#Dyeing, Drying, Finishing

2022-01-20

MonforClean brings big savings for Albarrie

Full configuration of the Monforts and KMA Umwelttechnik line. © 2022 Monforts

Albarrie – a major player in North America’s industrial nonwovens industry – is now benefiting from one of the first Monforts Montex stenter installations equipped with the full range of MonforClean heat recovery and exhaust air purification technologies.

With the new three-chamber Montex stenter at its plant in Barrie, Ontario, the Canadian company is treating specialised needlepunched nonwovens up to 4mm thick. These have applications in a wide range of filter media and performance fabrics.

The new Montex is enabling Albarrie to heat set and dry its materials to produce denser, higher quality fabrics which can also be finished and delivered to customers more rapidly.

Across timezones

It took a crew of skilled millwrights, electricians and product specialists to build the line which was delivered in 11 shipping containers to Albarrie’s production facility. The line was originally scheduled to be fully operational in the Spring of 2020, but the ongoing global Covid-19 pandemic inevitably led to several delays during the start-up and commissioning process.

“Through the challenges of the pandemic, Albarrie staff worked remotely across time zones with Monforts technologists and product specialists to access and configure the machine and run it through a rigorous testing schedule prior to launch,” said Kevin Horner, Albarrie’s Director of Operations.

The line’s MonforClean capabilities include an air-to-air cross flow heat exchanger and an electrostatic precipitator. © 2022 Monforts

Assistance closer to home also came from PSP Marketing, which represents Monforts in North America from its base in Charlotte, North Carolina, and reports that there is currently a push for the replacement of stenter frames in the USA.

“There’s a move by a number of our customers to bring more manufacturing back to North America which is definitely a benefit to us,” said PSP vice-president Alex Franco. “And the trend to smaller lot sizes and speed to market is something at which the latest Monforts technologies excel.”

Finished roll coming off the line at Albarrie. © 2022 Monforts

Energy savings

The Albarrie Montex line’s MonforClean capabilities include an air-to-air cross flow heat exchanger and an electrostatic precipitator providing the ability to purify the exhaust air and to recover energy to a maximum of 22,500 cubic metres of air per hour, resulting in a radical reduction in the conventional heat supply required. The MonforClean was developed in cooperation with partner KMA Umwelttechnik, based in Königswinter, Germany.

The fully automated system is powered by a Siemens SPS S7 controller and KP 700 touch panel from which the recycled energy can be continuously monitored and savings calculated.

“The further integration of a washing system which automatically cleans the heat recovery and the exhaust air filter is a serious benefit to US manufacturers because the labour costs for the normally manual cleaning work is so high,” said Franco.

The Albarrie team at the new machine in the company’s plant in Barrie, Ontario. © 2022 Monforts

“This is an exciting time here at Albarrie and this new Montex stenter will ultimately open new doors for our business,” said Horner. “We have noticed significant improvements in many areas compared to our old unit, such as the cleaning access and the ability to easily clean, which reduces down-time, while the efficient burners and exhaust system allow quicker start up and cool down periods. In addition, more controllable features allow for increased quality control and the air filtration system reduces smoke and pollutants, keeping pollutant-free air in our neighborhood.”

The three-chamber Montex stenter is fitted with the latest Monforts Qualitex 800 PLC control system with WebUI, providing ease of operation, a full operating cost overview and maintenance monitoring.

“The new stenter has been very easy to learn for the operators,” Horner said. “It is easy to monitor and the controls are simple and easy to understand. While reviewing the requirements for the new machine, energy savings were part of our OEM score card. Energy costs are rising, and with carbon taxes being implemented, having our stenter use natural gas will result in energy savings. We are still early in the process of reviewing the consumption data from the new unit compared to the older unit, but currently, the early data indicate that we are consuming on average the same amount of energy, but achieving 1.5 times the amount of BTUs per hour for the same consumption. Most importantly, all of our products run without problems.”

“This was a big investment for Albarrie, but it was an investment for the future, one that will ensure we have the capability to remain competitive in the fabricated textile market for years to come,” added Executive Director Margaret Driscoll.

Monforts sees growing potential for technical textiles in Türkiye

For many years now, Türkiye has been one of the most important markets for textile finishing, coating and continuous dyeing equipment, making ITM 2026 from June 9-13 a key event for Germany’s Monforts. At the Istanbul exhibition at stand 1117D in Hall 11, the company will put the emphasis on its machines which continue to lead the field in conventional dyeing and finishing, and also highlight the strong opportunities for Turkish textile manufacturers in the growing field of technical textiles.

SETEX turns dyeing and finishing data into daily production control

At ITM 2026, SETEX will show how textile mills can use machine, recipe, quality and energy data for more reliable daily production decisions — not as another reporting layer, but as part of the running dyeing and finishing process. With OrgaTEX X3 MES, E390x/C390x controllers, CamCOUNT and FabricInspector Portable, SETEX connects planning, machine execution and fabric-related quality insight within existing mill structures.

Tradition and Innovation – Phoenox Textiles Ltd. relies on state-of-the-art carpet back-coating line from Brückner

For more than 70 years, Phoenox Textiles Ltd. has been synonymous with quality, reliability, and inno-vation in the textile industry. Founded in 1954 in Huddersfield (Yorkshire, UK), a region with a long tradition in textiles, this family-owned business has continued to evolve without losing sight of its roots. Today, in its fourth generation under the leadership of the Mosley family, Phoenox successfully combines decades of experience with a clear, forward-looking corporate strategy.

Smart Quality Control for Technical Textiles

In the end, what matters is the result: a filter that performs reliably, a membrane that remains stable in storm conditions, a composite material with precisely defined properties. But the path to achieving this is demanding. In the production of technical textiles, numerous parameters interact – and even the smallest deviations can have major consequences.

The address for environmentally friendly dyeing and finishing systems: ITM 2026

Dyeing and finishing technologies, one of the most critical and value-added areas of the textile sector, have gained strong growth momentum on a global scale. Technologies that are pioneers of this transformation focused on sustainability, quality and efficiency will meet with sector professionals at the ITM 2026 International Textile Machinery Exhibition. Dyeing and Finishing Hall (11–12) will host the latest technologies that increase efficiency, optimize resource use and reduce environmental impact in textile finishing processes.

2026 general meeting of the Friends and Supporters of RWTH Aachen at ITA

The Friends and Supporters of RWTH Aachen e. V. (proRWTH) looked back on a successful year of support at their 2026 general meeting. The meeting took place at Institut für Textiltechnik (ITA) of RWTH Aachen and was combined with a joint session of the Executive Board and the Administrative Board. Before the general meeting began, participants were given a guided tour of ITA, providing them with fascinating insights into current research and development topics in textile engineering.

Cotton ConneXions Insight to Impact brings supply chain leaders together around cotton innovation

Cotton Incorporated’s Cotton ConneXions Insight to Impact brought together more than 300 industry leaders from 140 companies across 10 countries, including more than 45 top global brands and sourcing organizations, underscoring strong global interest in cotton-rich product development, sourcing and supply chain collaboration.

Footwear innovation enabled by warp knitting technology– insights from New Balance

The future of the athletic shoe is increasingly being shaped on warp knitting machines. For KARL MAYER, the footwear industry is one of the most important growth markets – and one of the sectors where innovative textiles can realize their full potential. In his keynote address at the opening of KARL MAYER’s TEXTILE INNOVATION CENTER in Obertshausen in April, Vishnu Prakash Muthusamy, Senior Textile and Materials Engineer at New Balance, explained the opportunities that warp knitting technology opens up for performance, sustainability, and faster development processes, and why textile manufacturers are transitioning from suppliers to development partners.