AUTEFA Solutions – Your Partner for High-Quality Needle Punching Lines

AUTEFA Solutions is a leading supplier of carded-crosslapped needle punching lines, offering also turnkey solutions and state-of-the-art machinery for various nonwoven processes, including, airlay, spunlace, and thermobonding. With a strong focus on high productivity, low maintenance costs, and flexibility, AUTEFA Solutions meets the growing industry demand for efficient, high-quality production lines. Our proven technologies enable manufacturers to produce a wide range of unique nonwoven fabrics. Beyond equipment, AUTEFA provides comprehensive engineering services, from start-up and production support to quality and capacity assurance, ensuring seamless integration and optimal performance.

With the renowned companies AUTEFA in Friedberg (Bavaria, Germany), Fehrer in Linz (Austria), FOR and OCTIR in Biella (Italy), and Strahm Hi-Tex in Switzerland, AUTEFA Solutions represents a group with a rich tradition and decades of success in the global market. 

Needle punching is a web bonding technology that provides strength through mechanical interaction – without the aid of chemical or thermal influences. The fiber web is formed in a carding machine, which is then layered by a crosslapper and compacted by a webdrafter. This configuration enables high flexibility concerning product weight range and product width.It is important to bring the unconsolidated web even and closely to the needling zone to enable a reliable and fast infeed to the needle loom. During the actual needle punching process, special needles with small barbs repeatedly penetrate the nonwoven fabric. As the needles move through the material, they catch and interlock the fibers, creating a strong bond within the structure. This targeted fiber entanglement results in high material strength. A wide variety of settings – from individual needle properties to various machine equipment – enable different product characteristics.

Versatile & Efficient Needle Punching Technology

AUTEFA Solutions needle punching lines are characterized by high flexibility and efficiency, allowing the processing of a wide range of fibers. These include synthetic fibers such as PP, PES, PA, PAN, PTF and viscose, as well as glass and carbon fibers and natural fibers such as flax, hemp, jute, wool and cotton.

The range of product parameters is remarkable, from very light nonwovens of only 50 g/m² to dense materials of up to 1,800 g/m².

Needle-punched nonwovens are primarily used in technical applications such as geotextiles, automotive textiles, and filtration media for gas and liquid filtration. They are also widely used in home furnishings and upholstery, as well as many other industrial applications.

Opening & Blending- Superior fiber treatment right from the start

AUTEFA Solutions offers complete lines, starting from bale opening up to the finished product. All process steps are based on proven and economical technologies which are integrated in turnkey solutions. A wide range of opening and blending equipment is available, starting from bale openers, storage of fibers, up to fine opening and card feeding, according to the different fiber properties, final product specifications and customer requirements. AUTEFA Solutions reliable equipment focuses on easy maintenance and high flexibility for fully automated processes.

Carding- Highest speeds, proven quality and reliability

The nonwoven card plays a crucial role in the drylaid process and ensures the production of high quality nonwovens. AUTEFA Solutions, with its proven F.O.R. carding technology, offers a range of specialized models, each designed for specific applications. Thanks to the modular design, customers benefit from customized specifications tailored to their functional and quality requirements.

AUTEFA Solutions nonwoven cards are characterized by flexibility, high production speeds and process efficiency. They ensure improved web uniformity and quality, optimized productivity and minimized maintenance, while maintaining high reliability.

The Web Master FUTURA card is specifically designed for high-speed production with a focus on reducing maintenance costs. Its innovative modular design separates key components - including the infeed group, main cylinder, transfer group and doffer - into individual carriages, forming a "train" system. This structure provides easy access for cleaning and maintenance, maximizing efficiency and uptime.

 

Web Profile Control – Precision with WebMax Technology

AUTEFA Solutions’ WebMax technology is designed to eliminate the "smile effect," ensuring exceptional product quality in nonwoven production. WebMax ensures that the carded web weight is already being altered at the crosslapper infeed. Through the layering carriage control, the carded web is placed on the layering belt in such a way that the lapped web weight is controllably lighter in the edge areas compared to the center areas. This adjustable concave weight profile counteracts weight variations caused by material shrinkage, ensuring maximum weight uniformity in the final product. WebMAx relates exclusively to the AUTEFA Solutions Crosslapper Topliner and is compatible with these crosslappers with working widths of 2.0 - 4.0 m.

Crosslapping - Maximum Weight Accuracy

Weight accuracy in the bonded lapped web is the most critical quality feature of a nonwoven line. AUTEFA Solutions Topliner Series crosslappers are designed for high infeed speeds and precise weight distribution to ensure optimum performance. These crosslappers take the carded web from the card at a constant speed and gently transfer it to the delivery belt, maintaining consistent web integrity.

Topliner crosslappers increase web uniformity and throughput speed, effectively eliminating bottlenecks in the production process. Their uniform web laydown, combined with WebMax and the Closed Loop System, optimizes material usage, resulting in significant fiber cost savings.

With lapping speeds up to 200 m/min, AUTEFA Solutions Topliner crosslappers maintain consistent web quality thanks to a short web path. They offer full productivity potential and precise laydown across all working widths by incorporating composite components. In addition, energy consumption (kWh per kg) is further reduced by the latest drive technology with energy recovery.

Web Drafting – High Infeed Speeds and Precise Weight Distribution

A web drafter is a crucial component in nonwoven production lines, enhancing the quality and uniformity of the web. Positioned between the crosslapper and the first needleloom, it plays a vital role in optimizing the characteristics of the nonwoven material.

The Web Drafter WD is installed at this key stage, featuring up to 8 drafting trios that draft the crosslapped web in the machine direction (MD). This process enables high infeed speeds and ensures precise weight distribution, leading to web optimization in terms of tensile strength and elongation. Especially when processing lightweight nonwoven products, the Web Drafter WD enhances web uniformity, ensuring consistent material quality.

By employing multiple drafting trios, the Web Drafter WD significantly improves the mechanical properties of the web, resulting in higher tensile strength, elongation, and uniformity. Its ability to fine-tune web characteristics makes it an essential element in the production of high-quality nonwovens.

Needle Punching - High Performance Level

Needle punching machines mechanically bond fibers by needling. AUTEFA Solutions offers a range of single, multi-board and structuring needle punching machines based on the well-known and proven Fehrer technology, backed by the know-how of more than 3,000 machines in operation worldwide. The product range includes single and double board needle looms, tandem needle looms as well as velour, structuring and patterning needle looms, all based on the Needleloom Stylus NL and Needleloom Stylus VARILIPTIC drive concepts.
The unique elliptical drive of the Needle Loom Stylus Variliptic reduces drafts and improves coefficient of variation (CV) values at all quality levels. This drive allows continuous adjustment of the horizontal stroke during needling, increasing needle life, minimizing the risk of breakage and optimizing the fabric surface while protecting the fibers. AUTEFA's Stylus needle punching machines feature optimized bed and stripper plates, advanced needle patterns with conical bed plate holes and improved feeding systems for pre-needle looms. When processing recycled, natural or short fibers, an optional dust extraction system is available and recommended to ensure efficient operation and maintain product quality.

Line configurations

Artificial leather - vegan leather
Filter - inline production
Technical felts
Carpet
Autefa Solutions show room Linz 2016 E movie

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AUTEFA Solutions Nonwovens Competence Center

The AUTEFA Solutions Nonwovens Competence Center in Linz, Austria, offers excellent trial facilities to support customers in the development of new advanced products. Four nonwovens production lines with different bonding technologies (needling, thermobonding, hydroentanglement) and a special line for carbon fiber processing are available.  The installed equipment provides a realistic impression of the quality, workmanship, capability and performance of AUTEFA Solutions machinery. 
We offer our customers a wide range of technologies for web forming and web bonding of nonwovens on an industrial scale. A team of specialists develops technical and technological product optimization based on customer and market requirements. 

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AUTEFA Solutions Germany GmbH
Paul-Lenz-Strasse 1 b
86316 Friedberg . Germany
T: +49 821 2608 0
germany@autefa.com

For any inquiries or additional information, please feel free to contact us. Our team will get back to you promptly.

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