Textile Technology section
Monforts: wide range of coatings with magnetic roller system
Flexibility, product uniformity and automation are the keys to success for coating businesses in today’s rapidly-changing technical textiles industry. The MontexCoat magnetic roller coating option of the manufacturer of textile machinery A. Monforts Textilmaschinen GmbH & Co. KG, Mönchengladbach/Germany, allows a wide range of coatings and finishes to be carried out, while being easy to handle and to clean at the end of the process.
The magnetic roller system has a range of options due to the fully-adjustable positioning of the magnet within the roller and with 4 different magnet positions possible. It can be set to operate both as a direct coating system and as an indirect coater.
With traditional dip coating systems, as well as with many standard knife coating technologies, there is always a difference in the tension between the center and the edges of the wide width fabrics being treated. 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 m. 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.
The accuracy that is now being demanded by today’s most exacting customers is met with an optional carbon fiber roller – especially in dealing with the winding tension required in the processing of materials such as prepregs for composites and other heavyweight fabrics. Applications for the MontexCoat 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.
Autefa: high process reliability with reproducible quality for face masks
A fully automated production line for the production of protective/face masks has been developed by the manufacturer of textile machinery, Autefa Solutions Germany GmbH, Friedberg/Germany. HiPerMask produces protective masks in accordance with the EU FFP2 and FFP3 standards as well as the US N95 and N98 standards.
Particularly noteworthy is the high process reliability with reproducible product quality and a production output of over 50,000 masks/day. The HiPerMask production line consists of a material feed, nose clip feed and positioning, ultrasonic welding units, ear loops or headband stations, mask folding, punching, and dispensing of the masks into a collection container. Numerous state-of-the-art individual units are joined together into this machine solution. Among other things, an unwinder with 6 stations ensures a warp-free synchronized material feed.
The production line is topped off with comprehensive full-service packages for starting production and procuring consumables for meltblown and spunbond nonwovens as well as other accessories. Autefa also offers companies assistance with certification. The resulting short delivery times and the fast "time-to-market" guarantee a successful entry into manufacturing FFP2 and FFP3 masks.
Karl Mayer: efficient production of warp knitted terry fabric
A terry cloth product with double-sided fabric and lively motifs in bright colors has been developed on a warp knitting machine TM 4-TS EL by textile machinery manufacturer Karl Mayer Textilmaschinenfabrik GmbH, Obertshausen/Germany. One side features a dense layer of cotton loops which quickly absorbs moisture from the skin after bathing. The other side consists of sheared polyester (PET). The smooth finish makes it both easier to print on and quicker to dry.
Afterwards the material has been printed at the screen and digital printing machinery manufacturer Zimmer Austria, a business unit of J. Zimmer Maschinenbau GmbH, Kufstein/Austria, using a digital printing process.
Warp knitting technology with a firmly integrated terry loop is very resistant to thread pullers. The long service life and ecological advantages in production distinguish warp knitted terry articles from their weaving counterparts. The TM 4-TS EL does not require compressed air like conventional air-jet rapier looms and therefore consumes around 87% less energy/kg of fabric produced. The sizing process is also eliminated in warp knitting. This saves textile chemicals, waste water and energy to the tune of approx. 0.20 US$/kg. This corresponds to about 30% of the manufacturing costs – excluding yarn – for the production of the raw material. Apart from saving costs, the terry warp knitting machine is very efficient. With a width of 186” and a speed of 800 rpm, the TM 4-TS EL produces around 1,800 kg of terry cloth weighing 400 g/m² every day in 24-hour operation. This is around 250% more than on an air-jet rapier loom.
Karl Mayer: recyclable polyester-based tricot fabric with elasticity
In Germany alone, 390,000 tons of textile waste is produced every year. Every German person produces 4.7 kg of textile waste, of which only 0.5 kg are recycled. The rest is incinerated or dumped.
A key reason contributing to the low recycling rate is the purity of the material. The new fabric developed by the textile machinery manufacturer Karl Mayer Textilmaschinenfabrik GmbH, Obertshausen/Germany, offers an ecological alternative. The textile is made from yarns of different polyester polymers: a semi-dull version for a soft look and a bicomponent fiber that offers moderate mechanical elasticity with a well-thought-out structure. The elements of the stretchable fiber also consist of different polymers and show different shrinkage behavior: when heated, a spiral crimp is formed. As the bulky deformation is not mechanically induced – unlike in textured yarns – it produces a more permanent elongation in comparison.
The 2 polyester yarns were processed into a dense fabric on a high-performance HKS 3-M tricot machine in gauge E 32. The fabric weighs 202 g/m². It stands out thanks to its dense, rich feel and a heavy drape. Clothing made from it is comfortable to wear, easy to wash, does not need to be ironed and can be recycled after removing accessories such as buttons and buckles.
Power-Heat-Set: new dual leadership
Since January 1, 2021 Marcus Köhler, Commercial Manager, and Kurt Frank, Technical Manager, have teamed up to lead the textile machinery specialist Power-Heat-Set GmbH, Töging/Germany.
Köhler, General Manager of the company since 2015, will continue to be responsible for commercial aspects such as customer support, sales, purchasing and administration. Frank, who is also the Technical Manager at the sister company Resch Maschinenbau GmbH, Töging, will be responsible for the areas of development, production and the so-called ‘Technikum’ (showroom). Under his leadership an additional 5 engineers and product designers have joined the R&D team.
Trützschler Nonwovens/Voith: start-up of machine for sustainable wet wipes
A new system for specialty paper production from the manufacturer of paper technology Voith Paper Walztechnik AG, Zurich/Switzerland, part of the Voith Group, Heidenheim/Germany, and the textile machinery manufacturer Trützschler Nonwovens & Man Made Fibers GmbH, Egelsbach/Germany, has been delivered to the paper factory Papel Aralar, Amezketa/Spain.
In December 2020, the PM 5 successfully started up and is now stably producing adult and baby wet wipes that are completely plastic-free, flushable and biodegradable, a characteristic that conventional wet wipes do not have. With the recent investment, Aralar now has 2 Wet-Laid Spunlacing (WLS) lines with a total production capacity of 45,000 tons/year.
The HydroFormer from Voith, one of the main components of the new system, the suspension is heavily diluted to produce nonwovens made completely of cellulose, a renewable resource. Besides this, the company has supplied the BlueLine stock preparation, a master reel, and the wet end process for the new system.
Trützschler Nonwovens completes the production line with the well-proven AquaJet in an innovative configuration for hydroentangling (spunlacing) and an energy-efficient multi-drum dryer. Its many years of expertise form the basis of the web bonding and drying components that have been adapted to the needs of the wet-laid process.
ACIMIT: Italian textile machinery orders still on downturn in Q4/2020
The index of orders intake for Italian textile machinery compiled by the Association of Italian Textile Machinery Manufacturers (ACIMIT), Milan/Italy, for the period from October-December 2020 was down by 5% compared to the same period in 2019. The negative performing trend both abroad and in Italy has weighed on the overall result. On foreign markets, orders intake recorded a 5% decline, while the domestic market recorded a decline of 6% on the 4th quarter (Q4) of 2019.
On an annual basis, the total index declined by 26% compared to 2019. This result is primarily due to a marked downsizing in orders intake for the first half (H1) of 2020, which was not entirely balanced by the progressive recovery in Q3 and Q4/2020. The decrease amounted to 25% abroad and 30% on the domestic side.
Severe travel restrictions along with the cancellation of most trade fairs, as evident consequences of the Covid-19 pandemic, have heavily influenced business operations, already compromised by a general slowdown in investments in the textile sector.
ITM: virtual product development at ISPO Munich
Showcasing its expertise in the field of virtual product development, the Chair of Assembly Technology for Textile Products at the Institute for Textile Machinery and High-Performance Textile Materials Technology (ITM) at TU Dresden, Dresden/Germany, presents itself for the first time at ISPO Munich Online 2021 – the international fair for sporting goods from February 1-5, 2021.
Its know-how in the determination of material parameters, digital data processing, and data transfer will be presented as well as its competencies in 3D/4D body shape recording using scanning, data animation for the 3D product development for functional clothing, and simulation for wear comfort/usage visualization.
Researchers from the ITM have been actively involved in the preparation and digital representation of material samples for the ISPO Textrends Forum. Thus, the material parameters of the ISPO Textrends Award textiles were determined for 3D fit simulations in Vidya (Assyst/Vizoo), automatically analyzed, and digitally processed by the specially developed "Material Analyzer" software.
This software in addition to other state-of-the-art CAE infrastructure, such as the recently installed 4D Scanner Move4D, are essential for the further establishment and promotion of its leading position in the field of digitalization and virtual product development for garments for high-tech applications.