Modular machine design for nonwoven carding installations

1
Modular machine design for nonwoven carding
installations

• Dr. Stefan Schlichter, Oerlikon Neumag Austria
  GmbH
• Chetan Bhagat, Oerlikon Textile India Pvt. Ltd.
• Conference Technical Textiles at IIT, Delhi
• 11th to 13th Nov. 2008

2

• Introduction
• Company presentation
• Role of the card in nonwoven process
• Requirement profile of card
• Function based modular card concept
• Summary

3

• Introduction
• Company presentation
• Role of the card in nonwoven process
• Requirement profile card
• Function based modular card concept
• Summary

4
Company Overview 170 locations around the world
Global presence of Oerlikon

• 35 countries
• 19,250 employees
• 1,500 scientists

Oerlikon locations
5
Oerlikon at one glance Six core competences
6
Product Chain
Staple Fiber BCF Nonwoven
7
Neumag Along the Nonwoven Value Chain
8
Oerlikon Neumag Locations
Oerlikon NeumagNeumünster Germany
Neumag ItalyBiella Italy
Neumag Austria Linz Austria
AutefaFriedberg Germany
Carding Division
9
Carding Division

Sales / Service Engineering R
D Fulfilment
Preparation Carding Airlay
Oerlikon Neumag Italy
Crosslapper
Autefa automation
Needle Looms
Oerlikon Neumag Austria
10
Oerlikon Neumag Italy S.p.A.
Location Biella / Italy
11
Oerlikon Neumag Italy Technologies

• F.O.R. Nonwoven Preparation and Carding machines
• Aerodynamic web forming machinery
• (Fehrer technology)
• OCTIR Woollen Cards

12
Oerlikon Neumag Italy S.p.A.
Roller manufacturing
13
Oerlikon Neumag Italy S.p.A.
Roller manufacturing
14
Oerlikon Neumag Italy S.p.A.
3-Level Dynamic Balancing
15
Oerlikon Neumag Italy S.p.A.
Cylinder manufacturing
16
Oerlikon Neumag Italy S.p.A.
Cylinder manufacturing
17
Oerlikon Neumag Italy S.p.A.
Cylinder manufacturing
18
Oerlikon Neumag Italy S.p.A.
Card assembly
19
Oerlikon Neumag Italy S.p.A.
Card assembly
20
Autefa Automation GmbH
Location Friedberg / Germany
21
Autefa automation GmbH

• AUTEFA Crosslapper Technology

22
Oerlikon Neumag Austria GmbH
Location Linz / Austria
23
Fehrer Technologies

• Needle punching machines
• Papermaker felt needle
• punching machines

24
Carding Competence Center Linz Line 1 card
crosslapper webdrafter - needlelooms
25

• Introduction
• Company presentation
• Role of the card in nonwoven process
• Requirement profile card
• Function based modular card concept
• Summary

26
Role of the card for the process nonwoven carding

• Key technology for carding segment
• (no line without card)
• main technology for product quality
• (no machine shows more improvement of product
  properties between input and output)
• machine configuration extremely driven by
  technology
• (process know-how decisive for configuration)
• superior carding technology represents
  the most important success guarantee when
  producing high-tech products

27
Base functions of nonwoven cards

• fibre opening and alignment
• fibre orientation
• eveness in MD and CD
• web thickness and width
• web structure

28

• Introduction
• Company presentation
• Role of the card in nonwoven process
• Requirement profile of card
• Function based modular card concept
• Summary

29
Focus of requirements for a modern nonwoven card

• reproducibility
• flexibility
• scaling of settings
• ease of setting and maintenance
• variable web structure

30

• Introduction
• Company presentation
• Role of the card in nonwoven process
• Requirement profile of card
• Function based modular card concept
• Summary

31
Card configuration - status quo -
application experience design
?
?
?
?
?
32
Modular card - overview -
web take-off
infeed control
Tuft feeder
main cylinder
preopening
web link
feed zone
transfer
doffer
33
Modular card - module 1 -
1 tuft feeder

34
Modular card - module 2 -
2 infeed control
Belt weighing
Servolap
35
Modular card - module 3 -
3 feed zone
Bottom feed table
Top feed table
Roller feed
36
Modular card - module 4 -
4 preopening
37
Modular card - module 5 -
5 transfer
standard transfer
doffer transfer
38
Modular card - module 6 -
6 main cylinder
worker/stripper air transfer
worker/stripper roller transfer
INJECTION
39
Modular card - module 7 -
7 doffer
1 doffer
2 doffer
3 doffer
40
Modular card - module 8 -
8 web take-off
random
parallel
2 roller
1 roller
41
Modular card - module 9 -
9 web link
2 doffer
3 doffer
short
medium
long
42
Modulare card specification matrix -
43
Modular card function decides about
specification -
example fibre length strongly influences
44
Modular card function decides about
specification -
example fibre length strongly influences
45
Modular card - example of application -

• Medical Hygienic Application
• fine fibres
• medium fibre length
• ultrahigh output speed
• Spunlace

46
Modular card - example of application -
47
Modular card - example of application -
48
Modular card example of application -
49
Easy Opening
50
Easy Opening
51
Easy Opening
52
Easy Opening
53

• Introduction
• Company presentation
• Role of the card in nonwoven process
• Requirement profile of card
• Function based modular card concept
• Summary

54
Modular card - summary -

• card is the key machine regarding quality
• flexibility is decisive for successful
  products
• modular design allows specification
  based on function
• modular design enables retrofitable
  function elements
• applicable also for other machines

55
.. thank you for your attention!