Orion Engineered Carbons Announces Investment In Acetylene Carbon Black To Drive Technological Strength In Batteries And Other Premium Segments

Orion Engineered Carbons S.A. (NYSE:OEC), a worldwide supplier of specialty and high-performance Carbon Black, announced on November 1, 2018, that it has reached an agreement to acquire Acetylene Carbon Black manufacturer Société du Noir d’Acétylène de l’Aubette, SAS [SN2A] from LyondellBasell Industries Holdings B.V. and its French affiliate. SN2A was founded in 1987 and is headquartered at Berre l’Etang, near Marseille, France.

Acetylene Black is an ultra-pure premium Specialty Carbon Black distinguished by its high electrical and thermal conductivity. Lithium-ion batteries and high-end electrical cables are key applications for this material.

“SN2A brings us a skilled team, proven technology and an operating plant. With this platform we are going to significantly strengthen our capabilities in the lithium-ion battery market and broaden our position in other attractive markets,” said Corning F. Painter, Chief Executive Officer of Orion Engineered Carbons. “This bolt-on acquisition is a perfect fit with Orion’s focus on Specialty Carbon Blacks. We look forward to welcoming the SN2A team to Orion and bringing Acetylene Black into our portfolio.”

The agreement with LyondellBasell includes provisions for a secured long-term feedstock supply. Orion plans to strengthen production capabilities at the Berre l’Etang facility.

The transaction closed on October 31, 2018.

About Orion Engineered Carbons S.A. (NYSE: OEC) Orion is a worldwide supplier of Carbon Black. We produce a broad range of Carbon Blacks that include high-performance Specialty Gas Blacks, Furnace Blacks, Lamp Blacks, Thermal Blacks and other Carbon Blacks that tint, colorize and enhance the performance of polymers, plastics, paints and coatings, inks and toners, textile fibers, adhesives and sealants, tires, and mechanical rubber goods such as automotive belts and hoses. Orion runs 13 global production sites and four Applied Technology Centers. The group has approximately 1,409 employees worldwide. For more information visit our website www.orioncarbons.com.

Type Of Lotion To Be Used In Infant Clothes And Improving Product Performance Based On Application Area

Çağla Bektaş / Senior R & D Engineer – Chemical Engineer

Evyap Sabun Yağ Gliserin Sanayi ve Ticaret Anonim Şirketi

ABSTRACT

Today, disposable diapers are high performance products designed to keep the sensitive baby skin dry and healthy. Diapers are basically composed of nonwoven fabric in contact with the skin, disintegrated cellulose and biologically inert polymers. Diapers may contain additional raw materials such as lotions, perfumes and/or creams depending on consumer preference. Considering the sensitivity of the baby skin, the compatibility of these raw materials with the skin and its performance on the finished product are of paramount importance. In this study, parametric studies have been conducted on lotion and/or perfume type, application system, application area and optimization of odor density on diaper. According to the study result, in addition to suppressing the odor after using the diaper, it was made possible to provide the diaper for consumers by minimizing the amount of wetness released to the skin from critical performance parameters.

 

Key Words: Diaper, lotion, perfume, lotion application, perfume application, diaper performance, odor density, perfume, cream

 

INTRODUCTION

One of the most important consumer products in the 20th century is smaller, cheaper, more useful and more environmentally friendly disposable diapers. [1]

As a result of the development and commercialization process, which started as a mere cellulose layer, today diapers comprise various parts such as a breathable/nonbreathable backsheet that forms the outer layer of the diaper and prevents the urine from infecting the baby’s clothing, a topsheet –the top layer of the diaper in contact with the baby skin–, adhesive side tapes used to attach the diaper to the baby, frontal tapes, where the side tapes adhere to each other when the diaper is dressed on the baby, elastic&nonelastic back ears with side tapes, the absorption and distribution layers placed under the topsheet (ADL; acquisition / distribution layer,) leg cuffs (barriers) used to prevent the urine from overflowing from the legs and the elastic leg barrier used in the backsheet, the superabsorbent polymers (SAP) used in the absorbent core layer, the pulp (cellulose) to provide a homogeneous distribution of the SAP particles on the absorbent core layer in the absorbent core layer, the nonvowen/tissue core cover which holds the SAP and the pulp together, the front ear which makes it easier for the mother to hold the baby while dressing, and the lotion specially developed to prevent bad smells after using the diaper and all the glue raw materials that make all these components stick to each other.

A Typical diaper layers are shown in Figure 1. [1]

 

 

Figure 1: Layers of a typical diaper

Diapers have the basic features that consumers expect, such as not causing rash, dryness, absorbency, resistance to long-term use, and minimizing bad odors after using. The lotion applications used in diapers help the diaper to suppress the bad odors after using, as well as affect the critical performance characteristics such as the duration of urine-sucking (strike throught time) and the amount of wetness released from the wet diaper to the skin depending on the type of lotion used and the application area. For this purpose, perfumes or cream applications can also be used.

In the study shared in Figure 2, perfume areas (85) were created in the backsheet layer (26) with the diaper’s outer surface to ensure that urine does not pass through the baby’s undergarment in order to suppress the bad odor in the diaper. Perfume areas have binders (82), which contain perfume releasing agents (65). Binders are attached to the outer surface (52) of the backsheet raw material. The perfume releasing agents and the binder are also protected by a strip (80), which separates them from the outer surface. The pulling strip preferably comprises a material containing polyethylene, polypropylene, nonwoven and/or a cellulosic substance. When this strip is removed, the separating agents make an odor explosion and/or a constant state diffusion. Perfume releasing agents may also provide a mechanism for entrapping the odor into the microcapsule in the urine. [2]

 

Figure 2: A side view of the perfume area showing a type of microcapsule before separation of the pulling strip from the perfume area (Fig. 2), a side view of the perfume area during separation of the pulling strip from the perfume area (Fig. 2A) [2]

Looking at the working principle of the microcapsule technology shown in Figure 2; it can be seen that it works by releasing the perfume out when the diaper is put on the baby, and taken off from the baby or while it is on the baby, since it is exposed to friction effect. The pulling strip produces a shear force to facilitate the breakage of the microcapsule along its upper portions, thus releases the perfume from the peeled part of the pulling strip. [2]

Looking at the principle of preventing odor from urine in the diaper, the odor is entrapped by the capsule being torn off and the perfume exploding or by the controlled release of the perfume through diffusion over time. The odor is entrapped with a structure like zeolite or activated carbon. [2]

The amount of perfume used in the diaper in the market is subject to the control of the manufacturer’s preference by changing the following parameters:

  • Microcapsule size and wall thickness
  • Type of connector used
  • Type of binder used
  • Amount and type of perfume used
  • Tearing/explosion strength of microcapsules
  • Number and distribution of microcapsules
  • Adhesion resistance of a binder according to the breaking resistance of microcapsules

Microcapsules can be made by chemical encapsulation or by mechanical encapsulation. These different techniques lead to production of microcapsules in different sizes, alternative materials for composition of the capsule shell and various different functional materials inside the shell.  Attaching the binder (with microcapsules) is possible by methods of air knife, engraving and pressing including silk screening, gravure coating and flexographic techniques. The binder (with microcapsules) can be applied as a continuous or discontinuous pattern on the outer surface of the backsheet. [2]

In another study, as shown in Fig. 3 and Fig. 4, a study was conducted for lotion application on the topsheet layer, which is the top layer of the diaper contacting the baby skin, was studied. Lotion application on the topsheet was conducted in 2 different ways:

  1. Application of lotion on the topsheet raw material before combining with other raw materials making the diaper

Figure 3: Spraying lotion directly on the topsheet raw material [3]

  1. Application of lotion on the topsheet, which is the top layer of final product during diaper production

Figure 4: Spraying the lotion directly on the topsheet of finished product during diaper production [3]

The amount of lotion composition applied to the topsheet depends on the proportion of the molten lotion composition to the sprayed amount from the spray station and to the speed parameters at which the conveyor belt passes under the spray station. [3]

In the study, the benefits of the lotion applied to the topsheet are explained as follows:

  • The lotion composition changes the skin’s surface energy, and forms a “barrier” to reduce the skin’s interaction with the feces.
  • It makes it easier to clean by reducing the tendency of feces to adhere to the skin.
  • Less lotion is required to apply the desired level of therapeutic or protective lotion. [3]

Looking at the lotion and/or perfume applications recorded in the literature, it is observed that the works carried out by application areas with microcapsule applications are limited due to their difficulty of use in diaper production lines working at high speeds. At high speed and in long production lines, microcapsules cause breaking of the capsule due to mechanical stretching and pressing forces they are subjected to while passing through conveyors, rollers and printing equipment. For this reason, the lotion and/or perfume is released before the product enters in the package. In cases where the lotion is applied to the top layer of the diaper such as topsheet, however, the lotion plugs the liquid passages of the nonwoven fabric layer, and blocks the capillary paths, thus prevents the urine transmission to the substrate. And this affects the diaper’s critical performance parameters such as STT (strike through time) and the amount of wetness released into the skin (rewetting). In this study, lotion and perfume applications are examined whereby lotion and perfume are easily applied in production lines and they positively affect the diaper’s critical performance parameters. Since lotion and perfume applications are conducted at the same time in the study, it will be referred to as lotion application in the following chapter’s of the study. Many parametric studies on the type of lotion used, application area, application method and odor density were carried out. The studies were compared with the lotion application of the reference product. The lotion application method is applied on the reference product with an air pressure of 1.5 bar. The lotion tank in the air-pressure system is as shown in Figure 5. Application on the diaper with air-pressure lotion application equipment is shown in Figure 6.

Figure 5: The lotion application tank in the air-pressure system

Figure 6: Application to baby diaper with air pressurized lotion application equipment

MATERIAL AND METHOD

The trials consisting of numerous parametric studies have been conducted for the case where the existing odor density is optimized with the applied lotion amount while changing the used lotion type and lotion application area, odor notes are optimized in the new lotion type, no stain observed on the baby diaper together with the new lotion application area and corrosion is minimized with elimination of water based lotion use in the production system and diaper performance is improved while making all these changes. Nordson LP 90 lotion application system has been used as an alternative to the reference air pressurized lotion application system during the studies and the visual of the system is provided in Figure 7.

Figure 7: Nordson LP 90 lotion application system

 

  1. 1st Parametric Study for Baby Diaper Lotion Type, Application Area, System and Conditions

The trials no. 1-12 from 23 trials set out in Table 1 have been performed with Nordson LP90 system by using oil based lotion 1 containing 5% perfume with no allergen substance, designed compatible with the baby skin. The trials no. 13-23 have been performed by using water based lotion, air pressurized lotion application system containing the same 5% perfume. The trial no. 23 is the study representing the reference and where 5% water based lotion is conducted with air pressurized lotion application system in 1.5 bar.

Table 1: Trial list of 1st Parametric Study for Baby Diaper Lotion Type, Application Area, System and Conditions

  Hertz Bar Lotion Application Area Application System Lotion Type
1 50 Under Absorbent Core Nordson LP90 Oil Based Lotion 1
2 60 Under Absorbent Core Nordson LP90 Oil Based Lotion 1
3 70 Under Absorbent Core Nordson LP90 Oil Based Lotion 1
4 40 Inner Backsheet Nordson LP90 Oil Based Lotion 1
5 50 Inner Backsheet Nordson LP90 Oil Based Lotion 1
6 60 Inner Backsheet Nordson LP90 Oil Based Lotion 1
7 40 Outer Backsheet Nordson LP90 Oil Based Lotion 1
8 30 Outer Backsheet Nordson LP90 Oil Based Lotion 1
9 20 Outer Backsheet Nordson LP90 Oil Based Lotion 1
10 40 Leg Elastic Edge Nordson LP90 Oil Based Lotion 1
11 50 Leg Elastic Edge Nordson LP90 Oil Based Lotion 1
12 30 Leg Elastic Edge Nordson LP90 Oil Based Lotion 1
13 1.5 Leg Elastic Edge Air pressurized system Water Based Lotion
14 2 Leg Elastic Edge Air pressurized system Water Based Lotion
15 1.5 Inner Backsheet Air pressurized system Water Based Lotion
16 2 Inner Backsheet Air pressurized system Water Based Lotion
17 2.5 Inner Backsheet Air pressurized system Water Based Lotion
18 1.5 Outer Backsheet Air pressurized system Water Based Lotion
19 1 Outer Backsheet Air pressurized system Water Based Lotion
20 2 Under Absorbent Core Air pressurized system Water Based Lotion
21 1.5 Under Absorbent Core Air pressurized system Water Based Lotion
22 2.5 Under Absorbent Core Air pressurized system Water Based Lotion
23 1.5 On the Absorbent Core Air pressurized system Water Based Lotion

 

  1. 2nd Parametric Study for Baby Diaper Lotion Type, Application Area, System and Conditions

The trials no. 1-8 from 17 trials set out in Table 2 have been performed with air pressurized system by using water based lotion containing the same 5% perfume. The trials no. 9-14 have been performed by using oil based lotion 2 and air pressurized lotion application system containing 5% perfume. The trials no. 15-17 have been performed by using oil based lotion 1 and Nordson LP90 lotion application system containing 5% perfume. The trial no. 1 is represented in 1.5 bar where 5% water based lotion is applied on the absorbent core in Table 2.

 

 

Table 2: Trial list of 2nd Parametric study for Different Lotion Type Applications with the Baby Diaper

  Hertz Bar Lotion Application Area Lotion Application System Lotion Type
1 1.5 bar On the Absorbent Core Air pressurized system Water based Lotion
2 3 bar Under the Absorbent Core Air pressurized system Water based Lotion
3 3.5 bar Under the Absorbent Core Air pressurized system Water based Lotion
4 4 bar Under the Absorbent Core Air pressurized system Water based Lotion
5 3 bar Inner Side of Backsheet Air pressurized system Water based Lotion
6 3.5 bar Inner Side of Backsheet Air pressurized system Water based Lotion
7 4 bar Inner Side of Backsheet Air pressurized system Water based Lotion
8 3 bar Under the Absorbent Core Air pressurized system Oil Based Lotion 2
9 3.5 bar Under the Absorbent Core Air pressurized system Oil Based Lotion 2
10 4 bar Under the Absorbent Core Air pressurized system Oil Based Lotion 2
11 3 bar Inner Side of Backsheet Air pressurized system Oil Based Lotion 2
12 3.5 bar Inner Side of Backsheet Air pressurized system Oil Based Lotion 2
13 4 bar Inner Side of Backsheet Air pressurized system Oil Based Lotion 2
14 75 Hertz Under the Absorbent Core Nordson LP90 Oil Based Lotion 1
15 65 Hertz Inner Side of Backsheet Nordson LP90 Oil Based Lotion 1
16 70 Hertz Inner Side of Backsheet Nordson LP90 Oil Based Lotion 1
17 75 Hertz Inner Side of Backsheet Nordson LP90 Oil Based Lotion 1

 

  1. 3rd parametric study for Different Lotion System Applications with the Baby Diaper

6 trials set out in Table 3 have been performed with air pressurized lotion application system. The trial no. 1 represent the reference water based lotion containing 5% perfume. The trials no. 2-6 have been performed by using oil based lotion 1 and air pressurized lotion application system containing 5% perfume.

Table 3: Trial list of 3rd Parametric study for Different Lotion System Applications with the Baby Diaper

  Hertz Bar Lotion Application Area Lotion Application System Lotion Type
1 1.5 On the Absorbent Core Air pressurized system Water Based Lotion
2 4 Under the Absorbent Core Air pressurized system Oil Based Lotion 1
3 4.5 Under the Absorbent Core Air pressurized system Oil Based Lotion 1
4 5 Under the Absorbent Core Air pressurized system Oil Based Lotion 1
5 5.5 Under the Absorbent Core Air pressurized system Oil Based Lotion 1
6 6 Under the Absorbent Core Air pressurized system Oil Based Lotion 1

 

  1. 4th parametric study for Different Lotion Concentration Applications with the Baby Diaper

7 trials set out in Table 4 have been performed with air pressurized lotion application system. The trial no. 1 represent the reference water based lotion containing 5% perfume. The trials no. 2-4 have been performed with oil based lotion 1 containing 15% perfume and the trials no. 2-7 have been performed by using oil based lotion 1 and air pressurized lotion application system containing 10% perfume.

Table 4: Trial list of 4th Parametric study for Different Lotion Concentration Applications with the Baby Diaper

  Hertz Bar Lotion Application Area Lotion Application System Lotion Type
1 1.5 On the Absorbent Core Air pressurized system Water Based Lotion
2 3 Under the Absorbent Core Air pressurized system Oil Based Lotion 1- 15% perfume modified
3 4 Under the Absorbent Core Air pressurized system Oil Based Lotion 1- 15% perfume modified
4 5 Under the Absorbent Core Air pressurized system Oil Based Lotion 1- 15% perfume modified
5 3 Under the Absorbent Core Air pressurized system Oil Based Lotion 1- 10% perfume modified
6 4 Under the Absorbent Core Air pressurized system Oil Based Lotion 1- 10% perfume modified
7 5 Under the Absorbent Core Air pressurized system Oil Based Lotion 1- 10% perfume modified

 

RESULTS

  1. 1st Parametric Study Results for Baby Diaper Lotion Type, Application Area, System and Conditions
    • Odor Density Determination

Table 1 includes the trial list with 23 parameters where 5% oil based lotion 1 is performed by using Nordson LP90 system and 5% water based lotion is performed with air pressurized system. The first evaluation on the baby diaper samples conducted for identifying the odor density by the odor specialist. The trials have been compared with the reference sample no. 23 in Table 1. Those no. 3, 6, 7 and 11 having oil based lotion 1 have been found to have the similar odor density with the reference, evaluated by the odor specialist. Those no. 14 and 22 having water based lotion have been found to have the similar odor density the reference, evaluated by the odor specialist. The trials no. 1, 2, 4, 5, 8-10, 12, 13, 15-21 included in Table 1 have failed in terms of odor density when compared with the reference and they have been disqualified for the following tests.

  • Stain control

It has been investigated whether or not there is any stain resulting from lotion application by conducting visual controls for the trials no. 3, 6, 7, 11, 14 and 22 in Table 1 whose odor density parameter is found to be similar to the reference. The trial samples for the stain control have been compared with the reference no. 23. The visual of the reference sample is provided in Figure-8.

Figure 8: Reference sample no. 23

Stain formation has been found on the backsheet surface in the trial no. 3. The visual of the stained sample is provided in Figure-9.

Figure 9: Lotion stain in the sample no. 3 in Table 1.

No stain formation has been detected on the baby diaper in the trial no. 6-7.

No stain formation has been detected on the baby diaper in the trial no. 11.

Stain formation has been found on the leg elastics area in the trial no. 14. The visual of the stained sample is provided in Figure-10.

Figure 10: Lotion stain in the sample no. 14 in Table 1.

No stain formation has been detected on the baby diaper in the trial no. 22.

  • Performance control

Table 5: Performance results of Trial 1

  3 6 No. 11 & 14 22 No. 23
3. Rewet (gr) 0.39 0.45 0.95 1.44
3. STT (sn) 64 67 63 55
Lotion Type Oil Based Lotion 1 Oil Based Lotion 1 Oil based Lotion 1 & Water Based Lotion Water Based Water Based
Lotion Application System Nordson Nordson Nordson & Air Pressurized System Air Pressurized System Air Pressurized System

 

Rewet performances of the trials no. 3 and 6 are significantly better when compared with the reference no. 23 according to the data shown in Table 5. STT performances are close to the reference and there is no significant difference in terms of performance with the reference. As the lotion applied on the leg elastics edge no. 11 and 14 has not affected rewet and STT performance of core, so performance has not been evaluated here. In the trial no. 22, rewet performance is better when compared with the reference. But, no performance improvement has been observed as it has been observed in the trial no. 3 and 6. As the lotion applied on the outer surface of the backsheet, backsheet couldn’t get dried immediately on outer side of the fabric in the trial no. 7. Therefore, this application has been found to be difficult in practice and performance evaluation has not been conducted.

  1. 2nd Parametric Study Results for Baby Diaper Lotion Type, Application Area, System and Conditions

 

  • Odor Density Determination

Table 2 includes the trial list with 17 parameters where 5% oil based lotion 1 is performed by using Nordson LP90 system and 5% oil based lotion 2 and 5% water based lotion have been performed by using air pressurized system. The first evaluation on the baby diaper samples has been conducted for identifying the odor density by the odor specialist. The results of the trials have been compared with the reference sample no. 1 in Table 2. Those no. 2, 3 and 4 having water based lotion have been found to have the similar/better odor density with the reference, evaluated by the odor specialist. The trial no. 14 conducted by using oil based lotion 1 have been found to have the similar/better odor density with the reference, evaluated by the odor specialist. The trials no. 5-13 and 15-17 included in Table 2 have failed the odor density test when compared with the reference and they have been disqualified for the following tests.

  • Stain control

It has been investigated whether or not there is any stain resulting from lotion application by conducting visual controls for the trials no. 2, 3, 4 and 14 in Table 2 whose odor density parameter is found to be similar/better to the reference. The trial samples for the stain control have been compared with the reference no. 1. The visual of the reference sample is provided in Figure-8.

No stain formation has been detected on the baby diaper in the trial no. 2-4 and 14.

  • Performance control

Table 6: Performance results of the Trial 2

No. 1 No. 2 No. 3 No. 4 No. 14
3. Rewet (gr) 1.42 1.27 1.19 1.14 0.87
3. STT (sn) 64 70 71 69 60
Lotion Type Water Based Lotion Water Based Lotion Water Based Lotion Water Based Lotion Oil Based Lotion 1
Lotion Application System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System Nordson LP90 System

 

Rewet performance of the trial no. 14 is significantly better when compared with the reference no. 1 according to the data shown in Table 6. STT performances are close to the reference and there is no significant difference in terms of performance with the reference. Rewet performance has been better when compared with the reference in the trials no. 2, 3 and 4; however, no performance improvement has been observed as it has been observed in the trial no. 14.

  1. 3rd Parametric Study Results for Baby Diaper Lotion Type, Application Area and Conditions
    • Odor Density Determination

Table 3 includes the trial list with 6 parameters where 5% oil based lotion 1 and 5% water based lotion have been performed by using air pressurized lotion application system. The first evaluation on the baby diaper samples conducted for identifying the odor density by the odor specialist. The results of the trials have been compared with the reference sample no. 1 in Table 3. Required odor density similar to the reference has not been acquired in all samples according to the evaluation by the odor specialist.

  • Stain control

The trial samples for the stain control given in Table 3 have been compared with the reference no. 1. The visual of the reference sample is provided in Figure-8.

No stain formation has been detected on the baby diaper in the trial no. 2-6.

 

  • Performance control

Table 7: Performance results of Trial 3

  No. 1 No. 2 No. 3 No. 4 No. 5 No. 6
3. Rewet (gr) 1.46 0.12 0.20 0.17 0.15 0.21
3. STT (sn) 68 62 66 61 70 59
Lotion Type Water Based Lotion Oil Based Lotion 1 Oil Based Lotion 1 Oil Based Lotion 1 Oil Based Lotion 1 Oil Based Lotion 1
Lotion Application System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System

 

Rewet performances of the trials no. 2-6 are significantly better when compared with the reference no. 1 according to the data shown in Table 7. STT performances are close to the reference and there is no significant difference in terms of performance with the reference.

  1. 4th Parametric Study Results for Baby Diaper Lotion Type, Application Area and Conditions
    • Odor Density Determination

Table 4 includes the trial list with 7 parameters where 10% and 15% oil based lotion 1 and 5% water based lotion have been performed by using air pressurized lotion application system. The first evaluation on the baby diaper samples conducted for identifying the odor density by the odor specialist. The results of the trials have been compared with the reference sample no. 1 in Table 4. Odor density of the sample no. 2 evaluated by the odor specialist has been found similar to the reference. As odor density of the samples no. 3-4-6-7 is higher than the reference and odor density of the sample no. 5 is weaker than the reference, they have been disqualified from the evaluations.

  • Stain control

The trial samples in Table 4 have been compared with the reference no. 1 for the stain control. The visual of the reference sample is provided in Figure-8.

No stain formation has been detected on the baby diaper in the trials no. 2-7.

  • Performance control

Table 8: Performance results of Trial 4

  No. 1 No. 2 No. 3 No. 4 No. 5 No. 6 No. 7

 

3. Rewet (gr) 1.46 0.27 0.30 0.25 0.35 0.38 0.29
3. STT (sn) 68 62 66 61 62 59 65
Lotion Type Water Based Lotion Oil Based Lotion 1- 15% perfume modified Oil Based Lotion 1- 15% perfume modified Oil Based Lotion 1- 15% perfume modified Oil Based Lotion 1- 10% perfume modified Oil Based Lotion 1- 10% perfume modified Oil Based Lotion 1- 10% perfume modified
Lotion Application System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System Air Pressurized System

 

Rewet performances of the trials no. 2-6 are significantly better when compared with the reference no. 1 according to the data shown in Table 8. STT performances are close to the reference and there is no significant difference in terms of performance with the reference.

FINDINGS and DISCUSSION

The samples related to each trial performed under parametric studies have been respectively subjected to the following evaluations:

  • Determination of odor density similarity between trial sample and reference sample by the odor specialist
  • Determination of lotion stain control on the product in the trial samples which odor density is detected to be similar with the reference sample
  • Determination of the finished product performance tests results which odor density is detected to be similar with respect to the reference sample and no stain observed on it

 

The findings related to the study conducted accordingly are as follows:

23 trials have been conducted in the 1st parametric study contained in Table 1. The trial no. 23 represents the reference and the other 22 trials have been compared with this reference sample. The samples related with these trials have been firstly evaluated by the odor specialist for determination of the odor density. The trials which odor density are found to be similar with the reference sample no. 23 are the trials no. 3, 6, 7, 11, 14 and 22. As odor density similar to the reference has not been determined in the other trials, they have been noted as failed. As lotion stain has been determined in the trials no. 3 and 14 that are successful in determination of odor density, these trials have been noted as failed. As it is estimated when the lotion application area in the process is taken into consideration in the trials no. 7 and 11, this will cause complication in the process during routine production, backsheet inner side and leg elastics edge applications have been removed from the trials in the following trials. The trials no. 6 and 22 have successfully completed the criteria of odor density, stain and performance in the list of parametric studies in Table 1.

17 trials have been conducted in the parametric study contained in Table 2. The trial no. 1 represents the reference and the other 16 trials have been compared with this reference sample. The samples related with these trials have been firstly evaluated by the odor specialist for determination of the odor density. The odor density of the trials no. 2, 3, 4 and 6 have been found successful when compared to reference sample by odor specialist. As odor density similar to the reference has not been determined in the other trials, they have been noted as failed. No stain occured for these 2, 3, 4 and 6 trials and noted as successful in terms of stain control.  When comparing for the final product performance, all samples have better rewet and STT performance from the reference sample no. 1, they have been deemed successful. However, there is still an area to be improved for rewet performance.

6 trials have been conducted in the parametric study contained in Table 3. The trial no. 1 represents the reference and the other 5 trials have been compared with this reference sample. The samples related to these trials have been firstly evaluated by the odor specialist for determination of the odor density. Since similar odor density has not been achieved in all trial samples with respect to the reference no. 1, all trials are notes as failed.

7 trials have been conducted in the parametric study contained in Table 4. The trial no. 1 represents the reference and the other 6 trials have been compared with this reference sample. The samples related to these trials have been firstly evaluated by the odor specialist for determination of the odor density. Only odor density of the trial no. 2 has been founded to be similar with the reference sample no. 1 and have been noted as successful. Since the similar odor density has not been achieved in the other trials, they have been noted as failed. The trial no. 2 have become successful in the criteria of odor, stain and performance controls.

CONCLUSION

Given all parametric trial studies conducted in Table 1, Table 2, Table 3 and Table 4, similar odor density with respect to the reference, no lotion stain and the best finished product rewet performance is achieved in the trial no. 2 given in Table 4 with 0.27 gr rewet performance. Upon the release of the diapers produced in this manner, the expectation of the consumer will have been met in the most accurate way.

REFERANCES

[1] Dyer, D., “Seven Decades of Disposible Diapers: A record of Continuous Innovation and Expanding Benefit”, 2005, Edana.

[2] EP0957869B1, “Diaper Having Perfume Zones”, P&G, 2016

[3] US6118041A, “Diaper Having a Lotioned Topsheet”, P&G, 2000

Oerlikon to Cooperate with Shaoyang

Oerlikons business unit Nonwoven will cooperate with the Chinese machine and plant manufacturer Shaoyang Textile Machinery for nonwoven solutions in the hygiene market.

The aim of both cooperation partners is to jointly advance the international sales of Spunmelt lines for hygiene applications in the field of disposable nonwovens outside China. Oerlikons business unit Nonwoven will be responsible for the entire project in the future. To this end, the Neumünster-based company will contribute its know-how in plant engineering to the partnership.

Additionally, Oerlikon acquires the CE certifications of all exported Shaoyang Spunmelt lines. Oerlikon will also be responsible for product and process guarantees and will provide worldwide customer services outside China. Shaoyang Textile Machinery, on the other hand, supplies the Spunmelt plant technologies. “With Shaoyang Textile Machinery, we have found a renowned Chinese plant manufacturer with extensive know-how in the construction of Spunmelt plants for hygiene applications, which achieves international standards with its nonwoven qualities,” explains Oerlikon Manmade Fiber Segment CEO Georg Stausberg.

Rainer Straub, Head of Oerlikons Nonwoven Business Unit, adds: “The partnership enables us to gain a foothold in the highly competitive hygiene market. Our many years of engineering experience guarantee our customers production lines according to international standards for high-quality nonwovens”.

 

New Solutions for Nonwoven and Finishing Technologies from Andritz

International technology Group Andritz presented its innovative nonwovens and textile finishing technologies for the Asian markets at the ITMA Asia + Citme 2018 Fair.

In response to market demands, Andritz has yet again raised the bar for turnkey and customized solutions for drylaid, spunjet, thermobonding, and wetlaid, as well as for conversion of absorbent hygiene products. Andritz offers unique technologies tailored to each customer’s individual needs.

Andritz Air-Through Bonding Technology – A New Solution For The Hygiene Market

Air-through bonding lines are the preferred choice for producing nonwovens with the best quality of  softness and bulk for acquisition and distribution layers, top sheets, and back-sheet products. With Andritz carding machines and the new flat belt oven, customers benefit from high production capacities and high-performance fabrics from 16 to 80 gsm, produced with bicomponent fibers. Several Chinese customers have already invested in Andritz aXcess carding machines, which provide perfect web uniformity. In addition, the CETI (European Center for Innovative Textiles) in Lille, France, has recently installed an air-through bonding oven from Andritz. Customers can compare the technical results obtained from two different options: bonding with the flat belt oven or with the drum (both supplied by Andritz). If customers would like to see the new solution for themselves, they are most welcome to conduct trials at the CETI (European Center for Innovative Textiles) in Lille, France.

Full Drylaid Processes Offer With The Andritz Axcess Range

Thanks to its aXcess portfolio, Andritz offers the full range of drylaid processes for medium production capacities. During the past few months, Chinese spunlace producers have invested in several aXcess lines with direct-line and crosslapped configurations manufactured by Andritz Wuxi. This booming market goes hand in hand with new trends such as the development of the facemask industry and continues to be driven by the growth of wipes applications.

In the medium-capacity needlepunch area, Andritz signed a cooperation agreement in 2017 with ShanTou SanFai Nonwoven Machinery, a leading supplier of needlelooms in China. This cooperation fits together perfectly, uniting the advantages of proven technologies and providing reliable solutions for a wide range of applications in the needlepunch industry. The Andritz aXcess range for web forming and SanFai’s needlelooms offer a big advantage in terms of investment security, innovation, and quality, and this combination also meets the increasing demands of a strong, growing market.

To better serve the local market, Andritz Wuxi focuses on in- creasing efficiency and shortening delivery time – from project management and design, to service work.

New Development In Textile Calendering

With the latest development in textile calendering, Andritz in co-operation with Rolf Ramisch, who has over 45 years of experience in this specific business and commands excellent expertise in deflection-controlled roll technology, is again raising the bar for the textile calender market.

The new teXcal raconip calender is versatile, operator friendly, and provides IIoT (Industrial Internet of Things) features for a smart production process. Sensors on the machine collect and archive all machine data and send them to a monitoring system. This intelligent production equipment offers a transparent and optimized process as well as a forecast for maintenance planning. In addition, the calender includes an optimized, deflection-controlled roll with unrestricted profiling possibilities over the entire roll width.

This ensures maximum production flexibility and reproducible product properties – e.g. absolute flatness and ideal air permeability for technical textiles.

Dilo: Lines for Artificial Leather, Geotextiles and Hygiene Articles

DiloGroup delivers complete lines for the production of needled staple fibre nonwovens. In its 116 years of history, Dilo has always set new standards. Innovative technologies such as DI-LOOP, DI-LOUR and Hyperpunch have opened new markets and contributed to their growth.

To further develop the Asian market, Dilo has opened a subsidiary in India near New Delhi. This enables a closer relationship to customers as well as faster support for sales and service.

DiloGroup delivers complete lines for the production of needled staple fibre nonwovens. In its 116 years of history, Dilo has always set new standards. Innovative technologies such as DI-LOOP, DI-LOUR and Hyperpunch have opened new markets and contributed to their growth. Current developments offer custom-made lines which do not only increase capacity but also fulfill endproduct property requirements.

Hyperlayer

The production of very light-weight hygiene products on water-entanglement lines requires a high web quality and a low area weight. At the same time, the Asian market requires a balanced MD/CD strength ratio. To realize high productivity with these demands, Dilo has resumed and revised the principle of the camel-back crosslapper. The kinematic solution of the Hyperlayer lays down the web gently and precisely even with a small number of layers.

As the web is guided through the complete laydown process on both sides, highest production speeds (web infeed speeds up to 200 m/min), precise edges and a minimum of draft can be realized depending on the fibres used.

Compact line, carbon recycling

A positive trend to lightweight construction in recent years has led to the substitution of metal structures by carbon composites in large quantities. With its new compact line, Dilo has contributed significantly to the recycling of composites. Recycled carbon staple fibres are reprocessed into felt and can then be further converted to new structural elements. In contrast to most staple fibres, carbon fibres have characteristics (smooth surface, no crimp, low cross strength) which require adaption of web forming within the carding machine. Withits compact card (DCL) Dilo has met these challenges and introduced a stable web forming process. The compact line also meets the requirements for a production of small quantities of needle felts made from other high quality special fibres like ceramics or PTFE. Dilo presented the compact line first in 2015. It is now in use in industry and research. With a card working width of 1.1 m and a layering width of 2.2 m, it requires a floor space of only 60 m².

Hypertex

Nonwoven filter media consist of a sandwich structure which combines the filtration characteristics of felts with the high strength of yarns or filaments. The HyperTex process allows the production of reinforced felts online and eliminates an additional stage for producing the scrim. In the HyperTex process Dilo combines a scrim fabric machine of Messrs. OnTec with a Hyperpunch needleloom. The structure derives its strength from needling scrim, upper and bottom felt together. Very high production speeds up to 40 m/min can be reached. Infinitely variable mesh sizes in the scrim and a wide variety of different reinforcing yarns offer a great flexibility to the customer. The high efficiency in regard to fibre and energy consumption and the low space re- quirement are further significant advantages of this technology.

Starlinger: Recycling Specialist in Research Project for the Separation of Mixed Textile Waste

Within the textile network PlasTexTron©, Starlinger recycling technology is searching for an ecologically and economically sound solution for the recycling of mixed textile waste of multi-material composition. Three universities and eight Austrian companies are involved in the COIN-project TEX2MAT, which is led by the Plastics Cluster of ecoplus, the business agency of Lower Austria, and funded by the Austrian Federal Ministry for Digital and Economic Affairs (BMDW).

The project TEX2MAT addresses the recycling of different kinds of old textiles that consist of a mixture of polyester and cotton. The first step is the enzymatic separation of polyester and cotton in a procedure developed by the Viennese University of Natural Resources and Life Sciences; after appropriate reprocessing, the materials are reused in new products. The input material is supplied by the com- panies Herka Frottier, Salesianer Miettex and Huyck.Wangner Austria (Xerium Group), which are all located in Lower Austria. Starlinger recycling technology – a business unit of Starlinger which manufac- tures recycling lines and has already developed solutions for closed loop production in the field of polyester textiles – provides recycling services and expertise for the project. To achieve an optimal result, regular controls of the material properties are performed by the University of Leoben.

The project partners are working on specific case studies:

  • Mixtures of polyester and cotton from the production of towels as well as old textiles in the form of bed linens and working clothes are shredded by Starlinger recycling technology in Weissenbach and then undergo enzymatic treatment at the Technical University of The goal is to develop a sample process for closed loop production.
  • Technical nonwovens made of polyamides are shredded and turned into regranulate by Starlinger recycling technology; Thermoplastkreislauf GmbH then adds substances such as glass fibers, additives and/ or colors as needed (a process commonly known as compounding). The companies Multiplast Kunststoffverarbeitung and Fildan use this customized material in the production of highly technical plastic parts such as components for fire extinguishers or bra

The project TEX2MAT started in November 2017 and will be running over the course of two years. The project partners meet in regular intervals to align the individual steps and discuss the overall progress.

 

ANDRITZ and BCNonwovens celebrate successful long-term partnership

International technology Group ANDRITZ and BCNonwovens, Spain, have been working together successfully as business partners for the past 15 years. This cooperation started in early 2003 right after BCNonwovens was founded.

By offering state-of-the-art technology, including tests and trial runs at ANDRITZ’s technical center, and providing comprehensive expert know-how, ANDRITZ has supported and helped the family-owned company BCNonwovens to become one of the leading producers of spunlace fabrics for the wipes market as well as for medical and industrial applications.

BCNonwovens is now running two ANDRITZ spunlace lines successfully, producing high-quality products that are sold globally. To cope with the demand for higher productivity and product quality as well as for lighter products and patterned webs, BCNonwovens’ R&D team and ANDRITZ process engineers were able to retrofit the existing lines to bring products up to the standard currently requested by the markets. Sergio Rosales, R&D Director of BCNonwovens says: “Thanks to ANDRITZ, we have been able to test the latest innovations available on the market and adapt them to our production lines.” As BCNonwovens has always been commited to responsible and sustainable production, the company has installed ANDRITZ’s proven neXecodry system, thus achieving a significant reduction in consumption of water and gas.

Didier Vulliet, General Director of ANDRITZ Perfojet, says: “For years we have been building a strong partnership with BCNonwovens. They used our ANDRITZ spunlace pilot line for validation of new products or implementation of new fibers, and we were able to test new developments under industrial conditions.”

ANDRITZ is accompanying BCNonwovens in the development of new products with new fibers and features that are increasingly innovative or meet the demands of converters with ever more relevant end-products. Miguel Vinas Pich, CEO of BCNonwovens, concludes: “ANDRITZ has been supporting us for years in our development, which has been allowing us to offer our customers some of the most competitive and highest quality products in the world.”

We Will Provide the Consist of Sense of Trust When Jelly Tekstil is Called

Wholly invested by China’s Dongguan Jelly Cloth & Embroidery Accessories Co. Ltd., which, as one of the leading manufacturers of interlining in China, equipped with over 50000 m2 self-owned workshops and 20 production lines, has the capacity of over 500000 m woven and over 500000 nonwoven interlinings per day.

With the development of business, Jelly kicked start its pace of internation- alization in the year of 1995 and has established its processing factories or service outlets respectively in Thailand, Indonesia, Vietnum, Cambodia, Burma, Turkey and so forth. Jelly Tekstil, with the input value of over USD2.20 million, is located in Niğde Turkey, has bought 16.000 m2 land and constructed 2000 m2 workshops locally, equipped with the whole line from the processing of base cloth to the gluing and packing. It already has the capacity of producing 100000 m nonwoven interlinings per day. Further extending its capacity and aims to increase its market share in the Turkey market Jelly Tekstil, has already built strong business ties with some top listed interlining distributers in Turkey.

We made interview with Selim Güleş, Turkish Representative of Jelly Textile for this issue of our Nonwoven Technical Textile Tecnology Magazine.

First of all, could you tell us about yourself and your company?

I am a Turkey representative of Jelly Tekstil. I am interested in Turkey links of our international company which has production facilities in five different countries. The strongest of these facilities is located in China. We will gather all our factories on a land of 40 decares at one point. The area of 20 decares is now completely ready. We have started to produce new products in the field of technical textiles.

Jelly Tekstil, when started its production activities in Turkey?

Our facility, which was established in August of 2013, started to operate as a coating facilitie towards the end of the year. By integrating our facilitie in the course of time, we have become able to produce all of our garment nonwoven interlinings in Turkey.

Could you give us some information about your work?

Out of the garment interlining and nonwoven interlining; We are preparing to produce make-up wipes, diapers and cleaning wipes, masks, gowns, disposable towels, disposable sheets, disposable underpad. We also plan to manufacture several products in the packaging industry. We will produce packaging tapes and double-sided tapes again which we interrupt production. In addition to this, we will also activate our embroidery interlining groups. Easy tearable, water-soluble, embroidery threads are also in our plans. We are planning to produce our new high textile products in Turkey, and will enter the market with a new brand. The most important point is creating brand awareness. For this reason, We will provide to the consist of sense of trust when jelly textile is mentioned about.

Could you tell us about your most popular products?

We are currently concentrating on garment products. Our products which attracted the most attention are from the group of nonwo- ven interlining and garment interlining.

Could you give us information about your investments?

We have recently doubled our factory capacity in Niğde. We are planning to increase our capacity by adding new production lines in line with market demands. We also plan to build new factory buildings on our land. In line with the supply-demand-and of course the market conditions are very important – we are aiming for continuous growth. Production doesn’t have in Turkey not provide too much of an advantage in terms of both our country and our company. As Turkey is located on an important point position, making production here will be our first priority.

What do you think about the approach of the market to your compnay and your brand awareness?

We think we are at a competitive level with the market. Making our production in Turkey, gives us the relative price advantage. Especially our customers coming from abroad say that they want to work with us for this reason.

Could you tell us about your after-sales service?

Our goal is to protect the brand value of all of our products therefore we always give importance to quality. We provide solutions to problems that our customer is experiencing. As Jelly Tekstil, we are completely customer focused. We also guarantee that there will be no problem in our products.

Packaging Methods Threaten Human Life

People who work with food packaging feel tied down by all the regulations and standards that exist to guarantee safety. However, the regulations for packaging medical technology (“medtech”) products are equally complex. These products must be manufactured in a sterile environment and then transported all the way into an operating room without risking contamination. Otherwise, people’s very lives could be in danger.

One of the most important requirements is that the packaging solution can successfully deliver the product – which might be an implant or surgical equipment – into the operating room. To ensure this, numerous standards place demands on the packaging material’s permeability, that it can withstand the sterilisation process, that its closures are durable, that the materials do not allow microorganisms to pass through them, and much, much more. All these requirements must not only be met, they must also be documented with the support of statistically significant data. The natural explanation for why medtech packaging regulations are so stringent is partly that people’s lives can be at risk. Another reason is that the product itself is of high value, especially if its underlying R&D costs are included in the calculations. Last but not least, huge costs could result if something goes wrong – if a product’s packaging is inadequate the manufacturer may have to do a major recall and could also be held responsible for non-delivery.

“I’ve seen examples where a med- ical implant is packed in a sealable bag made of a plastic material, put inside an outer packaging made of paperboard, and then put inside a transport packaging made of cardboard,” says Ian Huskinson, Technical Service Manager at Iggesund Paperboard. “Then the transport packages are stacked onto a pallet and secured with shrink wrap. The whole pallet is then loaded into a sterilisation chamber and sterilised.” Supplying material for use in medtech packaging can also involve demands that rarely occur in other industries. Because all input materials must go through extensive and thereby costly qualification and validation processes, subsequently altering or replacing them is strongly discouraged.

“Sometimes we must commit to not making any changes to the product’s composition for a number of years into the future. That might mean we have to abstain from improving a product even though we could do so – but that’s the price of being considered as a supplier to the medtech market,” Ian Huskinson emphasises. “One of our foremost assets in this context, in addition to the purity and hygiene that are associated with using virgin fibre, is our strong focus on product consistency,” he adds.

Both of Iggesund Paperboard’s paperboard brands, Invercote and Incada, are used in a number of medtech applications.

IsraVision, Avoids Errors in the Production of Nonwoven

IsraVision has developed an application called Web-Monitoring. Thanks to the application, visual error detection can be done, users can obtain reliable information about the surface weight and uniformity of the material.

How uniform is the material distributed in the final product? The answer to this question helps manufacturers of nonwovens to do more than just optimize their use of resources. Mistakes occurring during production often show up as varying material thicknesses in the final product.

To ensure uniform weight for nonwoven materials, a new inspection solution now controls the material distribution within the web, thus increasing efficiency and yield of production lines.

The application, often called Web-Monitoring, extends an already proven system: in addition to visual error detection, users receive reliable information on surface weight and uniformity of the material. Beyond basic weight, the system also checks for “cloudiness”, i.e., fiber distribution within the material. This allows for quickly detecting exceedingly thin or thick spots. Even more complex faults such as craters that occur during coating can be reliably captured with the inspection expansion. As a result, goods with deficiencies will not be processed or delivered.

Higher quality for the entire production process Comprehensive inspection of surface and homogeneity not only reflects the quality of the product but also the quality of the manufacturing process. The inspection for example, makes deficiencies in the rolls’ functionality easily visible: both roller tracks on the material surface and uneven material distribution are decisive indications that a roller might be defective. Employees working along the line can thus be quickly alerted to faults in the process and take appropriate action to avoid producing rejects.

Versatile expansions contribute to multifaceted inspection for optimum production results

Extending existing inspection systems with additional features provides a cost-effective, fast and sustainable way to increase an inspection’s efficiency and thus the quality of the final product. A wide range of options is available for this purpose, including intelligent use of defect data while materials are being cut as well as so-called beyond inspection features. The latter utilizes defect data to enable of retroactively repairing and produced rolls thereby improving quality. Particularly interesting for nonwoven manufacturers among these extensions is the so-called embossing control. Intelligent LED along with software extension make a precise testing of embossed materials possible. Never has a modern inspection performance package been more versatile or powerful. Producing to the highest standards of quality thus becomes child’s play for manufacturers.