From the Sector

The KARL MAYER GROUP and the Südwolle Group have joined forces in a project to explore the possibilities of merino wool for warp knitting technology. The project was triggered by the increasing demand for textiles made from sustainable and environmentally friendly materials. The cooperation was to develop innovative fabrics from renewable raw materials for use in underwear and functional sportswear. The focus of the work was on the use of wool as a material with excellent comfort properties and the look and feel of lightweight single jersey goods. The natural fiber fabric qualities are not typical for warp knitting processing, so the challenges during the project work were diverse.

Merino wool yarns with good running properties
Regarding the choice of material, the product development team of Südwolle Group recommended the Hidalgo yarn from their product portfolio. The yarn was created using the in-house developed Betaspun technology, in which a filament was twisted around a merino core. When natural fibres such as wool, cotton or silk are combined with sustainable fibres such as biodegradable polyamide as the filament, the spinning process can create durable, lightweight yarns that disintegrate completely without residue after use. The yarns made from the two components also have good running properties for use in warp knitting. "The polyamide content of the yarn increases its tenacity, reduces hairiness and makes it an excellent choice for warp knitting technology," confirmed Gabriela Schellner from KARL MAYER's Textile Product Development Department.

Shape stability paired with single jersey "look and feel"
The Hidalgo yarn, which is made from merino wool, was processed on a warp knitting machine using a carefully thought-out lapping selection to produce a light, soft fabric which, above all, retains its shape. The textile specialists at KARL MAYER had experimented with two different single bar fabric qualities beforehand and had thus adopted a new approach for jersey machines.

The first results are promising. Now more trials are needed to perfect the technique. Development partners are needed, including fabric producers, brands, and garment manufacturers, with whom the fabric qualities, machine equipment and orientation to the end applications can be refined. The KARL MAYER GROUP and the Südwolle Group are also unanimous in their desire to push the boundaries of what is possible with merino wool and knitting technology and to develop new solutions for the textile industry through further project work.

International technology group ANDRITZ has received an order from Albaad Massuot Yitzhak Ltd. to supply a neXline wetlace hybrid line for their Dimona facilities, Israel. The line will produce a wide variety of pulp-based wet wipes and is scheduled for start-up during the third quarter 2023.

The state-of-the-art neXline wetlace hybrid is the perfect combination of inline drylaid and wetlaid web forming with hydroentanglement and drying, including quality control equipment and a Metris Industry 4.0 package. All components will be delivered by ANDRITZ and are designed to produce first-class fabrics, including biodegradable, carded-pulp and flushable/dispersible nonwovens for end uses as wipes.

Tobias Schäfer, Vice President Sales at ANDRITZ Nonwoven, comments: “Our innovative production line gives Albaad enormous flexibility in the production of wipes. In addition, the Metris digitalization package by ANDRITZ will provide Albaad with highly efficient and smart operation.”

Dan Mesika, CEO and President of Albaad, says: “We are dedicated to developing new products – such as eco-friendly, biodegradable wipes. As pioneering manufacturers of our Hydrofine® flushable wipes, we are committed to environmental sustainability. Thanks to the new ANDRITZ line, we will enlarge the product portfolio at our Dimona production site with innovative fabrics and high efficiency.

Gadi Choresh, President of the Nonwovens Division at Albaad, says: “Our knowledge and experience in drylaid and wetlaid technology, together with the state-of-the-art equipment supplied by ANDRITZ, will enable us to provide the market with natural-source nonwovens and the best answer to the market demand.”
 
Albaad is one of the world’s three largest wet wipe manufacturers and is committed to delivering excellent wipes for every need. The company runs world-leading production facilities on three continents, each equipped with the latest technologies. Albaad produces spunlace and flushable fabrics in its facilities as well as purchasing from other roll goods suppliers in order to support production of a wide variety of wipes.