Exploration of mogul

Another company that has chosen to focus its spunbond products beyond the health market is mogul in Turkey. The company's Madaline nonwovens (please refer to

[Madaline will change your understanding of nonwovens]) has the characteristics of mixed Microfibre fabrics. It uses the most advanced two-component patented technology to extrude unique filaments, and then through high-pressure water jet, the fibers form nets, tangles and consolidates microfilaments into non-woven materials. According to serkan gogus, commercial director, the properties of Madaline materials allow it to easily handle processes such as dyeing, printing, cutting and stitching similar to traditional textiles.

'This hybrid technology brings two of the best,' he said. 'On the one hand, it is a unique two-component spunbond technology, but the fixed net is made by the spunlace process which can form microfilaments. It gives materials unique properties, such as softness and drapability, thus bringing similar textile properties. On the other hand, we believe that hybrid technology is the future of this industry, which can open up new applications in clothing and interior decoration for non-woven fabrics. That's why we invest in this technology. '

The microfilament of Madaline material is 100 times thinner than that of human hair, which makes it have good barrier and filtering performance, as well as energy saving, ventilation, quick drying, heat insulation and wind resistance.

The application fields of Madaline include clothing, sportswear, artificial leather, mattress cover (anti allergy mattress), filtration, dry wipe, packaging, etc. as improved non-woven fabric or substitute for other materials and traditional textiles.

Improvement of Hartge's non-woven fabric

Perry Hartge, who worked for several non-woven companies in the 1980s and 1990s, has been an external expert in engineering and product development for the past two decades. Many of his past businesses have combined cutting-edge technology with research and development, but he recently started his own projects. Hartge has worked with a Florida based machinery company to simplify the spunbond process, making fiber formation and netting a process by balancing air flow and energy consumption.

The H2 process that Hartge and his partners have developed over the past 10 years is likely to be 90% less expensive than the current production line, with 50% less labor requirements, smaller footprint, fewer precision machine parts, and simplified operation. The key is the patent of H2 process and the impact spinneret system protected by PCT (Patent Cooperation Treaty), a powerful high output process, which can produce quite widely used spunbond products. The system can produce high-speed spinneret, however, the mesh forming technology will slow down the speed of the fiber reaching the mesh belt, making it easier to lay the mesh, similar to the melt blown process.

This method can allow customers who need to add melting nozzles on the production line.

For the current requirements of health products in terms of uniformity and low weight, Hartge believes that high-cost investment and the complexity of these production lines make the market lack of diversity.

'It's just a matter of time, sooner or later, new competitors will emerge,' he said. 'If you want to change the market, you need to create the ability to invest only a tenth of your capital and produce ten times more products. This is the trend of technological development. Eventually someone will innovate this market, and we will see the change of material supply. '