Dilo Group is a global leader in the manufacturing of machinery and complete production lines for the nonwovens industry. With a rich history dating back to 1902, the company has solidified its position as an innovator and market leader in this sector. Dilo Group’s machinery finds applications across a wide range of nonwoven products, including Technical Nonwovens, Industrial Nonwovens, Hygiene and Medical Textiles, Home and Clothing Nonwovens. Dilo Group is a driving force behind the nonwovens industry, enabling manufacturers to produce high-quality, innovative products efficiently and sustainably.

Production Process and Efficiency

How does Dilo optimize the needle-punching process for geotextile production?

Needle Punch Non-Woven production is a continuous process, which follows the necessary steps of Fibre Opening and Blending, Carding, Cross Lapping and Needle Punching. This process is best optimized when every stage is equipped with the most reliable set of machines. For example, a high-capacity production line should have all the machines with matching capacity of each other. Dilo is having a good experience in optimizing this continuous process with our state-of-the-art machines starting from Bale Opener to last Needle Loom in such a way that there is no bottleneck in the entire production sequence.

What are the key factors that contribute to efficient production rates?

The key factorthat contributes to the efficient production of Non Wovens or for example Geotextiles, is to ensure that the entire production line is fully available for the production all through. This is achieved by careful planning and focus on some of the important parameters such as Raw Material availability, PredictiveMaintenance of the Machines, Periodical Cleaning and Lubrication, Continuous Process Monitoring by skilful technicians and operators. Geotextiles production lines now a days are configured with a very high capacity which can be realized by keeping the above factors in mind.

Can you elaborate on a typical machinery and line concepts specifically designed for geotextile applications?

Though the configuration of a Needle Punch Non-Woven Geotextile line varies from one project to the other, most commonly used line concept may be as:

• Fibre opening and blending for at least 2 types of Fibres, with Bale Openers, Carding Willow, Intermediate Storage and Fine Openers.
• A high production Carding Machine has a working Carding width of 2.5 to 3.5 Mts
• A High precision Cross Lapping Machine with Batt Weight Control System having layering width as per the end product requirements.
• Lap Drafting and Felt Drafting systems.
• 2 to 3 Needle Punching Machines as per the width requirements.
• Heat Setting and Stretching Machines as per the end uses.
• Accumulator, Cutting, Winding, and Packaging Machines.

Innovation and Technology

What recent innovations has Dilo introduced in needle-punching technology for geotextiles?Dilo is known for the innovations and brining new technologies to the industry. Every new development is bringing immense benefits to the end user, be it achieving highest productivity, excellent evenness, minimum downtime and very low cost of maintenance, our efforts are always in the direction of keeping our customers way ahead in their field. Though there are many, but to name a few, our VQC carding system is one of the most efficient and highest production Carding machines available today. Similarly, a Vector DLSC Cross Lapper system is not only achieving the highest production but also ensuring the highest quality standards too. Both these machines are very much suitable for meeting the ever-growing expectations of our customers.

Are there any advancements in needle loom design that enhance product quality and performance?

Our in-depth understanding of the technology has resulted in developing various needle patterns to facilitate the most even stitch pattern distribution through our needle looms. Mostly, all the needling machines are now a days equipped with dust suction and filter systems to avoid accumulation of short fibres in the bed plate and needle boards, thus ensuring long life and uninterrupted working of the machines. Automatic lubrication system and many other features are included in our machines to give a comfort to our end users.

How does Dilo address variations in fibre types and fineness (e.g., PP, PET, PA, recycled fibers)?

Our process system is very much flexible and can adapt to different fibres like PP or PES or PA or

other fibres as required and the variations which are there in those fibres.Production parameters are stored in a recipe management system, which enables quick material changes.We encourage our customers to spell out their expectations and we always find a good solution for them; this enhances their confidence in Dilo and we make sure that they get the best performance on their products.

Quality Assurance

How does Dilo ensure consistent and high-quality nonwoven output during the production process?

Continuous monitoring of the process through multilocational process control PC Terminals is a very useful tool where in it allows the flexibility to visualize and operate the line at any terminal seamlessly. Any unlikely deviation from the set parameters is immediately detected and set right with in no time to ensure the continuous highest quality output from our lines.

What quality control measures are in place to maintain consistent geotextile quality?

For us, quality control starts with the opening and blending section, where in fibres are mixed in a correct ratio and proportion as required by the end products, foreign particle detection and removal, application of antistatic agents, metal detection, fire alarms and emergency bypasses are the key features of our lines which help in maintaining consistent quality of our Products.The automatic and contact-free measurement of area weight in cross and machine directions is now state of the art in quality control and also important for automatic process control.

Can you share insights on any specific processes or features that contribute to superior geotextile quality?

Apart from the factors mentioned above, we use our CV1 batt weight control system to ensure that the end product is having maximum evenness throughout the width including the edges and thus avoiding edge cutting and fibre hard waste to a large extent, a scanning gauge during the process gives real time analysis of web quality and consistency.  Condensing rollers at carding machine or drafting systems control MD/CD strength ratio.

Resource Efficiency

How does Dilo promote resource-efficient production in terms of energy consumption, raw materials, and waste reduction?

We are a very adaptive technology provider and always keeps ourselves with the rapid changes happening in the industry. We have not only developed energy efficient products but also adopted best practices of the industry, especially in the fibre preparation area. For example, speed-controlled fans, return of extracted fibres and reopening of edge cut,  superior process visualization and effective logical displays on the screens. These give a very good ease of working for technicians and operators. As already explained earlier that all our lines are equipped with CV1 batt to reduce the wastage of expensive raw material and better end-product quality realization.In addition, we keep the production of waste during startup and product changeoveras low as possible by using optimized process flows.

Are there specific features in your machines that contribute to resource savings during geotextile manufacturing?

All our machines are equipped with remote diagnostic features, which enables our experts to guide and support the customers so that they can implement the required optimization on the process and parameters, upgradations and thus facilitate our customers to continue enjoying state of the art technologically superior products.

Why efficient use of Raw Material is very important in the Non-Woven Industry, particularly in segments like Geotextiles?

In Non-Woven Industry, raw material cost is a major factor in the end product cost and thus both quantity and quality of the production is very much important for the success of any project. in the specific segments like Geotextiles this becomes more critical as the staple PP Fibre is not only expensive but a good quality fibre availability is also an important subject.