CUSTOMER MAGAZINE OF LINDAUER DORNIER GMBH No. 17 | December 2 010

Back into the Future – DORNIER and Carbon Fibres A time journey through the new Dornier Museum in Friedrichshafen

From Vision to Reality From CLS comes A1 and P1 Tradition meets Technology Finest wool from Johnstons of Elgin, Scotland

(article page 8) page (article The Dornier Museum in Friedrichshafen, opened in 2009 in opened Friedrichshafen, in Museum Dornier The

Aerobatic squadrons with Dornier/Dassault Alpha Jets Jets Alpha Dornier/Dassault with squadrons Aerobatic

Front and backside cover pictures: cover backside and Front

15 – 13

daily use. daily

in been have control FT with machines weaving

drive and control concept, over 300 DORNIER DORNIER 300 over concept, control and drive

practical use. With the forward-looking, patented patented forward-looking, the With use. practical

The highlight of ITMA 2007 in Munich is now in in now is Munich in 2007 ITMA of highlight The

From Vision to Reality to Vision From

- pro exclusively to proud are we tor,

From CLS comes A1 and P1 and A1 comes CLS From - sec our in few the of one As future.

thoroughly optimistic view of the the of view optimistic thoroughly

12 – 11

Peter D. Dornier D. Peter force, create the conditions for a a for conditions the create force,

most modern DORNIER technology. DORNIER modern most - work qualified highly our ticularly,

Johnstons of Elgin has continuously invested in the the in invested continuously has Elgin of Johnstons

Yours faithfully Yours - par and, lines, production ficient

reputation for quality through many centuries. centuries. many through quality for reputation

- ef more and buildings New Euros. Scottish weaving mills have enjoyed an excellent excellent an enjoyed have mills weaving Scottish

Lake Constance! Constance! Lake million 200 some to amounted

Tradition meets Technology meets Tradition

ward to welcoming you at beautiful beautiful at you welcoming to ward velopment in the last 10 years has has years 10 last the in velopment

Finest wool from Johnstons of Elgin, Scotland Elgin, of Johnstons from wool Finest - for look we – us visit and Come - de and research in investment our

tions. Unsparing in terms of innovation, innovation, of terms in Unsparing

10 – 8

- innova pioneering other many side with our fast-moving lives today. today. lives fast-moving our with

- along 1973, in components fibre to 30 years are by no means a rarity, rarity, a means no by are years 30 to fibre reinforced plastics (CFRP). plastics reinforced fibre

mass-produced aircraft with carbon carbon with aircraft mass-produced the first serial built speedbrake made from carbon carbon from made speedbrake built serial first the products, whose useful lives of 20 20 of lives useful whose products,

From the first large all-metal aluminium aircraft to to aircraft aluminium all-metal large first the From plane in 1916 through to the first first the to through 1916 in plane We contrast durable high quality quality high durable contrast We

- aero all-metal first the from ment more efficient. more DORNIER and Carbon Fibres Carbon and DORNIER

– Future the into Back - develop chronological the see to our production methods better and and better methods production our

construction. Here you will be able able be will you Here construction. and new products, whilst making making whilst products, new and

in Friedrichshafen in

spirit and innovative lightweight lightweight innovative and spirit tinue our search for new solutions solutions new for search our tinue Museum Dornier new the through journey time A

through 100 years of pioneering pioneering of years 100 through - con to motivated are and ligation

7 – 6

make an inspiring journey in time time in journey inspiring an make - ob an feel we this From time. long

desirable materials – silk. – materials ­ desirable mere 20 km away – enables you to to you enables – away km 20 mere confidence by so many for such a a such for many so by confidence

ago was revealed is still today one of the most most the of one today still is revealed was ago

richshafen – a a – richshafen ­ Fried in year last been shown such great trust and and trust great such shown been

What, according to the legend around 5,000 years years 5,000 around legend the to according What,

The Dornier Museum, opened only only opened Museum, Dornier The extremely happy and proud to have have to proud and happy extremely

On the Trail of the Silkroad the of Trail the On

our technology center in Lindau. Lindau. in center technology our textile and plastics industry. We are are We industry. plastics and textile

machines stand ready for you in in you for ready stand machines world with its equipment for the the for equipment its with world Les Tissages Perrin, France Perrin, Tissages Les

plus a new generation of weaving weaving of generation new a plus name for itself throughout the the throughout itself for name – weaving silk of year 80th

in the field of textile technology technology textile of field the in the meantime established a good good a established meantime the

5 – 3

New and interesting developments developments interesting and New lowing the 2nd World War, it has in in has it War, World 2nd the lowing

through technical progress. progress. technical through - fol works Dornier the of activity

on different products in different industries. industries. different in products different on it seeks its success first of all all of first success its seeks it Peter Dornier, as the first industrial industrial first the as Dornier, Peter

originate from a long tradition, building its strength strength its building tradition, long a from originate

characteristic of our company that that company our of characteristic this year. Founded by my father, father, my by Founded year. this

lead by the founding family. Both companies companies Both family. founding the by lead

duce “Made in Germany”, and it is is it and Germany”, in “Made duce LiDO celebrates its 60th birthday birthday 60th its celebrates LiDO

SRF is – like DORNIER – a business professionally professionally business a – DORNIER like – is SRF

Technical Textiles Technical

Lindauer DORNIER GmbH, GmbH, DORNIER Lindauer

Global Player in Precision Films and and Films Precision in Player Global

Dear readers, dear friends of of friends dear readers, Dear

­

“Made in Germany” in “Made

SRF Ltd., India, relies on technology technology on relies India, Ltd., SRF

Editorial Contents SRF Ltd., India, relies on technology “Made in Germany” GLOBAL PLAYER IN PRECISION FILMS AND TECHNICAL TEXTILES

SRF is – like DORNIER – a business professionally led by the founding family. Both companies originate from a long tradition, building its strength with different ­products in different industries.

Take-up unit of a DORNIER film stretching machine at the SRF factory in Indore

Group history Company profile in India and also enjoys global leader- SRF Ltd. traces its origin to the lineage of SRF was originally established in 1970, ship leadership in others. the famous Lala Shri Ram, who not only under the name of “Shri Ram Fibres”, by The company prides itself to be equipped ranked among one of the country’s lead- its parent company DCM to manufacture with state-of-the-art R&D facilities, for ing business visionaries of all times, but is mainly nylon tire cords. Over the years the process innovations and product develop­ also the founder of the reputed Shri Ram company diversified and eventually the ment. It was the first tire cord company Group of companies. The Group’s exist- name “Shri Ram Fibres” was changed to outside Japan to win the prestigious ence spans more than a century, starting SRF in 1990. Today, its business portfolio “Deming Award”, for adopting TQM way back in 1889 when its parent company covers technical textiles, chemicals, pack- as a management strategy. SRF remains Delhi Cloth Mill, now known as DCM aging films and engineering plastics. In committed to creating a culture of excel- Group, was founded. In the ensuing­ pe- technical terms SRF could be described as a lence through personnel development and riod, the DCM Group expanded its busi- multi-business entity engaged in the manu- an employee friendly approach. Through ness interests into a very diverse product facture of chemical based industrial inter- its social wing, the SRF Foundation, the portfolio comprising sugar, automobiles, mediates. However, common language company strives to make meaningful con- finance, fertilizers, fine chemicals, rayon, tells that SRF is in the business of making tributions to its community on a sustain- tire cord and textiles etc. Respected as an people’s daily lives both safer and more able basis. ethical company, the group is known for comfortable with its products. its contribution to art, culture and edu­ Technical textiles cation. In particular, the group is also Headquartered in Gurgaon, India, the 550 Building on its dominant position in the known for establishing some of the most million $ company, with a global workforce domestic market, SRF also enjoys a signifi­ famous academic institutes of the country of around 4,000, has operations in three cant presence in the global market for all such as “The Lady Shri Ram College”. other countries, United Arab Emi­rates, three product lines within its “Techni- Thailand and South Africa. SRF is the mar- cal Textile Business”. This business unit ket leader in most of its businesses ­sectors manu­factures nylon tire cord, conveyor

3 spending power, along with changing de- mographics and changing lifestyles. Mr. Chatrath of SRF states: “We think that demand for polyester film will see robust growth in Asian economies, especially in India and China. As for Europe and the USA around 2% growth is expected an- nually with an increasing demand for speciali­ty products”.

The final applications of the PET film pro- duced on the DORNIER line are prima- rily packaging applications for food such as confectionery. Other applications are per- sonal care products and detergents, cosmet- ics as well as some electronics applications such as capacitor films. Some important customers’ brands are Unilever, Lux, Surf, Dove, Head & Shoulders and Pantene. The PET film portfolio of SRF is more DORNIER tire cord weaving plant of SRF focussed towards international customers and into smaller sized packages. 50% of the belting and coated fabrics. The tire cord was done in 2005. Now a great number of sales are exported. is used worldwide as reinforcement for all DORNIER weaving machines are in oper- kinds of tires, ranging from the humble bi- ation at SRF with plans for further expan- Close connection to DORNIER cycle to the heavy commercial trucks and sion in the years to come. In the past, SRF had only seen DORNIER even aeroplanes. Coated and laminated as a very well-known leading global manu- fabrics have found their end use in prod- Packaging films facturer of weaving machines. However, the ucts such as awnings, tarpaulins and cano- The packaging films business of SRF company had been delivering film stretch- pies for boats, trucks and car covers. Other manu-factures Bi-axially Oriented Poly- ing machines since 1960 to companies such end uses include fabrics to cover cricket ethylene Terephthalate (BOPET) or Poly- as Agfa-Gevaert, ICI, Kodak, Celanese and pitches, tennis courts and sports fields as ester (PET) Film, which is predominantly Fuji as well as Toray and Teijin and had well as fabrics for so called “shamianas”, used in flexible packaging applications for become a global technological leader in tents used for wedding parties. SRF is the the conservation and protection of a wide this business sector also. SRF approached second largest manufacturer of conveyor range of products. DORNIER in 2002 for the first time for belting and ­nylon-6 tire cord fabrics in In 2009, the packaging film business an upgrade of an existing TDO (transverse the world. doubled its capacity by adding a new direction orientation) line at their Kashipur DORNIER film stretching plant. With an plant. Just one year later, as a result of this In 1987, SRF purchased their first output of 3.9 tons per hour the new plant successful upgrade, DORNIER received DORNIER weaving machines for the produces packaging film of 8 to 50 mi- another order for the supply of a complete production of conveyor belting and have crons. To run the production line requires polyester film production plant, which was continued to add more and more ma- around 25 people per shift including main- commissioned successfully in 2004. chines over the years. The first investment tenance and support. SRF states about the DORNIER film in DORNIER tire cord weaving machines So whether it is the widely-used shampoo stretching plant: “The machine is sturdy. sachet or a bar of soap made by some of However, we faced some problems in the ­India’s largest FMCG (fast moving con- beginning, but all the issues were settled sumer goods) companies it is likely that swiftly with the support of the DORNIER the film brand of SRF “PETLAR” with its team”. After the positive experience with ­properties of excellent printability, strength the first machines, it was clear to SRF that and aroma retention are at work. The fo- they should maintain their partnership cus of the business is to always move up the with DORNIER. Especially appreciated value chain of packaging films. To this end, are qualities like customer orientation, an SRF also produces metallised and holo- easy approach, the professional and ethical graphic films for highly sophisticated appli- behaviour of the people, and, of course, the cations in addition to plain and chemi­cally first class technology. treated polyester films. Total quality management It is expected that Indian and Asian mar- SRF manages its business through effec­ kets are yet to realise their full potential, tive implementation of Total Quality Candies wrapped with metallised film from SRF as a result of increases in population and ­Management (TQM) in an integrated

4 manner combining principles, methods, ­Laminated Fabrics plant and the second Family business systems and tools. SRF built its entire or- line of ­BOPET Film, the company also “Our Companies are very similar. Like ganisation on this foundation and this has saw the commissioning of dipping facili- DORNIER we are a business professionally contributed significantly to its success. ties for tire cord fabrics with a capacity of led by a founding family. SRF is a value- 11,500 tons per annum. driven organisation where respect and care The company’s TQM activities are built on for individuals, trust, creativity, innova- a three-pronged strategy: With the commissioning of the polyester tion and equal opportunity, without any • Enhancement of customer satisfaction industrial yarn plant SRF has become the discrimination, are the main principles. • Continual improvement in every pioneer in this sector in India. This will That’s the backbone of the People System. business activity enable the company to enter two new ar- We value high standards of integrity and • Involvement of everyone in the eas – tire cord fabric for radial tires and ethics, and also encourage (non-monetary) organi­sation. the reinforcement cords for V-Belts. This contributions to society by employees. Our project also offers SRF the capability to values can be seen in action through our SRF prides itself on its staff participation manufacture High Modulus Low Shrink- people’s policies which are practised day in activities, which involves nearly every em- age (HMLS) polyester yarn and an assort- and day out”, says Mr. Chatrath. ployee in the organisation in improvement ment of high tenacity and low shrinkage Building on its heritage, the company activities such as Kaizen and Quality Con- yarns for various industrial applications. strives to ensure the utmost transparency trol (QC) Circles. Significant improvement Thus SRF has become one of the few com- in company affairs by appointing well in cost structures, continual reduction in panies in Asia, offering multiple compli- qualified, reputed professionals from di- waste, sustained increase in cost compe­ mentary technical textile reinforcement verse fields as independent members of the titiveness and an enviable record for main- products. In fact, it is now a one stop board. These professionals form the major- taining high standards of safety, health and shop for reinforcement fabric to the tire ity of the Board. environment in its work premises are some companies in India since it will be able to of the results of TQM practices in SRF. cover the full spectrum of tire cords from Based on totally different business areas in ­nylon-6 to polyester. independent markets and with the constant aim of improving their products and pro­ The successful commissioning of the lami- cesses, SRF is well positioned for the future nated fabrics project has enabled SRF to in order to keep, and even strengthen, their complement its fabrics product portfolio. dominant role in both domestic and inter- The laminated fabrics are largely used for national markets. applications such as flexible banners, sig- nage etc. The project also helps to reduce the company’s technical textiles business reliance on tire cord fabrics. Other ongoing projects within the com- pany include expansion of the coated fab- rics division and development of a Chemical Complex at Dahej in Gujarat.

Textile tire cord – the stabilising component of every tire © Oerlikon Saurer

More importantly, the company has devel- oped a TQM based management model, which can be successfully replicated while setting up and managing a new plant or business.

Growth and expansion Pursuing its goal to achieve global market leadership by 2020, SRF has embarked on a long and challenging journey of growth and expansion for all its businesses through both organic and inorganic routes. Over the last four years the company has made investments of around Rs. 1,250 crore (about € 200 Million) mainly in aug- menting and upgrading production facili­ ties in different businesses. Apart from the Polyester Industrial Yarn plant, the Family day at SRF – an event regularly taking place in all company locations

5 80th year of silk weaving – Les Tissages Perrin, France ON THE TRAIL OF THE SILK ROAD

What, according to the legendary Chinese empress Xiling Shi around 5,000 years ago was revealed when a silkworm cocoon fell into her tea, is still today one of the most ­desirable materials for elegant clothing, shimmering robes and flattering fabrics – silk.

Sébastien Perrin and Peter D. Dornier (from right) in the weaving shop of Perrin & Fils, Le Grands-Lemps

Along the silk road to Lyon ­ceremonial handing over of the baton to the fifth gen- Along the silk road in the Middle Ages luxurious silk fabrics eration, represented by Jean-Laurent, Jean-Hugues and reached the strategically well located city of Lyon, where, Sébastien was effected in a festive setting during the an- in the trading of this expensive material, it was dispatched niversary cele­brations on the 80th year of existence of the throughout flamboyant France and even as far as the royal company on June 12, 2009. palace. On the grounds of the palace’s high level of ex- Utilizing 60% of the French imports, ­Perrin & Fils is the penditure on the desirable silk, Louis XI decided in 1466 biggest consumer of raw silk and silk yarns in the whole to produce silk himself in France for the future. In this way of France, occupying top place in its own country in the Lyon was honoured with the silk trade monopoly in 1536 production of woven silk ­fabrics. as the “Silk Capital” of France. With 168 employees, the finest silk, cashmere or blended Near Lyon in Le Grand-Lemps, France’s greatest silk and elastic yarn fabrics – primarily for French fashion weaver masters, like no other, the production of precious brands – are produced on 42 DORNIER dobby and woven silk fabrics with the aid of the most modern tech- Jacquard rapier weaving machines. Only 15% of the fabric nology. The Perrin & Fils company, partly owned by the is exported, with neighbouring European countries being Hèrmes Group, has recently celebrated its 80 years of ex- the main customers with 76% of the total. istence, looking back on a long-standing, successful com- The exclusive end-products range from accessories, such as pany and family history. scarves, neckties and handkerchiefs via lingerie and swim- ming fashion through to women’s outerwear. The roots of a traditional company Eugène, the eldest son of weaver Alexandre Perrin, and Luxury – made in France formerly an employee of famous Lyon silk producer The ultimate goal for every employee is the achievement of ­Bianchini-Férier, founded his own silk weaving company the best possible quality. Even 10% of employees are exclu- “Les Tissages Perrin” in 1929 during the most severe eco- sively responsible for quality control at the various produc- nomic crisis of the last century. Since then, the art of silk tion stages. Every centimetre of finished fabric is checked together with the successful company, has been transferred with extraordinary care. The “making-up” of the products is from generation to generation, from father to son. The a great art in itself. Supremely “fairy-fingered” seamstresses

6 to the gentle weft tension cycle and the contact-­free path of the rapier rod through the open shed. The finest products using high numbers of threads up to 210 ends/ cm are produced on dobby and Jacquard weaving machines with a large number of shafts and hooks respectively. Yarns down to 13 to 15 denier (15 dtex) are standard, which can be inserted with high efficiency and excellent fabric quality.

Creation to customer requirements The Perrin company places extreme value on innovation in addition to first-class product quality. A team of internal and external designers is constantly designing Dyed silk cocoons new collections in the women’s outerwear and accessories fields and also in the under- with great expertise are busy in dressing, been constantly maintained at a modern wear and swimwear sectors. The “Première pressing and packaging the ­finished gar- level, and consists today exclusively of ­Vision” in Paris is one of the most impor- ments and accessories. Everything is hand- DORNIER rapier weaving machines. tant exhibitions for Perrin & Fils for pre- crafted in a routine of thousand-fold The production is dedicated on the one senting those innovations directly to the repeated operations. The making-up de- hand to delicate, single-color woven silk customer. All in all, approximately 200 new partment especially specialises in the tai- fabrics in satin weaves which are subse- creations are designed per year, following lor-made production of elaborate details quently printed and finished. basic in-house market trend observations like flower petals, trimmings or bows, and On the other hand, elastic and, to some on one hand, and special customer require- also the manual sewing of handkerchiefs, extent even bi-elastic, colored Jacquard ments on the other. Based on its flexibility scarves and the confection of neckties. fabrics, for which the DORNIER rapier and creativity and against the background weaving machine is the optimum tool, are of the constantly growing popularity of The circumspectly operated teamwork a speciality. A secure, spring-back-free grip French luxury goods all over the world, throughout the whole value creation chain, on the weft end is guaranteed by its open- Perrin & Fils views the coming years with which incidentally takes place exclusively in shed weft insertion and the secure interlac- confidence. France, finally produces a perfectly superior product which makes Perrin a figurehead for the French and also the international silk industry. The company’s success is based not least on a perfect harmony of values between respect for the past and tradition together with the skill and far-sightedness of constantly pro- moting innovation and creativity in order to persist successfully in the future.

In 2007, Perrin & Fils was honoured with the “Entreprise du patrimoine vivant” (liv- ing company heritage) award for its spe- cial technical know-how in silk handicraft. This distinction is awarded to selected French firms which are masters of special skilled handicraft, or have special know- how in industrial manufacturing. The modern weaving plant with DORNIER dobby and Jacquard weaving machines

„Quality creates value“ ing of the weft end in the fabric selvedge In order to produce the utmost quality, before the right-hand rapier head opens. Perrin has always placed high value on a These highly elastic fabrics, particularly for well-equipped, modern weaving mill with further processing into swimwear and un- reliable weaving machines. The teamwork derwear, are woven with up to 50% con- between the two family companies ­Perrin traction. and DORNIER has endured for over 30 The fine, low-tear-strength silk and cash- years. In that time, the machine park has mere yarns are carefully inserted thanks

7 A time journey through the new Dornier Museum in Friedrichshafen BACK INTO THE FUTURE – DORNIER AND CARBON FIBRES

From the first large all-metal aluminium aircraft to the first serial built speedbrake made from carbon fibre reinforced plastics (CFRP) – 60 years after its replacement, Dornier, as the pioneer of metal aircraft construction, brings woven fabric back into the structure of a mass-produced aircraft.

The Dornier/Dassault “Alpha Jet” – the first European mass-produced aeroplane with carbon fibre-reinforced plastic components © Austrian Armed Forces

The first flight – in 1973 – of the ­Dornier/ Group with headquarters in Friedrichshafen branch had introduced to the market the Dassault “Alpha Jet”, a light twin-jet combat and Munich, this presented a thrilling tech- most ­flexible – and best suited for technical and trainer aeroplane for the German air- nical challenge. The weaving of carbon fi- fabrics – weaving machine to date. force and the French “Armée de l’Air”, cre- bres was virtually unknown in those days. Very fragile carbon fibres could now there- ated a milestone for the material technolo­gy Consequently, every textile and process- fore be transformed into high quality car- used in modern aircraft construction and ing technology parameter had to be newly bon fibre reinforcing woven fabrics in close for Lindauer DORNIER GmbH. worked out from scratch in collaboration cooperation with French weavers who had The design of the “Alpha Jet”, developed with the Brochier glass weaving company, already successfully processed zero-twist under German/French collaboration, our French partner, and the Ciba Com- glass filament yarns for the first time at high provides, for the first time, the use of posite Division (today HEXCEL Corp./ speed on the DORNIER rapier weaving textile-reinforced­ plastics (Carbon ­Fibre HUNTSMAN Advanced Materials) as a machine. Reinforced Plastics) for components of producer of fibre and matrix material along the primary structure of a mass-produced with the prepregs (resinated woven mats). A look back on 1915 ­(approx. 500 units) sonic-speed aircraft. In the course of this project, the fact that In the initial years of the First World War The components involved in this instance Lindauer DORNIER GmbH had, at the an aircraft of gigantic proportions for those are the so-called “speedbrakes” or air brakes, beginning of the 1950s, restarted the first days comes into being at Friedrichshafen,­ on designed to decelerate the aircraft in a dive industrial activity of the Dornier Works Lake Constance. Built in the then new ma- or on landing. in Lindau following the war, proved to terial aluminium (“duralumin”), the Rs I de- be extremely useful. Just in 1970, with the signed by young constructor Claude Dornier For our company, Lindauer DORNIER production of the first “positively control- is, with a 45 metre wingspan and a 10 tons GmbH, then still part of the large ­Dornier led rapier weaving machine”, the Lindau take-off weight, the biggest and heaviest

8 severe winter storm just before Christmas completely destroys the flying boat moored to a buoy on Lake Constance near Manzell. Dornier’s dream of a large metal aircraft lies in ruins. But he does not give up. He persuades Zeppelin to give him and his team an- other chance, and, within only a year, an equally large but somewhat more conven- tionally created giant aeroplane is already floating on Lake Constance – the Rs II. But this time it not only floats – it flies – and so the era of the large metal aeroplane – continuing to this day – begins in Ger- The Rs I – the first large aeroplane made from aluminium © EADS/Dornier GmbH many in 1916 (the equally brilliant Ger- man designer Hugo Junkers had also been ­engine-powered aeroplane in the world, and Here, as a design principle, Dornier, from the successful a few months earlier with his J1 the first to be entirely produced in metal. start, refuses to use the classic wood, fabric project, a lightweight all-metal single-seater and piano wire construction applied by re- fighter). The giant Dornier Do X flying From the textile fabric to aluminium puted aircraft manufacturers Blériot, Fokker boat, with over a 50 tons take-off weight Count Ferdinand von Zeppelin, Dornier’s or de Havilland for the production of com- and 170 passengers at a record flight over employer, at that time is producing huge bat and reconnaissance aircraft coming into Lake Constance in 1929, forms the tran- rigid airships for the German Navy in his use in the war at that time. Wood, as a “natu- sient high-spot of this development and hangar in Manzell. These huge colossi – ral composite fibre material” and coated wo- finally silences the last doubters of this con- over 200 m long – with hydrogen-filled en- ven cotton fabric, i.e. textiles, ­appears to him cept. America’s subsequent world leading velopes still made of fabric, are equipped to be too “unpredictable”, too “light” and aircraft industry, with its reputed design- with load-bearing inner frames, already not efficient enough for the job of carrying ers Douglas and Boeing, will only put its produced in “duralumin”. a 1,000 kg “payload” to ­London. first large all-metal aeroplanes on the mar- At that point Dornier already has five event- Instead, he goes all out for aluminium, ket in the 1930s. ful years of work behind him in the ­service whose discovery and large-scale produc- of the Count: This includes ­journeys to tion had only taken place in the previous The aluminium construction philosophy Paris in order to visit Gustave Eiffel and 60 years, and at that time is a much more discovered by that time was constantly fur- to study aerodynamics in the ­wind-tunnel expensive and notably heavier material in ther developed and has proven to be the there, along with riveting technology and comparison with wood, fabric and wire. impressive and only possible way to manu- its application to aluminium construc- He also decides to build a seaplane – a so- facture heavyweight engine-powered aero- tion. Innumerable hours of calculation called “flying boat” in preference to a land- planes right up to this day. Only in glider and testing follow to optimise the light- based aircraft, and with a hull like a ship, manufacture could metal construction – weight ­aluminium structures which ensure with ribs and metal planking. But as alu- too heavy and too expensive for that pur- stability within the interior of the mighty minium can not yet be welded like steel, the pose – never gain acceptance. Here, for ­Zeppelins. Intensive discussions take place individual components have to be ­ri­veted decades, development followed the increas- with the Count and his colleagues in his together. ingly sty­lised wood and fabric construction, ­design office as to whether the airship, with however the emergence of glass fibre-rein- its expensive logistics and ­vulnerability, The Rs I is completed and ready for its first forced plastics very quickly replaced the promises in any way to be a suitable and flight in the late autumn of 1915, but a older wood/fabric combinations in the successful aircraft.

Zeppelin however is undogmatic and fair. He recognises young Dornier’s potential and the one of “heavi­er-than-air” aircraft, which quickly proves to be an indispensa- ble and reliable means of observation and reconnaissance not least for the artillery in the big battles of the World War. When Dornier asks him if he might de- velop such an aircraft, which would be just as suitable as the Zeppelin for attack- ing London docks, he agrees. The “Do” department set up for that purpose in the Zeppelin Group devotes itself full-stretch to its new task. Woven carbon fabric – produced on a DORNIER rapier weaving machine

9 other things, this also contributes in ­doubling system performance from 300 to today’s 600 picks per minute. The high technical level of carbon ­fibre composite material processing know-how also led to the emergence of several start- up firms, founded by former Dornier employees in Friedrichshafen and its neigh- bourhoods, after the Dornier Group’s dis­ integration as a consequence of being taken over by Daimler-Benz. The world’s largest carbon fibre producer, Japanese company TORAY, has only recently acquired a mi- nority shareholding in one of those – the ACE company. A particularly noteworthy event in view of the great importance of The Do X – public attraction during its global flight in 1929 © EADS/Dornier GmbH CFRP materials in the bodywork field for future electrically driven vehicles. 1960s. From around 1975, carbon fibres, machine” newly developed by LiDO at that produced for the first time in the 1950s time, also benefits directly from the car- The most interesting potential of this new by the British textile group “Courtaulds” bon fibre know-how gathered by ­Dornier technology, in addition to the already and the “Royal Aircraft ­Establishment”, be- in Friedrichshafen. standard use of carbon fibres in military came available in the relevant quality for In subsequent years, highly stressed com- equipment and their growing importance civil applications, and were immediately ponents of that machine, such as rapier in civil aviation (Boeing 787, A380, A350) tested and subsequently used in glider rods and laminated springs, which op- as well as in large wind power units is to be ­construction. erate at frequencies up to 10 hertz, i.e. found both in this and the civil engineer- 10 times per second – for more than ing field. Carbon fibres in use for the first time 100 million times one after the other – Just as the 19th century became known as The carbon fibre era also began for the are developed from this material and the century of steel, and the 20th century ­Dornier company at the start of the 1970s. very successfully employed. Among represents the era of light metals and “first Their entry into satellite construction let to generation” plastics, our 21st century may a very close examination of this almost un- well be decisively marked and remembered known and extremely expensive material for these high-tech plastics “of the second at that time. Here, the material properties generation”. Modern engineering science which suddenly became available opened a can make an important contribution to the whole new era of functionality and suita­ urgent task of today and the future – the re- bility which were not achievable with met- duction of CO2 emissions by way of intel- als (extremely lightweight construction ligent lightweight construction using these with high-modulus fibres, thermal stability carbon fibre composite materials. via tailoring fibre orientation etc). ­Carbon fibre compounds are well-established and indispensable in space flight today. The hazardous business of designing and producing an important component out of this material for use in the primary struc- ture of a mass-produced aeroplane, was The course of this unique development then undertaken for the first time in the can be followed in the very appealing and “Alpha Jet” project. well laid out Dornier Museum, opened in The technique of calculating, producing 2009, directly alongside the airport in and testing such components had to be Friedrichshafen. Those interested in the worked out, practically from scratch, by return of textile technology into modern Dornier itself, similar to aluminium 60 material technology will find here – with years before. well-informed guidance – diverse examples Concerning the production of the neces- and inspiration for further thought and sary textile reinforcement of the plastic, discussions. reference was made to the vast experience gained by weaving customers of the Lindau For further information about the museum branch works – Lindauer DORNIER please go to: www.dorniermuseum.de GmbH (LiDO). The pioneering “positive rapier weaving Off-shore wind power unit with GFRP/CFRP material

10 Finest wool from Johnstons of Elgin, Scotland Tradition meets technology

Scottish weaving mills have enjoyed an excellent reputation for quality through many ­ centuries. Johnstons of Elgin has continuously invested in the most modern DORNIER technology in order to meet the ever increasing demands of modern markets, and to continue to play in the top quality league.

like Hermès, Chanel and Burberry along with Bogner and Brioni, are numbered among Johnstons’ customers today. At the same time, the own brand “Johnstons”, which can be purchased in the company’s own retail shops, on-line and from cata- logue, is becoming ever more popular in this respect.

The management Managing Director James B.H. Dracup has now been with the company for nine years, but has already worked in the textile in- dustry for over 30 years. He is supported by ­Sinclair Patterson as manufacturing di- rector, and Thomas Stewart as weaving manager. He feels at home in this com- pany with its long history. “Johnstons is an outstanding employer. The family owned company, with 600 employees, is led in accordance with traditional principles but Johnstons of Elgin can look back on 200 years of successful activity with a modern management style. The fact that Johnstons is a family company makes Long history day distinguished by their tartans, and are us independent of financial problems. The The company was founded by young identified by the different patterns. company is led by a professional manage- ­Alexander Johnston in 1797. Linen, flax, These were originally very heavy cloths ment team, not by accountants”. tobacco and oats were Johnstons’ most im- produced from Scottish wool in order to The well-trained personnel are especially portant trade goods. The linen business was withstand the wind and the weather in the important in today’s hard-fought market- replaced by wool in 1801, and just a few Highlands. Around the turn of the cen- place. Johnstons has a good mix of young years after – by 1810 – the company was tury however the fabrics were becoming and experienced employees. “We place already established as a market leader in the ever lighter in weight, finding increasing great value on staff training. We see that wool sector. entry into general clothing. Many of the as an important basic principle of a family Today, Johnstons is the sole, vertical, op- luxurious cashmere fabrics in the collec- company – one could also say under cor- erational textile company in Great ­Britain, tion today can trace their origin back to porate responsibility”. carrying out by every production stage from this tradition. Johnstons also offers a spe- the raw fibre through to the finished cloth- cial service for landowners and customers The weaving mill ing, in both woven and knitted fabrics, in in addition to the approximately 30 designs The weaving machines are regularly re- the highest quality wool. Production is car- produced: They can have their own designs placed in order to keep production up to ried out in the weaving mill in Elgin and woven from a delivery quantity of 2 x 60 date. At the beginning of 2009, Johnstons also in the knitting mill in Hawick. metres. again replaced some older machines by 20 new DORNIER rapier weaving machines. From the 1840s the so-called “Estate Big names Today therefore, weaving is carried out on Tweeds” cause a great sensation, and Johnstons has been regarded as a pioneer in 20 new and 4 older DORNIER weaving ­Johnstons, seeing a good business opportu- cashmere and vicuña wool in Scotland since machines of which 18 are equipped with nity, also entered the market. Patterns simi- as long ago as 1851. Fine Scottish woollen dobby and 6 are Jacquard. Johnstons has lar to Scottish tartans identify the proximity fabrics were becoming increasingly popular been a loyal customer of DORNIER since to families living particularly in the neigh- in the 1920s. Large reputed fashion houses 1973. And why DORNIER precisely? bourhood of the mill. It was the ­fashion like Coco Chanel and Jean Patou processed ­Sinclair ­Patterson: “Over the years we for both the Lairds and their followers to the finest cashmere into pullovers and cos- have bought numerous weaving ­machines wear garments with the same pattern, in a tumes. The big clothing brands in Western from DORNIER – all rapier machines. similar way to the clans which are still to- Europe, the USA and J­apan, with names For us these weaving machines are the

11 most ­versatile with regards to weft inser- to differentiate ourselves from the compe- shop in St. Andrews, world famous with tion, product change and they are well tition. The speed at which we can attend golfers. These shops alone generate around engineered. The good customer service is to demand trends is of outstanding impor- 4.5 million pounds in turnover. not to be underestimated. When there is tance”. New sales channels, like on-line ordering, a production problem we are attended to Product origin, the right working condi- will continue to increase. Despite that, the immediately, and the problem is solved as tions and the social environment are also traditional retail business will not decline, quickly as possible. DORNIER is simply becoming of ever greater importance for and customer service is still to be improved exemplary here. A good relationship with him. These factors have a say in the success further. suppliers is of outstanding importance to us of today. “Made in Scotland is very impor- in order to give our own customers satis­ tant for us. We must not leave production Royal riding breeches faction in return”. Thomas Stewart makes to others, it must remain here. We must Johnstons is regarded as market leader in particular mention of quick style change, overcome the difficulties and challenges this sector. This is also honoured time which is the most important characteris- here, and that will also be rewarded by our and again by politicians and the country. tic of a modern weaving machine. “The 20 customers. With our organisation we are Johnstons received the “Queen’s Award” new DORNIER rapier weaving machines in a position to produce new products­ con- in 1978. In 1982, Margaret Thatcher, the give us even more flexibility both in terms tinuously. The situation is not an easy one, prime minister at the time, visited Elgin, of pattern lengths and in industrial produc- but we are very optimistic”. and in 2008 HRH Prince Charles paid a tion. We always have to be faster, as our cus- visit, and opened the new Courtyard Shop tomers are always requesting shorter delivery Markets and Heritage Centre. Prince Charles even times. Thanks to this investment we are con- This Scottish company exports about 60% had a cloth made expressly in the pattern stantly improving our quality and efficiency. of its production, with 40% staying in Great of his favourite hunting breeches. Britain. “The largest export markets today Last year Johnstons was awarded the “Scot- are Japan, the USA and Western ­Europe, tish Textile Brand of the Year” award. and the export proportion should rise fur- “Every year 50 to 60 percent of new pro­ ther in the future. Huge expansion possi- ducts are introduced to the market, and bilities are certainly in view: South America that interval has to become ever faster” says and India in particular are in our sights as James B.H. Dracup. “The period from the new sales markets.” idea to the finished product is now four weeks. Only the best is good enough. Speed The future is everything, so we must maintain the And how has market and customer beha­ tempo. The new DORNIER rapier weav- v­ior changed in the last five years? Design ing machines are supporting us in these Johnstons of Elgin excells in all production­­ stages from the and innovation are the most important. efforts with their flexibility, and we will raw fibre to finished clothing In the past, business could be done with continue to hold on to our successful posi- few products, and in all price ranges in fact tion in the market in this way”. I can say that we are already 10 percent faster from low to high. Today Johnstons oper- than before”. “The return on investment”, ates exclusively in the high price segment, according to James Dracup, “will certainly offers even more fashion products, and is become apparent in a very short time”. becoming increasingly faster. Whereas a Johnstons consumes approximately 500 tons company like Johnstons still had a fixed of the finest wool per year. The weaving mill product range with two main seasons in produces around 450 piece lengths of 65 to earlier times, there are a number of col- 70 metres every week, but production is not lections and lighter weight all-year-round just for in-house making-up: Some 80,000 products in the range today. In contrast to m of woven fabric is resold each year, plus times gone by, many more 100% cashmere 2.5 million garments as accessories, such as products are sold today. Extra-fine merino knitted scarves and gloves. products are top sellers in the range. There is complete agreement at Johnstons Creativity and trends that the markets will continue to change. A fashion company stands and falls by Even in the wool industry there are new the creativity of its collection. 20 peo- markets – and not only for the winter ple work in Johnstons’ design depart- season. ment. In earlier times, according to James The successful lighter weight products are ­Dracup, ­Johnstons were a “Scottish firm living proof of that. Johnstons maintains with ­Scottish products”. Today many fa- sales offices in Tokyo, Düsseldorf, New mous labels are supplied. “Our objective is York City, London, Elgin and Hawick. not the production of large quantities, we Successful too are the retail shops in Elgin, want to generate added value for custom- with the weaving shop and the new Court- ers and ourselves and, to that end, we must yard Shop and Heritage Centre – a veri- The traditional Estate Tweeds are produced exclusively manufacture tailor-made products in order table furnishing house – and also the new on DORNIER rapier weaving machines today

12 From CLS comes A1 and P1 FROM VISION TO REALITY

The highlight of ITMA 2007 in Munich is now in practical use. With the forward- looking, patented drive and control concept, over 300 DORNIER weaving machines with FT control have been in daily use in a variety of applications, since its introduction into the market during the 2009 customer days.

Modern weaving plant in Turkey with DORNIER A1 air-jet weaving machines for denim

Into the future with pioneering spirit is in this case “weave by wire”. The machine monitors What distinguishes a pioneer? When something does not itself, thereby ensuring maximum process reliability. exist or does not seem to be possible, the pioneer has to in- vent it. This has been the case since the very beginning of DORNIER ErgoWeave® the company DORNIER. Whether it is Claude Dornier Communication between man and machine is effected and his concept of using an aluminium shell construction via an intuitively operable 15 inch touch screen panel. for aircraft production in 1918, or with Peter Dornier in tex- Vivid graphic function cycle displays facilitate opera- tile machinery engineering, with the introduction of posi- tive hand­ling. Whether for the comprehensive input of tive weft transfer on the rapier weaving machine in 1967 ­values for start-mark correction, or for setting the most and CAN-Bus-based weaving machine control in 1989. The important ­parameters for standard products: The values goal in all develop­ments was – and still remains – to be able are completely reproducible and the setting is achieved to offer maximum customer benefit with the best available with only a few operational steps. As on a domestic PC, technology.

Fast-Ethernet-Technology With the introduction of the new Fast-Ethernet-Tech- nology control into the series-produced machine in 2009, this pioneering electro­nics concept was used on weav- ing machines for the first time. FT technology origi- nates in aircraft construction, and is currently the most modern data transfer communication structure available. It makes possible the reliable transfer of large quantities of data in real time. Consequently there is always some- thing of “the flying dream” present in every DORNIER weaving machine. What is described in aeronautics as “fly by wire”, i.e. that functions are controlled via elec- tric cables to servomotors or electromechanical actuators The intuitively operable DORNIER ErgoWeave® touch screen panel

13 Other important improvements are also to Another optimisation provides the option be found in the throttle block and the re- of using only two relay nozzles per valve, lay nozzles. The throttle block can be easi­ly reducing the dead volume in the air lines repositioned to the required fabric width and therefore air consumption. These im- with only one tool. If necessary, the width provements are decisive success factors of adjustment can also be made symmetri- the new technology in practice. cally. The flow-optimised DORNIER sin- gle hole relay nozzle is maintenance-free TandemPlus and the PWC clamp and uncomplicated. The special conical An important enlargement of the weft bore of the nozzle ensures that an air stream yarn range of air-jet weaving machines is which impinges on the tip of the weft yarn effected through the combination of the TandemPlus­ main nozzle and the PWC The single-hole relay nozzle with bore conicity weft clamp which is positioned at the main nozzle outlet. Here, the weft end is held pattern or product data is transferred via by means of a mechanical clamp instead of USB stick or, alternatively, by Ethernet by air. For the first time, this enables core, Inter­face if the weaving machine is linked elastane, fancy along with low-twist yarns, to a bidirectional­ operating data system. to be processed gently and efficiently for DORNIER ­ErgoWeave® offers the weaver clothing and home textile applications on various useful functions, such as the produc­ ­ air-jet weaving machines. tion of statistical evaluations over the ­entire weaving process or the recording and elimi- P1 rapier weaving machine nation of stoppage causes via a system dia­ The P1 combines intelligent solutions gnosis tool. Reduced air consumption by way of 2 nozzles per valve which, in their totality, ensure optimised resource usage, and allow extremely flexi- DORNIER system family at ­supersonic speed does not destroy it, ble machine operation. Diverse component In the modular construction of the but carries it through the shed in the most groups and their functions have undergone DORNIER system family, comprising air- ­efficient way. With these features machine decisive feature changes – beginning with jet and rapier weaving machines, the im- downtimes are further reduced and fabric the drive, through filling insertion to rapid portant elements of FT control also provide quality is improved. and reliable product reproducibility with significant benefits. Approximately 95% of the possibility of retrieving statistic evalu- electronic and 65% of the mechanical sub- Process reliability and new valve ations. Weaving personnel workload is re- assembly components are of identical con- technology duced by shorter set-up times and increased struction. This simplifies the maintenance The patented DORNIER PIC® system maintenance-friendliness, with a resultant and operation of the machine types in weav- (Permanent Insertion Control) recognises increase in productivity. ing mills which utilise both DORNIER imprecise operation in the case of every ­rapier and air-jet weaving machines. Tex- magnetic valve involved in weft insertion Filling insertion tile production obtains optimum flexibil- from the very beginning, thereby guaran- Filling insertion component guidance is ity and productivity for current market teeing maximum process reliability. Con- perfectly resolved in the case of the P1: requirements in this way. siderable reductions in air consumption are The patented DORNIER AirGuide® guides also achieved with the new valve technology the rapier with extreme precision through A1 air-jet weaving machine due to there ultra short switching times. the shed, prevents capillary damage in the The new control architecture also has an ­effect on the “hardware”, i.e. on the ma- chine structure. This is clearly recognizable­ on the A1 air-jet weaving machine with the patented DORNIER ServoControl®-2, by the total redesign of the new, compact ­throttle block as well as the new tube layout for up to 8 main and tandem nozzles. Even with running speeds of more than 1,000 rpm, this layout prevents the compressed air tubes from getting into contact with each other which, if they do, can result in leakages and premature failure. In addition, this provides a clearer view and, in case of a filling break, a trouble-free ­access to the weft ends. The integrated pressure regula- tion plus semi-automatic filling threading also greatly improves operator handling. The new P1 rapier weaving machine with CompactDrive and FT control

14 case of ­filament warps, and also makes it possible to weave high warp densities prob- lem-free. The Electronic Color Selector ECS and the electronic yarn brake with integrated fill- ing stop motion EFC are based on modern stepping motor technology. In micro-step operation, yarn presentation in the color se- lector is effected with an automatic moni- toring and correcting function of the yarn needle stroke. Low tear strength yarns and highly tensioned heavyweight weft yarns, such as 2,400 tex glass for example, can be processed without any problems. Dif- ferent yarn needle motion profiles can be conveniently selected on the DORNIER ErgoWeave® panel. Due to the modu- lar construction system of the presenta- tion unit, individual modules can be added quickly and easily. A single-color machine can therefore be converted up to 16 colors at little cost. Throttle block and DORNIER ServoControl® unit of the air-jet weaving machine are disposed so as to be easily accessible and taken in at a glance The new drive concept A new drive concept with three options terning possibilities with improved fabric has shown that a reduction in compressed has been developed for the A1 and P1 sys- quality. Markedly smoother machine run- air requirement of 10 to 20% is achiev­ tem families: ning, and consequently a smaller load on able. The complete “weaving mill” system, DirectDrive – a reliable and low-mainte- the shaft/heddle system, produces a very including compressed air supply from the nance drive with no clutch-brake unit. It is good fabric quality and results in a longer compressors, should be considered here. A optimally suited to the production of stand- working life of mechanical components. lower compressed air requirement in volu- ard weaves with cam shedding motion. metric and pressure terms means a smaller CompactDrive – a powerful motor with Energy efficiency and sustainability energy requirement and therefore reduced maximum rotational stability even with a All of Lindauer DORNIER GmbH´s environmental CO2 pollution. This is a large number of shafts or with a high hook develop­ments are considered from the im- contribution to sustainability which will, in count in Jacquard machines. The flywheel portant viewpoint of energy efficiency and time, be followed by others. It also includes for the reliable weaving of heavier styles sustainability. In the case of energy effi- fully responsible handling of the yarn mate- is integrated in the drive motor. The air- ciency, it comes down to the sum of the rial to be processed. For example selvedge cooled motor’s clutch-brake unit is easily individual components, so that, at the bot- waste can be reduced by over 50% with accessible, and therefore maintenance- tom line, a user will see appreciable savings. the new DuoColor unit for ­rapier weaving friendly. This is the overall aim of the FT control con- machines. Such solutions also make it clear DORNIER SyncroDrive® – the innova- cept, which consists not only of the drive that the pioneering spirit is still alive in the tive, patented direct drive, where shedding motor but also of the weft insertion control company DORNIER and will ensure a is controlled by a separate motor. with the DORNIER ­ServoControl®-2 in continuation of the successful ­co­operation All drive variants have integrated speed combi­nation with the PWC clamp in order with our customers. control, and are designed for high eco­nomy to save on holding air. Experience to date and precision. They are also belt-free and require very little maintenance. Depending on the application required, whether it is colorful patterned Jacquard fabrics, high- density heavyweight conveyor belt fabrics, simple plain or twill weaves at high speed, ­always the optimal drive can be used.

DORNIER SyncroDrive® This intelligent drive enables very low speed variation, faciliating a so far unachievable speed potential for dobby and ­Jacquard weaving mills. Shed closing times are also adjustable via the DORNIER ErgoWeave® even at full speed, giving rise to new pat- The new A1 air-jet weaving machine with DORNIER SyncroDrive® and FT control

15 Quality creates value

Publisher and Copyright: Lindauer DORNIER GmbH 88129 Lindau/Germany Telephone +49 8382 7030 Telefax +49 8382 703386 [email protected]

Editor: Marion Heisler

Layout: evoq communications AG, Zürich 7301/w3/12/10 – All rights reserved! Issued once a year Date of this edition: December 2010 Reprinting only with our previous written consent, even for extracts

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