DiloGroup Launched New Green Needling Technology ‘MicroPunch’
ITMA 2023 in Milan, DiloGroup showed on a floor space of 750 m2 “Micropunh”, a complete production line for intensive needling, time the new development in a complete production line for the first.
Dilo MicroPunch; is a real green production technology which offers a great potential for lightweights to be used in the fields of hygiene, medicine, technical application, garment and home textiles. The company ran it with fibre at ITMA for the first time worldwide to demonstrate the industrial use of Dilo MicroPunch technology.
MicroPunch is advanced intensive needling technology and uses an extremely high needle density. This is a breakthrough for Dilo as it is now possible to use needling technology economically for the production of lightweight nonwovens in a range of about 30 g/m² to 100 g/m².
The production of personal care, single use wipes with weight range between 30 and ca.60 g/m2 made of fine fibre, often with blends of polyester and viscose, has been up to now a domain of hydroentangling technology. As this product is a typical disposable, it is in the focus of sustainability and recyclability. For this reason, biologically degradable fibres are a goal for more environmental sustainability.
Furthermore, the evaluation of the consolidation technology with regard to a low carbon footprint and minimum use of energy for the production is another decisive factor.
The classical needlepunching technology and its use for the production of lightweight fleeces at low cost per kilogram of the nonwoven thas been proven technologically and economically over many years of research and development work. This has been made possible by a high density of needles in the boards, and by very fine barbs on specialty needles which allow economic loading and a fast exchange based on the new module technique.
The MicroPunch line consisted of DiloTemafa fibre preparation, opening by a BALTROMIX bale opener, carding willow and dosing opener of the latest design followed by the successful DiloSpinnbau MultiCard fed by a universal card feeder including the new IsoFeed system for reduced weight variation.
IsoFeed can add the correct amount of staple fibre volume in areas of lower mass in the flock mat plane, thus correcting weight deviations and improving the overall CV value by ca. 4 %. The very regular web mass at the end of the card allows a reduction of the average weight by approximately 10 % resulting in considerable fibre savings when a minimum weight associated with a high regularity must not be exceeded. The MultiCard was additionally equipped with the new “variogap and speed controller” which allows an optimum of gap and speed adjustments at the fifth worker and at the doffers.
It reduces energy consumption of about 75% compared to hydroentangling
All visitors have confirmed that the current commercial and environmental issues concerning sustainability, critical energy supplies at increasing prices, shrinking of water reserves as well as the outlook for fibre material savings should attract our utmost attention. These concerns find an answer in the field of lightweight nonwovens production through Dilo’s brand new MicroPunch production technology which will become relevant when investments take place for nonwoven production in a weight range between 30 up to more than 100 g/sqm. Compared to hydroentangling, the “MicroPunch” needling line allows a reduction of the energy consumption (electricity and gas) of about 75% based on the complete installation. MicroPunch does not consume water. Gas is not needed to dry the material. Needling does not also create fabric waste since vacuumed good fibre of a minimum staple length can be recycled easily in the process.
It has been illustrated that depending on the individual costs for electric power, gas and water, production cost savings may be as high as 25 % associated with around 40 g/sqm and even up to 50 % for products around 100 g/sqm.
At ITMA, Cooperation of DiloGroup with Dell’Orco & Villani and TechnoPlants
With regard to current and imminent requirements to strengthen and promote the recycling of garment waste in order to safe valuable textile fibre in the European but also worldwide textile economy DiloGroup announced at ITMA 2023, the start of a close cooperation between Dilo, Germany and the Italian companies Dell’Orco & Villani and TechnoPlants. This cooperation forms a strong group of expertise to supply complete projects in the area of textile recycling.
Dell’Orco & Villani is a long term highly experienced and innovative specialist in the field of tearing equipment to recycle textile garment clippings. This technology maintains as much as possible the staple length of reopened fibre from yarn in knitted and woven textiles. This special tearing process avoids the downgrading and shortening of the staple.
TechnoPlants is a highly experienced specialist in the field of aerodynamic web forming and through air technology with particular emphasis on reclaimed fibre for various applications as for example in acoustic and thermal insulation, car parts, upholstery and bedding.
DiloGroup with DiloSystems GmbH is a general contractor who is specialized in the area of fibre preparation, carding, cross-lapping and needling. The great expertise of the three companies together is a source for the complete know-how in this large area of applications to reuse fibre from textile waste in new nonwoven material.
