ENVIRONMENT – CLEANER.PRODUCTIONS

Warp knitted alternatives to save water for an environmentally friendly textile production

CLEANER.PRODUCTIONS are intelligent, end-use applicable concepts as an environmentally friendly alternative to traditional production methods.

Environmental protection is an important topic for KARL MAYER, and sustainable production is becoming increasingly important in textile production and therefore also at our customers as well as all textile producers. That is why our support is made up of efficient machines that score highly in terms of environmental protection through the latest technological innovations.

Our latest environmental contribution CLEANER.PRODUCTIONS stands for zero water pollution compared to other production methods especially water jet looms. This protects sustainable resources while contributing to a cleaner environment. 

Warp knitted fabrics – ecological advantages for production

Warp knitted fabrics score points, not only with regard to their variety, but also in relation to their ecological benefits.

NO WATER POLLUTION

No water pollution during the production process on TM 3 machines, this also means that no of the sizing agent PVA* is drained. (*Polyvinyl alcohol)

HIGHER PRODUCTIVITY

This warp knitting machines operate at an impressive level of efficiency – with a speed of 2.000 rpm, the TM 3 has a daily production rate of about 3206 sqm/d – one waterjet weaving machines produces only 12 % of a TM 3

LOWER ENERGY CONSUMPTION

The total energy consumption to produce the same amount of fabric is 2,7 times less than with waterjet weaving.

LESS FACTORY SPACE NEEDED

By using Warp Knitting instead of Waterjet Weaving less than one third of  factory space is needed. This means a 3 times higher GDP value per square meter of factor space (for the same output as with waterjet weaving). It means also less amount of sealed industrial land surface, and less investment cost for purchasing the land!

TRICOT MACHINES – your environmental  friendly alternative compared to water jet loom machines 

TERRY.ECO

Sustainable Production of Terry fabrics. See below how you can save up to 30% of cost with the production of warp knitted terry instead of woven and at the same time contribute in preserving the planet for our children.

KARL MAYER offers a complete range of machines for the production of warp knitted terry fabrics:

  • Warp knitted machines with online brushing
  • Warping machines for filament yarns
  • Warping machines for staple fiber yarns

Publication ITMA 2019 – BRUCKNER

COMUNICADO DE PRENSA
Leonberg, mayo 2019
Contacto: Verena Ruckh – Head of Advertising & Marketing Department
BRÜCKNER en ITMA 2019
70 años de éxito mediante innovación
Desde hace 70 años, BRÜCKNER es el socio mundial para todos aquellos que secan, recubren y acaban los materiales en forma de red: ya sea tejido para ropa, no-tejidos, moquetas, vidrio o revestimientos, la variedad de materiales a procesar nunca ha sido limitada.
Hoy en día, ya no es sólo una cuestión de máquinas, sino de automatización y control de los sistemas. El tema de la digitalización y la industria 4.0 abre posibilidades completamente nuevas para aumentar la productividad, reducir el uso de recursos y mejorar la calidad. Además, la creciente escasez de trabajadores cualificados puede resolverse mediante un software más inteligente.
BRÜCKNER ha invertido, desarrollado e implementado mucho en este campo en los últimos años:
• Los sistemas de asistencia inteligentes supervisan los ajustes de la máquina en segundo plano y proporcionan al operario información sobre cómo hacer funcionar el sistema de forma aún más productiva y con menor consumo de recursos. Los estudios han demostrado que la optimización de los parámetros de producción puede aumentar la velocidad de producción hasta en un 40% y/o reducir el consumo de energía hasta en un 30%.
• Una herramienta de simulación recientemente desarrollada ayuda a optimizar las recetas existentes. Los numerosos parámetros de máquina que se deben ajustar se han reducido a lo esencial y en el futuro podrán calcularse automáticamente sobre la base de los datos clave textiles.
• En lo que se refiere al servicio, hay una nueva herramienta de mantenimiento que da de forma proactiva al operador de la máquina o al departamento de mantenimiento instrucciones de servicio que se pueden seguir en un libro de registro. En el futuro, una plataforma de servicio en línea recientemente desarrollada apoyará a nuestros clientes en todas las consultas de servicio. Los técnicos se comunican directamente con el cliente a través de videoconferencia, en parte con realidad aumentada. Documentos como esquemas de circuitos o manuales de mantenimiento pueden ser vistos y explicados juntos y las piezas de repuesto pueden ser solicitadas directamente. Para los procesos de mantenimiento regulares, las ilustraciones fotográficas o de vídeo pueden almacenarse en el idioma local. Los tiempos de parada técnicamente ocasionados pueden reducirse considerablemente gracias a estos nuevos sistemas. Esto aumenta la disponibilidad del sistema y, por lo tanto, la productividad.
• El intercambio de datos de la máquina con una estación de control de nivel superior o sistemas ERP es fácilmente posible con OPC-UA. Esto permite racionalizar los procesos en la fábrica textil y controlar la calidad.

Además de estos esfuerzos en el campo de la automatización, BRÜCKNER también muestra la gran variedad de su experiencia y su cartera de productos. Esta diversidad y la competencia en consultoría se han ido desarrollando a lo largo de muchos años de innovación.
Por ejemplo, BRÜCKNER ha invertido mucho en el sector de la mezclilla y también ha aumentado su personal. Se ofrecen líneas de acabado integradas para el teñido de pigmentos, el acabado con resinas sintéticas y el recubrimiento. BRÜCKNER, líder del mercado y proveedor de sistemas, puede suministrar de una única fuente todos los componentes desde la entrada, por el foulard, el presecador IR, la unidad de aplicación mínima, la unidad de recubrimiento, la rama, la línea de condensación / hotflue, la refrigeración y la salida.

El sobreteñido o el acabado de ambos lados del tejido se realiza normalmente con el foulard de BRÜCKNER. La funcionalización o tintura por una cara se realiza con la unidad de aplicación mínima. Los expertos de BRÜCKNER responden a toda pregunta y están encantados de explicar las ventajas de los respectivos procesos.
Destaca especialmente el acabado económico con la técnica de aplicación mínima y otro componente importante en el acabado de la mezclilla es la probada línea Sanfor POWER-SHRINK de BRÜCKNER, que será presentada en esta feria. Los especialistas BRÜCKNER estarán encantados de proporcionarle más información en la ITMA.

BRÜCKNER puede ofrecer nuevos conceptos en el campo de la tintura continua. El presecador infra-rojo POWER-INFRATHERM, que ha sido mejorado en continua, tiene un tiempo de calentamiento y enfriamiento de menos de 5 segundos. Los segmentos del quemador de fibra metálica especial; secando sin rayas, y la amplia gama de control de temperatura garantizan una alta calidad de tejido constante y reproducible.
El hotflue POWER-COLORTHERM de BRÜCKNER garantiza un secado uniforme del tejido por todo el ancho de las cámaras. Incluso con tejidos estrechos en una máquina más ancha, los resultados de teñido son óptimos. Gracias a su diseño simétrico y a los ventiladores controlados por frecuencia, la distribución uniforme del aire por las toberas superior e inferior hace innecesario el ajuste del volumen a través de válvulas mecánicas. Opcionalmente están disponibles rodillos ensanchadores especiales accionados y patentados para un funcionamiento sin pliegues con tejidos delicados (satén rayado / percal / tejido elástico en trama), así como un sistema de limpieza de rodillos totalmente automático y de gran eficacia.
Los especialistas de BRÜCKNER en Barcelona también están a su disposición para responder a sus preguntas en este ámbito y estarán encantados de asesorarle.
BRÜCKNER también tiene algo nuevo que ofrecer en el campo de las ramas tensoras de pisos. Las ramas de pisos se utilizan principalmente cuando el espacio es limitado. Son adecuados para el acabado de tejidos planos o género de punto dimensionalmente estables, no-tejidos, fieltros punzonados, textiles técnicos o para la industria de la lana.
Para la nueva rama de pisos POWER-FRAME VNE de BRÜCKNER sólo se necesita un operario, ya que la entrada y la salida están en el mismo lado de la máquina. Esto se aplica tanto a la versión con dos y seis pasajes de tejido.
El nuevo concepto de máquina VNE ofrece la mayor densidad de potencia posible en un espacio pequeño o una larga sección de circulación del aire en un espacio muy reducido. El propio secador está equipado con el sistema de circulación del aire split-flow patentado por BRÜCKNER y la disposición alternada por medio campo garantiza además una circulación del aire y un tratamiento térmico óptimos y uniformes del tejido.
Otra ventaja es la cadena de transporte del tejido completamente libre de lubricantes de la rama de pisos, ya que en esta versión no hay aceite en el interior del secador.

 

ITMA 2019 forums draw strong industry support – Nonwovens, and chemical and colourant forums unveil key speakers

La imagen puede contener: una o varias personas y personas sentadas

7 February 2019 – The world’s leading textile and garment technology exhibition, ITMA 2019, will be complemented by several key forums when it is held in Barcelona in June, two of which are the ITMA-EDANA Nonwovens Forum and Textile Colourant and Chemical Leaders Forum.

Mr Fritz Mayer, President of CEMATEX, said: “As technological developments are happening at breakneck speed, and collaboration is becoming increasingly necessary in a globalised economy, the industry has to stay abreast of the latest developments and trends. Hence, ITMA will be staging several forums to help participants be ahead of the competition curve.

“The forums also offer a valuable platform for various associations and professionals to connect and network with the right players. This is especially important as collaboration and partnerships from research institutions to technology, chemical and raw material providers and users are increasingly more critical to business success.”  

ITMA-EDANA Nonwovens Forum

The Nonwovens Forum is jointly organised by ITMA and EDANA. To be held on 21 June 2019, it will highlight the latest innovations in nonwovens. The theme of the forum is ‘Nonwovens Manufacturing Processes for the 21st Century: More Flexible, More Efficient, More Sustainable’.

Mr Pierre Wiertz, EDANA’s General Manager said: “The nonwovens industry is a bright spark in the textile world. We are glad to be able to collaborate with ITMA to bring these exciting opportunities to visitors who are involved in or have the intention to move into nonwovens manufacturing.”

Providing the latest industry insights will be keynote speaker Mr David Allan, Editor, Nonwovens, RISI (United States). His presentation is titled ‘Global Trends in Nonwoven Processes under Economic and Sustainability Constraints’.

The forum will feature three sessions:

  • Circular economy/challenges & opportunities for processing bio-based & recycled materials on nonwovens machinery
  • Latest trends and innovation in nonwoven processes – including hybrids and composites
  • Innovations in nonwovens technology

In addition, there will be a panel discussion with experts from leading centres of excellence in nonwovens who will exchange their views on the nonwoven processes of the 2030s.

Textile Colourant and Chemical Leaders Forum

The 3rd Textile Colourant and Chemical Leaders Forum @ ITMA 2019 on 23 June will focus on the circular economy and resource sustainability strategy and how innovation will drive future industry success. Launched at ITMA 2011, the forum, is an industry initiative that draws lively participation from dyestuff, colour and chemical professionals from around the world.

Themed ‘Meeting Resource Challenges in the Circular Economy’, the 2019 forum explores how textile chemicals and innovative and cleaner technologies can help create a more sustainable future for the textile and garment industry.

Presentations at the forum are clustered into three sessions:

  • Resource management and Industry 4.0
  • Responding to sustainability challenges with innovation
  • Envisioning the future of the colourant and chemical industry

Chairing the forum is Mr Andrew Filarowski, Technical Director of Society of Dyers and Colourists. He said: “The forum has been an eagerly-awaited event at each ITMA edition as it is an inclusive industry platform that takes in perspectives from all stakeholders of the textile and garment supply chain. Organised by the industry, it allows like-minded industry players to exchange knowledge on the latest innovations and solutions, understand current issues and trends in a global context.”

Speakers confirmed for the forum include Ms Christina Raab, Global Implementation Director of The ZDHC Foundation. She will speak on the role of chemistry for circularity in textile, leather and fibre production. She will also elaborate on ZDHC’s approach and tools to drive the transition and uptake of safer and more circular chemistry, as well as the current state and findings of circular implementation projects from the sector.

Another speaker is Ms Dunja Drmač, Sustainability Officer of the European Apparel and Textile Confederation (EURATEX). Her presentation will enlighten participants on resource sustainability and relevant strategies in the journey towards a circular economy.

In addition to the forums, other knowledge sharing activities include the ITMA Innovation Lab. An important element of the lab is the ITMA Speakers Platform where all ITMA exhibitors have been invited to participate. The Platform will be complemented by a video showcase. A new highlight, the ITMA Innovation Video Showcase will provide a new channel for visitors to learn more about innovative exhibits at ITMA 2019.

Registration for both forums is open at itma.com. Details of other co-located events at ITMA 2019 can also be found on the website.

ITMA 2019 will be held from 20 to 26 June at Fira de Barcelona, Gran Via venue. The exhibition will feature over 1,600 exhibitors who will be showcasing their latest technologies and sustainable solutions for the entire textile and garment manufacturing value chain, as well as fibres, yarns and fabrics.


About CEMATEX & ITMA

The European Committee of Textile Machinery Manufacturers (CEMATEX) comprises national textile machinery associations from Belgium, France, Germany, Italy, Netherlands, Spain, Sweden, Switzerland and the United Kingdom. It is the owner of ITMA and ITMA ASIA. Considered the ‘Olympics’ of textile machinery exhibitions, ITMA has a 65-year history of displaying the latest in machinery and software for every single work process of textile and garment making. It is held every four years in Europe.

About ITMA Services
Headquartered in Brussels with a subsidiary in Singapore, ITMA Services is the appointed organiser of ITMA 2019 and future ITMA branded exhibitions. It is managed by professionals with extensive experience in organising ITMA and other major trade exhibitions around the world. It aims to maintain and expand ITMA’s unique selling proposition and relevance to a global audience.


Issued by CEMATEX and ITMA Services

Contacts:

Ms Maria Avery 
CEMATEX 
Tel: +44 7967 477305 
Email: info@cematex.com 
www.cematex.com
Ms Daphne Poon 
ITMA Services Pte Ltd 
Tel: +65 94789543 
Email: daphnepoon@itma.com 
www.itma.com

 

BRÜCKNER Heat-recovery and exhaust air pollution control at Getzner AG

Getzner AG in Vorarlberg, Austria is today the leading company for the production of African damask fabrics and one of the leading manufacturers of shirt fashion fabrics.
Brueckner Heat-recovery Getzner
Figure 1: Getzner AG in Bludenz, Austria.

The new production halls at Getzner AG’s main plant in Bludenz, fabrics are woven and finished for ready-made garments. The fabrics are finished in special processes mainly on new BRÜCKNER stenters.

As substances evaporate from the fabric during the textile finishing processes, the stenters have to be vacuumed off and this exhaust air has to be cleaned before being emitted into the environment.

The exhaust air treatment on the new stenters of Getzner AG is carried out by a multi-stage BRÜCKNER ECO-HEAT and ECO-AIR system.

In the first ECO-HEAT heat-recovery system, heated fresh air is generated for the drying process, which noticeably reduces energy consumption. In the second ECO-HEAT heat-recovery system, water is heated for the company’s internal heating system and thus, depending on the heating requirement, up to 85% of the invested heat energy is recovered.

The pollutants from the exhaust air are condensed and separated in the subsequent ECO-AIR exhaust air scrubber. A silencer behind the exhaust air fan reduces the exhaust noise to a minimum.

Brueckner ECO HEAT air Getzner
Figure 2: BRÜCKNER ECO-HEAT air/air heat-recovery system.

The proven ECO-HEAT components guarantee high heat transfer efficiency and a particularly robust and maintenance-friendly design. Since the heat exchangers have to be cleaned at regular intervals from unavoidable deposits in order to maintain full performance, they are easy to remove. The heat exchangers are boiled regularly in the cleaning bath supplied.

As Getzner AG has replacement heat exchanger modules in stock, the heat exchangers are cleaned without any time pressure.

With this modern multi-stage exhaust air system Getzner AG achieves a high energy efficiency because most of the exhaust air heat is recovered in BRÜCKNER ECO-HEAT systems.

In addition, the picturesque environment is not polluted by smoke, noise, and odors from the production process, thanks to the BRÜCKNER ECO-AIR exhaust air cleaning system.

LES RECIBIMOS CON MUCHO GUSTO EN LAS EXHBICIONES SIGUIENTES:

FEBRATEX Blumenau Brasil 21. – 24. agosto 2018
CINTE TECHTEXTIL Shanghai China 04. – 06. septiembre 2018
CAITME Taskent Uzbekistan 11. – 13. septiembre 2018
KTM Kahramanmaras Turquia 27. – 28. septiembre 2018
EXINTEX Puebla Mexico 02. – 05. octubre 2018
ITMA ASIA Shanghai China 15. – 19. octubre 2018
Vliesstofftage Hof Alemania 07. – 08. noviembre 2018

 

A Sustainable Improvement of the Production and Efficient Use of the Resources

Brückner presented in Frankfurt a wide range of application examples for Technical Textiles which can be finished on the tailor-made and resource-saving Brückner machines. A great number of special machines for very specific purposes show the competence of the creative Brückner team. The Southwest of Germany is a center for Technical Textiles which amount to about 50 % of the textile production. The family-owned company Brückner, managed in the second generation by the owner Regina Brückner together with her husband Axel Pieper, is just in the right place in Leonberg in Swabia and Tittmoning in Bavaria.

The proximity to textile research institutes such as e.g. the ITV in Denkendorf allows many joint projects and developments which are used in the special machines made by Brückner. Manifold product examples invite to discussions with the Brückner experts. Models of a Supra-Flow BX double belt oven for nonwovens and of the innovative Etro bow-shaped dryer which is particularly suitable for the coating with PVC or adhesives show only two of the machines offered by Brückner for the finishing of nonwovens and foils. In addition Brückner offers very different application systems for the coating of technical textiles and one of them is the Eco-Coat minimum application unit (in the picture). In the Technology Center in Leonberg the customers can develop their own innovations on different machines. Also padders, drying, heat-setting and curing ovens with maximum production capacity and lowest possible energy consumptions and the highest precision in the temperature distribution and air circulation are part of Brückner’s product range. Various cutting and winding machines to give a shape to Technical Textiles of any kind round the product portfolio.