Staple FORCE S 1000 facilitates on-demand production and opens up new market potential
Oerlikon Neumag makes low-volume production of manmade fibers for nonwovens economic
The global market for manmade fibers, such as polyester, polypropylene and bicomponents, used in the production of nonwovens grows around 5 % each year. In 2015, total demand is expected to amount to 3.2 million tons for carded nonwovens alone. They are primarily used in geotextiles for civil engineering, in filtration materials, for application in the automotive industry in insulation and interiors, and for numerous special applications. The market requires both smaller production quantities that can be delivered on short notice and cost-effective manufacturing processes. Up until now, these requirements were incompatible. While demand requires average daily production of 15 tons to 20 tons of fibers per production line, today's production lines are designed to produce significantly larger quantities, which makes them less flexible. "With the Staple FORCE S 1000, we can close the gap between demand, which is focused more on daily production, and cost-efficient production. At the same time, by integrating fiber production into operations, we enable downstream manufacturers to better coordinate product development and also improve quality control," says Stefan Kross, CEO of the Manmade Fibers Segment.
FORCE stands for "Fibers on Request and Compact Engineering"
The key to cost-effective, flexible operation is the system's compact design. The Staple Force S 1000 (FORCE stands for "Fibers on Request and Compact Engineering") is designed for simple, fast handling. It offers significantly faster changing times compared with conventional production lines. This in turn markedly reduces waste. Another central component of the system's cost efficiency is its production speed. At 1 000 meters per minute, it achieves speeds not seen before in one-step processes. To this end, Oerlikon Neumag adapted a stretching process that has been successfully used in carpet yarn plants for years. By omitting the steam and water-bath processes, the new procedure uses significantly less energy and water, which saves money and is better for the environment. The additional investment costs are also minimal. The extremely compact system only takes up 450 square meters of floor space and can be installed on a standard industrial floor. Special machine foundations are not required. "With Staple FORCE S 1000, we're setting new standards for synthetic staple fibers in terms of cost-efficiency, flexibility and compactness," Stefan Kross says.
Oerlikon (SIX: OERL) is a leading high-tech industrial group specializing in machine and plant engineering. The Company is a provider of innovative industrial solutions and cutting-edge technologies for manmade fibers manufacturing, drive systems, vacuum, surface solutions and advanced nanotechnology. A Swiss company with a tradition going back over 100 years, Oerlikon is a global player with around 13 000 employees at more than 150 locations in 34 countries and sales of CHF 2.9 billion in 2013. In 2013, the Company invested CHF 122 million in R&D, with over 1 000 specialists working on future products and services. In most areas, the operative businesses rank either first or second in their respective global markets.
About Oerlikon Manmade Fibers
Oerlikon Manmade Fibers with the product brands Oerlikon Barmag and Oerlikon Neumag is the world market leader for filament spinning systems used for manufacturing manmade fibers, texturing machines, BCF systems, staple fiber spinning systems and artificial turf systems and - as an engineering services provider - offers solutions along the entire textile value added chain. As a future oriented company, the Oerlikon Group segment's research and development is driven by energyefficiency and sustainable technologies. With the expansion of the product range to include polycondensation systems and their key components, the company now caters to the entire process - from the monomer all the way through to the textured yarn. The primary Oerlikon Barmag markets are in Asia, with Oerlikon Neumag's main markets in the US, Turkey and China. Correspondingly, the companies - with almost 2 500 employees - have a worldwide presence in 120 countries as part of the Oerlikon Manmade Fibers network of production, sales and distribution and service organizations. At the R&D centers in Remscheid, Neumünster and Chemnitz, highly-qualified engineers and technicians develop innovative and technologically-leading products for tomorrow's world.
Oerlikon Neumag Zweigniederlassung der Oerlikon Textile GmbH & Co. KG
Oerlikon Neumag is the worldwide market and technology leader for complete plants for the production of BCF carpet yarns as well as synthetic staple fibers. Furthermore, Oerlikon Neumag is also a leading supplier of a wide range of nonwoven technologies from spunmelt to airlaid technology.