Tcc Nonwovens.pdf

Card Clothing Nonwovens

Chemiekarde

C|D|E|R|S|T

2

Card Clothing – Nonwovens

Card Clothing – Nonwovens

4 Innovations 8 Service 12 Quality 16 Roller card clothings 22 T-Winder 23 Tools and accessories 24 Hygiene cards 26 Card clothing charts

3

4

Card Clothing – Nonwovens

A young company with a long tradition In 2003, Trützschler took over the activities of Messrs. J. D. Hollingsworth on Wheels outside the USA and thus also the main plant in Neubulach, Germany, where clothings have been produced for more than 60 years. In parallel, “Trützschler Card Clothing” – short TCC – was founded.

At the end of 2009, Hollingsworth closed down in the USA, too, and terminated its more than 100 years of company history, which was focussed on the production of clothings and on a mobile service network. The know-how about the production of clothings and the organisation of efficient services, however, were not lost, as TCC also took over Hollingsworth’s activities in the USA.

Thus TCC indeed is a comparatively young company – but one that benefits from an unequalled and well-founded know-how, which is fully available to our customers worldwide. TCC clothings are not only produced in our headquarters in Neubulach, but also at our locations in the USA, in Brazil and India.

Card Clothing – Nonwovens

For more than 60 years, card clothings have been produced here in Neubulach, Germany.

5

6

Card Clothing – Nonwovens

Trützschler Card Clothing – Part of a powerful network TCC is part of the worldwide network of the Trützschler Group. Trützschler itself is the No. 1 in the field of card technology and has about 2,500 employees worldwide. Trützschler Nonwovens is comprised of the former companies Erko Trützschler and Fleissner – names with an excellent reputation in card manufacturing. For the Trützschler Group it goes without saying that the development teams for both the Erko

roller cards and roller card clothings work closely together.

the card clothing together form an unbeatable team.

For when it comes to high-per­ form­ance roller cards, quality and performance improvements can only be achieved if the machine technology and card clothings are perfectly coordinated.

The variety of possibilities offered by the Trützschler technical centres at Trützschler Nonwovens directly benefit the development of the card clothing, too. Nowhere else will you find such targeted product development where the influences of the card clothings on the web quality can be determined under controlled conditions.

The combination of Trützschler Nonwovens design experience and TCC’s card clothing know-how ensure that the roller card and

Card Clothing – Nonwovens

Even today developing the innovations of tomorrow Today Trützschler Card Clothing’s range extends from basic to highend premium products. It is not just standard applications but solutions for meeting rare and very special requirements which are covered.

A whole range of new products was born out of the close cooperation with the mechanical engineers at Trützschler Nonwovens. As a result, almost all successful TCC products on the market today are less than four years old – clear evidence of the huge innovative strength and future potential of TCC.

Roller cards in the technical centres Trützschler Nonwovens & Man-Made Fibers GmbH, Egelsbach (left) and Trützschler Nonwovens GmbH, Dülmen (below)

7

8

Card Clothing – Nonwovens

Layoutbild (muss noch gekauft werden)

Perfect service combines competence – and above all speed When it comes to roller card clothings, in particular, service has a crucial role to play. At TCC this ranges from the professional mounting of the clothing to the quick availability of personnel on site when a fault occurs.

In these and in any other applications it is you who benefits from TCC’s extensive expertise. Our know-how in the field of card clothing service has grown over decades and even now is continuously expanding. At the same time we use state-of-the-art diagnostic technology to examine every card clothing in precise detail.

All of this is supplemented by the fast reaction times guaranteed by over 200 service technicians spread throughout our international subsidiaries. At the same time we believe it goes without saying that we speak your language – in both a technical and geographical sense.

Card Clothing – Nonwovens

9

10

Card Clothing – Nonwovens

Innovations

Service

Quality

Roller card clothings

Service – professional and everywhere

Mounting an interlinked wire in a service workshop

Even more than 100 years ago, J. D. Hollingsworth realized how important a qualified service on site was. Until today, this finding has not lost its truth. That’s why TCC offers a locally organised service in almost all places where cards or roller cards are in operation, right next to our customers. This is also manifested in the fact that we

are able to approach customers in the local language – regardless of the different working hours across the various time zones. Our service personnel know as much about roller cards as they do about clothings. This applies to both the latest roller card technology as well to decades-old machinery. This wealth of knowledge is continuously expanded through regular training courses and exchanges with our colleagues all over the world, with the result that specialist knowledge, be it on specific applications or exotic card types, can always be called upon too. Of course for TCC it is understood that the extensive know-how of our service personnel is fed directly into the further development of the clothings and the continuous improvement of our service.

Fixing the wire end to a doffer roller

T-Winder

Tools / Accessories

Hygiene cards

Card clothing charts

Card Clothing – Nonwovens

First-class mounting for first-class results

First-class assembly work requires top-quality tools and experienced personnel

TCC clothings are manufactured with utmost precision. In practice, however, it can only achieve outstanding results if it has been professionally assembled, adjusted and commissioned.

Bangladesh

Our modern service machinery is operated by service technicians who, at the same time, are experienced textile specialists. Their professional competence, which exceeds the pure mounting of the card clothing by far, is a considerable benefit for our customers.

France

TCC offers you tailor-made service products, from a single visit by a service technician via maintenance contracts through to clothing management. Here, too, the day-to-day cooperation between the roller card specialists at Erko Trützschler and the card clothing experts at TCC is having a positive effect – all over the world. Furthermore, the clothing service is supported by the international after-sales service organisation of the Trützschler headquarters and of the subsidiaries in the USA, in Brazil, India and China.

Italy

Brazil China Czech Republic

Germany Hungary India Indonesia

Iran Mexico Pakistan Poland Spain Syria Turkey USA Uzbekistan Thailand Vietnam

Production + Service from the Trützschler Group Service from the Trützschler Group

11

12

Card Clothing – Nonwovens

Quality to the very point: NovoStar plus and “T-wires” The production output of roller cards as well as the variety of raw materials used have continually grown, with the result that certain roller card components are subject to increased wear and tear. For these special applications TCC has developed corresponding highperformance wires, thereby increasing the service life by 15 - 35%.

These wires are called NovoStar plus. Even at very high carding output rates and with aggressive raw materials they guarantee top quality and an excellent service life.   Raw materials which have been contaminated with foreign particles, in particular, often result in damage to the wires. Wires with reinforced

profile cross-sections were developed for such applications. These types of wire are described with a “T” (= thick point) in the wire identification code.

Card Clothing – Nonwovens

Special wires for severely contaminated raw materials

4.20

Thick-Point (T) 0.35

4.20

0.20

1.30 (20G/")

1.30 (20G/")

Thick-Point (T) wire

13

14

Card Clothing – Nonwovens

Innovations

Service

Quality

Roller card clothings

Quality right from the start Measuring the hardness of a metallic wire

Part of the quality assurance system: permanent online monitoring

During the last few years, TCC has invested a lot of money in quality assurance measures. Safeguarding quality is therefore no longer left to the instincts of our staff alone; instead the mechanisms of the Trützschler quality management system now take over in the production of card clothings. The benefit of these efforts: our customers attest us a quality consistency which is unrivalled in the industry. Our basic principle is: quality must be produced right from the start. It is not sufficient to check the finished product. That is why, for example, the production lines at TCC, from the first to the last stage of production, are permanently monitored online. Quality “made by TCC” can be seen, for example, in the process for hardening our metallic wires: with conventional hardening processes, scale appears on the surface of the wire which has to be removed mechanically in a further process. This, however, may result in damage on the surface. The “scale-free” procedure developed by TCC avoids the development of scales directly during the production process and thus also quality losses through reworking. Hardness testing, too, has meanwhile been automated. The machines for these new manufacturing processes have been developed and produced

The metallic wires are produced on automated production lines.

T-Winder

Tools / Accessories

Hygiene cards

Card clothing charts

in-house by TCC. Here, too, our close cooperation with the mechanical engineers at Trützschler Nonwovens proved its worth. To ensure that the quality produced is also delivered to the customer, TCC has developed new wire coils with optimised unwinding behaviour and new robust packagings. For success can only be guaranteed if quality management is applied across the entire quality chain, from the procurement of raw materials through production to the use of the clothing on a roller card. It is precisely for this reason that our quality management system ensures that every single stage in the production of a wire coil can be traced back 100%.

1200

800

600

400

Vickers hardness (HV 0.2)

1000

200

0

Measuring points – distance from the tip [mm] 0.02

0.09

0.18

0.27

Result of a hardness test with a typical hardness profile

There are hundreds of different wire geometries for the various applications.

0.36

0.45

Card Clothing – Nonwovens

15

16

Card Clothing – Nonwovens

Only the right wires can unleash a roller card´s full potential The wires on a roller card play a decisive role in determining the web quality. At the same time they are extremely important in achieving high output and smooth running performance.

The correct selection of wire types and especially the interaction between the various wires are of crucial importance here. Only when each individual wire and every interaction between two rollers is perfect can the full performance potential of a roller card be utilised.

Card Clothing – Nonwovens

base or rows per inch: plain rib wires: base in mm/100 (e.g. 090 = 0.90 mm. 110 = 1.10 mm) or camlock wires: Cxx (e.g. C08 = 8 rows/“, C24 = 24 rows/“)

front angle [°] N = negative

shoulder width: [1/100 mm]

The letter code “C“ indicates a camlock wire with the numbers of rows per inch given. total height: D =  2.00 mm E =  2.50 mm F =  3.00 mm G =  3.50 mm H =  4.00 mm I =  4.50 mm J =  5.00 mm K =  5.50 mm L =  6.00 mm

M = 6.50 mm point density N = 7.00 mm Q = 7.50 mm [points per square inch] R = 8.00 mm S = 8.50 mm T = 9.00 mm U = 9.50 mm V = 10.00 mm

special versions: A =  thermically treated B =  mechanically treated D =  enhanced point E =  depth of cut F =  flat on point G =  groove H =  NovoStar® L =  low shoulder P =  chemically polished R =  banana shape S =  special T =  thick point W =  wool X =  serrations XX = double serrations

Trützschler Wire Identification Code – every TCC metallic wire is clearly defined by the Trützschler Wire Identi­fication Code. Here, the user can identify the tooth geometry, special versions or the surface quality immediately.

17

18

Card Clothing – Nonwovens

Innovations

Service

Quality

Roller card clothings

Roller card clothings – the crucial quality component The wide variety of applications and processing technologies in web production pose a challenge to card clothing manufacturers in particular. For nowadays a roller card is still used in most nonwoven facilities. The various roller card suppliers rely in part on different concepts, which in turn is reflected in the wide variety of roller arrangements.

An Erko roller card with 2 web delivery systems

The interaction between these rollers, their diameters and speeds, the drafts (positive and negative) as well as the distances from each other are crucial for the quality and appearance of the web at the machine output end. It is clear that the roller wires take on a variety of roles which also determine the web quality: opening, separating, parallelising, condensing, drafting, stripping, combing or randomising – these and many other functions need to be fulfilled using different wire shapes in the roller card.

Modular design of the Erko roller card

Several roller card types and aerodynamic web formers are equipped with special carding elements, the so-called TCC CARDMASTER system. A subsequent extension to machines up to 4.5 m in width is possible at any time.

T-Winder

Tools / Accessories

7

8

8

7 12 11 12 11 12 11

Hygiene cards

12 11

Card clothing charts

TCC card clothings for all roller card types However varied the roller card designs may be, TCC has all the necessary clothings for them. This includes even very special wire types which are only required for a certain type of roller card. The TCC card clothing service is offered for all types of roller card (just a few examples of which are shown on this page).

12 11

15

14

15

16

10 6 9

3

15

14

15

1 2

Erko 1

8

7

13

9

11

15

16

14

3

10

14

6

9

14

9

14

14

Autefa Solutions 1

7

8

13 11

12

11

18

18

10

17

6

19 9

3

Legend

Spinnbau 1

8

8

7

7

8

7 13

13

11

12

11

13

14

10 6 3

9

9 14

Asselin-Thibeau

13

Card Clothing – Nonwovens

16

1 Feed roller 2 Clearer roller 3 Lickerin 4 Lickerin Worker 5 Lickerin Stripper 6 Breast cylinder 7 Breast cylinder Worker 8 Breast cylinder Stripper 9 Transfer roller 10 Main cylinder 11 Main cylinder Worker 12 Main cylinder Stripper 13 Anti-turbulence roller 14 Doffer 15 Condenser 16 Take-off roller 17 Turbo roller 18 CardMaster segment 19 Random roller

19

20

Card Clothing – Nonwovens

Innovations

Service

Quality

Roller card clothings

More than 400 solutions for virtually any application

Wire without aftertreatment

Depending on the roller card configuration, the raw material to be processed, the production rate and other process parameters, TCC can offer more than 400 wire types for every roller of a card. This allows wire specifications to be used which are precisely tailored to customerspecific parameters, thereby ensuring optimal running performance levels for the machine.

Feed rollers profiles front angle points density (ppsi) height options

-10° to 30° 20 to 40 5,0 to 10,0 mm T – thick point

Lickerin profiles front angle points density (ppsi) height options

Breast cylinder Stripper profiles front angle points density (ppsi) height options

5° to 40° 50 to 200 3,2 to 5,0 mm T – thick point

Breast cylinder Worker

10° to 20° 30 to 70 5,0 to 6,0 mm T – thick point

Breast cylinders profiles front angle points density (ppsi) height options

TCC wires are different from each other both in terms of the tooth geometry and profile crosssection (e. g. interlinked or flat base), structure (e. g. grooves) or surface treatment (e. g. mechanically or chemically treated, scale-free). For high loads and special applications so-called “T-thick point” wires are available. The following illustrations show a small selection of wire types which may be used for the respective roller.

10° to 20° 50 to 200 3,2 to 6,0 mm T – thick point

profiles front angle points density (ppsi) height options

25° to 45° 50 to 200 4,0 to 5,0 mm T – thick point X – serrations B – mechanically treated

Transfer rollers profiles front angle points density (ppsi) height options

20° to 30° 75 to 200 4,0 to 5,0 mm T – thick point

T-Winder

Tools / Accessories

Hygiene cards

Card clothing charts

Card Clothing – Nonwovens

Wire with aftertreatment

Main cylinders profiles front angle points density (ppsi) height options

10° to 20° 100 to 550 2,5 to 4,2 mm T – thick point

Doffer profiles front angle points density (ppsi) height options

Main cylinder Stripper profiles front angle points density (ppsi) height options

5° to 40° 100 to 225 4,0 to 5,0 mm T – thick point B – mechanically treated



30° to 45° 100 to 380 4,0 to 5,0 mm T – thick point X – serrations B – mechanically treated

Random roller profiles front angle points density (ppsi) height options

10° to 25° 350 to 550 2,5 to 3,0 mm H – NovoStar T – thick point B – mechanisch entgratet

100 to 380 3,0 to 5,0 mm T – thick point X – serrations B – mechanically treated

Condensers profiles front angle points density (ppsi) height options

Main cylinder Worker profiles front angle points density (ppsi) height options

30° to 45°

40° to 45° 50 to 200 4,0 to 6,0 mm T – thick point B – mechanically treated

Take-off rollers profiles front angle points density (ppsi) height options

-30° to -18° 110 to 185 4,0 mm B – mechanically treated P – chemically treated

21

22

Card Clothing – Nonwovens

Innovations

Service

Quality

Roller card clothings

T-Winder The T-Winder is the only winding device which shows the real winding force. The special geometry of the front bracket prevents vibrations as well as the influence of “false forces” during winding. Recommendations on the correct winding tension are shown directly at the device The hinged quick-release fastener on the T-Winder with dual clamping device means it can be quickly fitted and removed in order to ­reduce maintenance times. Furthermore, various setting options on the T-Winder mean that work on rolls in the roller card which are difficult to access can also be carried out.

The T-Winder shows the actual winding tension.

Increased safety and reliability for winding Modern high-performance roller cards have huge potential with regard to quality assurance and service life. To fully utilise this potential while maintaining low costs, the use of a winding tool specific to the clothing is recommended. Since a different winding tool cannot be held ready for each type of clothing, TCC has developed the T-winder. It can be used for all roller cards thanks to its unique, stable design. Due to the specially-developed ceramic wire guide all wire gauges and types can be mounted with the T-Winder.

Top-wire + top winder = top performance • Simple working mode • One device for all cards • Utmost flexibility • For all wire types • Easy assembly • Short downtimes • Constant winding tension thanks to the special ceramic guide • Permanent display of the actual winding tension

In combination with the entirely new travller guide, the decoupling of the wire-guiding elements of the T-Winder guarantees a constant winding tension which is free of external influences.

Mounting a small-diameter roller

The winding tensions for all common wires are directly indicated on the T-Winder.

T-Winder

Tools / Accessories

Hygiene cards

Card clothing charts

Tools and accessories A fully comprehensive range Clothings need regular checking and maintenance. TCC offers all the machinery and equipment needed to do this, as well as tools for assembly, disassembly and maintenance.

This ranges from a complete flat workshop facility through special winding equipment to a setting gauge. Shown below is a small selection:

Winding device

Unwinder with coil holder

Fastening elements

Butt-welding device

Soft-soldering unit

Manual rubber stones

Ceramic braking unit

Ceramic brake shoes

Wire magnifier

USB microscope

Gauges for clothings

Manual cleaning card

Brass brushes

Mounting hooks

Card Clothing – Nonwovens

23

24

Card Clothing – Nonwovens

Innovations

Service

Quality

Roller card clothings

Clothings for hygiene cards Special machinery requires special clothings In the field of hygiene 1m-wide cards instead of roller cards are often used for processing bleached cotton or viscose. These machines were therefore built for special applications and accordingly they require “tailor-made” clothings.

Web joining for zig-zag cotton

The cards used for applications in the field of hygiene essentially differ in terms of their web delivery and web joining systems. These are: • Web delivery across the working width e. g. for cotton pads • Transverse sliver take-off with the formation of a sliver / web divider with the formation of 4 extra-fine slivers for producing cotton buds • Formation of a heavy sliver with a rectangular cross-section for the production of tampons

Condensers with very special wires are used in the delivery area of these cards for producing heavy web.

Here the web of a 1m-wide card is divided into 4 equal sections and formed into slivers. These slivers are a primary product for cotton buds.

Such slivers are also produced on cards as a primary product for the manufacture of tampons.

T-Winder

Hygiene cards

Tools / Accessoris

Card Clothing – Nonwovens

Card clothing charts

Example of clothing in the production of heavy web (40 – 200 g/m2)

1

2

8

3

11

4

6

10

5

Position 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

9

7

12

14

15

13

Description

T-Code

Feed Roller DFK Feed Roller ICFD Lickerin I Lickerin II Lickerin III Carding segments Lickerin Main Cylinder TWIN TOP Lickerin side Flat Tops Flats Strips Roll Flat Cleaning Roll TWIN TOP Doffer side Doffer 1st Condenser 2nd Condenser Stripping Roller

T35.00.300.0056.18/F T25.00.200.0122.08/F T50.00.315.0034.34/VX T50.20.160.0164.34/V T50.20.160.0210.35/VB TS.090/B T33.15.090.0220.24/FX1Z TS.090/R NovoTop 33S TR-DS TR-DP TS.090/R T55.40.130.0117.42/Z T55.40.130.0117.42/Z T50.40.160.0112.35/VR T40.30.180.0110.28/AESN

16

25

Material E 26

Card Clothing – Nonwovens

Innovations

Service Leistungsdaten

Quality

Roller card clothings

Produktion

kg/h/m, m/min

Vliesgewicht

g/m²

Bandgewicht

ktex

Endprodukt Verfestigungsverfahren

Card clothing charts / Questionnaire Bermerkungen All card clothings supplied by TCC are documented in detail in card clothing charts. You can therefore look up the relevant production conditions at any time. These card clothing charts are treated as strictly confidential,

therefore the charts shown should be seen as examples only. Please use the accompanying questionnaire. We will gladly compile for you a detailed card clothing chart.

Nonwovens - questionnaire Agent

Date

Customer data Mill no.

Customer Country Roller card data Manufacturer Working with Machine no. /ref. Roller diameter

Please enclose a dimensioned roller card drawing.

Wire specification

Please enclose if available.

Material data

Fibre type

Blend ratio

Fibre count (den, dtex) from

to

Material A Material B Material C Material D Material E Performance data Production

kg/h/m, m/min

Web weight

g/m2

Silver weight

ktex

End product Type of bonding Notes

Fibre length (mm, Zoll) from

to

T-Winder

Tools / Accessories

Hygiene cards

Card clothing charts

Card Clothing – Nonwovens

Trützschler Card Clothing GmbH P.O. Box 1151 · 75386 Neubulach, Germany Rosenstrasse 7-9 · 75387 Neubulach, Germany Phone: +49 7053 68-0 · Fax: +49 7053 7359 [email protected] www.cardclothing.de · www.truetzschler.com www.machines-for-textiles.com/blue-competence Disclaimer: All data and information contained in the brochure was compiled with the utmost care and to the best of our knowledge and belief. However, we accept no liability for any typing errors or technical modifications. The photos and illustrations are for information purposes only and display in part optional equipment not included in the standard scope of supply. We cannot guarantee or accept liability for the up-to-dateness, accuracy, completeness or quality of the information given. All liability claims against the company or the author which refer to material or non-material damage caused by the use or passing on of the information provided, even if the said information is proven to be inaccurate or incomplete, are excluded. All data and information are non-binding. Print no.: 13003-03/13-e · Agentur Brinkmann GmbH, Krefeld

27

S P I N N I N G

N O N W O V E N S

MAN-MADE FIBERS

CARD CLOTHING

Fiber preparation

Opening/Blending

Staple fiber lines

Metallic wires

- Bale opening

Card feeding

Filament lines

- Spinning

- Blending

Cards/Crosslapping

- BCF

- Nonwovens/

- Cleaning

Web needling

- Industrial yarn

- Opening

Hydro entanglement

Precursor lines

- Open End

- Foreign matter

Finishing

Carbon fiber lines

Flat tops

Longstaple

Drying

Fillets

- Dedusting

Heatsetting

Carding segments

- Tuft blending

Chemical bonding

Service machines

- Waste recycling

Thermobonding

Service 24/7

Cards

Winding

Draw frames

Slitting

separation

Combing machinery

www.truetzschler.com