Aus der Branche

ACG Kinna Automatic and ACG Nyström – members of TMAS, the Swedish textile machinery association – have delivered the first microfactory for the production of fully finished filter bags to an international filtration industry customer, in cooperation with JUKI Central Europe.

The microfactory’s configuration is based on two separate interconnecting modules – the Smart Filter Line (SFL) and the Filtermaster 2.0. The SFL handles the fabric feeding from rolls and its folding prior to seam construction, which can either be by automatic sewing, welding or with sewing and taping, depending on specifications. Very rapid changeover of the modular seaming methods can be achieved during product changes. The specific size of the now fully-tubular fabric is then precisely cut to size for each individual unit and further folded ready to be fed into the Filtermaster 2.0. The Filtermaster 2.0 then automatically attaches the reinforcement, bottom and snap rings onto the filter tube with a second Juki sewing head on a robotic arm, to form the fully finished filter bag ready for packaging.

Filter bags are employed in a wide range of industrial processes and while they may be largely under the radar as products, they represent a pretty significant percentage of overall technical textiles production.
They are used in foundries, smelters, incinerators, asphalt plants and energy production plants. Other key manufacturing fields – often where dust is generated – include the production of timber, textiles, composites, waste handling and minerals, in addition to chemicals, food production, pharmaceuticals, electronics and agriculture.

As a further example of the scale of the industry and the high volumes of fabrics involved, one supplier has delivered a single order of 30,000 filter bags to be used for flue gas cleaning at a European power plant. The bags can also be anywhere up to twelve metres in length and frequently have to be replaced.

In the fourth quarter of 2023 Italian textile machinery orders index, drawn up by the Economics Department of ACIMIT, the Association of Italian Textile Machinery Manufacturers, appears to be stationary compared to data recorded for the same period in 2022. In terms of absolute value, the index stood at 82.4 points (basis: 2015=100).

This is the result of an upswing in orders from foreign markets, counterbalanced by declining orders on the domestic front. While orders in Italy decreased at 18% rate, a 4% increase was observed abroad. The absolute value of the index on foreign markets amounted to 77.9 points, whereas it came in at 126.2 points domestically. Overall for the fourth quarter, the average order backlog yielded 3.7 months of assured production.

For the whole 2023 year, the index declined 25% overall compared to the 2022 average (absolute index of 82.4). On the home front however, the index dropped 24% (absolute index of 124.5), while slipping 25% abroad (absolute index of 78.4).

ACIMIT president Marco Salvadè commented the data: “The orders index for October – December 2023, as elaborated by our Economics Department, confirms an intake of orders that is still weak, with a negative trend in demand for machinery that is ongoing for the domestic market.” Nonetheless, the orders index abroad shows a slight increase. “We estimate that the global geopolitical context is still a source of concern,” continued Salvadè, specifying that, “For the first nine months of 2023, Italian exports on major global markets (i.e. China, Turkey, India and the United States of America), confirm a widespread decline. However, some positive signs emerged in the fourth quarter of last year, as reflected by the latest orders index. For 2024 we expect a consolidation of this trend reversal.”

Many end-users now expect recycled materials to be in textile products they purchase – and this is driving innovation throughout the industry. However, there are still many technical and economic issues facing yarn and fabric producers using recycled resources. Members of the Swiss Textile Machinery Association offer some effective solutions to these challenges.

Synthetic recycled materials such as PET can usually be treated similarly to new yarn, but there are additional complexities where natural fibres like wool and cotton are involved. Today, there’s a trend towards mechanically recycled wool and cotton fibres.

Spinning recycled cotton
The use of mechanically recycled fibres in spinning brings specific quality considerations: they have higher levels of short fibres and neps – and may often be colored, particularly if post-consumer material is used. It’s also true that recycled yarns have limitations in terms of fineness. The Uster Statistics 2023 edition features an extended range of fibre data, supporting sustainability goals, including benchmarks for blends of virgin and recycled cotton.
In general, short fibres such as those in recycled material can easily be handled by rotor spinning machines. For ring spinning, the shorter the fibres, the more difficult it is to guide them through the drafting zone to integrate them into the yarn body. Still, for wider yarn counts and higher yarn quality, the focus is now shifting to ring spinning. The presence of short fibres is a challenge, but Rieter offers solutions to address this issue.

Knitting recycled wool
For recycling, wool fibres undergo mechanical procedures such as shredding, cutting, and re-spinning, influencing the quality and characteristics of the resulting yarn. These operations remove the natural scales and variations in fibre length of the wool, causing a decrease in the overall strength and durability of the recycled yarn. This makes the yarn more prone to breakage, especially under the tension exerted during knitting.

Adapting to process recycled materials often requires adjustments to existing machinery. Knitting machines must be equipped with positive yarn suppliers to control fibre tension. Steiger engages in continuous testing of new yarns on the market, to check their suitability for processing on knitting machines. For satisfactory quality, the challenges intensify, with natural yarns requiring careful consideration and adaptation in the knitting processes.

From fibres to nonwovens
Nonwovens technology was born partly from the idea of recycling to reduce manufacturing costs and to process textile waste and previously unusable materials into fabric structures. Nonwovens production lines, where fibre webs are bonded mechanically, thermally or chemically, can easily process almost all mechanically and chemically recycled fibres.

Autefa Solutions offers nonwovens lines from a single source, enabling products such as liners, wipes, wadding and insulation to be produced in a true closed loop. Fibres are often used up to four times for one product.

Recycling: total strategy
Great services, technology and machines from members of Swiss Textile Machinery support the efforts of the circular economy to process recycled fibres. The machines incorporate the know-how of several decades, with the innovative power and quality standards in production and materials.
Stäubli’s global ESG (environmental, social & governance) strategy defines KPIs in the context of energy consumption, machine longevity and the recycling capacity in production units worldwide, as well in terms of machinery recyclability. The machine recyclability of automatic drawing in machines, weaving systems and jacquard machines ranges from 96 to 99%.

At ITMA ASIA + CITME end of November in Shanghai, 40 VDMA members will present their technologies and solutions for the Chinese and Asian markets under the heading "smart technologies for green textile production". This year’s ITMA ASIA is the first major post-Corona textile machinery fair in China.

The exhibiting VDMA members cover nearly all different machinery chapters with a focus on spinning and manmade fibers, nonwovens, weaving, braiding, knitting & hosiery, finishing & dyeing and textile processing.  

The VDMA Textile Machinery Association and VDMA China will be present in the industry hub in Hall 8 zone B to support the members before and during the fair. The industry hub is also contact point for visitors who want to inform themselves about the exhibiting VDMA members. 

A delegation of Italian textile machinery companies will attend the 2023 edition of TITAS TAIPEI, which will be held in Taipei, Taiwan, from October 17 to 19, 2023. Taiwan is judged as a very promising market for the Italian textile machinery industry, especially in the innovative sectors of technical textiles and nonwovens.

In 2022, Italian exports to the Asian country exceeded the value of 17 million euros, and in the period January-June 2023, the value has already reached 7 million euros. The attention for the Taiwanese market has led ACIMIT, the Association of Italian Textile Machinery Manufacturers, and Italian Trade Agency to set up a pavilion at the upcoming edition of TITAS TAIPEI.

Six Italian textile machinery manufacturers, all ACIMIT member companies, will exhibit in the pavilion: Ferraro, Danitech, Lgl, Ms Italy, Reggiani, Unitech.

At the upcoming TITAS TAIPEI, therefore, visitors will be introduced to Italian technology, once again a key player in the textile production process.

West Yorkshire is to have a first-of-its-kind apprenticeship training course for textile engineering technicians, reflecting a resurgence in the industry locally, and more generally in the UK.

Calderdale College has partnered with the Textile Centre of Excellence (TCoE) and the British Textile Machinery Association (BTMA) to develop the bespoke Level 3 apprenticeship course which will start in September 2023.

Engineering Technician apprentices at Calderdale College will receive training from the TCoE, helping them to develop the engineering maintenance skills required to close the skills gap in West Yorkshire’s textile industry.

While the region has been a flourishing hub for textile excellence since the 19th century and is being revitalised through digitalization and the localisation of supply chains, its success is currently being hindered by an ageing workforce and high staff turnover.

Through adapting the engineering training at Calderdale College to address the current requirements of the textile industry, the unique new course will ensure the passing on of vital know-how and good practice aligned with the new skills demanded by Industry 4.0 and automation.

Collaborative Apprenticeships
Calderdale College has developed the programme over a two-year period through close collaboration with the TCoE and the BTMA, as well as through consultation with British heritage weaver AW Hainsworth and a number of other local textile companies.

The course launch follows on closely from the success of the Collaborative Apprenticeships project launched in 2022 at Calderdale College. To date, this has seen the college engage with over 100 local employers on the benefits of increasing the quantity and improving the quality of the apprenticeships that they offer, as well as encouraging others to introduce apprenticeships for the first time.

“Over the years, we’ve seen how beneficial apprenticeships can be for several sectors, particularly in terms of helping businesses to retain staff and ensuring that they have a steady flow of skilled workers coming in,” said Claire Williams, head of employer engagement at Calderdale College. “Having identified that employers in the textile manufacturing industry were struggling to find apprenticeship training that was designed around their needs, we knew that alongside employers and our partners, we needed to satisfy this critical gap in the market. We hope that this programme will act as a leading example for the rest of the industry to follow.”

The EU's planned ban on the entire group of per- and polyfluoroalkyl substances (PFAS) would endanger many industrial processes, states VDMA Textile Machinery. Textile manufacturing would be affected twice – by missing important chemicals for technical textile production and by the lack of indispensable textile machine components. The latter would affect the whole supply chain from textile machinery manufacturers and its suppliers to the textile industry in the EU.

Solid PFAS parts are widely used in textile machinery production, especially where extreme conditions prevail. Verena Thies, Managing Shareholder Thies GmbH & Co. KG, explains: “Our textile dyeing machines are world leaders and set standards in efficiency and sustainability. They work under pressure at temperatures of up to 140° C using highly acidic, highly basic and/or oxidative or even reductive chemicals. This is precisely why PFAS is needed, for example, in seals and rings, flaps as well as valves for a long-lasting and high-quality machine concept – because there are no alternatives with qualitatively equivalent properties. In addition, PTFE semi-finished products enable a sliding and gentle contact with the textile fabric in ecologically important techniques in the transformation of textile wet finishing."

PTFE and also FKM are fluoropolymers (fluoroplastics and fluoroelastomers), a group within the broad PFAS range of about 10,000 substances which would be banned for production, use and sale in the EU. They are high-tech materials, and as so-called "polymers of low concern" are not a danger to the environment, according to the OECD. Furthermore, these components are installed inside a machine and exchanged or disposed of properly. PFAS such as PTFE and FKM must be exempted from the ban, demands the VDMA in its position paper.

"In this way, the association also supports the approach taken in Great Britain. With the 10,000 substances, everything is lumped together, although the various PFAS groups are very different," warns Dr Sarah Brückner, Head of VDMA Environmental Affairs and Sustainability. "We should take our cue from the UK and look at the substance groups in a differentiated way."
Apart from several types of dyeing machines, PFAS components are indispensable in textile drying machines (e.g., conveyor dryers, tumblers and stenters) and damping machines. They are also used in fully automatic chemical dispensing systems and pressure vessels for thermochemical treatment of textile recycling material, heat recovery systems and wastewater treatment technology. This means that a lot of machines needed for a sustainable textile production would be affected by the PFAS ban.

VDMA Textile Machinery will take part in the ongoing EU public consultation. The association will describe indispensable key functionalities and conditions of use in the textile machinery sector as well as the consequences for the companies and the customers in the EU if the ban is imposed. The consultation ends on September 25, 2023, and VDMA urged its members affected by the planned restriction to participate in the consultation at an early stage. This is the only way to ensure that the broad scope of the mechanical and plant engineering sector is represented.

Dr. Harald Weber wird zum 1. Januar 2023 neuer Geschäftsführer des VDMA Fachverbands Textilmaschinen. Der 44-jährige Wirtschaftsingenieur folgt auf Thomas Waldmann, der die Position seit 1991 innehatte und Ende des Jahres in den Ruhestand geht.

Nach seiner Promotion an der TU Darmstadt und einer Dozenten-Tätigkeit an der Technischen Hochschule Mittelhessen kam Dr. Weber 2011 zum VDMA. Im Fachverband Kunststoff- und Gummimaschinen war er seitdem als Referent für die Themen Technik und Innovation verantwortlich.

Dr. Janpeter Horn, Vorsitzender des VDMA Fachverbands Textilmaschinen und Geschäftsführer der August Herzog Maschinenfabrik erklärte zum Personalwechsel: „Dr. Weber verfügt aus seiner bisherigen Tätigkeit in der Kunststoffbranche über profunde Kenntnisse und Erfahrungen bei Themen, die auch im Textilmaschinenbau weiter an Bedeutung gewinnen. Als Beispiele seien Recycling und Kreislaufwirtschaft genannt sowie Digitalisierung und hier speziell der Schnittstellen-Standard OPC UA.“

Dr. Horn ergänzte: „Unser herzliches Willkommen an Dr. Weber verbinden wir mit einem großen Dankeschön an Thomas Waldmann. 30 Jahre Geschäftsführer beim Fachverband Textilmaschinen stehen auch für sich ständig ändernde Rahmenbedingungen. Herr Waldmann war stets am Puls der Branche und hat mit seinem Team die besonderen Interessen der Mitgliedsunternehmen vertreten: Von der Technikpolitik über Herausforderungen des Marktzugangs bis zur Leitmesse ITMA und dem europäischen Verband CEMATEX. Die ITMA 2007 in München war dabei sicherlich ein Highlight. Der Vorstand des Fachverbands wünscht Herrn Waldmann für den nun beginnenden neuen Lebensabschnitt alles Gute.“

High-performance yarns now offer almost unlimited possibilities for replacing traditional raw materials in a vast range of technical applications. Often tailor-made, these filament yarns go way beyond the conventional idea of ‘textiles’ – finding new uses in sectors such as automotive, aviation, maritime, medical and construction, among many others.

Technical textiles are everywhere in our daily lives today, even if we may not always realize it. Some are in more obviously textile products, from sewing threads to artificial turf. But then, take cars as an example: modern vehicles are stuffed with parts made from sophisticated yarns. It’s common for producers of automotive parts now to send template material and requirement lists to Swiss Textile Machinery members, trusting their expertise and experience. Members operate development and testing centers with latest machine installations, where their experts devise customized solutions, as well as calling on the pure innovative spirit which is part of their DNA.

At the extremes
Technology drives applications beyond our current imagining in the case of Heberlein air splicers. Developed for a wide range of uses with high-strength technical fibers, they have no problems splicing aramid fibers up to 16’100 dtex, carbon up to 30’000 dtex, Dyneema up to 5’500 dtex, and glass up to 4’800 tex. Using compressed air, the splicers produce a tear-resistant, homogeneous splice of material without interfering knots.

Retech has the technology to achieve specifications for filament yarns, drawing and stretching fibers to perfection. Top heated godet rolls – many customized – are developed for high-performance fibers. Temperatures up to 400 °C can be achieved. Combining the right settings and wide speed ranges for each specific process results in unique end-products.

Fabric producers of high-end applications must avoid any quality risk. Yarn producers are well aware of this responsibility, so they use precision package winders for technical yarns, developed by Rieter’s subsidiary SSM. Taking yarns from ring twisting bobbins, its specialist finish winders can produce coarse-count technical yarns up to 50’000 dtex, offering a new level of flexibility and winding quality.

Lifestyle essentials
At first glance, motorists might fail to notice many of the technical yarns ‘hidden’ inside their cars. These products have functions such as providing stability with hardly any weight, or absorbing tensile forces at defined elongation. This kind of controlled elongation behaviour, for example, arises from the choice of textile material and the special construction of the yarns used.

Such specifications make twisting and cabling machines essential for the automotive industry. Saurer offers machines for the production of technical yarns made from a variety of feed materials in a very wide yarn count range. They are needed for vehicle products such as tire carcasses, toothed engine belts, seat belts, airbags and lorry tarpaulins.

Technical yarns also play a surprising role in our mobile devices. Tapping, scrolling and swiping are second nature for billions, with our phones and a plethora of other lifestyle essentials. Yet, how many people would know that the touch-sensitivity we take for granted on these screens is largely made possible by twisted glass fibers. Bräcker, part of Rieter’s components business, offers a selection of vertical sinter metal rings and nylon travelers for glass fiber twisting, so that mills can achieve high levels of productivity and quality.

Future unlimited
Automotive and communication technology are already important industries for Swiss Textile Machinery members, along with well-known technical textiles markets in sectors such as medical, transport and construction. Smart-wear is already noted as a field with significant potential. Naturally, members are constantly investigating other possibilities. Swiss textile machinery is already applied in energy (batteries), and plastics.

The Swiss Textile Machinery Pavilion will be at the Techtextil exhibition in Frankfurt, Germany, taking place from 21 to 24 June 2022.

Originally conceived as a low-cost, high-volume alternative to knitting and weaving, nonwovens was already expanding its market boundaries by the 1970s with new applications in ‘disposables’ such as diapers, hygiene and teabags.

In the past five decades, the nonwovens business has exploded in all directions, reaching a global market worth USD 40.5 billion in 2020, projected to grow to USD 53.5 billion by 2025. This annual growth rate of 5.7% (MarketsandMarkets, Nonwoven Fabric Market Report) is based on countless new applications and expansion into durable, as well as additional disposable, products.

Major growth drivers include the hygiene sector, and filtration media for power plants and air conditioning systems. Especially during the peak of the COVID pandemic in 2020 and 2021, demand in the hygiene sector multiplied. Worldwide capacities for both meltblown and spunlace production rocketed compared to a normal business year. Swiss Autefa Solutions, for example, significantly benefited from this trend, notably with the launch of a fully-automatic machine for producing face masks.

The automotive industry is the second big growth area, with many new applications being pioneered. The trend to electric and hybrid vehicles has helped this, as nonwovens reinforced with carbon fibres are widely used as battery housings.

Swiss nonwovens competence
Innovative applications across all sectors have driven the rapid evolution of sophisticated nonwovens machinery. Today’s trends demand higher productivity, sustainability and Industry 4.0 compatibility – demonstrated by the full equipment portfolio of Swiss Textile Machinery member Autefa Solutions. With V-Jet Futura, the company recently sealed the link in its product range between web forming and drying technology. This latest Hydroentanglement Machine, together with the SQ-V Square Drum Dryer, embodies advanced technology combined with significant reductions in energy consumption compared to other process solutions.

A vital contribution to nonwovens production is offered by Rieter subsidiary Graf, a leading supplier of clothing and combs for carding and combing processes in spinning and nonwovens. Graf's Hipro card clothings – suitable for any man-made fibres in the nonwovens sector – are focussing on higher productivity. Their superior performance delivers up to 10% higher throughput and greater carding efficiency compared to conventional clothings. These reliable card clothing elements also ensure a consistently reproducible high web quality, as well as 20% fewer failures in the web, thanks to the precise fibre transfer to and from the cylinder.

Another constant trend in nonwovens today is the drive for better quality. Manufacturers want to take charge of contamination levels in their processes, as well as eradicating defects which may arise during production. Uster Technologies, a leading provider of quality management solutions from fibre to fabric, offers a combined solution to achieve both these required quality standards. At the fibre preparation stage, Uster Jossi Vision Shield N ensures the best possible initial inspection and removal of contamination. Then, at the end of the production sequence, Uster EVS Fabriq Vision N handles automated detection and marking of all the main defects caused during production. This combined solution avoids material waste and takes full advantage of the potential for process optimization.