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Dilo Group Focuses on Energy Saving, Sustainability and Industry 4.0

Dilo Group exhibited a complete operating production line at ITMA 2019. This line illustrated improvements and modifications as well as innovations in numerous machine design-engineering aspects.

The complete technological process starting with fibre preparation via card feeding, to precise web forming and the new Hyperpunch Hα needling shown at the exhibition.

We interviewed with Dilo Group General Manager Johann Philipp Dilo, who we visited at the booth during the ITMA 2019. Stating that they focus on sustainability, Industry 4.0 and environmentally friendly products, Philipp Dilo said that they are working on new products that will save energy.

Dilo Group exhibited a complete production line at ITMA 2019. Can you listen to the details and products of this line?

In the fibre preparation phase with DiloTemafa components, the “Baltromix Pro” showed a faster blend changeover which is a prerequisite for even higher throughput. An exact control of the filling level avoids idling or over-filling by feeding fibre bales with the aid of a “bale timer”. The sensor module “DI-LoWatt” assures fibre transport with a minimum of air and thus saves energy.

After the “VectorQuadroCard” the latest version of our high speed crosslapper “HyperLayer” included which allows highest throughput at small to medium layering widths and which is especially suited for hydroentanglement lines.

The needleloom on show – DI-LOOM OD-II SLHαV – is equipped with the new needle pattern 6000X to give a very homogeneous stitching distribution.

In the field of “textile additive manufacturing” the “3D-Lofter” offered further chances of fibre savings for needlefelts used in the automotive and other applications because topologically distributed fibre masses can be positioned in the felt where needed by so called “individual webforming spots.”

What are the advantages of assist operating system ‘diloline 4.0’?

“diloline 4.0” includes a wide variety of “smart manufacturing” actions in collaboration with Siemens which all aim at further simplifying operation, increasing transparency in web forming and consolidation thereby increasing efficiency. Production data are stored, documented and compared. An “alarm monitor” indicates disturbances. A production analysis documents the reasons for standstill times. This data can be used to avoid disturbances. Numerous information modules can be recalled via mobile apps and cloud data (mindSpheres). All these methods to control the machines and to generate production data will be helpful to further secure the complex functions within the production system independently of personnel and shift.

How does Dilo strive to deliver reliable and new machines?

When it comes to innovation, instead of adopting the classic approach of market research first, we think about what we can improve on our existing machines. We do our own research. So when we find an area that can be developed, we apply different models using our creativity. We first examine the idea we have found in different ways, and then exchange it with customers to launch the product. We have pilot customers with whom we work together during product development, in other words, customers who use our products for the first time. Then we gradually grow the idea into the market.

What have been your company’s biggest achievements over the past 12 months?

One of our biggest achievements is our fully functional needling line  which we exhibited at the ITMA. Dilo emphasizes the central position this technology takes in the worldwide nonwoven production. Needled products can be found in many applications such as floor covering, automotive interior linings, technical needlefelts,  filtration media, geotextiles, mattress, bed and upholstery, wipes and papermachine felts.  The needle pattern has changed in our new needle loom. This needle pattern allows you to get a much more regular service of the needle product. I consider that this a major breakthrough.

What is your company taking to adapt to sustainability in manufacturing?

Sustainability is an important term, an important issue, and we take this issue seriously. But we are in an area that involves the mechanical transformation of fibers into textile products. The mechanical solutions we have developed, such as carding, needling and cross bonding, are more consumer-friendly than previous solutions. We realized that 50% of the energy consumption was caused by fiber passing through tubes and we developed a new system that uses less electricity. With the reduction in energy requirements, we reduced the use of fans and continue to follow the process. By reducing the consumption in the tubes, we obtain the lowest energy consumption rate and the most efficient results.

If you assess in terms of export market, what is the importance of Turkey for your company?

Turkey has a great importance for our company and the textile industry. Because it is a very vibrant and very dynamic market. We know that the textile sector in Turkey is a powerful and innovative and constantly progressing. Of course there are ups and downs from time to time, but in the long run, there is a steadily increasing production, especially in the area of nonwoven fabric. Therefore, our sales and technical support teams have an office in Istanbul. In this way, we show that we stand behind our products in the market. We are continuously increasing our achievements and market share.

Interview: Dilek Hayırlı