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Spunlace Brochure former version Flipbook PDF
Spunlace Brochure former version
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Spunlace technology Jetlace systems and line concepts
www.andritz.com
nonwoven eXcellence
2
Explore the possibilities with a global leader in spunlace solutions
Whether used in a wipe, a surgical
Since
gown, or as substrates for artificial
continually developed a broad portfolio
leather, spunlaced materials are finding
of
applications in a broad range of end uses.
complementary capabilities to produce
Also known as hydroentanglement, the
disposable commodities in a more profitable
spunlace process employs water jets to
way, or to produce higher margin durable
entangle fibres and thereby provide fabric
products with the ultimate in production
integrity. Softness, drape, conformability,
flexibility.
1984,
ANDRITZ
hydroentanglement
Perfojet units
has with
Commodities or new products — disposables or durables In a growing market segment, there are possibilities to improve the efficient production of commodity products and to expand the product range to include newer, high margin offerings. ANDRITZ
high strength, and the fact that they contain
Perfojet
no chemicals are the major characteristics
Jetlace
hydro-entanglement
units produce fabrics using all types
that make spunlace nonwovens unique.
of
raw
materials,
staple
fibres,
and
continuous filaments for the hygiene, medical, and technical markets. These Hydroentanglement Fabric units grammage High-efficiency pre-configured units Jetlace Essentiel 30-120 gsm
Up to 500 m/min
Wipes, medical
Jetlace Avantage
Up to 170 m/min
Wipes, medical
30-400 gsm
Up to 200 m/min
Automotive, artificial
30-800 gsm
leather, filtration, e.o. Up to 1,000 m/min Industrial, surgical,
30-120 gsm
Line speed
End uses
Jetlace 3000
agriculture, insulation, filtration, apparel, e.o. Specialty units Jetlace CottonPad
140-270 gsm
in the treatment of several types of web formation: spunlaid, wetlaid, or airlaid.
Flexible configurable units Jetlace Evolution
units can be installed in in-line bonding and
Up to 70 m/min
Cotton pads, hygiene
Your benefits: ▪▪ ▪▪ ▪▪ ▪▪ ▪▪ ▪▪
Team of expert process engineers Comprehensive process solutions Energy efficient High-speed lines Customized design Unique experience
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Engineered features of all Jetlace systems State-of-the-art production enhancements Spunlacing forms a nonwoven sheet from
water injectors to the web, effective drainage
a web of loose fibres moving on a porous
and/or patterning of the web fabric, and
belt or perforated screen by subjecting the
ensuring the purity of recirculated water.
fibres to finely controlled high-pressure water jets. Critical to this process are the
ANDRITZ Perfojet has created the state-of-
efficient transfer of energy through the
the-art in each of these critical areas.
Injectors: the core of the spunlace process Considerable
are
First-class needle water is ensured by the
utilized in the spunlace process. The area
water
and
energy
advanced design of the water distribution
where these two resources — energy and
inside a Jetlace injector.
water — come together is the injector, which projects highly concentrated, very fine
A cartridge inside the injector body
water jets evenly onto any working width
performs final filtration of process water
at pressures of up to 400 bar. Improving
just before the water needle strip. Another
the energy transfer from water jet to web
Jetlace injector innovation is a patented
was a key consideration when designing
seal-holding system that allows routine
the high-efficiency, high-reliability Jetlace
injector maintenance without downtime
injector.
and ensures a perfect seal.
Injector design by ANDRITZ Perfojet
Your benefits: ▪▪ Perfectly homogeneous distribution of water
▪▪ Final filtration of process water just before the strip
▪▪ Quick access to the strip and the filtration cartridge
First-class needle water from ANDRITZ Perfojet injector
Strips: EXH solution to reduce operating costs Jetlace EXH (EXtra Hard) strips were
Each EXH strip is made with extra-
developed by a team of ANDRITZ experts
durable materials to resist wear caused
using the latest computer-based fluid
by water passing through the injector
mechanics modeling tools.
holes at high speeds.
The hole designs in the EXH strips are customized
to
accommodate
spunlace fabric requirements.
varying
Your benefits: ▪▪ Lower operating costs ▪▪ Long life ▪▪ Guaranteed quality: each strips checked in our technical center
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Engineered features of all Jetlace systems State-of-the-art production enhancements MPA Sleeve: improved bonding with energy savings
POLYESTER 60g
ANDRITZ Perfojet offers the unique and patented MPA sleeve — a random microperforated entanglement sleeve that is a significant improvement over the standard mesh sleeve.
MD + CD (N/50mm)
350 300 250 200 150 100 50 0 20
30
40
50
60
70
80
90
100
Pressure (bar) MPA sleeve
Mesh sleeve
Comparison of the bonding between MPA sleeve and
MPA sleeve
standard mesh
Your benefits: ▪▪ Up to 500% increase in bonding ▪▪ Reduction in operating pressures ▪▪ Energy savings
Customized patterning solutions for unique fabrics The market trend is toward patterns. ANDRITZ has developed a series of patterning
and
aperture
sleeves
or
thermo-embossing calenders to create designs on spunlace fabrics. The
latest
patterning
sleeves
use
neXimaging technology which allows full customization of spunlace fabrics, enabling the reproduction of virtually any logo or pattern in high-quality detail. Logo and pattern definition is enhanced, while optimal production speeds are maintained. Logos can be designed to customer requirements. ANDRITZ Perfojet’s technical centre assists by testing patterns for customer approval before an investment is made in the final industrial-scale version of the machine.
Example of patterning possibilities from ANDRITZ
Patterning/aperture sleeve technologies: ▪▪ PL: geometric design ▪▪ MPP: customized design for patterning
▪▪ MP+: 3D embossed patterning ▪▪ neXimaging: extra-fine 3D design for all types of patterning and/or aperture
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Engineered features of all Jetlace systems State-of-the-art production enhancements Efficient water recirculation and filtration
Jetlace Unit
Flotation cell
Bag filter
Water is a critical part of the spunlace process. Due to the large amount of water required, recycling and recirculating the water is essential.
Air supply
Bag filter
A high quality filtration system is necessary. The recycling ratio can be up to 99% for the
Tank
most advanced filtration systems.
Sand filter
Sand filter
Sand filter
Sand filter
ANDRITZ Perfojet has developed the sub-systems to treat and filter suspended
To drain
Example of filtration process flow diagram
solids and spin finish water. One priority is to optimize the filtration for synthetic and/ or natural fibre processing.
Flotation cell for natural fibres
Sand filters
Bag filters
The filtration process is optimized by removing all particles, from the largest down to the finest, by passing the process water through the main filtration systems: ▪▪ Flotation cell ▪▪ Band filters ▪▪ Sand filters ▪▪ Bag filters ▪▪ etc.
Your benefits: ▪▪ ▪▪ ▪▪ ▪▪ ▪▪ ▪▪
Highest fabric quality Full process guarantee Reduced water consumption Minimal wastewater discharge Increased line efficiency Reduced maintenance downtime
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The Jetlace product portfolio Jetlace Avantage The new standard for growing markets The
original
Jetlace Avantage
(2.5
m
width) is a proven concept that is perfectly designed to produce from 30 to 120 gsm spunlace fabrics for wipes and medical applications. Its success combined with the increased demand for lightweight spunlace, led to the introduction of a new Jetlace Avantage with 3.6 m width, which is already receiving excellent acceptance in growing markets. Jetlace Avantage produces lightweight fabrics at an attractively low operating cost with low energy consumption. Designed with two cylinders, this standard machine
can
produce
state-of-the-art
spunlace fabrics up to 170 m/min. Fabrics can be customized using a full range of patterning sleeves.
Jetlace Avantage
Jetlace Avantage line characteristics: ▪▪ Machine widths: 2.5 m and 3.6 m ▪▪ Product range: 30-120 gsm ▪▪ Capacity: up to 8,000 tonnes per year
▪▪ Compact design — reduced space requirements
▪▪ Patterning and aperture capability ▪▪ Perfojet unit (patterning option)
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The Jetlace product portfolio Jetlace Essentiel Top speeds for commodity products For nonwovens manufacturers looking for high capacity and low grammage, Jetlace Essentiel is the answer. The hydroentanglement unit has been optimized and rationalized for lightweight products. Jetlace Essentiel allows the manufacture of most synthetic/natural lightweight fabrics (30-120 gsm) for hygiene, medical, and wipes applications. It is available in five widths: 3.75, 4, 4.25, 4.5 and 4.75 m. Water pressure, vacuum level, production speed, and all nominal parameters are optimized to achieve efficiency of under 1 kWH/kg of fibre for a complete spunlace
Jetlace Essentiel
Jetlace Essentiel line characteristics:
line.
▪▪ Line speed up to 500 m/min ▪▪ Product range: 30-120 gsm ▪▪ Full choice of patterning and
Jetlace Essentiel is designed to reduce maintenance and operating effort.
aperture sleeves
It is capable of 24-hour production with
▪▪ High capacity ▪▪ Energy efficient ▪▪ Low draft
easy access, user friendly operation, and a minimum inventory of spares that require few maintenance tools
Isojet: increased tensile strength for converting The Isojet system increases cross-direction
This gives spunlace producers the ability
(CD) tensile strength by up to 70% and
to influence nonwovens tensile properties
allows the spunlace producer to adjust the
in CD after the cards.
balance of tensile strengths in both the machine-direction (MD) and CD directions. This optimizes web behaviour during converting.
N/50mm 90 80 70 60 50
MD:CD 4:1
Your benefits:
MD:CD 1:6:1
40
Isojet condenses the carded web at initial
30
compaction and bonding of the spunlace
20
process. The main advantage of Isojet is that
0
the web condensing is fixed immediately by the initial hydroentanglement.
10 Isojet 0%
50% MD
100% Condensation %
CD
45 gsm spunlace tensile properties versus Isojet condensation ratio.
▪▪ ▪▪ ▪▪ ▪▪ ▪▪
Increased CD tensile strength Improved bulk Draft control Adjustable MD:CD ratio Allows higher web weights
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The Jetlace product portfolio Jetlace Evolution Flexibility for tomorrow’s durable needs For the production of durables, or for the coating of automotive and filtration substrates, the Jetlace Evolution is preferred. The
lines
are
mainly
equipped
with
cross-lappers to create nonwovens with a balanced MD:CD ratio. Jetlace Evolution has a prewetting conveyor to control web compacting, maintain product quality, and save energy.
Jetlace Evolution
Jetlace Evolution line characteristics: ▪▪ Machine width: up to 4.5 m ▪▪ Product range: 30-400 gsm ▪▪ Perfectly designed for crosslapped or direct drylaid web
▪▪ No delamination
Jetlace CottonPad The pad production machine Jetlace CottonPad fabrics
with
produces
bulkiness
and
spunlace perfect
surface evenness. It is a compact unit with a standard configuration allowing widths of up to 3.6 m to be selected, depending on capacity needs.
Jetlace CottonPad line characteristics:
An option is the extremely successful Perfojet unit for customized pad fabrics.
▪▪ Machine width: up to 3.6 m ▪▪ Product range: 140-300 gsm ▪▪ Perfect surface hydroentanglement control
▪▪ Perfojet unit (patterning option) Jetlace CottonPad
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The Jetlace product portfolio Jetlace 3000 Fully customizable Huge technological strides have been made in spunlace technology, in part due to the Jetlace series. The first versions of these machines were introduced in 1984. Today, one of the best known hydroentanglement units is the Jetlace 3000. Jetlace 3000
has
extreme
flexibility
that allows it to be customized to each producer’s needs. It can achieve virtually all special requirements: capacity, fabric width, line speed, and fabric weight. The
newest
version
of
Jetlace 3000
includes the latest hydroentanglement developments from ANDRITZ Perfojet. The machine is perfectly designed to manufacture
nonwovens
fabrics
for
filtration, industrial wipes, agriculture, and surgical applications. Jetlace 3000 is also available in a pilot line version for universities, associations, and R&D departments.
Jetlace 3000
Jetlace 3000 line characteristics: ▪▪ ▪▪ ▪▪ ▪▪ ▪▪
Works with any kind of web forming Product range: 30-800 gsm Line speeds up to 1,000 m/min Machine widths up to 7 m Full choice of patterning and aperture sleeves
▪▪ Composite nonwoven capability
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Turnkey capabilities All components in harmony The core of ANDRITZ Perfojet’s expertise
ANDRITZ
is in arranging and configuring the main
ensure nonwovens manufacturers a cost-
process components in a production line
efficient, flexible, and reliable spunlace line
so that they work in harmony to deliver
covering the full spectrum from opening/
exactly the end product desired.
blending to the winder. We work with the most
Perfojet’s
advanced
web
turnkey
services
forming/winding
companies.
Your benefits: ▪▪ ▪▪ ▪▪ ▪▪ ▪▪ ▪▪
End fabric warranty Single source management Smooth project execution Controlled project schedule Budget control Single contact
Dewatering and dryer: high-efficiency combination For use in wetlaid and all kind of
irrespective of the line force. Additionally,
hydroentanglement processes, ANDRITZ
individual adjustment of the moisture profile
has developed the neXaqua high-efficiency
zones (side, center, side) is possible.
squeezing device. In combination with a suction device, the neXaqua system
In addition, ANDRITZ can supply its own
reduces residual moisture in the web
through-air dryer technology, Perfodry,
considerably and is especially useful at high
to meet the highest nonwovens line
production speeds. This leads to remarkable
performance levels. Perfodry dryers excel
energy reduction in the subsequent drying
in achieving high nonwovens product
process. The deflection-controlled S-Roll
quality while saving energy.
technology provides an even squeezing effect across the whole material width,
Examples for line concepts
Wipes, medical
S
S M
M
Hygiene
Filtration, wipes
neXaqua system
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Technical support and competence From development to order execution ANDRITZ maintains two technical centers that give nonwovens manufactures access to experts in process, product, and application. The
center
in
Montbonnot
(France)
specializes in trials, product development, marketing tests, technical training, and expert support. It features the most advanced spunlace technology – including a complete spunlace pilot line and lines for Spunjet Bond and Spunjet Soft production. There is also a laboratory for testing nonwoven fabrics. The technical center in Krefeld (Germany) provides additional nonwovens facilities
ANDRITZ Perfojet technical center in Montbonnot
such as equipment calenders or wetlaid pilot line. The spunlace pilot line is equipped with: ▪▪ Opening/blending ▪▪ High speed carding machine ▪▪ Hydroentanglement units: Jetlace Essentiel and Jetlace Evolution ▪▪ Airlaid formation system ▪▪ Hydroentanglement unit: Jetlace 3000
ANDRITZ Perfojet laboratory
▪▪ Perfojet unit for patterning ▪▪ Dewatering system: neXaqua ▪▪ Kiss roll: neXkiss ▪▪ Through-air dryer: Perfodry 3000 ▪▪ Winder
Your benefits: ▪▪ Expert support ▪▪ Latest technology equipment ▪▪ Integrated laboratory to test nonwovens fabrics
▪▪ Access to the experience of two technical centers (France and Germany)
ANDRITZ nonwoven Closer to our clients Germany Krefeld
China Shanghai
(Competence center)
(Sales / service)
Foshan
(Engineering / manufacturing)
USA Spartanburg
(Sales / service)
France Montbonnot
(Competence center)
India Mumbai (Service)
Bangalore (Service)
Service is the essence of a long-term
The global network of ANDRITZ subsi-
partnership. We offer global technical and
diaries and representatives ensures swift
technological advice, service, spare parts,
service solutions. Our customers benefit
training, repairs, upgrades and moderniza-
from the comprehensive experience of our
tion for the complete ANDRITZ nonwoven
technologists and service engineers all
program.
over the world.
ANDRITZ Perfojet SAS Montbonnot / France Phone: +33 (0) 4 76 52 23 11
www.andritz.com [email protected]
All data, information, statements, photographs and graphic illustrations made in this leaflet are without any obligation and raise no liabilities to or form part of any sales contracts of Andritz AG or any affiliates for equipment and/or systems referred to herein. © Andritz AG 2011. All rights reserved. No part of this copyrighted work may be reproduced, modified or distributed in any form or by any means, or stored in any database or retrieval system, without the prior written permission of Andritz AG or its affiliates. Any such unauthorized use for any purpose is a violation of the relevant copyright laws. Andritz AG, Stattegger Strasse 18, A-8045 Graz, Austria. PT.ub.01.eng.03.11