#Nonwovens / Technical Textiles

2022-11-23

Sustainable solutions at nonwovens - Reducing gas consumption at drying of spunlace production

Energy management and efficiency have never been more important than nowadays. This applies especially to energy intensive processes such as the nonwoven production. To address this topic, the Center of Excellence in Nonwovens at the STFI (Sächsisches Textilforschungsinstitut e.V., in Chemnitz, Germany aimed to design an energy efficient spunlace production.

Thus, at their spunlace laboratory facility a measurement and control concept by PLEVA was implemented to optimize the process to highest energy efficiency. This includes sensors for residual moisture, fabric temperature, exhaust humidity, and a process control system.

Solutions installed at spunlace production line of STFI

AF 120 After the spunlace process, a contactless microwave moisture measurement with the sensor AF 120 is used due to the conditionally high residual moisture content. The sensor consist of 2 measuring heads, the transmitter and the receiver. The measuring principle is based on microwave absorption by the water content of the nonwoven. The more water there is in the nonwoven, the lower the signal at the receiver. The magnitude of the absorption is a measure of the absolute residual moisture content of the nonwoven.

This determination of the water content is used to optimize the subsequent dryer.

TDS Inside of the drum dryer, the nonwoven temperature is monitored with 3 TDS infrared sensors. This ensures that the quality of the spunlace nonwoven is not affected by overheating. The used infrared measurement is based on heat radiation exchange between the spunlace nonwoven and the infrared sensor. The measuring range of the TDS sensor is 0 - 250°C.

FS X The exhaust air humidity in the screen drum dryer is monitored by the FS X air humidity sensor and can be regulated in the production process via a exhaust flap control. The absolute air humidity (water vapor) in the exhaust exit tube of the drum dryer is measured. The setting of the optimum air humidity value should be e.g. 90 g water/kg air under production conditions for textile dryers.

RR For measuring the low residual moisture after the drum dryer and thus for controlling the fiber-dependent drying temperature, an RR sensor is used. It is used in applications of up to max. 30 % residual moisture. This sensor is a tandem roller sensor which monitors the residual moisture measurement in the center of the nonwoven. The active principle is the contact measurement of very low residual moisture based on electrical conductivity. The defined contact pressure and perfect alignment to the nonwoven with the tandem roller sensor ensure the highest accuracy. Another advantage is the compensation of electrostatic charge at low residual moisture levels and for fabrics with synthetics.

PLEVATEC With the process visualization, the fabric temperature, residual moisture and exhaust air moisture measured by the corresponding sensors are monitored and the process values are adjusted on the spunlace system. Andreas Nestler, Research Associate at STFI highlights the newly achieved possibilities: “The profile of the residual moisture after the AquaJet and the drying temperature (fabric temperature) allow new optimization possibilities in the drying process. Gentle heating curves become possible, which prevent nonwoven surface damage. Also, the process and tolerance monitoring enables the improvement of the nonwoven quality, as it is not exposed to unnecessarily high drying temperatures.” This is also an important aspect in terms of sustainability, as there are no more second choice goods or rejects, which implies savings of valuable resources.

Furthermore, a comprehensive 10-day trend display/history and recipe management is possible. The drying process is carried out with highest energy efficiency and continuous data monitoring. The process visualization is a modular visualization and control system for the material moisture and for the drying process. At various customer trials with this implemented system of sensors and process control, the goal of achiving an energy efficient nonwoven production line was achieved. With the used technology it was possible to lower the drying temperature by 40°C (from 100°C to 60°C) running on target moisture. For viscose the residual moisture was set to 5-7%. In sum with this optimizations a used gas volume reduction of 20% was achieved with a given full transferability to industrial dryers.

More information about sustainable solutions and PLEVA can be found on

http://www.pleva.org

https://www.stfi.de/en/research/nonwovens

Smart automation to fix gaps of skilled staff

Advanced technology for high quality and efficiency at textile finishing - ITMA Asia 2025, Singapore As customer expectations rise and skilled labor becomes increasingly scarce, smart sensor technology and automated control systems have become essential in modern textile finishing. PLEVA meets these challenges with its renowned, robust and reliable sensors, specifically designed for the demanding conditions of textile production.

Generation change at Pleva: Kathrin and Stephan Pleva join the Management Team

PLEVA GmbH, a leading manufacturer of sensors, measurement and control technology for various industries, announces that Kathrin Pleva and Stephan Pleva have been appointed as Managing Directors of the family-owned company. Together with their father, Dr. Ralf Pleva, they will shape the future of the company.

SL Smart Weft-Straightener success at Harris Tweed Hebrides, UK

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ANDRITZ sets focus on textile recycling and durable nonwoven production technologies at ITMA Asia 2025

International technology Group ANDRITZ will be presenting its innovative nonwovens production and textile solutions at ITMA ASIA + CITME 2025 in Singapore, from October 28 to 31, 2025 (Hall 2, D106). ANDRITZ will showcase its MMCF production plants, textile sorting and recycling, bast fiber processing, needlepunch, airlay, and life-cycle service technologies, with a focus on sustainable solutions. Discover how these innovations can grow your business opportunities and support a greener future.

OUTLOOK™ 2025: Charting a sustainable and innovative future for the Nonwovens Industry

EDANA concluded its flagship event, OUTLOOK™ 2025, last week, marking it as a major success and addressing the biggest questions facing the industry. The three-day conference highlighted the urgent need for a unified approach to sustainability, regulation, and innovation in the absorbent hygiene and wipes sectors.

Global Nonwovens Alliance unveils Inaugural Board, advancing collaboration and growth worldwide

The Global Nonwovens Alliance (GNA), a tax-exempt federation jointly founded by INDA, the Association of the Nonwoven Fabrics Industry, and EDANA, the Voice of Nonwovens, announces the appointment of its founding Board of Directors. This group of leaders represents some of the most influential executives across the nonwovens value chain and reflects GNA’s mission to foster global collaboration, innovation, and growth in the industry.

Sustainable, lightweight, and sound absorbing: Polyester-based front trunk solution for BEVs

As car manufacturers look to further reduce their carbon footprint, Autoneum has developed an innovative front trunk solution for battery electric vehicles (BEVs), made entirely from polyester-based textile. The Ultra-Silent Frunk offers significant weight reduction, improved acoustic and thermal insulation, and uses up to 70 percent recycled material, supporting sustainable and efficient vehicle design. Autoneum, global technology leader in acoustic and thermal management for vehicles, has already received orders for the new frunk from three major OEMs in Asia and Europe to be built in three BEV models. Series production for two BEVs has been underway in China and Germany since last year.

Modern testing methods for raw cotton

The 38th International Cotton Conference Bremen will take place from 25 to 27 March 2026 at the Bremen Parliament. This conference has traditionally stood for in-depth expertise and international exchange. The program will focus on technical innovations, market trends, and regulatory frameworks across the entire value chain – from agriculture to the circular economy. With high-profile speakers, the conference is regarded as the key meeting point for the global cotton industry. Today’s focus: Cotton quality and testing methods.

Rieter responds to higher raw material prices

Global political and economic developments have been leading to rising raw material and energy costs for some time. The textile machinery industry is also affected by this trend. Rieter machines and components consist to a large extent of steel, copper, aluminum and electronics. These materials in particular have seen higher demand and higher prices in recent months.