A spunbonded nonwoven produced on a mono line is based on a single raw material. Such monofibres are either particularly soft, very strong or have a good barrier effect. If you want to combine these properties and get more out of your Reicofil line, you can upgrade your mono line with BiCo technology. A system modernised in this way combines two raw materials in one fibre. For example, two different PP raw materials or PP and PE.
As different materials behave differently when exposed to heat and cold, the fibre curls during production. This makes the fibre extremely voluminous, fluffy and yet very strong. BiCo technology can be used to produce very different fibre structures. For example, the core of the fibre can be made from a cheaper material and the sheath from a high-quality material (core/sheath structure). In the so-called side-by-side structure, the fibre consists of two materials in equal parts.
With BiCo technology, two materials are fed into the spunbond beam, where they are processed into one fibre. Manufacturers can choose between different fibre structures depending on the desired nonwoven properties.
‘BiCo technology offers system operators plenty of opportunities,’ says Viktoria Kaiser, Head of Services at Reicofil. ‘For example, they can expand their product range with premium products.’ These include ‘Extra High Loft’ products, or XHL for short, which require a large volume and enormous softness at the same time. ‘BiCo technology combines these market requirements in one nonwoven,’ reports Kaiser. ‘Manufacturers of hygiene articles in particular demand these qualities.’
Converting to BiCo technology is worthwhile for nonwovens manufacturers in several cases:
1. Opening up new product groups and markets
Line operators are expanding their range of applications with BiCo technology. This allows them to produce higher quality fibres that enable them to serve completely new product groups.
2. Save material
The upgrade from mono to BiCo systems is accompanied by more efficient production. One effect is downgauging, i.e. reducing the weight per unit area and therefore the amount of raw material used. Up to 20 per cent less material can be used while the quality of the nonwoven remains the same.
3. Increase profitability
High-quality nonwovens for premium products increase the revenue side. Downgauging also makes it possible to reduce material costs.
An upgrade to BiCo technology is possible from the Reicofil 3.1 system generation, which has been on the market since 1996. During modernisation, the spunbond beams are replaced, as are the melt preparation components, such as the extruder, screen changer unit, spinning pump and melt line.
Ideally, a system is modernised within a few weeks. ‘We know that downtime is always associated with a loss of revenue. That's why one of our main objectives is to find solutions that are in the interests of the customer,’ emphasises Hakan Yilmaz, Key Account Management employee at Reicofil.
Through partnership-based advice and good planning, the experts at Reicofil usually manage to limit the downtime as much as possible.
Are you interested in upgrading your Reicofil extrusion line to BiCo technology? Then please contact us: parts-rf@reifenhauser.com