From the Sector

• ANDRITZ receives an additional order for a high-speed spunlace line from Zhejiang Kingsafe, China

International technology Group ANDRITZ has received an order from Zhejiang Kingsafe Hygiene Materials Technology Co., Ltd. in Hezhou, China, to supply a complete new neXline spunlace line. The line is scheduled for installation and start-up during the second quarter of 2022.

This high-capacity spunlace eXcelle line will process either 100% biodegradable fibers or blends of polyester and viscose. It is dedicated to the production of hygiene and medical fabrics. The final products will have fabric weights ranging from 30 to 100 gsm, and the annual production capacity will be up to 18,000 tons.

ANDRITZ will deliver a complete line, from web forming to drying, also integrating two high-speed TT cards, the well-known JetlaceEssentiel hydroentanglement unit and the neXdry through-air dryer equipped with a neXecodry S1 system for energy saving. This combination is becoming the market benchmark for the production of lightweight spunlace fabrics dedicated to the hygiene market.

“We are proud to operate ANDRITZ nonwoven lines, which are very reliable and efficient. It helps us a lot in producing top-of-the-range, nonwoven roll goods, thus enabling us to be recognized as a key player among nonwovens producers worldwide,” says Kingsafe’s president, Mr. Huarong Yan.

Zhejiang Kingsafe Hygiene Materials Technology Co., Ltd., founded in 1987, is one of the largest companies in China producing spunlace and spunbond nonwoven roll goods, with several spunlace lines already in operation. The final products are exported all over the world and used in many fields, such as the medical sector, health care, high-tech agriculture, and high-quality consumer and household products.

The new line is now the ninth spunlace line supplied by ANDRITZ and the third with high-speed TT cards, thus confirming the successful, long-term partnership between ANDRITZ and Zhejiang Kingsafe. The order also proves that the solution provided by ANDRITZ is recognized as the benchmark for production of premium spunlace roll goods and contains the perfect combination for wipes converting machines.

International technology Group ANDRITZ has received an order from Lotus Teknik A.Ş., Turkey, to supply a neXline wetlace CP (carded pulp) line for the production of biodegradable, plastic-free wet wipes. Lotus Teknik A.Ş. is a leading nonwoven roll good producer and a member of the Sapro group. Sapro is based in Istanbul, Turkey, and is one of the top three producers of wet wipes globally.  

The neXline wetlace CP line is equipped with state-of-the-art stock preparation equipment, including approach flow and fan pump, opening and blending, TT card, wetlaid forming unit for pulp application, a hydroentanglement system, filtration unit, dewatering, and through-air drying. All components are perfectly designed to produce a first-class biodegradable wipe. The line is scheduled for start-up by the end of 2021.

ANDRITZ developed the new neXline wetlace CP line in order to serve the new market trend of sustainable wipes. Lotus Teknik supported the development from a roll goods producer and converter perspective. The partnership follows the successful installation of an ANDRITZ high-capacity spunlace line some years ago. The Wetlace CP new generation of production technology for biodegradable wipes has resulted from ANDRITZ’s extensive knowledge and considerable history of providing technologies for wood-based industries, spunlace and wetlaid roll goods, and the strong collaboration with Lotus Teknik.

Neumünster – Success is built by connecting the right people with the right product. In a global marketplace, this means collaboration is just as important as competition. Companies need to focus on their strengths, while finding practical ways to innovate and expand upon their capabilities.

An exclusive license from Procter & Gamble offers the best for nonwovens

In order to do so, working together often makes the most sense. This is what motivated Procter & Gamble and Oerlikon Nonwoven – Teknoweb Materials to agree on an exclusive license agreement to market and sell the Phantom platform worldwide.

The patented process for hybrid nonwovens combines the best of both airlaid and spunmelt technologies to deliver new, flexible ways of creating wet and dry wipes. Phantom technology offers additional benefits by reducing resources and cost, while increasing overall performance. The exclusive license gives Oerlikon Nonwoven – Teknoweb Materials distribute this technology worldwide. In addition, Oerlikon Nonwoven – Teknoweb Materials have further refined the process into their own Levra technology – an entry-level option which offers tailored production volumes with lower investment costs but is still suitable to be upgraded to the premium Phantom model in the future.

Quality products that cost less

Essentially, Phantom technology was developed to produce hybrid substrates. The spunmelt and airlaid processes are merged into one step to combine cellulose fibers, long fibers such as cotton, or even powders with polymer fibers in unprecedented ways. This technology has clear advantages in terms of resources, performance, and cost compared to the previous processes on the market. By removing hydroentanglement, it is no longer necessary to dry the material. Adjusting the process can optimize relevant product characteristics such as softness, strength, dirt absorption, and liquid absorption. In the end, this even increases the quality of the product itself.

The greater freedom for formulating continuous and discrete fibers allows for more flexible and absorbent structures and highly textured materials. Wipes feel softer to the touch while providing more protection for the hands. Up to 90% of the material can consist of pulp fibers, although natural alternatives like cotton or synthetic fibers can be added to the mix.

Phantom technology has not only found a practical application in a variety of wipes – such as hygiene wipes, anti-bacterial wipes, surgical wipes, or industrial wipes – but also in absorbent cores, for instance indiapers or fempro products. With so many applications, Oerlikon Nonwoven – Teknoweb Materials are fully prepared to deliver Procter & Gamble’s innovative Phantom technology to the global nonwovens market.

On Thursday, September 24, the Lenzing Group, a leading manufacturer of wood-based cellulose specialty fibers, and Hof University opened a new Nonwoven Development Center (VEZ). As a strategic partner, Lenzing has access to a state-of-the-art development line at the campus in Münchberg with immediate effect. This offers new opportunities for sustainable fiber and nonwoven innovations for a wide range of applications including hygiene, body care and medical.

In line with the sCore TEN corporate strategy, the Lenzing Group is focusing on sustainable innovations, which are agreed in an optimum manner to the needs of the value chain. „We offer our customers and partners a decisive competitive advantage: agility. The pilot plant in the VEZ allows the resource-efficient development of fiber and nonwoven innovations on a small scale”, Jürgen Eizinger, Vice President Business Unit Nonwovens at Lenzing, explains.

The VEZ was completed according to schedule in September 2020, after Lenzing and the University of Hof signed a cooperation agreement for its use in 2019. The timing is perfect. Developments at political level, such as the directive (EU) 2019/904 of the European Parliament and of the Council of 5 June 2019 on the reduction of the impact of certain plastic products on the environment, increase demand for responsibly manufactured nonwovens. The so-called Single-Use Plastics Directive aims at building awareness and greater transparency with regard to wet wipes and feminine hygiene products.

With its VEOCEL™ branded wood-based cellulose fibers, Lenzing has been laying the foundation for many years for sustainable nonwoven applications and will test and develop innovative ideas using the new possibilities offered by the VEZ. „We are noticing increasing interest in sustainable concepts from biodegradable cellulose fibers“, Jürgen Eizinger sums up the market development of the last months and adds: „We are aware that the fibers used have an enormous influence on the final product. For this reason our commitment goes beyond fiber production.“

With the spunlace pilot plant at the VEZ, Lenzing will support customers and partners more intensively in the development of new nonwoven applications and at the same time promote cooperation in the field of marketing. In the previous year, the company already established new certification standards for the VEOCEL™ brand. Since then certified manufacturers can only use the VEOCEL™ logo with blends of biodegradable cellulose fibers. With this measure, the VEOCEL™ brand allows consumers to make a more conscious product selection.

With its #ItsInOurHands environmental initiative, the VEOCEL™ brand also actively contributes to creating awareness. More detailed information can be obtained on itsinourhands.com.

• Australian production of medical masks to commence from April 2021 with Oerlikon Nonwoven meltblown technology

Neumünster/Germany, Brisbane/Queensland/Australia – Queensland company OZ Health Plus will establish Australia’s first manufacturing plant to make the critical fine plastic material used in most protective face masks. OZ Health Plus has purchased a plant of the Swiss-based technology company Oerlikon to establish a Queensland-based production plant for spun-bond and meltblown nonwovens. These fabrics are essential for Australia’s face mask manufac-turers, who currently produce about 500 million medical and industrial masks per year. However the fabrics have to be imported from overseas and access to these materials has been severely disrupted during the COVID-19 pandemic.

Oerlikon’s German-based business unit Oerlikon Nonwoven has now executed legal and commercial arrangements to supply the specialised machinery which can manufacture the nonwoven material lo-cally. The same machinery is used to make almost all face masks material manufactured in Europe. The world-leading Oerlikon Nonwoven meltblown plant will commence operations in April next year, with a second stage planned for late 2021.

The Oerlikon Nonwoven plant can produce meltblown fabrics for 500 million masks per year, along with other medical and non-medical grade products, filtration products, sanitary items, antiseptic wipes and more. Rainer Straub, Head of Oerlikon Nonwoven said: “We are very proud that we can now for the first time supply our Oerlikon Nonwoven meltblown technology to Australia. Due to the short delivery time, we hope to make our contribution to the Australian population and their safe sup-ply of high-quality protective masks as soon as possible.”

Queensland company secures manufacturing plant for the only Australian production of critical face mask material

OZ Health Plus director Darren Fooks said: “Australia has access to raw polypropylene feedstock but lacks the plant to convert that raw material to specialised spunbond and meltblown fabrics. These fabrics are essential for local mask manufacturing. The Australian-based Oerlikon Nonwoven plant will fill the production chain gap for Australia by producing the fabrics we need for mask production and many other products – it will reduce Australia’s protective mask supply chain from thousands of kilo-metres, to tens of kilometres.”

“Our decision in favor of Oerlikon Nonwoven was a given once we had analyzed the material samples. It was a matter of course for us that the Business Unit of the Oerlikon Manmade Fibers segment could supply high-quality machines and systems”, added Darren Fooks.

OZ Health Plus’ new facilities will take up 15,000 m2 of manufacturing space and will employ 100 full-time roles once the second stage of the project is complete. OZ Health Plus continues to work with both Queensland and Federal Government stakeholders and values their support in bringing this vital capability to Queensland.

Leading meltblown technology

Oerlikon Nonwoven meltblown technology, which can also be used to produce nonwovens for protec-tive masks, is recognized in the market as the technically most efficient method of producing high-separation filter media from plastic fibers. Most of the protective mask capacities available in Europe to date are produced on Oerlikon Nonwoven equipment.

For the sixth time now, Oerlikon Nonwoven will be showcasing market- and customer-oriented solutions for hygiene, medical, filtration and other technical applications at the globally-leading nonwovens trade fair INDEX in Geneva, Switzerland. Between March 31 and April 3, 2020, visitors to the trade fair can convince themselves of the Neumünsterbased systems constructor’s extensive product and process know-how.

Comprehensive spunbond portfolio – always the right solution
Oerlikon Nonwoven meanwhile has a very broad range of spunbond technology products and services. The process for manufacturing geotextiles from polyester or polypropylene has been optimized; it is characterized by high production capacities and yields, with simultaneously low energy consumption for producing benchmark nonwoven products.

For the manufacture of hygiene nonwovens, Oerlikon Nonwoven offers its new QSR (Quality Sized Right) systems. Here, the benefits of the Chinese machine construction partner’s nonwoven formation are integrated into the complete solution. The advantage for nonwovens producers: highly competitive solutions at attractive prices with comparably low investment.

Cost-efficiently manufacturing meltblown nonwovens
New, unique and highly sophisticated filter media can be easily and efficiently manufactured thanks to Oerlikon Nonwoven’s optimized meltblown technology. Whether as a stand-alone system with one or several positions, as ‘plug & produce’ installations for already existing systems or in conjunction with other technologies: the Oerlikon Nonwoven meltblown process already enables the cost-efficient manufacture of meltblown nonwovens with the quality requirements of tomorrow. Ever more producers are choosing the meanwhile extensively tried-and-tested and consistently further-developed Oerlikon Nonwoven meltblown solutions.

Airlaid technology for the nonwovens of tomorrow
Pulp or cellulose fibers as raw material for manufacturing nonwovens are currently virtually unrivaled with regards to sustainability and environmental compatibility. The Oerlikon Nonwoven airlaid process is the ideal solution for processing this raw material into high-end products for a wide range of applications. Today, there is huge demand for manufacturing solutions for high-quality, lightweight airlaid nonwovens with economically attractive production speeds and system throughputs. In this area, the patented Oerlikon Nonwoven formation process – which also permits the homogeneous mixing of the most diverse raw materials, while simultaneously guaranteeing superb evenness and homogeneous fiber laying – is setting standards even for nonwovens with low running meter weights. And the benefits of this technology are also increasingly gaining significance in sustainable recycling applications.

P&G patented PHANTOM technology from Teknoweb Materials
Also being showcased at the trade fair stand is the P&G patented PHANTOM technology from Teknoweb Materials, Oerlikon Nonwoven’s strategic partner for hygiene products and wipes. The PHANTOM technology is released to Teknoweb Materials by P&G in worldwide exclusive license. The PHANTOM technology is the superior dry laid alternative technology for manufacturing wet wipes from pulp and polymer fibers, for example. Compared to conventional, known processes, this technology offers superior performances with cost advantage in much more eco-friendly products. Dispensing with hydroentanglement renders subsequent drying of the material redundant. Targeted process management allows the optimal setting of the relevant product parameters such as softness, tenacity, dirt absorption and liquid absorption.

For Oerlikon Nonwoven, the IDEA, taking place between March 25 and 28 in Miami Beach, Florida USA, kicked off with the signing of a contract. The customer, a renowned European meltblown specialist, invested in a two-beam, stand-alone meltblown system from the Neumünster-based plant manufacturer in order to meet its strongly increasing demand. In the future, the system will be deployed to manufacture meltblown nonwovens for various application, especially from the filtration and wipes sector. The commercial production launch is scheduled for the first half of 2020. The market for meltblown nonwovens is expanding by an average of 6% per annum.

• Company to showcase innovation while marking its 100th anniversary

Paper Converting Machine Company (PCMC), part of Barry-Wehmiller, will showcase its extensive nonwovens converting experience at IDEA19, held March 25 to 28, 2019, in Miami. Attendees may visit booth #1660 to learn how PCMC’s modular equipment serves a variety of market needs, as well as join the festivities when the company commemorates its 100th anniversary with a cake celebration from 2 to 5 p.m. on Wednesday, March 27.

Offering hygienic, high-speed folding solutions, crossfolding machines that provide quick product changeovers and multi-servo cutting modules, PCMC can meet a wide range of production demands and enhance customers’ profitability, whether they’re creating cosmetic, medical, baby, dispersible, scientific, cleaning, polishing, sanitizing or drying wipes.

For interfolded and non-interfolded flat-pack wet wipes, PCMC’s modular, low-maintenance Clipper series can achieve 800 cuts per minute in hygienic and non-hygienic designs. With the compact footprint of the Marlin Pro, crossfold wipe customers can save space, while also reducing waste and achieving the lowest cost per wipe.