9th annual show in print of the international nonwovens industry.
JOA has been making fluff since 1942, when the company patented its first pulp fiberization and mat forming system designed to replace tissue wadding in sanitary napkins.
Today, we offer a complete line of JOA designed fiberizing systems, sized according to throughput requirements ranging from 500 kg/hr. for sanitary napkins to 1500 kg/hr. for baby and adult diapers.
We have dedicated the JOA Screenless Mill to the task of pulp fiberization for the higher capacity applications. The close running tolerance between rotor and housing that is built into the JOA hammermill allows it to produce fluff without the conventional hole screen.
Removing the screen eliminates fluff surge problems, reduces fiber damage with a "one shot" working of the pulp and, with a modest 100 horsepower (75 kw), the mill can process 1500 kg/hr.
Drum Forming of Absorbent Cores
JOA began drum forming absorbent cores for our sanitary napkin machinery more than 25 years ago. In 1984, our engineering group began a transformation of this process.
The result is a production proven drum forming system for the much larger baby and adult product cores.
With product advantages like strategic three-dimensional fluff distribution and superabsorbent blending and process advantages like the elimination of the leg cut-out operation and related chip return, drum forming of the diaper core has become a JOA standard.
Modular Frame and Drive
The classical JOA approach to machine design is based on a sectionalized frame and drive construction with modular subassemblies arranged according to process and product requirements.
This fundamental approach extends the life of any JOA machine by allowing for retrofit of new process modules, designed to produce thelatest product features. Many existing JOA machines, some placed in production in the early 1970s, have been prepared for the 1990s with this type of conversion.
Examples of some current product, hence machine, upgrades include: Boy/Girl core design, poly barrier, elasticized waistband, standing leg cuffs, reinforcing frontal tape and tri-folding.
No single component in the JOA process is more universally known throughout the world than the Model 115 Stacker.
The concept of arranging a counted stack by gathering product in a moving paddle chain dates back to September 2, 1941, when JOA was issued its first patent for a sanitary napkin stacker. This stacking principle has been applied to virtually all of our product handling needs, including baby diapers, adult products and tri-folded and wrapped sanitary napkins.
Higher machine speeds and market demands for packaging versatility constantly create new product handling challenges. JOA offers a broad range of experience coupled with creative engineering energy to achieve solutions.
59 Years of Experience
Experience builds teamwork and challenge improves performance. From engineering through manufacturing, assembly and testing, the JOA team has accumulated thousands of man-years of experience. This talented team looks forward to the next challenge.
Experience and teamwork not only set the trends in machine design, but also guide JOA through its growth.
Curt G. Joa, Inc. has engineering offices and manufacturing plants in both of its U.S. locations--Sheboygan Falls, Wisconsin and Boynton Beach, Florida.
In January, 1990, the Sheboygan Falls group moved into a newly-constructed, 8500 sq. meter facility, designed for the assembly and testing of converting machinery. In March, 1991, one year later, we broke ground to construct an additional 8500 sq. meters in Wisconsin and 2500 sq. meters in Florida as part of our expansion plan.
For the European market, JOA established service representation in 1980, with an office and parts warehouse in Markbreit, Germany.
In October, 1989, JOA opened its new plant in Volkach, Germany. With 1500 sq. meters of assembly and testing floor space, we have additional capacity available for European projects involving machine upgrades and product development.
Perhaps the most important lesson experience has taught us is the value of a trusting relationship between supplier and client.
JOA is proud of its heritage and reputation as a company with which our clients can work confidentially to develop machinery for their specific needs.
We appreciate the many years of opportunity we have shared in this industry. With excitement, we invite you to contact us to discuss the future.
"We have all the resources of a big corporation, without having to act like a big corporation."
The speaker is Ed Hart, Product Manager. The company is Veratec's Natural Fibers Group. The sentiment is shared by an increasing number of customers, all over the country and all over the world.
For them and for you, doing business with the Natural Fibers Group yields the considerable support of a global "player", while at the same time offering the responsiveness you'd expect from a much smaller company. A part of International Paper's Veratec division, Natural Fibers Group is the largest bleacher of cotton fiber in the United States. In addition, it operates bleacheries in Canada and the United Kingdom. In total, these large facilities are routinely put to applications as diverse and far-flung as nonwovens, personal care products, filtration media, spun yarn, and highloft structures.
Zeroing In On Total Quality.
To understand the Natural Fibers Groups' commitment to quality, you need only look at the language we use. Area teams. Task teams. Lead teams. At Veratec, quality is everyone's business, from the senior executives to the hourly employees, to a degree unprecedented in the industry. Statistical process control(SPC) has been implemented company wide. Such an approach to quality allows us to quickly identify problems and prevent re-occurrences, always keeping in mind our ultimate goal of meeting our customers requirements 100% of the time.
When It Comes to Cotton,
Breakthroughs Are Unexpected -- Except
To some people, cotton is cotton. Absorbent. Soft. Comfortable. Unchanging. As the market leader, we find such thinking rather short-sighted. In fact, if our engineers thought that way, they never would have developed a product like Easy Street [TM] Super-Opened Cotton.
We began receiving requests from the nonwovens industry for a cotton fiber which had the performance characteristics of a synthetic. Which meant developing a 100% cotton fiber of uncommon processibility. Our response was Easy Street [TM] Super-Opened Cotton. And it has enjoyed a universally positive reception.
Whatever You Have In Mind,
We'll Help You Customize It.
We may be the largest bleacher in the United States, but we still run jobs as small as you require. Once we know your parameters, we'll get to work. We can show you how your product will behave with different kinds of finishes. We can blend a number of different types of cotton fibers. Or tailor its processibility to your process needs. When it comes to customization, no one has a total package like the Natural Fibers Group.
It Doesn't Cost Any More
To Work With The Best
What generally surprises first-time visitors to the Natural Fibers Group is how lean we run. Our pound-per-employee ratio is the best in the business, thanks in part to our technologically advanced operation. In concert with our enormous capacity and the financial and technical backing of International Paper, we can offer highly competitive prices to large and small customers alike. No matter where you're located.
It pays to look into Veratec's Natural Fibers Group. Whether you're already a major manufacturer. Or simply on your way to becoming one.
Air Products and Chemicals, Inc. has been a leading producer of emulsions for the nonwovens industry for more than 20 years. One of the first to develop emulsions designed to balance wet strength and softness, the company continues to improve the performance of its existing products and develop new emulsion binders.
Air Products offers special technical service capabilities in airlaid applications, wet pipe production, industrial wipes, underpad coverstock, highloft applications, needlepunch fabrics, a variety of flame retardant applications requiring MVSS-302 and NFPA-701 approvals, protective clothing, filtration media, automotive fabrics, antimicrobial formulations, flushable wipes and low-formaldehyde binders.
Air Products produces a wide variety of vinyl acetate-ethylene (VAE) emulsions for a broad range of applications. Their excellent performance and relatively low price have made them popular substitutes for mroe expensive acrylic systems.
Mainstays in the company's VAE portfolio include Airflex [R] 105, 109 and 120 emulsions. These combine the softness and flexibility of polyethylene with the excellent adhesion characteristics of polyvinyl acetate. Airflex 113 emulsion, a relatively new product, is used in food service and medical product applications. It offers high wet strength along with compatibility with cationics, such as water repellents and antimicrobials. Still another relatively new product, Vinac [R] 138 emulsion, has found considerable acceptance in automotive applications where strength and moldability are required.
EVCLs - Versatile
Air Products is the only U.S. producer of ethylene-vinyl chloride (EVCL) emulsions, and one of only two manufacturers worldwide. The company's EVCL products are used by the nonwovens industry because of their fire retardant characteristics, and by manufacturers of needlepunch fabrics because of their many performance benefits.
For example, EVCL films are heat sealable at low temperatures when using dielectric or ultrasonic processes. Their adhesion to a broad range of synthetic fibers and compatibility with various crosslinking additives contribute significantly to fabric moldability. And, when used in conjunction with commercial flame retardant additives, Air Products' EVCL emulsions also greatly reduce the flammability of fibers. This allows fabric manufacturers to meet MVSS-302 and NFPA-701 requirements at a substantial cost savings over compounded systems based upon acrylics, styrene butadienes, vinyl acetate-ethylenes, and polyvinyl acetates. The company's EVCL emulsions also provide high dry and wet tensile strength, and good abrasion resistance.
New additions to Air PRoducts' product line include Airflex 124 emulsion, the first vinyl acetate-ethylene-based binder offering low levels of formaldehyde and high wet strength. A superior performing nonwoven binder with very soft hand and excellent absorbency, Airflex 124 emulsion can produce fabrics containing less than 15 ppm formaldehyde. This product runs well on process equipment without fabric blocking. It also has been FDA clearances, and is safe for skin contact.
Another new addition is the company's line of flushable binders. These binders disintegrate rapidly in water for easy flushing, yet provide the excellent in-use wet strength and bonding characteristics of regular wipe products.
Focusing on Customers
Air Products' commitment to its customers is evidenced by its continuing emphasis on customer service and research. The company's product line is backed by a highly skilled technical team that can make specific recommendations for customers or work hand in hand with them to formulate the right latex binder systems to meet their specific needs. This team also has developed an in-depth understanding of customers' end-use applications and manufacturing processes to help resolve any problems that may occur during production.
Source reduction is an effective way to address the environmental concerns of disposable nonwoven products. Nordson systems for the precise application of hot melt adhesives and superabsorbent powders allow end-product manufacturers to reduce the amount of adhesives, powders, plastics and nonwoven materials in their products.
Nordson's 1989 acquisition of Germany-based Meltex Corporation expanded an already impressive array of specialty application equipment that contributes to nonwoven product performance and manufacturing efficiency.
The first innovation in the drive toward source reduction in disposable diapers was the introduction of superabsorbent polymer (SAP) into the fluff pad. While the earliest versions of SAP diapers were a homogenous blend of fluff pulp and polymer throughout the pad, Nordson's introduction of the Flexi-Spray [R] powder dosing system allowed manufacturers to dispense a discrete layer of polymer within the pad in either a continuous or intermittent mode.
A United States patent recently issued to Nordson allows the layered dosing of SAP within the pad, leading to additional changes in the state-if-the-art diaper of the 1990s. For example, this dosing allows for SAP concentration that has proven to be advantageous for the production of gender-specific diapers.
With this process, the SAP is isolated from the polyethylene backsheet. In a homogeneously blended pad, the gritty, sand-like SAP can be felt, requiring a thickened plastic backsheet. This problem is further aggravated by new high compression packaging used in the disposable market. By isolating the SAP within the pad, the polyethylene thickness can be determined independently of the superabsorbent.
The Meltex 3003 powder application system uses a gravured wheel to apply powder, primarily in topical applications. The precise powder application of Nordson and Meltex systems allows the use of significantly less powder per application while optimizing the effectiveness of the superabsorbent.
A growing number of
The advances in disposable diapers challenge manufacturers to add competitive features while minimizing material usage. With the addition of features such as standing leg gathers, in-line coating of frontal tapes and the acceptance of foam waists in almost all private label and branded diapers, efficient adhesive applications are critical to high line productivity.
Nordson's approach to minimizing adhesive usage involves their proprietary Controlled Fiberization process for the application of adhesives. The Controlled Fiberization process, developed in 1986, uses directed air jets to create a high-frequency spiral of adhesive, minimizing both the heat content and the diameter of the adhesive filament while maintaining precise edge control.
In backsheet lamination applications, manufacturers have been able to downgauge the poly backsheet without increasing burnthrough or heat distortion. Because the process spirals the adhesive at speeds up tu 100,000 spirals per minuted, the centrifugal force draws the filament into a fine fiber while the rapid movement cools the fiber before contacting the poly. The result is an edge-to-edge seal without overspray. This has allowed many manufacturers to reduce the poly content by as much as 25 percent while reducing adhesive usage by over 30 percent.
New application technology has also reduced the amount of material in elastic leg bands. Meltex led the way with application systems to replace thick rubber and elastic strips with thin, comfortable and economically favorable elastic threads.
The Nordson Controlled Fiberization process has proven to be beneficial in the attachment of these temperature-sensitive hreads. Since most of the heat is removed from the adhesive prior to the point of application, heat damage to the elastic threads is eliminated.
A global focus on the
The Nordson Nonwovens Group, located in Atlanta, has product development and application engineering centers in Atlanta, Amherst, Ohio, Luneberg, Germany and Tokyo. Nordson greatly enhanced its global position with the addition of Meltex Corportion. The Meltex organization provides a strong European base and expands Nordson's product line with a variety of specialized application equipment.
The Meltex operation in Luneburg, Germany manages the full Nordson and Meltex product portfolio in support of the European market. The operation provides Nordson with unsurpassed application engineering, product development and manufacturing capabilities in Europe.
Source reduction . . . the
key to continued growth.
Source reduction of disposable products delivers benefits to consumers and manufacturers alike. Consumers enjoy lighter weight, lower-profile products with a growing choice of desirable features. Manufacturers benefit from savings in material costs and enhanced manufacturing efficiency. More important, source reduction addresses the difficult environmental the difficult environmental issue of disposables while continuing to offer consumers the quality, convenience and economy they have come to expect from disposable products.
Nordson technologies will continue to focus on systems to help the nonwovens industry reduce the consumption of raw materials without sacrificing product performance.
PCMC Offers Full Line of Diaper Machines
Paper Converting Machine Company offers a full line of baby and adult diaper machines to meet the needs of today's market. The new Series 530 Diaper Machine, advanced drum former, high compression packaging station, automatic cutoff and flying splice unwinds, and the barrier leg cuff feature are all part of PCMC's full complement of converting machinery.
New Series 530 Diaper Machine with
Drum Forming System
The new Series 530 Diaper Machine has been engineered with over 80 design improvements to offer increased production speed and flexibility, as well as simplified operation and maintenance. It is available with the advanced drum forming system, termed Model 530-D. This system provides an effective means to produce specially contoured and shaped fluff pads, which cannot be done efficiently on the alternate flat wire forming system. The drum forming system includes a newly designed hammermill, which results in better quality fluff and higher and integrity.
Barrier Leg Cuff Now in Demand
The barrier leg cuff (BLC) feature, also known as the standing leg cuff, is an important new development which greatly improves diaper containment.
It is predicted that nearly all private label producers will soon add this marketable feature to the diapers they manufacture. PCMC can provide a barrier leg cuff system, tailored to the design requirements of existing or new machines.
New High Compression Packaging
PCMC has responded to the needs of the marketplace with the introduction of a new high compression packaging station. Grant Craig, PCMC Sales Manager for Disposables Machinery, explains: "High compression diaper packaging substantially reduces shelf space requirements, packaging materials and shipping costs. The new PCMC compression station can be added to new or existing baby or adult diaper machines. This high capacity unit can reduce diaper stacks up to one half (50%) of their original machine-made volume. Compressed stacks are accumulated to produce dual tandem or quad-packs and then transferred through loading horns for manual or automatic bagging. This new system offers diaper manufacturers increased efficiency and cost savings."
New Feature Saves Operator Time
Automatic cutoff and flying splice unwinds are now available for use with poly, nonwoven and tissue parent rolls. The automatic transfer eliminates the need for operator attention by automatically cutting off the operating web and splicing in the standby parent roll. The process is activated in one of three ways: 1) by sensing the expiring tail; 2) by sensing a preset minimum roll diameter which then activates the automatic web cutoff and splicing system; or 3) by manually triggering the cutoff and transfer process anywhere within the operating roll, as may be required to cull out a troublesome or off-quality roll.
Adult Diaper Machine Meets Needs of
PCMC's Model 610 Adult Diaper Machine is designed to provide the added production flexibility and efficiency required by the rapidly expanding adult incontinence market. The Model 610 now includes change over capability to produce all sizes of adult briefs - in addition to underpads and chair pads.
Why not a fiber that's both
chlorine-free and biodegradable?
That's a good question when you consider a fiber used in many applications, produced without chlorine or chlorine containing chemicals, which is also biodegradable. But there is nothing strange about the chlorine-free viscose that Svenska Rayon introduced last year, which is already widely used in many of Europe's leading tampon brands, wipes and other nonwovens for cosmetic and medical applications.
One year after introduction on the market, Svenska Rayon is still the only manufacturer marketing chlorine-free viscose on a commercial basis. The company produces a wide assortment of fibers from 0.5 to 20 dtex. Most of all, Svenska Rayon has grown into a specialist on fibers for the hygiene and nonwoven industries, while also manufacturing fibers for textiles and flocking.
"The reception for chlorine-free fiber has been fantastic", says Bo Holm, the Marketing Manager atw Svenska Rayon. "In addition to the high-volume customers now using Swelan Chlorine-free, many others have tested it and are happy with its suitability for use within their manufacturing processes."
"We have great expectations for this chlorine-free fiber in the future", says Bo Holm. "Its manufacturing process is clearly more environment-friendly than that for traditional viscose, yet it has the same fine characteristics as chlorine bleached fiber."
In Europe, the Svenska Rayon share of the market for nonwoven fibers is about 20 percent, and about 30 percent for fiber used in the manufacture of tampons. About 250 employees at the plant in southern Sweden can produce about 30,000 tons of fiber annually. About 85 percent of the company's production is exported.
An important reason for the growth of Svenska Rayon within this special product area is its ability to tailormake fibers to customer requirements. The whole organization is tailormade to tailor make -- when needed.
"Clearly, the lion's share of our production is fibers in standardized specifications", says Bo Holm. "But we have both the will and the resources to manufacture in special specifications when required."
Svenska Rayon sees a lot of potential in nonwovens, not just the traditional dry-laid and wet-laid, but also in the spunlace technique. Super fine fibers for spunlace is perhaps the most exciting area at the moment. The method is developing quickly and the total number of spunlace manufacturers has increased greatly.
In the area of medical, surgical, and hygiene products, most work to date has been done on tampons, but chlorine-free and biodegradable wadding fiber works just as well in cosmetic and medical products.
For most products in the future, strict requirements for hygiene will be placed on manufacturers. Svenska Rayon already pays careful attention that its viscose fibers are not exposed to any foreign particles during manufacturing. The physical characteristics of the fibers are tested in its laboratory, but more important is its continuous checks for chemical and bacteriological purity, pH, etc. These tests are the basis for certification stating that deliveries meet standards such as those set by European Pharmacopoeia, FDA, BGA.
Svenska Rayon, since changing owners in 1990, has invested to meet stricter requirements for purity and environmental considerations. For example, at its plant, liquid petroleum gas has replaced oil as a source of energy. As Swelan Chlorine-Free becomes more and more successful, viscose bleaching and viscose raw materials promise to be chlorine-free to a greater extent.
The new consortium of owners which took over Svenska Rayon from KF, large Swedish industrial group, includes Goran Brorsson, Managing Director, and other industrialists with their roots in several areas of Swedish industry.
Latexes For All Your
As you develop nonwoven products, we at BFGoodrich develop new latexes to help you. Thanks to our extensive R&D efforts, we have expanded our broad line of latex products to meet the ever more demanding requirements of the nonwovens industry. We have also sharpened our process controls and manufacturing efficiencies. As a quality producer of a broad line of latex products, we will maintain a leadership position well into the future.
We have a family to new flame-retarding plasticizer-free Geon vinyl latexes. They are heat-reactive latexes for paper, textile and nonwoven applications where flammability, resilience and water-resistance are the critical properties. These new products join our family of plasticizer-free latexes, developed for applications where the presence of plasticizers may be undesirable because of their potential extraction or migration.
We also added new heat-moldable latexes for the nonwovens market. These are finding application for automotive, filter and textile uses--particularly as resin replacement systems. In recent years, the presence or evolution of formaldehyde has been the cause of government regulation and product modifications. For many years. BF Goodrich has produced formaldehyde-free vinyl chloride and acrylonitrile butadiene latexes. BFGoodrich also has new formaldehyde-free latexes to expand the choices available to the nonwovens producer.
Broad Product Line
The number of applications for nonwovens is rapidly expanding and we have four lines of versatile latexes to meet the industry's ever-changing demands:
Geon vinyl chloride latexes--These emulsions of vinyl chloride and vinylidene chloride copolymers are designed for coating, impregnation and saturation of fibrous materials such as nonwovens, textiles and paper. Their resilience, adhesion to polyester, resistance to laundering and drycleaning solvent, flame retardant capabilities and good color retention make them excellent binders for highloft nonwovens as well as nonwoven coatings.
Hycar acrylic latexes--This varied latex line features a broad range of glass transition temperatures (-55-103 C). These dispersions of acrylate copolymers combine properties such as heat reactivity, excellent adhesion characteristics and wet and dry strength. As nonwoven binders, they offer durability, light and heat resistance and good resistance to drycleaning solvents.
Hycar nitrile latexes--these acrylonitrile-butadiene copolymers help finished nonwovens achieve a pleasant, soft hand, high tensile strength and drycleanability. Hycar nitrile latexes are distinguished by the combination of solvent, oil resistance and resilience that they impart to nonwoven fabrics.
HyStretch elastomeric latexes--These unique elastic materials have the unusual ability to stretch and recover better than most rubber latexes. They also have excellent heat and light stability properties. When applied to nonwovens, these binders lend resiliency and liveliness, as well as ultra softness and durability.
Latexes are giving nonwoven fabrics added benefits in a variety of application areas:
Highloft Products--Geon vinyl latexes can be used to bind highloft polyester nonwovens. A properly fused nonwoven pad will have resiliency, loft retention and flame retardance. In addition, Geon latexes render these nonwovens formaldehyde-free, washable and drycleanable.
Filters--Lofty nonwoven fabrics, bonded with Geon and our Hycar latexes, are ideal for use with flame-retarded and industrial air filter applications. Many of these latexes have broad FDA acceptance, such as 177.2260 for use in filters for milk and potable water.
Medical/Surgical Products--Surgical drapes demand a very soft latex binder. Surgical packs consisting of face masks, hand towels, etc., are composed entirely of single-use disposable nonwovens. Hycar latexes help develop quality nonwovens for medical applications with low levels of lint and emulsifier.
Semi-Durable Towels--Binders made with Hycar latexes give the extra advantage of oil and solvent resistance to industrial towels. In addition, they offer wet tensile strength, abrasion resistance and soft hand. For household towels, Hycar acrylic latexes provide toughness and solvent resistance.
Other Products--Latex binders provide a host of added benefits to a vast number of nonwoven products. Interlinings, sleeping bag fillers, scouring pads, disposable diapers, personal hygiene products, fabric softener sheets, synthetic leather, permanent care tags and wall-coverings are just a few application areas where latex binders can improve the strength and flexibility of nonwoven products.
Consistent Manufacturing Quality
BFGoodrich has latex manufacturing facilities in Louisville, KY; Akron, OH: Avon Lake, OH: and Pedricktown, NJ. These manufacturing facilities are dedicated to meeting our customers' needs for a uniform latex product. These plant locations position BFGoodrich Specialty Polymers and Chemicals Div. as a dependable supplier of quality latex products--the same every time--now and in the future.
Nuova Red Italiana designs and manufactures a wide range of converting lines for baby diapers, adult diapers, incontinent pads, sanitary napkins and panty shields.
The company has a unique mix of technical know-how and exclusive patents and sales experiences so that it has been capable of reaching a prominent position in the international market in a few years, a position that is intended to be consolidated with skillfulness.
The capability of the Nuova Red engineers to develop and carry out new ideas is well renowned. It comes from a deep knowledge of diaper technology and markets and from the ability to notice the changes. Nuova Red Italiana is capable of responding to the most sophisticated market demands and providing flexible solutions tailored according to customer requirements, giving them a product of the highest quality standard.
Machinery Production Range
1. Baby diaper machine BA-180; maximum production speed 350 diapers/min., more recent developments on the baby diaper lines are:
- drum forming with individual pockets
- elastic waist applicator (foam)
- triple folder
- frontal tape applicator (for self adhesive tape)
- frontal tape applicator with glue coating on line
- horizontal stacker
- compacting unit
- leg gathers applicator
Other optional features for baby diaper lines include:
- water jet cutting
- blue poly barrier applicator
- S.A.P. applicator
- Lycra elastic threads
All this equipment can also be retrofitted to any existing machine.
2. Sanitary napkin machines. Currently there are two different series of sanitary napkin machines, one designed for 350 pcs/min and another designed for 550 pcs/min.
The machine model DH-560 + DH3-560 is designed for a maximum production speed of 550 pcs/min. The machine is equipped with a drum former for individual pockets and can also be retrofitted to any existing sanitary napkin machine, even those not made by Nuova Red.
All the splices of the raw materials are fully automatic and the machine can be equipped with a triple folder and an automatic packaging section.
The other sanitary napkin machine that is currently in production is the model AS-560 + PA-560, which is designed for a production speed of 350 products per minute.
3. Machine for making perforated polyethylene. This machine is designed to produce a roll of perforated P.E. with a width of 1200 mm at a production speed of 45 m/1'.
4. Adult diaper machine. The adult diaper machine model AD-760 is designed to produce adult diapers with elasticated legs at a production speed of 150 pcs/min. The machine can be equipped with the following options:
- drum forming with individual pockets
- elastic waist applicator (foam)
- triple folder
- frontal tape applicator (for self adhesive tape)
- frontal tape applicator with glue coating on line
- horizontal stacker
- compacting unit
- leg gathers applicator
Customer Oriented Company
The customer is never left without service as, with the machine, Nuova Red sells the experience and skillfulness of its personnel. Service and spare parts are always available, even for obsolete models.
Since it started, Nuova Red has had constant development and success, so that more and more companies all over the world have prized their efforts.
But the dependability of Nuova Red does not rely only on its firm consistency, but also on the continuous research to improve the ratio of cost/performance on the innovations that are always one step ahead and, most of all, on the customer service high quality standard.
ETS. ASSELIN, a member of N. SCHLUMBERGER's nonwovens group, has developed and refined the DCIN batt compressive feed system initially introduced at the 1987 ITMA in Paris. The DCIN is presently operating at more than 15 nonwovens factories worldwide and is now being introduced to the North American market.
The DCIN consists of two continuous aprons positively driven, which compress the cross-lapped batt and release the compressed batt at close as 0.44 inches from the first row of needles.
The two driven aprons, with speed control by DC drive, provide complete control of the batt both in the machine direction during the compression (forward drive mode), as well as side-to-side (cross directional control), enhancing the uniformity created by the cross-lapper for which ASSELIN is well reputed.
Due to the control of the entire batt, tensions of draft can be controlled from feed-in through the needle zone and the subsequent exit of the loom through the delivery rolls. This gives the customer an ability to induce tension on the batt at levels determined by the user, allowing for exact control of fiber migration within the needle loom.
N. SCHLUMBERGER (USA) will shortly have in their Fort Mill, South Carolina showroom a completely new nonwoven line with opening/blending equipment from HOUGET DUESBERG BOSSON (HDB) and carding (double doffer) by THIBEAU, feeding the ASSELIN cross-lapper, four meters in width.
The first of two looms, 3.5 meters in width, a single board down punch, will be fitted with DCIN batt compressive feed, with subsequent needle punching by a two board, up punch needle loom.
Mercer Corporation has been providing precision hot melt adhesive applications systems to the nonwovens industry for more than two decades. Mercer's nonwovens specialists are constantly working with leading disposable manufacturers, providing them with adhesive application equipment that increases productivity and improves product integrity.
Mercer is the originator of the patented "NO CHAR" multiple grid, "melt-on-demand" system, which melts the adhesive in up to five stages. This process isolates high temperature adhesive from oxygen...eliminating char. Mercer manufactures a complete range of hot melt application equipment with pumping and melting capacities to 2500 lbs/hr.
Research and development of techniques including extrusion, spray, and rotogravure printing are continued daily in our corporate laboratory and testing facilities. Additional satellite laboratories have been established in the Minneapolis/St. Paul area and the United Kingdom.
As spray technology becomes increasingly popular, a selection of hardware, preheat components and accessories has evolved. Mercer was a true forerunner in regards to spray technology and has offered systems since mid-year 1985.
Additional technologies are being developed and show merit in specific nonwoven applications where precise deposits of hot melt adhesive are essential. The recent introduction of a rotogravure coating system offers the ability to pattern print or continuous coat hot melt adhesives onto nonwovens as well as other substrates.
The TEKNACOAT rotogravure coating module combines an engraved gravure cylinder, a silicone covered backup roll and a completely enclosed pressurized reservoir. The completely enclosed fluid reservoir uses symmetrically opposing doctor blades to contact the cylinder. End seals conform to the engraved cylinder to close off the reservoir ends. This system provides a simple, clean, trouble-free application of hot melt adhesive to the substrate.
An alternative system, the TEKNAPRINT SP117 hot melt screen printer, offers the ability to pattern print or zone coat at high speeds.
Mercer has recently expanded its corporate facility and laboratory testing services to enhance its position as the "Performance Choice" for nonwoven converters. As a private family-owned business, it is believed that in order to serve...and maintain the proper reputation...a one on one commitment to each customer is essential.
Adult Diaper Machine Model ADI
The Model ADI is available with a drum forming section and bi-trifolding unit. A specially designed water jet shaping system allows easy and rapid change over size without substituting any cam. designed to meet the requirements of the incontinence product manufacturers, the Model ADI combines flexibility with the highest quality, maintaining the minimum waste level.
Hospital Underpad Machine
Specially engineered and built for hospital underpad production, the Model AUP is not a simplified version of an adult diaper machine and achieves the best output/price ratio. As do all of our production machines, the Model AUP incorporates the most advanced features, such as automatic on-the-fly splicer for unattended change of raw material rolls, tension control with shaft driven unwinders and web guiding systems.
Baby/Adult Bib Machine
The Model ABA-2 manufactures a new style disposable bib characterized by a three-layer structure composed of nonwoven (filtrant), tissue (absorbent) and polyethylene (water proof). Other typical features of the bib are the crumb catcher, the tummy tape and the shoulder fastening adhesive tapes. The Model ABA-2 is capable of manufacturing both baby and adult bibs with an easy changeover.
Lady Napkin/Panty Shield
Machine Model ALN
The Model ALN, in its various configurations, is able to manufacture lady napkins of any type and shape including winged sanitary napkins. Equipped with a molded forming wheel for the tridimensional shaping of the fluff pad, the Model ALN does not require the use of the tissue to allow significant savings on raw material cost. In addition, the Model ALN is also available with a thermobonding system for the activation of synthetic fibers in the absorbent pad.
OUR LATEST ACHIEVEMENT:
PERFORATED POLYFILM MACHINE MODEL AMP
Foam Waist Band Applicator
A unique system stretches and applies the foam material between the poly and the nonwoven at each end of the diaper. Flexible and reliable, the applicator Model RFW has been engineered to be easily retrofitted to any existing baby diaper machine.
Complimentary Units For: Elastic Waist Bank Application Tape Tab Application Trifolding of Baby/Adult Diapers Stacking and Packing Operations Thermobonding of the Fluff Pad Trifolding and Individual Packing of Lady Napkins Automatic Quality Control of the Finished Product
FAVOR SAB FAM
FAVOR SAB FAM, manufactured by Chemische Fabrik Stockhausen GmbH, is a line of superabsorbent polymers developed specifically for the absorption of blood and serous body fluids for utilization in feminine hygiene products.
Today's market preference for individually wrapped, ultra thin feminine hygiene products has necessitated new "state of the art" absorbent core technology, which can be greatly enhanced by Stockhausen's new FAVOR SAB FAM superabsorbent polymers. The introduction of this innovative product into the fluff matrix increases pad absorption and retention, and allows for the design of ultra thin, leakproof feminine personal care items.
FAVOR SAB FAM superabsorbent polymers feature a patented blend of organic components, low neutralization factor, and a particle size distribution ranging from 100 - 350 microns, which combine to improve total absorption, increase absorption speed, and prevent the "blackening" discoloration of the swollen superabsorbent particles (See Figure #1).
The research and development of FAVOR SAB FAM superabsorbent polymers for sanitary feminine hygiene products required special consideration of the chemical and physical properties of menstrual fluid (See Figure #2). The precise analysis of protein content, inorganic components, viscosity, density, pH values, and surface tension has enabled our scientists to formulate a prototype menstrual fluid for superabsorbent testing (Frauenklink der Universitat Muenster; Dr. C. Ebert, Professor Dr. F.K. Beller).
Suggested application rates for FAVOR SAB FAM superabsorbent polymers range from 0.8-1.2 grams per pad, dependent upon pad design and performance requirements. The retention capacities of FAVOR SAB FAM superabsorbent polymers have been measured to be approximately 14.5 grams fluid/gram superabsorbent in fluff combination tests. This value will vary slightly with the retention capacity of the absorbent core materials, which normally range between 1.5-1.8 grams fluid/gram core material (STN 2137/90).
FAVOR SAB FAM has been patented in a number of countries including: European Patent Office - 0071063/82106196.7 United States Patent Office - 4693713 - Sept 15, 1987.
Don't just respond;
Throughout Zuiko's history, bold ideas have let use develop new technology to meet consumer's desires before they become demands.
A good example is the idea of folding napkins in thirds to wrap them more discreetly. Women everywhere welcomed the unprecedented subtlety.
Today's consumers are beginning to recognize the problems of industrial waste. Zuiko is already addressing the issue by developing many types of ecologically sensitive aftertreatment equipment.
For example, our equipment individually wraps sanitary napkins in paper instead of plastic.
Our aim is constant: produce technology that will satisfy the market with minimum labor. We are confident of our technology in changing times, because we keep an eye on progress. We explore new directions -- before they become trends -- always seeking the best way to create a new generation of soft disposables.
The Ultimate Barrier Supplier
In 1976 Vintex introduced coated fabric barriers based on its coating "Formula 28" to manufacturers of washable and reusable incontinent pads and adult diapers. With 15 years of success throughout North America and Europe, literally tens of millions of yards have been consumed by industry.
The Vintex company has changed in many exciting ways since 1976.
In 1986, Vintex introduced itself vertically with the introduction of circular knitting to provide superior base fabrics to support the coating.
Vintex pioneered many new knitted fabrics including their renowned 08 fabric, which is made of 100% textured polyester. In addition, they were the first to introduce checker board and terry looped polyester fabrics designed to provide an anti-slip base to the incontinent pad.
During 1989 Vintex increased its knitting and coating capacity by over 250%. At this time they increased the coating width to 80 inches.
In 1991 Vintex added new knitting machinery which allows them to make an infinite number of patterns on an anti-slip backing.
The "Hidden Advantage"
The barrier's unique formulation allows the manufacture of an economical six ounce membrane coated onto a base fabric, formulated to withstand the rigors of multiple launderings while remaining impermeable and supple.
Each production lot is thoroughly inspected and tested to ensure the integrity and consistency of the coated barrier.
What About Service?
Vintex offers a turn around cycle averaging less than two weeks and production runs of 5000 yards or more, custom slit to your desired width, reducing your cutting requirements.
Formula 28 is available in almost any imaginable color. They offer a fast color chip service to show what the membrane color would be like.
While a six ounce per square yard is the industry standard, Vintex can provide increased weights when an application requires it. The base fabrics can vary from lightweight non-wovens or knitted jersey scrims to heavier knits and woven fabrics. This allows you to match the right coated fabric to your specific requirements.
Bikoma: Thirty Years Of
Machines For Hygiene
This saying sums up the production program and the business policy of the Bikoma Group.
The manufacturing program of Bikoma includes machines for disposable hygienic articles such as ladies' sanitary napkins and complete diapers for babies and adults as well as surgical compresses and hospital underpads.
Let us flash back to the year 1961, when the Bischkopf family took over the Drehsen & Dreesbach company. The founder of the Bikoma Group, Walter Bischkopf, was not at all an unknown newcomer in the sector of hygienic products. Since 1941 he had gathered experience in this line of business, gained on machines of the company he took over 20 years later.
This great experience was passed on by the father to his eldest son, Gerd Bischkopf, who is currently successfully conducting and steering the Bikoma company. It goes without saying that the clientele is also profiting from these 50 years of experience, besides others in respect of product structure and raw materials to be used, which are subject to a steady further development.
Bikoma stands for a very strong export orientation. The export share covers around 85-90% of the turnover and is spread over more than 80 countries all over the world.
There is no doubt about it, this considerable export share finds expression in the business policy of the company, which is not only oriented towards economic success but also considers intensively the problematic situation in the development area of the hygienic field, where "hygiene" is an abstract term. Unfortunately, it is still a matter of fact that, especially in countries of the so-called Third World, a lack of hygiene is the main reason for a high mortality rate among children and adults.
This export orientation has another positive secondary effect. The world is moving closer together. People of different cultures and mentalities become acquaintances and even friends, due to the frequent travels of Mr. Bischkopf and his staff to foreign countries and by numerous guests visiting the factory in Mayen.
Bikoma belongs to the sector of special mechanical engineering in this branch, having around 160 employees. Also on the site is a construction and development department, which secures the most effective and profitable constructions. By this Bikoma is in the position to offer suitable machine conceptions for each new product entering the market.
Moreover, the company is always keeping in mind the up-to-date automation and rationalization necessities and possibilities leading to the achievement of the best possible continuous maximum rating of their machine constructions and conceptions.
The coming decade at Bikoma is set under the motto:
Bikoma-- Traditionally For Progress
New Ultralight [TM] Aluminum
Idler Rolls Ideal for
Low Inertia Applications
Introduced for the first time at CMM8, Webex Ultralight [TM] idlers represent a new breed of lightweight aluminum idler rolls designed to meet the demands of low-wrap/low-tension applications or where web slip is unacceptable.
Like Webex standard aluminum idlers, Ultralights are dynamically balanced to operate at high speed. Weighing as much as 60% less than their standard aluminum counterparts, these low inertia idlers offer breakaway torques as low as 0.2 oz./in.
A standard 6" diameter aluminum idler with a 45" face length, for example, weighs 33 lbs., while the same size Ultralight weighs only 16-1/2 lbs. As a result, Webex Ultralights are ideal for low-tension applications and as a high-performance alternative to more expensive composite rolls.
Each roll is made entirely of aluminum except for bearings and shafts. A special steel stub-shaft eliminates the added weight of a full length shaft. Double bearings at each and keep stub-shafts true to the roll, minimizing bearing side-loading. These small diameter bearings are also oil filled for dependable free-running performance.
New Precision Vacuum
Rolls Ideal for Special
Web Handling or Control
Webex vacuum rolls are ideal for use in a wide variety of applications whenever specifications of the web or process require special web handling or control.
Unlike others, the Webex vacuum control roll design provides a maximum surface area to carry and support the web. This unique design provides superior web support and control to avoid marking or patterning the web.
The controlling vacuum is applied through a carefully determined combination of vacuum ports and spiral grooves. The size and concentration of grooves, number of ports and port size are all design details that will vary based on each specific process.
Vacuum ports are drilled through the roll at the exact centers of predetermined groove intersections. The spiral grooves distribute the vacuum equally across the face of the roll holding the web evenly in all directions.
The Webex vacuum roll is precision-engineered for maximum performance across a full range of web widths. The active vacuum field across the face length of the roll is adjustable providing precise control over the performance of the vacuum roll and the position of the web. It also allows running of varying web widths without having to change vacuum rolls between runs.
The active vacuum area across the radius of the roll surface can be specified from 30 to 180 degrees when ordering. Roll material can be specified in a variety of materials including steel, aluminum and stainless. Custom roll coatings and finishes are also available.
Delivery of Idler Rolls -- or
Order is Free!
WEB.EXpress is a new service developed to meet the demands of web converting and machinery manufacturing customers needing precision idler rolls in as little as 48 hours.
Customers can order from over 22 styles of precision idler rolls profiled in the Webex Idler Pricing Guide, presenting both steel and aluminum idlers with over 200 different combinations of roll and shaft diameters, wall thicknesses, face lengths and quantity pricing breakouts.
WEB.EXpress idlers can be ordered as either "3-Week" or "48-Hour" turn-around service. WEB.EXpress orders are limited to six idlers of the same size. All "3-Week" WEB.EXpress orders are guaranteed shipped within 3 weeks or a 10% credit is awarded for each late day. WEB.EXpress "48-Hour" orders incur a 50% upcharge to cover special handling and are guaranteed shipped within 48 hours hours of the order is free.
WEB.EXpress can help keep production schedules on schedule... complete a customer's machine order on time...or get your process line up and running again. Whenever you need a precision idler roll really fast, Webex delivers. Guaranteed!
W+D HAS ACHIEVED A NUMBER OF IMPORTANT ACCOMPLISHMENTS:
It was the W+D organization that perfected the now popular concept of vacuum forming the individual pads which constitute the defiberized pulp core for personal disposables.
W+D engineering has established new standards for product quality and for product efficiency by way of this interesting development.
The W+D vacuum pad former enables the feminine pad manufacturer to form pulp pad cores which are consistently uniform. This uniformity means that the physical size dimensions do not vary from pad to pad. it means that the weight and the density of the formed pulp core can be tightly controlled.
Vacuum forming means the ability to form single pads. The W+D vacuum former transports the individually formed pads by vacuum to the subsequent steps in the converting line. This is accomplished without die cutting the cores. The quality of the pad core is enhanced by eliminating any compacted or hard edges that are created by cutting operations.
This enhanced product quality goes hand in hand with improved efficiency. Eliminating cutting of the pad core also eliminates handling and recycling trim waste. Since the W+D vacuum former is creating individual pulp cores and can transfer them by vacuum, the carrier tissue is no longer required for the conveyance of the pulp cores. This feature represents major cost savings to manufacture the pad.
W+D IS EMERGING AS THE LEADER IN FEMININE PAD MAKING TECHNOLOGY:
W+D's perfection of the vacuum forming technique has cleared the way for new product potential. The individual pad forming chambers can be structured to create "shapes." These creative shaped cores can be tapered to fit more comfortably. The vacuum formed cores can be anatomically shaped to be more appealing to the user, which presents many new marketing possibilities.
W+D has established new standards for higher production speeds for the feminine pad manufacturer. W+D "high-speed" converting lines are now rated in excess of 700 pads per minute on specific machine configurations.
These new production speeds combined with the product quality which can be achieved on W+D feminine pad converting lines represent major accomplishments on the part of this equipment manufacturer.
W+D IS PROVIDING A NEW SERIES OF ONGOING INNOVATIONS:
In addition to such important factors as higher production speed potential and the additional product versatility, W+D has recently developed some further enhancements to their product lines.
During the time of the PaPro '91 Exhibition, W+D will be demonstrating at their plant in Neuwied new simplifications in the pad forming technique on their Model 640.21 pad line.
A very important W+D innovation is the Model 670 single pad trifolder and overwrap unit. W+D's 670 is simple in design and is very easy for the machine operator to understand. Maintenance for the unit will be minimal.
The 670 is available with a unique pad bypass system. This means that with minimal machine change, the pad manufacturer can virtually switch from flat pads to tri-folded pads or vice versa on the same converting line. This is an excellent way to increase machine utilization.
W+D IS ATTUNED TO TODAY'S ENVIRONMENTAL CONCERNS:
W+D's new finished pad delivery stacker will also handle either flat or tri-folded pads. The pad discharge out of the delivery stacker will transfer into existing paper cartoning or poly bagging equipment.
The new W+D Model 670 is designed such that the manufacturer can use poly film or treated paper for the tri-folded pad overwrap material. Machine change time to switch from one type of material to the other has been kept to a minimum as a result of W+D's simple sealing system.
W+D definitely warrants your personal visit during PaPro '91.
The SINGER Textile Laboratory
Our textile laboratory for needling technique of nonwovens is equipped according to the latest knowledge concerning needle development (felting and structuring needles), as well as nonwoven products for all application fields.
Besides an optimal lab equipment with needling machines having working widths of 150 mm, 400 mm and 800 mm, with needle densities of 1800 and 3000 needles per meter working width, we also have measuring devices to measure the weight and thickness, air permeability and density that is performed by textile technologists with long experience in all fields of the nonwovens industry.
Except a penetration force measuring device for single needles, all lab needling machines are equipped with measuring devices produced for a cumulative penetration force measurement. A quick test performance is guaranteed by direct availability of most different needle types for each corresponding application, with subsequent computer evaluation of the measuring data. For ensuring a quick needle change as well as for demonstration and training purposes, we can show you our machine for loading and deloading needles from needle boards.
Speak to us. We not only accept the challenge of our needle development, we are also ready to support YOU by solving your problems at any time. A confidential cooperation is the best basis for functional needle application resulting in optimal nonwoven products.
SINGER laboratory for application technique. Tel: 02405/609-250.
Small Sensor Continuously Scans, Measures and Controls
the Weight of Nonwoven Materials During Manufacture
In the arena of on-line weight gauges, NDC Systems is unique with a small flashlight-sized sensor that measures the weight-per-unit area of nonwoven materials from just one side of the sheet. Compared to traditional transmission gauges that require a large source and detector on each side of the web, the NDC gauge has the advantages of easier installation and mountability, smaller space requirement, lower cost, and greater reliability because of its inherent simplicity.
Typical applications include measurement of diaper cover material in the range of 20 [g/m.sup.2], interlinings at 80 [g/m.sup.2], skin wipe cover stock at 15 [g/m.sup.2], and heavier materials.
Coatings, adhesive weight, latex addition, and similar processes are measured by placing a sensor before the coater to measure the base material, and a sensor after the coater to measure the total of base and coating. After a predetermined lag to effect same-spot measurement, the two readings are subtracted to yield net coat weight.
NDC has developed a modular, building-block approach to gauging, allowing the user to choose from simple, fixed-sensor systems with digital readout of weight, to state-of-the-art systems featuring 19-inch color CRT split-screen displays with touch-screen controls for unparalleled ease of use and flexibility. Two-way communications with a host computer and optional automatic controls assure upward compatibility with ongoing plantwide automation. A mid-range system combines a simple scanning gauge with a PC (user's choice) for display of sheet profile, X-bar and R charts, and more.
NDC has been supplying gauging systems to industry for over 24 years and has over 3000 installations worldwide. Whether the application calls for a simple gauge or a sophisticated system, NDC can help increase quality, save material, reduce waste, and permit faster start-ups.
In 1986 the company Schott & Meissner Maschinen und Anlagenbau GmbH set up in business and is mainly working on lines for thermobonded and chemical stabilized nonwovens.
Scope of delivery of Schott & Meissner covers lines and plants for heat treatment and drying purposes. Lines for nonwoven stabilization and for rubber thread production represent the main range of application, particularly because they have many years of experience that enables them to determine special conditions on production processes and to offer optimized and perfected solutions.
Nonwovens stabilization starts after the fiber formation and ends by the stabilized, but uncut, nonwoven. This range of nonwoven stabilization covers thermobonding (melting fiber addition, melting powder addition) and chemical stabilization (spray application, impregnation, coating). Quilting fabrics and interlinings for textiles, mattresses, insulating pads and moldings for the automotive industry are examples for the range of application.
Supplementary machines such as spray cabins and impregnating units that are part of the production process will also be designed and delivered by Schott & Meissner.
The center of all plants is always the heating tunnel, where the material is treated specifically with hot air, and the conveying system, which is transporting the material through this heating tunnel. Only high-quality products from known manufacturers will be used for designing these plants. Electrical control can be realized either conventionally or by using program controls.
Apart from nonwoven stabilization and rubber thread production lines, Schott & Meissner takes care of nearly all matters that have to be treated with hot air and special designed lines and machines. According to the specifications given by the customer and, of course, by the product, a line concept will be developed accordingly.
The business practice is aimed at upright and lasting business relations with the customer. Even the design the customer requests will be included, leading to custom-designed plants.
User's experience in production processes and Schott & Meissner's experience in heat technology assure in this way most optimal solutions.
At the moment, they have employed 18 members, nine design engineers, four assembly supervisors and one electronic engineer.
Manufacturing of piece parts is done by reliable, specialized companies; pre-assembly, painting and packing will be done in the company's own workshop so they can use modern specific equipped sub-suppliers and are able to keep short delivery times.
For final assembly, start up and service, experienced engineering specialists are available.
Filtration -- Battery Separators -- Industrial
Products -- Apparel-Personal Hygiene -- Medical -- Disposable
What these industries have in common is May Coating Technologies. All of them use web-line applications, whether it be for adhesive coating, impregnation or heat lamination.
At a single location, May Coating provides human resources, technical expertise and physical facilities for your product development. See what our fully integrated approach can do for you.
Located in St. Paul, MN, May Coating Technologies' laboratory/pilot plant is available for product and process development work, methods testing, scale-up programs and semi-works product manufacturing.
Complete facilities and experienced personnel are provided for short-run testing or longer term development programs as well as full scale contract manufacturing of laminates, tapes, packaging materials and piggybacks made of paper, film, foil or nonwovens. This assures you that the same results achieved in testing will be evident in the product that comes off of your new May Coating unit.
We specialize in custom-built coater/laminators, but also offer standard lines of equipment--the CLS, the DCM and the PC series. We can meet your particular and specific requirements for coating methods such as slot die, spray, reverse roll, mayer rod and gravure. The modular design of our equipment allows a virtually limitless number of combinations when specifying a system, bringing you the cost benefits of using standard design features.
Our line of hot melt processing systems are all designed for heavy duty continuous processing of hot melt adhesives and other thermoplastic materials. They are easy to operate and also of modular design, allowing us to customize any unit with standard components.
From conception of your project through the finished product, we can help. Our business is improving your business. Call us.
On Tatham nonwoven cards, weight control from the volumetric hoppers is achieved with the Microfeed system, which is a dynamic regulation of fiber feed utilizing a microprocessor controlled weigh plate. As the fiber batt is transferred forward from the chute feed to the card feed rollers, it passes over the Microfeed weigh plate covered with a PTFE skin and supported on strain gauge type load cells. The weight change detected from a previously set value, monitored by a continuous signal from the load cells, is then entered into the memory of the Microfeed controller.
The time delay from when the weight change is detected to when that part of the batt is entering the feed rollers of the card is monitored by a rotary transducer providing pulse signals to the controller.
After the time delay, the speed of the feed rollers is changed--higher in the case of a lighter batt and lower in the case of a heavier batt--in order to maintain a constant fiber feed rate into the carding machine, improving medium and long term regularity.
A second transducer provides a reference speed signal for the line to ensure synchronization. As speeds are constantly monitored, this sytem can be programmed to display production data, i.e. production rate kg/hr, web weight "off" the doffer gm/sq. m. and doffer speed m/min.
Because of the variations involved in a dynamic weighing system, i.e. friction values, cohesion of fiber, batt modulus, etc., it is not possible to predict specifically the proportional weight acting on the weigh plate. It is therefore necessary to set up the running conditions without weight control to arrive at a required specification of end product and then tune the controller to this weight for improved control, i.e. the unit is initially set up in Manual Mode and the product weight checked before being switched to automatic. When in automatic, feed roller speed will automatically be adjusted.
The Microfeed MK4 system features adjustment to optimize on the speed compensations value up to 100%. Over and under weight indicator alarms are also incorporated to adjustable limits between 0-100%, as defined by the operator to provide an acceptable deviation factor.
Microfeed is another example where technology has influenced modern carding by maintaining or improving fiber feed regularity even at the significantly higher production rates associated with the latest cards.
Molecular Sieves For
Personal Care Products
A range of personal care and household applications are the targets of two unique high performance products from UOP's Molecular Sieve Group that "make even the smelliest smells disappear into thin air." The revolutionary ABSCENTS deodorizing molecular sieve powder is being used by UOP customers for application with baby and adult diapers, feminine hypgiene products, deodorants and foot and body powders.
A similar product, which goes under the SMELLRITE tradename, is being marketed to the household and pet care products markets.
Both ABSCENTS and SMELLRITE are trademarks of UOP, a 50/50 joint venture between Union Carbide and Allied Signals Inc. UOP is licensing the molecular sieve technology to personal care product manufacturers, who then incorporate it into their end products. UOP has expanded its molecular sieve production facilities at its Mobile, Alabama plant.
What Are Molecular Sieves?
The synthetic molecular sieve adsorbents were invented more than 30 years ago by the company that is now known as Molsiv Adsorbents, which is headquartered in Des Plaines, Illinois; research on both ABSCENTS and SMELLRITE is conducted in UOP facilities in Tarrytown, New York.
Molecular sieve adsorbents, which have already found broad commercial applications as desiccants, are inorganic, crystalline materials, usually aluminosilicate compositions, in which a solid framework forms a three dimensional network of internal cavities of a honeycomb-like nature.
These cavities can account for up to 50% of the total crystal volume and result in a large internal surface area. For example, a single tablespoon of a molecular sieve can have a surface area equal to that of an entire football field.
Typically, the internal cavities are fully connected by pore openings of uniform, molecular size. Because of these passageways between cavities, the entire internal surface area of the molecular sieve is available for adsorportion.
Most molecular sieves are highly hydrophilic. While this property is the basis of all desiccant applications for molecular sieves, it has precluded their use as odor removers in personal care applications. When they are exposed to even extremely small amounts of water vapor they rapidly fill with water. This made them ineffective in adsorbing other molecular species, such as those responsible for odors.
The ABSCENTS Improvements
The revolutionary ABSCENTS deodorizing powder is a new, high performance molecular sieve formulated by UOP to offer a unique approach to odor control in personal care applications. Through sophisticated chemical and structural changes, the internal surfaces of ABSCENTS deodorizing powder have been made organophilic (or hydrophobic). As a result, they exhibit a strong selectivity for odor causing compounds.
To put it simply, ABSCENTS attracts odors and traps them tightly within its porous structure, effectively removing odors from their surroundings instead of simply masking them with fragrance. The molecules that are literally captured within the molecular sieve are permanently held inside. ABSCENTS also maintains its odor removal capability in high humidity or in the presence of liquid water, conditions commonly encountered in personal care applications.
ABSCENTS is a versatile, broadly effective odor remover, not limited to a narrow range of odor types. In contrast to some odor neutralizers that rely on chemical reactions to break down odor, ABSCENTS simply eliminates them.
ABSCENTS may be formulated into dry powders or aqueous products or readily incorporated into nonwoven matrices for effective control in personal care products and related goods, including feminine protection products, baby diapers, adult incontinence products, body or foot powders, deodorants, nonwoven wipes and ostomy products.
Research And Promotion
Spurring Continued Consumer
Demand For Cotton Nonwovens
As cotton continues to gain in consumer demand for natural nonwoven products, cotton Inc. is making significant advancements in fiber processing, product development and market trend documentation.
New engineering of carding equipment has broadened the viability of cotton in nonwoven products. One of the most significant cotton programs is the introduction of opening kier bleached cotton. The process opens the bleached cotton using coarse wire wound cards.
The carding system enhances the usability of cotton in downstream processing steps. This process will produce well opened fiber with reduced nep content at the rate of 400 pounds per hour. This cotton with improved fiber characteristics has created new market opportunities.
A major effort in technical assistance to cotton bleachers will continue through 1997. Projects under way include a fiber fineness study and its relationship to nonwoven production efficiency and product quality. Other projects will include bleached fiber finishes to enhance fiber web forming processess and needlepunch adaptability.
Another logical step for cotton nonwovens was the cotton bale wrap--packaging raw cotton in a cotton wrap rather than a synthetic. A new nonwoven all-cottong bale wrapping was presented to the National Cotton Council Bale Packaging Committee in 1990. the new bale wrap has progressed to the field testing stage with a unique needlepunched cottong bale wrap, an application with annual potential for 80 million sq. yards.
The product presented to the Bale Packaging Committee--an eight oz/sq. yard needlepunch product--was treated with a vinyl copolymer to confer fabric durability and abrasion resistance. This chemical binder can be removed by general scouring processes for fiber recycling. Extensive field testing will continue through Fall, 1991 in time for specifications to be written for the Spring, 1992 committee meeting.
Cotton diapers have been another area that provides great potential for increased use of cotton in nonwoven products. Cotton Inc. has worked cooperatively with a manufacturer to develop a cotton/polypropylene thermal bonded nonwoven product. This material was constructed in a weight suitable for a diaper coverstock. A 60/40 cotton/polypropylene blended product demonstrated strength and water absorbency characteristics and satisties industry requirements for the next-to-the-skin diaper component.
Tracking the impact of consumer demand for cotton textile has become crucial to Cotton Inc.'s nonwovens program. A research study on consumer preference for personal care products offered an indepth insight on cotton's impact on the nonwoven market. The survey, conducted by R.H. Bruskin Associates, an independent market research company, provides a rationale for cotton nonwovens and specifically in personal care products, a preference for products made of cotton. Nonwoven consumers are also apparel and home fabrics purchasers and they clearly demonstrate a preference for cotton products.
The cotton industry continued to make market advances in 1990. Cotton apparel and home fabrics captured a 53% share of market in 1990, up from 50% in 1989. At that share level, cotton is the single most popular fiber sold at retail, excluding carpet.
Sales volume change of cotton apparel and hom fabrics on a fabric weight basis, excluding carpets, increased 4.6% in 1990, while other fabrics showed a decline of 5.4% The increase translates into an additional $4.5 billion in cotton apparel and home fabric sales for the year.
Solving the problems of manufacturers in the nonwovens industry utilizing process air technology is the principle driving force of Osprey Corporation. With a constant focus on practical, simple and efficient solutions, Osprey has designed a series of systems and equipment that save the producer money and create a cleaner environment.
The rotary drum filter is Osprey's "centerpiece" in fiber reclaim and air filtration. It serves to clean the air, recover particulate and return it to the manufacturing process. This filter is versatile and has applications in a variety of air laid production processes. the rotary drum filter (central fiber reclaim/air filtration system) provides constant air flow to the forming section, which results in consistent pad unformity, increased production rates and return of fines that were previously discarded. Serving more than 350 production lines all over the world, this system provides a cleaner environment and reduces waste in the manufacturing process.
A further development in solving the problem of waste reduction is the Osprey fluff reclaim system. This system allows total separation of non-absorbent material such as poly, tape, tabs, elastic, nonwovens and foam from the absorbent fluff and tissue content of soft disposable products. This system also collects and meters the reclaimed fluff back into the process as a percentage of the virgin pulp. Designed to handle between 100-350 kg/hr of reject product, the Osprey fluff reclaim system captures approximately 85-95% of available fluff with less than 1% impurities.
A recent addition in air filtration is the Osprey final filter. Utilizing reverse jet, cartridge-type filter modules, the exhaust air from the final filter is sop pure it is up to 10 times cleaner than the average office. The high efficiency filter media ensures efficiencies of 99.9% on all particles down to 0.3 micron in size. This unit can be a retrofit option for most existing Osprey drum filters. It has no moving parts and is automatically cleaned by low consumption compressed air.
Simple and effective, the Osprey SAP dosing and transport unit provides precisely controlled feed amounts of superabsorbent polymer according to line speed. It is inexpensive and requires minimal operator and maintenance attention.
The very latest wave is the Osprey SAP extraction system. It is capable wave is the Osprey 70% or more of the polymer from reclaimed of fluff with only one pass. This provides clean SAP for reapplication to the production line using the SAP dosing unit and provides reclaimed fluff with minimal polymer content.
Osprey is proud to be a leader in implementing the latest technology available to solve your process air problems. We will continue to improve our existing solutions and expand our reputation as a service-driven leader in the nonwoven industry.
CTC WEB SPLICERS
CTC Web Splicers automate the converting machines which manufacture sanitary napkins, diapers and other nonwoven products.
We offer 30 solid years of experience in the Nonwovens Industry with engineering know-how, diversity and technology to handle the most difficult web splicing problems.
CTC is an engineering oriented company dedicated to maintaining our position as the leader and primary innovator in Automatic Web Splicers for the Nonwovens Industry. Our equipment ranges in size from the very narrow webs used for sanitary napkins, up to the widest materials used in the manufacture of adult incontinence pads.
Our Web Splicers are application engineered for each specific installation. They are available in three types of construction:
* Free standing and completely independent of the converting machine.
* All components assembled on a customized mounting plate (not free standing).
* Furnished as modular components, to be assembled by the customer on their own mounting plate or converting machine frame.
Due to the wide range of materials which are used in the Nonwovens Industry, we offer four types of unwind systems for controlling the web feeding into the converting machine:
1. DC Motor (4 Quadrant regenerative drive) - controlling through the roll arbor.
2. Compensating type mechanical brake - controlling through the roll arbor.
3. Compensating type pneumatic brake - controlling through the roll arbor.
4. Surface drive on unwinding roll (4 Quadrant DC regenerative).
The selection of the proper splicing system for a particular application is based on the nature of the web, the maximum web width, and the type of splice required. Engineering assistance is provided to help with the design interface of the CTC splicing equipment with the customer's machine.
For maintaining extremely low web tension at high speed, the CTC unique and proprietary concept of combining the dancer and web accumulator into one dual function element is recognized as the simpliest and most dependable design. Our dynamically balanced low inertia precision tension control system produces the most accurate web tension available on any Splicer. As an optional feature, adding a driven pull roll at the exit of the web accumulator can enhance the degree of precision control, and when necessary, further reduce the tension in the web.
As the leading manufacturer of Automatic Splicers in this Industry, CTC pioneered, developed and introduced some major innovations, such as:
* Hot wire cutting of the web on Automatic Splicers (1972)
* Ultrasonic welding of thermoplastic material on Automatic Splicers (1984)
* Driven (powered) spindles for low tension applications, employing magnetic particle clutches on Automatic Splicers (1971)
* DC Regenerative drives on Automatic Splicers (1983)
We presently offer a range of eight types of patented splicing mechanisms, and have an ongoing engineering development program to constantly improve our products and maintain our position as the technological leader in our field.
New Generation Of STP Impianti
It has now been about ten years that STP Impianti SpA has been involved in the manufacture of equipment for spunbonding systems.
During this period, STP Impianti has carried out continous research and development work with the constant aim of improving both the production system and the properties of the product.
This unceasing and tenacious work has now led to such remarkable progress that it is legitimate to say that the latest STP Impianti equipment constitutes quite a new generation of spunbonding systems, with a new philosophy and the best available technology.
The development work of STP Impianti has been carried out following a comprehensive approach to the process, from the spinning to the filament drawing, from the filament distribution to the web bonding and winding. The constant aim has been to increase the economic validity of the system, by working in close contact with customers, on four well identified directions:
- high productivity
- good product quality
- simplicity of operation
- limited investment and production cost
Experience in extrusion and spinning process, matured in more than 25 years, has guided the STP Impianti engineers to design a spinning head that joins together the maximum of holes density and continuity with the maximum of operation flexibility and versatility.
The arrangement of the individual spinning packs in relation with the delivery apron has been accurately chosen in order to grant uniform coverage of the web surface; the mechanical independence of each spinning pack assures the continuity of the spinning operation even in case of any pack change during the operation.
It also allows a reduction of trimming waste to a minimum; the edge can now be continuously recycled.
The STP Impianti process is an aerodynamic melt-spinning process. The filaments are cooled in an air diffusion chamber of unique design, which allows very high drawing ratios, i.e., high strength properties.
Then the filaments are taken off by a large number of aerodynamic injectors that are operated by low pressure compressed air. The number of injectors and their design and arrangement make the system capable of running at the very high drawing speed that is required for achieving low denier and high strength. But this is not enough.
At the exit of the injectors, a specially designed traversing system deposits the filaments on the conveyor belt with an adjustable degree of entangling; this is essential for a uniform weight distribution as well as for the isotropy of the fabric properties.
Simplicity Of Operation
It has always been a pride of STP Impianti to be able to pay attention to the legitimate expectations of its customers for having an easy and friendly operation.
This is especially the case of the STP Impianti spunbonding systems; particular care has been taken in order to reduce the need for manual operations, to make machine start-up easy and quick and to ensure the repeatability of the production.
Automated and/or computerized control systems are available. The need for the operators to work in uncomfortable or noisy areas has also been reduced to a minimum.
And Production Cost
The STP Impianti spunbonding system has been designed now as a truly compact unit for whose installation there is no need of any special building or civil works. It can be installed in a normal industrial shed with very limited space requirements.
The automation of the operation makes the number of operators required very little; the design of each equipment part makes the maintenance work and spare parts consumption a very small source of cost.
The cost of the process equipment itself is also extremely attractive as the investment can be paid back in an extremely short period of time when compared with other plants of similar size and productivity.
Celli Winding System
STP Impianti has found an ideal integration to its spunbonding lines in the winding and rewinding/slitting system produced by A. Celli Spa in Porcari (Lucca). A. Celli has many years of experience in supplying winding systems to paper mills and to the non-woven industry as well and its machines are well known for their sturdiness and mechanical reliability, as well as for their optimal functionality.
A. Celli has specially designed and manufactured a new nonwoven peripheral winding unit. The new AC3 is equipped with automatic devices for parent reel change and web cross cut, which allows time saving and reduces rejected production. It can be equipped with inline trimming and slitting knives. The softness or hardness control of wound nonwoven webs is permitted by a winding pressure pneumatically operated. All the AC3 movements are totally controlled and programmed by P.L.C.:
- working width--up to 5000 mm
- basis weight range--from 15-150g/sq. m.
- speed range--from 2-250 m. min.
AC3 is a step forward in the nonwovens winding systems.
There's A Gelok Laminate
For Your Exact Needs
For the past several years super-absorbent laminates have played an ever-increasing role in the disposable personal care products market.
Since the superabsorbents offer excellent absorbency, fluid transport and fluid stabilization, they allow a thinner, drier, more comfortable end product. Plus, the decrease in bulk they provide allows savings in packaging, warehousing and shipping.
The problem, however, has been that different applications require different performance qualities. (For example, absorbency and transport properties of a sanitary napkin are much different than that of an incontinence pad.) And the range of performance available from the handful of laminate producers has not been very extensive.
But now, there are Gelok laminates--a new family of superabsorbents produced by Gelok International Corp.
The importance of Gelok is that it not only offers all the advantages of a superabsorbent, but its special construction can be customized to suit a whole range of applications perfectly.
How We Customize
All of the Gelok products consist of a composite laminate structure.
Typically, the laminate will contain a superabsorbent polymer base between two cellulose sheets. The degree of absorbency is determined primarily by the amount of polymer used.
Gelok International now has exclusive equipment and process advancements that let us control the laminate's performance qualities to a great degree.
Which means we can produce superabsorbent laminates to suit almost any specific need, including yours.
For more information, contact Richard LaVoie, general manager, at Gelok International Corp., Pine Lake Industrial Park, Dunbridge, OH 43414; or phone (419) 352-1482; fax: (419) 352-8340.
C.E. Shepherd Company:
Converter For The Nonwovens/Film Industries
As technology advances at an astounding rate in the nonwovens industry, manufacturers need an experienced converting company that is capable and willing to work with them to find innovative and cost-effective solutions to unique problems. C.E. Shepherd Company is that company.
The Shepherd Company has been an industry leader in the field of embossing for more than 25 years, with experience with various film substrates, including cellophanes, plastic film, laminates, nonwoven and woven fabrics, paper and foil.
While commodity type products form the "bread and butter" business of the Shepherd Company, growth comes from capitalizing on developing market opportunities. In fact, several Shepherd personnel are dedicated exclusively to seeking manufacturers developing new products requiring leading edge embossing technology and helping them bring their products to market.
The Shepherd Company is capable of processing material up to 140" in width and in roll diameter to 36." They can process criical temperature materials with a control of [+ or -] 3 degrees Fahrenheit monitored by optical temperature controllers. Specially designed machines allow processing of materials in excess of 500 degrees Fahrenheit.
Computer assisted processing controls web speed within .1% of line speed, permitting either absolute maintenance or alteration of product orientation for pcoessing multiple webs of various extensability.
Shepherd's technology permits even the most delicate of operations, including but not limited to .5 ounce per square yard nonwovens laminated onto moisture barrier films, perforated materials or semipermeable membranes.
Given the technological explosion in this field, it is often difficult to identify future viable markets. To accomplish this, the Shepherd Company draws on its many years of specialty embossing experience and the many contacts it has developed in the overall converting industry.
C.E. Shepherd Company works with product development and research personnel in proprietary ventures to create solutions for their material processing requirements. Shepherd is particularly interested in projects involving dual web combinations of nonwovens, films and other substrates, as well as embossing the above laminates.
The Shepherd Company has a reputation for successfully developing new products and has the resources for commercial production. Their longevity and success come from a commitment to rigid quality standards, use of state of the art technology and a willingness to work with companies to develop their ideas into profit making enterprises.
Web Converting Equipment: More Than A Manufacturer
"We do more than manufacture machines, we design solutions to our customers' most complex problems," says Wayne C. Ellett, president of Web Converting Equipment Corp.
The eight-year-old company, based in Glens Falls, N.Y., specializes in slitter rewinders, unwinds, rewinds and custom converting equipment.
"In today's competitive marketplace, companies are constantly looking for ways to improve their product and cut down on trouble spots during production," Ellett says. "That's where we come in. If there's a better, more productive way to do something, we'll find it."
Web's team of engineers, designers, technicians and field representatives have more than 70 years of combined experience in the converting industry. Two key members -- Vice President Jim Wood and Sales Engineer Wayne White -- came to Web from production engineering positions with a nearby converting plant.
"In the past, we were the guys doing the buying," says Wood. "So we know what companies look for in a piece of machinery. We also know firsthand how a converting facility operates, so we can tell you what will work in any given situation, not what should work. And when you're spending thousands of dollars on a machine, that makes all the difference in the world."
Like more and more "players" in the industry today, Web's design department is fully automated, utilizing state-of-the-art CAD technology.
But the high-tech approach doesn't extend into all facets of Web's operation. When it comes to customer service, Ellett says he's strived to inject a more personal touch.
"We look at our relationship with our customers as a partnership that extends from our very first meeting to post-installation service," Ellett says. "And partnerships should be personal. After all, we may be talking about machines, but we are human beings."
Stocko Fasteners Introduces A
Revolutionary New Line Of Snap
Fasteners Specifically Designed For
Interest in Stocko Fasteners, a division of the Stocko Corp. (formerly the Blackwood-Stocko Corp.), continues to grow due to Stocko's introduction of its new and exciting four part "Tenac" resin plastic snap closure.
The Tenac closure is ideally suited for both adult and children's disposable nonwoven diapers and reusable cotton diapers.
In addition to the announcement of the introduction of the Tenac resin plastic snap fastener, the Stocko Fastener company has recently announced that it has relocated to 495 Industrial Road, Carlstadt, New Jersey, where the parent firm, Stocko Corp., has just completed building its 42,000 square foot main facility, offices, warehouse and factory.
In addition to this snap fastener closure, Stocko Fasteners provides the Model WBM 200 attaching machine that simply and easily attaches the Tenac closure to the item being produced. The Model WBM 200 is a fully automatic attaching machine that positions the male or female parts of each closure securely in place.
The Model WBM 200 is able to accommodate disposable nonwoven materials with a compressed thickness of as thin as .004 in. For disposables, the Tenac resin closure has a firm "On" action and a soft "Off" action. For cotton or cotton blends the snap action can be varied to a more firm "Off" action due to the reusable nature of the garment and the stress that this application exerts on a plastic closure.
For more information and samples, please contact Stocko Fasteners, A Division of the Stocko Corp., 495 Industrial Road, Carlstadt, NJ 07072; (201) 933-0135; (800) STOCKO 1; Fax: (201) 933-4522.
Globe Manufacturing Co.
A Leader In Elastomeric Fiber Production
Globe Manufacturing Co., a leading producer of elastomeric fibers, supplies the nonwovens industry with a wide variety of Spandex fibers, extruded rubber thread and multiple-end fused rubber tapes. Since its founding in 1945, Globe has established itself as an acknowledged leadr in the production of extruded rubber thread and Spandex fibers used in the production of all types of elastic fibers and nonwoven products.
Innovations and Depth
Of Product Variety
Realizing the strong market for Spandex, Globe developed its own process to make the elastomer in 1962 and has continued to expand both its capacity and product line of this versatile elastomer ever since. Today, Globe remains the sole domestic competitor of Du Pont in the production of Spandex while continuing to offer is broad line of rubber threads and tapes. A firm commitment to the broad aspects of elastomer fiber applications has prompted Globe to innovate a wide range of rubber compounds and Spandex polymers to satisfy the myriad requirements for weight, width, elasticity, strength and modulus.
Technical Customer Service
Second To None
What probably sets Globe apart most from its competition is its commitment to service and the lengths to which it will go to innovate solutions to the satisfaction of its customers. In addition to its research and development laboratories, Globe maintains a separate facility devoted to the analysis of customer applications and practical problem solving. Whatever the application, Globe will assign a technical team to analyze an item or frame a problem and recommend a workable solution.
As Globe continues to expand, it remains committed to the hallmarks of its success to date... Total Quality and Customer Satisfaction.
New Oven From
Smart Machine Technologies
A nonwoven bonding oven was recently developed by Martinsville, VA firm Smart Machine Technologies.
The oven was developed for bonding a nonwoven material consisting of 20% polyester and 80% cotton. Depending on the loft requirements, the plenum will adjust to accommodate material with a 12 inch loft down to a 2 inch loft. It is also important for the product to cool quickly before it is rolled and shipped. When the product is unrolled by the customer, it must spring back to its original loft.
The 84 inch width, 15 foot length, 11 foot, three 1/4 inch high oven is constructed in two eight foot long sections. The oven is designed to be split for additional sections to be added at a lower cost for future added production needs.
The hot rolled steel structural tubing framework is enclosed with 4 inch thick, 18 gauge panels packed with type II TWI insulation. The lower pressure plenum is constructed of 14 gauge galvanized sheet, formed to provide belt support.
The correct air flow is critical so as not to disrupt material until it is bonded. Air flow is concentrated in a upward flow-through direction.
The upper suction plenum is fabricated with 16 gauge galvanized sheet. The upper plenum is adjustable, allowing for different types of materials to be run with different lot requirements. The face of the plenum has 14 gauge perforated nozzle sheets to provide a smooth face for the conveyor belt. The center of the plenum has a radius slip section to provide belt support to minimize sagging with the plenum face operating at top of product point.
An overhead conveyor is needed to keep material contained using an automatic belt guider located at the oven entrance.
This particular oven uses a Maxon 415 oven pak gas burner for natural gas. The temperature control is an electronic recording circular chart.
The penthouse section houses two backward inclined centrifugal fans, powered by A.C. motors with variable frequency speed adjustment.
At the exit end of the oven, a flow-through cooler section is required for this particular product. Also, at the exit end of the oven is a mounted press roll. The roll is carbon steel constructed and teflon coated to prevent product sticking. A press support roll is also included below the belt.
An electrical pre-wired control panel is provided to house necessary motor starters and burner controls.
"An oven developed specifically for the nonwovens industry is long overdue and Smart Machines takes pride in our ability to custom design any type oven to fit our customers' needs," states Irma Smart, president.
TSG Incorporated is presenting a new dust-attracting finish for non-woven wipes and filter media that they call Synpel-SS. This finish gives nonwovens an almost "magnetic" attraction to dust and airborne dirt. It can be applied to lightweight nonwovens for cleaning cloths that are designed to remove contaminants from delicate electronic equipment such as circuit boards, wire connections, tape heads, etc.
When applied to special nonwoven or lint-free knitted fabrics, Synpel-SS creates an excellent "optical wipe" for cleaning eyeglasses and photographic lenses. It has also been used for filter fabrics to trap dust and dirt in ventilation systems for laboratories and clean rooms.
Synpel-SS is available from Synthetics Finishing in Hickory, NC and Synfin Industries, North Wales, PA.
Irving Textile Begins 31st Year
Irving Textile Products, Inc., of Atglen PA, has entered its 31st year as a manufacturer of specialty nonwoven fabrics. The company originated in Chester, PA in 1961. It was formed as an outgrowth of James Irving & Son, Inc., a family-owned, woolen-yarn spinning mill, which was established in 1843. In 1968, the company moved to Atglen, situated between Philadelphia and Lancaster, PA.
Irving Textile is a major supplier of white, solid color and print bonded pattern nonwovens. Its fabrics are converted into disposable pillow cases, head rest covers and shoe shine cloths for the transportation and travel industry. Its "Context" nonwoven fabrics are also made into disposable dusting and wiping cloths for industrial, institutional and consumer end uses. Irving Textile also supplies nonwoven roll goods for use in medical/health care disposables, filtration and other consumer products and commercial industrial applications.
The Atglen facility produces dry laid, carded nonwovens in basis weights ranging from 0.5 to 3.5 oz. sq. yard. Roll goods are slit to customer requirements in widths up to 72 in. Special treatments available include nonwovens with variations of hand, FDA ingredients and flame and liquid repellent characteristics. Irving also specializes in color applications, supplying pad-dyed nonwovens to various markets.
Bill and Steve Irving and the management team awt Irving Textile have more than 90 years combined experience in nonwoven fabric manufacturing and product development. The company's smaller size relative to the industry's giants allows it to offer greater flexibility in product design and modification, production scheduling, minimum run size, service, delivery and other aspects of a satisfactory business relationship.
Irving has the ability to develop a material to meet specialized requirements in a very short period of time. This has turned out toi be an important consideration for present and potential customers alike. The fact that Irving does not convert end use products, and therefore will not be competing with its customers in the marketplace, remains the corner-stone of its corporate philosophy.
If you would like to purchase a quality fabric at a competitive price and enter a business relationship with a company that is responsive to your needs, call Steve Irving at (215) 593-5145. You will become a satisfied customer.
Rotor Spray System
Represented By Consultex Corp.
The Weko rotor damping system is in operation at reputable companies giving highly successful results. It is used for uniform wetting of fabrics and is particularly suitable for energy-conscious low add-on of concentrated liquors. This achieves an improved fabric quality, retains fabric structures, saves heating energy costs in drying and increases the output of the dryer.
The finishing liquors that are used should have good shear stability with a minimum foaming effect. The application quantities depend primarily on the absorption capacity of the fabric and the liquor concentration.
Depending on the speed and fabric weight, the desired wet pick-up level with Weko can be between 2-40%. Compared with the padding process, wet-pick-up is 60-80% (depending on the squeezing efficiency). The amount of water that has to be evaporated during the drying process is therefore reduced by up to 50% with the Weko unit.
Therefore, by being able to apply the exact amount desired, waste is practically eliminated, allowing for a short pay back period.
Some applications of the processing techniques are:
- application of softening agents
- flameproof applications and dirt repellent
- application of antistatic agents
Since this is a relatively new means of application, new fields are constantly being explored.
Some other features include:
- a filtration system that keeps lint from being recycled
- a rinsing system
- automatic spray rate adjustment in relation to machine speed
There are numerous features and benefits not yet stated. Consultex Corp. would be happy to discuss how the Weko rotary sprayer could be of benefit to your company.
Can Help You Process Your Products
Anywhere In The World
Fameccanica's growth in 1990 is the result of commitment using our knowledge of the "field know-how" to continually develop new processing lines and improve existing machines.
Extracts of Progress
The company has always concentrated its efforts on product design and process machinery fulfilling the needs of every converter. The recognition of this success is that many products are prepared and ready quite in advance and, at the snap of a finger, introduced by our sales staff to those who have the need for high quality equipment and the necessity to ameliorate their production machines and products.
Fameccanica has completed and successfully tested a compact module to apply "up-standing barrier cuffs" coupled either to our FA-X diaper line or to any existing equipment without compromising the total converting process efficiency. An array of cuffs can be produced allowing a complete versatility in diaper design.
The most updated technology for manufacturing boy/girl diapers made up of a dual core structure is smoothly running under industrial operation by well known companies around the world. A contoured pad constitutes the base fluff layer of the core, while individually formed extra pads guarantee ulterior absorbency capacity in a specifically located area of the pad. This new concept offers a fast and easy changeover from boy to girl configuration. It includes a remote hammermill or the patented Fameccanica "MODE" mill above the formation chamber. SAP compounds may be utilized according to customers' needs.
The latest accomplishment in contoured pad formation is the unique "SUPER JET SYSTEM" technology. This new fluff forming system consents to form one (or two, in case of a double drum) extremely consistent fluff layer(s), flat or bit/tridimensionally shaped, combined exclusively to a single or double Fameccanica patented multidisk "MODE" defibration mill. The superior pad integrity obtained by the SUPER JET system increases the absorbent/retention power of the diaper (either baby or adult) and reduces production costs by reducing the quantity of fluff (a constant 95 grams sq. meter) used to obtain the same quality standard.
Other important options available and successfully marketed are the foam elastic waistband and frontal tape application units. These reliable units are today working under industrial operation worldwide satisfying the local market segments to which the converters belong. These Fameccanica units can also be retrofitted to any existing diaper equipment, both in-line and off-line versions.
The company, the first in the industry to introduce the compact technology in the world diaper market (see advertisement in NONWOVENS INDUSTRY, September and October, 1989) has to date delivered around the world 50 dedicated Fameccanica "COMPACT" systems allowing converters to obtain the best answer to today's packaging and marketing requirements. "LESS BULK, MORE PROFIT" is not only a slogan, but a packaging philosophy.
For more than a year now a number of FNL production lines, manufacturing napkins with wings, are successfully working under industrial operation around the globe. This certainly is a meeting point of reciprocal satisfaction between the client and ourselves.
Sanitary Napkin Production
As to sanitary napkin production, our latest accomplishment is the introduction of a new compact machine, Model FAS, obtaining optimum results in Fameccanica's test room. The goal of this machine is to guarantee converter's maximum flexibility in product structure definition.
Besides being capable of producing standard napkins, this machine has been especially designed for the new generation napkin: the SUPER THIN sandwich contoured structure napkin, with or without wings, with or without fluff (lately successfully introduced on the worldwide market and being the product of the future) maintaining the highest quality, efficiency, reliability and minimum waste levels during production operation. The competitive price of this machine and its performance makes it the most cost effective capital investment in sanitary napkin equipment.
Last, but not least, so as to obtain a full integration of our or your process lines, completely automatic Fameccanica packaging systems for diapers, sanitary napkins and incontinent products have and are being delivered representing a significant increase in the profitability of any converting operation.
If you are looking for high quality equipment and products, you can surely count on Fameccanica's expertise and service; two essential vehicles to increase your home market share in disposable hygienic articles.
Call or write for more information: Fameccanica S.p.a., Via Aterno, Sambuceto 66020, Italy; phone 085/45531; telex 600226 Famec I; Fax 085/4460998
EPOCH INDUSTRIES Increases Productivity with
Graphite Composite Rollers and Shafts
EPOCH Industries was founded in 1988 with the objective of solving production problems associated with light and extendable webs. In order to solve these problems, a thin-wall composite roller is required. Because tubing to build these rollers was not available, EPOCH developed a proprietary process to manufacture premium braided tube.
Throughout the past three years they have produced braided graphite composite rollers and shafts using this tubing. Other products have also been developed to complement them.
The lighter tensions associated with nonwovens cause problems that result in line downtime and decreased line speed. EPOCH Industries has focused on this specific area of converting.
EPOCH's graphite composite rollers have been inertia than traditional rollers. This reduction in weight has several benefits. It enables them to turn more freely and to react quickly. Dancer rollers built in this fashon can reduce neck-in during web speed changes.
Another major benefit of these rollers is the ability to use removable bearing carriers. These innovative carriers, developed by EPOCH, dramatically decrease downtime. Bearing change time is reduced to a one-man operation requiring only minutes to complete. With the current cost of downtime, this feature alone justifies the cost of their composite rollers. They are available with a variety of surfaces and clad materials.
EPOCH's graphite composite shafts are a viable solution to lifting restrictions. They weigh from 15 to 50 percent of standard steel shafts. They are designed to be used with core chucks. Typical shafts are clad with a thin steel shell to protect the composite from damage. This cladding also provides a material with more compressive and shear strength than that of composite.
EPOCH's premium braided composite tubing is available to equipment manufacturers as well as users. Composites have been used very successfully in rollers, unwind shafts, and dancer arms. The future applications depend only on the imagination of its users.
EPOCH has recently increased their engineering staff to keep up with the heavy demand for their products. For more information about how these products can help you increase productivity, call or write EPOCH Industries at: P.O. Box 472633, Garland, Texas 75041, (214) 271-4295, Fax (214) 278-6631.
Melt Extrusion Technology Defined
The "spin beam" or beam is a common name used by many fiber producers and machine suppliers to describe the system that distributes molten polymer to various spinning positions at equal residence time and temperature. The beam also houses the various components described below and allows for convenient spin pack changes as required for replacement of filtration media and product changes.
Other familiar terms used to describe beam components are: "Spin Pack," which is several components bolted together including the entry plate (pack top), filtration media and spinneret; "Polymer Manifold," which distributes the molten polymer to the desired location; "Pump Block," which channels polymer from the manifold to the metering pump and then to the spin pack and mounts the metering pump. Some of the primary distinguishing features of various spin beam designs are:
Heating System: There are four typical variations. The first is a remote boiler. Second is an internal boiler to the beam. Third is circulated oil or other heat transfer media through beam. Finally, there is direct electric heating.
Pack Loading Type: Spin packs loaded from the bottom or from the top. Large, heavy packs are usually installed from the top, but bottom loaded packs inhibit cold spots caused by chimney effects.
Polymer Manifold Piping: Located internal within the vapor or external to the vapor. External manifolds are easier to maintain and generally provide adequate temperature uniformity.
Metering Pump: A special gear pump used to meter the polymer through spinneret.
Polymer Pump Mounting Blocks: Welded in place or removable. The welded block provides better heat transfer but is harder to clean out and maintain.
Metering Pump Drive Orientation: Pumps mounted horizontal or vertical to the beam. Horizontal mounted pumps reduce required building height, but maintenance is more difficult and dangerous.
Spin Pack Pierced Area Geometry: Filament bundle orientation can be round, rectangular or radial. Each provides advantages depending upon the product and polymer.
Hills continues its commitment to the development of spin beam and spin pack designs. A representative of Hills would be pleased to discuss the advantages and disadvantages of the options presented above and to develop a recommendation for your specific application. Complete extrusion and fiber processing systems are available. Please call Steven Fredricks at (407) 724-2370; telex 469353 or see us at Booth 100 at the Fiber Producer Conference in Greenville.
Fast folds with Overfalz-Elsner!
No other piece of folding equipment in its class can make Z-folds, C-folds and Quarter-folds on one machine faster than the Overfalz-Elsner A-100-V Folding Machine!
This high-speed folding machine features web speeds from 590 to 984 feet per minute -- without using vaccum! It's the productive way to fold wet wipes, medical swabs, surgical drapes, napkins, liners, towels, and table cloths.
Other folding machines are restricted to producing only one size of folded merchandise. The A-100-V machine can easily be converted to fold products of many sizes simply by changing the optionally supplied fold cylinders.
As a result of this built in versatility, you can increase productivity two-fold without the expense of purchasing a second machine.
Other productive features on the A-100-V include automatic tension control, infinite set count control, product stacking, and an automatic phot-electric shut-off switch, along with many options to customize each machine.
The A-100-V Folding Machine is produced by Elsner under an exclusive licensing agreement with Overfalz Maschinenbau Gmbh of West Germany. Over the years, versatility, productivity, efficiency and value have become synonymous with the Overfalz design. Today that proven design is being produced by Elsner to meet domestic size standards and customer requirements.
All manufacturing, sales, and service of Overfalz-Elsner equipment is done in Elsner's Hanover, PA, facilities.
Elsner provides the same high quality, dependability, and reliability they have traditionally provided to all rewinder and overwrapper customers...this includes a full supply of parts in a large, ready inventory.
Elsner Engineering Works was founded in Hanover in 1934. Since then, they have earned a worldwide role in the design and manufacture of rewinding and overwrapping equipment.
The combined line of Elsner and Overfalz products is represented by the large, established network of Elsner representatives, who arrange on-site service when and whenever it's needed.
Elsner also makes other converting equipment to produce wallcoverings, giftwrap paper, napkins, wipes, surgical pads, fabric softener, films, foils, and other consumer-sized roll goods. Virtually every type of consumer paper product can be folded, wound, or rewound on an Elsner-built machine.
Recent technological innovations include an automatic wallcovering border processing line and a sonic tension control device for web-fed machinery.
For more information on how an Overfalz-Elsner folding machine can make you more productive tomorrow, please call or write Elsner today at Elsner Engineering Works, Inc., 475 Fame Ave., P.O. Box 66, Hanover PA 17331, Tel:(717)637-5991, FAX:(717)633-7100
Best Cutting Die Company has been a manufacturer of dies of envelopes, labels, diapers, sanitary napkins, bandaids, and other paper products for over twenty years. The company is located in Skokie, II, approximately 15 miles north of Chicago. The company is a family business with Ed Porento, Sr. as president. For the past fifteen years his kids Ed Jr., marion, Gary and Rob have been working for the company in a variety of capacities including technical, administrative, sales and customer service.
Best Cutting Die was founded some twenty years ago by Ed Porento Sr. Progress came slowly, but Ed believed his knowledge of envelope dies and his sincere concern for his customer's satisfaction would prove to be a winning combination. Today Ed is recognized as the leading expert in the envelope field. His business philosophy of doing whatever it takes to satisfy the customer has B.C.D. without equal in terms of service and quality. This philosophy has been ingrained in the management staff of Best Cutting Die as well as in the worker on the floor. Although the number of employees has grown drastically in the recent years, many of Best's original people remain. This gives Best a reservoir of knowledge, experience and dedication to customer service.
As the Best's list of customers grew, Ed looked to expand both in plant size and equipment. Today Best has over 20 pieces of computer numerically controlled equipment. All inhouse facilities have further allowed B.C.D. to improve and maintain its short turn around cycle. B.C.D. recently installed vacuum heating equipment that allows it to ensure consistent high quality heat treating. This helps increased anvil and die life.
Best has successfully tackled the uniquely different cutting problems in the nonwovens industry. Dies for disposable dispers, sanitary napkins and bandaids all have different problems associated with them. Best's history of "staying with the problem until it's solved" has gained it knowledge and expertise in all cutting applications.
In addition to its many customers in the U.S., Best also services customers in many countries such as Mexico, Australia, Belgium, England, Singapore, new Zealand, Canada, Switzerland and others. many overseas customers claim that even with the transportation time included, Best gives better service than their local source.
New facilities, high tech equipment and solid epxerience allow Best to be competitive in large quantity precision dies. At the same time, its continuing devotion to the customer allows it to respond to unique, one of a kind problems. This has not gone unnoticed in the industry. In the past three years Best Cutting Die has been honored five different times as "Supplier of the Year. "These awards have come from major manufacturers in the converting industry.
High Quality Carpet Fibers From
Waste From PET Bottles:
An Example of Modern Recycling
With regard to the constantly increasing amount of waste, the recycling of materials becomes more and more important. Recycling has two functions:
1. The amount of garbage is reduced.
2. The raw material resources are saved if valuable raw materials are returned to the cycle of production.
Theoretical recycling processes for the different industries have already been discussed long before the new way of thinking, which takes care of the environment developed. There had already been technical solutions, e.g., the return of scrap iron into the steel cycle.
Another milestone was achieved in the paper industry. Wastepaper was recycled. One thing, however, is interesting. This industry uses a raw material source (wood) that grows again relatively fast and this does not apply to other raw material sources, such as oil.
The success of a recycling process in practice finally depends on economic conditions. These economic conditions also include the costs for clear material collection and material separation.
A new recycling process that will surely become more and more important is the production of fibers from PET bottles. These are then processed into, for example, high quality floor coverings. Since PET bottles are widespread in the drink industry in the U.S., it seemed reasonable to install a large installation there.
In cooperation with a renowned capret producer, the compact installation technique, which has proved its worth in the production of PP carpet and fine fibers and therefore seemed to be a good choice for this case of application, has been adapted to the changed process parameters.
There is an installation for which the Fleissner company has supplied the fiber draw line installed behind the spinning system of the Automatik company. This installation operates on 100% ground and correspondingly cleaned bottle waste. For a year, it has been producing 60 tons a day with a titer of 6.7-17 dtex.
The capacity of the installation is achieved by 32 spinning positions. For reasons of operation (simple handling) and since the quenching can be adjusted precisely, the rectangular nozzle has been used.
The Fleissner fiber draw line has a single-stage drawing. The drawstands can be loaded with up to 60 kN. Between the drawstands there is a heating duct with steam injection. A corresponding temperature control in the draw section as well as a regular tow covering on the drawstand godets, which is only achieved with rectangular nozzles (the ring nozzle leads to thick parts on the tow borders, dog's bone phenomena), are used to obtain those elongation and strength values that are normal for carpet fibers.
The constancy of the crimp (thick parts result in a higher number of crimps per inch) is also considerably influenced by the tow covering on the crimper rolls. This has to be kept as regular as possible. The high regularity as well as the precise stacking of the individual tows in the tow stacking unit are essential for a good crimping result. The crimper with a working width of 350 mm functions according to the well-known stuffer box principle. A two-dimensional crimping is produced. A tow tension control before the crimper, the purpose of which is to keep the two tension constant by adapting the speed of the crimper rolls, also influences regularity.
The hot air setting after the crimping ensures a good crimp stability. This is responsible for the quick recovery of the carpet, especially in case of high pile carpets. After the cutting and baling, the production of yarn as it is usual in secondary spinning takes place.
According to the producer, the finished carpets show a better dyeing behavior than carpets that have been made from fibers that are spun directly after polycondensation.
In addition to this large installation, which processes 500 million bottles a year, PET compact installations have been delivered to Belgium and Spain. These installations produce spun dyed fibers that are to be used in the automobile sector, where a high light and UV stability is required.
For the development and optimization of production installations for manmade fibers, a pilot line is available to the Fleissner company. it can be used for testing the usual fiber polymers.
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|Title Annotation:||Special Section: advertising and advertorial material provided by industry suppliers|
|Date:||May 1, 1991|
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