INDEX20, the world’s largest nonwovens exhibition, held in Geneva from October 19-22, 2021, was a resounding success, featuring over 500 exhibitors on more than 45,000 square meters of exhibition space.

“With over 9300 visitor entries over the four days, and an overwhelming sentiment among exhibitors of an unexpected attendance and quality of key decision-makers from across the globe, we are told by all those we have met that this is undoubtedly a resounding success under the circumstances,” says Pierre Wiertz, general manager of EDANA.

Following a record year for nonwovens production in Greater Europe, with a growth of 7.2% in 2020 to reach 3,075,615 tons (largely due to the highest ever demand for materials intensively used to fight the pandemic), this was the first opportunity in four years for the community of professionals from across the whole supply chain to meet in person.

The visitor count is even more remarkable considering that over a thousand further professionals joined the online version of INDEX, as the show was presented for the first time ever in a hybrid format, allowing exhibitors to match their live with virtual stands featuring their products and services. The virtual platform will stay accessible until November 15 to allow all on-site and virtual participants to watch the content from the six sector seminars (Sustainability, Filtration, Geosynthetics, Transportation, Smart Nonwovens and Infection Prevention) as well as the content provided by all the exhibitors.

“We are delighted to note that this ‘augmented reality’ offer was so well received, and since the Swapcard platform which supported this will continue to be accessible to the 2500 pre-registered delegates for several weeks, as well as any other new visitors, we expect that those who missed the numerous side events such as the six sector seminars, or wish to prolong their contacts with exhibitors, will continue to benefit from INDEX in an innovative way,” says Magali Fakhry Dufresne, INDEX exhibition director, Palexpo.

“Our business contacts at INDEX are usually all about long-term relationships and contracts, with additional new opportunities a plus; for this edition it has been first and foremost a matter of once again meeting business partners face to face after so many videocalls, and the pleasant surprise is that over all the result has exceeded our expectations. The level of engagement and quality of visitor makes INDEX a vital business development tool for industry players of all sizes, it remains the flagship exhibition of the nonwovens industry,” says Mikael Staal Axelsen, CEO of Fibertex Nonwovens.

Following this inspiring edition, EDANA looks forward to welcoming the entire industry back to Geneva in 18 months for INDEX23, taking place from April 18-21, 2023.

A.Celli Showcases Machinery Innovations
A.Celli Nonwovens exhibited a detailed look at its world-renowned solutions, including the E-wind winding and rewinding line; the R-Way packaging, palletizing and reel handling solutions; and the F-Line multifunctional lines for lamination, medical applications and spooling.

New to the company’s product range is the A.Celli Festooning line, an ideal solution for handling delicate materials highly sensitive to winding parameters.

A.Celli’s extensive offer is completed by its Iridium printing technologies for the hygiene industry and by the range of services offered in the field of industrial automation—Industry 4.0.
Francesco Buonocore, sales manager digital & IoT, delivered a speech at INDEX 20 focused on the company’s digital solutions and the use of data monetization in making a difference.

Andritz Offers Full Slate of Technologies
International technology group Andritz presented its innovative nonwovens production and textile solutions at INDEX. Its broad product portfolio covers state-of-the-art nonwovens and textile production technologies from air-through bonding to needlepunch, spunlace and natural fiber processing, among many others.

A highlight of this year’s tradeshow was the introduction of a new member of the Andritz Nonwoven division: Andritz Laroche. The company has been a critical partner for Andritz in the field of fiber preparation for drylaid nonwovens for over 10 years. Andritz Laroche is a leading supplier of fiber processing technologies. These include opening, blending and dosing, airlay web forming, textile waste recycling and decortication of bast fibers.

Sustainability is obligatory for the industry and Andritz’s “We Care” sustainability program combines all environment, social, governance initiatives, goals and achievements under one roof. For years, Andritz has offered different nonwoven processes, like spunlace, wetlace and wetlace CP, with the goal of reduction and elimination of plastic components while maintaining the high quality of the desired product properties. The Andritz neXline wetlace CP line is the latest development in this field. The fully engineered production line combines the benefits of wetlaid and drylaid technologies to produce a new generation of biodegradable wipes.

To better serve customers while offering the best possible R&D and service, Andritz has invested in and upgraded its technical center in Montbonnot, France, to a Wetlace CP line. It is the first nonwovens test center for wipes worldwide with integrated pulp formation. Customers can conduct trials and test all options for wipes together with its experts.

In response to the demand to save raw materials, Andritz is presenting its neXline spunlace for lightweight fabrics. Given the challenge of reducing weight per square meter while maintaining high MD and CD tensile strength, Andritz provides the well-known TT card web forming and the high-performance Jetlace hydroentanglement units, which can more than fulfill these demands. The spunlace roll goods can achieve weights of 25 gsm and even less for ultralight spunlace fabrics, and web uniformity is excellent.

Andritz also introduced its adult pants converting line, which offers top-class components and an innovative technology process. The growing market for adult incontinence products has resulted in a state-of-the-art process with highest quality standards, such as the development of ultrasonic side seam solutions with excellent results in terms of bond strength and system reliability. The machine speed no longer limits quality bonds. As a result, operations and size changes are faster and easier. The modern forming system for higher superabsorbent polymers concentration and the turning and placing system guarantee maximum process stability and put customers’ adult pants at the top of the adult hygiene market.

Another highlight at INDEX was the latest technology developments in the spunlaid sector. The patented nonwovens process called “Spunjet” is the in-line hydroentanglement of continuous filaments, creating a new generation of spunlaid nonwovens with unrivalled bulkiness and softness compared to standard spunbond fabrics. Spunjet offers customers the best properties ever achieved in existing and new nonwovens applications.

Binder Develops First Biodegradable Microplast
The Binder Group has been driving innovation for over 200 years, making the company a global technology leader for high-tech fastener systems. As a family-run, globally successful company, Binder Group offers technical solutions for a wide range of industries, such as personal care, automotive, transportation, aviation, consumer electronics, the industrial sector and medical and orthopaedic technology. To preserve their innovativeness, Binder places considerable emphasis on research and development as well as on collaborations with leading research institutes and universities.

One of Binder’s main products is Microplast, which has existed for over 20 years and—among others—is used for nappies and incontinence products. Microplast has been constantly optimized, making it thinner, lighter and more economical in terms of material, but now Binder is ready for the next step: biodegradability.

Binder has developed the first biodegradable Microplast for the personal care industry, the Binder BioHook. This is a crucial detail that allows nappies to become one with nature again after usage.

Two versions are available to its customers. In addition to the already well-known use of PLA materials based on lactic acid compounds, Binder is employing a new and innovative technology that makes biodegradability possible in polyolefins in accordance with BSI PAS 9017:2020. Moreover, Binder BioHook is compatible with all recent recycling systems for polyolefin-based materials.

Bostik Presents Adhesives Solutions
As a platinum virtual exhibitor, Bostik hosted visitors in a physical booth and exhibited innovative and sustainable adhesive solutions designed to meet diverse application needs across markets. Bostik also exhibited on a virtual platform provided by Palexpo with a digital immersive experience, especially for those unable to visit the exhibition in person.

Bostik introduced StayX Adhesive Technology for feminine hygiene and light adult incontinence pads. StayX delivers best-in-class stay-in-place performance, as verified by Staybility, a patent-pending test designed by Bostik to fill a gap in the typical product development testing process.

In addition to taking inspiration from StayX Adhesive Technology, manufacturers of absorbent hygiene articles and hygiene industrial players visited Bostik’s physical booth or its virtual booth to discuss Corporate Social Responsibility. Experts were on hand to provide details on Bostik’s ‘Responsibly for Hygiene’ commitment, which supports article producers to meet their own sustainable development objectives and the sustainability needs of their consumers.

“We appreciate the opportunity to show the disposable hygiene market our knowledge and understanding on CSR, sustainability and innovation,” says Diane Toonen, global strategic marketing director for Bostik’s Nonwovens Business Unit.

Colquímica Introducesd Adhesives Innovations
At INDEX, Colquímica Adhesives, one of the leading hot-melt adhesives players, presented KMELT SPRAYCARE W-2020, a new hot-melt adhesive for hygiene applications which addresses the current market need for more sustainable solutions for baby and adult diapers as well as feminine hygiene products. The innovation has been achieved by working closely together with Dow, a leading materials science company, and targeted to achieve a highly efficient as well as environmentally friendly outcome.

One of the key features of this technology is its excellent processability, being sprayed at low temperatures with no angel hair formation. A crucial aspect for this performance is the use of an adhesive which is based on olefin block co-polymer technology from Dow offering a wide operating window suitable for spray and slot applicators. The lower density of this technology and higher adhesion properties enables to reduce the glue consumption by up to 20%. Using less material to achieve enhanced performance has a positive impact on the carbon footprint of these applications and, ultimately, on the environment.

“Sustainability is a key driver in the evolution of the hygiene market. From the very beginning of this project, the aim to develop a more sustainable solution was identified as a key priority. The enhanced performance of this product is of great importance for us, matching the ever-evolving needs and demands of our clients. Our focus remains the same: to provide the market with highly efficient, safe and sustainable solutions,” says Igor Encarnação, Colquímica Adhesives procurement manager.

“Building on Dow’s polymer and Colquímica’s formulation expertise, we’ve delivered a concrete and market-relevant polyolefin-based solution which will help manufacture more sustainable hygiene products without compromising on performance,” comments Imran Munshi, global market segment leader for Hot-Melt Adhesives at Dow. “In our aim to support and advance the market needs for resource-efficient, mono-material and circular solutions, innovation like Colquímica’s new adhesive will lead the way to a more sustainable industry.”

Colquímica Adhesives and Dow are already working together on new projects and both maintain a strong focus on innovation as a key element to provide the hygiene market with green, highly performance technology.

Delta Introduces Pants Machine
Delta Machinery has introduced the Discreet X04 machine for the development of absorbent incontinence pants for men and women, wearable feminine hygiene products and baby pants. The line features a patented system for the construction of elastic bands that provide increased comfort, improved fit and discretion while saving 40% on elastic polyetheylene material.

The machinery is able to make absorbent products inspired by the latest fashion trends of the Italian lingerie market with the purpose to meet the personal needs and preferences of consumers. Discreet X04 products all have the same qualities and appearance as real stylish underwear and can be made in a variety of colors, sizes, softness and absorbency levels.

ExxonMobil Presents Polymer Solution
ExxonMobil presented its new breakthrough solution, which is designed to produce nonwoven fabrics with lofty thickness, ultra-cushiony cotton-like softness, and a silk-like smooth touch, at INDEX. Also offering low lint and uniformity, the solution provides a tailored balance of properties for nonwovens used in premium diapers, pant-type diapers, feminine care items and adult incontinence products.

A blend of ExxonMobil PP3155E5, ExxonMobil Achieve Advanced PP3684 and Vistamaxx 7050BF performance polymer, the solution is easily processed using bicomponent (BiCo) spunbond technology from Reifenhäuser Reicofil, an acknowledged market leader in complete nonwoven, meltblown and composite production lines.

By adjusting the formulation, nonwovens can be tailored to meet the needs of different hygiene product components such as the bellyband, backsheets and topsheets used in baby diapers, feminine care and adult incontinence products.

Offering the thickness required for cushiony softness, the nonwoven fabric is as resilient as it is lofty, while delivering good drapability, uniformity for consistent products and low lint for surface stability.  Formulation variations allow nonwovens to be produced with a different feel to meet the needs of the application, from a cottony touch to a silky touch.

Spunbond fabrics can be manufactured that are up to 15% thicker for outstanding protection compared to other BiCo spunbond high-loft solutions. Plus, 80% of the thickness is maintained after being placed under load for an extended period.

Farè Promotes Spunbond, Meltblown Lines
With more 500 industrial lines operating worldwide, since 1970 Farè has been designing and manufacturing equipment to produce synthetic fibers based on extrusion of a variety of polymers. Its projects deliver to the customer turn-key solutions for several sectors of application.

Farè manufacturers complete spunbond, meltblown and composite systems with customized solutions for the production of nonwovens suitable to cover all market demands from hygienic starting from 8 gsm to technical applications up to 1000 gsm. Configurations for Hi-loft and High-strength nonwovens mono or bicomponent layouts are available.

• Spunbond: from 1 beam (S) up to 3 beams (SSS)
• Composite: in combination with meltblown from 3 beams (SMS) up to 6 beams (SSMMMS)
• Meltblown (stand alone): from 1 beam (M) to 2 beams (MM)

Farè also manufactures staple lines for the production of a wide range of fibers like solid fibers, hollow fibers, neutral and colored fibers. Configurations available with mono or bicomponent layout as follows:

• One step process: from polymer to fiber in one plant to satisfy most of the market requirements. Low conversion costs and high flexibility make this solution a very attractive answer to most of the market requirements
• Two step process: for high-speed production of special fibers. Thanks to the high spinning speed, the two-step process is the right solution for the production of special fibers (especially cotton fibers) and it is the right choice whenever the staple fiber line is downstream of a polymerization or polycondensation system (direct spinning).

For all technologies the PET dryerless extrusion system  is available, which enables to overcome all typical issues related to the PET flakes processing such as viscosity and bulk density irregularities, presence of pollutants, the formation of dust, etc., bringing to the following benefits: Optimized melt homogenization, efficient melt decontamination and lower polymer degradation, maximum process flexibility with possibility to process up to 100% of PET recycled bottle flakes / R-PET in pellets, lower energy consumption with equipment space reduction.

In the perspective of a circular economy and sustainability, the Farè plants have the capability to process bio-based material with guaranteed production capacity.

Focke & Co. Introduces Diaper Packaging Systems
A new packaging system for diapers that stands for utmost care in product treatment, solidity, durability and proven technology, developed by Focke & Co. launched at INDEX. The modular machinery design of the new Focke stacker and bagger equipment offers economic solutions for various applications for the diaper industry. Increased efficiency and an open design enable easy operation and maintenance. Neither various bag styles nor sustainable materials effect the operation planning with this packaging line.

The stacker module itself stands for high flexibility to combine multiple modules such as one or more bagger and / or cartoner, flow wrapper, case packer as well as further packaging solutions. Using the new Focke Stacker Bagger model offers benefits of standard equipment customized to the needs of the operation, high compression capability and unique in-line compression for gentle product handling. Innovative machine functions supported by servo driven motion design sequences provide additional value to packaging.

Equipped with Focke VISU 3000 and in connection with digital services such as remote or condition monitoring aspects, this equipment is future proven. Focke VISU 3000’s new modular design allows simple extension by further functions and requirements. The on-screen help as well as integrated machine documentation support the operator in his tasks and enable quick solutions to any issues.

General Nonwovens Launches New Nonwovens
General Nonwovens of Turkey is a member of Imam Kayali Holding which is active in different fields of trade and industry since 1928. General Nonwovens has been producing nonwoven fabrics for over a decade. During this period, the company expanded its operations to three factories in Turkey along with the expansion in offerings made to the nonwovens industry. At the end of 2019 General Nonwovens announced its latest investment in Reicofil 5 plus technology which sets new standards for spunbond and composite nonwovens. The new multi-beam line is located at General Nonwovens’ third site in Sakarya, Turkey. The 4.2 meter wide SSMMS line is in commercial production now and primarily serves the hygiene industry, adding 26,000 tons of capacity to General Nonwovens’ operation.

General Nonwovens not only serves the local market but also to the U.S. and EU markets with a 50-50 split. Hygiene, automotive, filtration, medical, technical textiles, coated and laminated fabric end uses covers the majority of the markets served.

General Nonwovens’ HyGen brand products are widely used in the hygiene industry namely: topsheet, backsheet, ADL, leg cuffs, front ears and core-wrap. A very soft air through bond fabric is also served for those who are in search of soft-touch fabric for premium disposable product end uses. Apart from the HyGen brand; FilterGen brand is served for filtration industry, MediGen for medical industry, TexGen for coated and laminated fabrics as well as home textiles, AutoGen for the automotive industry and IndiGen for industrial and technical textiles applications.

Indorama Presents Sustainable Solutions
The Hygiene Fibers Group of Indorama Ventures (IVL) came together to present an all-inclusive range of recycled and biodegradable solutions for hygiene fiber and nonwoven applications. 

The combination of polymers, technologies, processes and global reach supported by the Hygiene Fibers Group—one of three business segments that make up Indorama Ventures—positions it uniquely within the hygiene industry to meet increasingly challenging market demand for innovative sustainable solutions within the hygiene sector. Across the six brands and companies that make up Hygiene Fibers Group—Auriga, Avgol, FiberVisions, Indorama Asia, Trevira and Wellman International—sustainability and supporting customers to achieve circular objectives is integral to all efforts and fundamental to the ethos of the hygiene business segment.

At the INDEX show, the Hygiene Fibers Group will launch CiCLO, a textile technology which allows polyester and other synthetic materials to biodegrade like natural materials do in wastewater treatment plant sludge, sea water and landfill conditions, reducing synthetic microfiber pollution generated during washing, and minimizing plastic accumulation in landfills caused by discarded textiles.

As a global leader in PET recycling, IVL is fully committed to the delivery of a circular economy and also recognizes that alternative sustainable technologies, such as CiCLO textile technology, provide valuable alternative solutions when recycling may not be possible. In line with the company’s commitment to support customers with high performance products, while also reducing the impact on the environment, several of the Hygiene Fibers brands, including Wellman International, Trevira GMBH and Auriga, have been working closely over the last 12 months with the IAM team and the CiCLO technology. Developments have focused on PET and rPET staple fiber and filament sustainable solutions for applications where recycling is particularly challenging, such as hygiene, home textiles and automotive applications.

Strengthening the profile of biodegradable offerings within the Hygiene Fibers Group’s sustainability portfolio, Trevira introduced a new range of bicomponent fibers based on PLA and PBS (polybutylene succinate) at the INDEX show. Both biopolymers offer an exceptional technological opportunity in terms of environmental care and sustainability, while delivering optimum performance. Equally to PLA, PBS is recyclable and up to 100% biodegradable under industrial conditions.

Efforts towards supporting customers to achieve circular objectives are a priority within the Hygiene Fibers Group. This is reflected in the recycled fibers expertise deployed across the segment. Four Hygiene Fibers Group brands, IVL Asia, Auriga, Trevira and Wellman International offer an extensive range of 100% recycled, accredited PET fibers, across a multitude of fiber and nonwovens applications. Through investments and evolving technological advancements,  Wellman International, as pioneers in recycling technologies for over 50 years, has broadened the range of PET that can be processed into other PET applications towards achieving a circular economy. The segment’s rPET product portfolio is represented under the  Deja brand platform, differentiated in the market by a performance-led suite of sustainable solutions that helps customers to achieve their sustainability targets, while also responding to end-consumers’ demand for transparency and environmental responsibility.

The development and evolution of sustainable technologies is central to activity across IVL’s Hygiene Fibers Group, with particular focus on sustainable polyolefin solutions. FiberVisions and ES-FIBERVISIONS, leading Polyolefin mono and bico fiber brands and sister company Avgol, have partnered with U.K.-based Polymateria to commercially harness the innovative ‘biotransformation’ technology pioneered by Polymateria. The patented technology alters the properties of polyolefins to make them biodegradable in a natural process. Other polyolefin sustainable innovations within the Hygiene Fibers Group featured at INDEX include biosurfactant and biocolourant developments being undertaken by the Avgol team with FiberVisons progressing sustainable design solutions, including lightweight, high performance, reduced carbon solutions. 

Nonwoven Wipe Made from Textile Waste
Infinited Fiber Company and Suominen, a manufacturer of nonwoven substrates for the wipes market, have created a nonwoven sheet made from 100% regenerated textile waste. 

The sheet is made with Infinited Fiber Company’s regenerated fiber Infinna, which is biodegradable, plastic-free fiber and made from discarded cotton-rich textiles, making it a resource-efficient alternative to the conventional materials used in single-use nonwovens, such as polyester and viscose. The nonwoven was developed through collaborative research and development efforts by Suominen and Infinited Fiber Company, whose shared values include sustainability and circularity. 

“Suominen aims to differentiate with innovation and sustainability. We see high potential in using recycled materials and are very excited to be able to support and participate in the development of Infinna for nonwoven applications,” says Suominen’s president and CEO Petri Helsky.

Infinited Fiber Company co-founder and CEO Petri Alava says: “Introducing materials that are made from resources that already exist—like discarded textiles—is a way of bringing circularity to the single-use nonwovens market. The material we have created with Suominen demonstrates a more sustainable future for nonwovens, and we look forward to continuing our close collaboration and co-development work in the years ahead.”

The nonwoven sheet co-created by the two Finnish companies speaks to the goals of biodegradability and plastic-free. These are now key focus points for the nonwovens industry, driven by the European Commission’s single-use plastics directive and increasing pressure from retailers and consumers looking for more sustainable, circular options in single-use items.

Jabil Introduces Sustainable Wipes Packaging
Jabil Packaging Solutions (JPS), a division of manufacturing solutions provider Jabil Inc., announced its reinvention of the wipes container. FusePack wipes packaging combine the most powerful features of multiple different packaging substrates, leveraging the best elements of rigid and flexible components. This lightweight but strong package is more sustainable and e-commerce-friendly than the legacy alternatives.

“Cleaning and sanitizing wipes have been steadily rising in popularity and since 2020, they’ve truly become a household staple,” says vice president of Technology Ayana Johnson, Jabil Packaging Solutions. “While wipes have become an essential part of our lives, traditional wipes canisters are incredibly bulky, using an excessive amount of plastic while tending to lose moisture, causing decreased shelf life. As home delivery has taken off, we’ve seen traditional canisters struggle with the bumps, shocks and vibrations of shipping directly to consumers. These factors drove us to reinvent the wipes container with FusePack packaging.”

The FusePack wipes container meets pressing market challenges head-on, including:

• Wasteful packaging—FusePack wipes container is 30% smaller than comparable rigid plastic alternatives but holds the same amount of wipes; its strength also reduces the need for excessive secondary packaging
• Shipping and shelf space inefficiencies—FusePack wipes containers nested structure, 68% weight reduction over comparable rigid packs and reduced package footprint means efficient transit and more units per shelf
• Cracking/opening in the harsh transit conditions of ecommerce—the flexible yet strong pack can withstand the shocks, vibrations and temperature changes of ecommerce fulfillment
• Wipes that dry out—FusePack is hermetically sealed, extending shelf life and eliminating leaking

Curt G. Joa Introduces ESC-8 Technology
Curt G. Joa, Inc., has introduced its patent-pending ESC-8 technology, the latest innovation in product size change flexibility. The ESC-8 technology increases product and insert combination capabilities, electronic size change capabilities, and speed. Offering annual savings on material costs and replacement size change hardware, the ESC-8 technology can be integrated into existing machines, regardless of the original manufacturer, with minimal downtime.

The ESC-8 technology enhances and simplifies  product performance features to improve product quality. The product insert is handed-off only once when placed onto the chassis web, eliminating unnecessary waste. Adhesive is applied all the way up to the end of the product insert, minimizing the risk of loose ends. Adhesive is also applied directly to the insert web, greatly reducing risk of exposed adhesive on the product insert.

This technology allows the user to configure nearly endless combinations of insert length and width and chassis pitch at high speeds with the push of a button. ESC-8 technology offers a wide range of chassis product pitches, electronic chassis pitch change, toolless insert pitch change and full machine speeds on all sizes.

In other news, the company has unveiled a modernized corporate logo, which retains the essence of the brand and its long history of quality while setting the stage for Joa’s transition into the future. The logo features a refreshed version of the shield from its legacy logo, symbolizing its continued commitment to protecting its customers’ reputations through world class, quality hygiene converting machinery.

Mobi-Air Begins Production of Drum Filter Technology
Mobi-Air based in Singapore, started production of its new low energy segmented drum filter technology in October. Rather than wait until Mobi-Air’s multi-vortex technology has been fully tested in multiple 24/7 production environments, the segmented drum technology provides a solution for end-users today which provides significant energy savings versus air filtration systems running with a higher face velocity. The segmented drum has a standardized interface with multi-vortex for future flexibility and plug and play options with down-stream active and passible modules.

Giovanni Requierme, sales engineer, comments: “Post-Covid the world has become far more environmentally friendly, and we are happy to introduce this new environmental technology as the world emerges from Covid.”

Martin Scaife, Mobi-Air CTO, comments: “We have a unique method to bring common drum filter processes together in a new format allowing far greater filter media to fit into a smaller space.

“The patent protected technology offers enhanced explosion protection as well as enabling a processing offering of up to 100KCMH. For customers wishing to save energy, we can dial down the face velocity to just 0.2 M/S which is far lower than incumbent drum filter systems which typically run at over 0.5 M/S. This lower face velocity saves massive amounts of energy as well as extending filter media life and improving air filtration performance. Energy prices vary around the world, in Europe a typical saving can reach as high as 50KEuro per year.

“Other features include, high power nozzle cleaning fan (1035 mmWG), Run4life drum seals, VPN process connect, and new ATEX safe inlet vacuum balancing technology.”

Yong Koh, manufacturing engineer, adds: “We are very proud of our new main system fan technology. Specifically designed for interfacing with a modular filter, the technology saves up to 15% of energy verses traditional main system fan technology. Additional built-in system redundancy features protect for drive failures meaning reduced spare-part inventory for the end-user.
“We have been hampered with Covid supply chain issues, however, we have re-built the effected parts of our supply chain. Post-Covid we are in a stronger position compared to pre-Covid.”

Mondon Presents CW Series at INDEX
French company Mondon has been designing and manufacturing converting machines for four decades. Thanks to its large experience in winding & unwinding machinery, Mondon offers equipment for hygiene, healthcare, automotive and construction sectors.

Mondon offers a full range of machines suitable for existing lines or new processing lines. Its portfolio includes turret unwinders, slitter rewinders, winders and spooling lines in several widths and with several options. Great attention has been paid in the capacity to manage very accurate tension control to low weight material at very high speed. Performance is reached thanks to its background in engineering expertise developed on large scale product machines and tests.

Mondon presented its CW-Series, a contact winder which offers maximum production quality through a fully automatic process for in-line rewinding. The CW-Series has become a major equipment for nonwovens production lines. “We wanted to bring a complete solution for customers, reduced to the maximum and developed with a special focus on productivity. It also offers the latest control systems, utmost efficiency and a smooth design for easy operations and maintenance of the equipment,” says Georges Forand, Mondon sales director.

Mondon machines meet quality, efficiency and reliability. They can be applied on existing lines by adapting the design to the product. They are available in different widths from 1000 mm to 4000 mm, with optional devices such as a lifting table to load or unload the rolls. Interface parameter adjustment and mechanical design offer to the end user reliable equipment easy to use and easy to maintain.

MS Ultrasonic Highlights Newly Developed Systems
The MS Ultrasonic Technology Group acts as a technology and innovation leader in ultrasonic technology, develops and builds flexible special machines, pioneering series machines, modular systems and efficient components for high-performance complete solutions. MS Ultrasonic thus covers the demanding needs of customers in the automotive, packaging/food, textile, medical technology, consumer goods and electrical components industries.

This enables them to optimally weld, punch, seal, cut and rivet thermoplastics, textiles and nonwovens, as well as cut food and other materials.

The MS Ultrasonic Technology Group is part of the listed MS Industrie AG with internationally active companies.

In addition to the company’s well-known activities, MS is now placing a new focus on the continuous welding of nonwovens and other materials.

The company is incorporating its many years of experience in mechanical engineering with drive and control technology, in combination with ultrasonic technology, into the new business area. This means that customers receive ready-to-integrate systems with maximum precision from a single source.

The new MS Competence Center in Ettlingen, Germany, provides continuous welding with an innovative location and maintains a high level of vertical integration through the headquarters in Spaichingen, Germany.

The newly developed systems (MS sonxSYS Combine) for the nonwovens segment have already been tested in the high-speed range up to 850 m/min and were presented to the trade public at INDEX.

The analysis and evaluation of various welding tasks is just as much a part of this as the in-house production of engraving rollers through to complete systems.

Omyafiber Improves Nonwovens Processability
Omyafiber, from Omya, is a tailor-made solution designed specifically to add value to polypropylene and polylactic acid fibers and nonwovens production. Its advantages include quality, processing, sustainability and economic values.

Omyafiber allows manufacturers to substantially reduce raw material costs, according to the company. It can also improve the quality of nonwoven fabrics in terms of improved aesthetics and product features such as soft cotton touch and mechanical properties.

Omyafiber has been recognized for complying to food contact regulation and is non-skin sensitized. It helps reduce the carbon footprint of the nonwoven fabric and is classified as a renewable raw material source by CCA Europe. When used with PLA nonwovens, the solution has been certified OK Compost Industrial by TUV Austria and proven to be compliant with the EU packaging directive.

Optima, Amotek Presented Packaging Solutions
Optima’s slogan at the INDEX trade show was “Packaging at its finest.” Optimal packaging design is essential in the area of paper hygiene. Together with the Italian subsidiary Amotek, Optima presented expert solutions for optimal packaging design, such as an innovative welding station.

“We are delighted that we can communicate directly with customers and prospective customers again,” says Oliver Rebstock, managing director of the Optima nonwovens GmbH. “Personal interaction is essential in special machine construction. Today’s consumers have high demands on packaging. They are expected to be unique, of high quality, individual and sustainable. At INDEX, we showed how we support producers with these trends.”

Safe and aesthetic closing of packaging can be achieved by means of an innovative welding station developed by Optima Nonwovens, for example. This has a positive effect on the quality of the packaging. Packaging can be closed safely and welded aesthetically. As the packaging systems by Optima Nonwovens are able to “learn by machine,” changes to the packaging can be detected automatically and the machine users can respond immediately. An automatic precise adjustment to each packaging format ensures that the first package after each format change is perfect. This avoids start-up and readjustment.

Differentiation in the marketplace is achieved both with improved packaging and with new packaging concepts. Optima Nonwovens is open to working collaboratively to develop new packaging solutions. Here, the options include alternative materials such as paper or starch films, new types of packaging such as cardboard packaging, or packaging with a new added value such as the opportunity to customize. However, there is also potential for completely new concepts, which Optima discussed with visitors.

Amotek, based in Bologna, Italy, leads the way in developing packaging machines for paper hygiene products and consumer goods. The company’s IS81 Performante packaging system is a new machine solution for diapers and feminine care products. Like all of Optima’s machine solutions, this allows packaging material to be changed flexibly—for example from PE to paper and vice versa. The machine also features a high output through the dual-web design and a quick and easy format changeover.

RadiciGroup Introduces New Nonwovens
RadiciGroup’s nonwoven innovations were on display at the INDEX trade fair in Geneva, Switzerland. Active in the spunbond production business for more than 30 years with the dylar product line, the group introduced Respunsible, a reduced environmental impact spunbond made from recycled polypropylene, and radimelt, the brand name for the group’s line of meltblown nonwovens and composite materials (e.g., SMS).

“Compared to the last edition of the fair,” says Enrico Buriani, CEO of the RadiciGroup Nonwovens Business Line, “we are introducing new products that, on the one hand, satisfy the ever-increasing demand for sustainability coming from our target markets, and, on the other hand, meet the need for local European industries to manufacture meltblown nonwoven, a material with extremely high filtering properties, until recently mostly imported from Asia.”

Buriani continues: “Additionally, during the pandemic, we set out to use our dylar as the main component of protective gowns for medical use. Starting from scratch and in record time, we set up a local supply chain for the production of personal protective equipment that is still going strong today and has led to the creation of a new business. In short, today we are at INDEX with a much more varied offering, which, I am proud to say, once again demonstrates the resilience of our group.”

Respunsible is a spunbond made from recycled polypropylene, a material appreciated for its excellent chemical properties and its versatility. Its high technical performance makes it suitable for any application, even the most demanding ones in terms of resistance and duration. Through recycling and recovery, production scraps are converted into polymers and then into spunbond, eliminating the need for additional virgin raw materials.

The company has received certification through International Sustainability and Carbon Certification PLUS (ISCC PLUS) and can thus produce spunbond from ISCC-certified materials.

Radimelt is the brand name identifying the group’s meltblown nonwovens, materials used for the manufacture of protective face masks and other personal protective equipment (PPE). This nonwoven fabric has excellent filtration performance even for microscopic particles, such as viruses, and ensures breathability and protection. In 2020, the group made a sizeable investment in a new technologically advanced meltblown production line. The machinery is very versatile and can produce products endowed with special technical characteristics, not only from polypropylene but also other polymers, such as polyester, polyamide and TPU polymers, products that find application in the medical and filtration sectors.

Ramina Presents Composite Meltblown Lines
Ramina is a leading Italian manufacturer of nonwoven turn-key plants and machines. At INDEX, Ramina presented its new Leonardo 1.0 of spunbond, meltblown and composite lines, striving to develop the most advanced and innovative technology to get the finest denier product, optimizing energy consumption, reduced manpower for line conduction and the minimum maintenance operations with a very cost-effective line. The concept is presented by means of the SMS pilot line installed in the factory, where it’s possible to process PP, PET and PLA polymer, with a max. speed of 1000 m/min, and a capacity of max. 200 kg/h/m for spunbond and 50 kg/h/m for meltblown. 

Ramina’s complete lines find application in different areas: from hygiene products to the medical and filtration sector, from the building sector to agriculture, from geotextiles to automotive and many more. The production ranges from the raw material preparation to the end-of-line, including: spinning units, web-forming units, thermobonding calenders, kiss-roll applicators, padders, drum dryers, winders, slitter re-winders and packaging systems. 

Reifenhäuser Reicofil Showcased Solutions for Sustainable Nonwovens
Under the slogan “Living Nonwovens,” the nonwoven line specialist Reifenhäuser Reicofil showcased solutions for the production of sustainable nonwovens for a wide range of applications.

“Nonwovens often accompany us from the first to the last day of our lives. In diapers, face masks or air filters, the material contributes to our well-being, safety and comfort. Nonwovens are close to our skin so they deserve only the highest quality. This is what we stand for, this is what we live for,” explains Markus Müller, sales director at Reifenhäuser Reicofil. “We also assist our customers to sustainably produce nonwovens from biobased raw materials or recycled material to leverage the global shift in sustainability as an opportunity.”

In fact, sustainable nonwoven production starts with the amount of material used—the less raw material needed, the better. The “Reicofil 5x” line series is specialized in this application and achieves fabric weights of 8 gsm (grams per square meter) or even less through efficient downgauging, even on 1000 m/min composite lines containing three spunbond beams.

In addition, Reicofil customers can reduce the use of fossil raw materials on request by processing biobased raw materials as an ecological alternative – for example for diapers. The topsheet material, made of bulky, soft, and industrially compostable high-loft nonwovens, meets maximum hygiene requirements at the same time.

For industrial applications, high-strength nonwovens can be processed even from up to 90% PET flakes from post-consumer waste. This is how Reicofil shows perfect ways to combine sustainability and high-performance nonwovens.

In the medical sector, the line manufacturer will also be exhibiting its leading solutions for high-barrier medical protective clothing. In addition, meltblown nonwovens for face masks—still in great demand in many regions due to Covid—provide reliable safety and are helping to combat the pandemic worldwide. Reicofil technology therefore guarantees maximum safety, with filtration efficiencies of up to 99% (N99 / FFP3 standard), minimum quality fluctuations, and extremely high line availability at the same time.

With the current RF5 machine generation, Reicofil also sets benchmarks in terms of quality, performance, availability, efficiency, and machine intelligence – for challenging applications in hygiene, medical and industrial sectors.

Reifenhäuser Enka Tecnica Exhibits Replacement Components
Reifenhäuser Enka Tecnica exhibited its wide range of replacement components for spunbond, meltblown, and composite lines at INDEX. The highly specialized custom manufacturer offers high-end technology “Made in Germany” that is 100% compatible with all globally installed lines.

Producers of nonwovens worldwide rely on Enka Tecnica components to manufacture products for complex applications in hygiene, medical or filtration to provide them with access to new profitable markets. Trade-show visitors gained a detailed insight into the entire range of products, from meltblown and spunbond spinnerets to meltblown cassettes and complete meltblown spinning beams designed with an energy concept optimized for sustainability. The outstanding quality of die tips and capillaries assures consistent product quality and precision, allowing producers to meet their tolerance specifications reliably and avoid scrap at the same time.

“We manufacture all components precisely to customer specifications to guarantee their seamless integration into existing line technologies,” explains Wilfried Schiffer, managing director of Reifenhäuser Enka Tecnica. “Our components help producers to increase both product quality and profit on their lines. It doesn’t always have to be a new component either—a refresh can often be the more economically feasible and sustainable choice.”

With its refresh service for refurbishing used components, Enka Tecnica not only offers a cost-efficient alternative to new parts, but also extremely fast delivery times, a factor that is often decisive to maintain daily production targets. Visitors were able to see the quality of refresh components displayed at the booth—a meltblown and a spunbond spinneret, half of which has been refurbished. They were able to see the condition of the capillary holes before and after the refresh through a microscope.

Another trade show highlight included jet strips for hydroentangling nonwovens. Depending on the application, they are offered in Smart, Advanced, and Premium versions and have a special unique selling point—the strips are fully hardened, whereas competitor products usually only have a hardened surface. This quality advantage results in significantly longer service lives, which is why they are also known on the market as “The World’s Hardest Strips.”

Shemesh Automation Launches Asterra
Following five years of extensive research and development, Shemesh Automation, a global maker of high-end packaging machinery, launches Asterra—a robust, versatile high-end industry 4.0-ready pioneering positive displacement Rotary Piston Filling Machine. It offers a filling tolerance of +/- 2ml and speeds of up to 300 containers per minute (higher throughputs available depending on the number of filling stations). 

The Asterra includes 16 filling stations specifically designed to fill a wide range of low and high viscous liquid with particulates (viscosities from 500 to 400.000 CPS). It is suitable for a wide range of products across varied market sectors including food & beverage, nonwovens, cosmetics, chemicals and household products.

The robust Asterra features a proprietary mechanical cam with built-in bottom-up Shemesh nozzles and portioning technology. And a programmable portioning speed graph for anti-foaming and drip prevention.

This technology has been developed using three decades of expertise in manufacturing high-quality and reliable filling and packaging machines.

Mechanical-cam based, Asterra’s technology also results in higher accuracy as the filling process itself does not depend on auxiliary air pressure, which may be unstable or sometimes liquid contaminated. Additionally, with this filling method, the portioning process is faster and more consistent – yet results in less waste and spillage. Thanks to its proprietary nozzles and mechanical cam technology, unlike other more common pneumatic based rotary piston fillers, Asterra can also easily fill highly viscous liquids, including particles such as sauces with fruit pieces inside, peanut butter, pastes, etc.

Sicam Offers Innovations in Spunlace, Wetlaid and End of Line Machines
INDEX20 has revealed itself as the perfect window for Sicam to showcase its latest innovations in the sectors of spunlace, pulp wetlaid and end of line machines.

2020 has affirmed Sicam as an Italian manufacturer of excellence in these fields thanks to many projects delivered and many in commissioning. INDEX is the place where Sicam decided to show all these achievements, not forgetting also to underline all of its other productions which made Sicam’s name famous over the years.

Technoplants Offers Hybrid Airlay Card Technology
Thanks to its 40 years of experience and continuous technological innovation, is able to meet all customer requests for any kind of nonwoven application.

The inventor of the modular MULTIline system, that combines few machines, is able to work in combination or stand alone with any kind of fibers, in very wide range from 80 up to 15,000 gsm.

The latest patent is about a new hybrid Airlay card, for light webs; it includes all the capabilities of Airlay technologies with in addition a doffer cylinder. The best solution for those who don’t won’t to choose between the traditional combination of Roller card and Crosslapper or the Airlay technology.

The main advantages are the wide range of thicknesses from 10 to 1500 gsm, no defects on the products, a machine with small footprint and practical use, capable to combing, separating and making parallel all types of natural, synthetic and regenerated fibers.

Complete with airlaying suction and with doffing system like traditional roller cards it is possible to produce:

• Carded webs with doffer
• Airlaid webs with top and bottom suction
• Partly carded and partly airlaid web creating an innovative product which currently does not exist on the market.

The light webs can than feed a Vertical lapper for the production of Fiberwave product.

It is suitable for many applications especially for the hygiene, filtration, ADL and medical sector.

The machine will be available in its 2.8m wide pilot line in Italy for tests with customers’ fibers by the end of the year; also to show its potential in combination with the Multiline FPC System that allows it to produce from 10 up to 15,000 gsm.

Wacker Unveils New Branding
Wacker, the Munich-based chemical group, presented a wide range of polymeric binders for nonwovens and textiles at INDEX. The company’s focus is on sustainable solutions based on the biomass balance approach. Wacker also unveiled a new name for the portfolio in question: products that until now have been marketed under the Vinneco brand name will be called Vinnapas eco going forward. From this point onward, the suffix “eco” will apply to all Wacker products that conserve fossil raw materials and instead use raw materials certified as sustainable according to the biomass balance approach.

Aqueous dispersions are indispensable starting materials for manufacturing nonwoven fabrics and technical textiles. When added to table napkins, wet wipes and feminine hygiene products, for example, dispersions improve the properties of these nonwovens, such as softness, mechanical stability and absorbency. Here Wacker offers a comprehensive portfolio of technologically mature dispersions suitable for a wide array of applications in both its classic Vinnol and Vinnapas product lines, as well as its exceptionally sustainable Vinneco products.

Wacker uses bio-based acetic acid to manufacture its Vinnapas eco polymeric binders. This substance is formed as a byproduct of wood-industry processes such as preparing fibrous material for paper manufacturing. The bio-based acetic acid used at Wacker has been certified by the PEFC (Programme for the Endorsement of Forest Certification) and stems from sustainably managed forests located within a radius of 400 km of Wacker’s Burghausen site. Wacker uses bio-based acetic acid and ethylene to produce vinyl acetate monomer, which—again using ethylene—is copolymerized to form vinyl acetate-ethylene (VAE). In production, bio-based acetic acid can be blended with conventional acetic acid, and is thus directly coupled into Wacker’s existing production line. The compound always exhibits the same chemical and physical behavior, regardless of whether it was derived from fossil-based or renewable raw materials, ensuring uniformly high quality.

W+D Promotes Paper Packaging Concept
W+D Hygiene Solutions introduced Green Manta, a paper envelope for disposable products, at INDEX20. The paper envelope features pre-creasing and cutting of paper, folding and closing envelope flaps and the marriage of a product with a paper sheet. According to the company, the use of this material can save up to 25 million square meters of plastic waste per year by replacing plastic single-wrap packaging in feminine hygiene products. It can be adopted by brands with an easy machine upgrade.