1 Worldwide locations of Trtzschler Germany BR/BH/Hof - - PDF document

BR/BH/Hof 2009/D/11.11.2009

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BR/BH/Hof 2009/D/11.11.2009

Production factories: Germany • USA • Brazil • India • China Subsidiaries: Turkey • Mexico • Italia Spain • Uzbekistan

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Worldwide locations of Trützschler

Germany

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Trützschler Nonwovens Group TNW

Consists of

• Truetzschler Nonwovens GmbH, Dülmen, Germany

(formerly Erko-Trützschler)

• Truetzschler Nonwovens GmbH, Egelsbach, Germany

(formerly Fleissner)

• Truetzschler Nonwovens GmbH, Bielefeld, Germany

(formerly Bastian)

• Trützschler Card Clothing

Complete Technology for Nonwovens Lines

• Fiber Opening, Blending, Web Forming,
• Mechanical Needling
• Binderbonding
• Thermobonding
• Spunlacing
• Winding
• Finishing

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Location: Dülmen // Founded: 1993 // Employees: appr. 100

Trützschler Nonwovens GmbH, Dülmen, Germany

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Location: Egelsbach // Founded: 1848 // Employees: appr. 250

Trützschler Nonwovens GmbH, Egelsbach, Germany

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R&D Center of TNW in Dülmen New opened in 2011

Erko Fiber Opening + Blending Erko Web Drafter EVST Erko Card 150 Erko Needle Loom ENL1 Erko Airlay Card EHLA Fleissner Belt Oven Erko Crosslapper EKL 439

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R&D Center of TNW in Egelsbach

Erko Fiber Opening and Blending Fleissner Throughair Bonding Truetzschler Card TC07H Fleissner AquaJet ERKO Card EWK 413 Fleissner Drum Dryer Fleissner Airlaid (Fluff Pulp)

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Nonwovens in Hi-GrowthApplication Challenges and New Developments India Situation

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To have a sustained growth, India will require

Investments to develop a strong support pillar-

• GEOTEXTILE
• FILTER
• AUTOMOTIVE

Source BCH

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Developed nations will be dependant on the emerging markets to take the opportunities available

Emerging nations- China, Indonesia, Mexico, Turkey, Brazil, Russia, India

Source BCH

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In Mexico, the toll roads are being re-privatised and Mexican market players – construction companies,

• perators, banks and institutional investors – are

enthusiastically looking for these investment

• pportunities, often in partnership with foreign

investors. MEXICO INDIA The government has announced in huge amounts to support and construct the infrastructure. Discussed in detail in following slides.

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To create economic activity, Russia plans to invest $6 trillion over the next 20 years in order to connect Europe and Western China and allow for the development of new territories and mineral deposits, producing a positive economic effect. China alone plans to spend $730 billion into infrastructure sector over the next three to five years, in a bid to stimulate domestic demand; to increase connectivity between towns & villages CHINA RUSSIA China plans to almost double its investment in railways to about 87.9 billion U.S. dollars a part of this will be used to build a total of 5,148 km of new rails,

Source BCH

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• The separation of water and land is one of the important

requirements of mankind

• Geotextiles manufactured by using nonwoven technology

are mainly used for the application like separation and filtration.

• Nonwovens are classified based on the way the fibres are

bonded together

• Thermally bonded
• Chemically bonded
• Mechanically bonded
• Spun laid and spun bonded
• For Geotextiles, needlepunch technology is in the forefront
• f production

Nonwoven Geotextiles:

Source BCH

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Geotextiles are textile structures such as fabrics, mesh materials, nonwovens, nets, and composites which are deployed in various areas

• f underground construction for

separation, support, protection, filter and/or drainage functions.

Source BCH

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Geotextiles- Applications vis-à-vis Functions

Application Function

Roads Reinforcement, Separation, Filtration Railways Reinforcement, Separation, Filtration Foundations Reinforcement, Separation, Filtration Drainage Systems Separation, Drainage, Filtration Erosion Control Reinforcement, Separation, Filtration Basins & dams Reinforcement, Protection, Separation, Filtration Canals Reinforcement, Protection, Separation, Filtration Tunnels & underground works Protection Solid waste Reinforcement, Protection, Separation, Filtration Liquid waste Reinforcement, Protection, Filtration

Source BCH

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Different technology for manufacturing Geotextiles

Woven Non Woven Warp Knitted

• Sub-grade

reinforcement, embankments, woven geogrids for ballistic reinforcement

• Reinforcement,

separation, Embankment are major applications

• Roads, highways as

separation, paving fabric

• Niche applications in

golf course fields, geo nets for Rock fall protection

• Geogrids are mainly

made up of knitted geotextile

• Applications
• 330 GSM
• 180-200 GSM
• 340 GSM
• Commonly used

GSM

• Weaving
• Needle Punched
• Thermal bonded
• Spun bonded
• Warp knitted
• Warp knitted with

Weft insertion

• Process
• Monofilament,

multifilament slit film fabricated

• Base fibres is

Polyester, Jute

• Continuous filament

staple fiber

• Base fibres is

polyester, PP& PE

• Produced by

interloping one or more fibres, yarns, filaments

• r other elements.
• Fabric and Raw

material

Separation Filtration Protection Drainage

Reinforcement Barrier function

Surface erosion control

General functions of geotextiles

Technology

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Applications for Geotextiles

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Roofing membranes with PES nonwovens carrier fabric

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Application of Nonwoven needle punched Geotextiles :

• Separation
• Filtration
• Barrier fabrics for roads, rails, erosion control and irrigation

Properties for Geotextiles :

• Tenacity
• Elongation
• Accuracy in terms of weight distribution

Nonwoven Geotextiles:

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Applications for Geotextiles

Damms Waterways Solid Waste Ground Support Streets Anti-Erosion Tunnels Liquid waste Railway Draining Installations

Geotextile Lines

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Geosynthetics

• Material used with soil for civil engineering applications
• Geotextiles are textile materials manufactured by using

synthetic fibres like

• Polyester
• Polyamide
• Polypropylene
• Polyethylene
• Geotextiles are non-visible, permeable fabrics used for

dams embarkment etc.

Source BCH

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• Choice of fibre type and tenacity are determining factors for the

product tenacity

• Fibre orientation at the card as the starting point of product

property

• Fleece orientation after the crosslapper ( laying Angle with

condensed web )

• Felt stability in needling process
• Control during heat setting process

Benefits of Truetzschler Nonwovens Line

• Less Draft : Less Shrinkage
• More control on the fibre orientation
• Constant control over the elongation

Requirements of Geotextiles:-

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Properties for Geotextiles between 100 – 200 g/m² such as :

• Tenacity
• Elongation
• Production
• Accuracy in terms of Weight Distribution

blend of fibres:

• PP 4,4 – 6,7 dtex 90 -120 mm
• High tenacity min. 4,7 cN/dtex

Source BCH

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The Fibre Choice as the Key to achieve the Properties

• By the Drafting of the Fibre the Tenacity will be influenced
• This Tenacity determines the Tenacity of the Product

significantly and thus the Product Properties

• This Treatment requires a very accurate Heat Setting if applied
• The precise Dosing and Blending of different fibre types is

essential to achieve „designed“ Product Properties

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Carded with Spunlace Spunbond and Needle Punched Carded and Needle Punched

Geotextile / Roofing Lines

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Geotextiles- Key Advantages

• Increasing life of the structure- Structures made more

reliable

• Reduces cost in long term- lowers frequency of

maintenance

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Indian Infrastructure- Opportunities

Source- Government of India, Committee on Infrastructure

Key Sectors Estimated investments 2008-2012 (US $ bn) Airports 8 Irrigation 54 Ports 18 Railways 63 Roads 76 Water Supply & Sanitary 49

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India… developing to developed

• India is the second fastest growing economy with an annual

growth rate of 8-9% in the last three years & can sustain a 7- 8 per cent growth rate till 2020

• Will overtake UK, Germany, Japan and finally the US before

2050, to emerge as the second-largest economy after China

• Is witnessing the highest rate of returns on investments

India: 19.33% ; China: 14.25%

Motivating for investors and active players!!!

Source BCH

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Geotextiles Market in India- A Quick Look

Seeing this under current and activities in the Indian infrastructure & geotextile sector, we can say that

• There is a huge potential for geotextiles in the years to come
• It is likely to see a 25% Compound Annual Growth Rate (which

can grow higher) for the next 20 years- infrastructure development is going to be maximum

There are huge

• pportunities

for- New players to manufacture geotextile products Existing players to exploit manufacturing capacities to the maximum not only for meeting domestic demands but also for exports

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Geotextiles- Potential in Emerging Markets

If 18311 Tonnes is the potential for geotextiles in India alone… … can you possibly calculate the potential that all emerging markets have to offer as a whole?? China + Indonesia + Mexico + Turkey + Brazil + Russia + India = ???

Source BCH

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Machinery and production lines for filter media

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• Cleaning of Exhausts and the Air
• Aspiration of Particles
• Filtration of Liquids

Nonwovens for Filtration

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Needle Felt Dust and Gas Filters

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Needle Punch Bag Filter Line: Process Data

• GSM: 90 - 500
• PPCM2: 500 - 600
• Fabric Width: 2.2 meter
• Fiber: PES 2.2 dtex, 50 mm cut length
• Process Requirements:
• Scrim supported for strength.

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Common Fiber Specification for Filtration

Raw Material PP, PA, PET, PPS, P-84, Meta Aramid, PTFE, Glass Fibre fineness 0.9 den. – 10 den Final web weight 100 - 800 g/m² Production capacity up to 800 kg/h

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Fibres

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Polyimide (PI) Polytetrafluorethylen (PTFE)

P84 Teflon

[g/cm³] 1,42 2,1 ... 2,3

high strength with good tenacity low elongation low mechanical strengh high glidability

[%] [%] [W cm] 10 17 10 18 [°C] 327 [°C] 400 [°C] [kJ/kg K] 1,1 1 [J/m s K] 0,31 0,23

low flammability flame-retardant self- extinguishing

[%] 36 - 38 95 Acid very good very good Basic solution moderate very good very good very good reliability Bakteria 21°C/65%r.L. 24°C/95%r.L. moiture influence thermical features melting temp. decomposition temp. self ignition point thermal conductivity LOI-Wert Density specific heat

mechanical und dynamical properties

Flammability moisture absorption electrostatic charge 21°C/65%r.L. 24°C/95%r.L. Resistor

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Fibres

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meta-Aramid (m-AR) para-Aramid (p-AR)

Keflar /Teijinconex Nomex / Twaron

[g/cm³] 1,38 1,44 ... 1,45 [%] 4,5 ... 5 3 ... 4 [%] 6,5 ... 7 4 ... 7 [W cm] 10 15 [°C]

• [°C]

> 370 550 [°C] 675

• [kJ/kg K]

1,2 1,4 [J/m s K] 0,13 0,04 not melting

not melting inflaming inflaming self- extinguishing extinct after 10-15sec.

[%]

28 29

Acid good to aceptable good Basic solution good to aceptable good very good very good Density

high compressiv strength high tensile strenght low tensile modulus high fracture strain high temperature resistance

Flammability moisture absorption electrostatic charge 21°C/65%r.L. 24°C/95%r.L. Resistor thermal conductivity decomposition temp. self ignition point LOI-Wert

mechanical und dynamical properties

reliability Bakteria 21°C/65%r.L. 24°C/95%r.L. moiture influence thermical features melting temp. specific heat

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Fibres

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Glasfiber (GF) Ceramicfiber

[g/cm³] 2,45 ... 2,60

Zirkonoxid 5,6 ... 5,9 Aluminiumoxid 3,25 high compressiv strength high tensile strenght low tensile modulus high fracture strain

[%] ~0 [%] low medium low high [W cm] 10 15 [°C]

• [°C]

400 [°C] 400 [kJ/kg K] 0,7 ... 0,8 [J/m s K] 0,8 ... 0,9

fireproof fireproof

[%] Acid very good Basic solution very good very good very good moiture influence thermical features melting temp. decomposition temp. self ignition point Density specific heat thermal conductivity LOI-Wert 21°C/65%r.L. 24°C/95%r.L.

mechanical und dynamical properties

Flammability moisture absorption electrostatic charge 21°C/65%r.L. 24°C/95%r.L. Resistor reliability Bakteria

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Nonwoven Line for Filtration 100 % PTFE

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Online with Batch Turner Offline Finish Needling

Filtration Line

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Web turner and scrim feeder

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Needle punching machine

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Batch Turner

Nonwoven Line for Filtration

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Bale opener EBO

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Weight Belt System EBWM with Blending Opener EMZL

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Blending Chamber EGRS

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Opener EFO-IV

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Vibratory Chute Feeder - Vibrafeed

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Card EK 150

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Profile Cross Lapper EKLB with 150m/min infeed speed

entweichende Luft einlaufender Faserflor

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Web Drafter EVST with 4 Trios

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Types

Single Board from top ENL-D1 Single Board from bottom ENL-U1

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Types

Double Board from top ENL-D2 Double Board from bottom ENL-U2

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Stich Plate Aspiration System

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bonded web Jet Head Jet strip Suction slot Web support (belt, wire mesh

• r sleeve)

preneedled web Water Jet

Spunlace Process

„The IMPULSE FORCE of the water jet moves and entangles the fibers“

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Jet Head Jet Strip – Holes in 1 Row

• Up to 400 bar water pressure:

Water Jets Cross Cut of a Single Hole

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Fleissner AquaJet and Dryer for Filterwebs

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AquaJet for Filter Webs 2,5 m WW – During Installation

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AquaJet for Filter Webs: Dewatering Unit

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Multidrum Dryer for Filter Webs with 4 Drums

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Pump Room for AquaJet for Filter Webs

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Thickness S = 1,9 mm

Fleissner AquaJet: Hot gas filter 410 g/m² Fibers with reinforcement as middle layer

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machine direction MD cross direction CD

10 370 170

Hot gas filter 410 g/m² Fibers with reinforcement as middle layer

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Hot gas filter 410 g/m² Fibers with reinforcement as middle layer

Mechanical needling breaks reinforcement fibers and filaments! Strength is generally 20 % higher in spunlacing as with mech. needling. weight strength at 10% elongation [N/5cm] thickness MD CD Mech. needled 410 gsm 250 N 150 N 2.8 mm Spunlaced 410 gsm 370 N 170 N 1.9 mm Comparison of strength:

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250 g/m² PET

Fleissner AquaJet: Oscillating Jet Head (patented) To remove water jet stripes, to improve filter efficiency

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100 % metal web of stainless steel 500 g/m²

Metal Webs for Hot Temperature Filtration

Advantages:

• Heavy weights
• smooth surface
• Composites with synthetic fibers or natural fibers possible

Mechanically pre-needled

spunlaced

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• AquaJet developments with
• Different drum shells , Nickel coated wires
• All filters for continuous production
• Pressures in production up to 400 bar
• Webs up to 1500 g/m²
• Advantages of Spunlacing for filtration webs
• Smoother surface compared to mechanical needling
• No needling holes
• No broken fibers in spunlacing process
• Spunlaced filters ensure high mechanical stability
• By Spunlacing higher production speed compared to mechanical

needling

AquaJet Spunlacing for heavy filter webs

• Summary -

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Willkommen III

Automotive

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Automotive-Nonwovens and Textiles in the car

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Nonwovens to find in the car

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Around the car and inside the car

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Natural Fiber Components in Mercedes C-Class

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Examples for the automotive industry

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Headliner

Automotive Lines

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Market Situation for synthetic leather in India

• Synthetic leather production 120 million meter (2009 -10)
• 50 % substrate are woven or knitted & balance 50% are

nonwovens.

• Nonwovens include spunlace, needle punch & spunbond
• Spunlace: 50 – 150 gsm, PES 1.7 dtex contributes 20%
• f indian consumption within nonwovens.
• Spunbond: 100 – 160 gsm, PES contributes 40% of

indian consumption within nonwovens.

• Needle Punch: 250 – 400 gsm, PES 2.2 dtex contributes

40% of indian consumption within nonwovens.

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Needle Punch Automotive Line: Headliner Process Data

• GSM: 150
• PPCM2: 150
• Fabric Width: 1.6 or 2.0 meter
• Fiber: Dyed PES 3.3 to 6.7 dtex, 60 mm cut length

Dyed PP 6.7 to 15 dtex, 60 mm cut length

• Process Requirements:
• Absolute surface uniformity for visual appearance.
• High production since constraint on price rise
• Avoid thin places since forming presses emphasizes on them.
• Line flexibility owing to small colour batches (below 1 ton)
• The machines must be designed for high efficiency.

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Needle Punch Automotive Line: Parcel shelf Process Data

• GSM: 300
• PPCM2: 200 + Velour
• Fabric Width: 1.6 or 2.0 meter
• Fiber: Dyed PES 3.3 to 6.7 dtex, 60 mm cut length

Dyed PP 6.7 to 15 dtex, 60 mm cut length

• Process Requirements:
• Absolute surface uniformity for visual appearance.
• High production since constraint on price rise
• Avoid thin places since forming presses emphasizes on them.
• Line flexibility owing to small colour batches (below 1 ton)
• The machines must be designed for high efficiency.

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Needle Punch Automotive Line: Trunk Liners & Interior Carpets Process Data

• GSM: 500
• PPCM2: 400 + Velour
• Fabric Width: 1.6 or 2.0 meter
• Fiber: Dyed PES 3.3 to 6.7 dtex, 60 mm cut length

Dyed PP 6.7 to 15 dtex, 60 mm cut length

• Process Requirements:
• Absolute surface uniformity for visual appearance.
• High production since constraint on price rise
• Avoid thin places since forming presses emphasizes on them.
• Line flexibility owing to small colour batches (below 1 ton)
• The machines must be designed for high efficiency.

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TRÜTZSCHLER NONWOVENS thanks you for your kind attention

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Thanks for your attention

For more information visit us at: www.truetzschler.com