Egelsbach, June 20, 2007

ITMA 2007 September 13-20, 2007 Munich / Germany Hall: A3, Stand: 107/302
Fleissner Machinery for the Nonwoven Industry

Fleissner is the system supplier per se for complete nonwovens production lines with bonding by hydroentanglement, binder bonding and thermofusion plus additional finishing of nonwovens. At the ITMA 2007 in Munich, Fleissner will present a selection of such machinery and equipment.

1) Fleissner AquaJet-Spunlace System for Spunlacing of Nonwovens

The AquaJet was put on the market by Fleissner more than 10 year 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 have been delivered so far, while the development of the AquaJet continues. The last 4 years' innovations will be presented at the ITMA.

Large-width Lines
Especially for spunlace lines with a width of more than 5 m and very high production speeds, a completely new JUMBO-AquaJet was designed. This line has been continuously operating for more than one year now (see Fig. 1).

Fig. 1

Fleissner LeanJet for Reduced Production Capacities

The Fleissner LeanJet was newly designed for reduced production capacities of high quality at lower investment costs (see Fig.2).

Fig. 2

Several of these lines are already operating successfully, being characterized by the following features:

• Designed for 1 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

Improved Product Properties
Fleissner offers perforating and structuring shells which allow webs to be provided with a wide range of designs during spunlacing, imparting individual aspect, softer touch and improved performance, such as absorption of moisture or retention of dirt for wipes.

An integrated expansion unit in the Fleissner AquaJet increases the CD strength of nonwovens.

AquaJet-Spunlace System for Uniform Surface Structuring
Nonwovens with a homogeneous streak-free surface can be produced using the patented oscillating jet head, which represents a special advantage for heavier nonwovens used as coating substrates.

Fleissner AquaJet Lines for Bonding and Softening of Spunbonds
The combination of spunbond production and spunlacing is predestined for very high production speeds. The technical design of the Fleissner AquaJet drums is especially favorable for optimum dewatering, which is of decisive importance for high production speeds and the resulting centrifugal forces of the water to be removed.

The Fleissner AquaJet line is suitable for softening usually calendered spunbonds at speeds of more than 600 m/min.

For several years, AquaJet lines have been used exclusively for spunlacing of heavy spunbonds. The advantage of this system consists in much higher production speeds compared to conventional mechanical needling. Moreover, the nonwovens are provided with a very smooth surface. Possible applications include roofing felts and geotextiles.

Spunlacing of light-weight spunbonds directly after spunbond formation was successfully optimized by Fleissner in cooperation with Reifenhäuser Reicofil. Much higher strengths were achieved compared to normally calendered spunbonds with volumes or web thicknesses doubled. These nonwovens are characterized by a very soft touch. Together with other renowned European producers of spunbond lines, Fleissner has developed spunlaced spunbond products.

AquaJet Production Lines for 2-Layer and 3-Layer Composites with Pulp and Spunbonds or Pulp/Spunbond/Staple Fiber Web (AquaPulp System): protected by patent
This technology combines spunlace and airlaid technologies:

3-Layer Composites with Pulp/Tissue for Wet Wipes (see Fig.3)

Fig. 3

Advantages of 3-Layer Composites with Pulp/Tissue:

• Webs offer high absorbency (pulp serves as absorbing pad).
• Advantages compared with 2-layer webs: no pulp on the outside, i.e. no risk of "dusting" during conversion and no deposit of pulp particles when wiping.
• Improved appearance compared with 100% fiber webs because pulp compensates the irregularities of the carding web.
• Strength practically identical with that of 100% fiber webs although consisting of 50% short fibers.
• Softness when wet identical with that of 100% carding webs.
• Thickness of products (SPC) with identical weight higher than for 100% fiber webs.

Fleissner AquaJet lines for multi-layer nonwovens made of fibers combined with pulp (CPC and CP) have been used successfully for years and a special filtration system was developed for the circulating water.

A further development stage resulted in the delivery of lines combining spunbond, 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. Moreover, optimized bonding of the three-layer webs results in an excellent soft touch (see Fig. 3).

Two-layer webs made of staple fibers combined with tissue for surgical gowns or cover sheets are successfully produced with AquaJet lines.

Hydrospace AquaJet Products
Nonwovens containing tubular hollows are produced in a continuous process based on a patent of Leeds (UK) university. These hollows can be filled with liquid, gel or solids during the spunlace process. Typical applications are nonwovens filled with liquid soap or lotion. Hydrospace webs with empty hollows have a strongly increased sound absorption capacity, which is an important feature in the automotive industry.

Roofing Lines
Fleissner has the experience gained in several decades of roofing felt production. By using Fleissner AquaJet technology instead of conventional needling, production speeds could be considerably increased while strength values remained the same.

Bonding of Nonwovens with Steam Jets
The Fleissner SteamJet was developed in cooperation with STFI in Chemnitz (Germany) for a completely new type of web bonding. The webs are characterized by a very soft touch. They are bonded both by hydraulic forces and thermal energy. This technology offers a chance for completely new products and applications.

2) High-Performance Lines for Nonwovens Production

• Lines for thermal bonding, spray bonding and chemical bonding with belt dryer (through-air/air jetting) or drum dryer
• Foam impregnation lines
• Heatsetting lines with width control
• Complete turnkey nonwovens production lines for carded webs, spunbonds and airlaid composite webs
• Needle felt bonding lines for floor coverings, filtes, geotextiles, roofing felts, for use in the automotive sector etc.
• Nonwovens production lines for
  • Agrotextiles
  • Architecture / Building / Construction
  • Clothing
  • Geotextiles
  • Home / Domestic
  • Industrial
  • Medical / Sanitary / Personal Care
  • Transportation
  • Environmental: Filters
  • Packaging
  • Safety and Protection
  • Sports and Leisure
  • Wipes
  • Composites / Laminates / Sandwich Structures