Mind your step – nonwovens manufacturers testify to improved fibre control with Bekaert’s SiroLock worker and doffer wire

Bekaert is continuously investing in new technologies and one of its latest developments for the textile industry is the SiroLock doffer and worker wire for nonwoven and long staple roller cards.
Sirolock1 This highly efficient card wire is provided with a unique step – as shown on the left – which brings fibre control to a whole new level, improving both web quality and the productivity of the cards.
The concept of the SiroLock wire was developed by Ken Atkinson of The Commonwealth Scientific and Industrial Research Organisation of Australia (CSIRO) and executed by the technical team of Bekaert.

Improved uptake
It performs best on workers and doffers of the breast section and of the main card cylinder. The wire takes up to 50% more fibres compared to any conventional card wire and as a result, there is less recycling of fibres on the cylinder, which leads to higher card productivity. Less recycling causes less loading of the cylinder wire, meaning less cleaning time too. In addition, the improved fibre control leads to the reduction of fly, which reduces the cost of the raw materials and leads to a more regular web. And because SiroLock wire also creates higher carding spaces, it allows for wider settings and better blending.
The first industrial results with SiroLock in the nonwoven industry have already shown very positive improvements in both quality and productivity. This also has to do with the versatility of the product – can be used to process a wide range of fibres and even special fibres and blends like hollowor siliconized types, aramids and those with a high percentage of melt fibere. It also accommodates a broad range of fibre densities. One Bekaert customer even uses SiroLock to card goat hairs in combination with 150 dtex uncrimped polypropylene. No other wire was capable of handling coarse and uncrimped fibres, but SiroLock manages the job perfectly.

Technical felts
Sioen-Nordifa in Belgium is one company employing SiroLock for the production of technical needle felts, including filtration fabrics.
The comany is processing a wide range of fibres, including polyester, viscose, acrylics and low melt fibres in densities of between 4-15 dtex and uses SiroLock on the workers and doffers of a Thibeau Excelle card.
The company reports that this has resulted in improved web regularity and web appearance, even colours, improved web tensile strength and increased production of between 20 to 40% depending on the fibre blends and the final product. in addition, dust formation in the card has been eliminated thanks to the improved fibre control and reduced fibre recycling on the cylinder.
Needled carpet producer Domo in Belgium, meanwhile, uses Thibeau and Spinnbau cards to process 3.3-15 dtex fibres, with SiroLock mounted on the workers and doffers of the breaker and the finisher cards.
Domo reports that as a result, it has increased increased production speeds by 20%, while reduced fibre load on the card has led to less card cleaning, reducing downtime.

Geotextiles
Australian company Elco Solutions is a producer of geotextiles and geosynthetic products for a wide range of applications such as highways, railroads, coastal protection, waste containment, mining and sports field applications. While looking for a way to upgrade both productivity and the quality of its products, the company opted to mount V20 SiroLock wire on its doffers.
“Soon after installing SiroLock we noticed that our productivity rates went up dramatically,” says Elco chairman Brendan Swifte.  “Furthermore, the quality of our products exceeded all expectations. Calculations showed that at this rate of production, the investment pay back was just three months. The performance of SiroLock is exceptional and we will continue to use this technology.”
Another Australian company – Textor Textile Technologies – is involved in the production of spunlaced wet wipes and has noticed direct benefits with SiroLock
“Initially we used the SiroLock wire on the workers and over time this permitted a 30% increase in capacity as well as an improvement in web picture,” said Textor director Phillip Butler. “We have just installed a finer version of the SiroLock wire on a new card and the fibre pick up was so great that the stripper wires now have to be upgraded.
“In our mill, we believe that SiroLock will be a valuable tool to increase productivity and web quality over the coming years. It is not a simple solution, since there is considerable card tuning necessary. It forces you to understand the science of carding. We are producing web weights and qualities that are world class and at rates which increase each year. Without SiroLock we would not be in this position.”

About Bekaert
Bekaert (www.bekaert.com) is a global technological leader in its two core competences – advanced metal transformation and advanced materials and coatings. It is a market leader in drawn wire products and applications.
The global company, with headquarters in Belgium, employs 23,000 people worldwide with customers in 120 countries. Its annual sales are €3.3 billion.
Bekaert is also an independent and recognised leader in the card clothing business through partnerships with textile machine builders and customers world wide. Its success in this field is down to technical know-how, in-house developed machinery,  careful wire rod selection and thorough understanding of the drawing, shaping, punching and heat treatment processes.

Sirolock2

Example of a modern nonwoven card with fibre flow from left to right:
1. Feed roller
2. Lickerin,
3. Breast roller
4 and 10. Fly strippers.
5. Breast workers
6. Breast strippers
7. Breast or intermediate doffer
8.Transfer roller
9. Main cylinder
11. Main workers
12. Main strippers
13 and 15. Random rollers
14 and 16. Main doffers
17 and 18. Condenser rollers
19. Take-off roller

SOURCE: Nonwovens Live

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