant glucose monitor.
IDEA Long-Life Product Achievement Award: Nanofiber Cabin Air Filter, Mann + Hummel GmbH
This hybrid media combine electret-based spunbond and a pure mechanical filtration layer of ultrafine polymer fibers, resulting in an outstanding separation of PM1 particles up to 95%, according to DIN EN ISO 16890. The technology enables filtration performance and efficiency to significantly improve air quality.
IDEA Sustainability Advancement Award: Fiber-based Screw Caps, Glatfelter Corp. and Blue Ocean Closures
Blue Ocean Closures partnered with Glatfelter and ALPLA to develop an alternative to metal and plastic screw caps. The two companies have accelerated producing sustainable and environmentally-friendly packaging solutions. The companies optimized renewable and recyclable wood fibers and airlaid materials to create paper-based screw caps that are durable, strong, and water-resistant.
IDEA Nonwoven Product Achievement Award: Hydraspun Aquaflo, Sustainable Nonwoven Substrates, Suominen Corporation
Suominen’s latest moist tissue product, Hydraspun Aquaflo achieves dry tissue dispersibility through a proprietary blend of 100% sustainable cellulosic materials, minimizing environmental impact. This flushable nonwoven has a premium hand feel, and passes dispersibility standards set by INDA (GD4) and the International Water Services Flushability Group (IWSFG.)
IDEA will next be held on its new 24-month schedule on April 23-25, 2024, in Miami Beach, FL. FiltXPO will make its return on its new 18-month schedule, Oct. 10-12, 2023, at Navy Pier, Chicago, IL.
The following is a look at what some exhibitors showcased at IDEA22.
“With the inherent strength of the 5K nonwovens, we are focused on our core technology and some new patents around what we trademarked as the name ‘Spun-Blown’ where we can make very strong fibers,” says CEO Douglas Brown.
Exhibited at IDEA, the company’s Spun-Blown Polypropylene is available in a variety of basis weights. This material is targeted for:
Alkegen brings together two of the world’s leading specialty materials platforms and represents a new chapter for a unified, innovation-driven company.
Alkegen is well positioned to be a specialty materials leader serving mission-critical systems that the world is focused on for the future, including battery technologies, electric vehicles, filtration media, and specialty insulation materials that enable customers to reduce fossil fuel consumption, save energy, and live greener.
John Dandolph, president and CEO of Alkegen, explains, “Our new name helps define this global platform with differentiated, sustainability-focused advanced materials. Customers will come to know Alkegen as a brand that helps the planet breathe easier, live greener, and go further than ever before. Alkegen is an exceptional specialty materials platform that we believe is unrivaled in the world today.
The name Alkegen is a modern adaptation of two words that are central to the company’s identity and mission. “Alke” is derived from the word “Alchemy,” which evokes transformational innovation and breakthroughs in what is possible. “Gen” is a shortened form of “Next Generation” and speaks to Alkegen’s focus on human health and a sustainable future. The green Alkegen “arc” in the logo represents collaboration, connectivity, and a horizon signifying the global nature of the company and its constant innovation and forward progress.
“Our new name is just the start of our journey as a brand,” adds Dandolph. “Our vision is to be the world’s leading innovative specialty materials platform dedicated to sustainability and human health while serving industries tackling some of the critical problems our society faces today.”
Alkegen also announced that it will be relocating its corporate headquarters to new offices in Dallas, TX, this spring. This new facility will serve as the headquarters for the company’s Filtration and Battery businesses. Unifrax’s current headquarters in Tonawanda, NY, will continue to serve as the headquarters for the company’s Thermal Insulation and Emission Control businesses.
Alkegen brings a diverse ecosystem of thermal management, construction and fire protection products, new step-change battery and filtration technology, and unmatched global reach with 60+ manufacturing facilities that service customers with innovation, speed and agility. With an experienced talent pool and a global base of 9,000+ employees, including some of the world’s top thermal management and filtration experts, Alkegen is well positioned to help customers positively impact the environment in meaningful ways.
Manufacturers that process with multiple patterns run the risk of damaging the live engraving during the traditional removal and loading of engraved rolls. In addition, it can take more than half the day to cool a roll down, unload it, place the next roll, and heat the roll to production temperature. The Alliance Turret Calender has become a solution to minimize the downtime and risk created from roll changeout.
Both the coating line and model 324MC-HD feature rugged construction and innovative technologies for productivity, roll quality and versatility. They offer automatic knife positioning, laser core-placement assists, slit web control systems and a streamlined roll discharge process.
Ideal for nonwovens, these machines have extremely wide torque and tension ranges and can handle diverse weights and thicknesses, cut sizes and web widths. They are capable of shafted or shaftless winding. As with all Catbridge slitter rewinders, these models incorporate a state-of-the-art, comprehensive safety system.
Catbridge can assemble 10-20 machines at any given time, seamlessly integrating engineering and construction under one roof, allowing for shorter lead times.
Aspun AT resins provide more of the benefits of PE in hygiene applications, including comfort and discreetness that are essential for crucial applications like adult incontinence and feminine hygiene products. The resins make it possible to produce much thinner fibers, helping brand owners bring to market softer and more comfortable nonwoven articles with strong abrasion resistance, better drapeability, a microfiber-like feel and a higher-quality appearance that consumers increasingly demand.
Additionally, Aspun AT offers improved drawability and thermal stability, allowing manufacturers to produce thinner fibers without breakage. The product also enables manufacturers to create longer, more stable line runs with fewer defects and higher yields for more efficient processing.
“We know many people are struggling to manually bag and fill wipes,” says Jay Roth, Elsner’s director of sales. “Many in the industry are adapting equipment designed for other applications. We decided to engineer a purpose-built bagger for larger count rolls such as gym wipes or cart wipes.”
The ERB Roll Bagger is integrated with the ENR-Series perforator rewinders that dominate the rolled wipes industry. With hundreds of machines in dozens of countries, Elsner has been part of driving the evolution of the wipes industry since it produced its first perforator in the 1970s. In reaction to Covid-19, Elsner has sold more ENR-Series machines than ever and has turned focus to providing solutions to keep the production not only moving but moving smoothly.
The Elsner engineering team built many efficiencies into the design. The ERB has HMIs integrated at both the bagger and the rewinder, so the line can be easily operated from either end. Solving the pain points involved with the slow process of manually filling, the bagger is designed to keep pace with ENR-Series production. The diameter range is generally 6” to 12” with the machine designed to optimize the bag opening for cost savings and streamlining of packaging as well as improved means of filling and sealing.
The ERB is built to typical Elsner standards with specifications that make production more efficient than ever. The machine is also supported in the same “we’re always working for you” Elsner way.
At IDEA, Freudenberg showcased a new Evolon made from recycled PET. With Evolon RE, Freudenberg offers an even more sustainable version of its high-performance microfilament textiles. Evolon RE is manufactured from an average of 70% recycled polyester, which the company makes by recycling post-consumer PET bottles in-house. Evolon RE is available for various applications, including high-tech wiping and technical packaging, in weights currently ranging from 80g/sqm to 300g/sqm. Evolon RE offers the same high quality and material performance as all other Evolon textiles.
Freudenberg also presented Colback Plus, a pleatable medium with a built-in filtration capacity layer for use as a carrier in the manufacturing of cabin air, room air and HVAC filters. In Colback Plus, the well-known performance characteristics of Colback nonwovens support media—ensuring low pressure drop and high pleat stiffness—are combined with a unique fine fiber technology leading to a unique filtration product with outstanding performance characteristics, creating new capabilities for manufacturing and added value to customers.
The new agreement allows GDM to integrate Kodak PROSPER S-Series and PROSPER Plus Imprinting Systems into its converting and packaging lines for disposable hygiene products. This will enable GDM to provide complete solutions that include digital printing of decorative designs, marketing messages and instructions for use during the manufacturing process of the entire range of disposable hygiene products.
Kodak PROSPER S-Series and PROSPER Plus Imprinting Systems use Kodak Stream Inkjet Technology which are perfect for these applications. With speeds of up to 600 m/min (1,000 ft/min), they keep up with the productivity of GDM equipment and enable high-quality monochrome or multicolor printing. Thanks to their compact design and flexible installation options, PROSPER Imprinting Systems can be easily integrated into GDM manufacturing lines. Kodak’s imprinting systems use cost-effective water-based, nanoparticulate pigment inks which are used for printing on the hygiene substrates that have passed U.S. and European certifications for direct skin contact and food safety.
The Kodak Stream Inkjet Technology and the GDM Converting and Packaging Technologies represent a “perfect know-how match.” Thanks to more than 20 years of experience and a strong commitment to innovation tied to efficiency and reliability, GDM is able to guarantee process flexibility and full control at high speeds. The integration of the two companies’ technologies will ensure an optimum Overall Equipment Effectiveness (OEE) for GDM’s converting-packaging lines.
“Our new partnership with Kodak is a major step forward for GDM to expand our added-value solutions. Combining Kodak’s continuous inkjet and sustainable ink technologies with GDM’s expertise in material handling will deliver a wide range of opportunities for our customers,” says Marco Rosani, market development manager, GDM. “Our customers will get increased flexibility, cost optimization and a more sustainable approach thanks to the inline integration.”
“Our collaboration with GDM is further proof of the suitability of Kodak’s unique continuous inkjet technology for a wide range of industrial applications,” comments Giuliano Bianchet, vice president sales EAMER, Kodak. “Integrating our PROSPER Imprinting Systems into GDM’s production lines makes digital imprinting a highly flexible, cost-effective step within an efficient, end-to-end manufacturing process.”
As a global leader in PET recycling, IVL is committed to the delivery of a circular economy and recognizes that alternative sustainable solutions, such as carbon neutral fiber and biotransformation technology, provide valuable circular solutions when recycling may not be possible. Deja Carbon Neutral polypropylene fibers have been developed in response to customer demand for solutions to meet sustainability targets and objectives. Having undertaken a fully accredited Life Cycle Assessment on their processes and materials, IVL Hygiene Group subsidiary FiberVisions in Covington, U.S., now offer this select polypropylene staple fiber range, which balance greenhouse gas emissions with verified carbon offset projects in partnership with Strive, a leading provider of global climate solutions.
Advancements in dual solution Biotransformation (PP), designed to be recyclable and time-set biodegradable, was featured at the IDEA Show. A shelf stable polypropylene and stored, treated fibers and nonwovens can be recycled as normal. If diverted into the environment, it is scientifically designed to break down in natural conditions and to biotransform, leaving behind no toxins or microplastics.
All the six brands that make up the Hygiene Fibers Group – Auriga, Avgol, FiberVisions, Indorama Asia, Trevira and Wellman International – were represented at the IVL booth. The IVL Hygiene Group offers a comprehensive range of sustainable polymers, technologies and material, a global and regional footprint, and security of supply. The range includes recycled materials, multipolymer biodegradable solutions for both durable and non-durable products, ISCC Plus Certified Fibers and Nonwovens, and Deja Carbon Neutral polypropylene fibers.
Significant advancements in recycled materials were highlighted with the Wellman International team, recycling pioneers for more than 50 years, at IDEA. Recently commissioned technologies at its site in Mullagh, Ireland, allow PET to be recycled without compromising on quality. Sister bands Auriga, IVL Asia, and Trevira also offer a strong recycled PET (rPET) fiber portfolio to the hygiene industry. IVL’s Fibers business segment’s rPET portfolio is represented by the Deja brand platform, differentiated by a performance-led suite of sustainable solutions that help customers to achieve sustainability targets while also responding to end-consumers’ demand for transparency and environmental responsibility. Fibervisons and Avgol continue to develop sustainable fiber and nonwoven PP solutions, including PP recycling technologies.
Trevira focused on the recently launched range of bicomponent fibers based on PLA and PBS (polybutylene succinate). Both biopolymers offer an exceptional technological opportunity for environmental care and sustainability. PLA and PBS are recyclable and 100% biodegradable under industrial conditions.
Avgol understands that there is no one single solution to nonwovens sustainable developments, and adopt a holistic approach. Biotransformation PP is a key area of development, seeking a safe, proven, sustainable solution for absorbent hygiene products. Incorporating natural components, improved recyclability for PP, are key areas of focus for the company.
Currently celebrating its 90th anniversary, Curt G. Joa, Inc. continues to provide innovative hygiene and specialty product converting platforms and technologies. Joa designs solutions for complex production problems based on a deep understanding of the goals each customer seeks to accomplish. Backed by proactive support, its state-of-the-art solutions are recognized for speed, quality and innovation the world over.
Innovation, which has been a core value of Joa’s for over three generations, continues to improve production processes for customers in an ever-changing market worldwide. Its innovative specialists can design and manufacture complex processes, from hygiene and specialty product solutions to even something as unique as a bottle opener.
The production line is located in the Jofo Hygiene “hub” and headquarters located in Weifang, China. Beyond the wipes applications, the technology also shows a unique fit for other applications in the hygiene and medical sector with smaller developments to the technology underway within Jofo R&D. Following the integration of Soshio, a Chinese contract manufacturer for Rockline, Jofo will now have the capability for vertical integration and OEM production.
In other news, Jofo has started of a state-of-the-art Reicofil 5 production line, designed and dedicated to the high-end medical nonwovens products in Wuxi, China. The line is currently in the commissioning stage with some products already commercialized. Krister Erlandsson says that this latest technology from Reicofil combined with the company’s know how in raw materials and technology will allow it to penetrate the high-end medical nonwovens markets with products that provide superior comfort, protection and cost structures.
S-2780 provides excellent water and alcohol repellency to fibers such as cotton, polyester/cotton and polyolefin fabrics (PP SMS barrier fabrics) with good hydrostatic head performance. The product is free of organic solvents and requires no special storage conditions except for protection from freezing.
“We offer the appropriate line technology for almost any application. From soft and bulky High Loft nonwovens, sustainable and bio-based fabrics to high barrier nonwovens with optimized properties and reliable filter characteristics to nonwovens made from post-consumer waste. With our current RF5 machine generation, we are also setting the benchmark in terms of quality, performance, availability, efficiency and machine intelligence,” explains Markus Müller, vice president, Sales & Marketing, Reifenhäuser Group.
In terms of sustainability, Reicofil offers various approaches to save fossil raw materials, such as the processing of bio-based raw materials as an ecological alternative—for diapers, for example. Here, the topsheet material, made of bulky, soft and industrially compostable High Loft nonwovens, meets maximum hygiene requirements. For industrial applications, high-strength nonwovens can be processed even from up to 90% PET flakes from post-consumer waste. This is how Reicofil shows perfect ways to combine sustainability and high-performance nonwovens.
Another highlight is the so-called BiCo technology. In this process, two different raw materials are combined in one fiber in the spunbond process, creating a bimetal effect and causing the fiber to crimp. This opens the door for manufacturers to completely new product properties that are unattainable with monofibers.
For the medical sector, Reicofil showcased its leading solutions for high-barrier medical protective clothing, and—together with its sister business unit Reifenhäuser Cast Sheet Coating—the pioneering Ultrathin Coating production process, which enables customers to produce film-nonwoven composites more cost-effectively and thus competitively. The coronavirus pandemic and current supply bottlenecks have exposed the dependence of companies on global supply chains. This situation is both a warning signal and an opportunity to fundamentally strengthen local semi-finished product production. The jointly developed process achieves significant cost savings and easier line maintenance by eliminating the need for hot melt adhesives. With the patent-pending Ultrathin Coating technology, producers reduce film grammage by 66%. Thanks to the perfectly compatible combination of Reifenhäuser nonwovens and extrusion coating lines, customers thus receive seamless semi-finished product production.
With the c.Hub, the new data platform of the Reifenhäuser Group, Reicofil offers its customers a digitization solution that is tailored to the requirements of nonwovens production. Customers can securely connect, centrally store and easily analyze data from their Reicofil machines, peripherals, ERP and MES systems via the c.Hub middleware. Together with various software bundles, c.Hub is offered as an on-premise solution. It can be deployed locally and remains under the full data sovereignty of the user. Via the web-based ExtrusionOS user interface, customers can keep an eye on their production and the status of their machines wherever they are.
Biolace Zero utilizes Veocel Lyocell fibers from Suominen’s long-term partner Lenzing. Biolace Zero is made of 100% carbon neutral Veocel Lyocell fibers.
“We are very excited to introduce Biolace Zero, which is not just Suominen’s first carbon neutral product, but also one of the first carbon neutral nonwovens on the market. Biolace Zero will be available as part of Suominen’s sustainable product portfolio,” says Marika Mäkilä, senior manager, Category Management, Europe.
Suominen’s Biolace Zero and Lenzing’s Veocel Lyocell fibers are certified as carbon neutral products by globally recognized company, ClimatePartner. Carbon neutrality means that the greenhouse gas emissions of nonwoven have been calculated—from the raw material production to the client’s production facility—reduced and are offset through certified carbon offset projects.
Suominen is a pioneer in sustainable nonwovens and has a wide range of sustainable nonwoven products for different applications. Suominen’s R&D team has excellent know-how on sustainable fibers and it is also continuously collaborating with innovative partners to develop new and innovative solutions with a reduced environmental impact into its product portfolio.
“With this new carbon neutral product Biolace Zero we are able to support our customers in their greenhouse gas emissions reduction targets. Innovating new products in collaboration with partners such as Lenzing by using carbon neutral Veocel Lyocell fibers is well aligned with our strategy and vision to be the frontrunner in sustainable nonwovens,” says Noora Rantanen, manager, Sustainability & Marketing.
“We have diversified our facemask offerings to provide various materials that have greater than 95% efficiency for standard flow rates,” says Bart Sistrunk, SWM’s commercial director - Filtration. “With our Delpore Advanced Filtration Media, N95 material can now be produced with a basis weight reduction of up to 30%. This reduction provides a more economic option for consumers, as well as increased comfort for all-day wear.”
SWM has a long history of supplying high-quality media integral to the manufacture and performance of facemasks used in the dental and surgical sectors as well as the construction and industrial sectors. Delpore Advanced Filtration Media allows for better airflow and breathability and is considered ideal for all day comfortable wear while maintaining key performance features.
SWM also offers Delnet apertured film, a lightweight nonwoven that is extruded, oriented and uniquely embossed for use as a flexible surface layer for medical face masks or as a comfort barrier in finger bandages.
Organized by INDA, IDEA also featured five essential nonwovens training classes; market presentations from China, Asia, Europe, North America and South America; industry recognitions with the IDEA Achievement Awards and the IDEA Lifetime Achievement Awards; and a welcome reception celebration.
Also, organized by INDA, FiltXPO featured five panels of global leaders in filtration and separation for the first-ever “Summit for Global Change,” discussing societal challenges such as indoor air quality, environmental sustainability, pandemic readiness, clean water, and filtration standards. The event also featured a 1.5-day filter media training course, and sessions highlighting filter media market trends and filtration industry statistics.
Exhibitors and attendees noted the welcome return to meeting face-to-face among industry senior leaders participating in the three-day event.
“While most professionals have now become accustomed to the greater flexibility working from home provides, and conducting Zoom or Team meetings, there’s no substitute to meeting face-to-face and in person,” INDA president Dave Rousse says. “The event attracted a high level of participation among key decision makers despite lingering travel restrictions, which is a testimonial to the show’s importance within the international nonwovens and engineered materials industry.”
A highlight of IDEA was the announcement of the IDEA Achievement Awards by INDA, in partnership with Nonwovens Industry magazine. Moderated by Rousse and Karen McIntyre, editor, Nonwovens Industry, the awards recognize the leading introductions in equipment, raw materials, short-life, long-life and nonwovens products, and sustainability, since the previous IDEA Exposition in 2019.
In addition, INDA presented the IDEA 2022 Lifetime Achievement Award to Val Hollingsworth, board chair and CEO of Hollingsworth & Vose, and Nonwovens Industry presented the IDEA Entrepreneur Achievement Award to Doug Brown, president of Biax-Fiberfilm/5K Fibres at the event.
The following awards were presented on March 30:
IDEA Equipment Achievement Award: Elastic Thread Anchoring (ETA) Sonotrode, Herrmann Ultrasonics, Inc.
This easy-to-use closed-loop feedback manufacturing solution, where the fixation of the elastic threads is accomplished with ultrasonic energy, offers a wide process window, without the need for adhesives or tool changeovers, at processing speeds above 2000 ft./min.
IDEA Raw Material Achievement Award: ODOGard, Rem Brands, Inc.
A revolutionary advancement in odor elimination using molecular bonding to malodors. Malodors are permanently attached to the ODOGard molecule, changing them permanently into non-odorous molecules.
IDEA Short-Life Product Achievement Award: LifeSavers Wipes, LifeSavers LLC
LifeSavers Wipes are personal hygiene wipes that change color if they detect abnormal health indicators in urine. A diabetic wipe is the launch product that will change color if there are abnormal levels of glucose in the urine. This innovative product assists with personal hygiene, acts as an early warning system, and serves as an instant glucose monitor.
IDEA Long-Life Product Achievement Award: Nanofiber Cabin Air Filter, Mann + Hummel GmbH
This hybrid media combine electret-based spunbond and a pure mechanical filtration layer of ultrafine polymer fibers, resulting in an outstanding separation of PM1 particles up to 95%, according to DIN EN ISO 16890. The technology enables filtration performance and efficiency to significantly improve air quality.
IDEA Sustainability Advancement Award: Fiber-based Screw Caps, Glatfelter Corp. and Blue Ocean Closures
Blue Ocean Closures partnered with Glatfelter and ALPLA to develop an alternative to metal and plastic screw caps. The two companies have accelerated producing sustainable and environmentally-friendly packaging solutions. The companies optimized renewable and recyclable wood fibers and airlaid materials to create paper-based screw caps that are durable, strong, and water-resistant.
IDEA Nonwoven Product Achievement Award: Hydraspun Aquaflo, Sustainable Nonwoven Substrates, Suominen Corporation
Suominen’s latest moist tissue product, Hydraspun Aquaflo achieves dry tissue dispersibility through a proprietary blend of 100% sustainable cellulosic materials, minimizing environmental impact. This flushable nonwoven has a premium hand feel, and passes dispersibility standards set by INDA (GD4) and the International Water Services Flushability Group (IWSFG.)
IDEA will next be held on its new 24-month schedule on April 23-25, 2024, in Miami Beach, FL. FiltXPO will make its return on its new 18-month schedule, Oct. 10-12, 2023, at Navy Pier, Chicago, IL.
The following is a look at what some exhibitors showcased at IDEA22.
5K Fibres Highlighted Spun-Blown Technology
At IDEA, 5K Fibres announced unique technologies to reduce the amount of fabric and associated fibers needed to make a number of hygiene and related products. 5K Fibres can eliminate the need to add spunbond and similar layers to the outsides of certain fabric media formerly added for strength.“With the inherent strength of the 5K nonwovens, we are focused on our core technology and some new patents around what we trademarked as the name ‘Spun-Blown’ where we can make very strong fibers,” says CEO Douglas Brown.
Exhibited at IDEA, the company’s Spun-Blown Polypropylene is available in a variety of basis weights. This material is targeted for:
- Spunbond replacement. Depending on the product, it allows for a finer fiber outer layer that offers a softer hand and drapability while not compromising strength.
- Strong wipes materials. Potentially for heavier duty jobs.
- Pleatable fabrics for filtration. HVAC and cabin air filters for automobiles.
- SMS replacement products for barrier products in hospital gowns. These can be made in one layer and have a softer hand with greater comfort for health care professionals.
Alkegen Exhibited for the First Time
Unifrax, a leading manufacturer of high performance specialty materials used in advanced applications, announced earlier in January that it had changed its name to Alkegen, to reflect the new company created following its acquisition of Lydall late last year.Alkegen brings together two of the world’s leading specialty materials platforms and represents a new chapter for a unified, innovation-driven company.
Alkegen is well positioned to be a specialty materials leader serving mission-critical systems that the world is focused on for the future, including battery technologies, electric vehicles, filtration media, and specialty insulation materials that enable customers to reduce fossil fuel consumption, save energy, and live greener.
John Dandolph, president and CEO of Alkegen, explains, “Our new name helps define this global platform with differentiated, sustainability-focused advanced materials. Customers will come to know Alkegen as a brand that helps the planet breathe easier, live greener, and go further than ever before. Alkegen is an exceptional specialty materials platform that we believe is unrivaled in the world today.
The name Alkegen is a modern adaptation of two words that are central to the company’s identity and mission. “Alke” is derived from the word “Alchemy,” which evokes transformational innovation and breakthroughs in what is possible. “Gen” is a shortened form of “Next Generation” and speaks to Alkegen’s focus on human health and a sustainable future. The green Alkegen “arc” in the logo represents collaboration, connectivity, and a horizon signifying the global nature of the company and its constant innovation and forward progress.
“Our new name is just the start of our journey as a brand,” adds Dandolph. “Our vision is to be the world’s leading innovative specialty materials platform dedicated to sustainability and human health while serving industries tackling some of the critical problems our society faces today.”
Alkegen also announced that it will be relocating its corporate headquarters to new offices in Dallas, TX, this spring. This new facility will serve as the headquarters for the company’s Filtration and Battery businesses. Unifrax’s current headquarters in Tonawanda, NY, will continue to serve as the headquarters for the company’s Thermal Insulation and Emission Control businesses.
Alkegen brings a diverse ecosystem of thermal management, construction and fire protection products, new step-change battery and filtration technology, and unmatched global reach with 60+ manufacturing facilities that service customers with innovation, speed and agility. With an experienced talent pool and a global base of 9,000+ employees, including some of the world’s top thermal management and filtration experts, Alkegen is well positioned to help customers positively impact the environment in meaningful ways.
Alliance Offers New Turret Calender Technology
The new Alliance Turret Calender technology has gone live and is currently being used in production in the U.S. The revolutionary turret design has provided facilities with the ability to streamline their roll changeout and avoid the need to remove and load live engraved rolls when altering bonding patterns. This system is equipped with three engraved rolls and one bottom-loaded smooth anvil roll. The rolls can be heated individually, which gives an operator the ability to preheat a second roll while production is occurring. Once the operator is ready to begin the roll change, they will open the nip, retract the drive and rotate the turret axis to the next roll. Every step of this process can be done from the calender’s PLC.Manufacturers that process with multiple patterns run the risk of damaging the live engraving during the traditional removal and loading of engraved rolls. In addition, it can take more than half the day to cool a roll down, unload it, place the next roll, and heat the roll to production temperature. The Alliance Turret Calender has become a solution to minimize the downtime and risk created from roll changeout.
Catbridge Machinery Makes Investments
Catbridge Machinery is in the process of building several nonwoven lines at its Montville, NJ, facility. The high-performance machines in production include a coating line and a model 324MC-HD laminating line.Both the coating line and model 324MC-HD feature rugged construction and innovative technologies for productivity, roll quality and versatility. They offer automatic knife positioning, laser core-placement assists, slit web control systems and a streamlined roll discharge process.
Ideal for nonwovens, these machines have extremely wide torque and tension ranges and can handle diverse weights and thicknesses, cut sizes and web widths. They are capable of shafted or shaftless winding. As with all Catbridge slitter rewinders, these models incorporate a state-of-the-art, comprehensive safety system.
Catbridge can assemble 10-20 machines at any given time, seamlessly integrating engineering and construction under one roof, allowing for shorter lead times.
Dow Introduces Aspun AT Next-Gen PE Resins
Dow announced the launch of Aspun AT, a new next-generation fiber-grade polyethylene resin designed to provide people of all ages with even more freedom to live comfortably and lead active lifestyles. Aspun AT is the newest addition to Dow’s well-known Aspun resin family and provides ultra-soft, cloth-like comfort to health and hygiene nonwovens, including wipes and diapersAspun AT resins provide more of the benefits of PE in hygiene applications, including comfort and discreetness that are essential for crucial applications like adult incontinence and feminine hygiene products. The resins make it possible to produce much thinner fibers, helping brand owners bring to market softer and more comfortable nonwoven articles with strong abrasion resistance, better drapeability, a microfiber-like feel and a higher-quality appearance that consumers increasingly demand.
Additionally, Aspun AT offers improved drawability and thermal stability, allowing manufacturers to produce thinner fibers without breakage. The product also enables manufacturers to create longer, more stable line runs with fewer defects and higher yields for more efficient processing.
Elsner Adds to Wipes Converting Machinery Line-up
Elsner has announced the introduction of the Elsner Model ERB Roll Bagger to its wipes production converting machinery line-up.“We know many people are struggling to manually bag and fill wipes,” says Jay Roth, Elsner’s director of sales. “Many in the industry are adapting equipment designed for other applications. We decided to engineer a purpose-built bagger for larger count rolls such as gym wipes or cart wipes.”
The ERB Roll Bagger is integrated with the ENR-Series perforator rewinders that dominate the rolled wipes industry. With hundreds of machines in dozens of countries, Elsner has been part of driving the evolution of the wipes industry since it produced its first perforator in the 1970s. In reaction to Covid-19, Elsner has sold more ENR-Series machines than ever and has turned focus to providing solutions to keep the production not only moving but moving smoothly.
The Elsner engineering team built many efficiencies into the design. The ERB has HMIs integrated at both the bagger and the rewinder, so the line can be easily operated from either end. Solving the pain points involved with the slow process of manually filling, the bagger is designed to keep pace with ENR-Series production. The diameter range is generally 6” to 12” with the machine designed to optimize the bag opening for cost savings and streamlining of packaging as well as improved means of filling and sealing.
The ERB is built to typical Elsner standards with specifications that make production more efficient than ever. The machine is also supported in the same “we’re always working for you” Elsner way.
Freudenberg, Low & Bonar and Filc Exhibit Together for First Time
For the first time since their merger in 2020, Freudenberg Performance Materials (Freudenberg), Low & Bonar and Filc shared their latest technical textile solutions together at IDEA. The companies work with the broadest technology platform on the market which enables the leading manufacturers of performance materials to equip technical textiles with an unparalleled variety of properties.At IDEA, Freudenberg showcased a new Evolon made from recycled PET. With Evolon RE, Freudenberg offers an even more sustainable version of its high-performance microfilament textiles. Evolon RE is manufactured from an average of 70% recycled polyester, which the company makes by recycling post-consumer PET bottles in-house. Evolon RE is available for various applications, including high-tech wiping and technical packaging, in weights currently ranging from 80g/sqm to 300g/sqm. Evolon RE offers the same high quality and material performance as all other Evolon textiles.
Freudenberg also presented Colback Plus, a pleatable medium with a built-in filtration capacity layer for use as a carrier in the manufacturing of cabin air, room air and HVAC filters. In Colback Plus, the well-known performance characteristics of Colback nonwovens support media—ensuring low pressure drop and high pleat stiffness—are combined with a unique fine fiber technology leading to a unique filtration product with outstanding performance characteristics, creating new capabilities for manufacturing and added value to customers.
GDM, Kodak Form a New Technology Partnership
Kodak and GDM have entered into a partnership to integrate Kodak’s high-speed inkjet technology into disposable hygiene production lines. Kodak is a leading global manufacturer focused on commercial print and advanced materials & chemicals; GDM, a company of Coesia Group, based in Offanengo, Italy, is a global leader in converting and packaging solutions for the disposable hygiene industry.The new agreement allows GDM to integrate Kodak PROSPER S-Series and PROSPER Plus Imprinting Systems into its converting and packaging lines for disposable hygiene products. This will enable GDM to provide complete solutions that include digital printing of decorative designs, marketing messages and instructions for use during the manufacturing process of the entire range of disposable hygiene products.
Kodak PROSPER S-Series and PROSPER Plus Imprinting Systems use Kodak Stream Inkjet Technology which are perfect for these applications. With speeds of up to 600 m/min (1,000 ft/min), they keep up with the productivity of GDM equipment and enable high-quality monochrome or multicolor printing. Thanks to their compact design and flexible installation options, PROSPER Imprinting Systems can be easily integrated into GDM manufacturing lines. Kodak’s imprinting systems use cost-effective water-based, nanoparticulate pigment inks which are used for printing on the hygiene substrates that have passed U.S. and European certifications for direct skin contact and food safety.
The Kodak Stream Inkjet Technology and the GDM Converting and Packaging Technologies represent a “perfect know-how match.” Thanks to more than 20 years of experience and a strong commitment to innovation tied to efficiency and reliability, GDM is able to guarantee process flexibility and full control at high speeds. The integration of the two companies’ technologies will ensure an optimum Overall Equipment Effectiveness (OEE) for GDM’s converting-packaging lines.
“Our new partnership with Kodak is a major step forward for GDM to expand our added-value solutions. Combining Kodak’s continuous inkjet and sustainable ink technologies with GDM’s expertise in material handling will deliver a wide range of opportunities for our customers,” says Marco Rosani, market development manager, GDM. “Our customers will get increased flexibility, cost optimization and a more sustainable approach thanks to the inline integration.”
“Our collaboration with GDM is further proof of the suitability of Kodak’s unique continuous inkjet technology for a wide range of industrial applications,” comments Giuliano Bianchet, vice president sales EAMER, Kodak. “Integrating our PROSPER Imprinting Systems into GDM’s production lines makes digital imprinting a highly flexible, cost-effective step within an efficient, end-to-end manufacturing process.”
Indorama Strengthens Sustainability Portfolio
Indorama Ventures Public Company Limited (IVL), a global chemical company, announced its Hygiene Fibers Group features a further strengthened sustainability portfolio with the launch of the Deja Carbon Neutral polypropylene fiber range and significant advancements in its Biotransformative Polypropylene Fibers and Nonwovens Technology.As a global leader in PET recycling, IVL is committed to the delivery of a circular economy and recognizes that alternative sustainable solutions, such as carbon neutral fiber and biotransformation technology, provide valuable circular solutions when recycling may not be possible. Deja Carbon Neutral polypropylene fibers have been developed in response to customer demand for solutions to meet sustainability targets and objectives. Having undertaken a fully accredited Life Cycle Assessment on their processes and materials, IVL Hygiene Group subsidiary FiberVisions in Covington, U.S., now offer this select polypropylene staple fiber range, which balance greenhouse gas emissions with verified carbon offset projects in partnership with Strive, a leading provider of global climate solutions.
Advancements in dual solution Biotransformation (PP), designed to be recyclable and time-set biodegradable, was featured at the IDEA Show. A shelf stable polypropylene and stored, treated fibers and nonwovens can be recycled as normal. If diverted into the environment, it is scientifically designed to break down in natural conditions and to biotransform, leaving behind no toxins or microplastics.
All the six brands that make up the Hygiene Fibers Group – Auriga, Avgol, FiberVisions, Indorama Asia, Trevira and Wellman International – were represented at the IVL booth. The IVL Hygiene Group offers a comprehensive range of sustainable polymers, technologies and material, a global and regional footprint, and security of supply. The range includes recycled materials, multipolymer biodegradable solutions for both durable and non-durable products, ISCC Plus Certified Fibers and Nonwovens, and Deja Carbon Neutral polypropylene fibers.
Significant advancements in recycled materials were highlighted with the Wellman International team, recycling pioneers for more than 50 years, at IDEA. Recently commissioned technologies at its site in Mullagh, Ireland, allow PET to be recycled without compromising on quality. Sister bands Auriga, IVL Asia, and Trevira also offer a strong recycled PET (rPET) fiber portfolio to the hygiene industry. IVL’s Fibers business segment’s rPET portfolio is represented by the Deja brand platform, differentiated by a performance-led suite of sustainable solutions that help customers to achieve sustainability targets while also responding to end-consumers’ demand for transparency and environmental responsibility. Fibervisons and Avgol continue to develop sustainable fiber and nonwoven PP solutions, including PP recycling technologies.
Trevira focused on the recently launched range of bicomponent fibers based on PLA and PBS (polybutylene succinate). Both biopolymers offer an exceptional technological opportunity for environmental care and sustainability. PLA and PBS are recyclable and 100% biodegradable under industrial conditions.
Avgol understands that there is no one single solution to nonwovens sustainable developments, and adopt a holistic approach. Biotransformation PP is a key area of development, seeking a safe, proven, sustainable solution for absorbent hygiene products. Incorporating natural components, improved recyclability for PP, are key areas of focus for the company.
Joa Celebrates 90th Anniversary
Established during the Great Depression, Joa is no stranger to overcoming the toughest challenges. In 1932, its founder Curt G. Joa applied for his first patent, which introduced automation to the world of disposable hygiene product manufacturing. His groundbreaking invention led to the creation of the first feminine sanitary napkin machine and set the standard for industry excellence. Decade after decade, that spirit of innovation has carried the company to new heights. For 90 years, Joa has made a tradition of innovation, continually improving production processes for customers in ever-changing markets worldwide.Currently celebrating its 90th anniversary, Curt G. Joa, Inc. continues to provide innovative hygiene and specialty product converting platforms and technologies. Joa designs solutions for complex production problems based on a deep understanding of the goals each customer seeks to accomplish. Backed by proactive support, its state-of-the-art solutions are recognized for speed, quality and innovation the world over.
Innovation, which has been a core value of Joa’s for over three generations, continues to improve production processes for customers in an ever-changing market worldwide. Its innovative specialists can design and manufacture complex processes, from hygiene and specialty product solutions to even something as unique as a bottle opener.
Jofo Exhibited Joform Wipes Technology
At IDEA 2022, Jofo Nonwovens showcased Joform, a first of a kind wipes technology. The Chinese-based company recently completed construction on a novel commercial production line for superior and unique wipes materials. The production line is scheduled to produce commercial products in the third quarter with commercial sampling to happen in the second quarter of 2022. Sven Krister Erlandsson, global VP of R&D, claims this new “breakthrough” technology will provide wipes materials with properties in strength, absorbency and comfort that outperforms the leading providers in this field today.The production line is located in the Jofo Hygiene “hub” and headquarters located in Weifang, China. Beyond the wipes applications, the technology also shows a unique fit for other applications in the hygiene and medical sector with smaller developments to the technology underway within Jofo R&D. Following the integration of Soshio, a Chinese contract manufacturer for Rockline, Jofo will now have the capability for vertical integration and OEM production.
In other news, Jofo has started of a state-of-the-art Reicofil 5 production line, designed and dedicated to the high-end medical nonwovens products in Wuxi, China. The line is currently in the commissioning stage with some products already commercialized. Krister Erlandsson says that this latest technology from Reicofil combined with the company’s know how in raw materials and technology will allow it to penetrate the high-end medical nonwovens markets with products that provide superior comfort, protection and cost structures.
Polyvel Develops Non-Fluorinated Topical Water and Alcohol Repellent
Polyvel’s S-2780 is an aqueous dispersion of a non-fluorinated polyurethane/wax that is useful for imparting water and alcohol repellency to various fibers such as cellulose, synthetic fibers and fabric blends.S-2780 provides excellent water and alcohol repellency to fibers such as cotton, polyester/cotton and polyolefin fabrics (PP SMS barrier fabrics) with good hydrostatic head performance. The product is free of organic solvents and requires no special storage conditions except for protection from freezing.
Reicofil Exhibited High Performance and Sustainable Nonwovens
Nonwovens line specialist Reifenhäuser Reicofil presented its portfolio of high-performance and sustainable nonwovens under the slogan “Living Nonwovens” at IDEA 22.“We offer the appropriate line technology for almost any application. From soft and bulky High Loft nonwovens, sustainable and bio-based fabrics to high barrier nonwovens with optimized properties and reliable filter characteristics to nonwovens made from post-consumer waste. With our current RF5 machine generation, we are also setting the benchmark in terms of quality, performance, availability, efficiency and machine intelligence,” explains Markus Müller, vice president, Sales & Marketing, Reifenhäuser Group.
In terms of sustainability, Reicofil offers various approaches to save fossil raw materials, such as the processing of bio-based raw materials as an ecological alternative—for diapers, for example. Here, the topsheet material, made of bulky, soft and industrially compostable High Loft nonwovens, meets maximum hygiene requirements. For industrial applications, high-strength nonwovens can be processed even from up to 90% PET flakes from post-consumer waste. This is how Reicofil shows perfect ways to combine sustainability and high-performance nonwovens.
Another highlight is the so-called BiCo technology. In this process, two different raw materials are combined in one fiber in the spunbond process, creating a bimetal effect and causing the fiber to crimp. This opens the door for manufacturers to completely new product properties that are unattainable with monofibers.
For the medical sector, Reicofil showcased its leading solutions for high-barrier medical protective clothing, and—together with its sister business unit Reifenhäuser Cast Sheet Coating—the pioneering Ultrathin Coating production process, which enables customers to produce film-nonwoven composites more cost-effectively and thus competitively. The coronavirus pandemic and current supply bottlenecks have exposed the dependence of companies on global supply chains. This situation is both a warning signal and an opportunity to fundamentally strengthen local semi-finished product production. The jointly developed process achieves significant cost savings and easier line maintenance by eliminating the need for hot melt adhesives. With the patent-pending Ultrathin Coating technology, producers reduce film grammage by 66%. Thanks to the perfectly compatible combination of Reifenhäuser nonwovens and extrusion coating lines, customers thus receive seamless semi-finished product production.
With the c.Hub, the new data platform of the Reifenhäuser Group, Reicofil offers its customers a digitization solution that is tailored to the requirements of nonwovens production. Customers can securely connect, centrally store and easily analyze data from their Reicofil machines, peripherals, ERP and MES systems via the c.Hub middleware. Together with various software bundles, c.Hub is offered as an on-premise solution. It can be deployed locally and remains under the full data sovereignty of the user. Via the web-based ExtrusionOS user interface, customers can keep an eye on their production and the status of their machines wherever they are.
Suominen Launches Biolace Zero
Suominen has launched a carbon neutral nonwoven, Biolace Zero. Biolace Zero is an ideal product for many kinds of wiping applications like baby, personal care and household wipes. It has excellent wet and dry strength and it’s very soft. It is made of 100% cellulosic lyocell fibers and the product is 100% biodegradable, compostable and plastic free.Biolace Zero utilizes Veocel Lyocell fibers from Suominen’s long-term partner Lenzing. Biolace Zero is made of 100% carbon neutral Veocel Lyocell fibers.
“We are very excited to introduce Biolace Zero, which is not just Suominen’s first carbon neutral product, but also one of the first carbon neutral nonwovens on the market. Biolace Zero will be available as part of Suominen’s sustainable product portfolio,” says Marika Mäkilä, senior manager, Category Management, Europe.
Suominen’s Biolace Zero and Lenzing’s Veocel Lyocell fibers are certified as carbon neutral products by globally recognized company, ClimatePartner. Carbon neutrality means that the greenhouse gas emissions of nonwoven have been calculated—from the raw material production to the client’s production facility—reduced and are offset through certified carbon offset projects.
Suominen is a pioneer in sustainable nonwovens and has a wide range of sustainable nonwoven products for different applications. Suominen’s R&D team has excellent know-how on sustainable fibers and it is also continuously collaborating with innovative partners to develop new and innovative solutions with a reduced environmental impact into its product portfolio.
“With this new carbon neutral product Biolace Zero we are able to support our customers in their greenhouse gas emissions reduction targets. Innovating new products in collaboration with partners such as Lenzing by using carbon neutral Veocel Lyocell fibers is well aligned with our strategy and vision to be the frontrunner in sustainable nonwovens,” says Noora Rantanen, manager, Sustainability & Marketing.
SWM Diversifies Air Filtration Offerings for Face Mask Applications
SWM International, a global producer of nonwoven media, has launched Delpore Advanced Filtration Media—ideal for surgical facemasks, N95 offerings, and other facemask applications.“We have diversified our facemask offerings to provide various materials that have greater than 95% efficiency for standard flow rates,” says Bart Sistrunk, SWM’s commercial director - Filtration. “With our Delpore Advanced Filtration Media, N95 material can now be produced with a basis weight reduction of up to 30%. This reduction provides a more economic option for consumers, as well as increased comfort for all-day wear.”
SWM has a long history of supplying high-quality media integral to the manufacture and performance of facemasks used in the dental and surgical sectors as well as the construction and industrial sectors. Delpore Advanced Filtration Media allows for better airflow and breathability and is considered ideal for all day comfortable wear while maintaining key performance features.
SWM also offers Delnet apertured film, a lightweight nonwoven that is extruded, oriented and uniquely embossed for use as a flexible surface layer for medical face masks or as a comfort barrier in finger bandages.
