From the Sector

International technology group ANDRITZ has successfully delivered, installed, and commissioned a converting line for manufacturing baby diapers at Naturopera’s new plant in Bully Les Mines, France.

The eXcelle converting line from ANDRITZ Diatec features special technology to produce both traditional and bio-based baby diapers, supporting Naturopera in its efforts to become a leading producer of a new generation of sustainable diapers.

While most diapers available on the market consist of 70% fossil-based plastic, Naturopera is preparing to produce diapers made of 90% bio-based raw materials. This groundbreaking diaper concept was developed in a close collaboration between Naturopera and ANDRITZ. It replaces the traditional spunbond and meltblown nonwoven layers with spunlace nonwovens mostly made of natural fibers. A prototype of the 90% bio-based diaper was recently produced at Bully Les Mines.

The ANDRITZ converting machine operating at Naturopera is highly flexible, taking just a few settings to switch to the production of bio-based diapers. It is designed for a multiple-size process, features an operator-friendly interface, and guarantees a production speed of 800 ppm.

Naturopera is a French company producing baby care, femcare and household products with a strong focus on local production and sustainability.

International technology group ANDRITZ has successfully started up the new velour loom it delivered to Foss Floors, Rome, United States (GA). The loom produces flooring from recycled plastic for a wide range of applications. Start-up took place in early 2023.

ANDRITZ is one of the global market leaders for supply of nonwoven production technologies, with a full range of needling technologies, including velour equipment, which allows customers to address a variety of applications such as automotive, household, flooring, acoustics, geotextiles, filtration, and synthetic leather.

Foss Floors is a leader in needlepunched felt products in North America. Its facilities are located in Rome and Chatsworth, Georgia, and it distributes a vast array of flooring products worldwide. One of the company’s key strengths is its agility for product diversification to satisfy customer needs. Foss Floors also strongly expresses its unwavering commitment to environmentally sustainable manufacturing.´

International technology group ANDRITZ has received an order from Predo Health Products Inc, Türkiye, for delivery of two high-speed hygiene converting lines to produce adult open diapers and feminine sanitary napkins. With this investment, Predo is entering the growing adult and femcare market. The company already operates four baby diaper lines from ANDRITZ.

The two state-of-the-art lines are designed for high-speed production and contain the most advanced forming technology for absorbent core and SAP (superabsorbent polymers) dosing. Based on their flexibility and user-friendly configuration, Predo will be able to produce a wide range of different product compositions and sizes. In addition, the lines are designed for zero waste production. This will enable Predo to produce high-performing products with a sustainable approach.

The lines will be installed in Predo’s factory in Gaziantep, with start-up scheduled for the first half of 2024.

Predo is one of the leading manufacturers of baby care products and is expanding its business to other hygiene sectors. The company exports to 55 countries across the globe.

International technology group ANDRITZ has delivered, installed, and commissioned a mechanical textile recycling line and an airlay line at Novafiber’s nonwovens production mill in Palín, Guatemala. Both lines have been successfully operating since December 2022.

The recycling line – the second tearing line ANDRITZ supplied to Novafiber – processes post-industrial textile waste from Central America. The recycled fibers feed the latest ANDRITZ Flexiloft airlay line, which produces nonwoven end-products for the bedding and furniture industries – a true example of a circular textile-to-nonwoven approach. The production process ensures complete material use as a state-of-the-art edge trim recycling system returns any waste directly to the tearing and/or airlay line.

This combination of ANDRITZ tearing and airlay lines allows Novafiber to process large amounts of post-industrial garments, controlling the supply chain from raw material to final product. In addition, it enables energy savings and a reduced carbon footprint due to the reduction of shipments.

Based in Palín, Novafiber is a leading company in Guatemala for producing nonwovens from post-industrial textile waste for both the local market and export.

RecyOuest, France, has successfully started up the world's first recycling line for agricultural plastic waste nets at its mill in Argentan. The innovative recycling line featuring a unique dry-cleaning system was delivered, installed and commissioned by the international technology group ANDRITZ in August 2022.

RecyOuest, based in Argentan, France, is a green economy company that handles the recycling contaminated filamentary thermoplastics such as round bale nets and twines. With its recycling process, RecyOuest is part of a circular economy approach.

The ANDRITZ recycling line can process up to 8,000 tons of waste and produce recycling fibers for nonwoven applications and also for pellets made of waste from agricultural single-use plastic nets and twines. These pellets are then returned to the plastics industry by mixing both recycled and virgin raw materials, thus reducing the amount of virgin plastic used.

This line, inspired by the techniques from textile wastes recycling, is equipped with a unique mechanical dry-cleaning system that allows resource savings by avoiding the use of water and chemicals. This state-of-the-art ANDRITZ equipment allows RecyOuest to produce recycling fibers for nonwoven applications and also pellets for ever new eco-designed nets and twines for the agricultural sector, with the lowest possible environmental impact.

International technology group ANDRITZ has received an order from Jasztex Fibers Inc., Canada, to supply a crosslapper to its site of Pointe Claire (Quebec province).
The line will be dedicated to the production of polyester blends for a wide range of applications, including home furnishing, filtration, blankets, architectural, fire retardant, transportation. Start-up is planned for the second quarter of 2023.

ANDRITZ has been a regular supplier of Jasztex. Over the last years, ANDRITZ provided crosslappers for previous investments in Toronto (Ontario) and Pointe Claire (Quebec).

Jasztex’s nonwoven products are sold throughout the bedding, furniture, filtration, acoustic and thermal insulation, transportation and medical markets.

ANDRITZ will be presenting its innovative nonwovens production solutions at CINTE 2022 in Shanghai, China (September 6–8). ANDRITZ will show its broad product portfolio covering state-of-the-art nonwovens and textile production technologies such as air-through bonding, airlay, needlepunch, spunlace, spunbond, wetlaid/WetlaceTM, converting, textile finishing, recycling, and natural fiber processing.

SUSTAINABILITY IS KEY
ANDRITZ supports nonwovens producers in the move to sustainability with the aim of reducing or eliminating plastic components while maintaining the high quality of the desired product properties. This applies to all types of sustainable wipes, such as flushable, biodegradable, bio-sourced, carded pulp or standard carded wipes. The latest development in this field is the ANDRITZ neXline wetlace CP line, which integrates the carded-pulp (CP) process. This is a fully engineered production line combining the benefits of drylaid and wetlaid technologies to produce a new generation of biodegradable wipes.

NEXLINE WETLAID AXCESS TARGETS SMALLER AND MEDIUM PRODUCTION VOLUMES
The neXline wetlaid aXcess targets smaller and medium production volumes and has been devised for new and existing lines. The compact line provides an entrance to the growing wetlaid market, with a variety of final applications and options.

ANDRITZ AXCESS DEVELOPED FOR MEDIUM CAPACITIES IN WUXI, CHINA
The aXcess range was specially developed at ANDRITZ (China) Ltd. Wuxi Branch to handle medium capacities. The facility in Wuxi has an experienced platform for production and service specially geared to serve the Asian nonwovens industry. It designs and manufactures cutting-edge lines to complement the ANDRITZ aXcess product range, which includes complete lines and individual machines for air-through bonding, needlepunch and spunlace processes. With the aXcess range, ANDRITZ has developed a hybrid line combining European and Chinese machines, which is the ideal combination to obtain the best added value from each component in the line and be very flexible to accommodate different business cases.

The service organization was set up to provide prompt delivery and excellent customer support, even during the COVID-19 pandemic. A team of technicians and process experts can be deployed quickly to customer sites requiring full-range assistance. The ANDRITZ facilities include a roll service center with state of-the-art grinding equipment and a test stand for various types of rolls.

In addition, our aXcess range manufactured in Europe also offers technologies for spunlaid and wetlaid processes. Increasing production speeds and widths, compact and reliable design, and affordable investment costs are what customers look for in a competitive market environment. To meet these requirements ideally, we recently enhanced our nonwoven calender and dryer ranges.

International technology group ANDRITZ has established a new inline Wetlace™ CP pilot line with an original design at its center of competence in Montbonnot, France. The line combines both spunlace and wetlaid technologies.

From now on, partners will be able to conduct trials and test all options available for wipes production – from carded staple fibers to pulp and various combinations thereof. The combination of both spunlace and wetlaid technologies offers to move forward to more sustainable options while maintaining a high level of product quality, in particular by achieving high CD strength and good linting properties.

Over the past few decades, ANDRITZ has continued to innovate with various nonwoven processes, like spunlace, WetlaceTM and Wetlace™ CP, with the aim of optimizing the use of raw materials and focusing on sustainability by reducing the synthetic fiber content. Facing the growing demand for bio-wipes in parallel with enforcement of the EU’s single-use plastics directive last year, ANDRITZ has decided to support its customers making their investment decisions.

The Montbonnot pilot line has been rebuilt to integrate the new headbox inside the spunlace line. Pulp can be fed in directly and entangled with carded staple fibers to produce unique nonwoven fabrics designed for end uses as bio-wipes.

International technology group ANDRITZ will be presenting its innovative nonwovens production and textile solutions at Techtextil in Frankfurt from June 21 to 24. The ANDRITZ product portfolio covers state-of-the-art nonwovens and textile production technologies, such as air-through bonding, airlay, needlepunch, spunlace, spunbond, wetlaid/WetlaceTM, converting, textile finishing, recycling, and natural fiber processing. For Techtextil, special focus lies on technologies for textile recycling, needlepunch, airlay, wetlaid glass fibers and textile calendering.

TEXTILE RECYCLING TECHNOLOGIES BASED ON TEARING
With the acquisition of ANDRITZ Laroche SAS, ANDRITZ has expanded its product portfolio to include airlay and recycling technology as well as bast fiber processing technologies. Complete recycling lines for post-consumer and industrial textile waste to produce fibers for re-spinning and/or nonwoven end-uses are one focus of this product range. Customer awareness and regulations are forcing clothing brands to recycle their textile waste in their own products. Recycled fibers can also be used in the nonwovens industry for various applications, for example in the automotive industry, for insulation, mattresses, and furniture felts.

ANDRITZ Laroche offers a complete process range of tearing lines from 50 up to 3,000 kg/h, which can be used for almost all types of pre/post-consumer textile waste. The aim is to preserve the character of the original fibers, for example cotton, by maximizing fiber length, strength and feel.

International technology group ANDRITZ will be presenting its special-purpose machines for needlepunch production (including its portfolio for carbon applications) at JEC World 2022 in Paris, France, from May 3 to 5.

Experience and Know-How
ANDRITZ designs, develops, and engineers special-purpose machines for very specific and sensitive applications, like aerospace, railway, and military needs. Therefore, it can provide the market with customized machines offering perfect solutions, whether they are needed for prototypes or for industrial production.

Skilled Engineers
In increasingly demanding markets, the skilled ANDRITZ engineers and technicians help customers get the most out of their investments. The variety of cases they face every day enables them to optimize both output and quality depending on the fibers used, the challenge, and the customer’s final application.

Carbon Expertise
Experience with conductive fibers enables ANDRITZ to overcome challenges and provide access to new product developments. The company’s expertise lies in textile know-how as well as a deep understanding of related constraints. It includes carded/crosslapped processes for nonwovens made from recycled carbon fibers, which can be delivered in rolls or die-cut shapes.

Unconventional Needling for End-Uses
ANDRITZ addresses customers’ challenges by offering solutions and expertise in terms of straight and multi-axial needling, enabling the consolidation of fibers on flat or non-flat surfaces (such as rounded shapes) and even of layers up to 350 mm thick. New developments are made possible thanks to the outstanding ANDRITZ testing facility.

Support and Development
The ANDRITZ needlepunch technical center in Elbeuf, France, is open to visitors. Innovative strength and adaptability are the characteristics that make ANDRITZ the preferred partner in the search for genuine, efficient, and reliable solutions in the interests of productivity and premium, state-of-the-art consolidation. Secrecy being key in such sensitive development work, ANDRITZ naturally always guarantees the utmost confidentiality.