NONWOVENS

GETTING FIBERS INTO SHAPE

C|D|E
 NONWOVENS
 4 it´s true 34 T-DRY: Drying

 6 Technology 36 T-WIND: Winding/Slitting

 8 T-BLEND: Fiber preparation 42 Trützschler Man-Made Fibers

12 T-WEB: Web formation 44 Configurations

18 T-BOND: Web bonding 49 Technical data

HYDROENTANGLING.................................. 18

WET-IN-WET PROCESSES............................ 22

MECHANICAL NEEDLING ........................... 24

THERMO- AND
CHEMICAL BONDING ................................ 28

Experience interactive added values with

our Trützschler Nonwovens App

1. Download the app

You can use the Trützschler Nonwovens App with Android
devices as well as iPhone and iPad. Download the app
free-of-charge from the Google Play Store (≥ Android
version 4.1) or the Apple App Store (≥ iOS version 8).

2. Use the Smartview function

Open the Trützschler Nonwovens App and activate
Smartview in the drop-down side menu.
SCAN
3. Scanning and viewing additional information
Scan the entire page that contains the scan icon with the
Smartview function. Touch the screen to play the video.
Get started.

www.truetzschler.com/apps
4 Nonwovens / it’s true

FARSIGHTED AND RESPON

We want you to be successful with the help of our
technologies and services. However, our actions are not
limited to economic aspects.
As family enterprise, we have experienced, accompanied
and shaped the business and its specifics for decades.
Thus we know that success is more than just numbers.

Business partner, with emphasis on partner Always innovative

Those who choose Trützschler will receive added val- Our actions, which are based on long-term success,
ues that cannot be taken for granted in view of the ensure that you have a partner that is always availa-
increasingly fierce competition. But in our opinion ble. But also the security to continuously profit from
they are imperative. technical innovations that can only be provided by
Trützschler in this quality.
Reliable and close
For four generations we have demonstrated that our In short: Trützschler attaches importance to com-
word carries the same weight as a contract else- mercial success, but even more to long-term part-
where. Though business numbers are taken seri- nerships.
ously by us, we will not bow to them. Instead, we
rely on real customer proximity in the textile markets
of this world through our international production and
service network.
 it’s true / Nonwovens 5

SIBLE ACTION

Customer benefits, with emphasis on benefits Long-term efficiency

What constitutes a good production installation? Our installations convince in terms of a well-known
Definitely a low TCO (Total Cost of Ownership). long service life and low energy consumption. At
The only response of some machine manufactur- the same time they make the best possible use of
ers is to lower investment costs. We use a different valuable raw materials. Our intelligent technologies
approach. retrieve additional good fibers even from alleged pro-
duction waste. The beauty of this particular type of
Compact and secure environment protection and resource conservation
The small footprint of our machine technology and its lies in the fact that it benefits nature and your pro-
high safety level are good for nature and user. One duction equally.
results in lower building and operating costs, and the
other protects the operator during his work. Anyone who expects sustained added value from an
installation throughout the entire production process
is demanding – and a Trützschler customer.
6 Nonwovens / it’s true

Convincingly strong performance

Advantages made by Trützschler Nonwovens

When deciding on a supply partner, various factors play

a role. We are convinced that competence, individuality,
efficiency and security of investment are of particular
importance. Therefore we offer you decisive advantages
exactly in those four areas.

Making use of proven expertise An intelligent way to save energy

Trützschler Nonwovens combines the know-how of In addition to raw material, the consumption of
the reputable Fleissner, Erko and Bastian brands for energy per ton or per square metre of end product
you. Trützschler Spinning is regarded as the leading is playing an increasingly important role. Particularly
specialist in fiber preparation. Trützschler Card Cloth- in the production of nonwovens, a lot of energy is
ing has been developing and producing high perfor- required for drying. Innovations such as the Stream-
mance clothings for roller cards and cards for many liner or the re-designed multi-drum dryer allow us to
years. On a global level, the Trützschler Group has make your production more energy efficient and thus
nine sites in six countries. The slogan "getting fibers more economical.
into shape" documents our core competence for
your success. Making more secure decisions
We support your decision on the optimal technol-
Profit from individual diversity ogy and layout with two fully equipped technical cen-
We are one of the few providers in the world that can tres in Germany where you can perform tests with
offer four different bonding processes and more than your own material under industrial conditions. When
ten types of carding machinery from a single source. doing so, make use of our comprehensive advice
This facilitates planning and the creation of custom- based on hundreds of successfully implemented pro-
ised solutions. The bottom line for you is an optimal jects and more than 150 years experience in textile
balance of quality and economic efficiency. machine engineering.

Fiber Drying/ Winding/ Packaging

Web forming Bonding
Preparation Finishing Slitting

Crosslapping
Carding Impregnating Inline Automatic
Webdrafting
Mechanical
Card Needling
Fiber Feeding Semi
opening Aerodynamic Webforming Smoothening Offline
automatic
Blending Hydro-
entangling

Unwinding Calibrating
Thermo-
bonding

Wetlaid Heatsetting
Chemical
Bonding
Meltblown, Spunbond Drying

Trützschler Nonwovens Partner

it’s true / Nonwovens 7
8 Nonwovens / T-BLEND

Opening, weighing and blending

Perfect start of quality chain

The initial process steps form the basis for the quality of the
finished product. It is essential to maintain a continuous,
uniform material flow from bale opener to the web former.
This is exactly what the fiber preparation system from
Trützschler Nonwovens enables you to do.
 T-BLEND / Nonwovens 9

The new modular fiber preparation

High throughputs without compromise

Modular machinery opens up the opportunity to indi-

vidually combine compactness, production capacity,
product quality and economic efficiency into an instal-
lation that is like a fingerprint of your requirements.

Blending chamber: consistent high quality

In high performance lines the blending chamber is
used as a fiber storage which ensures a continuous
flow of fibers to the web forming machinery.
If fibers of different types, lengths, counts and col-
ours are to be blended, the chamber allows for a
maximum homogeneity. It is easy to operate, safe
and reliable.

Exactly matching components Blending chamber with component-independent blending system

A high accuracy of measurement results in signifi-
cantly lower costs when processing expensive fiber • the conveyor belt with special elements to ensure a
types. Trützschler Nonwovens‘ new discontinuous uniform tuft distribution over the whole belt width,
pan and continuous belt weighing systems reduce also at high production rates
the addition of fibers to the necessary minimum. • the blending opener for further blending and gentle
Both systems deliver reproducible and perfect blend- fiber opening
ings – whether there are two or six different fiber
qualities. The new pan weigher
Trützschler‘s modular building set consists of vari- Advantages are a high accuracy and high perfor-
ous single components to be selected and arranged mance due to :
depending on requirements. : • 50% increased weigh pan volume
•d  ifferent bale openers • no connection between the weigh pan and the bale
• the newly designed, vibration-free pan weigher openers to prevent unwanted vibrations
with a larger volume and shorter weighing cycles • an innovative three-point suspension to prevent
• the proven belt weigher with highest measuring vibrations
accuracy

The new pan weigher

with 50% increased
weigh pan volume
10 Nonwovens / T-BLEND

Auxiliary units and feeding systems

Integral and optional components

Feed box Fine opener and feed box

The feed box is more than just a material buffer
between blending chamber and card feeder. Equipped
with large diameter feed rolls and a pinned opening
roller, it generates a uniform flow of small tufts to the
card feeder.
Fine opening in the feed box is clamp-free to prevent
stress on the fibers.
The speed of the feed rolls is continuously adjusted via
a pressure monitoring system that monitors the filling
level in the downstream card feeder ­(CONTIFEED).
The high demands of bleached cotton, natural and
recycled fibers are answered by a fine opener with a
special layout to gently open coarse fiber tufts into fin-
est tufts or single fibers.
For certain products this allows direct bonding, com-
pletely without intermediate roller card.

Edge opener
The edge opener can be applied inline as well as
offline and is used for opening of web waste. When
returning this web waste into the ongoing process,
the economic efficiency of the installation increases
significantly.
Depending on the feeding system, it is suited for
recycling of thermally bonded webs and needle felts
up to 2000 gsm (roller feeding) or spunlaced and
chemically bonded webs up to 1000 gsm (tray feed-
ing). Optionally, a spraying device is available.

Auxiliary units and accessories often go unnoticed

even though they are included in the scope of deliv-
ery of entire installations. Examples are feed boxes
as integral part of the installation and edge openers as
optional components.

Edge opener
 T-BLEND / Nonwovens 11

Homogeneous fiber
web via TWF-TF.

Tuft feeding: decisive for the quality Tuft feeder TWF-TF

Since tuft feeding is decisive for the subsequent The TWF-TF ensures homogeneous fiber feeding,
product quality, we developed state-of-the-art tech- whether processing coarse or extremely long fibers.
nologies for this purpose. They are based on the The downstream belt weigher monitors the process
principle of pressure feeding. This principle features and makes necessary adjustments.
such a high level of accuracy that for some products
a downstream roller card can be eliminated. The web
goes straight to bonding, thus lowering investment
costs without sacrificing quality.

Tuft feeder TWF-TF with belt

weigher and roller card
12 Nonwovens / Web formation
 T-WEB / Nonwovens 13

Roller cards
Individuality as basis for success

During carding on the roller card, opening of the fiber tufts

is continued and the individual fibers are parallelised to form an
unbonded web. Trützschler Nonwovens provides roller cards
for a variety of natural and man-made fibers. The random card
TWF-NCR, the Airlay solution TWF-NCA as well as the new
high-speed card TWF-NCT complete the product range of
the standard roller card TWF-NC.

TWF-NC: always the right solution

For carding, Trützschler Nonwovens offers six differ-
ent basic machine types that can be combined with
three different doffing systems (parallel web, random
roller, condensed roller). In combination with various
special executions, the right solution is available for
every production and every product. The things all
roller cards have in common are the extremely clean
take-off system, the customised TCC clothings and
the exemplary maintainability.

Clean card concept: Within shortest time, all maintenance points of the
roller card are perfectly accessible.

Modular roller card

concept
14 Nonwovens / T-WEB

NEW: TWF-NCT for high throughputs

Carding in high-speed spunlacing lines

The high-speed
card TWF-NCT

TWF-NCT: innovations… Trützschler Nonwovens’ proven doffing solutions

The new layout opens the door to higher line speeds adapt perfectly to your product requirements. Your
up to 300 m/min at the winder. By re-designing the choice is between parallel webs, condensing or ran-
pre-opening as well as the transfer section TWF- dom rollers.
NCT’s carding area is significantly enlarged.
Our Clean Card concept ensures a high machine
…and proven concepts availability. Various technical measures reduce the
As all roller cards the new high-speed card is risk of fiber contamination and allow for easy han-
designed for both flexibility and high efficiency. dling.

High speed without compromising on web quality

 T-WEB / Nonwovens 15

Random and airlay cards

Specialists for various materials

Random card, e. g. for

hygiene products

Random card TWF-NCR

Our special roller card for random web technology
is particularly well suited for subsequent spunlacing
processes. It allows a high random layer. This results
in fluffy, soft nonwovens, especially when process-
ing cotton. The use of only two different roll dia-
meters reduces clothing change time but still allows
large variability in web weight.

High random layer due to optimal arrangement of rolls

Airlay card TWF-NCA: first-class homogeneity

The card section of the airlay card ensures an opti-
mal opening while the airlay head forms a homo-
geneous random web. It only takes three different
roll diameters to combine high performance with
first-class precision. Other advantages of the airlay
cards are compactness, easy cleaning and a large
weight range.
An economic plus is that the TWF-NCA card can also
process cotton mill waste generated in the blow
room, card or comber.

Airlay card: especially for increased weights of hygiene products

16 Nonwovens / T-WEB

Crosslapper and web drafter

Top quality of the finished product

Roller card installation

with high-performance
crosslapper

Crosslapper: combined strengths Subsequent processes, for instance mechanical

The task of the crosslapper is to lay several layers bonding, have some unwanted side effects such as
of carded web accurately and at high speed to the increased web density in the edge area or increased
required width. At the same time it must generate surface weight. To ensure uniform control of the sur-
the desired surface weight. The required web weight face weight distribution – also referred to as profil-
is produced in cooperation with the downstream ing – Trützschler Nonwovens uses different control
web drafter. Trützschler Nonwovens provides differ- systems.
ent needs-based solutions – particularly the crosslap- The crosslapper TWF-CLH contains the CROSS-
per TWF-CLH. MASTER, a control system that works with specific
drafts.
 T-WEB / Nonwovens 17

High-performance
crosslapper
with web drafter

Advantages at a glance: Web drafter

• safe web transport without floating draft zones by

means of innovative web guidance in the upper
carriage and the lay-down carriage.
• reduced acceleration and braking loads due to reduc-
tion of the moving machine masses in conjunction
with rolls made of carbon fiber reinforced materials
• reduced machine load
• increased energy efficiency due to latest drive tech-
nology (AC servo motors with energy recovery).

4/6/8 web drafter: measurable increase in speed

Up to eight drafting zones turn the Trützschler
­Nonwovens web drafter into a high-speed solution:
Drafting in machine direction, result in up to 30%
higher line speeds when processing light-weight
products.

Web layer edges positioned precisely on top of each other result

in reduced edge trims and thus optimal material utilisation.
18 Nonwovens / T-BOND

Hydroentangling
Modular for individual installation concepts

To provide you with the best overall package for your application, the AquaJet is designed individually. The
core consists of 2 spunlace drums that can be combined with one of three compaction systems and one of
four suction types.
In addition, various special designs are available, ranging from MiniJet for small capacities all the way to the
specialist for wet-laid webs.

Random or roller card

One of more than ten installation concepts
for the production of wipes.

Blending Random or roller card

Bale opening

The spectrum of spunlaced nonwovens includes Modular AquaJet concept

light-weight wipes, medical textiles and cotton pads, • 3 functional units: compaction,
as well as heavy filter webs and coating substrates. bonding, dewatering
The highly flexible AquaJet machine concept ensures • Reliable layouts for standard products
a customised and energy-efficient bonding process. • Freely selectable combination of modules,
depending on product and process
• Easy retrofitting and conversion,
even after longer periods of operation
 T-BOND / Nonwovens 19

Due to the jet heads'

freely selectable
arrangement and high
precision, a perfect end
product is ensured.

AquaJet Drum dryer Winder

= standard installation

Material transport components as well as auxiliary

units have not been mentioned individually

Compaction Bonding
• 
Belt-belt compaction with advantages for • 
2 standard spunlace drums and
light-weight webs (patented) different executions
• 
Belt-drum compaction for heavy webs • 
Shells for structuring and perforation
• 
NEW: energy-optimized belt-strip compaction
for light-weight webs (patent pending) Dewatering
• 
One or two-sided dewatering
• Various types of dewatering belts
20 Nonwovens / T-BOND

AquaJet
Proven technology for every requirement

With the AquaJet spunlacing unit, Trützschler Nonwovens

is providing a modular system that can be specifically
adapted to different products and materials. Individual,
fast and efficient.
 T-BOND / Nonwovens 21

AquaJet: Perfection from small to large Structured and perforated nonwovens

In line with product and material, compaction and Special structuring and perforation shells, which can
dewatering as well as the number and position of easily be pushed onto the spunlace drum, are availa-
jet heads can be freely planned. AquaJet allows effi- ble for the structuring or perforation of the webs. For
cient web bonding and, in addition, structuring and/ this purpose, a perforated shell with a support mesh
or perforation. In practice, the unit convinces with is always used as basic drum.
its maintenance and user friendliness as well as its
excellent availability.

Microporous shell
MPS (microporous shell) for lighter
webs – with patented spiral type:
• Highest strength
Jet heads • Best surface bonding
• Robust design for water pressures • Uniform surface
up to 400 bar
• No filter inside the jet head Nickel coated wires for heavier webs Spiral type
• Double chamber system for turbulence Patented nickel-coated mesh:
free flow (patented) • Less open area compared to
• Fluidically optimized outlet of water jets standard mesh
(patented) • Better water jet reflection
• Self-sealing O-ring for patented jet strip • Softer web surface than with
change nickel shell
• Less fiber contamination on drum
• Easier web removal from drum
surface Nickel-coated mesh

The jet head design ensures perfect results at less pressure.

MiniJet in a cotton pad line Structured (top) and perforated nonwoven (bottom)
22 Nonwovens / T-BOND

Wet-in-wet processes 
Results of a highly efficient partnership

For the production of wet-laid nonwovens, Trützschler

Nonwovens teams up with Voith Paper, the pioneer in and
leading partner to the paper industry. The wet-laying process
for webs is similar to the production process for paper:
A suspension of fiber and water is filtered onto a perforated
belt to form a homogeneous fiber web. Hydroentangling
with the AquaJet results in perfectly bonded and, if required,
structured or perforated nonwoven fabrics.
Wet-laid, spunlaced webs –
a world full of potential
Nonwovens produced by wet-in-wet processes are
suitable for a wide range of applications. The use of
short fibers results in a very special characteristic.
This feed material allows for instance the production
of flushable wipes, i. e. hygiene and personal care
wipes that can be flushed down the toilet after use.
The excellent homogeneity of wet-laid webs in com-
bination with spunlacing also produces ideal personal
care and industrial cleaning wipes, filter materials or
coating substrates.

A popular end product: Flushable wipes.

An integrated solution with customised components

HydroFormer AquaJet
 T-BOND / Nonwovens 23

All components in one sweep Voith – the expert in wet laying

The high-performance installation concept of Founded in 1867, Voith employs more than 42,000
Trützschler Nonwovens and Voith Paper is adaptable people, generates € 5.7 billion in sales, operates in
to a variety of fiber blends and product requirements. about 50 countries around the world and is today one
The spectrum of possibilities ranges from single of the biggest family-owned companies in Europe.
layer viscose wipes made from renewable and bio- Voith Paper is a division of the Voith Group and the
degradable raw materials to multi-layer composites. leading partner to and pioneer in the paper industry.
The overall installation includes machines and com- Through constant innovations, Voith Paper is optimiz-
ponents for ing the paper manufacturing process, focusing on
• wet-laying developing resource-saving products to reduce the
• spunlacing use of energy, water, and fibers.
• drying With its HydroFormer, Voith Paper contributes the
• winding core component to the cooperation. It has been spe-
• water treatment and fiber recovery cifically optimised for the formation of wet-laid webs
and, with more than 70 successful installations, has
gained worldwide acceptance. In addition, Voith pro-
vides its expertise regarding stock and water sys-
tems, headboxes, press concepts and calendars.

Headbox of HydroFormer

Drying Winding
24 Nonwovens / T-BOND

Needling
The oldest bonding concept is as relevant as ever

Mechanically needled nonwovens are optimally suited for many industrial applications. High strength and low
elongation in longitudinal and transverse direction provide carpets, geotextiles, filter materials and technical
felts with high durability.

Installation concept for the production of geotextiles

Web drafter

Blending Random or roller card Crosslapper

Bale opening

= standard installation

Material transport components as well as auxiliary

units have not been mentioned individually

Material variety Large working widths

One of the main features of the needling process Large web widths are advantageous for end uses
is the variety of materials that can be processed. such as geotextiles. For this reason we offer needling
Thus, the spectrum ranges from popular man-made machines with a working width up to 8,000 mm. On
fibers such as polyester and polypropylene, high per- the other end of the spectrum are small laboratory
formance fibers (Aramid fibers, PPS ...) and natural installations whose requirements are covered by
fibers (cotton, wool, hemp, flax, etc.) all the way to fully functional needling machines with a working
glass and metal fibers. width as low as 1,000 mm.
 T-BOND / Nonwovens 25

Quick replacement of
needle boards

Needling machines

Calender

Needling machines Heatsetter Winder

Flexible installation layouts

As illustrated on the next page, Trützschler Nonwo-
vens offers various types of single board and double
board needling machines. Since the machines can be
combined and offer flexibility in terms of equipment,
they ensure the reliable and efficient production of
a large number of end products in an inline process.
They are also ideally suited as pre-needling stage in
offline processes with subsequent final needling or
hydroentangling.
26 Nonwovens / T-BOND

Needling
Cutting-edge technology in every respect

Versatile and durable and maintenance, resulting in lower operating costs

Trützschler Nonwovens offers no less than five and higher productivity. Furthermore, the proverbial
machine types for needling in all directions. Thus, reliability of our installations is increased once again,
the ideal solution can be selected for every require- even during 24/7 operation. In addition, the open and
ment. On a technical level, our needling technol- therefore easily accessible structure ensures maxi-
ogy convinces with highlights such as the patented mum maintenance friendliness.
swivel bearings: They operate absolutely free of wear

Installation for filter

materials with scrim
 T-BOND / Nonwovens 27

Patented, wear-free swivel bearings reduce maintenance and thus operating costs.

Demanding materials can be processed with a spe- ings of the double-shaft system are supplied via a
cial suction emitting compressed air pulses to keep central minimum quantity lubrication. It offers freely
the essential areas of the machine clean. The con- selectable intervals with a specified amount of lubri-
rod main bearings feature simple and reliable air cool- cant, thus reliably preventing machine contamination
ing with special filters. They ensure adequate cooling in the drive area.
and prevent contamination in the drive system even
in case of long maintenance intervals. All main bear-

Single-board needling machines

Double-board needling machines

28 Nonwovens / T-BOND

Thermo- and chemical bonding

Another application of the through-air principle

While needling and hydroentangling are based on entangling and knotting of fibers, here the single fibers
are bonded by "glueing". Depending on process, the results are light webs (for example for diaper liners)
or thick insulation materials.

A flexible installation configuration for the production

of ADL (Acquisition & Distribution Layer)

Liquid foulard Can dryer

Blending Random or roller card

Bale opening

New: Structured nonwovens

Up to now, structured nonwovens are primarily possible to structure webs without losing bulkiness
spunlaced. Thermally bonded nonwovens can be or softness. This inline process is similar to struc-
structured by means of calendering, though this turing via water jets: Bonding and structuring are
impairs the thickness and softness of the web, carried out in one step in the thermobonding oven.
i. e. the popular textile feel. With the patent-pend-
ing structuring drum for the thermobonder it now is
 T-BOND / Nonwovens 29

High-speed
liquid foulard

Drum dryer and Hotflue Winder Slitter / Rewinder

= standard installation

Material transport components and auxiliary units

have not been mentioned individually

New: High-speed foulard New: Maximum flexibility

The new foulard for the application of liquid bond- An interesting new development is a flexible
ing agents can be viewed as revolutionary: compared installation configuration that allows thermo- as well
to conventional methods, it may increase line speed as chemical bonding of light-weight webs. In thermo
during the production of light-weight webs by up to bonding, bicomponent fibers are used; in chemical
50%. This is due to the geometry and surface struc- bonding, the application of liquid bonding agents is
ture of newly developed sub-components. performed by the high-speed foulard.
30 Nonwovens / T-BOND

Thermobonding
Optimal air flow

High-performance thermobonding line

Concerning oven technologies, energy efficiency is Thermobonding via through-air flow

also more important than ever. Our drum ovens fea- The through-air principle has a double benefit: The
ture first-class insulation which reduces heat loss as suction effect created on the drum surface keeps
efficiently as possible and thus also keeps heating the web on the drum; at the same time air flows
costs at a minimum. through the web. High speeds with homogeneous
bonding are achieved specially with light-weight to
medium-weight products.
 T-BOND / Nonwovens 31

Chemical bonding
Absolutely uniform application

Reducing chemicals, but not quality – this is the "secret" of our foam High-speed liquid foulard
foulards.

Chemical bonding with foam Chemical bonding with liquid binders

This method is characterized by the fact that the With speeds up to 50% higher than conventional
chemicals are applied with particular precision. First- components, the high-speed foulard is designed for
class results are obtained with minimal use of bond- high-performance installations. As a result, in particu-
ing agents. lar the production of hygiene products becomes as
economical as never before.

One-sided or double-sided foam application with High-speed liquid foulard

1 or 2 mixers
32 Nonwovens / Finishing

Impregnation
Solutions for foam and liquid application

Impregnating by means of foam foulard

Impregnating according to requirements

For the impregnation of nonwovens and webs we
offer foam or liquid application, according to require-
ments. The use of foam foulards is advantageous for
light-weight webs with less density since complete
saturation is easy to achieve. For increased produc-
tion speeds as well as heavier and/or denser materi-
als we recommend liquid binders.

Nonwoven with hydrophilic (left)

or hydrophobic finishing (right)
 Finishing / Nonwovens 33

Smoothening/calibrating and heatsetting

Focus on uniformity

Calender and multi-drum dryer for roofing membranes Flexible treatment

via different
operation modes

Targeted smoothening/calibrating Precision heatsetting

Smoothening of the surface and calibration of the Compared to a conventional two-roll calender, the
nonwoven thickness are frequently used finishing heatsetting concept with drum oven offers decisive
steps. Our components create an absolutely uniform advantages: Needle rings hold the web in place, thus
pressure over the entire working width. The rolls can preventing the material from shrinking within the
be heated or cooled. In case of heated rolls, the dou- defined setting zone. At the same time the through-
ble shell ensures excellent temperature distribution. air principle ensures that web thickness, surface
softness and bulkiness are maintained.

Uniform line pressure, in connection with Needle rings ensure shrink-free setting. Heatsetter in Omega design
identical gap width, ensures optimal results.
34 Nonwovens / T-DRY

Drum dryer
The right technology for every requirement

Ω-dryer in a spunbond line Multi-drum dryer

Drum dryer Multi-drum dryer

Advantages of the drum dryer are its variability and Multi drum dryers are considered to be particularly
speed: due to its high specific drying performance it efficient because air flows through the nonwoven
dries a wide variety of nonwoven types within short- from the top and bottom side. Multi-drum dryers are
est time. In addition it features a compact design and available in horizontal as well as vertical design.
high uniformity of drying.
The modified series features an intermediate cham-
Ω-dryer ber for controlled flow of exhaust air and fresh air.
Ω-dryers have only one drum. Its long wrap length
extends the dwell time of the moist material in the Due to the intermediate chamber, they operate par-
drying room, which explains the high drying per- ticularly energy efficient and have a high air flow and
formance of this system. The Streamliner is a new temperature uniformity. The intermediate chamber
development of this dryer type. also opens up the opportunity to retrofit heat recov-
ery at a later time.
 T-DRY / Nonwovens 35

Streamliner

Streamliner
This spiral-shaped dryer type has the highest spe-
cific evaporation capacity. Correspondingly, its pro-
ductivity is at the upper end of technological fea-
sibility. Other convincing features are the optimized
air flow with low pressure loss, the targeted fresh air
supply that uses the temperature-dependent density
change, as well as the optimized heating system.

Exhaust air heat exchangers can be integrated into

the air duct for even more energy efficiency.

The Streamliner – designed for extremely uniform air flow and temperature.
36 Nonwovens / T-WIND

Automatic winders
Ready-for-sale and master rolls

Nonwoven fabrics and the respective

manufacturing processes differ greatly –
accordingly, Trützschler Nonwovens offers
various winding technologies.
Their advantage: all are based on the
proven know-how of Bastian, the specialist
in winding.

Material flow inside the automatic turret disc TWW-TD

T-WIND / Nonwovens 37
38 Nonwovens / T-WIND

Automatic turret disc winder TWW-TD

Fully-automatic turret disc winder with inline slitting Master roll winder for high-volume spunlace lines
capability For offline configurations Trützschler Nonwovens
Since our automatic turret disc winders TWW-TD are now offers a dedicated master roll winder. The sur-
equipped with an inline slitting system, ready-for-sale face-driven TWW-SD is equipped with an integrated
rolls can be produced directly in the manufacturing cross cutting and engagement system. The basic
or finishing process. Inline slitting guarantees gentle winder plus its several options meet the require-
material treatment since no additional rewinding is ments of large-scale production lines for robust,
required. Further advantages compared to an offline hydroentangled materials.
solution are lower investment and labour costs as
well as less space requirement.
Combining circumferential and axial drives results
in rolls with optimal hardness. Thus it is possible to
wind more material onto the rolls until the maximum
diameter is reached to lower shipping costs. Since
the tension is precisely adjusted to the material, it is
also possible to process sensitive materials such as
cotton pads and through-air bonded webs.

Master roll winder TWW-SD

 T-WIND / Nonwovens 39

Automatic unwinders
Continuous results at highest speed

Automatic unwinder Bastian TWW-UW Portal arms

Automatic precision unwinding During production, an absolutely continuous mate-

Whether coating, laminating, embossing or printing rial supply is ensured. The roll change is performed
– all these finishing processes begin with unwind- at production speed. Material from the new nonwo-
ing a nonwoven fabric. A task for the automatic turret ven roll is bonded to the web of the empty roll via
unwinder TWW-UW. It takes up the master roll into the ­"flying splice" method. Accumulators which could
the portal arms with their pneumatic chucking heads. affect the material are no longer necessary.
The portal arms can be adjusted by motors and allow
production of various material widths.

Automatic Unwinder Bastian TWW-UW

40 Nonwovens / T-WIND

Slitter rewinders
Perfect semi-automatic or fully automatic rewinding

Slitter rewinder

Slitter Rewinder with ready-for-sale-roles Longitudinal slitting equipment

Slitter rewinders Drive combination

Slitter rewinders convert previously produced mas- In addition to winding rolls with optimal hardness,
ter rolls into ready-for-sale units. This technology is the combination of circumferential and axial drive has
applied in converting, which includes coating, printing the following advantages: gentle material handling,
or embossing processes. more material on the rolls as well as lower transpor-
tation and shipping costs.

Slitter Rewinder Bastian TNW-RW

 T-WIND / Nonwovens 41

Automation
Quality all the way to packaging

Complete installation supplied by Trützschler Nonwovens

Solutions for shipping and storage Automatic concepts are the answer when the focus
At the end of the production line, the finished rolls is on maximum flexibility, handling of different roll
need to be prepared for shipping or storage. For this dimensions or a high throughput. This in­cludes instal-
final process step, Trützschler Nonwovens is able to lations that automatically take off finished rolls from
provide every required level of automation for roll the winder or the inline labelling unit. Systems for
handling and packaging. weighing, stacking and palletising as well as sorting
of faulty rolls also increase productivity.
Semi-automatic basic designs are particularly suited
for modest production speeds or low roll throughput.
Thus, when transporting the rolls to the packaging
unit, the operator is supported for instance by lift-
ing devices. Another tool is pallet wrappers that pre-
pare the material for shipping. They wrap stretch film
around a manually stacked roll bundle on a pallet.

Automatic handling and packaging system

42 Nonwovens / Other products

Trützschler Man-Made Fibers

Specialist for carpet yarns and industrial yarns

symTTex production line for BCF

Trützschler Man-Made Fibers is our specialist for

filament extrusion of thermoplastic polymers such
as polyamide, polypropylene and polyester. The
branch provides tailored concepts for the production
of carpet yarns (BCF) as well as of high-tenacity or
low-shrinkage filaments for industrial applications.

Proven cutting-edge technology

Developments in the areas of extruder, spin packs,
spin beams, quenching, drawing and winding allow
maximum efficiency and yarn quality. A special char-
acteristic is the excellent symmetry: The geometric
identity of each spinning position ensures a uniform
melt distribution and treats each thread exactly the
same. The results are: uniform filament character-
istics.

The core of BCF spinning: HPc texturing nozzle and cooling drum
 Other products / Nonwovens 43

Efficient manufacturing of demanding yarns Filament processes

symTTex and symTTec are two proven concepts for Polymer production
BCF and industrial yarn spinning plants. Configured
in a variety of ways, several hundred spinning posi-
tions worldwide, show how flexible, and cost effec- Granulates
tive the production of quality yarns can be.

Modernisation and maintenance Extrusion & filtration

Trützschler Man-Made Fibers offers a variety of mod-
ernisation packages and services to ensure that
investments will remain profitable for many years. Spinning and quenching
This includes for instance plasma coating of godets.
Upgrade kits for winders and electrical equipment or
for BCF texturing can also maintain or improve the Drawing Drawing
performance of existing installations.

Texturing

Winding Winding

BCF Industrial yarns

Partner
Trützschler Man-Made Fibers

DSR godets during production

44 Nonwovens / Installation configurations

Spunlacing
Installation configurations

Automotive Headliner

Opening Roller Cross- Web Drum

AquaJet Winder
& Blending card lapper drafter dryer

Coating substrates
Roller
Calender
card

Opening Roller Cross- Web Drum

AquaJet Winder
& Blending card lapper drafter dryer

Geotextiles

Drum
Spunbond AquaJet Winder
dryer

Hot gas filtration

Opening Roller Cross- Web Batt Drum

AquaJet Winder
& Blending card lapper drafter Turner dryer

Winder
Drum
Unwinder AquaJet
dryer

Medical textiles
Web
Crosslapper
drafter

Roller
card

Opening Roller Drum

AquaJet Winder
& Blending card dryer

Unwinder
for tissue

Spunbond
 Installation configurations / Nonwovens 45

Wipes single layer Roller/

Random
card

Opening Roller/
Drum
& Blending Random AquaJet Winder
dryer
card

Wetlaying

Spunbond

Wipes multilayer Roller/

Spunbond Random
card

Pulp

Roller/
Opening Drum
Random AquaJet Winder
& Blending dryer
card

Spunbond
Roller/
Random
card
Pulp

Cotton pads
Cross- Web
lapper drafter

Random Random
card card

Opening & Airlay Drum

AquaJet Winder
Blending card dryer

Cotton pads –
Flat top Airlay Flat top
alternative card card card

Drum
MiniJet Winder
dryer
Opening Flat top
& Blending card
46 Nonwovens / Installation configurations

Mechanical needling
Installation configurations

Automotive
Needle looms

Opening Roller Cross- Web Accu-

Winder
& Blending card lapper drafter mulator

Roofing membranes
Needle looms

Opening Roller Cross- Heat-

Winder
& Blending card lapper setter

Spunbond

Impreg- Drum
Unwinder IR dryer Calender Winder
nation dryer

Geotextiles Needle looms

Web-
drafter

Roller/
Opening Cross- Heat-
Random Calender Winder
& Blending lapper setter
card

Needle looms

Hot gas filtration

Opening Roller Cross- Web Batch Accu-

Winder
& Blending card lapper drafter Turner mulator

Needle loom

Winder

Unwinder

Needle looms
 Installation configurations / Nonwovens 47

Wipes
Needle looms

Opening Roller Cross- Impreg-

Belt Dryer Calender Winder
& Blending card lapper nation

Technical felts

Web
drafter
Needle looms

Opening Roller Cross-

Winder
& Blending card lapper

Carpets

Opening Roller Cross- Roller Cross-

Winder
& Blending card lapper card lapper

Needle looms

Carpet backings

Opening Roller Cross- Web

Winder
& Blending card lapper drafter

Needle looms
48 Nonwovens / Installation configurations

Thermo- and chemical bonding

Installation configurations

Interlinings

Foam
foulard

Liquid
Can dryer
foulard

Opening Roller Thermo-

Winder
& Blending card bonder

High loft nonwovens

ScanFeed Calender

Opening Roller Cross- Web

Belt dryer Winder
& Blending card lapper drafter

Airlay Stacker

Acquisition & Distribution layer (ADL)

Foam
foulard

Liquid
Can dryer
foulard

Calender Hot flue

Roller/ Thermo-
Opening Slitter /
Random bonder / Winder
& Blending Rewinder
card Drum Dryer
 Installation configurations / Nonwovens 49

Technical data

Opening and blending

PAN WEIGHER AND BELT WEIGHER HIGHSPEED CARD TWF-NCT
Installation output < 3,000 kg/h Fiber 1.0 – 3.0 dtex
Accuracy of weighing +/- 1% Fiber length < 60 mm
Mixing components 2 – 6 Web weight 14 – 55 gsm
Line Speed ≤ 300 m/min
BLENDING CHAMBER Working width ≤ 4,000 mm
Mixing components 2 – 20
Output per mixer < 3,000 kg/h RANDOM CARD TWF-NCR
Fiber 0.7 – 17 dtex
FINE OPENER Fiber length 14 – 60 mm
Working width < 2,500 mm Web weight 25 – 140 gsm
Output < 2,000 kg/h Output < 260 kg/hm
Working width ≤ 3,800 mm
FEED BOX
Working width < 1,500 mm AIRLAY CARD TWF-NCA
Output < 2,000 kg/h Fiber 0.7 – 17 dtex
Fiber length 12 – 60 mm
EDGE OPENER Web weight 20 – 400 gsm
Working width < 500 mm Output < 350 kg/hm
Production speed < 120 m/min Working width ≤ 3,800 mm

CROSSLAPPERS
Output over 140 m/min
Web formation Laying width < 8,000 mm
Number of layers 4 – 76 layers
TUFT FEEDER TWF-TF
Web weight 300 – 1,500 gsm WEB DRAFTER
Output < 500 kg/hm Drafting zones: 4 – 8
Working width < 9,000 mm
ROLLER CARD TWF-NC
Installation output 0.7 – 100 dtex
Fiber length 14 – 150 mm
Output < 450 kg/hm
Working width ≤ 4,200 mm
50 Nonwovens / Technical data

Web bonding Finishing

AQUAJET IMPREGNATING
Working width 500 – 5,000 mm Foam application Working width
< 500 m/min Output < 100 m/min
Speed (spunbond up to
1,000 m/min) Working width < 5,000 mm

WET-IN-WET PROCESS (HYDROFORMER) SMOOTHENING/CALIBRATING

Web weight 20 – 100 gsm Line pressure 50 – 600 N/cm

pulp, viscose, PET... Output < 100 m/min

Material
optional multilayer technology Working width < 7,000 mm
Working width 3,600 mm; 4,350 mm
Output < 400 m/min HEATSETTING
Cylinder diameter < 3,000 mm
NEEDLING Working width < 7,000 mm
Working width 500 – 7,500 mm
Strokes < 1,600 /min

THERMOBONDER Drying
Web weight < 10 – 200 gsm
Working width < 7,000 mm Ω-DRYER
Output < 1,500 m/min
CHEMICAL BONDING WITH FOAM Working width < 5,400 mm
Foam application 1-sided or 2-sided
Output < 100 m/min MULTI-DRUM DRYER
Working width < 5,000 mm Output < 800 m/min
Working width < 5,400 mm
CHEMICAL BONDING WITH LIQUID BINDERS
Liquid foulard One-sided STREAMLINER
Output < 120 m/min Output < 1,500 m/min
Working width < 5,000 mm Working width < 5,400 mm
 Technical data / Nonwovens 51

Winding and slitting

AUTOMATIC WINDER WITH INLINE SLITTING AUTOMATIC UNWINDERS
Material width < 3,400 mm Material width < 4,500 mm
Lap diameter < 1,500 mm Unwinding diameter < 2,400 mm
Production speed < 450 m/min Unwinding speed < 400 m/min

SURFACEDRIVEN WINDERS
SLITTER/REWINDER WITH DRIVE COMBINATION
Material width up to 3,600 mm
Lap diameter < 1,800 mm Material width < 3,500 mm
Production speed < 200 m/min Unwinding diameter < 1,500 mm
Rewinding diameter < 1,200 mm
Rewinding speed < 340 m/min

vo n
lu n
t a r y c e r tifi c a ti o

www.machines-for-textiles.com/blue-competence

Trützschler Nonwovens & Man-Made Fibers GmbH Trützschler Nonwovens GmbH

Wolfsgartenstraße 6 · 63329 Egelsbach, Germany Halterner Straße 70 · 48249 Dülmen, Germany
Telephone: +49 (0)6103 401-0 · Fax: +49 (0)6103 401-440 Telephone: +49 (0)2594 5099-0 · Fax: +49 (0)2594 5099-100
E-Mail: info-fleissner@truetzschler.de E-Mail: info-erko@truetzschler.de

Legal disclaimer:
The brochure has been compiled to the best of our knowledge and in good faith with the utmost care. However, it may be subject to type errors or
technical changes for which we assume no liability. The photos and illustrations are purely informative in nature and in part show special equipment
options which do not feature in the standard scope of delivery. We provide no guarantee as to the current nature, correctness, completeness or quality
of the information provided. Warranty claims for material or immaterial damage against us or the respective author based on the use or forwarding of
the information provided, even if the information is incorrect or incomplete, cannot be asserted. Our provided data is non-binding.

Print No.: 17011-03/17-e · Agentur Brinkmann GmbH, Krefeld

G E T T I N G F I B E R S I N T O S H A P E – S I N C E 18 8 8

Fib e r pre p a rat ion in st a l l a t io n s : B a l e o p e n e r s · M i x e r s · C l e a n e r s / O p e n e r s

Fore ig n P ar t Se p a r a t o r s · D u s t s e p a r a t o r s · Tu f t b l e n d e r s
Wast e c l e a n e rs | C a r d s | D r a w f r a m e s | C o m b i n g m a c h i n e s

Ba l e ope n e rs/ Mixe rs | C ard f e e d e r s | C a r d s / C r o s s l a p p e r s | We t l a y i n g l i n e s

H ydroe n t an g l in g , n e e d l i n g , t h e r m o - a n d c h e m i c a l b o n d i n g l i n e s
Fin ish in g , d r y i n g , w i n d i n g , s l i t t i n g m a c h i n e r y

Fil ame n t l in e s: C a r p e t y a r n s ( B C F ) · I n d u s t r i a l y a r n s

Me t a l l ic wire s: C a rds · C a rds l o n g s t a p l e · C a r d s n o n w o v e n s · O p e n - e n d s p i n n i n g

Flat tops | Fillets
C a rdin g se g me n t s | S e r v i c e m a c h i n e s | S e r v i c e 2 4 / 7

w w w . t r u e t z s c h l e r . c o m