Composites update.

what's new among suppliers of composite nonwovens

Ahlstrom Paper Group, Mount Holly Springs, PA, last year started up a 3.2 meter wide filter media line in Taylorville, IL. The line is designed to produce a variety of filtration and specialty products from a range of fibers, including polyester. Ahlstrom is also working on the development of a next generation "Hollytex" wet laid nonwovens line.

In the new product arena, Ahlstrom has added a lightweight (one ounce) wet laid polyester grade to its "Hollytex II" product line; the product is designed for uses where superiority and uniformity is essential, such as membrane substrates. In addition, the company is also offering a spunbonded point bonded polyester in weights from .5-3.0 ounces for general filtration and interleaving.

A new geosynthetic product, "TRC-Grid," has been introduced by Akzo Nobel Nonwovens, Arnhem, The Netherlands. TRC-Grid is made of a coated "Twaron" aramid mesh embedded in Akzo's "Colback" polyester nonwoven. TRC-Grid exhibits the properties of both reinforcement and separation and provides equal tensile strength in both longitudinal and transverse directions. In addition, it is UV-protected by the carbon black impregnated latex used for coating the Twaron.

TRC-Grid has been used in the Israeli port Haifa (pictured below) to improve the bearing capacity under a foundation at the container terminals and parking area and also at an expedition area of Scanglas A/S in Denmark, where differential rutting and settlement had occurred due to heavy transportation vehicles and containers on low-bearing capacity subsoil.

Roll goods producer Avgol Nonwoven Industries, Holon, Israel, is promoting its extrusion film laminating capabilities on a multiple head coextruder. The laminator has a variable width die that can handle up to 2.4 meters and can use 3-12 mil film on 10-100 gram per square meter spunbonds. The commissioning of a third spunbonded line is in the news at Don & Low Nonwovens, Angus, Scotland. The line, which utilizes "Reicofil ULT" technology, has doubled overall capacity of "Daltex" fabrics. In the new product area, Don & Low debuted "Daltex Roofshield," a spunbond/melt blown/spunbond (SMS) laminate (pictured here) in the 165 gram per square meter range. The triple laminate is used for underslate roofing and is waterproof, breathable, UV-stabilized and very strong.

Freudenberg, Weinheim, Germany, highlighted the move late last year that combined its Freudenberg Nonwovens and Freudenberg Spunweb businesses into one global business group, which is then divided into seven market-driven divisions. These include filters, hygiene/medical, footwear/synthetics, interlinings, technical nonwovens and carpet backings.

The company also focused on the addition of melt blowing capacity at its Kaiserslautern, Germany facility for the manufacture of hygiene materials. The line is expected to start up in the fourth quarter of 1998. Freudenberg is also debottlenecking spunbonded lines worldwide.

Several new products are in the works from Gelok International, Dunbridge, OH. A faster swellable tape is new at the company, as are new products introduced to capture, contain and control gases and odors, hydrocarbons and hazardous waste. The new products include baking soda, zeolite and activated carbon laminates. In other news, Gelok last year installed new equipment for the improvement of powder application. This resulted in very consistent lamination capabilities in both the machine and cross direction.

New composites for the automotive headliner market have debuted from Harodite Finishing, North Dighton, MA. The composites can include up to five layers, including core foam, fiber reinforcements, adhesives, barrier films and nonwovens.

Innovatec, Troisdorf, Germany, recently introduced a new line of roofing products. The line includes various laminates that can be made from different nonwovens, including melt blowns. Some of the material also incorporates water vapor-permeable foil.

Available from Johns Manville, Denver, CO, is its "R3100B" series of wet laid mats for insulation, ceiling tile and ductboard facing. The material is black, very flexible and has good tear and puncture properties. The company also promoted its respiratory protection media, liquid filtration media, allergen protection composites and specialty wet laid nonwovens for facing and reinforcing substrates from the newly-reorganized division of its Engineered Products Group.

News at Kappler Safety Group, Guntersville, AL, focused on its agreement with 3M, St. Paul, MN, that gives it exclusive worldwide rights to purchase and market 3M's microporous products for industrial safety apparel markets. The agreement also represents a formal process of technology transfer between the two companies. Kappler also acquired most of the assets of 3M's medical gown converting operations, including a supply agreement to purchase 3M microporous film components for the healthcare market. According to the company, the agreement gives Kappler access to the only two breathable disposable microporous fabrics - one of which is its own patented "Pro/Vent" fabric - proven to meet the OSHA Bloodborne Pathogens Standard for blood and viral protection.

In other company news, Kappler has reached an agreement with Hungarian protective coveralls producer Respirator to produce Kappler's nonwoven-based products for the Hungarian market. Respirator will be able to use Kappler's proprietary fabrics, including its "Pro/Shield 2" microporous fabric.

Finally, Kappler has also introduced several new products. "NuFab." which has application in protective apparel for nuclear operations and other radioactive work environments, is based on Kappler's patented microporous fabric technology and provides improved protection and comfort in a disposable garment. "Tempro," a premium line of limited-use water resistant and flame retardant apparel, is made from a fiber-based nonwoven and provides protection from moisture and sparks. Tempro is positioned as a cost effective cover for expensive reusable FR garments. "Dura/Vent" is a waterproof, breathable alternative to ultra expensive woven fabrics for various consumer products including a revolutionary activewear product called "frogg toggs."

A 16,000 square foot addition marks news at Midwest Filtration, Fairfield, OH. The additional space gives the company room for greater finished goods inventory. The company also operates five slitter/rewinders that allow it to offer widths from 1-150 inches.

Roll goods producer Pantex srl, Pistoia, Italy, started up its 3.2 meter hydroentangled line late in 1997. The line manufactures apertured and non-apertured products, primarily targeting wipe applications but also available for feminine hygiene and medical end uses.

Pegas a.s., Bucovice, Czech Republic, added a second spunbonded beam to its spunbond/melt blown line, increasing capacity by about 3000 tons per year. The company can now produce lightweight fabrics for barrier leg cuffs. The company also signed an agreement with Reifenhauser to develop spunbonds that are less them one denier in filament. The new line - with a capacity of 8000 tons a year - will come onstream in September 1998.

A strategic alliance has been formed between roll goods producer Sorbent Products Co., Somerset. NJ, and Rhodia AG, a division of the French Rhone Poulenc Group, bringing together melt blown manufacturing expertise and the marketing of a diverse line of sorbent materials. The alliance will form a marketing arm with a solid European-based manufacturing facility operated by Rhodia and based in Freiburg, Germany. The distribution and marketing will be orchestrated by SPC Europe, based in Mol, Belgium, and headed by Gerard Moeken, managing director.

Composites for the automotive industry are the concentration at Specialty Textile Products, Yardley, PA. Designed for applications including reinforcement for headliners, hoodliners and trim parts, the composites are based on combining nonwovens with natural and renewable fibers including kenaf for acoustical applications.

New capacity for the hygiene market has been added by Tenotex SpA, Terno D'Isola, Italy. An additional 6000 tons of spunbonded capacity and 4500 tons o f air through bonded capacity were installed last spring, while 4500 tons of spunbond/melt blown/spunbond (SMS) capacity were added in January 1998. All the lines are located in Terno D'Isola.

Vitaweb, Castleton, U.K., has expanded conversion and treatment facilities. Products include polyester spunbonds and polypropylene laminates.