Arrojamos luz sobre la jungla del reciclaje

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29 de octubre de 2020
Tecnología e innovación

Eva Trenz                                                                                         Por 

Upcycling, downcycling, reciclaje y un mejor uso de las materias primas son solo algunos términos para diferentes esfuerzos de sostenibilidad en la industria textil. El tema es complejo y puede tener muchas características diferentes.

Por un lado están las botellas PET de materia prima, es decir, antiguas botellas de agua unidireccionales, a partir de las cuales se pueden fabricar tejidos de vellón o incluso alfombras en el segundo ciclo de vida. Los artículos de moda de ayer, es decir, los textiles usados, también pueden convertirse en una materia prima codiciada y desempeñar un papel en la producción de hilo. Otra opción de reciclaje pertenece al área de utilización optimizada de la materia prima: gracias a las tecnologías avanzadas de las máquinas, hoy en día se producen hilos de alta calidad a partir de residuos de producción o incluso de borras.

¿Los pantalones obsoletos se convierten en un artículo de moda superior?

Desafortunadamente, el reciclaje de textiles no es tan simple. Solo en Alemania, cada año se recolectan más de un millón de toneladas de ropa vieja. Pero esta enorme montaña de material debe clasificarse, clasificarse y procesarse antes de que pueda utilizarse como materia prima. Parte de ella se comercializa como ropa usada. Otra parte se utiliza como materia prima y se procesa posteriormente, por ejemplo, para fabricar paños de limpieza, material aislante en automóviles o incluso billetes de banco. Y una proporción muy grande está destinada a acabar en el incinerador por su mala calidad inicial.

La ruta de reciclaje más sencilla: botella de agua con futuro

Se hace una distinción básica entre los procesos de reciclaje químico y mecánico. La recuperación de granulado de poliéster de botellas de PET se asigna al lado químico. Las botellas se trituran en copos, cuyos polímeros luego se disuelven. Estos polímeros disueltos representan la masa de hilado a partir de la cual se producen nuevas fibras o directamente una nueva banda.

Para este proceso, Truetzschler Man-Made Fibers ofrece una línea para producir hilos de alfombra de alta calidad, los llamados hilos BCF (Bulky Continous Filaments), directamente a partir de escamas de PET. El proceso tiene tres etapas y consiste en la fusión de R-PET (tereftalato de polietileno reciclado de botellas de PET), el hilado de un hilo multifilamento a través de la hilera y el posterior estirado y texturizado. El texturizado se refiere al rizado permanente del filamento.

Sin embargo, las fibras para hilos de fibras cortas cortadas (Truetzschler Spinning) o para bandas (Truetzschler Nonwovens) también pueden ser el objetivo. Para los conceptos de instalación de Truetzschler, no importa si la fibra de poliéster proviene de una materia prima secundaria o de una materia prima virgen. Desde un punto de vista puramente químico, no se puede rastrear en qué materia prima se basa la fibra.

Reciclaje mecánico

El grado de dificultad de los procesos de reciclaje siempre depende de la calidad inicial de las materias primas (secundarias). Los tejidos mezclados, por ejemplo, representan un problema básico en el reciclaje de materiales de fibra de ropa usados, porque la precisión de clasificación es realmente escasa en el mercado de textiles usados: el algodón, viscosa, poliéster, seda, poliamida, poliacrilonitrilo, lana, lino y otros materiales pueden mezclarse en una sola tela. Por otro lado, las materias primas secundarias también pueden clasificarse por tipo: los residuos o borras producidas directamente en la hilandería son de excelente calidad y pueden reciclarse perfectamente.

El camino hacia un nuevo comienzo

Cuanto más tarde se obtiene la materia prima secundaria, más complejo se vuelve el proceso de reciclaje. Los desechos de la preparación de hilatura se pueden procesar comparativamente bien. Un ejemplo de esto son las denominadas borlas, es decir, fibras y neps peinados, que son indeseables especialmente cuando se trata de hilos de alta calidad. Dado que el material ya ha pasado por la sala de soplado y sobre las tarjetas, es un “desperdicio” de alta calidad. Se trata de una materia prima reciclable que se utiliza, por ejemplo, en billetes de banco o productos de higiene o se hila en el propio hilo.

Ejemplo de residuos de producción: residuos de la sala de soplado

También es posible recuperar la parte de fibras buenas de los residuos de producción, como los residuos de la sala de soplado y del cardado, y reintroducirlos en el proceso de preparación del hilado. Una línea separada de reciclaje de residuos de Truetzschler con una limpieza particularmente intensiva con el Waste Cleaner CL-R aumenta el grado de apertura y permite el reciclaje hasta las últimas fibras buenas.

Los textiles usados ​​requieren muchos pasos intermedios antes de que la materia prima resultante pueda convertirse en hilo en una hilandería. Antes de funcionar en máquinas Truetzschler, el material debe clasificarse y cortarse primero, antes de que vuelva a convertirse en una sola fibra. El resultado son pacas de fibras secundarias abiertas y separadas, que luego pueden volver a alimentarse a la preparación de hilatura.

Ejemplo de regenera: fibras de jeans rotos

Las balas hechas de fibras 100% recicladas se pueden procesar a través de una línea de apertura de hilatura simplificada Truetzschler. Ya no es necesaria una limpieza intensiva adicional de las fibras, ya que ya se han limpiado antes de ser transformadas en textiles. Al procesar mezclas de fibras recicladas y algodón crudo o fibras sintéticas, se recomienda el uso de una línea T-BLEND. Esto puede garantizar la precisión de la proporción de mezcla deseada, incluso en los niveles de producción más altos. Para evitar perder demasiadas fibras en el proceso de preparación, las fibras recicladas ya no se exponen a un proceso de limpieza previa intensiva por separado, sino que se mezclan posteriormente con la materia prima.

Línea de reciclaje de residuos Trützschler, por ejemplo para la limpieza previa de residuos de la sala de soplado o de tarjetas.

Estas balas de materias primas secundarias no solo se utilizan para producir hilos, sino también para telas no tejidas cardadas en las líneas de no tejer Truetzschler. El método clásico que se aplica aquí es el hidroenmarañamiento. También son posibles la termounión, después de la adición de fibras bicomponentes, y la unión química.

Sostenibilidad y reciclaje: más que una simple tendencia

La industria textil ha puesto la sostenibilidad en la agenda. Los esfuerzos se centran en la protección del medio ambiente y los recursos, la sustitución de productos químicos, la promoción de fibras sostenibles y condiciones de trabajo humanas. Sin embargo, desde el cultivo hasta el reciclaje o la eliminación, hay una variedad de enfoques para lograr estos objetivos.

Como uno de los principales fabricantes de maquinaria textil, Truetzschler se enfrenta a esta responsabilidad. Al diseñar nuestras máquinas, hemos prestado atención a los procesos abreviados, la utilización optimizada de la materia prima, los componentes de la máquina duraderos y las máquinas que mejoran significativamente el proceso de reciclaje, y no solo desde ayer. Junto con nuestros clientes, podemos contribuir así a una cadena de producción textil sostenible.

Truetzschler presents at ITMA Barcelona 2019

Intelligent, individual, sustainable: Truetzschler presents new solutions for spinning preparation, nonwovens & man-made fibers at ITMA Barcelona 2019

Intelligent spinning preparation

Cost pressure, personnel bottlenecks and fluctuating raw material qualities: These are some of the most pressing challenges in spinning preparation. At the same time, spinning preparation is decisive for the yarn’s quality. In order to meet these requirements, Truetzschler counts on state-of-the-art sensor technology and digital integration – and opens up a new chapter in carding technology: The new intelligent card TC 19i automatically and continuously optimizes the carding gap whose setting has a critical influence on quality and performance. With a precision not achievable by humans, the intelligent card permanently realizes even the narrowest carding gap setting of 3/1000 inch. “This allows us to measurably improve our customers’ raw material utilization and productivity while achieving consistently high quality,” says Dr. Dirk Burger, CEO of the Truetzschler Group. In addition, new cloud-based digital monitoring and management systems provide yarn manufacturers with transparency over all processes in the spinning mill. The My Wires app, for example, provides information on the status of clothings and service intervals and helps with the planning of reorders. Competent service for re-clothing can be provided immediately by Truetzschler Card Clothing (TCC). “With the smart networking of machines as well as production and maintenance, we support customers in simplifying their entire spinning process,” explains Dr. Christof Soest, CTO of the Truetzschler Group, and emphasizes: “This is why our digital platforms work not only for Truetzschler technology”. 
The latest innovation in the blowroom offers more economy and quality as well: The Portal Bale Opener BO-P, with widths of 2,900 mm or 3,500 mm, allows significantly more bales to be placed side by side and processes them in parallel using two opening rolls. Thus, it results in significantly better blending and higher productions of up to 3,000 kg/h.
As a complete supplier for spinning preparation, Truetzschler is also breaking new ground in draw frames, the quality filters in the spinning mill. The autoleveller draw frame TD 10 automatically adjusts the perfect break draft for optimum sliver quality and realizes significant cost savings due to its compact design and energy-efficient suction system. Like the TC 19i and the BO-P, the TD 10 provides the operator-friendly T-LED remote display which visualizes important machine and production information in a simple way.

Individual, sustainable installation concepts for nonwovens and man-made fibers

Truetzschler Nonwovens presents sustainable concepts tailored to individual customer needs. The focus is on technologies for the production of biodegradable light-weight webs from renewable raw materials. In addition to proven solutions for carded, spunlaced nonwovens made of 100% cotton or 100% viscose, Truetzschler Nonwovens has developed an alternative technology in cooperation with Voith: In a wet-on-wet process, the web is formed from cellulose-based short fibers suspended in water and then bonded by means of hydroentanglement. The sustainable, high-quality wipes and cleaning cloths that result from this process can be completely degraded by microorganisms in the environment after usage by the consumer.
The Man-Made Fibers division presents the new four-end BCF machine MO40, which is based on the proven M40 concept. The symmetrical design in combination with the lamellaless HPc texturing results in maximum yarn and bobbin qualities. As each spinning position produces four BCF ends simultaneously, the machine achieves high productivity at moderate speeds, which ensures a stable process. “Higher, faster, further is not always the solution”, emphasizes Dr. Lassad Nasri, CTO at Truetzschler Man-Made-Fibers, “as with the entire Truetzschler Group, individual customer requirements always have priority for us. We support our customers with complete installation concepts, services and know-how – from the product idea to new business models.”

Competent service and tailor-made clothings

In addition to the highlights from the Spinning, Nonwovens and Man-Made Fibers business units, the Truetzschler Group will present the comprehensive services and high-performance clothings for cards and roller cards from TCC on 1400 m2. TCC completes its portfolio of special flat clothings with the MT 52, which demonstrates outstanding stability, particularly at high card productions in ring and rotor spinning. In addition, TCC has developed the new PRECISETOP flat clothing, which is essential for the intelligent self-optimization of the carding gap in the TC 19i. Thanks to the close cooperation between machine developers and clothing specialists at Truetzschler, customers benefit from tailor-made and compatible solutions along the entire value chain.

09.04.2019 Truetzschler will discuss sustainable nonwovens

From May 14th to 17th Truetzschler Nonwovens presents production lines for “green” nonwovens at Techtextil (hall 3.0 booth B03) 

Ince decades machine supplier answered requirements on enhanced product quality, better line efficiency and higher productivity with new concepts and innovative processes. Now we see a new dimension rising. As a supplier of complete production lines Truetzschler Nonwovens offers machinery, service and know-how out of one hand – everything from implementing product ideas to enabling new businesses.

At booth B03 in hall 3.0 the focus is on solutions for processing eco-friendly materials. Cotton fibers – both virgin cotton and comber noils – make an excellent raw material for top-quality wipes. Truetzschler’s random and airlay cards are especially configured to cope with variable fiber lengths and a high short fiber content. The NCR and NCA cards reliably and efficiently form webs for the kind of soft cotton wipes sought after in premium markets worldwide.

Another focus point is fully biodegradable wet-laid and spunlaced (WLS) wipes. Voith and Truetzschler go one step beyond flushable wipes and show pulp and lyocell-based materials with sufficient strength to compete with conventional wipes from polyester/viscose blends. Proven machinery from both companies – such as Voith’s HydroFormer and Truetzschler’s AquaJet – add up to a versatile wet-laying and spunlacing line for future-fit end products.

How do I become an engineer at Truetzschler? –

 

 

March 1, 2019

Ralph Thannisch

By 
How do I become an engineer at Truetzschler?

This year’s Valentine’s day was not only about spending time with the loved ones. At Truetzschler it was time to invest in the future. Therefore, 23 students from different schools in Moenchengladbach came around to learn about the tasks and demands on engineers in textile machine engineering.

How do I become an engineer at Truetzschler?

What are the different tasks of an engineer? Which skills and interests do I need for the job? Do I have to study at a university or are there any alternatives? What perspectives do I have working in a family business in the metal and electrical industry? Those and many more questions were answered at the “Business Day Engineering”. Students who are interested in working in (textile) engineering got the chance to spend the morning at our headquarter in Moenchengladbach. After providing some general information about the company, our different business units and locations, we told our guests about the options they have after having finished school. To make the information more lively, we asked some of our young students and employees to report from their perspective.

Beside 11 individual apprenticeships in four different areas, we offer a dual study program called “KIA”. This cooperative engineering training consists of a practical apprenticeship at Truetzschler, combined with a university degree of the University of Applied Sciences in Krefeld. Students undergo two phases. Henrik Klaassen and Matteo Manek are currently in the first stage of their dual studies. Within the first three years they spend three days working in the company and two days at the university. Not only does the KIA program efficiently shorten the training duration, it also provides a great deal of practical experience. 

After having finished the first phase you are a real full-time student. Only during semester break, students work at the company to handle some independent projects. From designing new transport trolleys for the electronics department to adjusting the appearance and functioning of a new product – Stefan Dammer and Andreas Muyres carried out a lot of hands-on projects during their dual studies. The two of them are currently in the final stage of their education and are about to write their bachelor’s theses this summer. 

Tour through technical centre and training workshop

In the technical centre our young employees showed the pupils our different machine types and explained how each one processes the fibres. Afterwards they visited the sheet metal production to demonstrate how the individual parts of the machines are being produced. To show where Truetzschler students spend a big amount of time, the training workshop was the next stop. Especially the 3D printer aroused the interest of our guests.

  • Managing efficiency

As a „manager for efficient processes”, Niclas Maasackers is part of several different applications.  From international production processes to quality assurance and factory planning – his fields of application are versatile. Since he successfully completed his dual studies in engineering and industrial engineering, Niclas works in the production area at Truetzschler. During his studies he enjoyed being coached very well by a mentor of the company. Another aspect he valued is that Truetzschler gives engineer students the special chance to implement and realize their own individual ideas, for example as a final dissertation.

From the idea to the finished product

Britta Luestraeten introduced the students to the work of a development engineer in mechanical construction. Therefore, she explained the winding machine TSL 12 – from the idea to the finished product. Her work is very diverse, because creating a machine requires passing different phases like competition analysis, product requirements, concept creation and construction.

Thank you!

We were very happy with the great interest in the event and are looking forward to see some of our guests again in our training workshop. Many thanks to our partners Agentur für Arbeit Mönchengladbach, MGconnect and ZDI Zentrum Mönchengladbach for this successful event and to our colleagues for their valuable insights.

 

 

TRUTZSCHLER NONWOVENS NEWS . TRADE FAIRS & CONFERENCES – ANDTEX 2019

Andtex
Booth               http://www.andtex.com/

TRUTZSCHLER – EcoWipes invests in Voith-Trützschler’s WLS-technology

EcoWipes is a young, innovative company that has become a leading manufacturer and converter of private label products for the hydro-entangled nonwoven segment. The firm, which is located to the north of Warsaw, was established in 2009 and has now already ordered its third nonwovens production line.
 

EcoWipes has a strong focus on innovation and sustainability and intensively monitors local and global market trends. In view of the rising consumer interest in biodegradable materials, EcoWipes opt for partners Trützschler Nonwovens and Voith to supply the new production line. The progressive and sustainable WLS (wet-laid spunlacing) concept developed by the two companies for manufacturing wet-laid hydroentangled nonwovens is a perfect fit for the EcoWipes product range. It is ideally suited for producing flushable wipes but also recyclable and biodegradable products. These materials meet consumer preferences for greater sustainability at the end of the product cycle.

The sale of this fifth WLS facility is testimony to the successful collaboration between Trützschler Nonwovens and Voith as established technology leaders in the wet-laid hydroentangled nonwoven segment.

The new production line at EcoWipes is a flexible wet-dry nonwoven facility. Voith is supplying the HydroFormer, one of the main components of the new line. The HydroFormer concept builds on Voith’s long experience in the paper and pulp industry. With HydroFormer technology the suspension is highly diluted, so nonwovens can be produced entirely from cellulose, a renewable and cost-effective raw material.

Trützschler Nonwovens is not just responsible for the hydroentangling, drying and reeling up, but will also supply its latest high-speed card. This flexible configuration enables EcoWipes to produce a broad product range of wet-laid/spunlaced or carded/spunlaced nonwovens.

EcoWipes invests in Voith-Trützschler’s WLS-technology

EcoWipes is a young, innovative company that has become a leading manufacturer and converter of private label products for the hydro-entangled nonwoven segment. The firm, which is located to the north of Warsaw, was established in 2009 and has now already ordered its third nonwovens production line.
 

EcoWipes has a strong focus on innovation and sustainability and intensively monitors local and global market trends. In view of the rising consumer interest in biodegradable materials, EcoWipes opt for partners Trützschler Nonwovens and Voith to supply the new production line. The progressive and sustainable WLS (wet-laid spunlacing) concept developed by the two companies for manufacturing wet-laid hydroentangled nonwovens is a perfect fit for the EcoWipes product range. It is ideally suited for producing flushable wipes but also recyclable and biodegradable products. These materials meet consumer preferences for greater sustainability at the end of the product cycle.

The sale of this fifth WLS facility is testimony to the successful collaboration between Trützschler Nonwovens and Voith as established technology leaders in the wet-laid hydroentangled nonwoven segment.

The new production line at EcoWipes is a flexible wet-dry nonwoven facility. Voith is supplying the HydroFormer, one of the main components of the new line. The HydroFormer concept builds on Voith’s long experience in the paper and pulp industry. With HydroFormer technology the suspension is highly diluted, so nonwovens can be produced entirely from cellulose, a renewable and cost-effective raw material.

Trützschler Nonwovens is not just responsible for the hydroentangling, drying and reeling up, but will also supply its latest high-speed card. This flexible configuration enables EcoWipes to produce a broad product range of wet-laid/spunlaced or carded/spunlaced nonwovens.

TRADE FAIR / DATES BY TRUTZSCHLER NON WOVENS NEWS

Shanghaitex

WELCOME TO  SHANGHAITEX   :          Hall E1, Booth C01

www.shanghaitex.cn

Colombiatex  del    23.- 25.01.2018

http://colombiatex.inexmoda.org.co/en/

DTG         Hall 2, Booth 286

www.bangla-expo.com/DTG/ 

Inlegmash   del    20.- 23.03.2018   

Hall, Booth ( not yet )

http://www.inlegmash-expo.ru/en/

Indo Intertex   04.- 07.04.2018

Hall, Booth ( not yet)

http://indointertex.com/

Truetzschler and Voith introduce new safety standard for wet-laid spunlaced nonwovens Machinery

In the shape of standard VN 3260/TN 0790, Voith Paper and Trützschler Nonwovens have developed a new safety standard for wet-laid spunlaced (WLS) Nonwovens machines. The standard will help producers of Nonwovens to ensure safe and reliable operation of their machines. It also provides the basic prerequisite for meeting expectations in respect of production and quality:
  • Basis for safe production of Nonwovens
  • Combination of proven standards for paper and textile machines
  • Standardization process by ISO initiated

Voith and Trützschler jointly developed the manufacturing process for wet-laid and hydroentangled Nonwovens. The machines on which the materials are produced consist partly of paper machine components and partly of components from Nonwoven machines. The manufacturing process for wet-laid Nonwovens is similar to that for producing paper: A suspension consisting of water and fibers up to 40 mm long is passed over a wire on which a homogeneous fiber mat forms. The hydroentangling or spunlacing process produces bonded Nonwovens that can be textured if required. Drying and winding of the Nonwovens are done on other machine components.

The newly developed standard combines various Voith and Trützschler safety standards for paper and textile machines in a new document and thus defines the safety requirements for new hybrid machines.

The safety standard has already been incorporated by the International Organization for Standardization (ISO) as the basis for developing an international standard, so as to achieve greater impact at global level.