Spunlace Lines with SPL FUTURA Spunlace Technology

AUTEFA Solutions offers complete Spunlace production lines combining proven AUTEFA full-line expertise with advanced hydroentanglement technology developed in cooperation with ZFJ. The new SPL FUTURA Hydroentanglement System is integrated into complete line concepts for both direct and crosslapped Spunlace production.

As a full-line supplier, AUTEFA Solutions combines fiber preparation, carding, crosslapping, hydroentanglement, water treatment, drying and winding into precisely coordinated production systems. The combination of AUTEFA and ZFJ technology provides customers with flexible Spunlace solutions designed for high productivity, consistent product quality and efficient use of water and energy.

The SPL FUTURA Hydroentanglement System uses high-pressure water jets for uniform and efficient bonding of the fiber web. Depending on the line configuration and product requirements, the technology can be applied to direct or crosslapped webs for a wide range of Spunlace applications, including wipes, hygiene, medical and technical nonwovens.

In combination with AUTEFA Solutions web forming technologies and the energy-efficient Square Drum Dryer SQ-V, the SPL FUTURA forms a key element of complete Spunlace lines from fiber preparation to finished fabric.

SPL FUTURA Spunlace Machine

The SPL FUTURA Spunlace Machine, developed in cooperation between AUTEFA Solutions and ZFJ, is designed for efficient and uniform hydroentanglement of nonwoven webs using high-pressure water jets. As the central hydroentanglement system within a Spunlace production line, SPL FUTURA can be integrated into both direct and crosslapped line configurations.

The machine combines pre-wetting, hydroentanglement and dewatering in a compact and flexible concept. An integrated pre-wetting injector ensures uniform humidification of the unbonded web before the first entanglement stage. The web is then bonded step by step by the SPL JetHeads and transferred through the machine for further hydroentanglement and dewatering.

AUTEFA Solutions SPL JetHeads provide a high level of pressure uniformity across the complete water curtain, supporting consistent and homogeneous web bonding. Adjustable suction slots remove the process water efficiently and transfer it to the filtration system. The V-slot flex design minimizes the gap between drum and suction slot, reducing false air and lowering energy consumption in the suction system.

The cantilevered machine design allows fast and easy exchange of belts, drum shells and SPL Jet strips. An automatic SPL Jet strip cleaning system with high-pressure water cleaning and air drying supports reliable operation, reduced maintenance effort and consistent process quality.

Material

  • Polyester (PES)
  • Viscose
  • Tencel / Lyocell
  • Polypropylene (PP)
  • Fiber blends and other suitable fibers for Spunlace applications

 

Machinery and line components

In the Injection Card, the traditional mechanical carding principle, using workers and strippers, has been replaced by anaerodynamic concept. While its first tambour is equipped with stripper and worker rollers, the second tambour is exclusively designed for carding and therefore provided with workers only. In this highly innovative design, the fibers are injected against the following worker roller by the stream of air produced by the rotation of the main cylinder, and taken off the worker rollers by an aerodynamic effect generated by specifically shaped devices. This avoids considerable mechanical stress on the fibers, if compared to the traditional carding systems with stripper rollers. The carding action takes place at the tangent point of two convex surfaces and is very smooth. Moreover, the fiber path is completely on the inside of the card, thus reducing the negative effects caused by centrifugal forces. Combined with the patented EVO-2 and EVO-3 take-off systems, the Injection Card achieves very high production speeds with an excellent uniformity, even when working with fine fibers.

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The Layermaster Card is used as the second card in the line, after the crosslapper, and produces an excellent top web layer. The machine is equipped with a doffer and is specially designed for the highest quality.

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With the Topliner CL4006 SL AUTEFA Solutions offers a crosslapper with special features for the Spunlace application. Highest layering speeds and precise weight distribution are achived thanks to the integrated drafting unit, compensation belt, antistatic equipment and new designed transport aprons. 
These features are very important especially for light-weight applications in spunlace lines and ensures web laydown speed up to 200 m/min.

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The Web Drafter WD is installed after the speed compensation belt SC 123 of the Crosslapper. With up to 8 drafting trios, the unit  drafts the crosslapped web in material direction (MD), resulting in better tensile strength and elongation. When processing light-weight products, the Web Drafter increases the productivity of the line.

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The SPL FUTURA Spunlace Machine, developed in cooperation between AUTEFA Solutions and ZFJ, is designed as a flexible hydroentanglement system for efficient and uniform bonding of nonwoven webs. Depending on the required product and line configuration, the system combines pre-wetting, hydroentanglement, dewatering and water management in a coordinated machine concept.

AUTEFA Solutions SPL JetHeads ensure a high level of pressure uniformity across the complete water curtain for consistent web bonding. The machine concept includes adjustable suction systems for efficient water removal and can be combined with high-pressure pumps, filtration and water treatment technology. Its cantilevered design enables fast and easy exchange of belts, drum shells and SPL Jet strips, supporting flexible production and efficient maintenance.

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The nozzle system in the Square Drum Dryer SQ-V distributes the airflow in terms of speed and temperature uniform throughout the whole working width, providing best spunlace web and surface quality results. The suction nozzle design ensures a 100 % surface vacuum behind the conveyor belt, while the blowing nozzle design ensures impingement air jet for high heat transfer and high evaporation performance. For a capacity of 2.5 tons water evaporation per hour, the Square Drum Dryer SQ-V is using 4 chambers where the temperature, airflow and humidity profile is individually adjustable and controlled. A constant measurement of the exhaust humidity controls the maximum circulation air humidity. The reproducible drying performance guarantees a production with constant quality and residual product moisture.

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Service and spare parts for machines and complete lines

Customer service for AUTEFA nonwoven machines and lines includes comprehensive support throughout the entire life cycle of the production systems, from installation, maintenance and optimization to modernization. Our service department can help with problems and offers special service packages, the supply of OEM spare parts and retrofit solutions.

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Spunlace Line Assessment – Measure, Retrofit, Save

Works with any spunlace line – regardless of manufacturer, we measure performance, define upgrades, and guarantee energy savings

The AUTEFA Assessment for Spunlace Lines provides you with a comprehensive analysis of the savings potential of any existing spunlace machine - regardless of brand or manufacturer.

Based on your technical data, our experts calculate theoretical energy savings and determine the expected return on investment (ROI). During an on-site visit, we take detailed measurements of the machine and evaluate key dewatering settings such as vacuum levels, slot width, slot design, leakage points, and mechanical interfaces relevant to a potential retrofit. We then define optimized process settings and recalculate energy consumption based on a specific product. This analysis results in a guaranteed ROI that is documented in a binding retrofit contract. The retrofit is performed directly at your facility and typically takes only one to two days. After implementation, we validate the energy savings and help you achieve long-term efficiency gains - across all machine types and manufacturers.

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