Airlay - Aerodynamic web forming process

AUTEFA Solutions’ Airlay cards for aerodynamic web forming operate based on the aerodynamic principle, creating a fully randomized, three-dimensional fiber orientation. This results in isotropic web properties and an improved MD:CD ratio for superior product performance.

Airlay line solutions from AUTEFA Solutions stand out through high product quality, cost-efficient production, and exceptional reliability. The aerodynamic process enables fiber opening down to single fibers, allowing for maximum flexibility in fiber selection — including natural, synthetic, recycled, and technical fibers.

The FUTURA design ensures easy machine access for cleaning and maintenance. All line components are mounted on a linear guiding system for quick serviceability. The modular machine concept allows for tailor-made configurations according to specific customer requirements.

Combined with the Stylus needle punching machines and the HiPerTherm thermobonding oven, AUTEFA Solutions delivers complete aerodynamic web forming lines from a single source.

Applications and products

  • Filter materials
  •  Automotive felts
  •  Automotive substrates
  •  Insulation materials for thermal and acoustic insulation
  •  Interlinings
  •  Mattress felts
  •  Medical and hygiene products
  •  Blankets (needled)
  •  Industrial wipes
  •  Waddings for upholstery and garments

Materials and quality

  • All types of staple fibers:
  • Man-made fibers (Polyester (PES), Polypropylene (PP), Polyamide (PA, e.g. nylon), Polyethylene (PE), Polyacrylonitrile (PAN, e.g. acrylic))
  • Natural fibers (cotton, flax, hemp, sisal, jute)
  • Recycled fibers, shoddy fibers
  • Carbon fibers and glass fibers
  • Web weight range: 80 – 7000 g/m²
  • Fiber properties: 1.7 – 200 dtex; up to 100 mm staple length

AUTEFA Solutions Airlaysystem processes recycled and natural fibers into high-performance nonwovens

Autefa Solutions Aerodynamic Web Forming Airlay FUTURA

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Watch now to see the Airlay FUTURA in action

Aerodynamic Web Forming Line V21/R– Airlay Card K12

Excellent quality and flexibility in two steps

With over 500 units installed worldwide, AUTEFA Solutions’ Random Card Airlay K12 in combination with the web forming machine V21/R sets the benchmark in aerodynamic web forming.

The V21/R – Airlay Card K12 line is ideal for a wide range of nonwoven applications and standardized production processes. This two-step system enables efficient fiber opening and randomization. The pre-web forming unit V21/R produces a uniform fiber batt, while the Airlay Card K12 further opens the fibers and creates the characteristic three-dimensional orientation typical of aerodynamic web forming.

The FUTURA design ensures easy access for cleaning and maintenance – all delivery, carding, and infeed components are mounted on a linear guide system.

Your benefits at a glance:

  • Intensive fiber opening improves material uniformity and performance
  • Electronically and recipe-controlled deflection tube ensures homogeneous fiber blending
  • Well suited for natural and recycled fiber blends
  • High flexibility thanks to modular design with components on a linear rail system

Airlay Card K 12 with High-Loft Device

Increases web volume

The High-Loft device can be integrated into any Airlay K12 system to increase the degree of vertical fiber orientation within the web structure.
This results in significantly higher web thickness and improved loft characteristics without compromising uniformity.

The Airlay Card K12 with High-Loft configuration is capable of processing a broad spectrum of fiber types and blends, including natural, synthetic, and recycled fibers. The system is compatible with both thermal and spray bonding processes, making it suitable for diverse nonwoven applications requiring elevated bulk and resilience.

Your benefits at a glance:

  • Reduced web weight at constant thickness or increased thickness at constant web weight
  • Improved web resilience and compression resistance
  • Enhanced dimensional stability and uniformity of the web
  • Increases web volume

     

Aerodynamic Web Forming Machine Airlay FUTURA V12/R

Compact and economic

The compact and cost-efficient solution for processing natural fibers such as coir, sisal, jute, hemp, cotton, animal hair, and textile waste is the aerodynamic web forming machine FUTURA V12/R.
Fed by a hopper feeder, the FUTURA V12/R produces webs in the weight range of 400–7000 g/m² while requiring minimal floor space.
Designed especially for processing recycled textile waste, shoddy, or coarse natural fibers like coir, this low-investment system provides reliable aerodynamic web forming technology at competitive cost.

The FUTURA design allows quick machine opening and easy access for cleaning and maintenance. All delivery, carding, and infeed components are mounted on a linear guiding system.

Your benefits at a glance:

  • Space-saving machine footprint
  • Low capital investment
  • Cost-efficient production
  • High throughput capacity
  • Optimized for recycling applications
Contact Our Team

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

If you have any questions about our products, services, or company, feel free to contact us directly – no matter which of our global locations you require support from.

Our team will coordinate your request and forward it. We look forward to hearing from you and will respond to your inquiry as quickly as possible.

Contact Our Team