nonwoven andritz agency meeting · •needlepunch automotive market is consolidating and represents...
TRANSCRIPT
ANDRITZ
AGENCY MEETING
NONWOVEN
JUNE 2019
I T M A 2 0 1 9 , B AR C E L O N A
01 ANDRITZ NONWOVEN
CHAPTER OVERVIEW
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02 NEEDLEPUNCH
03 SPUNLACE
04 AIR-THROUGH-BONDING
05 SPUNLAID & TEXTILE CALENDER
06 WETLAID
07 CONVERTING
08 INNOVATIONS
ANDRITZ is a globally leading supplier of plants, equipment, systems and services for hydropower stations, the pulp and
paper industry, the metalworking and steel industries, and solid/liquid separation in the municipal and industrial sectors as
well as for animal feed and biomass pelleting.
Global presence
Headquarters in Graz, Austria; over 280 production sites and service/sales companies worldwide
KEY FINANCIAL FIGURES:
THE ANDRITZ GROUP
3
SALES BY REGION 2018 (%)
Emerging
markets:
41%Europe &
North America:
59%
6,031
MEUR
UNIT 2018 2017
Order intake MEUR 6,646.2 5,579.5
Order backlog (as of end of period) MEUR 7,084.3 6,383.0
Sales MEUR 6,031.5 5,889.1
Net income (including non-controlling interests) MEUR 219.7 265.6
Employees (as of end of period; without apprentices) - 29,096 25,566
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A WORLD MARKET LEADER
WITH FOUR BUSINESS AREAS
4
Electromechanical equipment
for hydropower plants
(turbines, generators); pumps;
turbo generators.
PRODUCT OFFERINGS
HYDRO
Equipment for production of
all types of pulp, paper,
tissue, and board; energy
boilers.
PRODUCT OFFERINGS
PULP & PAPER
Presses/press lines for metal
forming (Schuler); systems for
production of stainless steel,
carbon steel, and non-ferrous
metal strip; industrial furnace
plants.
PRODUCT OFFERINGS
METALS
Equipment for solid/liquid
separation for municipalities
and various industries;
equipment for production of
animal feed and biomass
pellets.
PRODUCT OFFERINGS
SEPARATION
39 29 1022
% order intake* % order intake* % order intake* % order intake*
* Share of total Group order intake 2018
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STRENGTHENING OF MARKET POSITION
BY ACQUISITIONS
5
HYDRO PULP & PAPER METALS SEPARATION
2006 VA TECH HYDRO 2000 Ahlstrom Machinery 2010 Rieter Perfojet 2000 Kohler 2000 UMT
2007 Tigép 2000 Lamb Baling Line 2010 DMT/Biax 2002 SELAS SAS Furnace Div. 2002 3SYS
2008 GE Hydro business 2000 Voith Andritz Tissue 2011 AE&E Austria 2004 Kaiser 2004 Bird Machine
2010 GEHI (JV) 2002 ABB Drying 2011 Iggesund Tools 2005 Lynson 2004 NETZSCH Filtration
2010 Precision Machine 2003 IDEAS Simulation 2011 Tristar Industries 2008 Maerz 2004 Fluid Bed Systems
2010 Hammerfest Strøm 2003 Acutest Oy 2011 Asselin-Thibeau 2012 Bricmont 2005 Lenser Filtration
2010 Ritz 2003 Fiedler 2012 AES 2012 Soutec 2006 CONTEC Decanter
2011 Hemicycle Controls 2004 EMS (JV) 2013 MeWa 2013 Schuler (> 95%) 2009 Delkor Capital Equipment
2018 HMI 2005 Cybermetrics 2015 Euroslot 2013 FBB Engineering 2009 Frautech
2005 Universal Dynamics Group 2016 SHW Casting Technologies 2014 Herr-Voss Stamco 2010 KMPT
2006 Küsters 2017 Paperchine 2016 Yadon (52.9%) 2012 Gouda
2006 Carbona 2018 Novimpianti 2016 AWEBA 2013 Shende Machinery
2006 Pilão 2018 Diatec (70%) 2017 Powerlase (80%) 2016 ANBO
2007 Bachofen + Meier 2018 Xerium 2018 Farina Presse
2007 Sindus 2018 ASKO
2008 Kufferath
2009 Rollteck
Acquisitions by business area since 2000
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HYDRO PULP & PAPER METALS SEPARATION
ANDRITZ NONWOVEN
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Nonwoven Division
Andreas Lukas
One division fully committed to the nonwovens industry – from forming to finishing up to converting
“Within the nonwovens sector, ANDRITZ combines the expertise of leading Nonwoven companies with a long and
successful history to service, innovate and support.” Andreas Lukas, Senior Vice President Nonwoven Division
Within the ANDRITZ Group
Forming & Finishing Converting
Sales
Tobias Schäfer
Technology
Didier Vulliet
Operations
Johannes Haep
Service
Timo Hellgren
Operations/Technology
Luigi Mancini
Sales/Service
Letterio Villari
Key facts of ANDRITZ in nonwovens
ANDRITZ NONWOVEN
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Locations
ANDRITZ NONWOVEN
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9
NONWOVEN MARKET
Worldwide capacity
Source: INDA – EDANA 2015 1'000 tons
1‘729 2’095
1‘673 2’167 1’505 2’432
640 939 1’275
NAFTAEurope
China
Asia-Pacific
2014 20202009
2’857
2’876
South America
304 494 725
283 336 372
Japan
3’653
237 336
MENA
509
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CONVERTING
SPUNLACE
Excellent partner for your nonwoven production processes
FULL RANGE OF CAPABILITIES
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We’re here to give you support in every aspect of your nonwovens production from low to high capacities.
You benefit from the most advanced expertise and complete solutions for:
WETLAID SPUNLAID/CALENDER
NEEDLEPUNCH
10
AIR-THROUGH-BONDING
TEXTILE
FINISHING LINES
Technology - Innovation is a part of our DNA
FULL RANGE OF CAPABILITIES
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State-of-the-art technical centers
Covering the main nonwoven technologies and nonwoven
processes
Forming technologies : Drylaid, Wetlaid, Composites
Bonding technologies: Spunlacing, Needle punching,
Calender bonding, Air Through Bonding
Finishing: Kiss roll, foulard, calender, hydro-patterning
Open to ANDRITZ customers for their own R&D and
products development
From raw materials to finished rolls of nonwoven fabrics
Excellent correlation with real industrial production
conditions (speeds, basis weights, machines format)
Industrial IoT (Internet of things) solutions for smart production
FULL RANGE OF CAPABILITIES
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ANDRITZ AUTOMATION
ANDRITZ has combined its innovative Industrial IoT solutions under the technology brand „Metris“.
Based on extensive and long-term experience as a supplier of technologies and systems for the nonwoven industry, we offer a
broad portfolio of intelligent, digital solutions to help customers operate their production with even higher performance.
Benefit from:
Enhanced production efficiency and profitability
Optimized the use of resources
Constant and highest product quality
Increase of production uptime and maximum user-friendliness
13
The Big Picture – The Key Challenge Is
Pressure To Reduce Costs
Q5. Overall, what are the main challenges you currently face within the nonwoven industry?Base: 142
All Respondents
Cost Pressure33%
Improve productivity22%
Competition22%
Innovating and improving products
15%
Increase the quality of products
10%
14
EMEA significantly more likely to associate Andritz
with „Professional/ Expertise“
Americas significantly more likely to associate Andritz
with „Innovative“
APAC is significantly more likely to associate Andritz
with „Fair Price“
Q30. Thinking now about the Andritz Nonwoven brand, what words or phrases come to mind? What do you spontaneously associate with Andritz Nonwoven?
Base: 142All Respondents
„RELIABLE“ AND „QUALITY“ ARE TOP OF MIND
ASSOCIATIONS WITH ANDRITZ
*Responses mentioned more than once (n=160)
11%26%
68%
Positive
Negative Neutral
Key values
ANDRITZ NONWOVEN
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• High speed production line for wipes is a must (> 300 m/min) and customers visual quality and web uniformity
expectations are now increasing
• Needlepunch automotive market is consolidating and represents 40% of the needling industry. Concentration
among players is speeding up with large groups like Fibertex, Lydall, TWE. Key account management becomes
a key factor.
• Industry 4.0 is a marketing trend in Nonwoven but offering of solutions and references are still poor from OEMs
• Single Use Plastic EU Directive and microplastics in oceans is pushing for less thermoplastic polymers in
single use products.
• A growing recycling carbon fibers volume from production waste and second end of life cycle is monitored
growing.
IMPORTANT MARKET FACTS – FORMING & FINISHING
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• Service is becoming more and more a decisive element for capital projects and our customers have
expectations beyond our actual capabilities. We are not far away from our competitors but not offering what
especially bigger groups are expecting.
• Spunlaid OEM‘s are facing though competition from Asia combined with global overcapacity.
• Nonwovens production systems with better carbon footprints as traditionally used. (e.g. Waste fibers recycling,
Zero contamination, Energy saving)
• Empowerment of HTHI in the direction of systems supply for drylaid technologies. This strategy is supported by
Autefa Solutions Europe (subsidies of HTHI)
• Wetlaid for wipes demand raising to use pulp instead of Viscose fibers and develop biodegradable wipes (vs.
PET fibers in spunlace): Hybrid solutions combining wetlaid formation with second layers like carded and
spunbond materials. Wetlaid market demand for large system supply including EPC projects.
IMPORTANT MARKET FACTS – FORMING & FINISHING
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• Mature markets (Western EU, NA, Japan) minimum standard for baby diapers requires high speed machines.
1000ppm is today’s lowest standard with offerings already existing > 1200 ppm
• Adult incontinence is a key driver for growth with aging population, especially in Developed regions
• Increase income of consumers leads to higher demand for premium products. The growing sales of e-
commerce enlarges the range of products available online with personalized attributes.
• Sustainability: Growing demand for eco-friendly products, introduction of biodegradable diapers, reducing
polymers in diapers. Emerging market for Diapers recycling machineries.
• Africa offers the greatest potential for baby diapers growth thanks to low penetration rates today, high
demographic trend and growing GDP per Capita.
• India offers the greatest potential for feminine hygiene growth.
• APAC represents 70% of the world's baby diaper growth, with China counting for half of this growth. With
increasing purchasing power, increase in urban population, global ageing, China starts shifting to more premium
products.
IMPORTANT MARKET FACTS - CONVERTING
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• LinkedIn, WeChat
• Newsletters
• Web Site
Digital Marketing
COMMUNICATION
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01 ANDRITZ NONWOVEN
CHAPTER OVERVIEW
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02 NEEDLEPUNCH
03 SPUNLACE
04 AIR-THROUGH-BONDING
05 SPUNLAID & TEXTILE CALENDER
06 WETLAID
07 CONVERTING
08 INNOVATIONS
21
Market drivers
Key accounts seek to improve profitability by customizing their lines to specific range of products
Many players look for solutions to up-grade their existing production lines, for quality, for productivity
Higher needs of qualitative/esthetic end products
New entrants still coming, considering diversification
B markets reachable via the aXcess range without cannibalization towards eXcelle range
Market potential, among others…
Geotextile: market saturation in Europe, some perspective in Americas and Asia.
Filtration: stable market in Western economies, very active in China with growing export activity.
Automotive: more and more demanding in terms of needling aspect (“A” face products). Nonwoven market is supported by growing
applications with acoustic felts, lighter and safer materials (than plastic), possible combination with veloured “A” surface felts & composite
fabrics
Synthetic leather: mainly driven by Asia with key players as Japanese companies with a strong demand for a great surface aspect. Stable
market.
Other applications are of growing interest, such as protective felts for painting works, needled wipes, …
Market drivers, opportunities, facts, trends
ITMA PREVIEW – NEEDLEPUNCH
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Manifattura Fontana, Valstagna, Italy
Complete needle line for Geotextile
Up to 2000 kg/hour
Manifattura Fontana is the leading pioneer of Geotextile in Italy. It was a key Dilo
reference in Italy. The ANDRITZ is demonstrating must lower operating cost.
ITMA PREVIEW – NEEDLEPUNCHGeotextile - Lighthouse projects
22
Key success factors:
Mechanical properties with 10% lighter fabric, even weight distribution,
consistent quality over time
Turnkey production line, for 6,50 m wide fabrics
See press release, with customer quoting how satisfied he has been with quality
of process recommended, execution, support service, training.
First line with 3,5 m card, High speed crosslapper in 8,3 m w.w
Integration of co-partners
possible visit of Andritz potential customers, when not competing against M
Fontana.
Other successes in geotextile:
Thrace Linq USA (complete turnkey line), Akinal Turkey, Polyvlies (Germany),
Vtor Kom Russia (complete turnkey line) Afitex France, …
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Rubi (Grupo Sari), Madrid, Spain
Complete, multipurpose line (mainly for automotive application)
Qualitative solutions linked to optimized productivity
Rubi was taken back from Dilo as a customer reference.
Automotive, filtration - Lighthouse projects
MARKET REPORT PRODUCT – NEEDLEPUNCH
23
Key success factors:
Turnkey production line, added value technologies, multi bonding
technology including needling, air-through bonding, calendaring,
for 4,00 m wide fabrics
Training, support to set their first recipes was mostly appreciated.
Integration of copartners
Other successes in Automotive:
Fibertex (Czech Rep, USA), Milliken USA, NC Works USA, Suminoe
Mexico, Autoneum Mexico which includes a double velouring
needleloom, Filc and Konus in Slovenia, etc
Other successes in Filtration:
• Filc Slovenia, TTL Germany, Fujico Japan, Yanpai, Yubang, Kedi,
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TMS & TCF-X
• More than 95% of Andritz card feeders are chute feed
type
• No longer a bottle in production capacity, in fibre
length (up to 120 mm)
• Generates a much better fibre distribution in MD as
well as in CD with CV ≤ 3 % instead of 7 to 10% with
a volumetric system
• Allows higher through-put with lower # of folds at the
crosslapper
Easy to retrofit to boost quality and production capacity
in existing line
Short list….
LATEST NEWS & INNOVATIONS - NEEDLEPUNCH
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Short list…
LATEST NEWS & INNOVATIONS - NEEDLEPUNCH
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Airblade – for eXcelle cards
• Airblade replaces the Rotocomb with its DUR electric
comb
• It includes one stripping roller and a crossing nozzle bar
designed to supply an air curtain, preventing the card web
to wrap around the stripping roller during the starting
phase.
• The Airblade comes with a fan which air speed is
automatically adjusted as per the anticipated Andritz card
software
Comes with new cards as alternative to LDS.
Easy to retrofit on existing ANDRITZ cards
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ProDyn, …. ProWid and now,
ProWin to complete the widest range of
solutions to maximize production speed and to
optimize the fabric Weight evenness
LATEST NEWS & INNOVATIONS - NEEDLEPUNCH
26
Short list…
ProWid:
• Up-grade existing lines together
with a new crosslapper
• Available with self loop regulation
when supplied with a gauge
ProWid
ProDynProWin:
• ProWid and ProDyn speed corrections are not applied at the
same time.
• Patented technology that combines both ProWid and
ProDyn. As a result, weight profiling capabilities are
enhanced and operating speed limits are further increased
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• When associated with Prowid, ProDyn or ProWin, the
crosslapper becomes “Dynamic”
• The card is Dynamic only when associated with
ProDyn or ProWin
• « PRO-30-140 »
numbers following the « PRO. » are standing
o « 30 » standing for 3,00 m card
o « 140 » standing for 140 m/min
The speed is the max infeed speed, without inlet
speed variation (Dynamic)
• The name range of ANDRITZ crosslappers is now simplified. Only one way to identify a model, common to
ProDyn, Prowid and Profile crosslapping technologies.
• All short textile path crosslappers are names: “Profile”
Short list…
LATEST NEWS & INNOVATIONS - NEEDLEPUNCH
Needleloom
adjusting the fabric’s tensile strength
The market is requested more added value fabrics.
Andritz provides single or combined solutions to
generate fabrics
• with long elongation (i.e for later good thermo-
moldability) or
• with low elongation, even at low %
Among others, two key Andritz solutions:
• Moveable delivery press, with tooth racks
• Zeta, the high capacity pre-needled felt drafter
Short list…
LATEST NEWS & INNOVATIONS - NEEDLEPUNCH
28
%
N/5cm
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Short list…
LATEST NEWS & INNOVATIONS - NEEDLEPUNCH
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Needleloom
Creating value with needle patterns
The market is requested more added value fabrics.
« A » face products for the automotive industry as
other market applications require surface aspect with
no harmonics
New release of Andritz needle patterns allows to
boost production capacity by up to 3 times
ANDRITZ propose
• New progressive needle pattern with 5500 n/m
for the pre-needling phase
• Random 7000 n/m and 8000 n/m with patented
inverted set-up to further randomize needle
alignement
• Option to quickly exchange needle pattern of
optimum flexibility, when distance between
needles can be required
Production flow
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Short list…
LATEST NEWS & INNOVATIONS - NEEDLEPUNCH
30
Needleloom
Random velouring (« dilour »)
In particular for the Automotive market, Andritz offers
key competitive edges, key benefits, to its customers:
• Truly random velour carpets
• « tuft like » aspect when CD harmonics effect are
required
• Composite carpet to reduce the use of acrylic
binders
Autoneum's Di-Light based
nonwoven carpet
High « Up-time », low maintenance cost:
• No CD line brush pattern on carpet,
thanks to inclined brush positioning
• Long lasting brush thanks to combined
brush cleaning solutions, involving air
suction blades
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01 ANDRITZ NONWOVEN
CHAPTER OVERVIEW
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02 NEEDLEPUNCH
03 SPUNLACE
04 AIR-THROUGH-BONDING
05 SPUNLAID & TEXTILE CALENDER
06 WETLAID
07 CONVERTING
08 INNOVATIONS
SPUNLACE MARKET AND TRENDS
32
Markets & Trends
Absorbent Hygiene
Products
FiltrationIndustrial WipesMedical &
Healthcare
Personal Care
WipesHousehold
Clothing, Footwear & Baggage
Automotive
Market Trends:
• Less plastic more cellulose based nonwovens (EU SUP directive)
• Light basis weights for premium hygiene markets
• 3D patterns for differentiation
Technology Trends:
• Isotropy of tensile properties (face masks, technical markets)
• Zero wastes production process
Annual Growth
+ 6.0 %
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SPUNLACE MARKET AND TRENDS
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Carded hydroentangled product - facts
95% of the hydroentanglement (production) is from carded
Wipes (pre-moisted) are the main end-uses
Forecast to an additional 688 K tonnes from 2014 to 2020
In 2020, hydroentanglement will represents 16% of the worldwide nonwovens production
Source: INDA – EDANA 2015
34
SPUNLACE MARKET AND TRENDS
End-uses from Spunlace - Capacity
Source: ANDRITZ Perfojet
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NEXLINE SPUNLACE – EXCELLE SOLUTION
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ANDRITZ expertise in spunlace
Pioneer and innovative solutions for the production of spunlace nonwovens
• More than 30 years and more than 250 spunlace machines
• Main points
• Drylaid high speed lines for wipes: 300 m/min
• Drying Technology: a complete range
• Xline development with integration of aXcess range from Andritz Wuxi
NEXLINE SPUNLACE – EXCELLE SOLUTION
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State-of-the-art spunlace production line: neXline spunlace
Carding Hydroentanglement Dryer WinderCalender
Parameters
Material: Vis, PET, PP, PLA
Fabric weight: 25 - 80 g/m²
TT Card width: up to 5100 mm
Jetlace width: up to 6600 mm
Production speed: over 300 m/min
Capacity (50gsm): up to 20,000 t/p.a
Key facts:
High efficiency
Very high speed
Low energy consumption
neXecodry system
NEXLINE SPUNLACE – EXCELLE SOLUTION
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State-of-the-art spunlace production line: neXline spunlace
Web forming Hydroentanglement Dryer Winder
Parameters
Material: Vis, PET, Tencel, Cotton, Silk
Fabric weight: 30 - 120 g/m²
Web forming width: 3600 mm
Jetlace width: 3600 mm
Production speed: 120 m/min
Capacity (50gsm): up to 7,000 t/p.a
Key facts:
High efficiency
Isotropic web
Perfect web uniformity
Prodyn system
Team up with ANDRITZ (China) Wuxi branch
• Global network, local presence
• Full-line supply
• Lines efficiency and reliability
• Nonwoven technologies and processes
• aXcess technology: Opening & Blending
• aXcess forming technology: Drylaid
• aXcess bonding technology: Hydroentanglement
• aXcess drying technology: TAD
• Service
Optimize your investment in nonwovens
NEXLINE SPUNLACE – AXCESS SOLUTION
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neXline spunlace aXcess – Complete system supply configurations
NEXLINE SPUNLACE – AXCESS SOLUTION
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Direct line configurations for hygiene products
Crosslapped line configuration for durable and face masks end-uses
Features
• High productivity
• Low energy consumption
• Low investment
• Compact configuration
• User-friendly
Features
• Customizable design
• Fabric evenness
• Fiber saving
• Enhanced MD/CD ratio
Industrial line – hygiene aXcess spunlace line 7.000 tpa
NEXLINE SPUNLACE – AXCESS SOLUTION
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Jetlace series
HYDROENTANGLEMENT TECHONOLOGY
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Jetlace Essentiel Jetlace Avantage Jetlace CottonPad Jetlace 3000
Designed for emerging marketsDedicated for light weight
fabrics
Optimized for cotton pads
production
Customer-specific configuration
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ANDRITZ Injector: 5 granted patents
HYDROENTANGLEMENT TECHONOLOGY
neXimaging technology, a very powerful solution to produce either 3D patterns or holes:
Unlimited number of possible patterns
Any 3D shape and texture
Any fibers either natural artificial or synthetic
Start to think what could be next…
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HYDROENTANGLEMENT TECHONOLOGY
Embossing solution - Only for Jetlace by ANDRITZ Perfojet
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Embossing solution - Only for Jetlace by ANDRITZ Perfojet
HYDROENTANGLEMENT TECHONOLOGY
01 ANDRITZ NONWOVEN
CHAPTER OVERVIEW
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02 NEEDLEPUNCH
03 SPUNLACE
04 AIR-THROUGH-BONDING
05 SPUNLAID & TEXTILE CALENDER
06 WETLAID
07 CONVERTING
08 INNOVATIONS
ABOUT ATB PRODUCTS IN HYGIENE
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Main end uses of ATB products in hygiene
ABOUT ATB PRODUCTS IN HYGIENE
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Baby diapers and Adult Incontinence FemCare and light incontinence products
Topsheet
ADL
Topsheet
Backsheet
ADL
Topsheet
Backsheet
ADL functional tasks
ABOUT ATB PRODUCTS IN HYGIENE
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Acquisition Distribution
Typical fibre blends for topsheets, ADL and backsheets
ABOUT ATB PRODUCTS IN HYGIENE
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Topsheet
20 to 30 gsm
• PP/PE
• PET/PE
• 1,3 dtex to 3,3 dtex
• 100 % bico usually
• New blends developing with
bico and trilobal PP
ADL
30 to 80 gsm
• PET/CoPET pure or in blend
with PET
• PP/PE pure or in blend with PP
• Typical blends: 70/30 and 60/40
• 1,3 dtex to 6,6 dtex
Backsheet
20 to 30 gsm
• PP/PE
• PET/PE
• 1,3 dtex to 3,3 dtex
• 100% bico usually
• New blends developing with
bico and trilobal PP
Technology depending on region
ABOUT ATB PRODUCTS IN HYGIENE
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European production of Air-Through-Bonded nonwoven materials
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MARKETS AND TRENDS
Source: EDANA
+ 23,1%+ 13,1%+ 11,8%
[in 1,000 tons
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WEB BONDING TECHNOLOGIESATB process - Thermoplastic bonding fibres after heat treatment - FiberVisions
Technical Centre – Lille / two hours from CDG Airport
CETI
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Dedicated to innovative products
CETI – LILLE / FRANCE
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Customer CETI
Location France
Machine Pilot line
Installation date 2012
Market R&D for technical products
Options for ATB trials
POSSIBILITIES AT CETI TECHNICAL CENTER
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ANDRITZ flat ATB oven – 200 m/min max
POSSIBILITIES AT CETI TECHNICAL CENTER
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ANDRITZ flat ATB oven – 600 mm working width – 200 m/min max
POSSIBILITIES AT CETI TECHNICAL CENTER
Lighthouse project 2018
MARKET REPORT PRODUCT ATB
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EARNTZ, Shanghai, China
Two lines
First OB and one Vario card 3750 – 2doffers delivered by AWN for ATB
Oven and finishing
Operation since 12 months
Scope
Top sheet and Back sheet
To be connected as a DUAL line end 2019
Line operating at 120 MMN
Placeholder for pictures
Placeholder for pictures
Opening & Blending in the industry
AXCESS WEB FORMING TECHNOLOGIES
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The opportunity to run both directions with CA Vario
One line, one production team Double top sheet capacity
Top-sheet & A.D.L Hygiene components
THERMOBONDING LINES
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01 ANDRITZ NONWOVEN
CHAPTER OVERVIEW
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02 NEEDLEPUNCH
03 SPUNLACE
04 AIR-THROUGH-BONDING
05 SPUNLAID & TEXTILE CALENDER
06 WETLAID
07 CONVERTING
08 INNOVATIONS
SPUNBOND MARKET - CHALLENGES
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Significant challenges for the spunbond nonwoven industry
Challenges
• Overcapacity in each of the major regions
• INCO products growing slowly and don’t fully offset
lower diaper volumes
• Competing technologies: ATB and Spunlace
• Strong buyer’s market due overcapacities and falling
demand (Ebitda down to 12-15%)
• Tailored executions vs. leveraging a globally standard
product
• Political pressure on plastic waste side
MARKET TRENDS FOR HYGIENE
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Market needs
• Wearability/Fit
• Thinness/Weight
• Softness
• Eco-Friendliness
Market trends
• Pull up baby and adult
• Disposable pull-on underwear
• Industry 4.0 technology requirements
• Zero wastes production process
Trends for absorbent hygiene products
MARKET TRENDS FOR HYGIENE
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Trends for diaper applications
Market needs
• Ultra-light nonwoven fabrics
• Softness
• Bulkiness
• Capacity
• Free of potentially harmful substances
Market potential
• Spunjet Soft/Bond
• Engraving design for softening
• 3D patterns for differentiation
Trends in calender embossing design
MARKET TRENDS FOR HYGIENE
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• NTS technology (Nano-To-Surface) for
dramatically reduced fiber
contamination & roller cleaning
• Softer and bulkier final products by
• reduction of bonding area
• more round geometry of pins
• new embossing designs
• 3D structuring methods
Trends in calender embossing design
MARKET TRENDS FOR HYGIENE
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Intensive R&D support by ANDRITZ to customers with most
modern technologies for measurements, simulation and evaluation
of fibers, surfaces, structures, areas, volume etc.
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Innovative solutions in Spunlaid for new fabrics characteristics: Spunjet
SOLUTIONS FOR HYGIENE MARKET
Line characteristics
• Patented configuration
• Very high speed: up to 1,000 m/min
• Ultralight fabrics: from 10 gsm
• End-uses: Baby diapers, Feminine
hygiene, Adult incontinence
Spunjet equipment
• Treatment of spunlaid or spunbond
with in-line hydroentanglement
• New generation of spunlaid fabrics
- spunlaid strength and spunlace
softness
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Different Spunjet technologies
SOLUTIONS FOR HYGIENE MARKET
SpunjetBond
Process: In-line hydroentanglement
of spunlaid filaments
Characteristics
• Working width: up to 5,800 mm
(larger widths on request)
• Speed: up to 300 m/min
• Fabric weight: 25 to 250 gsm
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Different Spunjet technologies
SOLUTIONS FOR HYGIENE MARKET
High
pressure
water jets
Softend Spunbond:
SpunjetSoft
Spunbond
SpunjetSoft
Process: Jet finishing of spunbond
web for extra softness and high loft
Characteristics
• Working width: up to 5,800 mm
(larger widths on request)
• Speed: up to 1,000 m/min
• Fabric weight: 10 to 150 gsm
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Impact of SpunjetSoft on the bulkiness
SOLUTIONS FOR HYGIENE MARKET
Conventional Spunbond
After SpunjetSoft process
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From bonding to finishing in Spunlaid: neXline finish
SOLUTIONS FOR HYGIENE MARKET
Webfoming Thermobonding SpunjetSoftLow add-on,
dosingDrying
Process
control
Winding/
slitting
Supplied by ANDRITZ
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The state-of-the art of calender for high speed Spunlaid lines : neXcal twin pro
NEW DEVELOPMENT IN NONWOVEN CALENDERING
The neXcal twin pro is designed to increased needs of the market
Features
• Production speed up to 1,300 m/min with three different roll widths
• Clean Machine Concept (CMC) to prevent contamination of the
fabric and reduce manual cleaning hours
• Calender equipped with additional sensors to reduce downtimes
New drive concept for the Hot S-Roll and cooling rolls: Direct driven
to withstand the increased speed
TEXTILE CALENDER
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The cooperation and reason why
• We and Mr. Rolf Ramisch have signed an exclusive
cooperation agreement beginning of 2017
• Rolf Ramisch has more than 45 years of experience in the
textile business, with excellent expertise in deflection-
controlled roll technology – he works as an consultant for us
• Ramisch Guaneri has been market – and technology leader in
the field of piston controlled rolls
• Ramisch owns well-known brands like ramisch, Racolan,
Raconip, and Racoflex
• “Ramisch” is also a synonym for textile calender in the market
Cooperation with Mr. Ramisch
TEXTILE CALENDER
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Goals of this agreement and strategy
• Further strengthen ANDRITZ Küsters’ market position in the
textile calender business to become market leader
• Develop a premium brand by integrating the well-known
brands ramisch, Racolan, Raconip, and Racoflex
• Weaken the competitor Guarneri Technology
• Avoid new players in the market
Cooperation with Mr. Ramisch
• In a cutting-edge textile production plant
versatility and operator-friendly handling
along with excellent product quality and
process stability is necessary
• This top-notch textile calender sets you
apart in the race for smart production and
excellent product quality
• Highest flexibility is achieved with the
proven Raconip roll technology, providing
unrestricted profiling over the entire fabric
width by hydrostatic pistons.
teXal Raconip TT – the revolution in technical textiles
NEW DEVELOPEMENT IN TEXTILE CALENDERING
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Benefits
• Constant, stable and repeatable
production conditions and product quality
• Infinitely adjustable line force – ultimate
profiling
• Operator-friendly handling of machinery
during assembly and production
• Improved and transparent production
process
• All data at a glance with big data
management
NEW DEVELOPEMENT IN TEXTILE CALENDERING
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• Infinitely adjustable line force
of 30 – 400 N/mm
• Standard roll surface width: up to 3,600
mm (larger width possible for special
applications)
• Adjustable pressing width to suit change
in web width
• New C-frame with optimized web infeed
• Innovative Raconip deflection controlled
roll with new Racoflex plus sleeve
technology
• Contactless temperature measurement
of steel roll
Features
NEW DEVELOPEMENT IN TEXTILE CALENDERING
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01 ANDRITZ NONWOVEN
CHAPTER OVERVIEW
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02 NEEDLEPUNCH
03 SPUNLACE
04 AIR-THROUGH-BONDING
05 SPUNLAID & TEXTILE CALENDER
06 WETLAID
07 CONVERTING
08 INNOVATIONS
MARKET INFORMATION
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Markets and applications
Key applications of wetlaid
• Construction materials make the
largest part of wetlaid production.
It includes glass mats and
insulation in particular.
• Filtration is the second largest
category with ca. 20% share
followed by wipes (16%) and
wall-cover/furniture/bed (12%)
• Top four segments account for
nearly 80% of total wetlaid
production
28
2116
12
8
15
Source: Interviews
Construction / civil engineering
Filtration (liquid, air)Wipes
Medical / healthcare
Other, incl. packaging
Wall cover, furniture / bedding
Total=100%
MARKET INFORMATION
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Market drivers
• Plastic ban – increasing awareness of “bio” – legal regulations
• Lower basis weights for wipes, but maintaining bulkiness
• Growing markets and overcapacities
• In the GF segments needs for investments
Market potential
• Wipes: Production lines for bio-materials
• Glass fiber: Many old production lines and increasing demand require investments
• Other applications: Potential in niche markets (e.g. battery separators)
Market drivers, trends, opportunities
Main segments: consumer and industrial wipes
WETLACE™ FOR WIPES
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0
100.000
200.000
300.000
400.000
500.000
600.000
700.000
800.000
Baby Wipes PersonalCare
Home Care IndustrialWipe
FlushableWipes
ton
s
2017
2022
Consumer Wipes (CAGR: 6,8%)
2017: 815.000 tons
2022: 1.100.000 tons
Industrial Wipes (CAGR: 7,2%)
2017: 325.000 tons
2022: 460.000 tons
• Pulp fastest growing raw material
for wipes
• Expected growth rate for
flushable wipes 12-14% p.a.
Source: Smithers Pira
81
WETLACE™ FOR WIPES
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Basic layout plus unwinder
Flushable wipes
80% Pulp
20% Viscose
Baby wipes
50% Pulp
50% (Spl.) Viscose
Premium Tissue
40% Pulp Hardwood
40% Pulp Softwood
20% Viscose
Industrial wipe
65% Pulp
35% Spunbond
Disinfecting wipe
Pulp
Spunbond
Hybrid line layout
WETLACE™ FOR WIPES
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Further upgrade option: Unwinder for composite, SPL carrier plus pulp, SB carrier plus pulp
Basic Equipment plus Opening / Blending and Card
83
O/B
neXline wetlaceTM
WETLACETM FOR WIPES
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Stock preparation and headbox Hydroentanglement Dryer Winder
Parameters
Material: pulp / viscose / others
End uses: wipes
Fabric weight: 40 - 80 g/m²
Product width: 3.400 mm
Production speed: up to 250 m/min
Capacity: up to 15.000 t/p.a.
Benefits
Manufacturing of flushable and bio degradable
products
Manufacturing of composites
Low wood pulp raw material costs
Even and homogeneous fiber distribution, high
porosity
84
• Nature is threatened by synthetics and plastics
• Incorrect handling of products by end-user
• Wrong and misleading labelling
• Blocking of sewage systems
• „Use & throw away“ attitude
By 2023, only 1.9% of all raw materials used in
flushable wipes will be non-biodegradable
PRODUCT GROUP WETLAID
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Challenges & Answers
• WETLACETM supports proactively reduction of environmental
pollution
• Flushable wipes produced by WETLACETM technology are
flushable and dispersible according to regulations
• WETLACETM wipes are 100% biodegradable
• Mechanical bonding without chemicals
• Legal requirements in many countries are increasingly moving
in the direction of environmentally friendly products
• Investment in WETLACETM is an investment for the future and
for a cleaner world
Conclusion
WETLACETM FOR WIPES
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Growing wipes market
High production flexibility
Dispersible & biodegradable products
WetlaceTM is more than
flushable wipes!
86
Excursion glass fiber – production line
GLASSFIBER MATERIALS
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Specialty lines will produce various products in relative small
volumes
• Typical run time of a product between 2 hours – 2 days
• Production speed between 50 and 250 m/min
• Line width 1,5 – 4,2 m
• Wet Used Chopped Strands (WUCS) glass with various binders
as Starch, Urea-Formaldehyde (UF) resin, Acrylic Polymer,
Polyvinyl Alcohol (PVA)
• Base veil is sometimes in- or off-line coated or impregnated
Applications:
• Ceiling tiles (facers)
• Glass reinforced polymer surfacing (base for panels or pipes)
• Insulation (glass wool facer)
• Walls (printed or unprinted, substitute for wall papers)
• Geotextile (sometimes mixed with polymer fibers).
• Gypsum (facer, substitute for paper)
• PolyIso (facer for foam board)
• Filters
Bituminous roofing materials (60 – 100 g/m²)
GLASSFIBER MATERIALS
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Product composition
Wetlaid process stock
WUCS85%
Binder application
UF Resin15%
Coating or impregnation 0%
Battery separator (30 – 50 g/m²)
GLASSFIBER MATERIALS
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Product composition
Wetlaid process stock
WUCS73%
Binder application
Acrylic Polymer17%
Coating or impregnation 0%
Carpet tile reinforcement (40 – 70 g/m²)
GLASSFIBER MATERIALS
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Product composition
Wetlaid process stock
WUCS80%
Binder application
Malto dextrin and
dispersant polymer
20%
Coating or impregnation 0%
Cushion vinyl flooring reinforcement (25 – 40 g/m²)
GLASSFIBER MATERIALS
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Product composition
Wetlaid process stock
WUCS, PVA fibers85%
Binder application 0%
Coating or impregnation
PVA15%
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GLASSFIBER MATERIALS
92
High dilution
• Due to the low density of the suspension each individual fiber can move almost unhindered in the flowing liquid before settling onto the other fibers on the wire
Homogeneity
• This leads to the formation of a homogeneous product with controlled fiber formation and porosity
Wet Forming - control of fiber formation and porosity
neXformer aXcess
THE AXCESS APPROACH
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• Modular and compact design with maximum versatility
• Line width: up to 1,500 mm
• Line speed: up to 120 m/min
• Basis weight: 45-120 gsm
• Open headbox with gravity dewatering and manifold distribution
• Low- to medium-capacity production
• One-layer concept
• Size adjusted to container transport
• Fast installation time due to pre-assembly
• Lower market entry barrier
neXformer aXcess - Facts and figures
THE AXCESS APPROACH
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01 ANDRITZ NONWOVEN
CHAPTER OVERVIEW
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02 NEEDLEPUNCH
03 SPUNLACE
04 AIR-THROUGH-BONDING
05 SPUNLAID & TEXTILE CALENDER
06 WETLAID
07 CONVERTING
08 INNOVATIONS
Customers worldwide and current agencies
ANDRITZ DIATEC
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Current agencies:
Turkey: TSH
South Corea: CS
BABY DIAPER LINE
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Cellulose
defbration &
SAP application
Filter
Parameters
Linear speed: Up to 450 m/min
Production speed: Up to 1000 pcs/min
Uptime efficiency: 85%
Waste levels: 1 to 3%
Product dimension: W: 250 to 400 mm
L: 360 to 600 mm
Machine dimension: 25.500 x 9.700 x 6.200 mm (LxWxH)
Front ears
moduleDrum forming
module
Back ears
moduleTS construction
module
Final
cutStacking and packaging
BABY PULL-UP LINE
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Final cut
unit
Stacking and packaging
Parameters
Linear speed: Up to 300 m/min
Production speed: Up to 600 pcs/min
Uptime efficiency: 85%
Waste levels: 1 to 3%
Product dimension: Maximum width: 390 mm
Maximum length: 275 mm
Machine dimension: 30.000 x 11.000 x 6.200 mm(LxWxH)
Waistband
construction
Insert
moduleForming moduleCellulose
defibration + SAPFilter
ADULT PULL-ON LINE
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Parameters
Linear speed: Up to 300 m/min
Production speed: Up to 300 pcs/min
Uptime efficiency: 85%
Waste levels: 1 to 3%
Product dimension: W: 400 to 850 mm
L: 400 to 1050 mm
Machine dimension: 25.000 x 12.500 x 5.300 mm(LxWxH)
Preliminary layout – Machine under development
Added-value solutions for the converting market
OUR UNIQUE SELLING POINTS
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Full range of innovations
Flexibility of design and solutions
ANDRITZ consolidated
reputation
Easy to handle and performingmachines
FOOD PAD LINE
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Forming module
Parameters
Linear speed: Up to 150 m/min
Production speed: Up to 1200 pcs/min for each lane
Uptime efficiency: > 95%
Waste levels: < 1%
Product dimension: W: 50 to 300 mm; L: 75 to 700 mm
with single or double lanes (different
sizes upon request)
Machine dimension: 24.500 x 7.500 x 3.000 mm(LxWxH)
Cellulose unwinding Rewinding unitPress station Cut unit Reject systemMill
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LAMINATING LINE
Features:
Unwinders with manual or automatic splicing
units
Different sealing technologies, ultrasonic,
thermobonding or hot melt
Flexoprinting unit
Parameters
Linear speed: Up to 500 m/min
Max raw material width: Up to 3200 mm
SURGICAL DRAPES LINE
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Longitudinal
folding unit
Parameters
Linear speed: Up to 100 m/min
N° of raw material: Up to 7 (more on request)
Max raw material dimensions: W: 2400 mm, L: 4000mm
Max and min finished product dim.: 400 x 400 mm, 2400 x 400mm
Max and min. folded product dim.: 60 x 300 mm, 300 x 300 mm
(different upon request)
Features:
Inline lamination or pre-glued raw
materials
Robotized cutting units
Stacking units or roll-to-roll finished
product collection
Packaging by plastic bags or carton boxes
Unwinding unit Pressing
& final cut
Cross folding units Stacking
unit
Cutting unit
WINDING ROBOTIZED CELL SPOOLING
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Parameters
Linear speed winding spooling: Up to 400 m/min
Max raw material dimensions: W: 2400 mm, L: 4000mm
Max and min finished product dim.: 400 x 400 mm, 2400 x 400mm
Max and min. folded product dim.: 60 x 300 mm, 300 x 300 mm
(different upon request)
Features:
Winding technology up to 400 m/min
Robotized cell with palletizer
Multiple spooling unit connected to the line
Engineering made by ANDRITZ DIATEC
Full speed auto splice for winding
Winding robotized cell with palletizer Robotized cell
01 ANDRITZ NONWOVEN
CHAPTER OVERVIEW
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02 NEEDLEPUNCH
03 SPUNLACE
04 AIR-THROUGH-BONDING
05 SPUNLAID & TEXTILE CALENDER
06 WETLAID
07 CONVERTING
08 INNOVATIONS
WHAT IS INNOVATION?
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The innovation pipeline
KNW INNOVATION PROCESS
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IDEAS
GENER.
DEVELOPMENT PROJECT
(Study, realization, tests)
PRODUCT
LAUNCHCONCEPTS
EXPLORATION
FEASIBILITY
STUDY
INP
UT
S
G.1 G.2 G.3 G.4
MARKET
TEST
G.5
Ideas Categories:
• KNW Technology
• KNW Sales
• KNW Service
• KNW Operation
• KNW Others
KNW INNOVATION PROCESS
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Ideas and proposals categories / evaluation teams
Evaluation Teams
INP
UT
S
PLEASE PARTICIPATE AND CONTRIBUTE TO OUR
INNOVATION PROCESS!
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LATEST INNOVATIONS
AIR THROUGH BONDING AT CETI
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New Pilot Line for Air-Through-Bonding
New complete solutions for ATB nonwovens production
LATEST INNOVATIONS
AIR THROUGH BONDING AT CETI
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Crosslapped webs have always a non-uniform weight profile
LATEST INNOVATIONS
PRODYN PROWID PRO…
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• (1) Caused by the card
• (2) Caused by the overfeeding at the web edges during carriage reversal
• (3) Shrinkage of the nonwoven during bonding e.g. needle punching
LATEST INNOVATIONS
PRODYN PROWID PRO…
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Generating fabric evenness
• ProDyn: the state of the art in generating fabric
eveness
• ProWid: Upgrade existing lines
• ProDyn system: CV improved by 3 X
• ProWid: CV improved by 2 X
• Pro…: CV improved by ..X and
production by ..%
ProDyn
ProWid
Benefits
NW products quality, raw
materials costs savings
• Structural drum construction > 95% open area vs. Maximum
50% for a perforated plate
uniform drying, higher convection evaporation rate, energy
savings
softness and bulkiness for wipes
• Side position for double rope
• Straightness on 6 m width, Dia. 2,1 m < 2 mm
Innovation in drum construction and air flow management
LATEST INNOVATIONS
U-DRUM FOR ANDRITZ DRYERS
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Perforated plate U-drum
Benefits
Performances and NW products
quality
New complete range of dryers
LATEST INNOVATIONS
U-DRUM FOR ANDRITZ DRYERS
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• SPUNLACE
• WETLAID
• WETLACE
• AIRLACE
• SPUNBOND
• SPUNJET
• AIR THROUGH BONDING
• Energy recovery from final dewatering and drying
• 20% drying energy saving
• 25 industrial references
• High value for service retrofits
Innovation in water extraction before drying
LATEST INNOVATIONS
NEXECODRY SCORPIO
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Benefits
Energy savings and NW products
quality
The new generation of textile calenders
• Constant, stable and repeatable
production conditions and product quality
• Infinitely adjustable line force – ultimate
profiling
• Operator-friendly handling of machinery
during assembly and production
• Improved and transparent production
process
• All data at a glance with big data
management
LATEST INNOVATIONS
TEXCAL RACONIP TT
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Benefits
Fabrics quality, higher throughput,
flexibility, operator friendly
The new generation of nonwoven calenders
• Speeds of up to 1,300 m/min
• Line force adjustable (during production)
up to 130 N/mm over the entire web
width
• Standard roll widths:
3,800mm; 5,000mm; 6,000mm
• Roll surface temperature: 180°C
• Roll diameter:
Engraved roll 640mm
Hot-S-roll 580mm
LATEST INNOVATIONS
NEXCAL TWIN PRO
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Benefits
Highest uptimes, energy-efficient,
continuous bonding and roll
replacement concept, operator
friendly
DIGITALIZATION is key for our future success
BROAD PRODUCT OFFERINGS IN DIGITALIZATION
119
Annual report 2017 Metris as the “brand” Benefits for the customer
• Enhancing plant efficiency and
profitability
• Optimizing the use of resources
• Constant and highest product
quality
• Avoiding production downtime
• Maximum user-friendliness, e.g.
easy control via smartphone/tablet
PC/smart glasses
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This presentation contains valuable, proprietary property belonging to ANDRITZ AG or its affiliates (“the ANDRITZ GROUP”), and no licenses
or other intellectual property rights are granted herein, nor shall the contents of this presentation form part of any sales contracts which may be
concluded between the ANDRITZ GROUP companies and purchasers of any equipment and/or systems referenced herein. Please be aware
that the ANDRITZ GROUP actively and aggressively enforces its intellectual property rights to the fullest extent of applicable law. Any
information contained herein (other than publically available information) shall not be disclosed or reproduced, in whole or in part, electronically
or in hard copy, to third parties. No information contained herein shall be used in any way either commercially or for any purpose other than
internal viewing, reading, or evaluation of its contents by recipient and the ANDRITZ GROUP disclaims all liability arising from recipient’s use or
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