innovations beyond hygiene - hofer vliesstofftage · • innovations in meltblown technology •...
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Reifenhäuser Reicofil
Innovations Beyond Hygiene
09.11.2016 Hofer Vliesstofftage
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Agenda
• Spunbond Nonwovens for Technical Application
• Innovations in Meltblown Technology
• R&D Technology Center
09.11.2016 | Hofer Vliesstofftage 2016
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Well known application: Hygiene
REICOFIL® 4 SSMMMS line for hygiene nonwovens (baby diapers, feminine hygiene, pads)
09.11.2016 | Hofer Vliesstofftage 2016
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Agenda
• Spunbond Nonwovens for Technical Application
• Innovations in Meltblown Technology
• R&D Technology Center
09.11.2016 | Hofer Vliesstofftage 2016
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Nonwoven Works for Packaging
Turnkey technology
Eye-catching appearance
Lightweight
Easy handling
Fully recyclable
REICOSTAR Bag
Nonwoven + film
09.11.2016 | Hofer Vliesstofftage 2016
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Reicofil Spunbond Process
Extrusion system with Bico technology
Optimized resin recipe
Highest specific mechanical properties
Closed cooling and stretching system
Best homogeneity of laydown
Best isotropy
Smallest specific energy consumption
Highest line availability in the market
Low specific production cost
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Reicofil BiCo Technology
Possible cross
sections
+many more
09.11.2016 | Hofer Vliesstofftage 2016
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Reicofil BiCo Technology
Cross Section: Core Sheet
Strong Core
+
Ductile Sheet
Combination of high filament strength (core material) and good
bonding behavior (sheet material)
09.11.2016 | Hofer Vliesstofftage 2016
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Optimized Resin Recipe using BiCo for PP
Significantly increased tensile strength + ~15 %
PP BiCo
PP Reference
09.11.2016 | Hofer Vliesstofftage 2016
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Typical Tensile Characteristics vs. Fabric Weight
Anisotropy: Actual tensile strengths in machine and cross direction
MD/CD ≠ 1
Machine
direction
Cross
direction
09.11.2016 | Hofer Vliesstofftage 2016
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Improved Diffusor Geometry: Best Isotropy
MD = CD for fabric weight >40g/m² achieved!
Significantly improved tensile strength in CD
Machine direction
Cross direction
Optimized Diffusor
MD = CD
09.11.2016 | Hofer Vliesstofftage 2016
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BiCo Spunbond: Optimal Resin Choice
Different fabric weights require different resins for optimal tensile
strength
PET BiCo
PP Mono
PP BiCo
PET BiCo
PP
PP BiCo
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Highest Resin Flexibility in one Line
Reifenhäuser Reitruder:
Twin screw extrusion
Direct processing of post-
consumer PET bottle flakes
No energy and time
consuming predrying
necessary
Reicofil lines suitable for
PP, PET and PET flakes
available
09.11.2016 | Hofer Vliesstofftage 2016
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RF-COMPACT: Reduced Invest, moderate Output
Serve small volume markets with local
production at moderate capacity
Reicofil’s standard system reliability
(above 7200 h/year) with performance
guarantees
Specifications:
– No basement necessary
– State of the art RF4 Bico technology
– Output: 7.5 kt/year
09.11.2016 | Hofer Vliesstofftage 2016
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RF-Compact Typical RF4
Annual output [kt /a]
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Best solution for technical nonwovens…
Highest Resin
Flexibility in
one Line
Most advanced
laydown system
Tailored Line
Sizes Available BiCo Technology
REICOFIL:
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Agenda
• Spunbond Nonwovens for Technical Application
• Innovations in Meltblown Technology
• R&D Technology Center
09.11.2016 | Hofer Vliesstofftage 2016
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Reicofil Stand-alone Meltblown Technology
Reicofil® Single Meltblown line with calender, electrostatic charging and winder
09.11.2016 | Hofer Vliesstofftage 2016
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Reicofil Stand-alone Meltblown Technology
Integration Concept: Two in One
09.11.2016 | Hofer Vliesstofftage 2016
Singlerow Multirow
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Throughput
[kg/h/m] 10 – 100 40 – 150 150 - 300
Mean Fiber
diameter [µm] <0.5 - 5 3 – 15 10 – 30
Fiber diameter
distribution Narrow Broad Narrow
Filament strength Minor Medium High
Reicofil Toolbox
Characteristics of Reicofil® Technologies
Singlerow Multirow Spunbond
09.11.2016 | Hofer Vliesstofftage 2016
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Reicofil Filter Development
Filament diameter vs. retention
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100
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
90,0
100,0
0,0 5,0 10,0 15,0 20,0 25,0
Reten
tion
[%
] - N
aC
l 0
,3µ
m - 1
4,1
cm
/s
Fre
qu
en
cy D
istr
ibu
tio
n [
%]
Fiberdiameter [µm]
09.11.2016 | Hofer Vliesstofftage 2016
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10
20
30
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50
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80
90
100
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
90,0
100,0
0,0 5,0 10,0 15,0 20,0 25,0
Reten
tion
[%
] -N
aC
l0
,3µ
m -1
4,1
cm
/s
Fre
qu
en
cy D
istr
ibu
tio
n [
%]
Fiberdiameter [µm]
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Quelle: STFI – REM Aufnahmen Mik160_15//P20152636
09.11.2016 | Hofer Vliesstofftage 2016
0
5
10
15
20
25
30
35
40
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5
Freq
uen
cy [%
]
Fiberdiameter [µm]
Meltblown SR
35 hpi
0
5
10
15
20
25
30
35
40
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5
Freq
uen
cy [%
]
Fiberdiameter [µm]
Meltblown SR
50 hpi
Meltblown SR
35 hpi
0
5
10
15
20
25
30
35
40
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5
Freq
uen
cy [%
]
Fiberdiameter [µm]
Meltblown SR
50+X hpi
Meltblown SR
50 hpi
Meltblown SR
35 hpi
0
5
10
15
20
25
30
35
40
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5
Freq
uen
cy [%
]
Fiberdiameter [µm]
Meltblown SR
50+X hpi
Meltblown SR
50 hpi
Meltblown SR
35 hpi
Reicofil Filter Development
Feasible filament diameter MB SR
50+X hpi: PP only
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Agenda
• Spunbond Nonwovens for Technical Application
• Innovations in Meltblown Technology
• R&D Technology Center
09.11.2016 | Hofer Vliesstofftage 2016
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Reicofil Nonwovens Technology Center
Exploring present – shaping future
09.11.2016 | Hofer Vliesstofftage 2016
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Lab line at
Biax Fiberfilm
Lab line at NCRC
Lab line at STFI
3 lab lines at Reicofil
09.11.2016 | Hofer Vliesstofftage 2016