Our plant is unique and for 100 % used to produce medical nonwovens. As raw materials we only use white medical grade fibers such as viscose, polypropylene, polyester, polyethylene, super absorbent or a blend. We have a number of technologies to bind the fibres. Needle punching, malivlies, maliwatt and thermal bonding are technologies which give us the possibility to produce a wide range of different nonwovens in a weight range of 80 to 450 gram/m2. Cariers of diffent nonwovens like spunbonded, hydro-entanglement, airlaid and films of polyester, polypropylene and polyethylene are also used in the production. Small production runs are possible.
Needle punching is a method of mechanically interlocking fiber webs by physically repositioning some of the fibers as fiber tufts or bundles from a horizontal to a vertical orientation. The repositioning means is a barbed needle and fiber repositioning is achieved by penetrating the needle into the web in a manner that permits the barbs to carry groups of fibers from one layer to form a fiber plug and withdrawing the needle in a manner that permits the fibers to remain in their new position.
The degree of interlocking is dependent primarily on the extent to which the needle penetrates the web (depth of penetration), the needling density (penetrations per unit area of fabric), and the number of groups of fibers repositioned per penetration (needle design).
The stitch bond process maliwatt and malivlies
Stitchbonding is a mechanical method of consolidating fiber webs that employs knitting elements either with or without yarn to interlock the fibers. The fabric structures are most closely to conventional textiles.
Maliwatt is the machine that employs yarn; Malivlies is the machine that does not employ yarn.
Thermal bonding process
Thermal bonding methods interlock fibers through the use of heat energy to activate an adhesive system. The adhesive may be the actual individual fibers, portions of individual fibers, added binder fibers, or powders.
Thermal bonding is accomplished through a combination of heating, flowing, and cooling. The adhesive component-distributed in a nonwoven web in the form of a unicomponent fiber, bicomponent fiber, binder fiber, or powder particle-is subjected to heat. For binder fibers and powders, initial heat energy softens the binder surface, resulting in flow and larger contact area with other fibers; additional heat energy induces binder flow, resulting in molten binder-fiber wetting and expanded or extended contact zones.
As the adhesive approaches the melting point, its surface softens and contacts areas with more stable fibers to form potential bonding sites. Upon melting, the adhesive (now in liquid form) becomes attached to a network fiber; flows along the network fiber into a crossing of two or more fibers, or forms an adhesive bead. When the nonwoven is cooled the adhesive solidifies and forms a bond or thermal fusion at each fiber/binder contact. With this technology a bond is created by melting synthetic fibres and calendaring.