Since 2017: Autefa Solutions Focuses on Customers’ Requirements

Autefa Solutions, a market leader in China for high speed air through thermobonding lines for hygiene products, will inform the visitors at Since 2017 about the economic and technical advantages they provide as a full line supplier for carded‐ crosslapped nonwovens lines, needlepunch nonwoven lines, spunlace and thermobonding lines.

As nonwovens producers are facing more competition, they are looking for reliable and economic machines. They expect high quality and the best total cost of ownership (TCO), which is the key to success. There is a significant number of customers who hesitate to replace existing machines or invest in new machines, due to increasing prices. During the Shanghai International Nonwoven Conference and Exhibition (SINCE) Autefa Solutions will present its Nonwovens “LineONE” concept which operates at a very high level and sets new standards with an attractive costto‐performance ratio. Autefa Solutions nonwovens lines meet customers’ requirements for quality web formation and web bonding, active weight regulation, and minimal maintenance. With the Crosslapper UnilinerONE, Autefa Solutions supplies a highperformance machine based on the successful Crosslapper Topliner. Optimised infeed speeds of the carded web, layering precision, layering speed of 80 m/min (max.) and reliability are the mainbenefitts of the Crosslapper UnilinerONE. The Needle Loom Fehrer StylusONE is a compact needle loom for all needling applications up to 1,800 g/m2. With a maximum performance of 1,200 strokes/min, the Needle Loom StylusONE distinguishes itself through productivity, guaranteed longevity and maintenance‐free gear boxes.

Autefa Solutions delivers complete lines for the production of top sheets, acquisition and distribution layers (ADL) and back sheets. The consumer products benefit from the nonwovens features elasticity, softness and absorption. As a premium supplier, the company delivers machines for opening, blending and carding as well as ovens and dryers out of one hand. The company sets the focus on HiPerTherm, the high speed thermobonding oven for the manufacturing of hygiene products such as acquisition and distribution layers (ADL), top and back sheets. The key strengths of the Autefa Solutions belt oven are uniform airflow and the precisely adjustable temperature distribution, the ability to maintain loft or to create high densities.

Andritz Nonwoven Highlights its Cutting-Edge Technologies at Since 2017

Andritz Nonwoven, part of international technology Group Andritz, will be presenting innovative nonwovens production solutions that target technologies for the Asian markets at Since 2017 in Shanghai, China.

Andritz Nonwoven aXcess calender range: The key to spunbond applications
neXcal twin aXcess, the latest development in the Andritz aXcess calender range, originates from the reputed and proven technology of the neXcal twin. With a speed range of up to 600 m/min and a standard roll width of up to 3,800 mm, the neXcal twin aXcess is a spot-on solution for medium capacity production lines. With one engraving roll in production and one in the stand-by position, the three-roll cal- ender warrants significant flexibility in the medium-capacity nonwovens market. The neXcal compact two-roll calender completes the Andritz aXcess calender portfolio.

Raising the bar for Chinese market standards: Andritz neXline spunlace eXcelle with TT card and JetlaceEssentiel
Chinese nonwovens manufacturers are increasingly requiring higher capacities and top-class quality for spunlace nonwoven products serving local and export markets. Andritz Nonwoven has the right solution and offers neXline spunlace eXcelle with TT card web forming and JetlaceEssentiel hydroentanglement units for very high capacities. Several lines have been sold this year, the first line is scheduled to begin operations before the end of 2017. Cutting-edge Chinese nonwovens producers are clearly targeting this configuration. In addition, Andritz Nonwoven offers a neXline spunlace eXcelle in crosslapped configuration, which is especially suited for technical products and disposable face masks.

Andritz (China) Ltd. Wuxi: Supplier of complete lines and full service for the Asian nonwovens industry
As an all-round partner for the nonwovens industry, Andritz (China) Wuxi branch covers sales, technology, manufacturing, operations, and service competences for nonwovens aXcess lines and individual machines. The Andritz aXcess range focuses on producers with medium-capacity requirements, combining the advantages of proven technologies while providing reliable solutions in all nonwovens segments, such as hygiene, wipes, disposable face masks, automotive, filtration, and geotextiles.
Andritz Wuxi is the local manufacturer of key components, such as cards, crosslappers, drafters, needlelooms, hydroen- tanglement units, and dryers, attending to local market demands. In addition, complete lines and individual machines are pre-assembled and inspected at this facility before delivery. The Andritz roll service center in Wuxi com- prises state-of-the-art grinding equipment and a test stand for various kinds of rolls up to 1 m in diameter and 10 m in length. Here, Andritz offers customers complete roll service, such as repairs and upgrades, in line with European quality standards for the Asian textile, nonwovens, and paper indus- tries.Furthermore, the Andritz facility in Wuxi provides a top- notch needlepunch line on industrial scale, including card, crosslapper, pre-needler, and needleloom. The pilot line gives nonwovens producers the opportunity to conduct trials with newly developed or modified products under real production conditions prior to market launch.

Multitexx Spunbonds: High-Strength and Featherweights

Nonwovens are real allrounders. Thanks to their extreme versatility and adaptability, they are being deployed in more and more applications in the hygiene, medical, construction, industrial and environmental sectors. And thanks to their costefficiency, they are also increasingly replacing conventional materials.

There is a constantly growing demand for lightweight, high-strength spunbond nonwovens a demand to which the newcomer company Multitexx GmbH, based in Herdecke, Germany, is responding with highgrade polyester (PET) and polypropylene (PP) spunbonds for challenging applications. As a subsidiary of the Dörken Group – also headquartered in Herdecke – Multitexx has access to over 15 years of experience that its parent company has accumulated with Reicofil production line. One significant contribution to the efficiency of this demanding production process comes from the laydown belt deployed: a CONDUCTIVE® 7701 type belt made by GKD – GEBR. KUFFERATH AG. Multitexx and Dörken are so impressed by its durability, flexibility, antistatic features and excellent cleaning properties that they have decided to use the belt for a second, even more high-performance production line.
Through its membership in the internationally operating Dörken Group, Multitexx benefits from almost two decades of spunbond production knowhow.
The parent company, founded 125 years ago, was already developing and producing underlay sheets for pitched roofs as early as in the 1960s. In 2001, Dörken acquired a Reicofil spunbond line and began its own in-house production of spunbonds for the composite construction laminates market. After 15 years, the rapid growth of business made it necessary to procure a second, extremely highperformance Reicofil line. This solved the production capacity problems at Dörken, and also triggered the establishment of Multitexx. Since January 2015, the new company has been selling high-grade spunbonds made of thermocalendered polyester or polypropylene.

Oerlikon Neumag Presents Innovative Electro-Charging Unit For Meltblown Systems

Oerlikon Neumag launched its newly-developed concept for electrostatically charging meltblown nonwovens at the Index 2017 in Geneva. The new inline charging unit differs from other concepts currently available on the market as a result of its high level of flexibility when charging the most diverse nonwoven products, particularly in the case of nonwovens with lower basis weights and tenacities.

Users can set the optimum charging condition depending on the filter application. High wrapping angles at the guide rollers ensure optimum charging, which can be carried out on both sides, positive and negative. Laboratory trials have shown that – in conjunction with the Oerlikon Neumag meltblown technology – the Oerlikon Neumag charging unit can also be used to manufacture EPA- and HEPA-class filters. To this end, an H14-class filter with an efficiency of 99.995% was produced with an overall pressure loss of less than 100 Pa.

Electrocharging for superior filter separation performance
Oerlikon Neumag meltblown technology is one of the most efficient methods for producing very fine and highly-separating filter media made from plastic fibers. Depending on the application, the pore size of a meltblown nonwoven material ranges from 5 to 40 μm. Here, smaller pores increase the mechanical filtration performance, albeit at the expense of higher pressure losses. The fineness of the meltblown fibers used for filter media lies in the 200 to 2,500 nm range. However, even fibers with nanoscale fineness are often not sufficient to separate the finest particles from air or liquid flows. Electrostatically charging filter media can significantly and inexpensively improve the filter performance without increasing the throughput resistance.

Alpine Jacket Made Of Dyneema® Composite Fabric Achieves Wow Factor

Acclaimed technical apparel designer Conroy Nachtigall was commissioned by The Dyneema® Project to develop an alpine jacket of tomorrow with Dyneema® Composite Fabric. The short documentary ‘Sending It’ covers the “Wow!” response when the jacket – the strongest and lightest ever made – is tried by some of the big names living in Canadian extreme sports capital Squamish.

Many have attempted to come up with an alpine jacket that is light, strong and fitted to provide snowboarders with complete freedom of movement – while still being waterproof and breathable. But as the legendary Swiss snowboarder Romain de Marchi notes at the beginning of ‘Sending It’: “I haven’t found the ultimate jacket yet and I’ve been a pro snowboarder for fifteen years. So I keep searching…” Fifteentimesstrongerthansteel,butfloatsonwater,Dyneema® isworld’s strongest, lightest fiber and has long been used to moor oilrigs, stop bulletsandrepairhumanligaments.Asafabriccomponent,Dyneema® technology was first applied to sailcloth for the winning yacht of America’s Cup 1992. Since then, Dyneema® Composite Fabrics have been engineered with a whole range of different properties (breathability, colors, solar reflectivity, various sensor and telecommunication abilities, etc.) and for many different applications (airships, ultralight hiking equipment, heartvalves,flexiblecircuitry,etc.).Currently,Dyneema® CompositeFabrics are spearheading a revolution in the performance sports apparel industry. “Dyneema® CompositeFabricsisaprecisehigh-techmaterialyetstilllooks unfinished and raw due to its signature crinkly look,” says Nachtigall. “It’s a fabric but isn’t a fabric – bonded instead of woven, super lightweight yet supertough.Dyneema® shiftsperceptions.Andthat’swhatItrytodowith apparel.” When Nachtigall’s resulting prototype is taken for first inspection to Squamish, British Columbia – the extreme alpine sports hub of Canada – the response is a universal “Wow!” from those whose choice of apparel may mean life or death. “Being out on the mountains you’re at mercy of nature, so this durability factor is huge when you’re looking for a jacket,” observes the “skier’s skier” Dana Flahr. “It feels like you’re not wearing anything!” enthuses famed snowboard photographer Phil Tifo. “And I still feel warm!” The jacket and the accompanying film ‘Sending It’ is part of TheDyneema® Project.Thiscuratedprogrambringstogethertrailblazers– cuttingedge brands and state-of-the-art mills – to create fabrics and performance-inspired apparel, footwear and accessories that are stronger, lighter, smarter and more durable and comfortable than anything currently available.

EDANA Statistics Highlight The Industry’s Resilience

European nonwovens production grows 2.5% -continues to outpace GDP.

EDANA, the leading global association serving the nonwovens and related industries disclosed its preliminary 2016 annual statistics, on the opening day of INDEXTM17, the largest global meeting place for the nonwovens supply chain and their customers. Providing a comprehensive snapshot of the nonwovens industry across Greater Europe, the latest figures demonstrate both the industry’s momentum and durability.
Per the figures collected and compiled by EDANA, the over- all production of nonwovens in Europe grew by 2.5% in volume in 2016 to reach 2,378,700 tonnes despite an uncertain economic climate. While growth in output in the European Union outperformed Greater Europe overall, some countries demonstrated impressive development. Jacques Prigneaux, EDANA’s Market Analysis and Economic Affairs Director said “Germany, Italy and Spain all witnessed growth, with Spain’s particularly impressive at 5%, while recent star performer Turkey remained stable, more than compensating for the minor decline recorded in some other European markets.”
Divergent trends were also observed between the various production processes of nonwovens. The production of fibrebased materials Drylaid and Short-Fibre Airlaid technologies for example recorded an increase of 2.2% and 2.9% respectively, while Wetlaid remained relatively stable. Spunmelt nonwovens recorded a growth rate of 3.3%, reaching a production total of 1 million tonnes for the very first time. The highest growth rate was observed in material produced via the air-through bonding process, with a 13.1% increase.
Although the primary main end-use for nonwovens continues to be the hygiene market, with a 30.7% share of deliveries (by weight), significant growth areas for nonwovens were recorded in other sectors; agriculture and garments (both recording double digit growth), air filtration (+3.2%), construction (+4.5%) and food and beverage (+4.2%). Countering this, a minor decline of -1% was recorded in the automotive industry. Medical and personal care wipes sectors both remained stable with a very slight fall of 0.4%.
Jacques Prigneaux added “The whole EDANA team would like to thank participating companies for their valued input to our annual survey, and for delivering their information on time. This data, combined with continuous monitoring of the industry, ensures EDANA statistics are a valuable planning and benchmarking tool for all our member companies.”
Pierre Wiertz, General Manager of EDANA said “For over 40 years, the annual EDANA statistics – the most comprehensive report of its kind – have proved an invaluable source of business intelligence for our member companies, offering unparalleled insight into the industry thanks to exhaustive research and direct input from producers.” “EDANA’s leadership in nonwoven statistics gives us both an advantage and a responsibility to provide quality global industry data, and we are pleased to work with INDA in authoring and publishing the Worldwide Outlook 2014- 2020, which provides current and forecast statistics, supplemented with data from ANFA (representing companies form China, Japan, Korea, and other Asian nations). This global report is for sale from both EDANA and INDA.” continued Pierre.

Drylock Technologies Acquires The Business of Presto Absorbent Products Inc.

Drylock Technologies NV (“Drylock”) announces the acquisition of 100% of the business of Presto Absorbent Products Incorporated (“PAPI”) in the United States. All of the employees have been hired by Drylock’s whollyowned US-based subsidiary Drylock Technologies Ltd (“Drylock US”), the transaction was successfully executed.

Drylock, a Belgian family owned manufacturer of personal absorbent hygiene products, such as baby diaper, feminine hygiene and adult incontinence products has acquired the PAPI business in United States. This acquisition is in line with Drylock’s growth strategy and extends its current manufacturing and sales footprint beyond Europe and Russia. This presence in the Americas supports Drylock’s future expansion into the global personal hygiene market.
Bart Van Malderen, CEO of Drylock, quoted: “We are very proud to announce the acquisition of PAPI. It brings Drylock significant synergies, such as presence in the United States of America, further product portfolio expansion, access to a very attractive customer and manufacturing base as well as a highly professional and skilled management team. As also we are, PAPI is heavily focused on innovation and quality and we find many, if not all, of our core values reflected in PAPI. The conveniently located Eau Claire facility, which is based in the state of Wisconsin, will act as Drylock US’s headquarter and we are looking forward integrating all employees, facility and business in Drylock.”
PAPI, a daughter company of National Presto Industries, had been originally formed to acquire the assets of a struggling baby diaper company in 2001, whereas at present it reflects a very wellrespected innovator and manufacturer of adult incontinence articles, serving preeminent institutional and retail distributors. Given the acquisition by Drylock, the existing customers of PAPI will have instant access to the entire absorbent hygiene product portfolio of Drylock, which entails the complete assortment of baby, feminine hygiene as well as incontinence care products. Drylock is looking forward to meeting up with all stakeholders and is dedicated to ensure continuity of the existing business.
In describing the transaction, Maryjo Cohen, President of National Presto stated, “We are very proud of the strides our
absorbent product business has made in the last several years, but recognized that to move to the next level for full success, we needed to combine the operation with that of a major player in the industry.
This sale is a win-win for all parties involved. Those parties include not only the shareholders of Presto and the owners of Drylock but also the four other groups that are affected by this kind of transaction: our employees, our community, our customers and our suppliers. The acquisition affords Drylock with instant presence in the U.S. market, with a strong customer and manufacturing base. In turn it assures our employees of ongoing employment. The transaction provides Presto with a major tenant for its facility and secures for the Chippewa Valley an international player in the industry. In contrast to most acquisitions that typically reduce the number of competitors, the transaction actually broadens our customers’ choices by adding a significant and long term contender to the field. Our suppliers will enjoy the opportunity to increase their customer base through the addition of a new customer complete with the best introduction possible – their proven track records as PAPI suppliers.”
The entire transaction is valued at $71 million and includes substantially all of the assets and certain liabilities of PAPI. Drylock plans to operate the business in Eau Claire, Wisconsin, out of the current PAPI facility, which will serve as Drylock US headquarters under the Drylock Technologies Ltd name.

A New Technology From Trützschler Switzerland AG And EREMA For Production Of BCF Yarn From Recycled PET (R-PET)

All of us use plastic bottles almost every day. Especially life without bottled water is not conceivable in developing and developed countries.

Whereas glass was the main material for bottles in the last century, producers and consumers more and more favoured PET – polyethylen- terephthalate – since the late 1980s. These “polyester” bottles come with the distinctive advantages of being light weight and almost unbreakable. However, the success generates the new challenge of coping with billions of discarded bottles each year. When the bottle is empty we often throw it away, even though some of us would keep it for a second life. In many regions of the world recycling is an option. In Asia, for example, the probability that an empty bottle will be recycled is more than 75%. However, unfortunately there are also regions with recycling rates not exceeding 15%.Recycling in Asia is wide- spread because especially entrepreneurs in China early recognized PET bottles as a valuable raw material. Using recycled polyester flakes offers numerous advantages: the economical aspect (flakes are cheaper than virgin chips) and the sustain- ability/good image aspect (green label) are to be mentioned among them.

Recycling PET bottles
A long and complex process chain is needed to turn a used bottle into usable raw material. It all starts with the collection of the bottles and pressing them into bales. Afterwards, the bales are opened,
sorted out and grinded. The flakes obtained are washed (cold and hot) and separated from the polyolefin, which comes from caps and gaskets. After drying and metal separation, the flakes are practically ready to be filled into silos or big bags. A new cycle begins.
One of the main processes for recycled polyester is spinning staple fibers, which can be used for spun yarns, textile fillings or nonwoven materials for instance. These applications are well established with fleece shirts and throws being prominent examples. Besides, due to many factors, the collection and recycling rate of plastic bottles is growing worldwide. Therefore it is time to explore new end uses of the recycled PET like carpet application for example

Spinning BCF yarn from PET and R-PET
PET fibers offers numerous advantages in carpet applications. Especially the high stain resistance should be mentioned, which is even higher than that of chemically treated PA BCF. Moreover, PET can be spun in undyed form, which is not the case for PP. Undyed yarns can be twisted, heat set, dyed and tufted or the finished carpet can be printed. Compared to staple fiber production, using R-PET for manufacturing continuous filaments is much more challenging. In filament spinning the quality of the yarn is determined by the homogeneity of the raw material. Recycled flakes are an instability factor, small deviations in quality can lead to an increased number of filament breaks or broken filaments. Further, the variance in the flakes quality could affect the yarn’s colour pick-up so the finished carpet shows streaks.

The EREMA-Trützschler system
This challenge is the reason that Trützschler and EREMA started to collaborate. EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H. is a leading solution supplier in the area of plastic recycling systems and technologies. Both companies joined their efforts to develop a one-step system for pre-processing and spinning polyester flakes into Bulk Continuous Filament (BCF) for carpet applications.
The new system directly links EREMA’s VACUREMA® technology with Trützschler Switzerland’s symTTex BCF machinery (figure 2). The EREMA part consists of a vacuum reactor, a directly linked singlescrew extruder and a high-performance filter. Washed R-PET flakes are dried and decontaminated in the reactor, melted in the extruder and then forced through a large area filter of variable fineness. After that the high-quality melt is transferred to the Trützschler spinning system. The well-known and established high quality spin packs, dual shell draw rolls, the HPc texturizing system and fully driven winders form the filaments and wind them onto bobbins. An industrial line is already successfully running in Poland.

A one-step process for high-quality yarns
EREMA’s patented system enables the feeding of clean flakes directly into the reactor without using neither crystalliser nor dryer. A major advantage is the energy savings because energy-intensive drying and crystallizing steps are omitted.
When measuring the yarn’s viscosity we see that its IV value virtually reaches the IV value of the flakes (figure 3). This proves that the drying process is extremely efficient – the vacuum before the extrusion process removes moisture and volatile material very effectively.
The combination of EREMA’s and Trützschler’s systems allows for pro- ducing distinct BCF yarns with high efficiency, excellent process stabil- ity and low transformation costs (table 1). Market requirements and expectations when using 100% R-PET flakes or mixtures of flakes with virgin material are fulfilled. The cooperation of Trützschler with EREMA for recycled polyester constitutes a major pillar in Trützschler’s product portfolio of solutions. It perfectly adds to the already estab- lished systems for the production of PA6, PA6-6, virgin PET and PP BCF yarns. It is a step ahead toward market demand for more sustainable end products.

HyperTex From DiloGroup

DiloGroup – “HyperTex” Installation for the Production of Reinforced Multi-layer Needlefelts.

Numerous fields of application such as filter media, geotextiles, roofing mate- rial, floor coverings, other technical textiles and composites require needled nonwovens with high lowload resistance. This is generally achieved by using reinforcing meshs / grids. The DILO HyperTex installation with the “Turbotex” scrim fabric machine of Messrs. Ontec automation GmbH produces a reinforcing scrim which is fed between two needlefelts and then needled together by a Hyperpunch needleloom.
The mesh apertures of this scrim can be varied up to 20 x 20 mm, production speed is up to 40 m/min. The HyperTex installation in a working width of 2.5 m is ready for presentations and trials in DILO’s Textile Research Centre in Eberbach, Germany.

Smart Textiles of the Future

Entertainment, communications and electronics continue to exert an ever-growing influence on our lives, our achievements and our sense of well-being. This perpetuating trend increases the importance of incorporating electronic products and components into our clothing.

The goal is to make our lives more pleasant, safer, and more productive through the integration of electronics in the clothing and medical sectors. Modern examples include heating and cooling components, sensory properties, and lighting elements, as well as GPS functions.
To achieve this objective, we need to develop woven and knitted fabrics in which, besides the usual fibers, conductive textile materials, components and sensors can be incorporated or on which these elements can be applied. These elastic or non-elastic textile constructions must add real value for the wearer through reliable and worthwhile functionality. They must also provide the in-use properties expected of conventional garments and be producible on an industrial scale.

Exciting cooperation projects

To create these high-tech textiles of the future, cooperation between widely diverse specialist fields is essential.Schoeller Textil AG and Eschler Textil GmbH work closely together with partners from the garment and medical sectors as well as with electronic companies and research institutes.
There is immense scope for application. The broad variety of conceivable and achievable end-use sectors ranges from entertainment, sport and interior design to medicine. Schoeller is in the process of developing a heatable E-soft-shell material that can be cut to size as required.
This innovative laminate is structured like a conventional soft-shell with corkshellTM technology, and can be produced for sale by the meter. The heatable backing is manufactured by Eschler. Specially incorporated conductive yarns enable uniform heat distribution and specific heating surfaces are functional at the usual voltages. The material can also be dyed and washed. Another example of current cooperation is HYDRO_BOT. Schoeller is working together with Osmotex on an electro-osmotic membrane for use in outer- wear. Using highly conductive yarns, Eschler has in addition developed a textile surface that can monitor lung function in real time by acting as a sensor in electrical impedance tomography. This allows doctors and other medical professionals to see for the first time what is happening in the thorax of patients on artificial respirators and to adjust treatment as required.

Functional, Colour-Coordinated And Super Comfortable
Schoeller textiles for the motorcycle category combine a high degree of functionality with trendy looks and maximum comfort. Thanks to a coordinated colour concept, the various fabrics can be ideally combined with one another. Various Schoeller technologies furnish the hightech fabrics with additional benefits.Schoeller’s innovative and extremely sturdy motorcycle segment textiles are specifically designed to serve motor bike manufacturers, brands focused on motorcycle wear and urban commuting, as well as professional motorcyclists such as motorcycle police.
The schoeller®-dynatec and schoeller®-keprotec® protective fabrics are characterized by an extremely high degree of abrasion resistance. In addition to the DIN EN 17092 test for pro- tective garments for motorcycle drivers, they are also subjected to a special impact abrasion test in the fall simulator.
Coordinated colour concept The state-of-the-art motor bike collection makes a convincing impact not only in terms of functionality but also in regards to colors. The elastic or non-elastic hightech fabrics can all be perfectly combined with one another in shades of grey, black or red.
In conjunction with the innovative Schoeller technologies such as c_change® climate membrane (for optimum and breathable protection from wind and weather), coldblack® (for reliable protection from heat and UV rays) or ceraspaceTM (for extreme abrasion and heat protection in the case of a fall),Schoeller offers the ideal solution for the most varied range of uses. New washable schoeller®-reflex articles in a variety of colours also ensure extensive protection in poor visibility.