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18.11.2022

Monforts at Igatex 2022

Monforts will be presenting its finishing technologies at the forthcoming Igatex textile machinery exhibition, which takes place from December 1-4 at the Lahore Expo Centre in Pakistan.

The importance of the textile industry to Pakistan’s economy cannot be overstated – it accounts for 60% of the country’s overall exports and some of its industry’s players are very major employers. In the year to June 2022, Pakistan’s textile exports climbed by 25% to a record value of $19.3 billion according to the country’s Bureau of Statistics, as security of deliveries – especially to Europe and the USA – worked in the country’s favour, in the light of the Covid-19 pandemic and subsequent supply chain issues. It has a key role to play in quickly getting the country back on its feet after the devastation.

Monforts will be presenting its finishing technologies at the forthcoming Igatex textile machinery exhibition, which takes place from December 1-4 at the Lahore Expo Centre in Pakistan.

The importance of the textile industry to Pakistan’s economy cannot be overstated – it accounts for 60% of the country’s overall exports and some of its industry’s players are very major employers. In the year to June 2022, Pakistan’s textile exports climbed by 25% to a record value of $19.3 billion according to the country’s Bureau of Statistics, as security of deliveries – especially to Europe and the USA – worked in the country’s favour, in the light of the Covid-19 pandemic and subsequent supply chain issues. It has a key role to play in quickly getting the country back on its feet after the devastation.

Monforts customers in the regions around the country’s three biggest cities of Karachi, Lahore and Faisalbad include all of the main players in the fields of home textiles and denim production, including Afroze, , Al Karam Artistic Milliners, Azgard-9, Crestex, , Gul Ahmed, Interloop, Liberty Mills, Lucky Textile Mills, Mustaqim, Naveena (NDL), Rajby Industries, Sapphire Finishing, Soorty, Style Textile and US Denim.

These companies rely on established Monforts technologies including Montex stentering equipment, Monfortex sanforizing units and Thermex dyeing ranges. The company’s Matex Eco Applicator minimum application system has also proved a big hit in recent years.

Monforts has also achieved considerable success in Pakistan with its Econtrol®* dyeing system  – an effective and established dyeing process. More than 40 Thermex continuous dyeing ranges have been installed in Pakistan in recent years and operator training on the Econtrol®* process by sophisticated technologists is an additional service.

The Econtrol® pad-dry process has a number of immediate benefits. Compared to the common pad-dry-pad-steam process, no salt is used and no steamer is required for a separate fixation step. Compared to the pad-dry-thermofix process, no urea is used and no smoke or deposits are generated, and unlike with the cold pad batch process, direct feedback of the dyeing results ensures no batching time is necessary and guarantees good reproducibility from the lab to bulk production.

An immediate wash off is also unnecessary, allowing for flexible production planning. The process is suitable for pale to dark shades with very good fastness properties. Also waste water treatment is improved by this technology.

*Econtrol is a registered mark of Dystar Colours Distribution GmbH.

Source:

A. Monforts Textilmaschinen GmbH & Co. KG / AWOL Media

Photo: AWOL
20.09.2022

Halley Stevensons: Unique waxed cotton finishing with new Monforts line

Monforts has installed and commissioned a new Montex finishing range at the Baltic Works of Halley Stevensons in Dundee, Scotland, to further boost the weatherproofing specialist’s highly flexible operations.

The range, with a working width of two metres, was built at the Montex assembly plant in Austria and consists of a Montex®Coat coating unit in knife execution for paste and foam coating and a Montex 8500 6F stenter.

Founded in 1864, Halley Stevensons has amassed unique technical know-how and manufacturing experience in the art of waxed cotton for weatherproofed fabrics and is able to provide international orders in custom colours and finishes to very low minimum quantities where required. The company exports worldwide and its premium brand customers include Belstaff, Barbours, Filson and J.Crew.

The range has replaced one of the company’s older stenter/coating lines and has already enabled Halley Stevensons to recreate various products with lower coating applications at higher speeds than was previously possible.

Monforts has installed and commissioned a new Montex finishing range at the Baltic Works of Halley Stevensons in Dundee, Scotland, to further boost the weatherproofing specialist’s highly flexible operations.

The range, with a working width of two metres, was built at the Montex assembly plant in Austria and consists of a Montex®Coat coating unit in knife execution for paste and foam coating and a Montex 8500 6F stenter.

Founded in 1864, Halley Stevensons has amassed unique technical know-how and manufacturing experience in the art of waxed cotton for weatherproofed fabrics and is able to provide international orders in custom colours and finishes to very low minimum quantities where required. The company exports worldwide and its premium brand customers include Belstaff, Barbours, Filson and J.Crew.

The range has replaced one of the company’s older stenter/coating lines and has already enabled Halley Stevensons to recreate various products with lower coating applications at higher speeds than was previously possible.

Waxed cotton was originally developed by sailors in the early 15th century when Scottish North Sea herring fleets began treating flax sailcloth with fish oils and grease in an attempt to waterproof their sails. Remnants of these sails were used by the sailors as capes to withstand the high winds and sea spray.

By the mid 1850s, sailcloth was being treated with linseed oil, but while initially highly effective, it would yellow and stiffen through weathering over time and eventually lose its waterproofing qualities.

In the years that followed, various treatments were applied to cottons in an attempt to find the most effective weatherproofing solution, and the combination of densely-woven cotton impregnated with a paraffin waxed coating proved most successful. For over 150 years, Halley Stevensons created many different variations of both woven constructions and finishing treatments and now supplies thousands of metres of waxed cotton every year, with each roll produced to custom specifications.

“The beauty of waxed cotton is its durability and longevity,” says Managing Director James Campbell. “The fabrics are breathable, with the wax adjusting to ambient temperatures to be softer and more breathable in warm weather and stiffer and more wind proof in cold conditions.”
While traditional waxes are petroleum or paraffin based, Halley Stevensons has always been comfortable about using a waste product from industry and reusing it to make products that last a lifetime.  

“We are always exploring different finishing techniques and one of our most popular finishes is our hybrid aero – an emulsified blend of waxes,” Campbell says. “This fabric is water repellent but has little wax in the mixture so the handle is much drier to touch than the traditional wet waxes.”

The company has also recently launched a new 100% plant-based wax – Ever Wax Olive – consisting of a blend of olive oil, rape seed and castor bean with comparable water repellence to petroleum and a far better rating than other natural waxes which have come before it.

“The high tradition of skills and fabric innovation imposed by our original guildsmen is still our benchmark standard of honest workmanship today,” Managing Director James Campbell concludes “We use responsibly sourced cotton fabrics and processes that are gentle to the product and low impact to the environment. Our dyeing methods use very low levels of water and our waxes are simply heated up for application and cooled down to store when not in use, meaning no waste discharges. Now, with this new Monforts line, we are also achieving running speeds two-to-three times faster than with the older stenter, combined with less gas usage. It’s proved a great partnership.”

08.09.2022

Monforts at ITMA ASIA + CITME

Monforts will highlight its technologies for special technical textile applications at this year’s ITMA ASIA + CITME which takes place at the National Exhibition and Convention Center in Shanghai, China, from November 20-24.

One of Monforts' developments is the Montex 8500 XXL stenter system for the production of technical fabrics in widths of up to 6.8 metres. Among the products made on this system are treated nonwovens for the geotextiles and filter media markets, tarpaulins, advertising banners, black-out curtains, membranes and many more.

On Montex©Coat coating lines, meanwhile, the possibilities range from the single-sided application of finishing agents for outdoor clothing and adding functionality to home textiles, to the creation of materials for sophisticated lightweight construction and automotive and aerospace components.

Monforts will highlight its technologies for special technical textile applications at this year’s ITMA ASIA + CITME which takes place at the National Exhibition and Convention Center in Shanghai, China, from November 20-24.

One of Monforts' developments is the Montex 8500 XXL stenter system for the production of technical fabrics in widths of up to 6.8 metres. Among the products made on this system are treated nonwovens for the geotextiles and filter media markets, tarpaulins, advertising banners, black-out curtains, membranes and many more.

On Montex©Coat coating lines, meanwhile, the possibilities range from the single-sided application of finishing agents for outdoor clothing and adding functionality to home textiles, to the creation of materials for sophisticated lightweight construction and automotive and aerospace components.

“Many more applications are possible, such as the overdyeing of denim, the creation of double-face coated materials, fabrics awnings, tents and medical drapes and the pre-treatment of substrates for digital printing”, explains Gunnar Meyer, Monforts area sales manager for China. “A range of different doctor blades and their combinations can be supplied to meet individual requirements, including air knife, roller knife, foam, screen and magnetic roller coating. The latter option is recommended for lines with working widths of over 2.4 metres.”

In addition, Monforts can provide the necessary explosion-proof ranges for solvent-based coatings and high temperature processes up to 320°C, such as the PTFE coating of nonwoven filter material. These lines are equipped with special burners, stenter chains, and insulation.

Source:

 A. Monforts Textilmaschinen GmbH & Co. KG / AWOL Media

(c) A. Monforts Textilmaschinen GmbH & Co. KG
07.07.2022

Monforts: New orders for machines at Techtextil 2022

The recent Techtextil show in Frankfurt emphasised the diversity of applications for nonwovens and technical textiles, according to finishing technology specialist Monforts.

“We fielded enquiries at top management level from an extremely wide range of companies, all with very different ideas for new product applications during the show,” said Alexander Fitz, who joined the company a year ago as engineer for textile technologies and co-ordinator of the Monforts Advanced Technology Centre (ATC). Fitz brings a background in both technical textile technology and processes to the role, having previously worked for a nonwovens machinery builder and a roll-goods manufacturer.

The recent Techtextil show in Frankfurt emphasised the diversity of applications for nonwovens and technical textiles, according to finishing technology specialist Monforts.

“We fielded enquiries at top management level from an extremely wide range of companies, all with very different ideas for new product applications during the show,” said Alexander Fitz, who joined the company a year ago as engineer for textile technologies and co-ordinator of the Monforts Advanced Technology Centre (ATC). Fitz brings a background in both technical textile technology and processes to the role, having previously worked for a nonwovens machinery builder and a roll-goods manufacturer.

Trials
“We are now looking forward to interesting new trials and pilot production runs, as well as the commissioning of new orders for machines resulting from the extremely busy exhibition,” he says. “Obviously, everyone at the moment is looking to make energy savings, and we have developed a range of options for helping companies increase their resource efficiency, both on new lines and as retrofitted systems, but this is not stifling innovation at the new material level.

“There was a lot of interest in what is possible with the Montex®Coat coating system and the range of different techniques it enables, and at our ATC in Mönchengladbach, a Montex®Coat unit is integrated into the full technical textiles pilot line, on which it is possible to run new fabrics in widths of up to 1.8 metres.”

Explosion proof
The technical textiles line at the ATC incorporates a Montex four-chamber stenter and is fitted with an explosion-proof coating application chamber in order to allow treatment to be carried out with organic solvents and other volatile materials.

Every single component within the chamber has to meet the standards of the European Union’s ATEX directives for working in a potentially explosive atmosphere. A range of sensors linked to alarms operate at various levels within the chamber to ensure the specified lower explosion limit (LOL) is never exceeded and the ventilation adapts accordingly.

Advanced functions
Special features on the finishing line relate to further advanced functions such as the ability to treat materials not only at temperatures of up to 320°C, but also to be able to treat the top and bottom faces of certain materials at different temperatures within a single pass through the machine.

To achieve this, the first two chambers of the stenter are fitted with special, heavy duty TwinAir ventilation motors and separate burners for individual top/bottom temperature. A temperature differential of up to 60°C can be achieved between the upper and lower nozzles within the chamber, depending on the treatment paramenters.

Another key feature of the technical textiles line at the ATC is the special stretching device which is capable of pulling ten tons in length and ten tons in width – a huge amount per square metre of fabric and necessary in the production of materials such as woven or 3D knits for high temperature filter media.

Source:

A. Monforts Textilmaschinen GmbH & Co. KG / AWOL Media

(c) A. Monforts Textilmaschinen GmbH & Co. KG
20.06.2022

Monforts introduces range of modular upgrades

Monforts is introducing a range of modular upgrades that can be added to existing finishing lines already in production.

The Monforts universal Energy Tower – a flexible, free-standing air/air heat exchanger for recovering the heat from the exhaust air flow of thermal processes – can result in a 30% reduction in the energy consumed by a line, depending on the exhaust air volume and operating temperature.

A Monforts Eco Booster, completely integrated into the chamber design of the Montex stenter, is another retrofitting option. As a single state-of-the-art heat recovery system with automatic cleaning, it can be added to existing ranges. For ranges of up to eight chambers only one module is necessary to achieve significant energy savings.

On an eight-chamber stenter with an operating width of two metres carrying out a fixing process on a 150gsm woven fabric, for example, the energy savings have been calculated to be 35% over an annual schedule of 6,000 operating hours.

In addition, the Eco Booster consumes only minimal amounts of water during the cleaning cycle and the entire process is controlled and monitored automatically.

Monforts is introducing a range of modular upgrades that can be added to existing finishing lines already in production.

The Monforts universal Energy Tower – a flexible, free-standing air/air heat exchanger for recovering the heat from the exhaust air flow of thermal processes – can result in a 30% reduction in the energy consumed by a line, depending on the exhaust air volume and operating temperature.

A Monforts Eco Booster, completely integrated into the chamber design of the Montex stenter, is another retrofitting option. As a single state-of-the-art heat recovery system with automatic cleaning, it can be added to existing ranges. For ranges of up to eight chambers only one module is necessary to achieve significant energy savings.

On an eight-chamber stenter with an operating width of two metres carrying out a fixing process on a 150gsm woven fabric, for example, the energy savings have been calculated to be 35% over an annual schedule of 6,000 operating hours.

In addition, the Eco Booster consumes only minimal amounts of water during the cleaning cycle and the entire process is controlled and monitored automatically.

The Matex Eco Applicator is an alternative to the conventional padding process for energy-conscious finishing and achieving considerable savings in the energy required for drying treated fabrics. The precise amount of chemical can be applied to the fabric and with less residual moisture after application of only approximately 35% so that less drying capacity is required in the stenter, which leads to huge energy savings.

Finishes can be evenly applied on either or both sides of the fabric, and two separate treatments can be applied to front and back. This makes the unit ideal for the production of, for example, double-performance hydrophobic/hydrophilic fabrics for professional clothing, as well as the over dyeing or finishing of denim fabrics.

Source:

A. Monforts Textilmaschinen GmbH & Co. KG / AWOL Media

05.05.2022

Monforts at Techtextil showcasing its finishing and coating technologies

The Techtextil and Heimtextil Summer Special exhibitions, taking place together in Frankfurt from June 21-24, represent an opportunity for Monforts to showcase its finishing and coating technologies for two of its major markets – especially at a time when energy prices continue to soar for textile manufacturers in Europe.

Existing customers of Monforts include many manufacturers in the field of home textiles, as well as those making geotextiles, automotive fabrics and other functional materials – all of whom will be well represented in Frankfurt this June. Dedicated Montex lines have also been supplied to producers of airbags, flame retardant barrier fabrics and spacer fabrics, as well as high-temperature filter materials.

The Techtextil and Heimtextil Summer Special exhibitions, taking place together in Frankfurt from June 21-24, represent an opportunity for Monforts to showcase its finishing and coating technologies for two of its major markets – especially at a time when energy prices continue to soar for textile manufacturers in Europe.

Existing customers of Monforts include many manufacturers in the field of home textiles, as well as those making geotextiles, automotive fabrics and other functional materials – all of whom will be well represented in Frankfurt this June. Dedicated Montex lines have also been supplied to producers of airbags, flame retardant barrier fabrics and spacer fabrics, as well as high-temperature filter materials.

Energy prices are rising steeply everywhere and a particular emphasis for Monforts in Frankfurt will be on the energy and heat recovery that can be achieved with Montex stenters, through features such as better insulation of the treatment chambers or the MonforClean system, in which waste heat from the drying process is used to pre-heat the drying air resulting in a radical reduction in the conventional heat supply required compared to gas and thermal oil heating. The modular system for heat recovery can also be extended for exhaust air cleaning and odour elimination. Monforts can provide a range of further resource-saving and energy recovery options tailored to each individual line installation including modification of the heating source.

With the 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.

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.

All of these very different materials require coating and finishing for maximum efficiency, using Monforts technologies which provide the ultimate in flexibility and the ability to switch quickly from one fabric run to the next, without compromising on the economical use of energy or raw materials.

The Monforts EcoApplicator offers further potential for sustainably achieving perfect finishes via a precise direct application system, as an alternative to conventional padding – where fabrics are immersed in a bath of the required finishing chemicals. It can significantly further reduce the energy and water required and finishes can be applied on just one side of the fabric, or both, and even separately on each side, to be sealed in place via different heating zones in the stenter.

Source:

A. Monforts Textilmaschinen GmbH & Co. KG / AWOL Media

(c) A. Monforts Textilmaschinen GmbH & Co. KG
07.04.2022

Montex stenter at ITM

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.

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.”

Source:

A. Monforts Textilmaschinen GmbH & Co. KG

31.03.2022

Monforts at Techtextil North America

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.

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.

Source:

AWOl Media / A. Monforts Textilmaschinen GmbH & Co. KG

(c) Monforts / AWOL Media
07.02.2022

Monforts: Turkish upholstery leader opts for the Montex®Coat

Turkish powerhouse in home textiles and furnishing fabrics Altun Tekstil has just commissioned the first Montex®Coat coating system in Turkey.

The advanced machine has been installed at the ever-expanding family-owned company’s industrial complex in Bursa and is being employed to provide an anti-slip and textured backing to upholstery fabrics with a stable and uniform foam, via knife-over-roller coating.  

Founded in 1993, Altun exports its fabrics to more than 60 countries, with its major export markets being Russia and Ukraine, as well as many Middle Eastern and European countries.
Its integrated operations include the production of texturized yarns, weaving and raschel knitting, in addition to dyeing and finishing. With a major focus on tulle curtains and upholstery, the company’s fabric range also extends to a wide variety of apparel styles.

Turkish powerhouse in home textiles and furnishing fabrics Altun Tekstil has just commissioned the first Montex®Coat coating system in Turkey.

The advanced machine has been installed at the ever-expanding family-owned company’s industrial complex in Bursa and is being employed to provide an anti-slip and textured backing to upholstery fabrics with a stable and uniform foam, via knife-over-roller coating.  

Founded in 1993, Altun exports its fabrics to more than 60 countries, with its major export markets being Russia and Ukraine, as well as many Middle Eastern and European countries.
Its integrated operations include the production of texturized yarns, weaving and raschel knitting, in addition to dyeing and finishing. With a major focus on tulle curtains and upholstery, the company’s fabric range also extends to a wide variety of apparel styles.

Altun has installed eight stenters in various widths at its two plants since 2016 – coincidentally the year Monforts Turkish representative Neotek was founded. All of the stenters are engineered for specific product lines and the Montex®Coat unit is integrated into the latest of these lines, which has a maximum working width of 2.2 metres and eight chambers.

Source:

A. Monforts Textilmaschinen GmbH & Co. KG / AWOL Media

06.01.2022

Monforts presents Econtrol® at VDMA Webtalk in February

Monforts textile technologist Jonas Beisel will outline the benefits of the company’s Econtrol® continuous dyeing process during the next free-to-attend VDMA Textile Machinery Webtalk which takes place on February 3rd 2022 at 13.00 (CET).

“Our customers are increasingly looking at shorter production runs and the more economical use of dyestuffs, as well as reducing water and energy consumption,” says Beisel. “We have gained many years of experience in the optimisation of dyeing processes through working with our customers, both at their own plants and in our Advanced Technology Centre (ATC) in Mönchengladbach, Germany.

“Our Thermex universal hotflue for continuous dyeing, curing and thermosoling achieves unrivalled reliability even at high fabric speeds, for exceptional cost-effectiveness when dyeing both large and small batches of woven fabrics. The Econtrol® process for reactive dyestuffs now has an impressive number of references on the market, as a quick and economical one-pass pad-dry and wash off process. This is the ideal process for fast change technology and operational savings.”

Monforts textile technologist Jonas Beisel will outline the benefits of the company’s Econtrol® continuous dyeing process during the next free-to-attend VDMA Textile Machinery Webtalk which takes place on February 3rd 2022 at 13.00 (CET).

“Our customers are increasingly looking at shorter production runs and the more economical use of dyestuffs, as well as reducing water and energy consumption,” says Beisel. “We have gained many years of experience in the optimisation of dyeing processes through working with our customers, both at their own plants and in our Advanced Technology Centre (ATC) in Mönchengladbach, Germany.

“Our Thermex universal hotflue for continuous dyeing, curing and thermosoling achieves unrivalled reliability even at high fabric speeds, for exceptional cost-effectiveness when dyeing both large and small batches of woven fabrics. The Econtrol® process for reactive dyestuffs now has an impressive number of references on the market, as a quick and economical one-pass pad-dry and wash off process. This is the ideal process for fast change technology and operational savings.”

Among key benefits are the saving of resources compared to conventional continuous dyeing methods, excellent reproducibility of pale to dark shades, from lab to bulk, and greater flexibility in production planning due to a resulting dry fabric that does not need an immediate wash off.

Econtrol® is a registered trademark of DyStar® Colours Distribution GmbH, Germany, and Bertram Seuthe of DyStar® will be providing recommendations for dyes and auxiliaries for the process during the VDMA event.

A third speaker, Guido Seiler of Fong’s Europe, will explain how Goller washing ranges help to significantly reduce the water that is conventionally wasted in the washing off process, through a combination of process and chemistry know-how and advanced technologies.

More information:
Monforts VDMA Textilmaschinen
Source:

Monforts Textilmaschinen GmbH & Co. KG by AWOL Media

14.10.2021

Monforts: Automated finishing at Knopf’s Sohn

Knopf’s Sohn, a contract finisher of technical textiles, has installed a fully automated Montex stenter at its plant in Helmbrechts, Germany.
Knopf’s Sohn is processing technical textiles for the automotive, aerospace, home furnishings and workwear markets, based on wool, cellulose, polyamide and polyester fabrics, along with elastane blends, in weights of 80-800gsm.

The Montex machinery range is constantly being upgraded to meet evolving customer needs for greater automation, ease of operation and energy optimisation. The latest ten chamber line at Knopf’s Sohn, with a working width of up to 2.0 metres, was engineered to specific requirements in order to accelerate the company’s move to fully automatic control of its production, and high scaffolding was required for its installation.

The line benefits from two integrated ECO Booster modules to provide high energy savings. These compact, air-to-air heat exchangers, installed within the roof structure of the line, exploit energy from the exhaust gas to preheat up to 60% of the incoming fresh air entering the stenter.

Knopf’s Sohn, a contract finisher of technical textiles, has installed a fully automated Montex stenter at its plant in Helmbrechts, Germany.
Knopf’s Sohn is processing technical textiles for the automotive, aerospace, home furnishings and workwear markets, based on wool, cellulose, polyamide and polyester fabrics, along with elastane blends, in weights of 80-800gsm.

The Montex machinery range is constantly being upgraded to meet evolving customer needs for greater automation, ease of operation and energy optimisation. The latest ten chamber line at Knopf’s Sohn, with a working width of up to 2.0 metres, was engineered to specific requirements in order to accelerate the company’s move to fully automatic control of its production, and high scaffolding was required for its installation.

The line benefits from two integrated ECO Booster modules to provide high energy savings. These compact, air-to-air heat exchangers, installed within the roof structure of the line, exploit energy from the exhaust gas to preheat up to 60% of the incoming fresh air entering the stenter.

The use of a single ECO Booster unit has been calculated to save up to 35% in energy costs, based on fixation processes. Fully automatic operation, set at the Monforts Qualitex control unit, ensures there is no additional burden on the machine operator.

The line is powered by Exxotherm indirect heating, which practically eliminates the yellowing which can be experienced during the treatment of certain polyamide and elastane-based fabrics, and is also equipped with a Conticlean circulating air filter system for constant high drying capacity.

Software
The latest Qualitex visualisation software offers operators reliability and easy control with its full HD multi-touch monitor and slider function, dashboard function with individual adaptation to operating states and faster access to comprehensive recipe data management.

With the Monformatic control system, the exact maintenance of the dwell time in combined treatment processes (drying and heat-setting) can be monitored. When the heat-setting point is reached, the fan speed is automatically adjusted, keeping energy consumption fully under control.

Source:

A. Monforts Textilmaschinen GmbH & Co. KG / AWOL Media

Monforts: A complete finishing line upgrade for Wülfing (c) A. Monforts Textilmaschinen GmbH & Co. KG / AWOL Media
A completely new joint control system joins the two machines seamlessly.
06.07.2021

Monforts: A complete finishing line upgrade for Wülfing

Wülfing GmbH is one of the oldest but also one of the most modern home textiles companies in Germany, with its main weaving and finishing operations located in Borken, North Rhine-Westphalia, and a further jacquard weaving mill in Steinfurt, as well as with a making up and packaging plant in the Czech Republic.

At its Borken plant, Wülfing has employed a Monforts sanforizing line since 2009 to guarantee the required dimensional stability and shrink-fastness of its high quality bed linen. With a working width of over three metres, the sanforizing process is a central pillar in the production of typical wide-width cotton fabrics for home textiles.

In 2017, the company was able to acquire a second Monforts sanforizing line from another company which, although built in 2005, had been virtually unused. It was overhauled and installed behind a Monforts equalizing frame of a similar age.

“Unfortunately, the two machines had to be operated separately via individual controls and did not represent an integrated unit,” says Schulte-Mesum. “This resulted in deficits in the desired productivity and in the control technology.”

Wülfing GmbH is one of the oldest but also one of the most modern home textiles companies in Germany, with its main weaving and finishing operations located in Borken, North Rhine-Westphalia, and a further jacquard weaving mill in Steinfurt, as well as with a making up and packaging plant in the Czech Republic.

At its Borken plant, Wülfing has employed a Monforts sanforizing line since 2009 to guarantee the required dimensional stability and shrink-fastness of its high quality bed linen. With a working width of over three metres, the sanforizing process is a central pillar in the production of typical wide-width cotton fabrics for home textiles.

In 2017, the company was able to acquire a second Monforts sanforizing line from another company which, although built in 2005, had been virtually unused. It was overhauled and installed behind a Monforts equalizing frame of a similar age.

“Unfortunately, the two machines had to be operated separately via individual controls and did not represent an integrated unit,” says Schulte-Mesum. “This resulted in deficits in the desired productivity and in the control technology.”

Wülfing consulted with Monforts on a number of upgrade options and opted for a completely new joint control system to merge the two machines, as well as a new connecting inlet, a tensioning and damping field and a steaming unit.

“Monforts provided a fast and precise erection and commissioning of the technology in spite of the difficult pandemic circumstances,” says Schulte-Mesum. “The result has been an increase in production speeds by 20% and enhanced uniformity in fabric width through a much improved guidance system.

“We are also achieving energy savings as a result of the new control and drive technology and operation has been simplified and improved as a result of the unified control. We benefit from simplified access for maintenance work such as the grinding of the rubber blanket, but most of all we have greatly improved our flexibility and now have two almost identical Monforts sanforizing lines.”

Source:

A. Monforts Textilmaschinen GmbH & Co. KG / AWOL Media

Klaus Heinrichs (c) A. Monforts Textilmaschinen GmbH & Co. KG
22.04.2021

Monforts: Vice-President Klaus Heinrichs is to retire at the end of May

Klaus Heinrichs began working in marketing for the company in 1992. “From the very beginning until today Klaus used his great flair and networking skills to secure and improve the company’s international presence and public relations, especially at seven successive ITMA textile machinery exhibitions, beginning with the show in Milan in 1995,” said Monforts Marketing Manager Nicole Croonenbroek.  “Later, he also took care of customer service, sales administration and exports in his uniquely calm and quietly-spoken style.”

“He has always been a guarantor of successful product launches for Monforts technical and technological highlights such as the TwinAir principle of independent airflow regulation, the Hercules LTM stenter chain, the Econtrol® dyeing technology or the Montex®Coat device - to mention only a few.”

Klaus Heinrichs began working in marketing for the company in 1992. “From the very beginning until today Klaus used his great flair and networking skills to secure and improve the company’s international presence and public relations, especially at seven successive ITMA textile machinery exhibitions, beginning with the show in Milan in 1995,” said Monforts Marketing Manager Nicole Croonenbroek.  “Later, he also took care of customer service, sales administration and exports in his uniquely calm and quietly-spoken style.”

“He has always been a guarantor of successful product launches for Monforts technical and technological highlights such as the TwinAir principle of independent airflow regulation, the Hercules LTM stenter chain, the Econtrol® dyeing technology or the Montex®Coat device - to mention only a few.”

Klaus has also been active on the VDMA’s Exhibition and Marketing Committee since 1993, which he chaired from 2005 to 2008.  
“Klaus always enriched the industry discussions with practical and future-oriented proposals and thus also advanced ITMA,” said Thomas Waldmann, Managing Director of the VDMA Textile Machinery Association. “We sincerely thank him and wish him all the best for this new chapter of his life.”

“We will miss Klaus as a colleague and as a manager because of his skills, character and his engagement,” added Monforts Managing Director Stefan Flöth. “He truly represents the Monforts commitment to our customers to be helpful, accurate, fast and reliable, and we keep him as a friend. I’m sure the many friends he made throughout the world during his career with the company will join us in wishing him all the best for his next phase of life together with his family.”


* Econtrol is a registered trademark of Dystar Colours Distribution GmbH.

Source:

A. Monforts Textilmaschinen GmbH & Co. KG

Coating expertise brings sustainable comfort and convenience to the face mask (c) A. Monforts Textilmaschinen GmbH & Co. KG
The masks are based on 100% woven cotton and the active ingredients in the finish are a reaction mass of titanium dioxide and silver chloride
21.09.2020

Coating expertise brings sustainable comfort and convenience to the face mask

  • Gorilla Protect is a new company formed in May this year to promote the Catus face mask – a major leap forward in the effectiveness of personal protection products that are available to consumers in the fight against Covid-19.
  • Behind Catus and the new company is Nova Textil, the established fabric finishing company based in Grefrath, Germany, and now run by father and son team Rainer and Oliver Hurtz.

Single stenter

Rainer Hurtz founded Nova Textil with a single Monforts Montex stenter and just five employees in 1999 and has steered its constant development and growth over the past twenty years.

“Our initial focus was on the coating of mainly glass fibre fabrics, awnings and sun protection products for outdoor furnishings,” he said. “We had a great customer who was providing us with so many orders that by 2005 we took the decision to order a second Montex stenter, in a special configuration. This also allowed us to enter the market for blackout and digital printing fabrics. We’ve had a great ongoing relationship with Monforts from the beginning.”

  • Gorilla Protect is a new company formed in May this year to promote the Catus face mask – a major leap forward in the effectiveness of personal protection products that are available to consumers in the fight against Covid-19.
  • Behind Catus and the new company is Nova Textil, the established fabric finishing company based in Grefrath, Germany, and now run by father and son team Rainer and Oliver Hurtz.

Single stenter

Rainer Hurtz founded Nova Textil with a single Monforts Montex stenter and just five employees in 1999 and has steered its constant development and growth over the past twenty years.

“Our initial focus was on the coating of mainly glass fibre fabrics, awnings and sun protection products for outdoor furnishings,” he said. “We had a great customer who was providing us with so many orders that by 2005 we took the decision to order a second Montex stenter, in a special configuration. This also allowed us to enter the market for blackout and digital printing fabrics. We’ve had a great ongoing relationship with Monforts from the beginning.”

A third Montex stenter line was installed at the company’s Grefrath plant in 2015, by which time the company had grown to 40 people and a major new market had opened up in the supply of fabrics for promotional materials at exhibitions and trade shows.

“We had a fantastic two years in 2018 and 2019 and everything was going great for the first three months of this year, but in April it all came crashing down,” said Oliver Hurtz. “Coronavirus put an end to trade shows in 2020, which had a very serious impact on our business.”

At the same time, however, the company was exploring the potential of a new biocidal product from one of its chemicals suppliers which has both antiviral and antimicrobial properties.

Filtration

“We had already been producing coated fabrics for hot gas filtration and realised that in combination with this new microporous coating we had the basis for a very effective single-layer face mask,” Rainer said. “Achieving this with a single layer product rather than the usual three has resulted in a significant advance in comfort for the wearer and because the mask is able to disinfect itself and helps regulate humidity, it can be worn a number of times without needing to be washed, for greater convenience. It only needs to be washed when it gets dirty and can also be washed up to twenty times without losing its properties, which has to be preferable to single-use disposables.”

Catus face masks are based on 100% woven cotton and the active ingredients in the finish are a reaction mass of titanium dioxide and silver chloride certified to ISO 20743 for their antibacterial effect, and to ISO 18184 for their antiviral effect.

They are proven to  eliminate over  99.99% of the human coronavirus 229 E, with the multiplication of microorganisms such as germs and bacteria prevented by the biostatic action of silver salts and viruses destroyed by oxygen-releasing substances and a mechanism that attacks their fatty envelope. The virus membrane loses its cholesterol content and the virus is inactivated.

Colours

Gorilla Protect next plans to make the masks available in four colours – black, Bordeaux, olive and grey – and is also working on colour branding and printing labels.

“It’s not possible to print on the surface of the mask after it has been coated, but its is possible for volume orders to be printed before the treatment,” Oliver Hurtz said.

“Face masks are going to become an established part of life in the West like they are in Asia and need to be as comfortable and convenient as possible for the wearer,” his father concluded. “With these things in mind, we believe Catus is a significant step forward.”

New Monfortex line part of a long-term vision for Kettelhack (c) Monforts
The Monfortex sanforizing line with integrated Qualitex 800 control has now been operational at Kettelhack’s plant in Rheine, Westphalia, for a number of months.
24.08.2020

New Monfortex line part of a long-term vision for Kettelhack

  • Kettelhack GmbH – a German leader in the dyeing and finishing of monochrome fabrics for high-quality and durable workwear and bed linen – has this year retired its existing Monforts sanforizing line after 35 years of daily service, replacing it with a new one.

The first line was installed in 1985 during a decisive time for the company.

Taking the helm in the early 1980s, Jan Kettelhack – the current CEO, owner and great grandson of Heinrich Kettelhack who founded the company back in 1874 – made a number of decisions that have secured its success over the following decades.

In 1982 Kettelhack had to vacate its existing plant in the city of Rheine due to urban development restrictions and despite a general sense of crisis in the European textile industry at that time, opted to relocate and build a new highly automated plant that was not reliant on mechanical and personnel-intensive processes. This was aligned with a greater focus on competitive international sales.

  • Kettelhack GmbH – a German leader in the dyeing and finishing of monochrome fabrics for high-quality and durable workwear and bed linen – has this year retired its existing Monforts sanforizing line after 35 years of daily service, replacing it with a new one.

The first line was installed in 1985 during a decisive time for the company.

Taking the helm in the early 1980s, Jan Kettelhack – the current CEO, owner and great grandson of Heinrich Kettelhack who founded the company back in 1874 – made a number of decisions that have secured its success over the following decades.

In 1982 Kettelhack had to vacate its existing plant in the city of Rheine due to urban development restrictions and despite a general sense of crisis in the European textile industry at that time, opted to relocate and build a new highly automated plant that was not reliant on mechanical and personnel-intensive processes. This was aligned with a greater focus on competitive international sales.

From 1986, the company’s proficiency as a specialist in solid-colour textiles led to workwear textiles becoming a bedrock of the business. Continuous investments in machinery and technical equipment have resulted in a fully integrated and rationalised single source site dedicated solely to what the company does best – the expert dyeing and finishing of textiles.

Crucial process steps

These stages in the textile value-added chain, Jan Kettelhack has observed, are crucial to the quality of a final product in workwear – whether it stands the test in everyday use, how comfortable it is, and how many washes it can withstand.

Central to this is the sanforizing process, which pre-shrinks a fabric by compressing it prior to washing. This limits any residual or further shrinkage in a made-up finished garment to less than 1%, to ensure perfect comfort and fit over an extended lifetime.

“We certainly can’t complain about the performance of the old Monfortex sanforizing line which gave us so many uninterrupted years of service, but certain spare parts for it were becoming increasingly hard to source, the control unit was becoming a little unstable and we couldn’t risk potential interruptions to our production schedule,” says Kettelhack plant manager Hendrik Pleimann. “In many ways, the new Monfortex sanforizer is much the same as the old one in terms of its mechanical reliability and robust construction, but of course today’s drives are much more efficient, and when it comes to the automation features and control units – and the data we can generate and analyse for increasing efficiency – that’s a whole new world.”

Qualitex 800

The two-metres-wide Monfortex line benefits from the latest Qualitex 800 control system which allows all parameters to be easily automated via the 24-inch colour touchscreen, including production speed, control of all fabric feed devices, rotation spray or steaming cylinder options, the width of the stretching field and the rubber belt pressure.

The integrated Compactomat system allows a continuous indication and control of the shrinkage values and the temperatures of the shrinking cylinder and felt calender. Up to 10,000 separate process parameter records can be generated and stored by the data manager.

Full line management can be optimised via the batch-specific calculation of all process material consumption and water and electricity use, with any standstill times analysed and immediately corrected for the future.

Any further assistance required is available via Monforts Teleservice, with direct connection to technicians and virtual access to machine analysis.

Professional

Commissioning of the new Monfortex line at Kettelhack commenced in January and it was fully operational in a relatively short time.

“This was a very professional installation provided by the Monforts team with whom we have a very good relationship dating back many years, and everyone knew what was required from both sides,” says Mr Pleimann. “Our operators have found the new line very user friendly and we are very pleased with how everything proceeded so smoothly. An unexpected benefit is that the new line is also a lot quieter, of course, which is something our operatives are appreciating.”

Key features of the Monfortex line are the proven fabric preparation, weft straightening and spreading units, prior to the compressive shrinkage machine with a 750mm shrinking cylinder, and a felt calender equipped with 2,000mm diameter drying cylinder. The line also features an integrated automatic grinding unit.

Customer service

Kettelhack is processing primarily cotton and polyester woven fabrics, with lyocell becoming increasingly popular in workwear for its softness and comfort.

As part of its customer service, the company stocks more than a million metres of grey fabric and at least 1.2 million metres of finished and rolled standard fabric in its warehouse at any one time, with a further 750,000 metres permanently in production.

While a significant cost, this commitment ensures Kettelhack customers can be fully flexible and rely on it as a partner.

“As a family-run company with around a hundred employees, Kettelhack operates very differently to bigger businesses which have to constantly consider their immediate quarterly profits,” Mr Pleimann concludes. “The thinking at Kettelhack is in terms of the next twenty years and ensuring that the business will be just as successful for the next generation as it is today. We also have a very flat organisational structure in which everyone is involved and takes an active part, which makes it a very nice place to work.”

Source:

On behalf of A. Monforts Textilmaschinen GmbH & Co. KG by AWOL Media.

Sustainable leadership for GtA with new Monforts Montex wide width lines (c) AWOL Media
GtA Managing Director Andreas Niess
27.07.2020

Sustainable leadership for GtA with new Monforts Montex wide width lines

Following the successful commissioning of two new Monforts Montex wide-width stenter lines and additional environmental management equipment at its plant in Germany, GtA – Society for Textile Equipment GmbH – is aiming to be the first textile finishing company to become entirely CO2-neutral in the manufacture of all of its products by 2025.

GtA is a partner company to Germany’s large-format digital printing fabric leader, Georg and Otto Friedrich GmbH, which has has this year been able to considerably expand its portfolio due to the new Monforts lines.

Headquartered in Gross-Zimmern, close to Frankfurt, Georg and Otto Friedrich GmbH and its partners in Germany have an annual production of 37 million square metres of warp knits for a range of end-use applications, including garments, automotive interiors and technical textiles, but increasingly with a concentration on digital printing substrates.

Fault-free textiles

Following the successful commissioning of two new Monforts Montex wide-width stenter lines and additional environmental management equipment at its plant in Germany, GtA – Society for Textile Equipment GmbH – is aiming to be the first textile finishing company to become entirely CO2-neutral in the manufacture of all of its products by 2025.

GtA is a partner company to Germany’s large-format digital printing fabric leader, Georg and Otto Friedrich GmbH, which has has this year been able to considerably expand its portfolio due to the new Monforts lines.

Headquartered in Gross-Zimmern, close to Frankfurt, Georg and Otto Friedrich GmbH and its partners in Germany have an annual production of 37 million square metres of warp knits for a range of end-use applications, including garments, automotive interiors and technical textiles, but increasingly with a concentration on digital printing substrates.

Fault-free textiles

A new standard in pure white, 100% clean and fault-free textile substrates has been demanded by this market in recent years due to the rapid growth in digitally-printed banners and billboards – often referred to as ‘soft signage’.

The substrates of choice for digital printing are 100% polyester warp knits which are resilient and allow excellent take-up of inks, and vibrant colours and clear and precise images to be achieved with digital printing techniques. The knitted construction also has the advantage of elasticity, which is a plus in terms of flexibility for installers.

Critically, the warp knitted fabrics have extremely smooth surfaces which is becoming increasingly important due to the general move away from PVC coatings which were the standard in the past.

It was to finish these fabrics for Georg and Otto Friedrich GmbH as well as providing such services for many other customers, that the GtA plant in Neresheim, Baden-Württemberg, was established in 2015.

The purpose-built plant on a greenfield site was initially equipped with a fully-automated, 72 metre long Monforts installation comprising a washing machine integrated with a 3.6 metre wide, seven-chamber Montex stenter. The line quickly went from single to double shift production and then to 24/7 operation  to meet demand.

Expanded widths

Building on the success of this installation, GtA has now installed two more Montex stenter lines – both in expanded working widths of 5.6 metres and purpose-built at Montex GmbH in Austria.

A six-chamber Montex unit is combined with a washing machine to guarantee the purity of the substrates, while a five-chamber line is integrated with a wide-width coating machine. This new coating capability at GtA has led to a number of new additions to the Georg and Otto Friedrich DecoTex range for digital printing, including wide width fabrics with flame retardant, antimicrobial and non-slip finishes.

The new Montex stenter lines benefit from all of the latest innovations from Monforts, including the Smart Sensor system for the optimised maintenance planning of key mechanical wear components on the stenters. A comprehensive overview of the condition of all parts at any time is now available for operators within the highly intuitive Qualitex visualization software.

With Qualitex, 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.

Environmental commitment

GtA is run by a seasoned team of textile professionals led by Managing Director Andreas Niess.

“We have received excellent service from Monforts from the outset and we were happy to place the order for these two new lines as part of our ongoing cooperation,” he says. “With all of the latest Monforts advances in technology we are fully in control of all production and quality parameters with these lines, as part of our significant commitment to innovative environmental technology.”

The GtA plant, which operates in near-cleanroom conditions, has also been equipped with proprietary technology to fully exploit the Monforts air-to-air heat recovery systems that are now standard with Montex stenters.

“Around 30 per cent of our investment volume at the site goes to energy-saving measures and we are sure that this commitment is worthwhile,” Mr Niess says. “As an example, our integrated heat recovery system fully exploits the waste heat from the process exhaust air and the burner exhaust gases of the Monforts stenters, allowing us to achieve an exhaust air temperature of  between 30 to 34°C, compared to what would conventionally be between 140 to 160°C. Another focus has been on exhaust air purification technology and here too, the latest technology has been installed with integrated heat recovery elements.”

This, he adds, saves 52% of the energy that would normally be used – equating to 5,800,000 KwH per year. The necessary audits for energy-efficient companies are also carried out annually.

In addition, GtA has purpose-designed the automatic chemical mixing and dosing systems that feed the padders for the key treatments that are carried out on the fabrics through the stenters.

The company is going further, however, in its pursuit of clean production and raw materials.

"We want to be an asset and not a burden on our immediate environment and therefore do not use any additives containing solvents," Mr Niess says. “We were the first to use fully halogen-free flame retardant chemistry, and we use bio-based, finely ground alumina products for the washing process instead of surfactants. PES polyester yarns made from recycled material are also increasingly used and the latest additions to our raw materials portfolio, the RC-Ocean products, are made from recycled sea plastic.

“We are now planning a combined heat and power plant for the production of electrical energy and heat and we will also build a photovoltaic system that converts solar radiation into electrical energy. GtA wants to be the first textile finishing company to be CO2-neutral in the manufacture of all of its products by 2025. The complete heat supply and heating for the 13,000 square metre production hall, as well as the office building and the hot water supply for the domestic water, is already energy-neutral. We are convinced that this commitment will pay off in the long term and our positive business development proves that sustainability and business profitability are perfectly compatible.”

In addition to the products for Georg and Otto Friedrich GmbH, GtA  offers its manufacturing capacities for other customers as a contract service.

All products are manufactured in accordance with Öko-Tex Standard 100, product class 1 and the company is also involved in the research and development of new sustainable manufacturing processes, in cooperation with many regional universities and funding project partners.

Source:

AWOL Media for A. Monforts Textilmaschinen GmbH & Co. KG

(c) A. Monforts Textilmaschinen GmbH & Co. KG
24.01.2020

Talking sustainability with Monforts denim customers

In the latest short film released on the Monforts YouTube Channel – captured at the recent Denim Première Vision show in London – some of the leading global manufacturers discuss their initiatives for more sustainable denim production.

Cone Denim, based in Greensboro, North Carolina, for example, can lay claim to having put in place its first environmental control measures back in the 1940s when the company first started recycling its water.

“It was a method of efficiency even back then, eighty years ago,” says Gabriel Magopat, of the company’s UK customer service centre, “but  producing high quality products is another method of being sustainable and of being efficient, and I think that’s what Cone stands for. We have an amazing history.”

Cone Denim is known for its signature S Gene® stretch denims which have traditionally incorporated polyester components to provide the stretch. It has now partnered with Intrinsic Advanced Materials of Gastonia, also in North Carolina, to introduce patent-pending CiCLO stretch polyester fibres into its denim collections. 

In the latest short film released on the Monforts YouTube Channel – captured at the recent Denim Première Vision show in London – some of the leading global manufacturers discuss their initiatives for more sustainable denim production.

Cone Denim, based in Greensboro, North Carolina, for example, can lay claim to having put in place its first environmental control measures back in the 1940s when the company first started recycling its water.

“It was a method of efficiency even back then, eighty years ago,” says Gabriel Magopat, of the company’s UK customer service centre, “but  producing high quality products is another method of being sustainable and of being efficient, and I think that’s what Cone stands for. We have an amazing history.”

Cone Denim is known for its signature S Gene® stretch denims which have traditionally incorporated polyester components to provide the stretch. It has now partnered with Intrinsic Advanced Materials of Gastonia, also in North Carolina, to introduce patent-pending CiCLO stretch polyester fibres into its denim collections. 

While still being synthetic based, CiCLO polyester is able to biodegrade in marine environments, wastewater treatment plants and landfill conditions, at rates similar to natural fibres like wool. 

This more sustainable solution for stretch is also being introduced to China for the first time by another leading denim supplier, Advance Denim.

“Advance Denim is spending its resources on being the most technologically advanced company in China, and also the most sustainable,” says Mark Ix, the company’s Director of Marketing. “We are investing heavily in our manufacturing to save both water and chemicals to create cleaner products.”

Monforts denim customer Berto is a family-owned company with its main denim mill in Bovolenta, a small rural town near to Padua in the north east of Italy, where respect for the environment has always been a must.

“The family has always been focused on respect for the environment,” says Berto’s Marketing Manager Francesca Palento. “In particular, we have a river next to the company from which we take our water for production and we then return it cleaner than it was before. We are also now producing GOTS and Global Recycling Standard jean produced with yarns made from our own internal waste production.”

Pakistan’s Soorty has recently received Cradle to Cradle Gold certification – the most stringent and exacting sustainable standard currently in existence – for its Pure D range of denims. These are produced using the company’s proprietary Zero Waste Water dyeing technology, in combination with the most advanced Monforts finishing machines. 

“Our very latest collection is called Climate Jeans, because every single product we now produce draws attention to the climate emergency we are living through right now,” says Eda Dikman, Soorty’s Marketing Communications Manager. “Sustainability is very important to us because we produce at scale and all of the actions we take reflect on the planet.”

Monforts: Half a century of excellence (c) A. Monforts Textilmaschinen GmbH & Co. KG
Monforts: Half a century of excellence
20.01.2020

Monforts: Half a century of excellence

The origins of both Industry 4.0 and an awareness of the need for more sustainable manufacturing methods can arguably be traced back to the year 1971.

It was in 1971 that the first microprocessor was introduced by Intel, and also that the first and perhaps now most well-known environmental campaigner, Greenpeace, was founded.

As such, a direct line can be charted from that year to today’s automated textile manufacturing machinery concepts, as well as the drive to develop more increasingly resource-efficient processes.

All of the recent innovations which have been introduced to the market by A. Monforts Textilmaschinen GmbH & Co. KG, for example, are being powered by the possibilities of Industry 4.0 and developed in response to the market demand for more sustainable production.

The origins of both Industry 4.0 and an awareness of the need for more sustainable manufacturing methods can arguably be traced back to the year 1971.

It was in 1971 that the first microprocessor was introduced by Intel, and also that the first and perhaps now most well-known environmental campaigner, Greenpeace, was founded.

As such, a direct line can be charted from that year to today’s automated textile manufacturing machinery concepts, as well as the drive to develop more increasingly resource-efficient processes.

All of the recent innovations which have been introduced to the market by A. Monforts Textilmaschinen GmbH & Co. KG, for example, are being powered by the possibilities of Industry 4.0 and developed in response to the market demand for more sustainable production.

They include the new ‘digital twinning’ capability introduced in 2019 for all Monforts machines, with advanced sensor technologies which make it possible to access comprehensive technical machine data from any location using the company’s Smart Support and Smart Check apps. In addition, the digital twin system provides information on individual wear parts, such as, for example, converters or gears.

These latest developments have been very favourably received by Monforts customers, especially in Europe.

50th anniversary
The very first Heimtextil – the leading trade fair for the home textiles market – was also held in Frankfurt in January 1971 and Monforts customers Bierbaum Group and Konrad Hornschuch AG are amongst the German companies who were there from the very start and have attended every annual show since.

Bierbaum Group, based in Borken, is the company behind the well-known Irisette bedding brand and is celebrating its own 125th anniversary in 2020. It has also introduced products bearing the German government’s new Grüner Knopf textile seal of approval for sustainable production.

As a specialist in synthetic leathers for home surfaces, as well as vehicle interiors, Konrad Hornschuch AG, of Weissbach, has been a member of the €44 billion automotive giant Continental AG since 2016.

Representatives from both companies received memorial trophies at a special presentation held on January 7th during the 50th anniversary Heimtextil show.

The home textiles market remains very strong in Germany, with sales amounting to some €9.6 billion in 2019, according to analyst IFH Cologne.

Global growth
The first Heimtextil in 1971 was a significant success, attracting 679 exhibitors from 26 countries.

This year’s show, however, attracted a total of 2,952 exhibitors from 66 countries, reflecting not only the growth of the home textiles industry, but also the globalisation which has taken place over the last half century.

Monforts now has customers for its advanced finishing technologies around the world, with home textile customers from India and Pakistan being particularly well represented at Heimtextil 2020.

Among stand outs from Indian companies at this year’s show was the 2020 collection of Welspun India’s famous Christy England brand, inspired by botanical studies of the gardens of British stately homes. Welspun towels meanwhile benefit from the company’s HygroCotton hollow core yarn technology, produced by a proprietary spinning method which ensures they become softer, fluffier and more absorbent after every wash.

An equally ground-breaking new technology is being introduced by Trident Group, which is one of India’s largest vertically-integrated home textiles manufacturers and two years ago installed five complete Monforts finishing ranges for its new linen department.

Trident’s patented Air Rich yarns feature pores throughout their cross sections for high breathability and absorbency, as well as rapid drying.

Monforts home textile customers from Pakistan stressed the resource efficiency of their processes and products as a result of investments in advanced technology, and during the show the ‘Sustainable Pakistan’ initiative was announced.

Supported by GIZ, the German Society for International Cooperation, the initiative aims to reshape global perceptions of Pakistan’s manufacturers and their innovations. So far, twenty producers have been carefully chosen to be presented on this global platform and will help rebrand Pakistan’s textile industry at the Heimtextil exhibitions going forward.

Heimtextil’s organiser Messe Frankfurt also announced its own new alliance with the United Nations Office for Partnerships, in order to support the UN’s Sustainable Development Goals.

Constancy
Many things have changed since 1971 and home interiors are certainly no longer predominantly orange and brown – and perhaps unlikely to ever become so again.

It’s clear, however, that there has been a constancy in the push to consistently improve textile technologies, processes and products that may have originated in Europe, but have subsequently spread around the world.

And the significance of both microprocessors and sustainability in 2020 could only have been guessed at back in 1971.

 

Monforts ‘Denimized’ customers take the lead in London (c) Monforts Textilmaschinen GmbH & Co. KG
Monforts ‘Denimized’ customers take the lead in London
13.12.2019

Monforts ‘Denimized’ customers take the lead in London

Of the twelve participating denim mills who took part in Habitat 21 – a special Smart Creation showcase at the recent Denim Première Vision exhibition in London – no less than eleven were valued Monforts ‘Denimized’ finishing technology users.

The aim of Habitat 21 was to highlight those companies taking an eco-responsible approach to denim manufacturing via the use of recycled, organic and bio-based fibres, in combination with resource-saving dyeing and finishing technologies. Monforts customers involved in the project were Advance Denim, Berto, Bossa, Calik, Evlox/Tavex, Kilim, Naveena, Orta Anadalou, Rajby Industries, Raymond Uco and Soorty. Their innovations were detailed in a major presentation on trends for the Spring/Summer 2021 season by Manon Mangin of the Première Vision Fashion Team, based on three key themes – Sensation, Hybridisation and Expansion.

Of the twelve participating denim mills who took part in Habitat 21 – a special Smart Creation showcase at the recent Denim Première Vision exhibition in London – no less than eleven were valued Monforts ‘Denimized’ finishing technology users.

The aim of Habitat 21 was to highlight those companies taking an eco-responsible approach to denim manufacturing via the use of recycled, organic and bio-based fibres, in combination with resource-saving dyeing and finishing technologies. Monforts customers involved in the project were Advance Denim, Berto, Bossa, Calik, Evlox/Tavex, Kilim, Naveena, Orta Anadalou, Rajby Industries, Raymond Uco and Soorty. Their innovations were detailed in a major presentation on trends for the Spring/Summer 2021 season by Manon Mangin of the Première Vision Fashion Team, based on three key themes – Sensation, Hybridisation and Expansion.

Monforts at Techtextil India (c) Monforts
A recent Monforts texCoat installation.
20.11.2019

Monforts at Techtextil India

Monforts Textilmaschinen GmbH & Co. KG will be providing information on its extensive range of coating and finishing technologies for the production of nonwovens and technical textiles at the forthcoming Techtextil India exhibition.

“India is already a very important market for Monforts and there are exciting prospects ahead for Indian manufacturers of technical textiles, who are well positioned to capitalise on growth opportunities,” says Monforts Head of Denim Hans Wroblowski, who will be at the Monforts stand in Hall 4, booth C52 at the show. “India has one of the largest working-age populations in the world and a complete textile value chain for both natural and synthetic fibres.”

In addition, he adds, India’s government, through its Ministry of Textiles, has been actively promoting the growth of technical textiles through various programmes based on investment promotion, subsidies, the creation of infrastructure and the stimulation of consumption.

Monforts Textilmaschinen GmbH & Co. KG will be providing information on its extensive range of coating and finishing technologies for the production of nonwovens and technical textiles at the forthcoming Techtextil India exhibition.

“India is already a very important market for Monforts and there are exciting prospects ahead for Indian manufacturers of technical textiles, who are well positioned to capitalise on growth opportunities,” says Monforts Head of Denim Hans Wroblowski, who will be at the Monforts stand in Hall 4, booth C52 at the show. “India has one of the largest working-age populations in the world and a complete textile value chain for both natural and synthetic fibres.”

In addition, he adds, India’s government, through its Ministry of Textiles, has been actively promoting the growth of technical textiles through various programmes based on investment promotion, subsidies, the creation of infrastructure and the stimulation of consumption.

As a result, India’s Ministry of Textiles is forecasting that the growth of technical textiles in the country will be over 18% annually in the next few years, from a value of US$16.6 billion in 2018 to US$28.7 billion in 2021.

Value addition

High value-added technical products such as wide-width digital printing substrates, carbon fabrics for high-performance composites, filter media, flame retardant barrier fabrics and heavy-duty membranes are now being coated on Monforts texCoat ranges and finished with the company’s industry-leading Montex stenters.

“Since we acquired the technology that our coating units are based on in 2015, we have made a lot of refinements,” says Hans. “All of these developments are reflected in higher coating accuracy and the resulting quality of the treated fabrics. At the same time, our latest multi-functional coating heads offer an unprecedented range of options, with a wide range of modules available.”

The texCoat user interface is now equipped with the unique Monforts visualisation system and the magnetic doctor blade has greater power reserves. Options include a carbon fibre-reinforced composite coating drum with a more scratch-resistant surface and maximum rigidity and remote control which simplifies exact adjustment for the operator.

Montex stenters in special executions are meanwhile ideal for the drying and finishing of both technical woven fabrics and nonwovens and characterised by high stretching devices in both length and width.

“The European-built Montex range of stenters has earned its leading position in the technical textiles market due to the overall robustness, reliability and economy of these machines,” Hans concludes. “Whatever the intended end-product – and we continue to discover potentially new areas in which technical textiles can be utilised all the time – we have the machine specification and know-how to turn ideas into reality. In India we also benefit from the strong sales and service support of A.T.E. Enterprises.”

Texchtextil India takes place alongside World of Composites at the Bombay Exhibition Centre in Mumbai from November 20-22.

Source:

A. Monforts Textilmaschinen GmbH & Co. KG by AWOL Media.