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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

(c) VDMA
Chairperson and Vice Chairpersons of the VDMA Textile Machinery: Verena Thies, Dr. Janpeter Horn, Regina Brückner.
31.03.2022

VDMA: Dr. Janpeter Horn New Chairperson of Textile Machinery Association

Dr. Janpeter Horn, Managing Director of August Herzog Maschinenfabrik, is the new Chairperson of the VDMA Textile Machinery. Dr. Horn was elected at the members’ meeting of the Association in Leonberg. The new Executive Board is completed with Ms. Regina Brückner, Managing Associate of Brückner Trockentechnik and Ms. Verena Thies, Managing Shareholder of Thies Textilmaschinen, who were elected as Vice Chairpersons.

After his election, Dr. Horn stated: “I am pleased to have Ms. Brückner and Ms. Thies by my side. Both have been serving on the Executive Board of the VDMA Textile Machinery as well as the European Committee of Textile Machinery Manufacturers CEMATEX for many years. With this team, we are well prepared to effectively represent the interests of the industry at national and international level.”

Based in Oldenburg, Northern Germany, Herzog is a company with a long tradition and at the same time the most innovative developer and manufacturer of braiding and winding machinery. Worldwide references in braiding and winding technique confirm the company’s technical and quality leadership.

Dr. Janpeter Horn, Managing Director of August Herzog Maschinenfabrik, is the new Chairperson of the VDMA Textile Machinery. Dr. Horn was elected at the members’ meeting of the Association in Leonberg. The new Executive Board is completed with Ms. Regina Brückner, Managing Associate of Brückner Trockentechnik and Ms. Verena Thies, Managing Shareholder of Thies Textilmaschinen, who were elected as Vice Chairpersons.

After his election, Dr. Horn stated: “I am pleased to have Ms. Brückner and Ms. Thies by my side. Both have been serving on the Executive Board of the VDMA Textile Machinery as well as the European Committee of Textile Machinery Manufacturers CEMATEX for many years. With this team, we are well prepared to effectively represent the interests of the industry at national and international level.”

Based in Oldenburg, Northern Germany, Herzog is a company with a long tradition and at the same time the most innovative developer and manufacturer of braiding and winding machinery. Worldwide references in braiding and winding technique confirm the company’s technical and quality leadership.

The new Executive Board of the VDMA Textile Machinery for the legislative period until 2026 is composed of:

  • Dr. Janpeter Horn (Chairperson), August Herzog Maschinenfabrik
  • Regina Brückner (Vice Chairperson), BRÜCKNER Trockentechnik
  • Verena Thies (Vice Chairperson), THIES
  • Peter D. Dornier, Lindauer DORNIER
  • Stefan Flöth, A. Monforts Textilmaschinen
  • Arno Gärtner, KARL MAYER STOLL Textilmaschinenfabrik
  • Markus Kleindorp, MEMMINGER-IRO
  • Andreas Lukas, ANDRITZ Küsters
  • Benjamin Mayer, Mayer & Cie.
  • Dr. Jörg Morgner, Temafa Maschinenfabrik
  • Benjamin Reiners, Reiners + Fürst
  • Dr. Uwe Rondé, Saurer Group
  • Eric Schöller, Groz-Beckert
  • Georg Stausberg, Oerlikon Textile
  • Heinrich Trützschler, Trützschler Group
Source:

VDMA e. V.
Textilmaschinen

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

24.02.2022

VDMA textile machinery webinar on sustainable dyeing involved Monforts, DyStar® and Goller

Over 600 delegates from 58 countries subscribed to the latest VDMA textile machinery webinar on sustainable dyeing held on February 3rd, 2022 – a record since the monthly online series started in June 2020. The webinar, entitled ‘Resource-saving in Textile Processing – Continuous Dyeing and Washing’, involved the three companies Monforts, DyStar® and Goller.

In outlining the capabilities of Monforts Thermex hotflue lines for the Econtrol® continuous dyeing process, the company’s Textile Technologies Engineer Jonas Beisel observed that the current industry focus is very much on cleaner processes and products in accordance with the Corporate Social Responsibility (CSR) commitments of the major fashion brands, and with further regulations to be expected.

Cellulosics
Econtrol® is a continuous process for the dyeing of woven cellulosic fabrics that has already been well proven on the market, with over 150 Monforts Thermex lines already in operation at mills worldwide.

Over 600 delegates from 58 countries subscribed to the latest VDMA textile machinery webinar on sustainable dyeing held on February 3rd, 2022 – a record since the monthly online series started in June 2020. The webinar, entitled ‘Resource-saving in Textile Processing – Continuous Dyeing and Washing’, involved the three companies Monforts, DyStar® and Goller.

In outlining the capabilities of Monforts Thermex hotflue lines for the Econtrol® continuous dyeing process, the company’s Textile Technologies Engineer Jonas Beisel observed that the current industry focus is very much on cleaner processes and products in accordance with the Corporate Social Responsibility (CSR) commitments of the major fashion brands, and with further regulations to be expected.

Cellulosics
Econtrol® is a continuous process for the dyeing of woven cellulosic fabrics that has already been well proven on the market, with over 150 Monforts Thermex lines already in operation at mills worldwide.

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 at a temperature of between 120-130°C and a relative humidity volume of 25-30%.

Benefits
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.

Complementary services and systems
Complementing the Monforts presentation during the webinar, Bertram Seuthe, Global Business Development Manager at DyStar, outlined the importance of specific Levafix® /Remazol® reactive dyes and Dianix® disperse dyes for sustainable dyeing processes such as Econtrol®, Cadira® Continuous and CPB knit. In these processes Sera® auxiliaries are also employed for optimised wash-off results.

Guido Seiler, Area Sales Manager at Fong's Europe, also introduced the latest developments of the Goller brand for the washing process, which can reduce water consumption by between 10 to 20%, as well as reductions in both heating energy and waste generation, depending on the specific fabric construction and required shade.

Source:

Monforts  / DyStar Singapore Pte Ltd

(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

(c) Monfort
Full configuration of the Monforts and KMA Umwelttechnik line.
20.01.2022

Monforts: MonforClean brings Energy Savings for Albarrie

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

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

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

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

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

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

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

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

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

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

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

Source:

Monfort

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

Azgard 9’s innovative fabric absorbs carbon dioxide while simultaneously producing oxygen. (c) Azgard 9
23.07.2021

Monforts customers at Première Vision Digital Denim Week

Denim manufacturers employing Monforts technologies showcased their latest activities, including sustainable fabric manufacturing, new advances in fibres, dyes and chemicals, as well as process and supply improvements and recycling options, at Première Vision’s Digital Denim Week, held from July 5-9.

The users of Monforts equipment included AGI Denim (Pakistan), Azgard 9 (Pakistan), Berto (Italy), Bossa (Turkey), DNM (Turkey), Kilim (Turkey) and Orta (Turkey).

The new Naveena Denim Mills (Pakistan) Holistic collection, for example, employs a suite of sustainable materials such as organic cotton and post-consumer and post-industrial waste cotton that has been shredded and recycled at its in-house unit in Pakistan.

Supply chain transparency is also becoming increasingly important, and Turkey’s Bossa is now sharing information on its dyes, energy sources and recycled content use with its customers. For organic cotton in particular, Bossa provides QR codes with which brands can identify the names of individual farms and their locations, as well as details such as the origins of specific seeds and the use of irrigation by growers.

Denim manufacturers employing Monforts technologies showcased their latest activities, including sustainable fabric manufacturing, new advances in fibres, dyes and chemicals, as well as process and supply improvements and recycling options, at Première Vision’s Digital Denim Week, held from July 5-9.

The users of Monforts equipment included AGI Denim (Pakistan), Azgard 9 (Pakistan), Berto (Italy), Bossa (Turkey), DNM (Turkey), Kilim (Turkey) and Orta (Turkey).

The new Naveena Denim Mills (Pakistan) Holistic collection, for example, employs a suite of sustainable materials such as organic cotton and post-consumer and post-industrial waste cotton that has been shredded and recycled at its in-house unit in Pakistan.

Supply chain transparency is also becoming increasingly important, and Turkey’s Bossa is now sharing information on its dyes, energy sources and recycled content use with its customers. For organic cotton in particular, Bossa provides QR codes with which brands can identify the names of individual farms and their locations, as well as details such as the origins of specific seeds and the use of irrigation by growers.

Turkey’s Orta’s new Denim Route – inspired by the historical Silk Road for trade between the East and West – is an interactive supplier map detailing the regions from which it sources cotton, dyestuff, chemicals and various fibres to complement its other transparency initiatives.

Meanwhile, a living and breathing piece of clothing that absorbs carbon dioxide while simultaneously producing oxygen was introduced at Digital Denim Week 2021 by Azgard 9 (Pakistan) .

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

Monforts takes part in Webtalk by VDMA’s textile machinery division (c) Monforts/Pleva
13.05.2021

Monforts takes part in Webtalk by VDMA’s textile machinery division

Monforts Head of Technical Textiles Jürgen Hanel will take part in the next international webtalk to be held by the VDMA’s textile machinery division on May 20th.

He will be joined by Johannes Lutz, Research and Development Engineer at Pleva, to provide full details of how the latest Monforts coating technology is supported by special microwave measuring systems.

The Montex®Coat magnetic roller coating option allows a wide range of coatings and finishes to be carried out, while being easy to handle for operators and much easier to clean at the end of the process.

“This roller provides textile finishers with an expanded range of options due to the fully-adjustable positioning of the magnet within the roller and with four different magnet positions possible, can be set to operate both as a direct coating system and as an indirect coater,” Hanel said.

Lutz will provide an overview of the use of Pleva microwave measurement technology in coating processes, in addition to the latest developments in electronic evaluation.

Monforts Head of Technical Textiles Jürgen Hanel will take part in the next international webtalk to be held by the VDMA’s textile machinery division on May 20th.

He will be joined by Johannes Lutz, Research and Development Engineer at Pleva, to provide full details of how the latest Monforts coating technology is supported by special microwave measuring systems.

The Montex®Coat magnetic roller coating option allows a wide range of coatings and finishes to be carried out, while being easy to handle for operators and much easier to clean at the end of the process.

“This roller provides textile finishers with an expanded range of options due to the fully-adjustable positioning of the magnet within the roller and with four different magnet positions possible, can be set to operate both as a direct coating system and as an indirect coater,” Hanel said.

Lutz will provide an overview of the use of Pleva microwave measurement technology in coating processes, in addition to the latest developments in electronic evaluation.

To ensure a constant high quality in coating operations it is necessary to accurately measure and control the amount of chemical being applied, and Pleva’s series 700 devices achieve this via contact-free microwave moisture measurement technology which can be supplied either as single- or three-point units, or as a traversing measurement unit.

The free-to-attend webtalk will take place on May 20th from 2-3pm (CEST) and registration can be made here, along with further information.

Source:

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

How to do more with less explored at Kingpins24 Flash (c) Monfords
Monforts has a leading position in the field of denim finishing with its well proven Thermex continuous dyeing systems, Montex stenter dryers and other lines for resource-efficient and economical processing.
09.03.2021

How to do more with less explored at Kingpins24 Flash

  • Major Monforts denim customers continue to pioneer new initiatives that are pushing the boundaries of sustainable production.

Recycling their cotton waste has become one way these companies can do more with less, and at the recent Kingpins24 Flash online event, Sedef Uncu Aki, director of Orta, headquartered in Istanbul, Turkey, announced a new partnership with leading recycling operation Gama Recycle.

Traceable
“Through this local partnership we will supply the waste from our spinning mills and return around 3,000 tons of premium quality cotton back to them,” she said. “We have established a truly controlled and traceable system and partnering with a domestic recycling centre is important because a lot the carbon emissions associated with recycling usually come from transportation.”

  • Major Monforts denim customers continue to pioneer new initiatives that are pushing the boundaries of sustainable production.

Recycling their cotton waste has become one way these companies can do more with less, and at the recent Kingpins24 Flash online event, Sedef Uncu Aki, director of Orta, headquartered in Istanbul, Turkey, announced a new partnership with leading recycling operation Gama Recycle.

Traceable
“Through this local partnership we will supply the waste from our spinning mills and return around 3,000 tons of premium quality cotton back to them,” she said. “We have established a truly controlled and traceable system and partnering with a domestic recycling centre is important because a lot the carbon emissions associated with recycling usually come from transportation.”

Orta’s ZeroMax range meanwhile uses no cotton at all, being based on Lenzing’s Tencel cellulosic fibre, while the company’s involvement in denim production for a recent launch by Levi Strauss, of jeans made with organic cotton and Circulose – a breakthrough material developed by re:newcell of Sweden and partners – was hailed as a further step forward.

To make Circulose, re:newcell repurposes discarded cotton textiles, such as worn-out denim jeans, through a process akin to recycling paper. The incoming waste fabrics are broken down using water. The colour is then stripped from these materials using an eco-friendly bleach and after any synthetic fibres are removed from the mix, the slurry-like mixture is dried and the excess water is extracted, leaving behind a sheet of Circulose. This sheet is then made into viscose fibre which is combined with cotton and woven into new fabrics.

Circular Park
Omer Ahmed, CEO of Artistic Milliners also announced plans for his company’s new 70,000 square-foot Circular Park in Karachi, Pakistan, at Kingpins24 Flash.

Once complete, this will add three million square metres of additional denim capacity a month to the company’s production and take its total recycled output to a monthly five million metres.
Ahmed observed that there is currently a lack of sustainable fibres that are readily available to use for denim production at scale.

“Organic cotton is too expensive, and in my opinion always will be,” he said. “Cottonised hemp is also not cheap and it’s hard to mix with cotton, while the new regenerated cellulose fibres that are now emerging are promising, but currently in short supply. Recycled polyester is meanwhile still based on petroleum resources which we want to move away from. As a consequence, there are only a few other options for us as a manufacturer and this new project will help us minimise our own waste while significantly lowering our carbon footprint.”

Other Monforts denim customers to introduce cotton fibre recycling operations at their plants recently include AGI Denim, Bossa and Soorty.

Vertical savings
Refresh is the name of the latest collection from AGI Denim – reflecting the company’s significant reduction in water consumption.

The company has just opened new fibre spinning and denim mills at its complex in Karachi, Pakistan.

“Over the years we’ve gone through a series of backward integration steps to become fully vertical,” said AGI Denim executive director Ahmed Javed, at Kingpins24 Flash. “In our latest expansion, we revisited every step of the production processes in order to make resource savings.”

Innovations have included the installation of proprietary robotics for garment finishing, but the most attention has been paid to water savings.

“Pakistan is one of the largest cotton-producing companies in the world and we’re fortunate that the type of cotton that is grown here is well suited to denim production and also helps us lower our carbon footprint, with everything done in close proximity,” Javed said. “In the lifecycle of a pair of denim jeans, however, cotton fibre production contributes 68% of water consumption. While we cannot control how much water cotton needs for it to grow, we can rethink the way we use it in our factory.”

Refresh-branded denims are washed from 100% recycled water as a result of the company’s new wastewater treatment plant, which puts production wastewater through a series of steps beginning with equalisation, followed by aeration and concluding with sedimentation. The water travels through filtration and ultrafiltration systems before being subjected to an activated carbon system and finally a reverse osmosis system to reduce any dissolved salts.

AGI now recycles 4.4 million gallons of water each month – enough to wash a million pairs of jeans.

Sustainable
Monforts has a leading position in the field of denim finishing with its well proven Thermex continuous dyeing systems, Montex stenter dryers and other lines for resource-efficient and economical processing.

“Our denim partners are constantly setting themselves new goals in respect of sustainable production – and more importantly, achieving them,” says Hans Wroblowski, Monforts Head of Denim. “We work closely with them with the aim of constantly optimising processing parameters and achieving further savings in energy, water and raw materials throughout the dyeing and finishing stages of production.”

The latest Monforts innovation for denim is the CYD yarn dyeing system. This technology is based on the effective and established dyeing process for denim fabrics that is now being applied for yarn dyeing. The CYD system integrates new functions and processes into the weaving preparation processes to increase quality, flexibility, economic viability and productivity. A full CYD line is now available for trials at the company’s Advanced Technology Centre in Mönchengladbach, Germany.”

The Montex®Coat ticks all the right boxes for coating success in 2021 (c) Monforts
A recent Montex®Coat installation at a European mill.
24.02.2021

The Montex®Coat ticks all the right boxes for coating success in 2021

Flexibility, product uniformity and automation are the keys to success for coating businesses in today’s rapidly-changing technical textiles industry, explained Jürgen Hanel, Monforts Head of Technical Textiles, at the recent 1st World Congress on Textile Coating.

Introducing the latest Montex®Coat magnetic roller coating option to virtual delegates from around the world at the conference organised by International Newsletters, Hanel explained why this technology makes perfect sense now

“The magnetic roller system allows a wide range of coatings and finishes to be carried out, while being easy to handle for operators and much easier to clean at the end of the process,” he said. “It provides textile finishers with an expanded range of options due to the fully-adjustable positioning of the magnet within the roller and with four different magnet positions possible, can be set to operate both as a direct coating system and as an indirect coater.”

Flexibility, product uniformity and automation are the keys to success for coating businesses in today’s rapidly-changing technical textiles industry, explained Jürgen Hanel, Monforts Head of Technical Textiles, at the recent 1st World Congress on Textile Coating.

Introducing the latest Montex®Coat magnetic roller coating option to virtual delegates from around the world at the conference organised by International Newsletters, Hanel explained why this technology makes perfect sense now

“The magnetic roller system allows a wide range of coatings and finishes to be carried out, while being easy to handle for operators and much easier to clean at the end of the process,” he said. “It provides textile finishers with an expanded range of options due to the fully-adjustable positioning of the magnet within the roller and with four different magnet positions possible, can be set to operate both as a direct coating system and as an indirect coater.”

With traditional dip coating systems, he added, as well as with many standard knife coating technologies, there is always a difference in the tension between the centre and the edges of the wide width fabrics being treated – and hence the amount of pressure with which the coating is applied. With the use of a magnetic roller, equal pressure is applied across the full width of the fabric, with consistent results even at wide widths of over 2.4 metres. In addition, adjusting the roller surface, rather than changing the coating formulation to match the required add-on and viscosity for each coating effect required, leads to much higher output from the line.

Cleaner and less wasteful
The contribution of such flexible and resource-saving new technologies to a cleaner and less wasteful textile industry was a key theme at the congress – held virtually across the four afternoons of February 11th, 12th, 18th and 19th – as was digitalization and the many advantages it is providing.

“A typical integrated Monforts coating line is automated from the inlet feed to the winder,” Hanel told delegates. “Adjustments can also be made simply and easily from the touchscreen and with the new hand-held remote controller which has recently been introduced for the Montex®Coat unit.”

Manual adjustment, he added, is time consuming and needs the attention of an experienced operator or the reproducibility will not be accurate between coating operations. The adjustment by motors allows each coating to be stored and downloaded again for 100% reproducibility.

The motors can be fully controlled from the touchscreen and all necessary adjustments carried out remotely, making switching from one process to another extremely quick and easy.
The accuracy that is now being demanded by today’s most exacting customers is met with an optional carbon fibre roller – especially in dealing with the winding tension required in the processing of materials such as prepregs for composites and other heavyweight fabrics. Typical applications for the Montex®Coat include the finishing of tents 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 can all be accommodated.

“The World Congress on Textile Coating was characterised by some very stimulating presentations and forums between the speakers and a global audience of textile specialists,” Jürgen Hanel concluded. “It truly reflected the high level of positive changes now taking place in not just textile coating, but the entire textile industry. I look forward to the next edition, which hopefully will be a face-to-face event for even deeper level discussions and debate.”

Advanced Monforts automation is the key for Hamle (c) Monforts
07.12.2020

Advanced Monforts automation is the key for Hamle

  • Leading Turkish textile printing company Hamle has installed a new Monforts Thermex dyeing range as part of its ongoing strategy of continuous investment.

“Investment in new technology and capacity expansions are very important to us, in order to stay ahead in terms of sustainable, high quality production,” says general manager Gürkan Uzuner. “We carefully assess the benefits of each advanced new technology in order to thrive in a sector that is constantly changing.

“The Zara Group is a major European customer for us, along with well-known Turkish brands such as LCW and De-Facto, and it’s no accident that Çorlu, due to its proximity to Istanbul and the ease of supplying to Europe, has become the epicentre of Turkish textile production. The quality of textiles coming from the region is now very well proven.”

Integration

  • Leading Turkish textile printing company Hamle has installed a new Monforts Thermex dyeing range as part of its ongoing strategy of continuous investment.

“Investment in new technology and capacity expansions are very important to us, in order to stay ahead in terms of sustainable, high quality production,” says general manager Gürkan Uzuner. “We carefully assess the benefits of each advanced new technology in order to thrive in a sector that is constantly changing.

“The Zara Group is a major European customer for us, along with well-known Turkish brands such as LCW and De-Facto, and it’s no accident that Çorlu, due to its proximity to Istanbul and the ease of supplying to Europe, has become the epicentre of Turkish textile production. The quality of textiles coming from the region is now very well proven.”

Integration

Hamle’s plant in Çorlu already houses a Monforts ten-chamber Montex stenter and two Monforts sanforizing ranges on which the company carries out an extensive range of finishing processes. The new Thermex range further integrates a number of processes on technology all from a single supplier. The Thermex universal hotflue for continuous dyeing, condensing and thermosoling achieves unrivalled reliability even at maximum fabric speeds, for exceptional cost-effectiveness when dyeing both large and small batches of woven fabrics. The new range installed for Hamle benefits from the Econtrol® process* for reactive dyestuffs. This is quick and economical one-pass pad-dry and wash off process, with drying in the hot flue at 120-130°C and controlled humidity (25-30% by volume) to obtain fixation in 2-3 minutes.
Econtrol® ensures excellent reproducibility of all colours, improved dye penetration on difficult fabrics and no risk of the browning of cotton or other cellulose fibres due to the low fixation temperature.

As such, it is the ideal process for fast change technology and operational savings. “The new Thermex range has some very advanced automation features which ensure our machine operators have full control over the entire system,” Mr Uzuner concludes. “ As the Monforts representative in Turkey, Neotek has been our solution partner in the installation and commissioning and has been with us every step of the way.
.
* Econtrol® is a registered mark of DyStar Colours Distribution GmbH, Germany.

 

Source:

AWOL Media for Monforts