Nonwovens - Mareintexmareintex.com.ar/.../truetzschler-man-made-fibers/Nonwovens.pdf · 2 Nonwovens Disclaimer: This brochure has been created by us to the best of our knowledge and

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Nonwovens

Nonwovens2

Disclaimer:This brochure has been created by us to the best of our knowledge and with great care. We are however not liable for any spelling mistakes or technical changes. Photographs and illustrations are of informative value only and some show special optional equipment that is n ot included in standard delivery.We provide no guarantee for the current relevance, correctness, completeness or quality of the information provided. All liability claims against us or the respective author pertain-ing to material or immaterial damages caused by the use or circulation of the provided information, even if found to be incorrect or incomplete, are excluded. Our information is non-binding.

Print No.: 13018-12/13-e · Agentur Brinkmann GmbH, Krefeld, Germanywww.machines-for-textiles.com/blue-competence

Trützschler Nonwovens GmbHHalterner Str. 7048249 Dülmen, GermanyPhone: +49 2594 5099-0Fax: +49 2594 [email protected]

Trützschler Nonwovens & Man-Made Fibers GmbHWolfsgartenstr. 663329 Egelsbach, GermanyPhone: +49 6103 401-0Fax: +49 6103 [email protected]

Trützschler Nonwovens & Man-Made Fibers GmbHBetriebsstätte BielefeldSunderweg 433649 Bielefeld, Germany Phone: +49 521 948539-0Fax: +49 521 [email protected]

American Truetzschler, Inc.12300 Moores Chapel Rd.Charlotte, NC 28214P.O. Box 669228Charlotte, NC 28266Phone: 704-399-4521Fax: [email protected]

Truetzschler Textile Machinery(Shanghai) Co.,Ltd.Qingpu Industrial ZoneNo. 1033 Hui Jin RoadShanghai, P.R. CHINAPostal Code: 201707Phone: 0086 21 39203300Fax: 0086 21 [email protected]

3Nonwovens

4 Company

14 Technical Centre

16 Opening / Blending

18 Web Forming 24 Web Bonding 32 Finishing 34 Slitting / Winding 42 Man-Made Fibers – Staple Fibers 44 Man-Made Fibers – Filaments 46 Precursor / Carbon Fibers

48 Film Winding

4

If you are concerned about value creation you should contact us. Because no matter what the raw material you intend to process or the end product – we can offer you a unique process variety from a single source for each production step.

Nonwovens

Our core competency includes the entire nonwoven process, from fiber production to finished prod-uct. The type of installation con-figuration best suited for your goals depends on a variety of factors:n Product type and product propertiesn Square metre weight

n Purity and finenessn Production volumen Qualitiesn Economic aspects

Our experts will be pleased to assist you with the individual arrangement of the optimal components.

From raw material to finished productTHE BEST WAY TO MAXIMISE VALUE CREATION

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TRÜTZSCHLER NONWOVENS production lines are always made-to-measure.

We are at the top BECAUSE WE ARE SUPPORTED BY A STRONG TEAM

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The Trützschler group is a special-ist in fiber preparation for the yarn spinning industries as well as a competent manufacturer of machin-ery and systems for the chemical fiber industry. Trützschler produces excellent equipment at nine loca-tions in six countries worldwide.

The TRÜTZSCHLER NONWOVENS brand has been formed by the nonwoven assets of the long-established companies Erko and Fleissner. Nonwoven producers worldwide find knowledge and competence in all matters relating to fiber opening and blending, web forming and bonding as well as fin-ishing and winding. Two specialised technical centers in Egelsbach and Dülmen are available for tests and product developments. Now the company is the only manufacturer offering four different entangling methods.

Under the brand name of TRÜTZSCHLER MAN-MADE FIBERS the company supplies complete systems for state-of-the-art spin-ning plants for staple fibers, carpet and industrial filament yarn as well as PAN-based precursor and carbon fiber lines. The roots are going back to Fleissner which grew up with the man-made fiber industry and was one of the leading suppliers of wet-spinning lines for polyacrylic fibers.

A brand name with tradition: FleissnerFleissner was a well established and competent manufacturer of machinery and systems for the chemical fiber industry. Innovation and high quality have been the driving forces – the invention of through-air drying, used frequently in nonwovens and staple-fiber spinning manufacturing, speaks for

itself. Since the 1960ies, the com-pany supplied spinning plants for the production of staple fibers and early engaged in nonwovens equip-ment manufacturing, one example being the AquaJet, the leading solu-tion for hydroentangling.

ERKO productsToday’s solutions for bale opening, fiber blending and fiber opening originate from Erko, the successor of Hergeth. The expertise is based on many years of experience and also covers web formation with roller card or airlay, crosslapper, web drafter and web bonding.

Bastian technologySince April 2012 the name of Bastian stands for the most complete pro-gramme for winding web and film materials within the TRÜTZSCHLER NONWOVENS brand. Since the 70ies, Bastian has been a leading

7Nonwovens

Fleissner Jumbo AquaJet

Production plant at customer (Erko high-performance roller card in the background)

manufacturer in the field of auto-matic winders, unwinders and slitting/rewinders for all kinds of nonwovens, films and composite materials.

Trützschler SwitzerlandThe latest addition to the TRÜTZSCHLER MAN-MADE-FIBERS brand are the products now offered by Trützschler Switzerland. After taking over the expertise of a Swiss landmark in PA, PP and PES fila-ment spinning technologies, the company now supplies turnkey solutions and components to the versatile and dynamic carpet and industrial yarn market.

Trützschler SpinningSince its founding in 1888, Trützschler has been building machines for spin-ning preparation, thus bringing out the best in fibers. In the spinning sector, Trützschler is the technology market leader for openers, mixers, high production cards and draw frames. Whether cotton or Man-Made Fibers – Trützschler stands for innovation, quality and efficiency. In addition to the headquarters in Mönchengladbach, Germany, production facilities are located in China, India, Brazil and USA.

Due to the extensive experience gathered in processing of staple fibers in the spinning sector, Trützschler Mönchengladbach not only is at home in the field of yarn production but for decades in nonwovens as well, from fiber preparation to width-controlled roller card feeding.

Trützschler Card Clothing (TCC) TCC, which emerged from the former JDH companies, has long been known for its high production clothing for roller cards and cards for spinning as well as nonwovens, and has a worldwide presence. Trützschler Nonwovens is the only company in the industry that has its own clothing manufacturer (TCC), which is a clear advantage: Cloth-ings that are perfectly matched to all machine types, ensuring first-class results.

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True partnership TRANSCENDS BOUNDARIES

Worldwide present in the global textile markets our profound com-petence in consulting and support is linked to our knowledge of localcharacteristics and international wealth of experience. To ensure fast and competent service, sub-sidiaries, service and spare parts centres are available around the world.

Our continued business success is based on a clear focus on the mar-ket, the end-products and the cus-tomers – across the entire globe.

Excellent Service includes profes-sional maintenance, first-class cloth-ing service, smooth spare parts supply and quick on-site service.

Our worldwide team of competent and experienced techniciansmakes this level of performance standard for our customers.

Servicepoints round the world enable us to match your require-ments from any place in world at the earliest.

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MaintenanceOn-site quality control

Process optimisation

Process variety is one of the strengths of TRÜTZSCHLER NONWOVENS: Whether fiber opening/blending, web forming, bonding, finishing or winding – we can offer you several and not just one technical solution for all production areas. Among them at least one that precisely meets your requirements.

Products, AS VERSATILE AS YOUR REQUIREMENTS

The wide range of machinery dem-onstrates our solution expertise in this sector.

Based on years of experience and extensive industry-specific expertise, our technical advisors will provide you with detailed information on what is technically feasible and eco-nomically convincing, without being

restricted by an inflexible product range. The focus is entirely on your wishes and requirements.

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WebFeeding

Carding

Aerodynamic Webforming

CrosslappingWebdrafting

MechanicalNeedling

Hydro-entangling

Thermo-bonding

Impregnating

Calibrating

Smoothening

Heatsetting

Drying

ChemicalBonding

Opening/Blending

Winding/Slitting

Partner

Bonding Finishing

Inline

Offline

Packaging

Automatic

Semi automatic

Web forming

Trützschler Nonwovens

Fiber production

Meltblown, Spunbond

Wetlaid

Fiber openingBlending

Production of staple fiber

Unwinding

As machine manufacturer, Trützschler focuses on customer requirements. At the same time we do not loose sight of other matters. For instance the responsibility for our environ-ment and the future.

Thus, Trützschler participates in the sustainability initiative ”Blue Competence“ of the German mechanical engineering industry. In doing so, we are committed to sustainable action in different areas. During the development of

Sustainable action,ECONOMIC PROFITABILITY

our technologies and manufacturing of our products we make sure that they are environmentally friendly, energy efficient and resource-saving, improve the quality of life and meet the requirements of the market.

Against this background, ”Blue Competence“ stands also for our leadership in innovation and technology based on verifiable criteria. These include, for in-stance, increased plant productiv-ity or reduced energy consump-

tion – advantages that benefit the environment while at the same time allowing a faster RETURN ON INVESTMENT.

Using the example of a spunlace system, discover concrete benefits that convince by an increase in ef-ficiency and reduction of operating costs.

12 Nonwovens

www.machines-for-textiles.com/blue-competence

+ 68 t/a

1. More production hours for more profit

The innovative suction concept and the special card wire from TCC result in reduced maintenance effort.Standard cards require 172 mainte-nance hours / a (4h each 160 produc-tion hours) at 7,200 total production hours / a. The Erko card requires only 104 maintenance hours / a (4h each 270 production hours).Productivity gain = 68 t/a*

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– 258,600 €/a

* Example: 3,6 m wide AquaJet, Speed 120 m/min, material: wet wipes, 45 g/m2, 1 t/h, 7.200 manufactoring hours p/a, cost for electrical energy 0,20 E/kWh, cost for gas energy 0,05 E/kW.h

3. Effective perforation with new drum shells

The new Fleissner drum shell TEP (patented) allows a perfect per-foration with less pressure than a standard wire mesh shell.Energy Cost Savings = 84,000 €/a*

4. Effective drying saves costs

A new exhaust air flow and an ad-ditional heat recovery system allows an homogeneous drying after the Spunlacing with less heating energy.Energy Cost Savings = 102,600 €/a*

2. Spunlacing for wipes is double optimized

The new Fleissner jet head design reduces the pressure for entangling while keeping the product properties.With optimized jet strips (36 HPI) we can achieve the same product charactaristics compared to stand-ard jet strips with 40 HPI.Energy Cost Savings = 72,000 €/a*

Drum Shell TEP (patented)

New exhaust + heat exchangeEnergy saving: 30%

Omega DryerJet Strip

Before investing in systems en-gineering, a number of questions must be answered. For example, whether a system works as perfect in practice as in theory. Or whether you will be able to achieve the desired result with the existing raw material under the existing production conditions. The two TRÜTZSCHLER NONWOVENS Technical Centres give a clear an-swer to these and other questions.

First be sure, THEN INVEST

On a total area of more than 5,000 m2 you have the opportunity to test all production methods on a large industrial scale – of course also with your own materials. Next, detailed material analyses are possi-ble in our well equipped laboratories at both locations. They provide you with accurate information on the ad-vantages offered by TRÜTZSCHLER NONWOVENS production methods.

14 Nonwovens

Our Technical Centre in Dülmen, Germany (top) and our Technical Centre in Egelsbach, Germany (bottom)

15Nonwovens

Material analysis in the laboratory

16 Nonwovens Opening / Blending Web Forming Web Bonding Finishing

Belt WeigherThe highest level of precision is required for continuous weighing and blending of fibers after bale opening. With its unique high accuracy of measurement, our belt weigher ensures that the addition of fibers is restricted to the neces-sary minimum. This results in significantly lower costs, which translates into an economic ad-vantage especially in case of expensive fibers. For lower production efficiencies, discontinuous weigh pans are available.

A measuring tolerance of +/- 1 % makes the Erko belt weigher the most accurate one on the market. This allows significant savings in material.

Highest degree of homogeneity

Mixing ChamberOur modern tuft blending installations optimally mix fibers of different types, lengths, finenesses and colours. In addition, our mixing systems are individual, easy to operate, reliable and depend-able. This is of particular importance when a large amount of different fibers requires ab-solutely homogeneous processing.

Erko high performance mixing system

Mixing system with continuous Erko belt weighers

Precision pays off

Installation output: < 6,000 kg/h

Accuracy of weighing: +/- 1 %

Mixing components: 2 – 6

Mixing components: 2 – 20

Output per mixer: < 2,000 kg/h

The optimal use of the Erko mixing chamber reduces downtimes during lot change

Component-independent mixing system

17NonwovensSlitting / Winding Other Products

Erko fine opener Erko chute feeder

Supreme quality

Continuous feeding

Fine OpenerThe fine opener lives up to its name and opens fibers in such a fine and gentle manner that for certain products direct bonding is possible with-out any intermediate roller cards. In other cases the fine opener allows the use of roller cards with less carding points. This lowers investment costs and increases productivity.

Chute feederThe Erko chute feeder serves as material buffer between blending line and card feeding. It features feed rolls and a pinned opening roller that ensures uniform card feeding with small tufts. The speed of the feed rolls is continuously adjusted (CONTIFEED) via a pressure monitor-ing system that monitors the filling level in the downstream card feeder. This guarantees a con-sistently high web quality in the finished product.

Working width: < 2,500 mm

Output: < 2,000 kg/h


Output: < 2,000 kg/h

The Erko fine opener allows a reduction of carding points in roller cards or reduction of roller cards, resulting in lower investment and operating costs and higher productivity CONTIFEED ControlCONTIFEED

Stock Trunk Tuft Feeder


The direct way to outstanding quality

Tuft feedingAt this point, the basis for future product quality is irrevocably established. For this reason we have developed – and are successfully imple-menting – two high-performance alternatives to the state-of-the-art technology. They are based on the principle of pressure feeding, which has such a high degree of accuracy that with some products even downstream roller cards can be eliminated. The web is passed directly into the web bonding machines, resulting in outstanding quality at low investment costs.

EDSWLWhether very coarse or extremely long fibers – the EDSWL ensures homogeneous fiber feed-ing, which can be permanently monitored and adjusted by a downstream belt weigher.

SCANFEEDThanks to the homogeneous fiber feeding, the web quality at this point is already very good. In lines for lightweight products without crosslap-per, the additional web profile regulation (VPR) provides further improvement.

Erko SCANFEEDErko EDSWL with belt weigher

Web weight: 300 – 1,500 g/m2

Output: < 500 kg/hm

Web weight: 300 – 1,500 g/m2

Output: < 500 kg/hm

Needling machine

Hydro-entanglement (Spunlace)

Thermobonding oven

Tuft feeder SCANFEED TF

The downstream Erko belt weigher ensures reproducible quality standards

Our profile regulation system allows an even better web accuracy in cross direction on Erko SCANFEED.


Maximum flexibility during web forming

AirlayAirlay ensures maximum flexibility during web forming. The webs are formed by suction on a perforated roll, covering a large weight range. The low exhaust air output demonstrates the particular energy efficiency of Airlay – the air use is according to the actual requirement. Typical for Airlay is also the easy processing of waste fibers.

Production of various web weights with reclaimed fibers as well as standard fibers at low energy costs with Erko Airlay

Erko Airlay line for high loft products

Fiber: 1.7 – 100 dtex

Fiber length: < 60 mm

Web weight: 100 – 5,000 g/m2

Web height: < 200 mm

Output: < 500 kg/hm


Producing high web weights at low energy input is no problem with Erko Airlay.


Individuality as basis for success

Roller cardAt TRÜTZSCHLER NONWOVENS, individuality means that you can combine six different basic machine types with three different doffing sys-tems (parallel fleece, random roller, condensed roller). Plus there are various special machines. They adapt perfectly to your production situa-tion, regardless of what you intend to produce. At the same time, our roller cards have impor-tant things in common. This includes extremely clean take-off system, specially adjusted TCC clothings and excellent maintainability due to optimal accessibility.

Modular roller card concept

Erko high-performance Roller card

Fibers: 0.7 – 100 dtex

Fiber length: 20 – 150 mm

Output: < 450 kg/hm


High-performance doffers for special applications

A time and cost advantage not to be underestimated: Within shortest time, all maintenance points of the roller card are perfectly accessibleSee pages 12 / 13


Our specialist for web entangling technology

Random cardOur special roller card for random web tech-nology is particularly well suited for subsequent hydroentanglement. It allows a high random layer, while at the same time offering large variability in web weight. The fact that it only requires two different roll diameters – which in turn greatly reduces clothing change – is a clear advantage. All in all an unequalled perfor-mance package.

High random layer due to optimal arrangement of rolls

Erko Random card, e.g. for hygiene products



Web weight: 25 – 140 g/m2

Output: < 400 kg/hm


Suction rolls allow low-distortion transport of lightweight webs at high speeds

High degree of evenness due to special web doffing

Cleaning brushes for the delivery belts extend maintenance intervals and thus increase machine availability


Triple performance

Airlay roller cardOur Airlay roller card, whose card section ensures an optimal opening, forms a homo-geneous random web in the adjacent Airlay head. It only takes three different roll diameters to achieve high performance and first-class precision. At the same time it is very compact, requires only a few clothings, is easy to clean and allows a large weight range.

Aerodynamic web formation

Erko Airlay roller card: Especially for increased weights of hygiene products

Web transport, gentle to the material



Web weight: 30 – 400 g/m2

Output: < 350 kg/hm


The Erko Airlay roller card delivers first-class results at minimum space requirement with just three roll diameters.

Precision layers

Web layer edges positioned precisely on top of each other result in reduced edge trims and thus optimal material utilisation

CrosslapperWithin a nonwovens line the crosslapper’s task is to lay several layers of carded web accurately at high speed to the required width and to gener-ate the desired surface weight. Depending on the purpose Trützschler Nonwovens offers dif-ferent models – especially the new crosslapper EKL 439.

Subsequent processes, such as mechanical needling, lead to increased density and weight in the edge region of the web. To counteract this effect and to guarantee a uniform weight distri-bution, control systems are used. The control of the surface weight distribution is referred to as profiling.

The new crosslapper EKL 439 features the CROSS MASTER control system to provide a


Quick drafting

Drafting zones: 4 – 8


Erko web drafter

By changing the fiber orientation, the Erko web drafter achieves an ideal MD/CD ratio.

Erko roller card installation with high performance crosslapper

Web drafterWith up to eight drafting zones, our web drafter impresses during material drafting – fiber-oriented in machine direction – with up to 30% increase in line speed when processing light-weight products.

Capacity: over 160 m/min.

Folding width: < 8,000 mm

Number of layers: 4 –76 layers

New belt path reduces oscillating masses

uniform weight distribution via targeted drawing and compressing.

The innovative web guidance in the upper and the lay- down carriage guarantees a safe transport of the web and prevents floating draft zones.

Another special feature of the EKL439 model is its low energy consumption: A systematic reduc-tion of the moving machine masses in conjunc-tion with rolls made of carbon fiber reinforced plastics (CFRP) lead to reduced acceleration and braking loads. The result is an increased energy efficiency that is even further improved by AC servo motors with energy recovery.


Modular efficiency

Hydroentanglement: AquaJetOur AquaJet hydroentangling is available as modular system, ranging from "Mini" to "Jumbo". The number and position of water beams are freely selectable to meet your individual product or material requirements. Thus, the AquaJet ensures super quick and efficient web bonding and also offers the additional function of structur-ing and/or perforation. Other convincing features are its maintenance und user friendliness Hence, it is no surprise that our customers applaud it for being a system with highest product availability.

Cover for spunlace drumsMPS (Microporous-Shells) – Spiral type (patented):• Highest strength• Best surface bonding• Uniform web surface

Cover for spunlace drums – type TESNickel coated wires on spunlace drums (patented):• Less open area as standard mesh• Better water jet reflection• Softer surface than nickel sleeve• Less fiber picking on drum surface• Easy release of web from drum surface

As additional function, structuring and/or perforation are available.

The new nozzle beam design allows perfect results with less pressure.Energy savings: see pages 12/13

Thanks to freely selectable arrangement and high

precision, the water beams ensure a perfect end

product.

Working width: 500 – 5,000 mm

Speed: < 500 m/min. (spun fleece up to 1,000 m/min.)

100 mesh Nickel coated

Spiral Type


Perfection in just one step

Low operating costs and bonding/structuring all in one step – the Fleissner SteamJet makes it possible

Working width: 1,000 – 3,600 mm

Speed: < 150 m/min.

Fleissner AquaJet

Fleissner MiniJet

Steam jet bonding: SteamJetFor water-sensitive fibers as used in the production of hygiene products and wipes, our SteamJet combines the advantages of the AquaJet with those of a "dry process". Steam generation requires only very small amounts of water, thus eliminating the need for expensive water treatment. For bonding and/or structuring of fibers, the SteamJet requires only one single step, not several. This results in high perform-ance and speed.

Fleissner LeanJet


Structured flushable wipes Wipes dispersed in water

An integrated solution with tailor-made components

HydroFormer AquaJet

High-performance wet laying and spunlacing

Wipes – a cosmos of possibilitiesWipes produced in wet-in-wet processes are extremely versatile. Short fibers up to 12 mm length give them a unique and exclusive charac-teristic and make them the ideal basic material for so called “flushable” wipes, i. e. cloths for

hygiene and cleaning purposes, which can be flushed down the toilet after use.Moreover, wet laid nonwovens stand out due to their high homogeneity. Intensive hydro-entang ling turns them into excellent industrial wipes, filter media and coating substrates.

Wet-in-wet processes To offer solutions for wet laid webs, Trützschler Nonwovens teams up with Voith Paper, the leading partner to and pioneer in the paper industry. Wet laying is a web forming process which resembles paper making: A fiber-water suspension is filtered onto a perforated belt to form a uniform web. Hydroentangling – with the Fleissner AquaJet in this case – results in bonded and even structured nonwoven end products.


Drying Winding

The headbox of the HydroFormer

Web weights 20 – 100 gsm

Materials pulp, viscose, PET, …with optional multilayer capability

Working width: 3.6 m

Production speed up to 400 m/min

A one-stop shop offerThe high performance line concept is adapt-able to most diverse fiber blends and product requirements. The range spreads from single layer cellulosic webs made from renewable and biodegradable primary resources to composites containing different layers.

The line includes machines and systems for• wet-laying • hydroentangling • drying• winding• water treatment and fiber recovery

Voith Paper – the expert in wet layingFounded in 1867, Voith employs almost 42,000 people, and is today one of the biggest family-owned companies in Europe. The group division Voith Paper is the leading partner to and pioneer in the paper industry. Through constant inno-vations, Voith Paper is optimizing the paper manufacturing process, focusing on developing resource-saving products to reduce the use of energy, water, and fibers. With its HydroFormer, Voith Paper contributes the core component to the cooperation. It has been specifically optimized for the formation of wet-laid nonwovens and, with more than 70 successful installations, gained worldwide ac-ceptance.

Due to its expertise, Voith offers support regard-ing stock and water systems, headboxes, press concepts, fabrics and calendars.


Versatile advanced technology

NeedlingOur needling machines impress with their tech-nology and versatility. Thus, you can select the ideal solution for needling in all directions from five machine types The patented swivel bearings are a technical highlight: In contrast to conven-tional bearings, they are absolutely free of wear and maintenance. This results in lower operating costs and higher productivity. A reliability that has set new standards even during 24/7 operations and an open and therefore easy to access design are additional advantages.

For processing special materials, a suction system is available which – in combination with a compressed-air pulse – keeps the critical areas of the machine clean. The simple and reliable air cooling of the conrod main bearings is equipped with special filters that ensure adequate cool-ing even in case of long maintenance intervals and prevent contamination of the drive system. A central minimum quantity lubrication supplies all main bearings of the double-shaft system in selectable intervals with a specified amount of lubricant, thus preventing contamination of the machine in the drive area.

Patented, wear-free swivel bearings reduce maintenance and thus operating costs.

Quick replacement of needle boards


ENL-D2


Strokes: < 1,600 /min.

Erko needling machine

ENL-U2 ENL-DU1 ENL-D1 ENL-U1

Recycling

Edge openerThe EROE can be applied inline as well as offline and is used for opening web waste. This waste can be returned into the ongoing proc-ess, thus significantly increasing the system's efficiency. The edge opener has a compact design, featuring a feed system and high-speed tearing rollers equipped with needles or cloth-ing. The edge opener is generally available with two different feed systems. With roller feeding (WEZ) it is suitable for recycling of thermally bonded webs and needle felts up to 2000 g/m².The version with tray feeding (MEZ) is used with hydroentangled and chemically bonded webs up to 1000g/m². Optionally, a spraying device is available.

Erko edge opener

Working width: < 500 mm

Production speed < 120 m/min


Oven technologies for highest demands

Through-air flow and jetting

Fleissner belt oven

The optimised insulation offers high energy efficiency and economic operation

Since energy efficiency is an important aspect in oven technologies, we have "frozen" the heat loss of our belt and drum ovens at lowest level by means of a perfectly calculated insulation.

Thermal bonding via belt ovenFor the production of voluminous high loft prod-ucts, our belt oven offers the best solution. A high level of temperature accuracy and optimal flow over the entire width produce a very uni-form bonding.

Thermal bonding via drum ovenThe through-air principle creates a suction draft on the drum surface which safely keeps the web on the drums; at the same time air flows through the web. High speeds are achieved when processing lightweight to medium weight products; 1 to 10 drums are possible in series.

Web weight: < 10,000 g/m2

Working width: < 7,000 mmWeb weight: < 10 – 200 g/m2


Best results thanks to a drum design that is gentle on the material, high precision and optimised surfaces

High-performance thermal bond card installation

Belt oven Drum


Perfect chemical bonding

Chemical bondingWith our method for high-speed chemical bonding, e.g. of hygiene products, the required chemicals are applied with high accuracy. This produces top results and at the same time saves bonding agents. By adding our AquaJet upstream, the processing speed is increased by 100%.

Fleissner foam application

Reducing chemicals, but not quality – this is the "secret" of our high-speed chemical bonding.

Foulard liquid: One-sided

Output: < 120 m/min


Foam application: On one or both sides

Output: < 100 m/min; with AquaJet up to 200 m/min


One-sided or double-sided foam application with 1 or 2 mixers


Foam application: On one or both sides

Output: < 100 m/min


Perfect impregnation

ImpregnatingFor our impregnating methods we prefer foam foulards, which reduce the use of chemicals and at the same time the drying requirement. Even heavy webs can be completely saturated with minimum application of foam and energy. This is another contribution to increased efficiency through energy reduction.

Smoothening/calibratingDuring smoothening and thermal stabilisation of webs, our systems engineering creates an ab-solutely uniform line pressure, while the heated and/or cooled systems ensure high temperature uniformity. Best conditions for technically so-phisticated web material at constant high quality.

HeatsettingThe advantage of our heatsetting concept be-comes quickly apparent when comparing it to a conventional two-roll calendar Needle rings hold the web in place along the width. This prevents the material from shrinking within the defined setting zone. At the same time the through-air principle ensures uniform web setting.

Fleissner calender for carrier web for roofing membrane

Optimal smoothening and secure fastening

Line pressure: 50 – 600 N/cm

Output: < 100 m/min


Fleissner impregnation station

The high-quality impregnation improves the functionality of the webs at minimum use of chemicals

Uniform line pressure, in connection with exactly the same gap width, ensures optimal results

Flexible treatment via different operation modes

Drum diameter: 3,000 mm



Quick drying

A belt dryer with several cooling and heating zones

Belt dryerThe belt dryer presents an alternative for drying thick webs or staple fiber tows. This drying method uses a conveyor belt instead of a drum. Drying is performed by air jetting in case of materials fully or mostly impermeable to air or through-air flow for air-permeable webs.

Output: < 150 m/min.


In 1929 the perforated drum was patented. This invention by Hans Fleissner opened up the area of through-air technology. Today Trützschler Nonwovens is a leading supplier in this field and looks back to a history of more than 6,500 dryer delivered.

Drum dryerAll drum dryers offer a high specific drying performance, compact design and high uni-formity of drying. Its large working width and high drying speed are also impressive. For high efficiency drying tasks multi drum designs are available in which the web surface is reversed from one drum to the next.

Output: < 1,500 m/min.

Working width: < 7,000 mm Fleissner high-speed drying

Fresh air

Standard

Energy consumption: 100%

Exhaust

3 steps to improve

Controlled high moisture level

Energy consumption: 90 - 95%

New exhaust design

Energy consumption: 80 - 85%

New exhaust + heat exchange

Energy consumption: 70%

See pages 12 / 13.

Streamliner – an energy-efficient drum dryerThe new dryer generation achieves specific evaporation capacities – and productivities – go-ing far beyond the commonly achieved values. The spiral-shaped machine features • an optimized airflow with low pressure loss• an optional fresh air supply using the tem-

perature dependent density change• an optimised heating systemEnergy efficiency is increased by external air treatment and possibilities of heat recovery.

Output: < 1,500 m/min.

Working width: < 6,000 mmThe Streamliner – a design for extremely uniform air flow and temperature

The various manufacturing and finishing processes of nonwovens require different standards of winding technology.

Therefore TRÜTZSCHLER NONWOVENS pro-vides a wide variety of Inline and Offline machin-ery solutions based on Bastian know-how.

Turret Disc Winder Bastian BWT 202-02

Turret Shield Winder Bastian BWT 201-05

Turret Disc Winder Bastian BWT 202-02

Inline Winding and SlittingAn Inline system allows producing “ready for sale” rolls in an integrated step directly after the manufacturing or finishing process of the nonwovens. Winding and slitting are executed simultaneously by automatic win ders with integrated longitudinal slitting systems.

With the Inline system no further rewinding steps are needed and additional material stress is avoided. In addition, the investment cost as well as the required space and labour cost are lower than for an Offline system.


Maximum flexibility for your winding task

Material Width: < 3,000 mm

Winding Diameter: < 1,500 mm

Production Speed: < 450 m/min




Support Roller Winder Bastian BWT 206-01

Through-air bonded nonwovens

Longitudinal slitting system

Bastian BWT 206-01

Tapered WindingThe nonwoven winders of TRÜTZSCHLER NONWOVENS provide a combination of circum-ferential and axial drive to achieve the best pos-sible roll hardness. Simultaneously, the tension can be set very accurately for processing sensi-tive products such as cotton pads or through-air bonded nonwovens.


Horizontal Slide Winder Bastian BWT 203-10







For the production of so-called master rolls the automatic Horizontal-Slide-Winder Bastian BWT 203-20 is used. This finished master roll is transferred automatically from the winder to a dwell and stock position. From there the master roll is lead into the unwinding section of the Slit-ter Rewinder Bastian BWT 306-04. If requested, the Winder Bastian BWT 203-20 also produces “ready for sale” rolls.

Master Roll WinderSpecific features of the Master Roll Winder Bastian BWT 203-20 are the integrated cross cutting and engaging system and the combined circumferential and axial drive.

This engaging system ensures a faultless start of the web from the first layer on the steel core, minimizing loss of material.

The combined circumferential and axial drive en-sures optimum hardness of the big rolls without stressing the material especially on the core.

Winding process Bastian BWT 203-20Horizontal Slide Winder for Master Rolls Bastian BWT 203-20


Offline: A combination for high capacity




Slitter Rewinder Master rolls up to a max. diameter of 3,200 mm are transferred to the automatic Slitter Rewinder Bastian BWT 306-04 for conversion.

The Slitter Rewinder Bastian BWT 306-04 allows the production of ready-for-sale rolls. Equipped with a combined circumferential and axial drive optimum winding hardness of the finished roll is achieved without applying stress to the material.

Slitter Rewinder Bastian BWT 306-04 Slitter Rewinder Bastian BWT 306-04

The slitter rewinder provides easy access to the length cutting unit in order to adjust the knives without any difficulties. An automatic knife adjustment system is optionally available.



Rewinding Diameter: < 1,500 mm

Rewinding Speed: < 1,800 m/min

Automatic Unwinders The productivity of a plant can be increased by adapting a variety of process technologies, bringing together different systems to achieve cost savings. With regard to manufacturing processes such as coating, laminating, emboss-ing and printing the following examples provide these opportunities.

For feeding the backing material (e.g. nonwo-vens, films, papers, textiles) to the finishing process the automatic Unwinder Bastian BWT 208-01 or 208-02 can be integrated into the pro-cess. The automatic Unwinder is characterized by a continuous feeding of material during pro-duction without reducing the production speed during the reel change. Accumulators which could affect the material are not necessary. The splice is being realized by the so called splicing-in method which bonds the unwound web with the new web at production-speed (flying-splice).

At speeds of about 500 m/min overlaps of approx. 200 mm are reachable. This of course minimizes the the waste material. The classic design of such unwinders is the Turret Unwind-er. The parent roll take up can be realized with or without winding shafts.

Additionally TRÜTZSCHLER NONWOVENS offers automatic Turret Unwinder Bastian BWT 208-10. This kind of Unwinder takes up the parent roll by pneumatic-chucking-heads which are integrated into width adjustable portal-arm-supports. Due to such portal arms different material-widths are possible. The drives are placed directly in the arms. The portal arms are adjusted by ball-screw spindles and servodrives. The edge of the material is aligned according to the new edge of the parent roll before splicing. The new unwinding position after splicing is edge-controlled by the ballscrew spindles. Auto-matic unwinding can be effected in both direc-tions. The design allows taking up parent rolls of up to 3.200 mm in diameter and 5,500 mm in width.

Automatic Unwinder Bastian BWT 208-10

Portal armsAutomatic Unwinder Bastian BWT 208-10

Automatic Turret Disc Unwinder Bastian BWT 208-02


Continuously feeding at full line speed


Unwinding Diameter: < 3,200 mm

Unwinding Speed: < 500 m/min

Slitter Rewinders Slitter Rewinders are utilized for the converting of separately produced master rolls into “ready-for-sale” rolls by rewinding and slitting.

In this classic field of converters TRÜTZSCHLER NONWOVENS offers customized Slitter Rewind-ers for all processes within production, finishing and converting of web materials. The BWT 306-series of semi- and automatic Offline slit-ter rewinders offer the typical TRÜTZSCHLER NONWOVENS combination of circumferential and axial drive with all its benefits.

Combination of drivesWinders with a combined circumferential and axial drive permit to wind rolls of optimized hardness. More metres are wound on the same roll diameter, lowering transportation and ship-ping costs and at the same time putting less stress to the material.

Slitter Rewinder Bastian BWT 306-04






Bringing more material on your diameter

Material Width < 5,500 mm

Unwinding Diameter < 3,200 mm

Rewinding Diameter < 1,500 mm

Rewinding Speed < 1,800 m/min

Short Roll Winders When it comes to the production of short rolls, flexibility and productivity play a major role. With its various Inline and Offline solutions, TRÜTZSCHLER NONWOVENS gives an answer to the following requirements:

• short cycle times around 20 seconds (e.g. 3 short rolls per minute)

• winding with or without cores • production of multiple webs at the same time • winding with a high grade of automation

The following winder types represent the large programme of automatic short roll winders for the fields of plastic film, paper, nonwoven, lami-nates and composites.

Short Roll Winder Bastian BWT 202-05

Automatic Short Roll Winder Bastian BWT 202-13

Short Roll Winder Bastian BWT 202-11

Coreless wound short roll

Coreless windingA great advantage of TRÜTZSCHLER NON WOVENS' short roll winders is the possibil-ity to wind either with or without paper cores on the same machine.


Increasing efficiency by winding short rolls

At the end of the production line the rolls need to be prepared for shipment or storage. For this final process step TRÜTZSCHLER NONWOVENS is able to provide roll handling and packaging solutions of different levels of automations.

Basic semi-automatic designs are applied if line speeds are modest and / or if the single roll throughput is so low that it can easily be handled by the operator. For such cases lifting devices that support the operator in transferring the rolls to the packaging unit can be employed. Pallet wrappers which wrap a manually stacked bundle of rolls with stretch film on a pallet represent a simple way to prepare the material for shipment.

Automatic solutions feature highest flexibility when it comes to the handling of different roll dimensions and high throughputs. Line layouts equipped with automated take-over units, with Inline labelling of rolls and batches, weighing, stacking palletising, and quality control systems etc. contribute to an increase in productivity and a reduction of labour costs.

Automatic roll handling and packaging system

Complete line supplied by TRÜTZSCHLER NONWOVENS


NONWOVENS:

Packaging


Man-Made Fibers in perfection

TRÜTZSCHLER MAN-MADE FIBERS is known as a competent manufacturer of machinery and systems for the chemical fiber industry with the Fleissner machine brand.

Based on the vast experience of more than 350 supplied fiber lines, Fleissner fiber lines have always created new standard for improved operability and excellent fiber qualities at eco-nomical production costs.

TRÜTZSCHLER MAN-MADE FIBERS fiber lines produce a wide range of fibers, such as• Cotton-type fibers• Fibers for nonwovens• Carpet fibers• Filling fibers• Dope-dyed fibers• 2D/3D crimped fibers• Hollow fibers• Bicomponent fibers• Precursor• Carbon fibers


Polymer Production

Resins PET, PP, PE, PLA, PA6, Others

Postconsumer-PET-Bottles Flakes

Crystallation / Drying

PET Direct Spinning Feeding

Tow in Cans2-Stage Process

1-Stage Process

Can Creel

Dope Prepera-tion (Rayon, PAN, LYOCELL, VISCOSE...)

Wet (Solution) Spinning

Extrusion & Filtration

Spinning SystemFiber Tow Production

Trützschler Man-Made Fibers Partner

Drawing, Heat Setting, Crimping, Drying, Cutting, Baling

Fiber Line

Modular Melt Spinning System• Optimal designing for extrusion and

melt filtration• Bottom loading spin packs• Symmetrical melt distribution from centre

inlet port to ring• Unique spin pack sealing and fixation to beam• Quick spin pack exchange• Enclosed filament quenching system Solution Spinning System (PAN) Bicomponent Spinning System

Tow Draw-off Systems • Spinning walls with suction/cutting blocks

and entangling jets for reduced down times and little waste

• Capstan units for fiber tow draw-off• Sunflower reel plaiters• Can traversing systems and cutting devices

ensuring minimized waste• Spin finish systems

Fiber Processing Lines • Improved dip bath with gentle fiber treatment• Efficient draw bath• Drawstands of sturdy construction with and

without heating or cooling of rollers; up to 2 m roller length

• New Draw Unit with direct driven rollers (SDD)• Thermosetting units with steam supply by

steam cascade for minimization of energy costs

• Drawstands and thermosetting units with high-accuracy double-jacket rollers providing optimum temperature uniformity for heating or cooling

• Cable tension control by wear-free load cell technology

• Stuffer box crimpers providing a highly uniform crimp without readjustment

• Optimum tow distribution on the plate belt dryers by oscillating chute or belt conveyor

• Reliable and maintenance-free plate belt and drum dryers with uniform hot air distribution and up to 3 m working width

• Fiber cutting machines operating to the proven rotary cutting principle, with optional rapid reel change system


Filaments: Spinning equipment for carpet yarns and industrial yarns

Trützschler Switzerland is a specialist for ma-chines for filament extrusion of thermoplastic polymers such as polyamide, polypropylene and polyester. The company based in Winter-thur, Switzerland provides custom concepts for manufacturing carpet yarns as well as high-strength or low-shrinkage filaments for indus-trial applications.

Sophisticated and sound technologiesIn-house developments in the areas of extrud-ers, spinning packs, spinning beams, quench-ing, drawing panels and winders combine economic operation with top yarn quality. The

The heart of a BCF spinning factory: HPTex texturing nozzle and cooling drum

A highly productive symTTex line for BCF


Polymer production

Resins PP, PET, PA6, PA66, others


Spinning and Quenching

Drawing

Texturing

Winding

Drawing

Trützschler Man-Made Fibers

Partner

Winding

Filament processesDSR draw rolls in production

systems stand out through maximum sym-metry; each spinning position is geometrically equal, enabling a uniform distribution of melt, equal treatment of each thread and thus homo-geneous filament properties.

Efficient manufacturing of demanding yarnssymTTex and symTTec are two equally proven concepts for BCF and industrial yarn spinning mills. In a broad range of configurations and several hundred facilities installed worldwide, they offer flexibility, optimum yarn quality and low production costs to manufacturers around the world.

An important point: modernisation and maintenanceThe experts from Winterthur offer a variety of modernisation packages and services so your investments will remain profitable for years. Besides plasma-coating godets, upgrade kits for

winders, electrical equipment or BCF texturing are most widely used to maintain or improve the performance of existing facilities.


Solutions for precursor and carbon fiber

Our recent developments of improved PAN precursor lines are creating new standards.

PartnersTogether with institutes, customers, suppliers and partners from the industry, we are continu-ously working on new technologies, thus adding to the know-how of our products, processes and systems.

PrecursorOnly precise tow-guiding, defined draw-ratios and an accurate speed control ensure the required high tow uniformity in the production of precursors. This is the prerequisite for con-stantly producing high product qualities at highly economical production costs.

Therefore TRÜTZSCHLER MAN-MADE FIBERS offers a system using all the experience and state of the art technology.

The systems consist of all required process steps, including the Fleissner spinning system, the de-solventing, low friction drives and draw stands, the dryer and heatsetting system and finally our intelligent process control. Our visu-alization always allows quick and easy access to all relevant machine and process parameters.Systems are available with up to 96 tows allow-ing capacities of up to 5,000 t/a (depending on tow size).

Precursor lines S• Wet- and air-gap spinning• Coagulation• De-Solventing• Drawing• Drying / Heatsetting• Winding

Simplified sketch of a precursor line

Spinneret Draw stands


Postconsumer-PET-Bottles Flakes

Crystallation / Drying

Tow in Cans2-Stage Process

1-Stage ProcessFeeding

Can Creel

Dope Prepera-tion (Rayon, PAN, LYOCELL, VISCOSE...)

Wet (Solution) Spinning


Drawing, Heat Setting, Crimping, Drying, Cutting, Baling

PAN Polymerisation

PAN

Solvent Recovery

Solvent

Dope Preparation

Dope Precursor Carbon Fiber

Spinning

Coagulation

Trützschler Man-Made Fibers Partner

De-Solventing

Drawing

Drying

Winding

Unwinding

Oxidation

Carbonization

Surface Treatment

Sizing/Drying

Winding

Simplified sketch of a carbonization line

Components for carbon fiber linesFor the subsequent carbonization process TRÜTZSCHLER MAN-MADE FIBERS offers a sophisticated fiber conveying system with tension stands and deflection rollers as well as surface treatment and sizing with corre-sponding can and contactless dryers.

Since fiber qualities and line efficiencies depend much on defined tensions at each point of the line, this conveying system plays a key role in the process beside the oxidation and carboni-zation technology.

As in the precursor lines the overall process control is completely visualized for quick and easy access to all relevant machine and process parameters.

Carbon fiber lines• Unwinding• Oxidation• Carbonization• Surface treatment• Sizing/Drying• Winding

The capacities range from pilot scale up to 2,000 t/a of heavy tows on industrial lines of up to 4 m width.

Surface treatment DryingGuiding


Film winders: The ideal winder design for the most demanding materials

With their Bastian product brand, TRÜTZSCHLER NONWOVENS continues the success story of winders, unwinders and rewinders from West - phalia. Founded in the 70s, the Bastian company quickly grew into one of the leading suppliers of automatic winders for plastic film, compos-ites and nonwoven fabric. By integrating into the group, TRÜTZSCHLER NONWOVENS'

customers can benefit from the broad range of machines and many years of experience in this area.

Films and composites: infinite varietyA life without plastic film is unthinkable nowa-days. Next to a variety of types – calendered sheets, cast film, stretch film, blown film and thermoformed film as well as coated films and composites – there are at least as many differ-ent materials.

TRÜTZSCHLER NONWOVENS addresses the innovative companies of this area with its com-prehensive range of machines for automatic in-line cutting and winding of films. Besides machines for standard tasks, high-end solutions for speeds of up to 600 m/min, multi-ply in-line cutting, up to 1,200 mm diameter rolls and product widths of up to 2,800 mm on 3“ bob-bins are also available.

Automatic Turret Disc Unwinder Bastian BWT 208-02

Winding programme

• Automatic turret disc winders; standard winders and custom models for two winding directions

• With overhung shafts

• With standstill feeding system

• Automatic unwinders

• Short roll winders

• Custom design for heavy films of up to 3,000 µm

• Custom design for minimum cycle times of 20 seconds

Winders can be equipped with accessories for in-line labelling, packaging, roll hand-ling, automatic bobbin feeding, weighing systems, etc. according to requirements.

Engaging system of a short roll winder


Short rolls ready for shipment

Bastian BWT 202-09

Film materials• PVC• PET • A-PET• PS• PP• LDPE• HDPE• PC• PMMA• TPO• EVA• PVB

And many more

Core features for top roll qualityThe feeding system and the cross-cutting system substantiate the good reputation of the Bastian name.

Feeding occurs without wrinkles onto a non-prepared bobbin, even when used repeatedly. Hence, there are no residual adhesives or strips on the inner material layers, so that the entire length can be used. Additionally, 3“ to 10“

diameter bobbins can be used without making mechanical changes to the machine.

If the material can be cut with a serrated blade, this is done at full production speed of up to 600 m/min. Otherwise, the material is cut dur-ing dwells by the flying blade and the counter blade. In this case, the machine is equipped with a reservoir to enable uninterrupted manu-facturing.

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N O N W O V E N SS P I N N I N G MAN-MADE F IBERS C A R D C L O T H I N G

Opening/Blending

Card feeding

Cards/Crosslapping

Wet laying lines

Web needling

Hydro entanglement

Chemical bonding

Thermobonding

Finishing

Drying

Heatsetting

Winding

Slitting

Fiber preparation

- Bale opening

- Blending

- Cleaning

- Opening

- Foreign matter

separation

- Dedusting

- Tuft blending

- Waste recycling

Cards

Draw frames

Combing machinery

Staple fiber lines

Filament lines

- BCF

- Industrial yarn

Precursor lines

Carbon fiber lines

Metallic wires

- Spinning

- Nonwovens/

Longstaple

- Open End

Flat tops

Fillets

Carding segments

Service machines

Service 24/7

Documents

Nonwovens - Mareintexmareintex.com.ar/.../truetzschler-man-made-fibers/Nonwovens.pdf · 2 Nonwovens Disclaimer: This brochure has been created by us to the best of our knowledge and