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Egelsbach, February 15, 2008
INDEX 2008, Geneva/Schwitzerland, 15 - 18 April 2008, Hall 2, Stand
2331
Fleissner Innovations for the Nonwovens Industrie
Fleissner is a system
supplier for complete nonwovens production lines with hydroentanglement,
binder bonding or thermofusion and additional finishing of nonwovens.
At the INDEX Fleissner as usual will present technologies for production
and bonding of nonwovens. At the same time, new products for the hygiene,
sanitary and medical sectors and for technical nonwovens, military garments
and other uses will be shown in a large innovation and inspiration center.
1)
Fleissner-AquaJet-Spunlace System for hydroentanglement of nonwovens
The AquaJet was
put on the market by Fleissner more than 10 years ago and has been used
for bonding of all kinds of nonwovens from low weights (20 g/m²) to
very high weights (500 g/m²) ever since. The main focus of these spunlaced
products is on nonwovens made of natural fibers, synthetic fibers and
spunbond webs.
More than 80 AquaJet lines, which naturally are combined with Fleissner
heavy-duty dryers, were delivered so far. The designs of AquaJets and
dryers have been continuously improved. The latest developments for
product innovations, improved product quality, minimum maintenance requirements
and energy saving will be presented at this fair.
- Fleissner
Jumbo AquaJet with maximum working widths of up to 5 m and typical
user-friendly design: Easy operation possible only from the operator
side, quick change of jet strips, disconnection of suction slots not
required, quick change of structuring drum shells, simple replacement
of spunlace drums and perforated belts.
- Fleissner
AquaJets for production speeds of up to 300 m/min for nonwovens
made from fibers. Especially important for high speeds is the design
of the spunlace drums for optimum dewatering and the layout of the
suction system for uniform dewatering underneath the jet heads (see
Fig.1).
Fig. 1: Fleissner-AquaJet-Spunlace
production line for technical applications
- Two-layer nonwovens
made of staple fibers and combined with tissue for surgical
gowns and cover sheets or absorbing technical wiping cloths are successfully
produced on AquaJet lines. The special design of the Tissue AquaJet
with newly developed jet heads for perfect water jets and self-cleaning
surface ensures crease-free bonding of tissue paper to staple fiber
web and results in dense top layers for optimum hydrophobic end products
and a homogeneous surface free from spots and stripes.
- Fleissner
AquaPulp production lines for two-layer and three-layer composites
with pulp and spunbond or pulp/spunbond/staple fiber web: These Fleissner
AquaJet lines for multi-layer CP and CPC nonwovens have
been operated successfully for years, including a special filtration
system for circulating water. Advanced versions of these systems were
delivered as production lines for combinations of spunbonds, pulp
and staple fibers (SPC). The special advantage here lies in
the use of spunbonds for increased web strength while at the same
time reducing web weight.
In addition, optimum bonding of three-layer webs results in an excellent
soft touch. The use of pulp as absorbing component instead of viscose
and the replacement of fibers by spunbonds with a lower areal weight
considerably reduces raw material costs. In view of the rising costs
for PET, PP and CV the use of pulp and spunbond is gaining in importance.
No other technological process offers our customers so many possibilities
to produce at lower costs and be more competitive.
- Fleissner
High-Speed AquaJet for production speeds of more than 600 m/min
for spunbonds which are directly spunlaced after the spinning process.
Apart from the use of spunlacing technology, the spunbonding/spunlacing
combination is used more and more often for upgrading of calendered
spunbonds and also for new technical nonwovens products.
The major advantages that are valued by customers in the spunbond-spunlace
process are significantly higher strengths than those of calendered
or mechanically needled webs, the possibility of providing calendered
webs with more textile properties, and producing much faster even
with heavier webs and thus in a more cost-effective manner than by
mechanical needling. Spunlaced spunbonds can be subsequently calendered
without losing their textile properties. The AquaJet allows spunbonds
to be bonded and at the same time structured and perforated. These
products meet with great interest in the hygiene industry.
- Fleissner
AquaJets for high pressures up to 400 bar have been used for years,
also for heavy-weight spunbonds. These multi-stage AquaJets are now
used for splittable spunbonds and composite fabrics made of nano-webs,
micro-fibers or staple fibers in combination with woven or knit goods.
These composites result in completely new products for synthetic leather,
sportswear, functional fabrics, nano-fiber webs and applications for
shoe industry, filter production, automotive interiors and furniture
industry.
- Hydrospace
AquaJet products
Nonwovens with tubular voids are produced in a continuous process
(patented by University of Leeds). The voids can be filled with liquids,
gels or solids during the spunlacing process. Typical applications
are nonwovens filled with liquid soap or lotion. Hydrospace products
with empty voids offer a strongly increased sound absorption capacity,
which is an important feature in the automotive industry.
- Fleissner
LeanJet
The Fleissner LeanJet was newly designed for reduced production capacities
at lower investment costs while maintaining a high web quality (see
Figure 2). Several of these lines are already operating successfully,
being characterized by the following features (see Fig. 2):
- Designed for one card before the LeanJet
- Max. speed of 120 m/min for 60 g/m² web
- Working widths: 1.2 m / 1.8 m / 2.6 m / 3.6 m
- PET, PP, CV, cotton and blends
- Plain, perforated and structured
Fig. 2
- Fleissner
AquaJet lines for natural fibers:
The AquaJet process for natural fibers has been optimized by numerous
trials conducted together with our customers. Bonding of flax and
hemp made it possible to produce nonwovens for the automotive and
home sectors with weights of up to 1500 g/m².
The AquaJet process has gained general acceptance in particular for
the use of cotton; this includes cotton pads for make-up removal
or cotton webs from 30-300g/m² with smooth, perforated or structured
surface for medical, hygienic, sanitary and cosmetic applications,
for wipes and wet wipes. Consumers more and more prefer 100 % natural
fibers without chemical binders and synthetic binder fibers.
2)
Fleissner SteamJet lines for the production of nonwovens
- The Fleissner
SteamJet was newly developed together with STFI Chemnitz. This
machine bonds nonwovens by means of steam jets which are generated
in steam heads with rows of holes similar to those in an AquaJet.
The steam is overheated to prevent condensation in the product. Drying
after the SteamJet is not required. Steam jet bonding offers the following
advantages:
a) Hydraulic and thermal bonding with simultaneous structuring or
perforating.
b) Bonding from one or two sides on belts or drums.
c) Sterile steam jets.
d) Suitable for processing all kinds of synthetic fibers, filaments,
blends with natural fibers.
e) Web weights from 15 g/m² to more than 100 g/m² for multi-layer
products.
f) This process is particularly suitable for the production of nonwovens
from fibers sensitive to water such as super-absorbent fibers and
PVA.
g) Possible combination with thermobonding ovens for preliminary bonding
and SteamJet for final bonding and structuring.
Many products
will also be presented at INDEX, such as 40 g/m² nonwovens with
a 15% share of super-absorbent fibers and 85% of PET-Co-PET and
a water absorbing capacity of 1800%. Or 20 g/m² nonwovens made of
PP, produced at a speed of 100 m/min. Or thermobonded nonwovens
additionally bonded and structured by a SteamJet (see Figure 3).
The Fleissner SteamJet will complement the spunlaced products range
by a new generation of completely novel web qualities with special
properties.
This has been
the first new technology in the nonwovens industry after quite a
long time which will strongly influence the market.
Fig. 3
3)
Fleissner bonding and finishing lines for nonwovens
- Processing lines
for thermobonding and chemcial bonding with drum dryers of Omega or
horizontal design.
- Foam impregnation
lines
- Heatsetting lines
with width control
- Complete turn-key
bonding lines for carding webs, spunbond webs and airlaid webs
- Needle felt bonding
lines for the production of floor coverings, filters, geotextiles,
roofing felts, car interiors and more.
Fleissner heavy-duty
dryers and thermobonding ovens
Fleissner has more than 70 years of experience in designing through-air
dryers. The Fleissner perforated drum dryer has long been known all
over the world, and more than 45,000 perforated drums were produced
so far. It shows the reliability of this dryer type that dryers more
than 40 years old are still in operation. Drying rates and production
speeds have constantly gone up during the past 10 years. The design
of the dryers with respect to fan capacity, heating capacity and working
width has therefore been continuously improved while maintaining their
operational reliability. In view of rising energy costs, energy efficiency
is also gaining more and more importance. Fleissner will present at
the INDEX its innovative energy saving concept for drum dryers which
reduces exhaust air temperatures to a minimum and saves a lot of energy.
4)
FLEISSNER as system supplier
Our competence as
system supplier in the nonwovens sector is based on the close cooperation
with ERKO-Trützschler from fiber opening to carding and Fleissner equipment
for bonding, drying and finishing. Together with the production lines
for man-made fibers built by Fleissner, this machinery program allows
our customers to discuss complete projects from polymer to finished
nonwoven roll.
(Author: Dr.-Ing.
Ullrich Münstermann, Head of Product Development)
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