From the Sector

From September 11 to 14, 2024, the Trützschler Group will present its latest innovations at CAITME in Tashkent, Uzbekistan - featuring machines and technologies in spinning, card clothing and nonwovens.

Trützschler Spinning
A highlight will be Trützschler’s next generation card, the TC 30i. In recent customer trials, the TC 30i has achieved up to 40 % higher productivity while reducing energy consumption by up to -18 %. In addition, the team will share insights about the Integrated Draw Frame IDF 3, which enables shortened processes that save resources, energy and production space. Visitors will also have the opportunity to discover the TCO 21XL, a 12-head comber. This comber makes it possible to increase productivity by 50 %, while requiring 25 % less space.

Visitors will also get the chance to learn about Trützschler’s new brand for textile recycling, TRUECYCLED. The company enables its customers to produce high quality tapes while turning waste into value.

Trützschler Card Clothing
Trützschler Card Clothing (TCC) will present a range of technologies from its card clothing portfolio, covering the full spectrum of applications in the spinning and nonwovens markets. A key feature will be the Flexible Bend Control (FBC), which ensures flat setting for all card models within a few seconds and guarantees optimum quality.

Trützschler Nonwovens
Trützschler Nonwovens will focus on solutions for the production of cotton nonwovens for wipes, pads and medical products from virgin fibers, comber noils or blends. In addition, the team will provide insights into T-SUPREMA needle-punching lines and show its solutions for the specific requirements of high-potential markets such as geotextiles, filter media, automotive textiles or other durable products.

As a traditional textile country, India has also established a strong position in the field of manmade fiber production in recent decades. The West Asian country has now become the second largest polyester yarn manufacturer in the world. The Indian textile industry covers the entire value chain from the melt to the finished textile end product.

The technical textiles sector in particular is regarded as a future market. With an average growth rate of 12% since 2013, this dynamic sector accounts for around 13% of the entire Indian textile and clothing market, according to the government organization Invest India. The market volume has almost doubled in the past ten years. In India, the production of industrial yarn has so far relied heavily on polyamide. Oerlikon Barmag has a strong market position here. "In recent years, we have commissioned plants for numerous customers," says Dr. Wolfgang Ernst, Head of Sales of the Oerlikon Business Unit Manmade Fibers Solutions.

Increasing demand for industrial polyester yarns
The construction boom and the increasing use of geotextiles and industrial textiles in various infrastructure projects as well as in agriculture and aquaculture show enormous growth potential. This is supported by the government's 2021 industrial development program, which includes technical textiles as one of ten priority sectors. The program is based on reducing dependence on imports. Until now, a large proportion of the technical textiles and yarns required in the country have been imported.

The trend towards high-quality technical textiles for the domestic market has also been noted by the Remscheid-based machine and plant manufacturer. "We are receiving more and more inquiries from Indian customers for spinning systems for industrial yarns," says Dr. Wolfgang Ernst. "What is new is the great interest shown by companies from downstream processes that are looking for backward integration. We attribute this to the stricter regulations of the Bureau of Indian Standards. Until now, industrial yarns were mainly imported from China. In order to guarantee the quality of the processed yarns, this has been strictly regulated by the government since last year. It therefore makes sense for Indian textile producers to enter the yarn manufacturing sector." This development was also noticeable at this year's Techtextil in Frankfurt, where the experts from Oerlikon Barmag were able to hold a disproportionately high number of technical discussions with Indian customers and interested parties.

The flexible spinning concepts of Oerlikon Barmag enable a variety of possible yarn products for numerous applications. The portfolio includes processes for the production of polyamide and polyester yarns with the required physical properties for a wide range of end applications, whether HMLS yarns for car tires, yarns for geotextiles, safety belts or even airbags.

Mahlo GmbH + Co. KG announces its participation in the Febratex trade show from August 20 to 23, 2024. The event will take place in Blumenau, Brazil, a hub for textile and garment production.

The company will present its latest advancements in straightening technology and process control. The booth will be jointly hosted by Mahlo’s sales agency MBR Textile and Christian Matthias, the head of Mahlo’s application department. They will be available to provide in-depth knowledge and demonstrations of Mahlo's solutions.

Mahlo’s technology addresses the critical needs of textile manufacturers, ensuring high-quality production with minimized distortion and optimized processes. The company’s automatic straightening system guarantees thread-
straight fabric across various applications, thanks to its modular design that can be tailored to individual production environments. Additionally, Mahlo offers several process control systems designed to optimize stenter frame operations by measuring and controlling parameters such as dwell time, thread density, and residual moisture. These systems help manufacturers improve textile quality, save raw materials, and reduce energy costs.

In a position paper published, the companies organised in the VDMA Textile Machinery Association comment on the ambitious EU regulations and their national implementation for the sustainable and circular transformation of the textile and clothing industry.

The production of textiles requires a large number of resources, such as water, energy and chemicals. “The members of VDMA Textile Machinery support customers with products worldwide to utilise great potential already at the textile production stage to thereby reduce CO2 emissions“, explained Verena Thies, Deputy Chairwoman of VDMA Textile Machinery.

The position statement emphasises the importance of efficient processes, circular economy and binding rules for all market participants. Besides, the position paper summarises the status of textile-to-textile recycling processes as well as the framework conditions for reprocessing of recyclates. The companies of VDMA Textile Machinery develop processes and technologies for recycling and provide the technical prerequisites for the efficient reuse and recycling of textile raw materials, whether natural or man-made fibres.
The Executive Board of VDMA Textile Machinery stresses additionally, that the new EU regulations for circular economy and their national implementation must be designed with realistic targets, measurable effects and as little bureaucracy as possible. Furthermore, market surveillance is needed to ensure a level playing field for all market participants.

On behalf of the industry, the VDMA Textile Machinery Association calls for creating better location conditions in Germany and EU as a favourable environment for innovation und competitiveness for textile machinery manufacturing to significantly advance the sustainability of the textile industry: The Textile Machinery Association strongly emphasises the need for a wide range of low-cost green energy, which is essential for the implementation and sustainable use of recycling solutions in the manufacturing industry. The association also sees the positive shaping of location conditions (the potential for skilled labour, a reduction in bureaucracy, shorter approval periods, investment security and predictability as well as a reduction in the tax burden) as a decisive factor for supporting sustainable business in the highly competitive textile and clothing industry.

Trützschler’s next-generation carding machine entered the market in January 2024. The machines have achieved great results during tests with customers in Türkiye and in other countries. It achieved up to 40 % higher productivity while reducing energy consumption by up to -18 %.

Higher productivity, less energy consumption
Mayfil Tekstil is a leading company in the Turkish textile industry for the production of textured yarn. It is headquartered in Nilüfer/Bursa. Founded in 2005, it has grown rapidly by prioritizing customer satisfaction. In 2022, Mayfil invested in a modern vortex airjet spinning facility that can produce up to 35 tons per day. And the company was keen to take a close look at the TC 30i for man-made fibers to explore its potential to drive progress toward Mayfil’s ambitious growth plans. In February 2024, Mayfil Tekstil conducted tests with the TC 30i. The next-generation carding machine produced 140 kg/h viscose, which is more than 40 % higher than the 95 kg/h Mayfil produces with the current benchmark. The new carding machine also decreased electricity consumption by 18 %. Based on these results, Mayfil is purchasing further TC 30i cards.

Results confirmed
Göl Iplik Şeremet Tekstil Sanayi ve Ticaret A.S., located in Inegöl Bursa, operates three factories that deliver a variety of high-quality products, with a specialization in blended yarns. Investment in modern equipment and pioneering new products that expand its portfolio are at the heart of Göl Iplik’s success across almost four decades. Göl Iplik also tested the TC 30i for man-made fibers in early 2024. This Trützschler customer took a close look at the TC 30i during rigorous viscose trials. The TC 30i achieved a 40 % higher productivity rate with the same level of quality, while consuming 15 % less power. Göl Iplik now intends to include the TC 30i in its future investment strategy.

Benefits of the TC 30i

1. Best quality from any raw material: High levels of productivity and yarn quality thanks to 35 % more active flats, the longest carding length in market and the T-GO automatic carding gap optimizer.
2. Operator-independent performance: Consistent results without relying on manual operators thanks to automatic, real-time optimization of the carding gap with T-GO.
3. Value-adding waste handling: Innovative waste suction system collects and separates different types of waste. More than 50 % of card waste can be reused or sold to third parties for an attractive price.

The German companies Brückner, Groz-Beckert, the Karl Mayer Group and Thies invite representatives of the Brazilian textile industry to a symposium with presentations and discussion panels in Blumenau, Brazil, on August 21, 2024. The event will be held at NS Armazém, Fortaleza, Blumenau and will focus on the current demand trend for warp knitted elastic fabrics.

The aim of the symposium is to provide a platform where knowledge can be exchanged and cooperation intensified. The symposium offers a wide variety of technical presentations as well as best practice examples and showcases cutting-edge technologies and innovations in warp knitting technology.

Interactive sessions and discussion rounds promote exchange among participants and provide networking opportunities. The event language is Portuguese.

Those interested in attending the symposium may contact the sales representatives: Frank Bernhard or Fabricio Rampani (Brückner, Thies & Karl Mayer), or Diomar Gomes Vieira (Groz-Beckert) to register.

On July 16, 2024, Rieter and Shanghai Digital Intelligence World Industrial Technology Group Co., Ltd. (DIW) have signed a purchase contract for more than 700 of the company’s winding machines Autoconer X6. This represents the largest order in the history of Rieter China. The agreement also strengthens the strategic partnership between the two companies that aims to develop spinning operations and achieve unprecedented levels of quality, productivity and efficiency.

DIW has placed an order for more than 700 of Rieter’s winding machines Autoconer X6. The winding machine serves as the final quality assurance in the ring spinning and compact-spinning process and is key to the performance of subsequent process steps. With its productivity, intelligent process automation, great splicing and winding quality, the Autoconer X6 is widely recognized in the market. The order will help DIW strengthen the vertical integration of its operations and accelerate its growth strategy in the cotton spinning industry, further underpinning its position in global markets. This order follows the initial batch placed in March 2024, when Rieter and DIW signed their first strategic partnership to develop intelligent yarn manufacturing technology that utilizes digitization and automation to minimize conversion costs and maximize value for customers.

Finishing machinery specialist Monforts will exhibit at the upcoming Febratex textile machinery exhibition taking place in Blumenau, Brazil, from August 20-23, along with Uniferro, its new regional partner.

This new alliance follows the retirement of Herbert Erdmann of the service agency Euro Texteis, who has worked with Monforts over more than 30 years to secure a leading position in the region for Montex stenter dryers, Thermex dyeing ranges and associated finishing technology.

With offices in Sao Paulo and Ceara and sub-agents across Brazil, Uniferro has been active in the textile industry for over 50 years.

coaTTex
At Febratex, Monforts will introduce its latest coaTTex coating unit exclusively dedicated to air knife and knife-over-roller coating. For single-sided application with paste or foam, the versatile coater is suitable for both incorporation into existing finishing ranges as well as installation with new Monforts Montex stenter systems.

A wide range of coatings can be applied to fabrics for providing functions such as waterproofing, liquid and gas protection and breathability, in addition to foam lamination and black-out coating.

Denim hub
Brazil remains a buoyant hub for textile manufacturing with a particular stength in the denim dyeing and finishing sector and many Monforts Thermex hotflue dyeing systems are already operational in the region, reaping the benefits of the Econtrol® process.

Econtrol® is a continuous process for the dyeing of woven cotton and cellulosic fabrics, especially denim, in which reactive dyestuffs are fixed into the fabric in a one-step dyeing and drying process with a controlled combination of steam and air. The entire pad-dry process takes just two-to-three minutes.

“Differentiation is the key in the highly-competitive denim fabrics industry, whether through the successful incorporation of new fibres, accommodating new fabric constructions or exploring the many options for how to treat them at the finishing stage, to gain a market advantage,” says says Monforts Regional Sales Manager Achim Gesser. “Our lines allow users to be extremely versatile and respond quickly to market demand, while also allowing very short production runs.”

Because finishing is a particularly energy-intensive part of the textile production chain, it is exactly where convincing results can be achieved, he adds, and Monforts has developed a wide range of energy-saving. These included a range of heat recovery systems, such as the Universal Energy Tower and the ECO Booster. Both can also be retrofitted to existing ranges to make production more resource-efficient and economical, yet without having to invest in a new machine.

“Energy costs tend to be high in Brazil and can account for up to 70% of production costs for our customers, so there is great demand for ways of saving money,” says Gesser. “Cutting energy usage also helps in terms of global warming and reducing carbon footprint, of course, so these latest technologies are a win-win for fabric finishers. As we look forward to a promising partnership with Uniferro in Brazil, we would like to extend our thanks and best wishes for the future to Herbert Erdmann for his hard work over the years.”

The first installations of the Trützschler Card TC 30i and the Trützschler Integrated Draw Frame IDF 3 are now complete – and the first customers have finished rigorous testing in direct spinning applications.

The Italian company Marchi & Fildi, headquartered in Biella, was one of the first to test the new IDF 3. The company specializes in producing pure and blended yarns made from natural or man-made fibers for flat knitting, circular knitting and weaving. Its products are used for fashion, furnishings and technical applications worldwide. It also places a strong focus on reducing its environmental impact.

Marchi & Fildi’s first trials were carried out with different fiber blends. This included a blend of 70 % soft waste cotton and 30 % polyester as the raw material for rotor direct spinning, with a yarn count in a range of Ne 8 to Ne 12 and Ne 30.
Later tests involved fiber blends of 50 % PET and 50 % recycled cotton from hard textile waste for rotor direct spinning with a yarn count of Ne 30. Experts at Marchi & Fildi stated that this material blend is typically very challenging. Processing secondary fibers made from hard textile waste requires very high competence in yarn production, which Marchi & Fildi impressively demonstrates. It also requires advanced technologies. This is due to technological challenges such as significantly lower fiber length. Trützschler’s IDF technology has a special drafting zone geometry that ensures reliable fiber guidance and controls floating fibers. It generates lower drafts than a conventional draw frame passage and avoids the risk of false drafts and count variations.

Decades of experience with the IDF technology have demonstrated that the higher the short fiber content, the better the result with IDF compared to conventional two draw frame passages. In combination with the TC 30Ri, a variant of TC 30i that has been specifically equipped and configured for processing recycled fibers, the IDF 3 delivers maximum possible quality for the production of sustainable yarns.

Overall, the company’s results showed a 75 % increase in productivity over the previous card model and a 14 % reduction in energy consumption at higher production rates. Combining the TC 30Ri and IDF 3 also enabled Marchi & Fildi to skip the drawing stage from its process, which boosts quality while saving resources and cutting costs.

KARL MAYER Technische Textilien launches the new MAX GLASS ECO, a composite machine with a focus on standard non-crimp fabrics made of glass fibers.

The MAX GLASS ECO incorporates proven solutions from the KARL MAYER GROUP's range of multiaxial machines, including features from its predecessor, the MAXTRONIC®, and combines these with sophisticated new technical developments. The result is a production machine for the economical manufacture of standard glass fiber articles, especially non-crimp fabrics for the wind power industry.

The multiaxial warp knitting machine is extremely efficient, affordable and, unlike the previous MAXTRONIC®, sufficiently flexible thanks to various optional functions. At a rotational speed of up to 1,800 min^-1, a maximum output of 410 m/h is achieved.

The MAX GLASS ECO is available with a working width of 101″ and is suitable for laying angles of +/-45°. A complementary layering system ensures a uniform take-up speed and therefore gentle processing of the fiber material. This sophisticated weft tension compensation device is one of a whole series of tried and tested features of KARL MAYER multiaxial technology that have been integrated into the new machine. Other adopted solutions include the Fiber Chopping Unit, which allows glass fiber chips to be introduced into the laying process and thus cover more fields of application, and a single pin transport chain for a processing method with less waste.

Newly developed innovations also ensure even better performance, including the fixed layer system, which ensures high placement precision at all laying angles. Other equipment details with added value for the customer include a conveyor belt across the full working width, the walking needle system, which prevents the formation of lanes even with long stitch lengths, and the fitting of single compound needles, which can be changed efficiently.