From the Sector

• Renowned global denim event goes live again after two years
• Bangladesh Denim Expo brings together the global denim supply chain
• The show has a sustainability focus, and a central theme of ‘Beyond Business’
• Bangladesh is the 2nd largest denim exporter to the EU and the third largest to the United States

After a two-year break, Bangladesh Denim Expo will once again open its doors in the international Convention City, Bashundhara (ICCB) in Dhaka on May 10th & 11th 2022. The event is now firmly established as one of the world’s leading denim trade shows, and its live return is a huge boost to the global denim manufacturing sector.

“Beyond Business” is the theme of the 12th edition of the show. Bangladesh Denim Expo addresses the new opportunities for successful & sustainable business, in a world that now demands that industry leaders to go “Beyond Business.”

79 Exhibitors are set to attend the event, consisting of both local and international participants.

In this edition exhibitors will display fabrics, garments, threads, machinery, finishing equipment and accessories, positioning the show as a true representation of Bangladesh’s denim industry - the second largest denim exporter to the EU and third largest to the United States.

Through a series of product displays, seminar sessions & panel discussions, the Expo will encourage robust debate and interaction among exhibitors and visitors.

8 seminar sessions conducted by exhibitors at the two days event, and two panel discussions, reflecting the overriding sustainability theme of this edition of the Expo.

Industry experts will gather to discuss how the denim industry can improve, not only from a business perspective, but also considering social and environmental impacts and goals.

Monforts and its Turkish representative Neotek are looking forward to the forthcoming ITM 22 international textile machinery show taking place from June 14-18 at the Tüyap Fair and Congress Centre in Istanbul, after a three-year break.

With the TwinAir heating chamber system within a Montex stenter, top and bottom airflows can be regulated completely independently of each other, ensuring heat is only applied when and where it is required. The Optiscan balancing system ensures continuous automatic evaluation of the distance between the nozzles and the fabric for highly economical and contact-free drying. The resulting constant evaporation rate within the stenter ensures optimum energy utilisation and also avoids markings on the fabric.

With the latest Montex stenters, overall energy savings of up to 40% can now be achieved compared to a conventional stenter with no heat recovery or energy optimisation measures like high-quality chamber insulation.

The Montex stenter also benefits from full digital control, with the Qualitex 800 PLC control system providing ease of operation and rapid access to line and management data, including full operating cost overviews, as well as maintenance monitoring.

Advances in digital technology mean that there are also now significant gains to be made in the retrofitting of existing Monforts machines with the latest automatic drives and control systems, going far beyond the basic replacement of spare parts.

“We will be emphasising the robustness and versatility of the Montex stenter for essential processes such as drying, stretching, heatsetting and coating at the Istanbul show,” said Monforts Area Sales Manager Thomas Päffgen.

“With energy prices rising steeply everywhere, features such as the MonforClean system, or the EcoBooster, in which waste heat from the drying process is used to pre-heat the drying air, are proving more invaluable than ever,” added Ahmet Kilic of Neotek. “Monforts can provide a range of further resource-saving and energy recovery options tailored to each individual line installation.”

Monforts will highlight its advanced finishing and coating technologies for the production of technical textiles at Techtextil North America, which takes place at the Georgia World Congress Center in Atlanta from May 17-19.

The company and its US representative PSP Marketing, of Charlotte, North Carolina, will be part of the centrepiece VDMA German Pavilion at the show.

Energy prices
With energy prices continuing to go through the roof, an emphasis at Techtextil North America will be on the energy and heat recovery that can be achieved with Montex stenters, through features such as the MonforClean system, in which waste heat from the drying process is used to pre-heat the drying air. This results in a radical reduction in the conventional heat supply required. A range of further resource-saving and energy recovery options can be specified per individual line installation.

Advanced machine operation
With the highly intuitive Qualitex 800 visualization software, all article-specific settings can be stored and the formulations for thousands of treatment processes called up again at any time. Individual operators can also personalise their dashboards with the most important machine functions and process parameters.

The Qualitex 800 system is available for the automatic and continuous operation of the company’s Montex stenters, as well as its Thermex continuous dyeing ranges, Monfortex shrinking systems and Montex®Coat coating units.

Versatility is the key
Monforts Montex®Coat coating units serve an equally diverse number of markets, including tents, tarpaulins and awnings, black-out roller blinds and sail cloth, automotive interior fabrics and medical disposables. Full PVC coatings, pigment dyeing or minimal application surface and low penetration treatments and solvent coatings (in explosion-proof conditions) with knife coating, roller coating or screen printing can all be accommodated with this system.

In response to pandemic containment efforts, Intertextile Shanghai Apparel Fabrics – Spring Edition and Yarn Expo Spring will be merged with the respective Autumn Editions of the shows from 29 – 31 August, whilst Intertextile Home Textiles will also be moved to the same aforementioned dates. The fairs will still take place at the National Exhibition and Convention Center in Shanghai where they were originally due to be held from 14 – 16 April 2022.
 
Ms Wendy Wen, Senior General Manager of Messe Frankfurt (HK) Ltd explained the decision: “In view of recent outbreaks in multiple provinces and cities in China, and to support the government’s pandemic control measures, the organisers of the fairs have decided to adjust the three spring shows by combining the Spring and Autumn Editions of Intertextile Apparel and Yarn Expo, and holding these concurrently with the Spring Edition of Intertextile Home. The decision is necessary to reduce the risk of transmission and to ensure the welfare of all our participants. We will keep in close communication with all parties involved and we look forward to providing an effective sourcing platform for the textile industry when it is safe to do so. As we continue to adapt during these challenging times, we’d like to express our thanks to all participants for their unwavering understanding and support.”
 
Intertextile Shanghai Apparel Fabrics is co-organised by Messe Frankfurt (HK) Ltd; the Sub-Council of Textile Industry, CCPIT; and the China Textile Information Centre. The co-organisers of Yarn Expo are Messe Frankfurt (HK) Ltd and the Sub-Council of Textile Industry, CCPIT. Intertextile Shanghai Home Textiles is co-organised by Messe Frankfurt (HK) Ltd; the Sub-Council of Textile Industry, CCPIT; and the China Home Textile Association (CHTA). 

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.

Reifenhäuser Cast Sheet Coating - specialists for cast film, sheet extrusion and extrusion coating lines - will showcase a new production process for cost-effective film/nonwoven composites with an exceptionally low grammage at ICE (International Converting Exhibition) Europe. The leading international trade show for paper, film, and foil conversion and processing will be held at Messe München (Munich trade fair center) from March 15-17, 2022.

The Covid-19 pandemic and current supply shortages have exposed the dependence of companies on global supply chains. This situation is both a warning signal and an opportunity to boost and reorganize the local production of semi-finished products from the ground up. Reifenhäuser Cast Sheet Coating has now developed a trend-setting production process termed Ultrathin Coating, in particular for the sector of medical protective clothing. The process will permit customers to produce particularly lightweight film/nonwoven composites with greater cost efficiency and, as a result, more competitively. The patent-pending process has several advantages: It cuts film grammage by 66%; material consumption in the overall composite is reduced by 28%; and it slashes costs by up to 34% compared to conventional semi-finished products. Significant cost savings are achieved in various ways, for example, by replacing hotmelt adhesives, which reduces line maintenance to a great extent at the same time.

Mark Borutta, Sales & Marketing Specialist bei Reifenhäuser Cast Sheet Coating, erklärt: „Wir erleben derzeit einen nachhaltig wachsenden Mehrbedarf für medizinische Schutzbekleidung verbunden mit einer Rückholstrategie für lokale Produktionskapazitäten. Vor diesem Hintergrund erzielen Produzenten mit ‚Ultrathin Coating‘ einen schnellen Return on Invest und hohe Profitabilität – auch bei einer Produktion innerhalb Europas.“ Die Vlies-erfahrene Schwesterfirma Reifenhäuser Reicofil –führender Hersteller von Vliesstoffanlagen – hat die Entwicklung unterstützt.

Mark Borutta, Sales & Marketing specialist at Reifenhäuser Cast Sheet Coating, explains: "We are currently experiencing a sustained increase in demand for medical protective clothing combined with a return strategy for local production capacity. Against this backdrop, producers achieve a fast return on investment and high profitability with Ultrathin Coating - even when production is based in Europe." The sister company, Reifenhäuser Reicofil, an experienced and global leading manufacturer of nonwoven lines, provided their support to the development.

Even if manufacturers already produce medical protective clothing and prefer to handle the coating process internally in the future instead of importing the necessary composites, it is worthwhile to set up an in-house production facility. In either case, the investment in Ultrathin Coating usually pays for itself in less than 12 months. The lower material input also reduces the consumption of fossil raw materials and this in turn responds to the increased demand for more sustainable products.

Groz-Beckert will be exhibiting its Felting and Carding product areas at IDEA in Miami, USA, from 28 to 31 March 2022. Groz-Beckert experts will be presenting the latest products and solutions for the production of nonwovens.

Whether hydroentanglement, traditional needling or service: The product group Felting gives visitors comprehensive insights into the portfolio for the nonwovens industry. For spunlace customers, Groz-Beckert presents its HyTec® P jet strips, with a high hardness excellent scratch resistance.

In the area of traditional needling, the patented GEBECON® felting needle is one of Groz-Beckert’s highlight products. Thanks to its geometry, it offers optimized bending resistance with high flexibility.

Visitors can take a virtual tour through the technology facility in the Groz-Beckert Technology and Development Center (TEZ) in Albstadt, Germany and experience the staple fiber needle punch line (SVL).

At IDEA, the Groz-Beckert InLine card clothing series is the main focus of the product group Carding. Thanks to a new and patented production method, Groz-Beckert has developed a new range of metallic card clothing, which offers improved process reliability and increased up-time of the card for the nonwovens industry. At the same time, the new production method also reflects the corporate principles of environmentally-friendly and resource-saving production.

The card clothings are characterized by a controlled and very precise hardening of the teeth, a reduced rib height of 1.3 millimeters and  completely scale-free surfaces without burrs. An exhibit at the booth will highlight how this differs from conventional production methods. It shows an impressive comparison between the new Groz-Beckert InLine card clothing and the previous generation.

The SiroLock™ plus worker and doffer wire was developed as the first special geometry of the Groz-Beckert InLine card clothing series. In addition to the advantages of the Groz-Beckert InLine card clothings, the SiroLock™ plus impresses with a more effective fiber take-up, control and transfer. The functionality and operating principle behind the SiroLock™ plus can be experienced by IDEA visitors via Augmented Reality.

• Winners in Six Categories to be Announced at IDEA® 2022 in Miami Beach

Online voting for the IDEA® Achievement Awards representing the “best of the best” innovations in the global nonwovens and engineered fabrics industry in six categories will open on Feb. 28.

Industry professionals will have the opportunity to vote for the winners from the finalists and see award-winning achievements in person at IDEA® 2022, the World’s Preeminent Event for Nonwovens & Engineered Fabrics, March 28-31, at the Miami Beach Convention Center.

Presented by INDA, in partnership with Nonwovens Industry magazine, the awards recognize the leading introductions in equipment, raw materials, short-life, long-life and nonwovens products, and sustainability. To vote on the Nonwovens Industry website, visit: https://www.nonwovens-industry.com/idea-reg-achievement-awards

In addition, INDA will unveil the IDEA® 2022 Lifetime Achievement Award honoree and Nonwovens Industry will announce the IDEA® Entrepreneur Achievement Award recipient at the event.  

All of the winners will be announced on March 30 at a ceremony at IDEA® from 9:30 a.m. to 10:30 a.m. moderated by Dave Rousse, President, INDA and Karen, McIntyre, Editor, Nonwovens Industry.

The INDA Technical Advisory Board, consisting of technical professionals from member companies, has narrowed the competition from more than 100 online nominations to the following 18 finalists selected for their leading innovations since the last IDEA show in 2019.

The industry will have the chance to select their top choices from the three finalists in each of the following six categories through the online voting process:

IDEA® Equipment Achievement Award

• ESC-8 – Curt G. Joa, Inc.
  Imagine endless combinations of insert and chassis designs for adult incontinence production at the push of a button. With patent-pending ESC-8™ Electronic Size Change Technology, JOA has addressed the need for automated product size change. The release of this industry-leading, first-of-a-kind technology gives customers the flexibility to configure endless insert and chassis combinations while maintaining higher production speeds and minimizing raw material usage. The ESC-8™ can be integrated into new and existing machines.
   
• Elastic Thread Anchoring (ETA) Sonotrode – Herrmann Ultrasonics Inc.
  Elastics are an integral component to many hygiene products. Imagine a diaper or incontinence product that is reliable, adhesive-free and extremely soft. Herrmann Ultrasonics Elastic Thread Anchoring (ETA) Sonotrode technology provides just that, in an industry first, easy-to-use closed-loop feedback manufacturing solution. The fixation of the elastic threads is accomplished with ultrasonic energy that offers a wide process window, without the need for tool changeovers, at processing speeds above 2,000 ft./min.
   
• Doffer Airlay Card – Technoplants SRL
  With airlaying suction and a doffing system like traditional roller cards, the Doffer Airlay Card makes it possible to produce carded webs with doffer in thicknesses from 10 to 1.500 gsm. With top and bottom suction, it can produce a partly carded and partly airlaid web. This card can comb, separate and make parallel all types of natural, synthetic and regenerated fibers for applications including hygiene, filtration, medical and gradient acquisition distribution layer (ADL).

IDEA® Raw Material Achievement Award

• sero™ premium hemp fiber – Bast Fibre Technologies Inc.
  sero™ 100 percent premium hemp fibers are the result of years of the company’s top-to-bottom supply chain experience. BFT’s proprietary processing technology is employed to carefully clean, individualize, and soften bast fibers that meet stringent nonwoven technical standards and are plastic-free, tree-free, and compostable. sero™ fibers are a plug-and-play replacement for plastic fibers that run seamlessly on major nonwoven platforms without compromising production speeds, efficiency, or uniformity.
   
• ODOGard – Rem Brands, Inc.
  Rem Brands, Inc.’s patented ODOGard® technology is a revolutionary advancement in odor elimination. This next-generation odor elimination mechanism works by covalent molecular bonding to malodors. Malodors are permanently attached to the ODOGard® molecule, changing them into non-odorous molecules forever. ODOGard® can be impregnated into pulp fluff and other kinds of media. Whether  malodors come from the air or from hygiene products, ODOGard® has it covered.
   
• SharoWIPES™ – Sharon Laboratories
  SharoWIPES™ by Sharon Laboratories, Israel, is a technological breakthrough from in-depth scientific research addressing industry needs for more “clean label, non-irritating, eco-friendly” consumer wet wipes. With their unique anti-biofilm mechanism, SharoWIPES™ offer dual protection from microbial contamination of both the wet wipe formula, as well as the non-woven fabric. SharoWIPES™ preservation systems deliver broad-spectrum protection at low levels contributing to wet wipe brand equity with free from, microbiome friendly, vegan and biodegradable claims.
   

IDEA® Short-Life Product Achievement Award

• MDP™ – Dermasteel, Ltd.
  MDP™ presents a breakthrough approach to restoring the quality of life for men experiencing bladder leakage. MDP™ is a revolutionary nonwoven product for men coping with light urinary incontinence that is invisibly discreet, effective, comfortable, and reliable. It features Body ID Technology™ for customized adjustment, variable elasticity strapping, self-reflexive side panels for unimpeded breathability, form-fitting to the unique characteristics of each man’s anatomy, and the smallest carbon footprint of any comparable male incontinence option.
   
• Organic 2.0 – Ellepot A/S
  In young plant propagation, plastic products are used in large quantities. Ellepot’s new paper is a game-changer supporting plastic exit strategies. During six years in development, Ellepot and Ahlstrom-Munksjö partnered with OrganoClick, the developer of special binders using organocatalysis, a field of chemistry awarded the Nobel Prize in 2021. The product is approved for organic crops in Germany, the UK, Denmark, The Netherlands, Sweden and Canada and certified okay home compostable and biodegradable in soil.
   
• LifeSavers Wipes – LifeSavers LLC
  LifeSavers Wipes are personal hygiene wipes that change color if they detect abnormal health indicators in the urine. The launch product is a diabetic wipe, which will change color if there are abnormal levels of glucose in the urine. The wipes are therefore triple purposed as they assist with personal hygiene after urinating, act as an early warning system, and serve as an instant glucose monitor. UTI and kidney disease wipes are next in line.
   

IDEA® Long-Life Product Achievement Award

• Canopy Hero Pro – Canopy
  Today’s reusable respirators are uncomfortable, limit communication, and can lose effectiveness after cleaning. Disposable options pose similar issues and generate waste. Canopy® has created a next-generation, reusable respirator for healthcare workers that’s comfortable, easy to clean, exceeds federal safety standards, has a transparent front to allow for improved communication, costs less than disposables, and can help save 7,200 tons of waste daily. Its patented, transparent, fully mechanical filter helps protect those who protect us.
   
• Long-Life Cellulose-based Nonwovens for Higher Performance in Reusable Baby Diapers – Kelheim Fibres GmbH and Sumo Diapers
  Innovation exemplified: the trend-setting Sumo Baby Cloth Diaper shows how needle-punched/thermobonded nonwovens find their way into reusable diapers, thanks to Kelheim Fibres’ specialty viscose fibers with adjusted cross-sections (trilobal and hollow). This technology pushes liquid management capabilities and the absorbency of washable hygiene products to new levels, creating a unique duality of high-performance and high-sustainability credentials, and opening up new fields of application.
   
• Nanofiber Cabin Air Filter – MANN + HUMMEL GmbH
  MANN+HUMMEL has developed a hybrid media by combining electret-based spunbond and a pure mechanical filtration layer of ultrafine polymer fibers. The result: an outstanding separation of PM1 particles up to 95 percent, according to DIN EN ISO 16890. This technology enables stable filtration performance and long-term efficiency over the whole filter lifetime. The nanofiber layer can be combined with any cabin air filter media of the MANN+HUMMEL range, improving air quality in a vehicle’s cabin significantly.
   

IDEA® Sustainability Advancement Award

• Pureflow8 – In Flight Material Separator – Diaper Recycling Technology Pte. Ltd.
  New bolt-on additions to the company’s Generation 8 recycling platform guarantee increased performance in terms of material purity and work efficiency. While recovering up to 87 percent of diaper waste raw material’s financial investment, DRT pushes the boundaries further to meet sustainability targets and include active pulp scanning, fluidizing SAP re-gen technology, and gravimetric pulp refeed processes. DRT recognizes its teams and suppliers who have worked tremendously hard to complete this major milestone.
   
• Fitesa® 100 Percent BioBased Bico – Fitesa
  Fitesa® S Bico 100 percent BioBased PE/PLA is a technically sophisticated plant-sourced nonwoven that has been successfully applied in innovative baby diapers as topsheet, backsheet, and front ear components to deliver classic spunbond strength with good abrasion resistance and converting performance. It is responsibly sourced, PE soft, and sustainable, leaving a negative carbon footprint by reducing environmental CO2. It represents the next generation of hygienic nonwovens designed to make work easier and life better.
   
• Fiber-based Screw Caps – Glatfelter Corp. and Blue Ocean Closures
  Finally, an alternative to metal and plastic screw caps! Blue Ocean Closures partnered with Glatfelter and ALPLA to accelerate and produce sustainable and environmentally-friendly packaging solutions. The companies optimized their use of renewable and recyclable wood fibers and airlaid materials by creating paper-based screw caps that are durable, strong, and water-resistant. The method of proprietary vacuum press forming allows for low production cost and high scalability.
   

IDEA® Nonwoven Product Achievement Award

• Sontara® Silk – Glatfelter Corp.
  Sontara® Silk perfectly fits facial contour, is luxurious on the skin, and has a minimal environmental impact. When infused with lotion, these masks have enhanced elasticity, conform closely to the skin, and have excellent adhesion. Sontara® Silk has superior translucency and ensures even penetration of active ingredients onto the skin. Sontara® Silk fabric is manufactured with premium fibers derived from natural raw material. These sustainable materials allow the product to be biodegradable and compostable.
   
• HYDRASPUN® Aquaflo – Sustainable Nonwoven Substrates – Suominen Corporation
  Suominen’s latest moist tissue product, HYDRASPUN® Aquaflo achieves dry tissue dispersibility through a proprietary blend of 100 percent sustainable cellulosic materials, minimizing environmental impact. This flushable nonwoven has a premium hand feel for a luxurious consumer experience. In addition, it passes dispersibility standards set by INDA (GD4) and the International Water Services Flushability Group (IWSFG.) HYDRASPUN® Aquaflo is produced in Europe and North America and represents multi-year development and market insights to deliver a personal care product ideal for today’s consumer.
   
• LS SAF™ Nonwoven Fabrics –Technical Absorbents
  Technical Absorbents developed a new grade of Low Shrink (LS) superabsorbent fiber (SAFTM) for use within a new range of nonwovens that are more resistant to shrinkage. The new LS SAFTM fiber and resulting fabrics were developed in response to demand from the medical industry for a superabsorbent nonwoven suitable for use in advanced wound pad dressings. The new fiber was engineered to be capable of withstanding the moisture used in the EtO sterilization process.

Moving forward after this year, the IDEA® Achievement Award will be presented every two years under the new cycle announced for the event with the subsequent IDEA® taking place April 23-25, 2024.

Dilo, a leading equipment supplier of complete lines for staple fibre nonwoven fabric production, will exhibit at IDEA 2022 in Miami, end of March.
 
The most recent machine concepts from DiloGroup companies DiloTemafa, DiloSpinnbau and DiloMachines will be promoted with the emphasis on new equipment components which improve product quality, increase line capacity and also enable new opportunities in nonwoven production.
 
DiloTemafa will promote the improved bale opener series “Baltromix Pro” with design features for the operating assistance with the I4.0 components “Bale Timer”, cleaning control, better accessibility for maintenance and the “DI-LOWATT” system for energy savings in fibre transport. The proven carding willow with modified workers and separate drives to create the prerequisites for a good fine opening will also be part of the presentation as well as the fine opening stage which may be installed over the material box of the new card feeder FRS-P to achieve a high dosing accuracy in cross and longitudinal direction.  
 
DiloSpinnbau has a new “Unifeed” card feeder (VRS-P) which combines the principle of volumetric charged feeding with the characteristics of a chute feeder but without the conventional overhead trunk which allows for lower ceiling height requirement. The fibre flock matt is condensed by a vacuum delivery apron to give better uniformity of mass distribution. The distribution over the working width is controlled by additional flaps. This feeder can be adapted for medium/fine, coarse/medium or long staple fibres.
 
The “VectorQuadroCard” by DiloSpinnbau incorporates a modular transfer group between breast and main section. The quick change facility of this roller group provides different carding options. The delivery system is also flexible to provide parallel laid, random or condensed web. The preopener section on this card has 4 worker/stripper pairs with five pairs on the main cylinder. Emphasis is on high throughput with good web quality.
 
The revised HyperLayer NT offered by DiloMachines presents the latest state-of-the-art highspeed precision layering technique setting new standards which play an important role especially in hydroentanglement lines. In this application, it is important to achieve layering speeds up to 190 m/minute using sophisticated viscose fibres and a layering width of about 4 m while at the same time having a high layering precision in cross and longitudinal direction.  
 
DiloMachines will also present its portfolio to improve quality and reduce costs. The FutureLine study “3D-Lofter” – first presented at ITMA 2019 in Barcelona – is part of this programme. In this study individual web forming units can deposit fibre masses on freely programmable spots in longitudinal and cross direction thus saving overall fibre mass in applications such as deep moulded parts for the automotive interior. This ability reduces costs in production and operation. The “IsoFeed” concept for a more even flock mat for direct cards and aerodynamic web forming is another interesting field of web mat quality improvement.

Albarrie – a major player in North America’s industrial nonwovens industry – is now benefiting from one of the first Monforts Montex stenter installations equipped with the full range of MonforClean heat recovery and exhaust air purification technologies.

With the new three-chamber Montex stenter at its plant in Barrie, Ontario, the Canadian company is treating specialised needlepunched nonwovens up to 4mm thick. These have applications in a wide range of filter media and performance fabrics.

The new Montex is enabling Albarrie to heat set and dry its materials to produce denser, higher quality fabrics which can also be finished and delivered to customers more rapidly.

Across timezones
It took a crew of skilled millwrights, electricians and product specialists to build the line which was delivered in 11 shipping containers to Albarrie’s production facility. The line was originally scheduled to be fully operational in the Spring of 2020, but the ongoing global Covid-19 pandemic inevitably led to several delays during the start-up and commissioning process.

Energy savings
The Albarrie Montex line’s MonforClean capabilities include an air-to-air cross flow heat exchanger and an electrostatic precipitator providing the ability to purify the exhaust air and to recover energy to a maximum of 22,500 cubic metres of air per hour, resulting in a radical reduction in the conventional heat supply required. The MonforClean was developed in cooperation with partner KMA Umwelttechnik, based in Königswinter, Germany.

The fully automated system is powered by a Siemens SPS S7 controller and KP 700 touch panel from which the recycled energy can be continuously monitored and savings calculated.

The three-chamber Montex stenter is fitted with the latest Monforts Qualitex 800 PLC control system with WebUI, providing ease of operation, a full operating cost overview and maintenance monitoring.