GET INTO BABY CARE WITH THE RIGHT CONVERTING TECHNOLOGY - NONWOVEN FOR YEARS TO COME
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CONTENTS Company profile 4 Build your future in hygiene converting 6 Dedicated service 8 Full range in nonwovens production 10 TE CH N O LO GY SO LUTI O N PROV I D E R Develop your hygiene products with our experts 11 As the market becomes more and more demanding, ANDRITZ Diatec Innovative solutions for hygiene products 12 offers the latest technology solu- tions with a wide range of custom- ization options to help customers Foresee digitally with Metris 14 find the right machine configuration to save time and money. Baby diaper converting machines 16 Baby pants converting machines 20 F U LL M ACH I N E P O R TFO LI O R A N G E ANDRITZ Diatec is able to supply turnkey converting machines for the production of a comprehensive range of sanitary products: • Baby diapers • Baby pants • Adult diapers • Adult pants • Underpads • Light Inco products • Shaped pads • Sanitary napkins • Panty shields • Food pads 2 • Lamination
A reliable partner ANDRITZ Diatec designs and manufactures a wide range of machines K E Y TO S U CCE S S D I S TI N C TIV E TR A IT and technology solutions for the production of baby diapers, baby The key factor in our success is the Important added-value from YO U R B E N E F ITS relationship that we create and ANDRITZ Diatec is the capability to pants, adult incontinence products, sanitary napkins, panty shields maintain with our customers from respond quickly and promptly to • Customer care and underpads. Always at the forefront of innovation, ANDRITZ Diatec the design of the machine to the the changing needs of the • Customer satisfaction has broadened its production horizons by delivering new lines for food “nurturing” phase during machine present-day market, allowing • Spare parts pads, lamination, medical products, disposable gloves, headrests, installation intended to offer customers to seize opportunities • After-sales assistance specialized support for a smooth and translate them into concrete • ANDRITZ guarantee surgical drapes and spool winding equipment. ANDRITZ Diatec is now start-up in the customer’s plant. projects. We also provide full part of the ANDRITZ Nonwoven business. project management, from planning control to start-up of the line in order to secure a prompt return of investment. 4 5
Build your future in YO U R B E N E F ITS hygiene converting • Easy machine management • Fast size change • Limited number of operators required In order to cover all of your final product and production requirements, • Linear production process our machine portfolio ranges from market entry to high capacities, • Optimized raw material consumption precisely designed to meet your needs. The machines are built with • Reduced energy a modular frame that allows customized configuration. Moreover, consumption the compact layout ensures a smooth start-up and easy machine maintenance. Machines and retrofits can be installed easily according to customers’ requirements. The full servo-technology simplifies ordinary operations and adaptation of the raw materials to the environmental conditions. B E N E F IT F RO M A TR U S T WO R TH Y PA R TN E R ANDRITZ Diatec machines are characterized by the use of high-precision mechanical tooling and high levels of automation. The bulky structure of the core formation provides stability and ensures minimized vibrations, thus making the production environment more pleasant. The production process is easy to monitor and adjust during operations. Our machines achieve high efficiency in terms of OEE and low waste rates. The use of top- notch components ensures long- term reliability of the machines and consistent savings in terms of spare parts and technical intervention. CO N S TR U C TI O N PH I LOSO PH Y also ensure that we respect the easily set, stored in the memory, All our machines are designed, project timing in order to meet recalled and changed according manufactured and tested entirely customer’s requirements. We are to the needs of the customer. All in Italy, using EU or US components, able to offer a full-range of operations are carried out with the in compliance with CE regulations. extensions and retrofitting kits to highest efficiency and security Depending on customers’ needs, keep our customers’ machines levels in order to simplify daily ANDRITZ Diatec offers customized state-of-the-art. operations on the machine. A fast solutions according to production and easy size change volumes, product recipes and all M ACH I N E M A N AG E M E NT configuration reduces machine requirements relating to the Our machines are easy to manage. downtime and hence increases customer’s production plant. We All machine parameters can be production output. 6 7
Dedicated service We know how important uptime is for your production efficiency: We do everything to keep interruptions to a minimum. With remote assistance and a highly responsive service team, we can react to your issues in the shortest time possible. FAS T M ACH I N E S TA R T- U P layout, which leaves wide spaces promptly. In this way, operators’ Our machines are thoroughly for movement around the machine. maintenance skills are improved checked before shipment so as to Every process is linear and com- and after-sales costs for interven- speed up the start-up in the plies with the highest safety levels. tions and machine stoppages are customer’s plant and reduce Cost and time savings, efficiency reduced. machine downtime. and durability are guaranteed by the high quality of engineering and A F TE R-SA LE S S E RV I CE S PA R E PA R TS components used. ANDRITZ Diatec shares trust and We guarantee the supply of growth with customers. This value original spare parts with onsite R E M OTE AS S I S TA N CE is mirrored in the wide range of installation, in accordance with the ANDRITZ Diatec is there for you at services that we offer. customer’s timing and efficiency all times. Remote assistance is demands. critical to guarantee that machine performance is kept high. Our M A I NTE N A N CE engineers are always at your Machine maintenance is made disposal by helping you identify easier by the compact machine problems and find remedies YO U R B E N E F ITS • Spare parts installation • Safety inspections • Preventive inspections for routine maintenance • Production supervision • Technical documentation U P G R A D E S A N D R E TRO F ITS Our machines have a long lifecycle. The modular and S E RV I CE S U PP O R T compact frame makes refurbishment operations easier. Throughput can be optimized significantly by • Control equipment and software upgrades means of tailored upgrades, which also enable the • Analysis of existing machines to upgrade and final product structure to be updated in line with optimize production market demands. • Training programs for machine operators 8 9
Full range in nonwovens Develop your hygiene production products with our experts Let our experience drive your innovation: A remarkable impact on Continuous research and development targeting your needs: In an ever nonwovens technologies: Whether hygiene or medical, automotive or more demanding market, get the most out of your investment with the building, household or technical – nonwovens applications are support of our test equipment and highly skilled engineers. You can benefit manifold. Their outstanding properties require excellent engineering in from more than three decades of experience and expertise. an increasingly changing and growing market. You can rely on a competent partner: with a passion for nonwovens technologies and R E S E A RCH A N D D E V E LO PM E NT fields of application like embossing for both flat and Omega ovens with spot-on solutions perfectly suited to your specific needs. Being dedicated to high quality for wipes, calibration for melt- for prototyping the fast growing and innovative production tech- blown material, laminating of trends in hygiene applications. nologies propels us to seek ideal roofing material or filters, thermo- solutions. Let our combined forces bonding, perforating of top- achieve maximum results. sheets, compacting of wetlaid fabrics, comparisons between Highly skilled staff provide unique thermal and ultrasonic laminating, YO U R B E N E F ITS know-how drawn from our installed or textile finishing. base and continuous R&D. • Process expert support WE TL A I D TE CH N I CA L CE NTE R • Equipment containing the S PU N L ACE TE CH N I CA L CE NTE R Our wetlaid pilot line in Krefeld, latest technology Our spunlace pilot line in Germany includes state-of-the-art • Integrated laboratory to R AW M ATE R IA L S N O NWOV E N CO N V E R TI N G R E TA I L Montbonnot, France, includes equipment test nonwoven fabrics FA B R I CATI O N & D I S TR I B UTI O N state-of-the-art equipment to to produce a wide range of wetlaid • Simulation tool produce a wide range of spunlace fabrics for the automotive, aero- Man made fibers, man Processes, lines and Lines and processes for fabrics. During the trials, the pilot space, agriculture, construction, made filaments, components for the converting. line is able to operate at up to medical, wipes and hygiene natural fibers etc. production of roll Applications: hygiene 500 m/min. Tests can be conducted industries, as well as the household suited to your specific goods. These raw and medical dispos- in-line with the TT card or off-line goods sector. Arrangement of the needs materials are used for able products, e.g. with an unwinder. It is also components on a rail system hygiene and medical face masks. equipped with a complete water ensure highest flexibility when applications. filtration system so that trials can be extensions or modifications are conducted with all types of fibers. needed. You can test natural or synthetic fibers, short or long fibers, paper A I R-TH RO U G H - B O N D I N G fibers, and so on. TE CH N I CA L CE NTE R N O NWOV E N S U N LI M ITE D possible end uses bring unique CETI, the European Center for ANDRITZ is a machinery supplier to added-value for the nonwovens S PU N L A I D TE CH N I CA L CE NTE R Innovative Textiles, is a research offer nonwoven processes for roll industry. Hygiene is a part of the Our spunlaid technical center in center for new textile applications goods production and also DNA at ANDRITZ and thanks to the Krefeld, Germany, includes a wide and is located in Lille, France. converting lines. In this way, spunbond, spunjet, air-through range of pilot calenders for ANDRITZ has been supplying the ANDRITZ covers a great part of bonding and spunlace pilot lines, different applications and needs, institute with the latest nonwoven nonwovens value chain. Its all materials used in the converting more than 200 engraved rolls and technologies, including air-through expertise in the treatment of raw lines can be tested and approved shells, various sleeves, measure- bonding. The air-through bonding materials and market know-how of by the market in advance. ment systems and a 3D-microscope. pilot line provides CETI and its It is well-equipped to handle many customers with a R & D platform 10 11
Innovative solutions CO M PLE TE S PU N B O N D F I N I S H I N G LI N E S ANDRITZ spunbond solutions: You benefit from the highest capability, reproducibility, reliability, and Benefit from reliable, flexible and proven technologies based on more than 750 innovations with worldwide patents along with innovative processes and engi- for hygiene products efficiency. Find the best solution, perfectly suited to your needs, for thermobonding and finishing process- es like embossing, compacting, lamination, or neering depth. Depending on your final product and its parameters, perforation. Besides calendering technologies, you’ll such as strength, softness, or air permeability, our ANDRITZ offers you customized solutions: For the production find solutions for your complete finishing process with nonwoven calender portfolio ranges from low and of hygiene products, we can deliver tailor-made processes. neXline finish. This encompasses calender, spunjet medium capacities (aXcess range) to high capacities technology, finishing solutions, and dryer – turnkey (eXcelle range), precisely designed to meet your Take advantage of the vast expertise that ANDRITZ has to offer in a wide solutions from just one source. needs. range of hygiene nonwovens technologies, such as web forming and finishing (air-through bonding, spunlace, spunlaid, spunjet, wetlace) and PR E C I S E LY WH AT YO U N E E D S PU NJ E T – A B O N D I N G S O LUTI O N FO R E N D LE S S converting (baby diapers, feminine hygiene, adult incontinence). If you need a complete system solution, a single unit, F I L A M E NTS a rebuild, an automation system, or comprehensive The patented nonwovens process called Spunjet is the life-cycle services: We can meet your demands and in-line hydroentanglement of continuous filaments, deliver precise technologies, from bonding to finish- creating a new generation of spunlaid nonwovens. CO M PLE TE A I R-TH RO U G H CO M PLE TE S PU N L ACE LI N E S ing, for your product. Spunjet offers you the best properties ever achieved B O N D I N G ( ATB) LI N E S ANDRITZ is an active player in most YO U R B E N E F ITS in 80% of existing and in new nonwovens applications. The ANDRITZ air-through bonding of the world’s spunlace production. TH E E XPE R TS I N CA LE N D E R I N G lines deliver all nonwovens fabric In order to meet the market • ANDRITZ expertise Let your products benefit from over 60 years of By combining two first-class bonding technologies, characteristics for hygiene end demands, ANDRITZ offers you a in hygiene market experience and comprehensive project manage ment. you can benefit from the typical strength of spunlaid uses, such as top-sheets and wide range of complete spunlace • Perfect web uniformity With more than 600 nonwovens calenders in operation as well as the softness of spunlace. The spunjet acquisition distribution layers, lines combining performance, • Versatility of fibers worldwide and installations in all high-end nonwovens process offers you additional softness, bulkiness, and back sheets. The well-known efficiency and profitability. • Technical centers: spun- lines, you are ensured top performance from ANDRITZ. drape, and tensile strength while maintaining the ANDRITZ carding machines are The premium line layout combines lace in Montbonnot, isotropic MD / CD ratios in your fabric properties. the key to success in achieving very high capacity of up to 25,000 France; spunbond/calen- perfect web uniformity and t/a with low energy consumption dering/wetlaid in Krefeld, Through-air dryer comfort. With the ANDRITZ air- and is able to produce all types of Germany and air-through through bonding line, you can spunlace roll goods. bonding at CETI, France Scanning gauge Slitter + rewinder* benefit from high production Spunlace fabrics are made from all • Expertise in testing capacity and high-performance types of raw materials – natural or and converting fabrics from 16 to 80 gsm made synthetic. Softness, drape, com- from bi-component fibers pro- fort, comfortability, high strength, duced at high speeds of up to and the fact that they contain no Spunlaid* Calender Kiss-roll Winder* 250 m/min. chemicals are the major charac- applicator teristics that make spunlace ANDRITZ spunlaid finishing line for hygiene and medical end-uses, 8-80 gsm nonwovens unique. Pulling Scanning Card Card Flat oven unit gauge Winder Through-air dryer Hydroentanglement Hydroentanglement Scanning gauge Slitter + rewinder* Opening/ Chute Chute Air Ironing Blending feeder feeder cooling roller ANDRITZ air-through bonding line for hygiene end-uses, 16-80 gsm Hydroentanglement Quality Control Card Card System Spunlaid* Calender Dewatering Kiss-roll Winder* Unwinder applicator ANDRITZ spunjet line for the production of new generation spunlaid nonwovens, 20-80 gsm * Technology provided by cooperation partners Opening/ Chute Chute Through-air dryer Winder Blending feeder feeder ANDRITZ spunlace line for medical and wipes end-uses, 30-100 gsm 12 13
Foresee digitally with Metris Industrial Internet of Things (IoT) Industry 4.0, digitalization - current buzzwords that industries use when seeking to improve their performance and equip themselves for the future of industry. A CO N S TA NTLY G ROWI N G technologies, Smart Service plant is the most recent of our IoT P O R TFO LI O concepts, and Venture activities. developments. With Metris solu- The depth and effectiveness of the The main technological advance- tions, customers foresee digitally Metris portfolio continues to ments integrated into individual due to the continuously improved improve thanks to ongoing R&D, Metris products are derived from portfolio and its performance – collaboration with key customers big data analytics, smart sensor and to ANDRITZ providing tailored and institutions, and venture technologies, and augmented and fully integrated digital solu- activities. Portfolio options all rely reality solutions. The Metris UX tions from a single source. on the three strategic focus areas platform providing full support of the Metris brand: Industrial IoT throughout the entire lifecycle of a Metris - ANDRITZ Digital Solutions • IIoT solutions across business segments • Combined know-how from ten years’ experience with Metris OPP Benefits • Using the latest smart sensor technologies • Big data analysis with tried-and-tested models for deviation analysis • Providing information locally with augmented reality • Extensive solution and process engineering knowledge • Cyber security solution to safeguard data on the network A N D R IT Z D I G ITA L S O LUTI O N S M E TR I S O PP As a technology leader with extensive and long-term One of the flagship capabilities of the Metris assort- experience in supplying industrial measurement, ment is its ability to optimize industrial processes with control, and optimization solutions for various indus- Metris OPP. It has been developed over the past tries, ANDRITZ is combining process and equipment decade within the pulp and paper sector and has expertise with the latest enhancements in the digital recently been introduced to the nonwovens industry. It era. The result of this powerful combination is Metris: combines powerful analytical and data mining a portfolio of ANDRITZ Digital Solutions. software with the knowledge of the world’s top process experts to deliver a smart service initiative for customers. 14 15
Baby diaper converting PRODUCT COMPOSITION machines 13 1. T/T loop 12 2. TXT backsheet 3. Leg elastic 11 10 4. Front ears 9 5. Lower tissue Baby care solutions fitting in with market needs: As a result of its unique 6. Core fluff + SAP 8 7 7. Upper tissue experience in the baby care industry, ANDRITZ Diatec offers turnkey and 8. Acquisition layer 6 comprehensive solutions to cover the needs of all producers around the 9. Hook tape 10. Back ears 5 world with its D-TECH baby diaper machines. Each machine platform 11. Topsheet center 3 can be customized according to customer requirements. Our machine 12. 13. NW leg cuffs Elastic cuffs portfolio is able to cover the whole range of production speeds: low, 2 4 medium and high. Our flexibility in providing the best possible solution makes us the ideal partner for producers all around the world. 1 Open baby diaper Automatic splice for raw materials Zero waste baby diaper PRODUCT FEATURES with shaped back and front ears • Different sizes and customizable shapes • Thin, comfortable, highly elasticized products • Sinusoidal zero waste front ear; back ears available in six different styles (zero or low Baby diaper with rectangular back ears waste, shaped or rectangular, symmetrical or asymmetrical) • Back ears created with an elastic material with side tapes applied inline D-TECH baby diaper line • Back ears folded onto the nonwoven topsheet • Leg cuffs provided as standard and created Low waste baby diaper with shaped back and offline, with glue, ultrasonic or thermosealing front ears • Stacking and packaging phases made easier by longitudinal folding, bifolding system, rotary blades and final press Traditional baby diaper with leg shaping Preparation for folding process Stacker for final product 16 17
MACHINE SPECIFICATIONS Linear speed Up to 450 m/min Production speed Up to 1,000 pcs/min Uptime efficiency 85% Waste 1-3% Product dimensions W: 250-400 mm YO U R B E N E F ITS L: 360-600 mm • State-of-the-art Electric power supply 220/480 Vac, 50/60 Hz technology 3 phases + N + PE (24 Vdc • Fully customized solutions auxiliary) • Process flexibility Consumed/installed 330-600 kW • Fast size change electric power • Full lifecycle service and support Compressed air supply/ 6 bar/2,500 Nl/min • Full project management consumption Overall dimensions (LxWxH) 25,500 x 9,700 x 6,200 mm Third-generation channel technology Total weight 95-105 tons Required crew 2 persons (1 operator + 1 auxiliary) In baby diaper machines, components can be freely combined and configured for the specific product required. Safety standard CE CORE FORMING MODULE • Topsheet (nonwoven and leg OPTIONAL EQUIPMENT • Cellulose pulp stand cuffs) unwinder • Second drum former with pad • S.A.P. dosing system • Cuff elastic unwinder repitch and deposition 90° offline unwinder • Compact disc mill (or hammer • Leg cuff creation system • Core channels mill) with double inlet (thermosealing, glue or • Rotary filter with second stage • Drum former, 3D or flat, ultrasonic) • Additional size change kits continuous or discrete • Front ear application module • Horizontal stacker • Core processor • Back ear application module • Manual exit for stacker • Take-away drum with reduced trim or zero-trim • Single packaging system • Pad wrapping system (single or • Three-roll press/pulling unit • Packaging machine double layer, C-folding or flat) • Cartoning machine • Core cutter FOLDING AND FINAL CUTTING AREA • Soundproof cabin • Longitudinal folder • Quality system LS with line scan PRODUCT ASSEMBLY AREA • End-sealing system (ultrasonic) camera • Backsheet unwinder with online • Final cutting unit • Ultrasonic sealing lamination and registering • Turning device • Wetness indicator control • Final longitudinal folder • Metal detector • Leg elastic unwinder • Reject system • Lotion application system • Acquisition layer unwinder with • Sanyprint kit for flexographic cut and slip unit • Full servo-motion system printing on backsheet • Elastic waistband unwinder with • Web guiding system • Glue vision system disc applicator • Hot melt system • Material handling units • Frontal tape unwinder with inline • Manuals, drawings and software lamination and registering Closure for wrapped core Cut and place for AQL Front ear preparation control 18 19
Baby pants converting PRODUCT COMPOSITION 13 12 machines 1. Disposable tape 2. Lower external NW 11 3. Waist elastic 4. Upper internal NW 9 5. PE backsheet 10 6. Leg elastic Baby care solutions trust a global supplier: With its unique experience 7. Lower tissue 8. Core fluff + SAP 8 6 in the baby care industry, ANDRITZ Diatec is able to offer tailor-made 9. Uppertissue machines and technology solutions for the production of baby pants 10. 11. Acquisition layer Topsheet center 7 5 combining performance, efficiency and profitability. Our baby pants 12. NW leg cuffs 3 13. Elastic cuffs machine portfolio is able to cover the whole range of production speeds: 4 1 low, medium and high. 2 Baby pants Closure system for core wrapping PRODUCT FEATURES D-TECH baby pants • Elastic waistband • Topsheet • Skin care lotion • Absorbent core • Acquisition layer • Elastic for cuffs • Leg elastic • Cloth-like or breathable PE backsheet • Wetness indicator • Disposable tape Slitting for waistband Rotator for final product and operator panel 20 21
MACHINE SPECIFICATIONS Linear speed Up to 320 m/min Production speed Up to 800 pcs/min Uptime efficiency 85% Waste 1-3% Product dimensions Maximum width: 420 mm Maximum length: 275 mm Electric power supply 220/480 Vac, 50/60 Hz YO U R B E N E F ITS 3 phases + N + PE (24 Vdc auxiliary) • Modular and full servo Consumed/installed 400-650 kW technology for easier size electric power change • From concept and engi- Compressed air supply/ 6 bar/4,000 Nl/min neering to start-up and consumption service, our experts are close to you Overall dimensions (LxWxH) 30,000 x 11,000 x 6,200 mm • Fully customized configurations Total weight 100-110 tons • Easy to handle Required crew 2 persons (1 operator • Process and machine + 1 auxiliary) reliability Safety standard CE D-TECH baby pants Final turning unit In baby pants machines, components can be freely combined and configured for the specific product required. CORE FORMING MODULE • Elastic cutter • Final cutting unit • Cellulose pulp stand • Topsheet (nonwoven and leg • Reject system • S.A.P. dosing system cuffs) unwinder • Bi-folding unit • Compact disc mill (or hammer • Cuff elastic unwinders mill) with double inlet • Leg cuff creation system • Full servo-motion system • Drum former, 3D or flat, discrete (thermosealing, glue or • Hot melt system with pad wrapping ultrasonics) • Manuals, drawings and software • Core pressing unit • Insert cutting, rotator and repitch • Core cutter system OPTIONAL EQUIPMENT • Cross-folder • Backsheet registered PRODUCT ASSEMBLY AREA • Disposable tape applicator • Core channels • Backsheet unwinder • Offline unwinder with automatic • Leg cuff thermobonding closure • Acquisition layer with cutting and splice • Wetness indicator slip unit • Lotion application system • Elastic unwinders for waistband FOLDING AND FINAL CUT AREA • Stacker and bagger with tension control • Final press unit • Ultrasonic elastic bonding • Waistband creator system • Ultrasonic side seam 90° insert deposition Single yarn control unwinding system 22 23
GET THE MOST OUT OF YOUR INVESTMENT At ANDRITZ Nonwoven, we know that your business depends on satisfied customers and efficient processes. That’s why we support you in every aspect of your nonwoven production. Take advantage of technology that lets you produce consistent quality for decades to come. Profit from the highly efficient use of energy and raw materials that our production provides. You can rely on our responsive service teams, who will protect your investment and optimize your processes. Experience how innovative approaches and digital services give you more control than ever before. With ANDRITZ, the leading supplier for the nonwovens market, you get the most out of your investment. ITA LY GERMANY U SA ANDRITZ Diatec S.r.l. ANDRITZ Küsters GmbH ANDRITZ Inc. Collecorvino, Italy Krefeld, Germany Spartanburg, USA p: +39 085 82060-1 p: +49 2151 34 0 p: +1 864 587 4848 diatec@andritz.com kuesters@andritz.com nonwoven-americas@andritz.com F R A N CE CH I N A ANDRITZ Asselin-Thibeau SAS ANDRITZ (China) Ltd. Elbeuf, France Wuxi branch office p: +33 2 32 96 42 42 Wuxi, P.R. China asselin-thibeau@andritz.com p: +86 510 8536 1269 nonwoven-china@andritz.com ANDRITZ Perfojet SAS Montbonnot, France I N D IA p: +33 4 76 52 23 11 ANDRITZ Technologies Pvt. Ltd. perfojet@andritz.com Chennai, India p: +91 44 4293 9393 nonwovenservice.india@andritz.com A N D R IT Z .CO M/CO N V E R TI N G - N O NWOV E N S All data, information, statements, photographs, and graphic illustrations in this leaflet are without any obligation and raise no liabilities to or form part of any sales contracts of ANDRITZ AG or any affiliates for equipment and/or systems referred to herein. © ANDRITZ GROUP 2020. All rights reserved. No part of this copyrighted work may be reproduced, modified or distributed in any form or by any means, or stored in any database or retrieval system, without the prior written permission of ANDRITZ AG or its affiliates. Any such unauthorized use for any purpose is a violation of the relevant copyright laws. ANDRITZ AG, Stattegger Strasse 18, 8045 Graz, Austria. KNW.bc.01.eng.09.20
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