From the Sector

Indian Tufropes is partnering with Truetzschler Nonwovens and Voith to install its unique pentamerous technology. The company’s first nonwovens production line will be capable to produce 5 different eco-friendly, hydroentangled products.

Truetzschler Nonwovens and Voith are thrilled to be the technology partner for Tufropes’ (patent pending) unique nonwoven line based on pentamerous technology. The new installation relies heavily on Truetzschler/Voith core components for wet-laying, carding and hydroentangling. Proprietary refinements will allow Tufropes to produce any possible hydroentangled nonwoven material, including bio-degradable, natural fibre, eco-friendly high-performance nonwovens. Globally this would be a first industrial-scale pentamerous technology-based nonwoven project. Based in Gujarat, India, the line is expected to be commissioned next year.

Korteks, one of the world’s biggest yarn producers based in Bursa, Turkey, has started the production of recycled polyester filament yarn in its production facility using a Starlinger recycling line.

With the new recycling facility, which comprises a total closed area of 17,000 m² and has a monthly production capacity of 600 tons, Korteks was able to reduce the production waste at its virgin PES yarn site to zero.

The Starlinger recoSTAR universal 165 H-VAC iV+, which is part of Korteks’ 10 million dollars investment in a new polymer recycling facility, took up operation in May 2021. It has a production capacity of 7,200 tons per year and currently processes clean in-house polyester fibers from production scrap together with washed post-consumer PET flakes at a ratio of 50/50. Korteks uses the polyester regranulate at a share of 100 % for its new polyester filament yarn line it is going to market under the name “TAÇ Reborn”. With this investment, the company has made an important step towards establishing a circular economy in the Turkish textile industry.

The Starlinger recycling line is the first of its kind in Turkey and is equipped with special components for filament yarn recycling. A RSC (Rapid Sleeve Changer) candle filter developed by Starlinger ensures finest melt filtration down to 15 μm. It has been specially designed for polyester recycling and reaches an output of 1000 kg/h. For continuous operation the filter elements are changed “on the fly” without interrupting production, which significantly limits melt loss.

The viscoSTAR SSP unit at the end of the recycling process guarantees consistent IV increase according to the first-in-first-out principle. This makes sure that the produced regranulate has the ideal properties required for filament yarn production. The technical configuration of the line does not only allow the processing of a polyester fiber/PET flake mix as input materials, but also 100 % polyester filament scrap or 100 % PET bottle flakes.

Korteks expects the recycling market in general to grow as there is increased acceptance for recycled products in the society, and predicts the need for recycling solutions also for other synthetic and natural fibers.

Kornit Digital Ltd., a worldwide market leader in digital textile production technologies, released its 2020 Impact and Environmental, Social, and Governance (“ESG”) Report. This inaugural report affirms Kornit’s commitment to achieving specific ESG goals. This includes the way Kornit conducts business, creates meaningful impact in local communities, and achieves environmental sustainability, in addition to how Kornit will continue to build a diverse and inclusive company culture, foster employee growth and development, and empower fair and safe labor practices globally.
 
In addition to enabling eco-friendly production processes with technology and consumables that use less water, reduce waste, and minimize the carbon footprint, Kornit technology solutions enable sustainable production on demand, which eliminates overproduction of apparel and other textile goods. A 2021 Life Cycle Assessment conducted on two flagship products, the Kornit Atlas MAX and Kornit Presto S, demonstrated that relative to traditional analog processes, Kornit’s digital production systems used up to 95% less water and 94% less energy, and produced up to 83% less greenhouse gas (GHG) emissions for the Presto S system and up to 93% less water and 66% less energy, and produced up to 82% less greenhouse gas (GHG) emissions for the Atlas MAX system.

Based on this study, in addition to past sustainability performance results and strategic projections for business growth and market expansion, by 2026 Kornit Digital’s sustainable on-demand solutions are expected to enable the production of approximately 2.5 billion apparel items in a responsible manner to deliver:

• Zero overproduction: By moving the industry to on-demand manufacturing, Kornit will help eliminate the estimated 1.1 billion apparel items overproduced using traditional production methods, based on an industry average of 30% overproduction. This is about 1 apparel item for each and every person living in Europe and North America – saved.
• Zero water waste: In addition to eliminating overstocks, Kornit-enabled production on demand will support saving an estimated 4.3 trillion liters (1.1 trillion gallons) of water. This is the estimated amount of drinking water needed for the entire U.S. population for 11 years.
• Reduced CO2 emissions: By enabling sustainable on-demand production, consuming less energy, and generating less waste, Kornit will prevent an estimated 17.2 billion kilograms (37.9 billion pounds) of greenhouse gas emissions, compared to traditional manufacturing methods. This is equivalent to the estimated amount of carbon dioxide emitted from circumnavigating the entire planet with a car nearly 2,400 times.

Furthermore, the report outlines Kornit’s commitment to achieving KPIs that address waste, chemicals, GHG emissions, energy, product development, employee training, diversity and inclusion, and the company’s supply chain.

• Robotik für mehr Produktivität, Flexibilität und beste Arbeitsbedingungen
• Tonnenschwere Entlastung für die Mitarbeiter in der Garnproduktion

Gemeinsam mit ABB, einem Pionier in der Robotik und Automation, entwickelte die HUESKER-Gruppe - einer der weltweit führenden Hersteller von technischen Hochleistungstextilien für Tiefbau, Agrarwirtschaft, Industrie und Leichtbau- einen Prototyp, der gezielt für die Handhabung und Palettierung schwerer Garnrollen eingesetzt wird.

In einer seiner Produktionsanlagen für Basisgarne, die teilweise zu 100 Prozent aus recycelten Materialien stammen, setzt die HUESKER Gruppe jetzt auf die Unterstützung eines Roboters.
„Wir haben uns in jüngster Zeit verstärkt Gedanken darüber gemacht, wie wir Robotik und Automatisierung bestmöglich für uns und unser Personal nutzen können. Bei der Handhabung und Palettierung von Garnrollen, die bis zu 15 Kilogramm auf die Waage bringen, lagen die Vorteile sofort auf der Hand: Roboter entlasten unsere Mitarbeiter von dieser anstrengenden Tätigkeit und geben ihnen die Möglichkeit, höherwertigere Aufgaben zu übernehmen“, betont Dr. F.- Hans Grandin, Geschäftsführender Gesellschafter der HUESKER Gruppe.

In Zusammenarbeit mit dem Unternehmen ABB wurde ein Roboter implementiert, der neben hoher Leistungsfähigkeit auch besonders niedrige Gesamtbetriebskosten aufweist. Aus drei Produktionsmaschinen mit jeweils zwei Entnahmemulden nimmt der Roboter die fertigen Garnrollen zuverlässig auf. Die Mulden befinden sich weit oben und unten –unergonomische Positionen für die Mitarbeiter, die diese Tätigkeit bisher verrichtet hatten. Hinzu kommt: Je nach Produktionsauftrag sind die Garnrollen unterschiedlich in Durchmesser und Gewicht, was für den auf bis zu 150 Kilogramm ausgelegten Roboter kein Problem darstellt. Im Schnitt nimmt er dem Mitarbeiter rund 2,5 Tonnen pro Tag ab.

Auch filigranere Arbeiten kann der Roboter ausführen: Jede fertig produzierte Garnrolle hat ein offenes Fadenende, das gesichert werden muss, um ein Abspulen auf der Palette zu verhindern. Dafür gibt der Roboter die Rolle an eine Bearbeitungsstation, an der ein Klebeetikett angebracht wird, das den Faden fixiert. Zudem hat der automatische Spulenwechsel zur Folge, dass ein so genannter Reservefaden übersteht, welcher in den folgenden Verarbeitungsschritten jedoch nicht benötigt wird. Um ihn zu entfernen, fährt der Roboter die Spule an eine weitere Vorrichtung, wo der Faden mit einem Heizdraht abgebrannt und abgesaugt wird.

Für die Palettierung setzt der Roboter die Spulen hochkant und auf eine Palette. Sobald eine Ebene voll bepackt ist, entnimmt er eine Zwischenlage aus einem Magazin und legt sie passgenau auf. Anschließend folgt das Bestücken der Maschinen mit Leerhülsen, um so den Produktionsbetrieb zu unterstützen.

Die Mitarbeiter überwachen und assistieren sporadisch, etwa wenn eine fertige Palette abtransportiert, Zwischenlagen aufgefüllt oder Leerhülsen nachgefüllt werden müssen. Diese Aufgaben nehmen nur wenig Zeit in Anspruch und fallen pro Schicht höchstens ein- bis zweimal an. Somit läuft die gesamte Anlage, bis auf diese kurzen Unterbrechungen, nahezu autonom.

Nach erfolgreicher Implementierung der ersten Automatisierungsanlage sieht HUESKER viel Potenzial darin, Robotik für weitere Anwendungen zu nutzen – etwa für die der Garnproduktion direkt vorgelagerten Prozesse. Auf diese Weise werden durchgängige Automatisierungslinien geschaffen, die dem Unternehmen helfen, Produktivität und Flexibilität zu steigern sowie die Arbeitsbedingungen für seine Mitarbeiter weiter zu verbessern.

„Your reliable partner in the nonwoven industry“ – the slogan speaks for itself: Oerlikon Nonwoven is exhibiting at the world’s leading nonwovens trade fair – the INDEX in Geneva, Switzerland (October 19-22, 2021) – with one of the market’s broadest portfolios. The Neumünster-based systems constructor will be focusing on market- and customer-oriented system solutions for filtration, hygiene, medical, geotextile and other industrial applications. Trade fair visitors can delve deep into the company’s comprehensive product and process know-how both live at trade fair stand no. 2314 and via the INDEX online platform.

• Nonwovens for filtration, insulation and sorption applications
• Comprehensive spunbond portfolio
• Quality Sized Right-Technology: spunmelt systems for the hygiene and medical market
• Wipes using Oerlikon's Phantom technology
• Airlaid technology for sustainable nonwovens

Zünd Connect compiles production data from integrated Zünd cutting systems into meaningful key performance indicators, such as cutter capacity, availability, and overall equipment effectiveness. Zünd Connect creates transparency and identifies areas in the digital cutting workflow with potential for optimization.

There are many ways to optimize digital cutting and ensure maximum productivity, which is the reason why Zünd now offers Zünd Connect, a monitoring tool that helps the user recognize this potential and increase productivity. Using Zünd Connect, the user can see at a glance when and, more importantly, why machine interruptions occur, how much time is spent in setup, and what the availability of each machine is.

The web-based monitoring tool gives the user access to cutter- performance data at a glance, any time of day. Reliable key performance indicators are available at all times to help users maximize productivity. The system records productivity levels over a freely definable period using Zünd Cut Center – ZCC (Version 3.4 or later) as data source. Data monitoring provides information users need in order to make informed decisions. This comprehensive overview of production data reveals connections that are often overlooked. Zünd Connect supplies valuable key performance indicators for assessing how efficiently cutting systems are working. To be able to improve cutter efficiency, potential areas of improvement must be uncovered and recognized. This potential lies primarily in the technology but also in the way it is being used.

Zünd Connect is available in a "Monitor" or an "Analyzer" version.

• Luc Tack und Stefaan Haspeslagh resign with immediate effect

The two members of the Board of Directors Luc Tack und Stefaan Haspeslagh announced on August 30, 2021, that they are resigning from the Board of Directors with immediate effect.

Rieter will inform the law enforcement authorities that there is no interest in continuing the criminal proceedings any further.

The Board of Directors welcomes the fact that a joint solution was found that is in the best interests of Rieter and Picanol, both of which are among the world’s leading textile machinery manufacturers.

According to Luc Tack, the Picanol Group (Belgium) will remain a shareholder of Rieter.

• Achievement Ahead of Schedule

All of Sateri’s five viscose mills in China are now fully compliant with the emission limits set out in the European Union Best Available Techniques Reference Document (EU-BAT BREF) on Polymers, following recent verification of Sateri Jiangsu and Sateri China mills.

Verified by independent consultant Sustainable Textile Solutions (STS), a division of BluWin Limited (UK), the parameters assessed included resource utility efficiency, wastewater discharge and air emission.

Allen Zhang, President of Sateri said, “Sateri Jiangsu was established in 2019 following an acquisition while Sateri China was built in the same year. We had aimed to have both mills meet EU-BAT’s recommended emission levels by 2023. To achieve this two years ahead of schedule underscores our continuous efforts in process improvement and control of pollutant emissions, and resource utilization efficiency. We will continue to pursue manufacturing excellence and invest in best-in-class technologies for all our mills – existing, acquired, and newly constructed ones – as part of our Vision 2030 commitment towards closed-loop and cleaner production.”

Chen Xinwei, Chairman of China Chemical Fiber Industry Association, said, "China's regenerated cellulose fibre industry has been progressing steadily in recent years. As a major viscose manufacturer, Sateri has demonstrated leadership in benchmarking itself against advanced domestic and international standards, focusing on low-carbon development, energy-saving and emission-reduction technology, and cleaner production to advance sustainable development, as well as enhance the company’s competitiveness. All other players in the industry should be encouraged to follow suit."

Sateri is a member of the RGE group of companies; Sateri’s other three mills - Sateri Fujian, Sateri Jiujiang and Sateri China (Jiangxi) - had attained EU-BAT compliance in 2020.

After a long break, the international nonwovens industry will meet again in Geneva, Switzerland, from October 19 to 22, 2021 on the occasion of INDEX. DiloGroup offers tailormade production systems from one supplier and will inform about its portfolio and the latest equipment developments from fibre opening to the finished felt.

A new, simplified elliptical needle beam drive makes Hyperpunch technology also attractive for standard application. Hyperpunch HαV allows a more uniform stitch distribution in the preneedling process especially in combination with the new needle pattern 6000X. In a complete needling line this felt homogenization process can be improved further by using the new needle pattern 8000X which is a milestone in the needle pattern development process and results in endproduct surfaces with low markings over a wide range of advances/stroke.

The “3D-Lofter” which was first presented during ITMA 2019 in Barcelona offers a wider range of nonwovens applications by exploring the third dimension. A series of single web forming units which work according to the aerodynamic web forming principle deliver defined fibre masses in varied patterns on a base needlefelt. A stress oriented production of technical formed parts resulting in fibre savings or patterned DI-LOUR or DI-LOOP felts are two examples for this technology which explores new application areas for needlefelts The 3D-Lofter technology may also be used “inverted” for filling up bad spots in web mats and thus achieves a better homogeneity of e. g. spunlace, thermobond or airlay products.

The DiloLine 4.0 concept offer I4.0 modules which not only support the user but also facilitate quality control and maintenance by a maximum data transparency in production and control of operation. The Dilo solutions “Smart Start” for a fully automatic start of the production line or “DI-LOWATT” for energy savings are accompanied by Siemens solutions which can be selected via App or Data Cloud “MindSphere”.

Apart from machines for needling technology we offer in cooperation with partner companies also production lines including thermobonding and hydroentangling components.

Originally conceived as a low-cost, high-volume alternative to knitting and weaving, nonwovens was already expanding its market boundaries by the 1970s with new applications in ‘disposables’ such as diapers, hygiene and teabags.

In the past five decades, the nonwovens business has exploded in all directions, reaching a global market worth USD 40.5 billion in 2020, projected to grow to USD 53.5 billion by 2025. This annual growth rate of 5.7% (MarketsandMarkets, Nonwoven Fabric Market Report) is based on countless new applications and expansion into durable, as well as additional disposable, products.

Major growth drivers include the hygiene sector, and filtration media for power plants and air conditioning systems. Especially during the peak of the COVID pandemic in 2020 and 2021, demand in the hygiene sector multiplied. Worldwide capacities for both meltblown and spunlace production rocketed compared to a normal business year. Swiss Autefa Solutions, for example, significantly benefited from this trend, notably with the launch of a fully-automatic machine for producing face masks.

The automotive industry is the second big growth area, with many new applications being pioneered. The trend to electric and hybrid vehicles has helped this, as nonwovens reinforced with carbon fibres are widely used as battery housings.

Swiss nonwovens competence
Innovative applications across all sectors have driven the rapid evolution of sophisticated nonwovens machinery. Today’s trends demand higher productivity, sustainability and Industry 4.0 compatibility – demonstrated by the full equipment portfolio of Swiss Textile Machinery member Autefa Solutions. With V-Jet Futura, the company recently sealed the link in its product range between web forming and drying technology. This latest Hydroentanglement Machine, together with the SQ-V Square Drum Dryer, embodies advanced technology combined with significant reductions in energy consumption compared to other process solutions.

A vital contribution to nonwovens production is offered by Rieter subsidiary Graf, a leading supplier of clothing and combs for carding and combing processes in spinning and nonwovens. Graf's Hipro card clothings – suitable for any man-made fibres in the nonwovens sector – are focussing on higher productivity. Their superior performance delivers up to 10% higher throughput and greater carding efficiency compared to conventional clothings. These reliable card clothing elements also ensure a consistently reproducible high web quality, as well as 20% fewer failures in the web, thanks to the precise fibre transfer to and from the cylinder.

Another constant trend in nonwovens today is the drive for better quality. Manufacturers want to take charge of contamination levels in their processes, as well as eradicating defects which may arise during production. Uster Technologies, a leading provider of quality management solutions from fibre to fabric, offers a combined solution to achieve both these required quality standards. At the fibre preparation stage, Uster Jossi Vision Shield N ensures the best possible initial inspection and removal of contamination. Then, at the end of the production sequence, Uster EVS Fabriq Vision N handles automated detection and marking of all the main defects caused during production. This combined solution avoids material waste and takes full advantage of the potential for process optimization.