Laser-bonded Electrospun Nonwovens

More from the EDANA NIA 2013 Conference in Roubaix...

Christoph Hacker of RWTH Aachen University (Germany) observed that the electrospun webs needed to improve the filtration efficiency of drinking water filters are very fragile and therefore hard to laminate to stronger meltblown or spunbond nonwovens.  They are easily destroyed by hydroentanglement, needlepunching or thermal bonding, and the use of lasers alone fails because the polymers do not absorb laser energy.  The solution is to electro-spray submicron droplets of an energy absorber onto the substrate before electrospinning the fibrous layer, and for the purposes of these experiments the droplets contained carbon black to indicate how uniformly the spot-bonds were distributed.

The beam from a 100watt diode laser was spread using a prism to 35mm wide and as the laminate containing the droplets – held under pressure beneath a glass plate - was illuminated by it, the droplets heated up and spot-bonded the layers together without destroying any of the electrospun filaments.

Microscopy and peel strength tests showed the bonding process was successful and filtration testing showed that the bond points did not affect filtration efficiency.

Work continues to convert this batch demonstration process into a continuous process with wider lasers, simultaneous electrospinning and electrospraying, and a search for improved energy absorbers.  Mr Hacker thought the process might ultimately run at 10m/min.

Hydroentangled Air-laid flax Nonwovens

More from the EDANA NIA 2013 Conference in Roubaix...

Philippe Mesnage of ITFH (France) is evaluating hydroentanglement as an alternative to needlepunching for making flax nonwovens for composite reinforcement. The raw flax contains ~70-75% cellulose with 10-15% of hemicellulose, 3-5% lignin and a similar proportion of pectins. Mechanically refined flax (MRF) tows were cut into lengths of 25-35mm for airlaying and compared with a more fully refined 45mm flax intended for spinning into yarns (SF). MRF was coarse – 34 to 90 on the IFS scale (Flax Standard Index) compared with 20-30 IFS for the SF fibres. These long fibres clogged the air-lay drums and further work was carried out with fibres chopped to 15mm which could be successfully laid into ~150gms sheets.

After hydroentanglement, nonwoven tensile strengths were highest for the SF fibres (358N/5cm) compared with 215N/5cm for the best of the MRF.  Tear strengths were however comparable, presumably due to the higher denier of the MRF.  The extra stiffness of the MRF samples was not just down to the coarser fibres.  Mr Mesnage thought the non-cellulose components of the fibre were being solubilised in hydroentanglement and acting as a chemical binder.  Asked what advantages this route might have over the needlepunched route he thought there was a potential for higher productivity from the faster laying and bonding machinery and added that the end product was completely natural, made in the EU and used no added binders.

The Flexibility of Life Cycle Analysis

Adrian Wilson's paper on Life Cycle Analysis presented at INDA's Vision Conference in Dallas by Calvin Woodings on 30/1/2014 follows in full.

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Life cycle assessment (LCA) is increasingly being applied to support public policy making, to the consternation of some researchers and practitioners.

Initially during the 1990s LCA methodology helped to develop eco-labels and certification schemes, evolving to inform policy documents and eventually packaging legislation in Europe. It was also employed to guide alternative-fuel policies in the US.

LCA has continued to gain ground in the 21st Century and was incorporated into the ‘Integrated Product Policy’ of the European Union (EU). It was also intrumental in the establishment of several life cycle-based carbon footprint standards and regulations for transportation fuels in the US, EU and Canada.

Critics, however, have started to question the validity and usefulness of results from LCA.

The many studies on disposable and reusable diapers have been held up as a prime example of how widely varying conclusions can be drawn from LCA comparisons of competing products.

But it is especially the use of LCA findings to make performance-based regulations (PBRs) – such as in the European Renewable Energy Directive (RED) relating to biofuels – that the most concern has been voiced.

Kelheim Fibres and Krones develop alternative medium for beer filtration

The development of a substitute for diatomite in precoat filtration in the brewing industry is the subject of a joint research project between Kelheim Fibres, world leading manufacturer of viscose speciality fibres, and Krones AG, globally successful producer of beverage and food technologies, which has been running since mid-2013.

In recent years diatomite has come under criticism as its heavy dust emissions have proven to be damaging to the health of the user’s operatives and because the increased cost of disposal. Viscose fibres consist of 100% cellulose and are therefore renewable and environmentally sound. They are completely biodegradable and compostable. Viscose fibres are neutral in taste, physiologically and hygienically sound and therefore ideally suited for applications in sensitive food applications.

In the past, there have already been attempts to substitute diatomite by alternative filter media, such as virgin cellulose fibres. Viscose fibres - an environmentally sound and tailor-made alternative. The new joint research project takes this idea one step further: in contrast to virgin cellulosic fibres, viscose fibres are regenerated cellulosic fibres and therefore their physical and chemical properties can be perfectly adapted to meet the needs of the user. It is therefore possible to control the parameters of filtration – such as the degree of filtration, the pressure drop or the selective removal of undesired elements – in a precise and custom-designed way.

First results of the joint research project demonstrate a high level of suitability of Kelheim Fibres viscose products as a filtering aid. The main focus of the project is the clarification of the beer and its physical stabilisation by the use of functional viscose fibres, which can also be adapted to meet the specific filtration requirements of the beer.

Both research partners, Kelheim Fibres GmbH and Krones AG, are contributing their industry-specific expertise to the project and the practical evaluation of viscose fibres in beer filtration – and by so doing are laying the best foundations for the success of the project.

This joint research project is subsidised by the Bavarian Ministry for Economy and Media, Energy and Technology in the context of the program “New Materials.

www.kelheim-fibres.com

EDANA and INDA Launch New Shared Mission and Vision

BRUSSELS, Belgium, and CARY, N.C. — January 27, 2014 — EDANA™ and INDA® associations for the nonwovens and engineered fabrics industry based in Europe and North America, respectively today announced that they will harmonize their mission and vision to advance the success of their member companies.

Responding to the needs of each association’s member companies, including those companies who belong to both organizations, this new initiative was drawn from the values and missions pursued by both associations for their more than 40 years of operation.

INDA and EDANA have kept parts of each association’s individual positions that are essential to their own nature and character, and have formed a mutual position that not only strengthens the relationship between the two associations, but seeks to provide cohesion and consistency on a global basis. Each organization will continue to operate independently.

The new joint vision for INDA and EDANA is to provide “global leadership to create an environment beneficial to sustainable and profitable growth of the nonwovens and engineered fabrics and related industries to best serve their customers.”

The new joint mission is to be “recognized within the global nonwovens and engineered fabrics and related industries as the associations that consistently provide products, services and events of the highest value to members and industry participants worldwide.”

Members of both global organizations are involved in the complete nonwovens supply chain from raw materials, machinery and equipment to roll goods, converters and end products. The services provided by each association are similar in nature, but unique in delivery and influence.

Both associations provide services in product stewardship (safety standards, test methods and sustainability); government and regulatory affairs; commerce and innovative industry events; industry awareness and trust; and training, education and market research.

“The vision and mission of our organizations direct what we do — how we serve our members is distinctly different. Harmonizing our vision and mission statements makes sense in this increasingly global industry. Our respective members need the assurance that the essential services provided by their industry association will be consistent in structure and intent, yet tailored to locally defined needs,” said Todd Bassett, Chair of the INDA Board of Directors.

“In defining our joint goals, we established ‘what do we do or aspire to do.’ How we implement these strategic goals will continue to differ, based on our respective members’ needs and their specific business and social environments,” said Patricia Featherstone, Chair of the EDANA Board of Governors. “We will continue to act based on our local requirements and demands, but with a greater level of compatibility and support both for and from our partner association."

Freudenberg Upgrades Spunlaid Lines

Weinheim, January 17, 2014 – Freudenberg Nonwovens, one of the world’s largest and most diverse producers of nonwovens, is upgrading its spunlaid production. The company is investing several million euros at its Durham and Kaiserslautern sites. Both investment projects relate to the further technical development of existing lines and follow Freudenberg’s decades-long tradition of continuous process improvement.

Both major projects will enhance product quality. Following modernization the lines will be able to manufacture nonwovens of a higher quality with improved performance properties. The investment in Durham will also increase Freudenberg Nonwovens’ flexibility in supplying global markets. “As a result, we are strengthening our global position as a technological leader and responding to market demand for higher-quality materials”, Dr. Frank Heislitz, CTO of Freudenberg Nonwovens, said.

Advanced production technology will be installed on one of the three existing spunlaid lines in Durham, allowing the company to further improve the quality of its nonwovens used for filter materials, OEM automotive carpeting and carpet tile backings. “We are optimizing our manufacturing process and enhancing the performance of our production system with this investment”, Raoul Farer, Technical Director in Durham, commented. The Durham facility was opened in 1983 and currently has a headcount of some 160.

In Kaiserslautern, which currently employs just under 260 people, an existing pilot line which provides a good platform for product developments already at the planning stage or in the pipeline for the future will be upgraded. “This project will lead to improvements in the quality of the product’s physical properties, allowing us to proactively serve the needs of our customers”, Dr. Volker Röhring, Head of Process Development in Kaiserslautern, said. This will bring benefits not only in the automotive, carpet and filter segments, but also for customers in the shoe and construction sectors. The original unit commissioned in 1970 was one of Freudenberg Nonwovens’ first spunlaid lines in Kaiserslautern.

Both investments will be completed during the fourth quarter of 2014. The investment at both sites is a clear commitment to spunlaid technology and part of a comprehensive international technology strategy.

EDANA NIA: New Hydroentanglement and Dry-Lay equipment at CETI

The EDANA Nonwovens Innovation Academy began 7 years ago as the ”Nonwovens Research Academy” also in Roubaix and it remains one of the few meetings to feature original technical papers mainly from the European technical institutes. This year it was hosted by the European Centre for Textile Innovation (CETI) and commenced with a tour of the recently opened €50m nonwoven pilot plant. This comprises state-of-the-art pilot lines for carding, cross-folding, spunlaying of mono, bi- and tri-component fibres, meltblowing, thermal bonding, hydroentanglement, and needlepunching. Machinery has been supplied by Andritz, Laroche, Strahm and Hills Inc. The layout allowed continuous production of laminates of carded and SMS webs with either calender or HE bonding.

Photos from CETI follow:

The hydroentanglement zone is in line with both the Hills Inc spunbond system and the dry-lay card...

...and feeds an Andritz through-air dryer/bonder

The full-size Andritz card can feed a crossfolder for felt and wadding development or feed a narrower lighter web through the spunmelt zone into hydroentanglement

The Laroche Flexiloft airlayer feeds webs under the crossfolder for combination with card webs.

The New Melt-spun Nonwoven Pilot Plant at CETI

EDANA's Nonwovens Innovation Academy was held last week at the European Textiles Innovation Centre in Roubaix France.  Here are some photos of the new spunmelt pilot equipment now available for hire.

 The Hills Inc spunlaying head (left) and meltblowing (right)

Meltblowing

  

 Spunlaying

 

Simom Fremeaux of CETI describing Tri-component yarn spinning

Go to CETI for more details

600 jobs to go at Lenzing Austria

In the light of the ongoing difficult market situation, Lenzing has decided to proactively implement a massive, far-reaching cost optimization program. The initiative will enable cost savings of EUR 120 mn p.a. until 2015 as a means of safeguarding Lenzing’s cost leadership on the global market for man-made cellulose fibers. In this way Lenzing is responding to the current difficult market environment, which has led to increasingly fierce price competition.

“The difficult market situation will continue in 2014 and possibly well into 2015. We will resolutely counteract this unfavorable situation and adjust our cost structures to the new circumstances as quickly as possible”, says Peter Untersperger, Chief Executive Officer of Lenzing AG. “Our aim must not only be to expand our quality leadership and innovative strength on a sustainable basis, but also to regain the cost leadership in our industry. We continue to see attractive growth potential for our products, but we are already preparing ourselves today as optimally as possible for the increasingly tough competition. Cost discipline and cash generation will be our targets over the coming years.”

In particular, the sales and marketing organization will be strengthened as part of the current reorganization project. The entire organization will sharpen its focus to more strongly orient its activities to the important fiber markets of Asia and Turkey. Sales efforts in China especially will be expanded on the basis of additional technical experts and market development capabilities.

Lenzing will continue to invest, particularly in developing TENCEL® for high quality textile applications and sustainable nonwoven applications. Demand for Lenzing Modal® remains strong.

The expanded cost optimization program “excelLENZ 2.0” is a further, comprehensive step to sustainably safeguard earnings and future investment projects. It complements the initial “excelLENZ” cost-saving program which has been underway since the beginning of the year as well as the organizational restructuring of the Group. Improvement potential for all cost modules encompassing all operating units has been defined over the past weeks. The measures to be implemented on this basis will not only result in savings in material costs but also massive reductions in operating expenses and overhead, extensive increases in operating efficiency as well as a reduction in the total number of employees. All global sites will be affected. The staff at the Group’s largest production site in Lenzing, Upper Austria will likely be downsized by up to 15% from the current level of about 2,600 employees (including retiring employees and unfilled vacancies). On balance, a total of up to 600 jobs will be cut or vacant positions not filled.

The individual measures will be quickly carried out in the coming months, and thus already partially impact earnings in 2014. Lenzing expects one-off expenses related to the implementation of the “excelLENZ 2.0” drive in the mid double-digit euro range.

Source: Lenzing PR

Kelheim Fibres Presents New Fibre Solutions at Dornbirn

New challenges need new solutions – and true to this slogan of the 52nd Man-made Fiber Congress, Bavarian viscose speciality fibre manufacturer Kelheim Fibres presents its innovative products at this year’s industry meeting in Dornbirn. The spread of product or trademark piracy is one of these challenges as it inflicts an enormous loss on our global economy every year and is becoming increasingly explosive. Almost 70% of all businesses are affected.
Bernd Probst, a member of Kelheim’s R&D team, will present a range of speciality fibres that protect products from illegal counterfeits with a visible or invisible fingerprint.

Another hot topic is the mega-trend „Ageing Society” and the resulting increasing demand for convenient, discrete and safe incontinence products. Dr. Ingo Bernt presents viscose speciality fibres from Kelheim that enable perfect liquid and moisture management: their absorption levels range from “extra absorbent” to “hydrophobic”; hence they allow the production of incontinence solutions that consist completely of renewable materials and are at the same time washable and re-usable.

Dr. Philipp Wimmer will give a lecture on the opportunities that Kelheim’s viscose specialities offer in the filtration industry, a market which is growing in importance in our increasingly ecologically aware and health-conscious society. In contrast to other cellulosic fibres such as cotton, for example, viscose fibres stand out not only as a result of their definable and reproducible geometry, which enables a perfect match to be made to the specific processing route or end application. The porosity or surface
of a filter, for instance, can be precisely controlled by adding the appropriate viscose fibres with different cross sections. Further, the incorporation of functional additives allows the manufacturing of tailor-made fibres according to the end product’s exact demands.

And finally, Dr. Roland Scholz and Dr. Nina Köhne present a series of interesting analyses regarding ionically activated viscose fibres and their applications. By using different technologies, Kelheim’s R&D can deliver fibres with cationic or anionic functional groups and thus controls the fibre properties. Particularly when it comes to ion exchanging properties, fibres offer a distinct benefit: in comparison with common ion exchange resins, the diameter of the ionically functionalised fibres is considerably smaller and the active surface significantly larger. Hence they operate up to ten times faster!

With these different lectures, Kelheim Fibres scientists give a fascinating insight in their work – and again demonstrate their versatility and ability to develop cutting-edge products.