Interview with Hans Wroblowski

Within the textile production ‘chain’, finishing is recognised as a ‘value added’ component of the final product to ensure increased profitability. Finishing creates value to the end product. The market globally is therefore important for Monforts. The Southeast Asia region is particularly an important market for Monforts including not only the established markets of India, China, Pakistan, Indonesia and Bangladesh but also the emerging nations such as Vietnam. It includes the company’s with denim finishing and dyeing ranges particularly in the denim sector and high-end textile segments.

Eco line, Eco Applicator, Monfortex compressive shrinking range even in well proven 'Twin Shrink' configuration for energy savings and highest processing speeds and the latest Monforts coating head range are in demand with deliveries already made to India, Bangladesh and Vietnam for the latest ranges.

The challenges recognised by Monforts is to meet the environmental demands whilst providing the highest productivity and ensuring savings on water, steam and energy.

India, for example, is currently seeking continuous dyeing techniques for knit goods, thanks to its active research and programme, the company is today introducing new and advanced solutions for the sector such as Eco Applicator. The energy saving, Eco-Applicator soft coating process for the application of liquors and functional chemicals is now available for knitted fabric applications as well. Guidance for the knitted fabric has been specifically adapted to the needs of delicate knit treatment to eliminate ‘curling’ of the fabric edges. The Eco-Applicator offers significant energy savings with reduced liquor application. The multi-functional and multi-purpose process ensures the lowest energy input for consecutive drying to its minimal liquor application. It has been developed to apply liquor to one side of the fabric; to both sides of the fabric; and different liquor to either side of the fabric; or to apply two different liquors consecutively to a single side of the fabric.

Other developments in denim finishing include Eco line offering energy savings of between 20 – 25 per cent plus significant savings on steam. Generating steam is expensive. In India, for example, it costs 15 – 22 Euros to produce a tonne of steam per finishing line. With conventional ranges incorporating cylinder dryers, large quantities of steam are consumed. However, Monforts denim lines with an adapted Thermex acting as a thermo stretching unit is able to ensure savings of vast amounts of steam.

Sustainable policies endorsed by Monforts are to avoid pollution and excessive use of resources such as steam, water and salts and ensuring a reduction of chemical usage.

Firstly, a new complete coating line has been commissioned by Monforts in its Advanced Technology Centre (ATC) at the company's headquarters in Mönchengladbach, Germany; allowing customer's in-house opportunities to undertake trials with Monforts complete range of coating heads under fully confidential, real production conditions. Final trials on the coating line will have been completed in August for rotary screen printing. The facility also offers trials for a complete range of options for coating applications including knife over air, knife over roller, magnetic roller and printing head coating options such as, for example, magnetic roller coating for lacquering or minimal application. Fully enclosed, the coating line is set up for solvent flammable materials. Test can also be undertaken for PTFE at temperatures of up to 310° C and PTFE sintering. In addition to the new coating line, the ATC hall includes a full Thermex continuous dyeing range suitable for the Econtrol and T-CA process: a Montex 6500 stenter for knitted fabrics with vertical chain return and equipped with Eco Applicator: and a Montex 8000 stenter for technical textiles - incorporating Eco Applicator, high temperature and an explosion-proof execution for treating fabrics with solvents. Monforts technologists are also available for comprehensive customer's advice on all aspects of coating, dyeing and finishing for technical and classical textiles providing full assistance for economic and ecological processes. The hi-tech, world class facility is another example of Monforts policy to fully support its customers in achieving the best possible solutions in finishing its fabrics efficiently under ecological and economic al conditions. Secondly, the company is also developing new types of application units. For example, replacement of cylinder dryers and padder technology, where possible. Lastly, work is also under way in developing new types of processing including dry alkalising processes under special dry conditions to provide considerable resource savings.

The new Montex 8500 from Monforts includes several new features and options including an optional integrated support belt for heavy coated fabrics; a newly designed operator’s platform with improved access; enhanced visualisation introducing ‘smartphone’ slider features; a new maintenance free stentering chain; and an Eco Booster heat recovery module where an additional Exhaust Air Cleaning device can be added. The optional Eco Cleaner can be directly linked to the Montex 8500 integrated duct system extracting smell and visible particles in the air. VOC`s (volatile oxygen compounds) can be filtered out with an additional UV-C system. Built to a proven design by the German Company KMA Umwelttechnik GmbH featuring a steel housing, the cleaner is fully integrated on top of the Montex stenter ensuring a space saving modular feature. It is able to fulfill most limitations referring to hydro carbon, aerosol and smoke emissions; ensuring a minimum volume of filtered remainders.