Objective
The project is aimed at direct energy saving by means of :
- the reduction energy consumption due to the modification and, for some products the suppression of some steps in the traditional process (in particular the finishing phases responsible considerable thermal energy consumption)
- the elimination of waste water treatment due to new needling technology which avoids the use of water + resin mix.
- the elimination of emission treatment
Considerable indirect energy savings are related to :
- the substitution of gluing resins (requireing high quantities of energy for their production)
- the use of recycled fibers in substitution of new textile fibers (also requiring high quantities of energy for their production)
- the recovery of the energy content of the recycled fibers.
As a consequence the specific added energy per unit of product in the examined factory and the specific final energy content of the product will be much lower if compared to the traditional process.
The designed production plant consists of innovative equipment and some existing technologies and machines (which will be completely modified and rearranged) to obtain a completely new way of produce non-woven textiles. The innovative aspect of the project resides in the development and in the industrial implementation of a new technique to bond textile fibers through : - a random disposition of the fibers coming out from the carding machine
- the use of a new needling/punching technology
- the use of small quantities of thermo-retracting fibers associated with a successive thermal treatment.
The combination of the above methods will allow one to obtain the final product (semimanufactured sheet or carpet) with the desired mechanical characteristics without using gluing resins.
a) the production process starts with a rag-grinding machine and a bale opening device providing textile fibers to feed a mixing device where recycled textile fibers and new fibers are mixed with the addition of spinning oils. The mixture is fed through a pneumatic system to an accumulation box.
b) a feeding device arranges the fibers for the successive carding machine. Here the material undergoes a re-arrangement process with the opening of the fibers and their parallel orientation.
c) the layer of fibers coming out from the carding machine is folded in multiple laps to form a mattress.
d) The mattress passes through successive needling-punching stations where the mechanical action of an high number of needles with different orientation creates a close packing of fibers interacting with each-other with ties and frictional forces. In this way an initial cohesion effect is obtaind.
e) At this point the continuous sheet of fibers undergoes a further consolidation process varying according to the requirements of the planned production. We can have an heating machine to cause melting or thermal retraction of some fibers.
Fields of science (EuroSciVoc)
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques.
CORDIS classifies projects with EuroSciVoc, a multilingual taxonomy of fields of science, through a semi-automatic process based on NLP techniques.
- engineering and technologymaterials engineeringfibers
- engineering and technologyenvironmental engineeringwater treatment processeswastewater treatment processes
- engineering and technologymaterials engineeringtextiles
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Topic(s)
Call for proposal
Data not availableFunding Scheme
DEM - Demonstration contractsCoordinator
50041 FIRENZA
Italy