CORMATEX

description

Cormatex’s airlay technology is based on a new aerodynamic fibre batt formation system, capable of replacing traditional mechanical processes using carding machine and cross lapper, in many applications of the nonwoven sector. Thanks to an innovative process pressure control system, this new machine enables the formation of fibre batt, ready for needle punching and/or thermobonding processes, perfectly even both longitudinally and across the whole machine width.

Please find below some of the main application sectors of this technology:

Automotive: preformed panels, cotton wool for seats, thermal and sound insulating articles
Agriculture: agricultural land fertilization systems
Home furnishing: upholstering for sofas, armchairs, chairs, mattresses and quilts
Building: insulation items for roofs and walls, especially through the employment of 100% natural and eco-friendly materials
Soundproofing: soundproofing panels for various applications
Thermal insulations: thermal insulation panels for various applications
Hygiene/Bodycare: make-up articles
Clothing: stuffing for windcheaters or interlining supports for clothing and furnishing
Packaging: protective material for the shipment of fragile goods

COMPETITIVE ADVANTAGES compared to a traditional carding and cross lapper system

reduced production costs
reduced investment costs
reduced space occupation and energy consumptions
possibility of processing non cardable fibres and materials
higher production capacity
higher versatility in terms of types of processable raw materials and type of manufactured final products with the same line configuration
extremely limited ordinary maintenance
easy to run

COMPETITIVE ADVANTAGES compared to existing airlay systems

high production quality also when manufacturing light weight products (down to 150 g/m²)
high production versatility
easy to run, thanks to the centralised working parameter control system being installed

applications

Agriculture

Automotive Industry

Building

Clothing

Filtration

Home furnishing

Hygiene/bodycare

Packaging

Shoes/Leather goods

Soundproofing

Thermal Insulation

Wipes & cleaning

line layout example

opening and blending section
1
bale opener mod. AB
2
transversal collecting belt
3
beater mixer mod. B20
4
Oil emulsion system
5
Fine opener
lap formair section
6
intermediate silo
7
lap formair
bonding section
8
needle-punching machine
9
Thermobonding oven
cutting and wind-up section
10
Cutting and wind-up unit
accessories
11
opener for edge trim recycling
12
upper and lower support unwindig device
13
Pipeline metal detector

machines belonging to this line

opening and blending section

lap formair section

intermediate silo
lap formair

bonding section

needle-punching machine
thermobonding oven

cutting and wind-up section

accessories

details

Opening and blending section

Extreme versatility guaranteed by the possibility of processing natural and manmade fibres, both virgin and regenerated, including “non-cardable” fibres and other materials. Blending accuracy, especially with very heterogeneous blends, is achieved thanks to the employment of sophisticated micro-weighing feeding systems to determine the percentage of blend components.

Lap Formair section

Productivity over 1,500 kg/h and perfect control of the evenness of the output fibre batt also with weights below 150 g/m². Possibility of processing non conventional raw materials which are not used in traditional nonwoven processes (sugarcane fibres, polyurethane foam, coconut fibres, fibreglass, etc.).

Bonding section

The thermobonding oven equipped with a double belt transporting system is designed for the constant control of fibre thickness and density of the final products by calibrating it during the thermobonding phase. Alternative thermobonding systems may also be provided for (such as infrared or hot-calendering or perforated drum type) depending on the type of final application requested. In special cases a needle-punching process may also be combined.

Cutting and wind-up section

Transversal cutting without process interruption due to duly provided material accumulation devices. Longitudinal cutting according to requested sizes and automatic formation of large diamater and heavy weight rolls.

Guillotine or running blade type cutting systems. In special hi-density applications, the final product is cut into blankets and gathered on a duly provided conveyor belt, to allow piling it either manually or automatically by the installation of an automatic stacking device.

installations

PILOT LINE - ITALY

A complete airlaying pilot line, including opening and blending section, the newly developed airlay system (Cormatex patented technology), a thermobonding Oven and a Needle Loom, has been installed in our laboratories. The 1 meter wide pilot line characterizes for extreme production flexibility combined with high quality products achievement. It is possible in fact to process every type of material, either fibrous or not, to reach light weights such as 150 g/m² with a perfect uniformity of product density. Our technical staff is at customers full disposal to test new materials as well as to develop new and innovative nonwoven airlaid products.

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