The plant consists of two production units: Production Line B and
Pre-Mix Unit 5 (MA5).
PRODUCTION LINE B
Production Line B is a complete nonwoven needlepunch line consisting
of the following components listed in process order.
1. Suction / Filter Station (Filterstation)
Function: Fiber dust extraction and air filtration for the production
line.
2. Feed Shaft
Manufacturer: Spinnbau Bremen
Machine length: 3,970 mm
Machine width: 2,600 mm
Machine height: 6,233 mm
3. Belt Scale with Vibrating Shaft - Protec
Vibrating Shaft:
Length: 880 mm
Width: 2,800 mm
Height: 1,500 mm
Weight approx.: 870 kg
Belt Scale:
Length: 550 mm
Width: 3,000 mm
Height: 700 mm
Weight approx.: 550 kg
Power supply: 3NAC 400V 50Hz 20A
Description: The vibrating shaft produces a uniform fiber feed. The
belt scale measures the weight of the fiber material being transported
and regulates the feed speed of the downstream card accordingly.
4. Card
Manufacturer: Hergeth Hollingsworth
Year of manufacture: 1990
Control system renewed by Protec in 2016
Machine length: 4,210 mm
Machine width: 3,800 mm
Machine height: 2,500 mm
Machine weight approx.: 6,000 kg
Working width: 2,500 mm
Configuration:
Feed unit with electromagnetic safety clutch and 2 pairs of feed
rollers, diameter 94 mm
Pre-opening unit with lowerable trough, 1 pre-roller diameter 413 mm,
1 pre-roller diameter 550 mm, 2 pairs worker/stripper rollers diameter
219/123 mm, 1 transfer roller diameter 550 mm
Main cylinder unit with 5 pairs worker/stripper rollers diameter
219/123 mm, 1 main cylinder diameter 1,500 mm
Doffer unit with 1 doffer diameter 850 mm and 1 set of crush rollers
diameter 260 mm, web take-off via roller draw-off
Base frame height 700 mm
Fiber fly and dust extraction
Press roller diameter 2,500 mm
5. Cross-Lapper
Manufacturer: Autefa
Model: Topliner CL 4000/4002 and WebMax
Year of manufacture: 2006
CE conformity declaration available
Machine length: 3,815 mm
Machine width: 8,740 mm
Machine height: 2,165 mm
Topliner CL 4002 specifications:
Card working width: 2,500 mm
Maximum lapping width: 3,500 mm
Maximum web laying speed: 130 m/min
Take-off belt speed: 0 to 25 m/min
Lapper elevation: 100 mm
WebMax specifications:
Card working width: 2,500 mm
Description: The cross-lapper is designed for processing textile
fibers including synthetic, natural, and regenerated fiber webs, as
well as blends. Fiber fineness range greater than 0.7 dtex. Web
weights achievable up to 5,000 g/m2 by multiple layering of the card
web.
6. Web Drafting Unit (Streckwerk)
Machine length: 1,570 mm
Machine width: 3,640 mm
Machine height: 1,650 mm
Working width: 2,500 mm
Description: The web drafting unit re-orients cross-laid fibers
partially into the machine direction, balancing longitudinal and
transverse strength. It consists of three separately driven roller
trios with saw-tooth wire clothing. As a special design, the unit is
adapted to the rising web feed angle between the lapper exit and the
needleloom entry.
7. Double Needleloom
Manufacturer: Dilo
Type (upper beam): CBF 3, Number/Year: 9512/2006
Type (lower beam): DI-LOOM OUG-II HVSL 31, Number/Year: 9513/2006
Machine length: 3,340 mm
Machine width: 5,120 mm
Machine height: 4,475 mm
Machine weight: 38 t
Maximum working width: 3,100 mm
Maximum stroke frequency: 1,375 min-1
Needle beam stroke: 60 mm
Horizontal beam stroke: 0 to 6 mm
Number of needles: approx. 15,428 per 1 m working width
Main drive: 75 kW
Control panel: Siemens Simatic MP270
Description: Special high-performance needleloom with elliptical
needle beam kinematics. Installed on vibration isolators without
foundation. Needling from both top and bottom via 2 needle boards
each, alternating or simultaneous. Needle beams move vertically and
horizontally. Pneumatic clutch for rapid switching between alternating
and simultaneous needling, and for decoupling the lower needling unit.
Needle beams are aluminum special profiles with high bending and
torsional stiffness, with quick-clamping system for rapid needle board
changes.
8. Machine Outfeed: Goods Storage, Slitter, and Winder
Goods Storage Unit - Suchy WOB 3200:
Manufacturer: Suchy
Storage capacity: 40 m
CE conformity declaration available
Machine width: 4,300 mm
Machine length: 5,010 mm
Machine height: 5,270 mm
Minimum working width: 1,000 mm
Maximum working width: 3,000 mm
Roller top width: 3,200 mm
Fabric weight range: 50 to 2,000 g/m2
Working speed: 3 to 40 m/min
Production speed: 20 m/min
Compressed air connection: 6 bar, oil and water-free
Installed electrical power: approx. 5 kW
Voltage: 3x 400V, 50Hz, 3-phase
Control voltage: 230V, 50Hz / 24V DC
Longitudinal Slitting and Length Measuring Unit :
Manufacturer: Suchy
Machine number: 273/05
Year of manufacture: 01/2006
Weight: 250 kg
CE conformity declaration available
Up to 8 circular slitting knives can be operated via a central control
panel
Individual web width settings are adjusted manually
Incremental Winder :
CE conformity declaration available
Winding roller diameter: 350 mm
Minimum winding diameter: 3-inch cardboard core
Maximum winding diameter: 1,500 mm
Installed power: 5 kW
Edge Waste Recycler:
Electrical supply by Hepp-Schwamborn, Moenchengladbach
Nominal voltage: 400V, 3/PEN
Frequency: 50 Hz
Short-circuit breaking capacity: 10 kA
Full-load U6358834 current: 25 A
Maximum fuse: 32 A
Control voltage: 24V DC
Description: Picks up edge trim from the slitting process, shreds it,
and returns the shredded fibers via a blower to the feed shaft for
recycling into the production process.
9. X-Ray Measurement Device
Manufacturer: Protagon
System type: Quality Control System, X-Ray 5kV, CLP-c
Installed power: 1.5 kVA
Operating voltage: 230V AC, 1-phase, 50Hz
Auxiliary voltage: 24V DC
Description: The FLG/thickness measurement system is used for quality
control and evaluation of uniform basis weight and thickness of the
produced material web. The sensor is mounted in a scanning frame that
traverses across the web. Measurements are taken online and without
contact. Cross-machine profiles and machine-direction trends are
displayed. The system controls the Autefa cross-lapper via closed-loop
feedback based on the measured basis weight.
Additional: Machine Display Console (Maschinenanzeigetableau)
Central display console with individual operator panels for: Protagon
measurement system, Needleloom, Cross-Lapper (Leger), and Card
(Krempel).
PRE-MIX UNIT 5
The pre-mix unit is a fiber bale opening and pre-blending system. It
consists of three components listed below.
1. Feed Table
Roller conveyor table for feeding fiber bales to the bale opener
Overall combined feed table length: 2x 3,100 mm (6,200 mm total)
Feed table width: 1,600 mm
Table height at bale opener entry: approx. 1,250 mm
2. Bale Opener
Overall machine width (opener section): approx. 1,800 mm (inner
opening width approx. 1,585 mm)
Machine height: approx. 3,075 mm
Machine depth (opener body): approx. 2,450 mm
Overall installation footprint with feed table: approx. 3,750 x 3,950
mm
Description: Pre-opening machine for opening pressed fiber bales and
uniformly feeding downstream machines. Suitable for natural and
synthetic fiber bales.
3. Card Wolf
Manufacturer: Societe Anonyme des Ateliers Houget Duesberg Bosson
Model: 4260
Year of manufacture: 1972
Maximum working width: 1,500 mm
Configuration:
1 feed table
2 feed rollers
1 main cylinder with 3 worker/stripper pairs
1 output worker
Control cabinet dimensions (W/D/H): 1,600 mm x 600 mm x 2,200 mm
Operating hours recorded on counter: approx. 16,413 hours
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