NONWOVEN LATEST DEVELOPMENT OF NONWOVENS FOR HYGIENE
FOR YEARS TO COME
SEPTEMBER 2019 CHAPTER OVERVIEW
01 ANDRITZ NONWOVEN
02 NONWOVEN MARKET TRENDS
03 ANDRITZ SOLUTIONS FOR HYGIENE
04 CONCLUSION
2 / ANDRITZ NONWOVEN / BCH CONFERENCE SEPTEMBER 2019 / © COPYRIGHT THE ANDRITZ GROUP
ANDRITZ is a globally leading supplier of plants, equipment, systems and services for hydropower stations, the pulp and paper industry, the metalworking and steel industries, and solid/liquid separation in the municipal and industrial sectors as well as for animal feed and biomass pelleting.
Global presence Headquarters in Graz, Austria; over 280 production sites and service/sales companies worldwide
SALES BY REGION 2018 (%) KEY FINANCIAL FIGURES:
UNIT 2018 2017
Order intake MEUR 6,646.2 5,579.5 Emerging markets: (as of end of period) Order backlog MEUR 7,084.3 6,383.0 Europe & 41% North America: 6,031 Sales MEUR 6,031.5 5,889.1 59% MEUR Net income (including non-controlling interests) MEUR 219.7 265.6 Employees (as of end of period; without apprentices) - 29,096 25,566
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Key facts of ANDRITZ in nonwovens
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Excellent partner for your nonwoven production processes
We’re here to give you support in every aspect of your nonwovens production from low to high capacities. You benefit from the most advanced expertise and complete solutions for:
AIR-THROUGH-BONDING SPUNLACE SPUNLAID/CALENDER CONVERTING
WETLAID NEEDLEPUNCH FINISHING LINES TEXTILE ANDRITZ Solutions for Hygiene 5 / ANDRITZ NONWOVEN / BCH CONFERENCE SEPTEMBER 2019 / © COPYRIGHT NONWOVENS MARKET
A market driven by Wipes & Hygiene applications
Source: INDA - EDANA
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Most competitive solutions for Spunlace
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Impact of the TT card web forming in the spunlace market
Tons / year
28 000 30 000 28 000 Introduction 26 000 of TT Card 24 000 22 000 20 000 18 000 16 000 14 000 12 000 10 000 8 000 6 000 4 000 2 000
1990 1995 2000 2005 2010 2015 2020
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The ANDRITZ solution for the wipes market
Carding Hydroentanglement Dryer Calender Winder
Key facts: Parameters . High efficiency Material: Vis, PET, PP, PLA, Cotton . Very high speed Fabric weight: 25 - 80 g/m² . Low energy consumption TT Card width: up to 5100 mm . neXecodry system Production speed: up to 300 m/min . Energy control Capacity : up to 22,000 t/p.a . Complete filtration system
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neXjet injector by ANDRITZ Injector Strip
Water feeding
Water needles
Web
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Distribution Holes vs. Distribution Slot
First Generation with Distribution Holes / Perforated body
New Generation with Distribution Slot
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Energy saving thanks to the ANDRITZ injector design
2,5 Take Away: Distribution Slot allows 15% of energy savings in comparison with Distribution Holes 2
1,5
Distribution Slot
BI BI (N/g/m²) Distribution Holes 1
0,5 To reach the same Bonding Index, the 15% Distribution Slot requires 15% less energy than the Distribution Holes 0 0 10 20 30 40 50 60 70 80 90 100 Energy Required (%)
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Trends for diaper applications
Market needs: . Ultra-light nonwoven fabrics . Softness . Bulkiness . Capacity
13 / ANDRITZ NONWOVEN / BCH CONFERENCE SEPTEMBER 2019 / © COPYRIGHT ALTERNATIVE SOLUTIONS FOR SUSTAINABLE WIPES
WetlaceTM process from ANDRITZ – ONE line, THREE different wipes
Line characteristics: . Standard drylaid and/or wetlaid webforming . Fabric weight: 40 – 80 gsm . Line capacity: up to 15,000 t/a . Raw materials: Pulp / Viscose / Others . End-uses: Flushable and bio degradable wipes
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Performing Spunlace process
Line characteristics: . Only one card in-line . Ultralight fabrics: 25-30 gsm . High productivity: 1450 kg/h . Raw materials: PET, VIS, Cotton . End-uses: Top-sheet and Back-sheet
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Latest innovation – the Isoweb « TT » card
350 m/mn 200 m/mn
1000 m/mn
. Lower speed ratio between main cylinder and worker speed, means nicer final web homogeneity. . Higher worker speed generates optimum fibre distribution on the main cylinder. . This is in favour of a uniform aspect for the final web.
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From bonding to finishing in Spunlaid: neXline finish
Low add-on, Process Winding/ Webfoming Thermobonding SpunjetSoft Drying dosing control slitting
Supplied by ANDRITZ
17 / ANDRITZ NONWOVEN / BCH CONFERENCE SEPTEMBER 2019 / © COPYRIGHT STATE-OF-THE-ART CALENDER FOR SPUNBOND neXcal twin pro designed for high speed Spunlaid lines
The neXcal twin pro is designed to increased needs of the market
Features: • Production speed up to 1,300 m/min with three different roll widths • Clean Machine Concept (CMC) to prevent contamination of the fabric and reduce manual cleaning hours • Calender equipped with additional sensors to reduce downtimes • New drive concept for the Hot S-Roll and cooling rolls: Direct driven to withstand the increased speed
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The neXdry through-air dryer is especially designed to suit the demands of spunlaid processes
Features • Up to 6 m working width • Speed up to 1,200m/min • Equipped with the innovative U-Drum, which consists of 100% stainless steel and has an open area of 96% • Roll-out design, for easy maintenance • Controlled air-flow system • Double temperature zones • Optimized energy consumption
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Air flow management: Structured drum innovation
Perforated plate U-drum
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Industrial dryers
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Innovative solutions in Spunlaid for new fabrics characteristics: Spunjet
Line characteristics: . Patented configuration . Very high speed: up to 1,000 m/min . Ultralight fabrics: From 10 gsm . End-uses: Baby diapers, Feminine hygiene, Adult incontinence
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Impact of SpunjetSoft on the bulkiness
High pressure water jets Conventional Spunbond
Softend Spunbond: SpunjetSoft
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Air-through-bonding
Conventional line
Dual line
Line characteristics: . Perfect web uniformity . High Speed: up to 250 m/min . Grammage: 16 to 80 gsm . End-uses: Top-sheet and Back-sheet and ADL
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ANDRITZ flat ATB oven – 600 mm working width – 200 m/min max
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Mixing synergies for customer oriented solutions
ANDRITZ complements its product portfolio in Nonwoven and is now able to offer the complete supply and value chain, from the raw material, to web forming, finishing and converting.
DIATEC gains from the international competence and financial stature of ANDRITZ to offer to its customers a reliable and trustful partner with highest technology know-how and excellent project management.
Adult Diaper Baby Diaper Sanitary Napkin
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Converting lines - examples
Baby diaper
Topsheet Drum Stacking and packaging Final cut Back ears Front ears Cellulose Filter construction forming module module module + SAP module module
Baby pants
Filter Cellulose Forming Waistband Final cut Stacking and defibration & SAP module Insert module construction unit packaging
Lines characteristics: . Baby diaper line: up to 1,000 pcs/min . Pants line: up to 600 pcs/min . Sanitary napkin / Panty shield line: up to 1,500 pcs/min . Adult diaper line: up to 400 pcs/min . End-uses: Baby diapers, Feminine hygiene, Adult hygiene
27 / ANDRITZ NONWOVEN / BCH CONFERENCE SEPTEMBER 2019 / © COPYRIGHT ANDRITZ TECHNICAL CENTERS
State-of-the-art technical centers dedicated to Hygiene market . Covering the main nonwoven technologies : Spunlace, Spunjet, WetlaceTM, Air-Through Bonding, Converting
Open to ANDRITZ customers for their own R&D and products development . From raw materials to finished rolls of nonwoven fabrics . Excellent correlation with real industrial production conditions (speeds, basis weights, machines format)
Spunlace and Spunjet Air-Through bonding Converting
28 / ANDRITZ NONWOVEN / BCH CONFERENCE SEPTEMBER 2019 / © COPYRIGHT CONCLUSION
For years to come
• Provider of solutions for Hygiene
• Spunlace line for ultra-light fabrics including high speed TT card and neXjet injector
• WetlaceTM for Flushable / Bio degradable Wipes
• neXcal twin pro calender and neXdry dryer for higher Spunbond productivity
• Spunjet process for added-value on Spunbond fabrics
• Customized Air-Through bonding lines
• Converting machines for hygiene
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FOR YEARS TO COME
SEPTEMBER 2019