New Line Generation RF5
Entering the World of Digitalization
Machine supplier Reifenhäuser Reicofil, Troisdorf, Germany, presents to the market after more than 15 years of RF4 its new line generation for the production of spunbond, meltblown and composite nonwovens to set new standards in terms of quality, output, uptime, efficiency and machine intelligence: RF5.
One of the highlights of RF5 is the significant reduction of failures within the nonwoven. When running standard raw materials hard pieces will be reduced by up to 90 % in comparison to RF4 technology. By this Reicofil provides a solution for one of the major issues of contamination that exists in the industry. Producers running an RF4 line will be able to make use of this advantage by upgrading the line to RF4.5. RF5 Technology also fulfills the market demand for finer and finer filaments: the technology can produce up to 20 percent smaller fiber diameters. Thereby titers lower than one denier are producible for the first time. Compared to the RF4s technology the same titers can be achieved with higher outputs or finer titers are feasible with the same outputs, but can provide for better uniformity, strength and softness.
In terms of productivity the RF5 technology offers an output increase of up to 35 % – to up to 270 kg/h per meter beam width for spunbond and to up to 70 kg/h per meter beam for meltblown, according to the manufacturer. So, producers can run their lines at maximum speed even for higher grammages. The meltblown technology benefits from the increased output by a much wider process window, which raises the flexibility. Producers can decide now depending on their requirements whether to use the maximum output capacity and increase productivity by up to 35 %, or to produce 20 % higher meltblown quality at the present throughput levels. Of course, also a combination of a slightly higher throughput and a moderate quality increase is possible.
Looking at the line speed the new RF5 technology reaches the new peak value of 1200 meter per minute. As this value is the actual speed on the conveyor belt and not, as before, the speed at the winder, it can be fully utilized in production. Effectively producers can run their lines 30 % faster than they could on RF4 lines.
Paving the Way for Intelligent Machines
Both spunbond technology and meltblown technology have been newly developed for the RF5 platform and complemented by an additional technology for the first time: with RF5 Reicofil ventures into the world of digitalization and paves the way for intelligent machines and an intelligent production.
Reicofil developed solutions for more intuitive operation, continuous process and quality monitoring, predictive maintenance, and detection of anomalies. For example, the line will provide its operators with productivity analyses, predicts when a wear part is going to fail, warns the operator of drip formation before it occurs, and provides information to help solve the problem.
Jens Mager, responsible for digitalization at Reicofil says: „With digitalization we strengthen all the existing advantages of the Reicofil technology such as quality, productivity and reliability. In the future our lines will become an expert on themselves and will guide customers much more than today through the production process. Our solution will help customers to avoid both process failures and human mistakes, it will help to identify and exploit unused potential, to raise reproducibility and to find the best possible machine set-up for high quality and productivity.”
Reifenhäuser GmbH & Co.KG Maschinenfabrik
Reifenhäuser REICOFIL GmbH & Co. KG
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