From the Sector

„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

International technology Group ANDRITZ has received an order from Pratrivero s.p.a. to supply a new eXcelle batt forming line for their production facilities in Valdilana, Italy. The line will be dedicated to the production of Maliwatt products, used in furnishing, automotive, naval, medical, geotextiles, advertising, clothing, and packaging applications. Installation and start-up are scheduled for the third quarter of 2021.

The ANDRITZ batt forming line includes an eXcelle card and eXcelle crosslapper, a ProDyn™ web profiling correction system as well as a scanning gauge with a closed loop. The ProDyn system combines actions from the card doffers with dynamic speed variation at the crosslapper. This will result in substantial fiber savings and reduction in CV%, providing improved weight evenness in the final product. The ProDyn closed loop will ensure the best possible self-regulation for the equipment and thus enable Pratrivero to produce one of the best product qualities on the market. Pratrivero will be the world’s first company to use the ProDyn technology in the Maliwatt stitchbonding process.

Stitchbond is a nonwoven process made by mechanically interlocking fiber webs with continuous filaments, thus imitating textiles. Stitchbonded products are used in many applications due to their lower production costs compared to woven textiles. Among all the different nonwoven processes in which it operates, ANDRITZ is also a market-leading supplier of batt forming equipment for the stitchbonding processes producing Maliwatt, Malivlies and quilting.

Pratrivero is an important player in the production of nonwoven fabrics using stitchbonding technology.

• Swiss weaving machinery manufacturers are in the forefront of novel application development

Shoes and electronic calculators are probably not the first products people would associate with the textile weaving process. But they certainly signpost the future for woven fabrics, as two examples of the ever-wider possibilities of latest technology in the field. Fashion and function already combine in the increasing popularity of woven fabrics for shoes, and this is a present and future trend. Calculators in fabrics? That’s another story of ingenious development, using so-called ‘meander fields’ on the back and keys printed on the front of the material.

These glimpses of the outlook for modern weavers are among the highlights of developments now being pioneered by Swiss textile machinery companies. All weaving markets require innovation, as well as speed, efficiency, quality and sustainability. Member firms of the Swiss Textile Machinery Association respond to these needs at every point in the process – from tightening the first thread in the warp to winding the last inch for fabric delivery. They also share a common advantage, with a leading position in the traditional weaving industry as well as the expertise to foster new and exciting applications.

Technology and research cooperation
The concept of a ‘textile calculator’ was developed by Jakob Müller Group, in cooperation with the textile research institute Thuringen-Vogtland. Müller’s patented MDW® multi-directional weaving technology is able to create the meander fields which allow calculator functions to be accessed at a touch. A novel and useful facility, which suggests limitless expansion.

Today, the latest woven shoes are appreciated for their precise and comfortable fit. They score through their durability, strength and stability, meeting the requirements of individual athletes across many sports, as well as leisurewear. Stäubli is well known as a leading global specialist in weaving preparation, shedding systems and high-speed textile machinery. Its jacquard machines offer great flexibility across a wide range of formats, weaving all types of technical textiles, lightweight reinforcement fabrics – and shoes.

It’s possible to weave new materials such as ceramics, mix fibers such as aramid, carbon and other, and produce innovative multi-layers with variable thicknesses. Such applications put special demands on weaving machines which are fulfilled by Stäubli high-performance TF weaving systems.

Great weaving results are impossible without perfect warp tension, now available thanks to the world-leading electronic warp feeding systems of Crealet. Some market segments in weaving industry today demand warp let-off systems which meet individual customer requirements. For example, the company has recognized expertise to understand that geotextile products often need special treatment, as provided by its intelligent warp tension control system. Individual and connective solutions are designed to allow external support via remote link. Crealet’s warp let-off systems are widely used in both ribbon and broadloom weaving, for technical textiles applied on single or multiple warp beams and creels.

Functional, sustainable, automated
Trends in the field of woven narrow fabrics are clearly focused on functionality and sustainability. The Jakob Müller Group has already embraced these principles – for example using natural fibers for 100% recyclable labels with a soft-feel selvedge. It also focuses as much as possible on the processing of recycled, synthetic materials. Both PET bottles and polyester waste from production are recycled and processed into elastic and rigid tapes for the apparel industry.

For efficient fabric production environments, it is now recognized that automated quality solutions are essential. Quality standards are increasing everywhere and zero-defect levels are mandatory for sensitive applications such as airbags and protective apparel.

Uster’s latest generation of on-loom monitoring and inspection systems offers real operational improvements for weavers. The fabric quality monitoring prevents waste, while the quality assurance system significantly improves first-quality yield for all applications. Protecting fabric makers from costly claims and damaged reputations, automated fabric inspection also removes the need for slow, costly and unreliable manual inspection, freeing operators to focus on higher-skilled jobs.

Smart and collaborative robotics (cobots) offer many automation possibilities in weaving rooms. Stäubli’s future oriented robotics division is a driver in this segment with first effective installations in warp and creel preparation.

Control and productivity
Willy Grob’s specialized solutions for woven fabric winding focus on reliable control of tension, keeping it constant from the start of the process right through to the full cloth roll. Continuous digital control is especially important for sensitive fabrics, while performance and productivity are also critical advantages. In this regard, the company’s large-scale batching units can provide ten times the winding capacity of a regular winder integrated in the weaving machine.

The customized concept by Grob as well as design and implementation result in great flexibility and functionality of the fabric winding equipment – yet another example of Swiss ingenuity in textile machinery.  
There is even more innovation to come in weaving – and in other segments – from members of the Swiss Textile Machinery Association in future! This confident assertion is founded on an impressive statistic: the 4077 years of experience behind the creative power of the association’s member firms. It’s proof positive that their developments grow out of profound knowledge and continuous research.

International technology Group ANDRITZ has signed an agreement with Laroche, based in Cours, France, to acquire LM Industries comprising Laroche SA and Miltec SA, France. ANDRITZ will take over all Laroche entities and their business worldwide. Closing of the transaction, which is subject to approval by the ANDRITZ Supervisory Board, is expected at the beginning of 2021.

Laroche is a leading supplier of fiber processing technologies such as opening, blending and dosing, airlay web forming, textile waste recycling and decortication of bast fibers. The product portfolio further complements the ANDRITZ Nonwoven product range. ANDRITZ is now able to offer the complete supply and value chain, from the raw material, to opening and blending, web forming, bonding, finishing, drying, and converting. Laroche’s high-performance technologies for opening and blending enhance the ANDRITZ scope of supply for spunlace, needlepunch and wetlaid production lines. Moreover, both companies have agreed to further strengthen the development of their existing technologies for high-speed and high-capacity applications and also to continue pursuing the development of textile recycling processes in order to stay ahead of the changes the industry is facing.

Laroche SA has been developing fiber processing technologies for more than 100 years. With integrated manufacturing, the company supplies lines for a wide range of industries/products: spinning, bedding and furniture, automotive, acoustic and thermal insulation, geotextiles, filtration, wipes, and many more.

Robert Laroche, President of Laroche: “This acquisition is the logical conclusion in view of the successful long-term relationship between ANDRITZ and Laroche. We have been working in close cooperation for more than ten years and are very much looking forward to becoming a member of the ANDRITZ family.”

Andreas Lukas, Senior Vice President and Division Manager, ANDRITZ Nonwoven: “By adding Laroche’s state-of-the-art products and expertise to our existing capabilities, ANDRITZ Nonwoven will further strengthen its market and technology position.”

For the sixth time now, Oerlikon Nonwoven will be showcasing market- and customer-oriented solutions for hygiene, medical, filtration and other technical applications at the globally-leading nonwovens trade fair INDEX in Geneva, Switzerland. Between March 31 and April 3, 2020, visitors to the trade fair can convince themselves of the Neumünsterbased systems constructor’s extensive product and process know-how.

Comprehensive spunbond portfolio – always the right solution
Oerlikon Nonwoven meanwhile has a very broad range of spunbond technology products and services. The process for manufacturing geotextiles from polyester or polypropylene has been optimized; it is characterized by high production capacities and yields, with simultaneously low energy consumption for producing benchmark nonwoven products.

For the manufacture of hygiene nonwovens, Oerlikon Nonwoven offers its new QSR (Quality Sized Right) systems. Here, the benefits of the Chinese machine construction partner’s nonwoven formation are integrated into the complete solution. The advantage for nonwovens producers: highly competitive solutions at attractive prices with comparably low investment.

Cost-efficiently manufacturing meltblown nonwovens
New, unique and highly sophisticated filter media can be easily and efficiently manufactured thanks to Oerlikon Nonwoven’s optimized meltblown technology. Whether as a stand-alone system with one or several positions, as ‘plug & produce’ installations for already existing systems or in conjunction with other technologies: the Oerlikon Nonwoven meltblown process already enables the cost-efficient manufacture of meltblown nonwovens with the quality requirements of tomorrow. Ever more producers are choosing the meanwhile extensively tried-and-tested and consistently further-developed Oerlikon Nonwoven meltblown solutions.

Airlaid technology for the nonwovens of tomorrow
Pulp or cellulose fibers as raw material for manufacturing nonwovens are currently virtually unrivaled with regards to sustainability and environmental compatibility. The Oerlikon Nonwoven airlaid process is the ideal solution for processing this raw material into high-end products for a wide range of applications. Today, there is huge demand for manufacturing solutions for high-quality, lightweight airlaid nonwovens with economically attractive production speeds and system throughputs. In this area, the patented Oerlikon Nonwoven formation process – which also permits the homogeneous mixing of the most diverse raw materials, while simultaneously guaranteeing superb evenness and homogeneous fiber laying – is setting standards even for nonwovens with low running meter weights. And the benefits of this technology are also increasingly gaining significance in sustainable recycling applications.

P&G patented PHANTOM technology from Teknoweb Materials
Also being showcased at the trade fair stand is the P&G patented PHANTOM technology from Teknoweb Materials, Oerlikon Nonwoven’s strategic partner for hygiene products and wipes. The PHANTOM technology is released to Teknoweb Materials by P&G in worldwide exclusive license. The PHANTOM technology is the superior dry laid alternative technology for manufacturing wet wipes from pulp and polymer fibers, for example. Compared to conventional, known processes, this technology offers superior performances with cost advantage in much more eco-friendly products. Dispensing with hydroentanglement renders subsequent drying of the material redundant. Targeted process management allows the optimal setting of the relevant product parameters such as softness, tenacity, dirt absorption and liquid absorption.

• HPR is the highest status a plant can achieve for fire risk prevention and protection
• The site Beaulieu Fibres International is the fourth in the Beaulieu International Group to reach HPR status
• Underlines Group’s commitment to risk prevention at B.I.G. sites & to reinforcing our strong business contingency plan

Beaulieu Fibres International, one of the leading polyolefin staple fibre producers, is pleased to announce the achievement of Highly Protected Risk (HPR) status for its production site in Wielsbeke, a designation that means a facility meets the highest industry standards for property protection.

HPR status was awarded by FM Global, Beaulieu International Group’s (B.I.G.) industrial property and business interruption insurer for the past three years. The company offers B.I.G a unique concept that supports the Group in reducing its exposure to loss and increasing its business resilience. A dedicated worldwide team of engineers focuses on providing assistance and protection of its assets, helping the Group to achieve a higher level of risk protection.

The Beaulieu Fibres International site produces high performance fibres for a large variety of applications and market segments. It scored exceptionally well in its FM Global assessment which focused on aspects including fire protection, protection against natural hazards, mechanical breakdown of machinery, cyber risks and consequent business interruption.

Its overall risk mark of 83 ranks it within the top 25% of its industry for fire risk prevention and protection.

Commenting on the Award, Maria Teresa Tomaselli, Global Sales Director Fibres, said: “This HPR fibre production site reinforces strongly our supply chain security and demonstrates our engagement towards our customers and partners. Our contingency planning and risk management are essential, well-considered elements within our long-term business strategy to demanding sectors such as Automotive, Geotextiles, Flooring industries.”