Monforts: A Single Source Supplier For Sustainable Finishing

As energy costs continue to rise Monforts Vice President, Klaus Heinrichs, describes how solutions from Monforts are ‘bucking the trend’ with sustainable energy savings for finishing applications.

Monforts has a number of advanced technologies that can help mills who are finishing a diverse range of fabrics to achieve higher productivity and significant savings in both energy and raw materials. Most notably, the Eco Applicator soft coating unit as a replacement to conventional padder systems allows the very efficient application of finish coatings to fabrics via a highly sophisticated plc-con- trolled, so called ‘kiss’ roller system.
The unit itself does not actually save the energy, but by applying only the precise amount of moisture with functional finish, ensures the subsequent drying time is shorter – in some cases dramatically resulting in smaller dryer capacity.
In addition, the Eco Applicator is being made available for knitted fabrics, following the development of a guidance system specially- adapted to the needs of delicate knit treatments.
The Eco Applicator’s versatility allows mills to apply finishes to just one side of the fabric, or both, and even to apply separate finishes to each side or to specific areas of a fabric, for endless possibilities.

Eco Denim Line
Such savings extend to a wide range of fabrics, and while initially market-proven mainly on conventional woven fabrics, many major denim manufacturers are now reaping the benefits, with the Monforts Eco Denim concept.
The MonfortsThermo Stretch unit for the stretching and skewing of denim fabric under steam results in a much gentler treatment than was previously achievable.
This results in much less steam having to be applied. The larger fabric content of the Thermo Stretch unit in combination with the ‘double rubber’ twin compressive shrinking unit in minimum residual shrinkage values and highest production speeds which could not be achieved before.
In the denim industry, this concept is making a significant contribution to higher productivity and lower energy consumption and we now have references in Vietnam and Mexico.

Monforts texCoat
The recent acquisition of Austria-based Timatec and the integration of its range into the Monforts portfolio has further strengthened the company’s position in respect of coating technology. Nowadays we are the only manufacturer that can offer a completely integrated coating lines from a single source and the coating machine is tailored to the subsequent Monforts drying technology by offering a complete coating line from a single source – with all the benefits resulting from a fully integrated plc control.
Our system has the shortest fabric path from the coating unit into the stenter and we have all variations of coating application systems too, such as knife over air, knife over roller, magnetic knife or printing head. All of these options are available in wider widths too,wider widths too, with the engineering from a single source. I think that is a big advantage. Due to its structure, former Timatec units were only sold machines in Germany, Austria and Switzerland. Today we have new references in Turkey, Mexico, India, Pakistan and other markets.”
Eco Booster
The benefits of heat recovery are now being recognised globally. In the past, demand for heat recovery was mainly confined to Europe but this has now expanded to encompass all regions of the world. We are experiencing a high demand in countries such as China and Turkey, but also in countries where we never expected the issue to arise, such as in Algeria and Bangladesh.
Our Eco Booster heat recovery unit was initially offered as a machine which had to be cleaned manually, but is now fully automatic, putting an end to maintenance downtime.
A large denim producer in Turkey has recently installed five of these Eco Booster units which combine heat recovery with exhaust clean- ing as a fully integrated system.
Monforts was the first to offer heat recovery as a standard system, while all other manufacturers offered it as an option. The self-clean- ing function is a significant advantage.
The Eco Booster is equipped with an electric drive which makes computer-controlled optimisation of the heat exchanger’s perform- ance to the prevailing exhaust air streams possible and the auto- mated cleaning system eliminates down times for uninterrupted production.
It measures the pressure inside the system and automatically start- ing-up the cleaning cycle when necessary.
All of these technologies are engineered to provide our customers with highly effective, energy saving solutions with sustainable ben- efits.”

Rusvata Celebrates Its New Truetzschler Spunlacing Line

With more than 120 years of history, one of the most senior producers of the cotton wool and gauze market, the Russian- origin Rusvata extended an invitation to celebrate the inauguration of its new Truetzschler line for production of hydroen- tangled nonwovens on April 28 at their headquarters in Rjasan.

The spunlacing line was officially taken into service in the presence of the Rusvata management, investors, customers as well as the representatives of Truetzschler Nonwovens and its commercial agency Derux.Rusvata, the only company which has integrated the complete chain of cotton processing for cotton wool and gauze, now owns a modern and highly filexible spunlacing line with a monthly production capacity of more than 700 tons. Truetzschler Nonwovens has supplied a complete line consisting of machines for fiber opening and blending, carding, hydroentanglement, drying and winding, all of them manufactured by Truetzschler. Derux Group was involved in the project as commercial agency. Derux looks back upon more than a decade of business activity in Russia and CIS countries with focus on large-scale projects in nonwovens lines as well as many supplies of nonwoven fabrics by German top companies. The new investment is part of a long-term modernization strategy to expand the scope of products such as cotton buds, cotton pads and nonwoven towels. The new spunlacing line for cotton fibers has no analogues in Russia.

Textilwerke Todtnau Bernauer Invests in Brückner Stenter

Bernauer company plans with a tailor-made Brückner line for technical textiles, brand name BERATEX®, far into the future.

The origins of company Bernauer can be traced back as far as 1829. At that time already coloured yarn and woven fabric was produced in several factories. Since the early 1970s the company is active in the field of technical textiles and developed together with a leading tyre producer a special woven release/separation liner for the tyre industry. This fabric serves as release liner/textile for the production of tyres reducing on the long the process costs of the processing costs.

The BERATEX® fabric as such is woven of special polyethylene ribbons, made of a polyethylene film produced by the company itself. Depending on the quality it can be used up to more than 20 years without interruption. To increase the dimensional stability of this product, a heat-setting process is indispensable. For several years this had been made by different german commission finishers. Hanspeter Bernauer, owner of Textilwerke Todtnau Bernauer KG was always aware that the key of sustainable company success is the quality of the products itself. Aiming at a further control and optimization of the products it was for Mr. Bernauer a logical conclusion to integrate the final finishing of the fabric into the company. With the new heat-setting line made by Brückner the company reached now a 100 % value creating chain: from the granu- late to the woven high-quality PE fabric and to the international marketing in more than 46 countries.

Textilwerke Todtnau Bernauer KG decided to buy a state-of-the-art Brückner stenter because only a line with the alternatingly arranged thermo zones, which is typical for Brückner machines, ensures the required temperature accuracy across the entire length and width of the dryer. Temperature differences of a few degrees Celcius have an enormous influence on the heat-setting result and thus to the technical charac- teristics of the final product. In the conceptual design of the line the project team TWT Bernauer & Brückner turned the highest possible attention on an accurate fabric flow of the rigid and thus delicate articles and an operation which is not interrupted by batch changes.

First Ecosustainable Textile Collection from Clerici Tessuto

Clerici Tessuto presented at Première Vision Paris the first ecosustainable tex- tile collection, featuring beautiful organic silk and wool fabrics, GOTS certified, and next-generation high-tech fabrics.

Clerici tessuto has chosen the innovative EVO® yarn, produced by the Italian company Fulgar, to offer high-end fabrics combining maximum performance with high durability and minimum impact on the environment, in line with Clerici Tessuto’s commitment to sustainability.
EVO® by Fulgar is a yarn made from castor oil. A totally renewable resource that does not require high amounts of water nor subtracts land for human or animal food. Suitable for any textile application, EVO® by Fulgar is ultra-light, super stretch and extremely breathable, dries quickly and does not need ironing, also has thermal prop- erties and natural bacteriostatic. A whole range of distinctive values and benefits that ensure maximum comfort and unmatched performance, while retaining an intense eco-awareness.

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.