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Pioneer Of For Micropunch Technology Improving Sustainability

Your latest innovation, the Micro Punch technology, has garnered significant interest in the industry. To help our audience better understand its impact, could you provide a detailed overview of the Micro Punch technology and its relevance to the production of lightweight nonwoven fabrics?

1. Introduction of Technology: What are the key features of the MicroPunch technology, and how does it differentiate itself from existing technologies in the market?

MicroPunch is the first economically efficient method of needling lightweight nonwovens of approx. 30 to 120 g/m². The MicroPunch pre-needler features a needle density of 20,000 needles/m/board on 4 needle boards in a working width of 2.5 m. This classical intense needling includes slotted stitching plates and alpa-flex needle boards with individual drillings to accommodate the needles. The two finish needle looms of the MicroPunch S series mark the step to an advanced stage of intense needling. Instead of slotted stitching plates so called wire plates are used applying tensioned wire in a parallel array to create long slots for the needles on the board in a needle density of 45,000 needles/m/ board. This massive increase of needle density was only possible through an arrangement of needle modules positioned side by side accommodated within C-shaped cassettes/containers on the board. Thus, a total of 8 needle boards in the 2 finish needle looms are designed to create stitching arrays in the product’s, surface, similar to those of the water-entangling process.

2. Challenges in Intense Needling: Lightweight nonwoven fabrics present unique challenges during the needling process. Could you elaborate on the specific difficulties associated with intense needling in such fabrics and how Micro Punch technology addresses these challenges?

It was clear that the high production efficiency needed was only possible through the two-dimensional kinematics of the needle beam be it HyperPunch or CycloPunch. The necessary high advance per stroke of approx. 50 mm per stroke requires nevertheless very high stitching densities in order to gain enough abrasion resistance of the product, which calls for an extreme increase of the number of needles in the boards. Textile technological simulations showed that an increase from about 20,000 needles/m/board up to 45,000 needles/m/board would be necessary. At the same time, it was clear that the Dilo needle modules had to be loaded into a specialty needle board in order to fulfil a precise arrangement and a quick exchange when necessary. The complete needling zone had to be modified through “wire plates” which replaced drilled or slotted stitching plates. With all these changes we have managed to ensure smooth and efficient operation of the MicroPunch needle looms.

3. Advantages of Micro Punch Technology: What are the primary benefits of using Micro Punch technology in terms of fabric quality, performance, and overall production efficiency?

In our Technical Research Centers we carried out several product testings, which showed that the abrasion resistance, as well as the absorption capacity of intense needled products is very good. A soft touch is vital for the consumers feeling about the material and this is the most shared feedback to the needled material : its great softness.

4. Sustainability Aspect: How does the Micro Punch technology contribute to the sustainability of the fabrics produced? Are there any specific features or practices that enhance environmental benefits?

MicroPunch can be considered a valid alternative to hydroentangling for lightweight production in the range of approx.30 – 120 g/m² where needling production costs per kilogram of material are below hydroentangled products. Needling requires ca. 75 % less installed power compared to hydroentangling. MicroPunch does not consume water. Gas is not needed to dry the material. Needling does not create fibre waste since vacuumed good fibre of a minimum staple length can be recycled easily in the process.

5. Productivity: How does the Micro Punch technology impact the productivity of the production line compared to traditional methods? Are there measurable improvements in production speed or output?

The line design normally includes lap drafting which is improving the throughput and to some extent fibre orientation. CycloPunch

kinematics realize advances of approx.

50 up to 65 mm per stroke resulting in approx

. 50 to 65 m/min throughput speed in the needling

 line at 1000 strokes/min. Without regard to the

draft during needling and in end-of-line components,

including configurations of drafting units, nominal throughput speed range of approx. 125 up to approx.160 m/min at 2500 strokes/min can be expected.

Normally end of line speeds of hydroentangling lines when using 100 % viscose fibre are limited to approx. 210 to 230 m/min at the winder. This basic relation explains the limitation of economics of hydroentangling lines with their respective production capacity and makes obvious that the production capacity of “MicroPunch” needling at around 160 m/min has come very close to the production speeds of approx. 220 m/min of hydroentanglement lines when running viscose only. Therefore, the total costs per kg of nonwoven material from a needling line is considerably lower compared to a hydro-line because of the advantage of the dramatic savings in electricity and the complete elimination of water and gas consumption.

6. Capital Cost Comparison: Can you provide insights into the capital investment required for implementing Micro Punch technology? How does this compare to other available technologies in terms of initial cost?

When taking a holistic view, we must not only consider the investment costs of a new line, but also the running costs per kg of product. Since the configurations can be so different and a complete line from fiber opening to the consolidation is not always required. It would only be possible to specify the costs within a large range.

7. Running Cost of Plant: What can manufacturers expect regarding the ongoing running costs associated with Micro Punch technology? How do these costs compare to those of other technologies?

Simulations and calculations of production costs show that cost reductions mainly depend on product weight and are to be expected in a range of up to approx. 50 % when needling instead of hydroentangling is applied. These numbers, of course, have to be verified case by case while considering all fibre and production parameters through production tests possible on the Dilo R&D and demonstration line. Typically, for the production of wipes complete nonwoven lines are used in a working width of approximately 3.6 – 3.8 m. When water entangling is applied in such lines, the electric power is more than twice the power used for needling, needed for the high pressure pumps, for filtering the circulated water and for vacuuming the soaked fleece. Water and heating gas for drying is not used in the mechanical needling process. Also, the consumption of f ibre material is less in a needling line because its fibre waste is easy to recycle.

  05:35 PM, Oct 10

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