technology. By this Reicofil provides a solution for one of the major issues of contamination that exists in the industry. Producers
running an RF4 line will be able to make use of this advantage by
upgrading the line to RF4.5.
RF5 Technology also fulfills the market demand for finer and
finer filaments: the technology can produce up to 20% smaller
fiber diameters. Thereby titers lower than one denier are produc-ible for the first time. Compared to the RF4s technology the same
titers can be achieved with higher outputs or finer titers are feasible with the same outputs, but can provide for better uniformity,
strength and softness.
In terms of productivity the RF5 technology also raises the bar
significantly: the output increases by up to 35%—to up to 270
kg/h per meter beam width for spunbond and to up to 70 kg/h
per meter beam for meltblown. So, producers can run their lines
at maximum speeds even for higher grammages.
The meltblown technology benefits from the increased output
by a much wider process window, which raises the flexibility. Producers can decide now depending on their requirements whether
to use the maximum output capacity and increase productivity
by up to 35% or to produce 20% higher meltblown quality at the
present throughput levels.
Looking at the line speed the new RF5 technology reaches
the new peak value of 1200 meter per minute. As this value is
the actual speed on the conveyor belt and not, as before, the
speed at the winder, it can be fully utilized in production. Effectively producers can run their lines 30% faster than they could
on RF4 lines.
When it comes to energy efficiency Reicofil lives up to its own
claim of reducing the specific energy consumption with every
new line generation. For the production of composite nonwovens
RF5 saves up to 15% compared to RF4.
To further optimize the uptime, which had already reached a
very high level with RF4 technology, Reicofil took another close
look at maintenance time: Quench chambers and secondary air
gaps can now be cleaned much faster. The result is decreased
downtimes and increased productivity. In addition many of the
new digital solutions have a positive effect on the uptime.
Jens Mager, responsible for digitalization at Reicofil, says:“With
digitalization we strengthen all the existing advantages of the Re-
icofil technology such as quality, productivity and reliability. In
the future our lines will become an expert on themselves and will
guide customers much more than today through the production
process. Our solution will help customers to avoid both process
failures and human mistakes, it will help to identify and exploit
unused potential, to raise reproducibility and to find the best pos-
sible machine set-up for high quality and productivity.”
Reicofil developed solutions for more intuitive operation, con-
tinuous process and quality monitoring, predictive maintenance,
and detection of anomalies. For example, the line will provide its
operators with productivity analyses, predict when a wear part is
going to fail, warn the operator of drip formation before it occurs,
and provide information to help solve the problem.
Jens Mager adds: “First solutions with great customer benefits
are already developed. But digitalization still has huge potentials
for innovation that we want to exploit together with our custom-
ers. We can react to individual requirements and problems now.
That is a huge advantage of digitalization.”
Also at INDEX, Reicofil announced the Turkish nonwovens
producer Gulsan had committed to purchased a new Reicofil 5
line with an annual capacity of 35,000 tons. The new line will be
built in Turkey.
GDM Shows Off Machinery Upgrades
At INDEX, GDM promoted its complete product portfolio of baby
diapers, adult open, lady and light incontinence lines, turnkey
packaging solutions and its Option Zero program. With specific
reference to medium-high speed manufacturing machines, GDM
offers effective solutions responding to its customers’ needs in
terms of flexibility and production performance.
Machines of note include the B8-W Grey, a GDM baby open
diaper line that helps customers face production challenges
through innovative Zero Time technologies, minimizing size
change and raw materials setting adjustment time according to
manufacturers’ specific needs.
Based on magnetic floating principles, GDM’s patented in-novation“Linear Motion technology” is employed providing full
chassis width regulation, eliminating hardware replacement and
set-up. Within the Rear Wings application, thanks to its joined
actions with the dynamic shaping unit, it is possible to produce
up to four open baby diaper product sizes with no mechanical
For the most flexible solution GDM has also developed E-cams
that, installed on the final accelerator of Rear Wings application,
manage the final pitch adjustment, minimize machine setting
time without any mechanical regulation.
Andritz showcased solutions for spunlace, calendering and wetlaid nonwovens
at INDEX 2017.