Displaying items by tag: KelheimFibres GmbH

We have already introduced you to Olea, the first viscose fibre with intrinsic water repellent properties. Now, Olea has taken the next step towards a commercial launch: during the first production trial, we have confirmed that the fibre can be manufactured at a reliable quality level on a larger scale. The fibre process, including its stability and consistency, ran well within the anticipated parameters.

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After this first successful production trial, there are more tests planned which will prove Olea’s processing properties. First results have already shown that Olea fibre can be processed in the same way as our standard viscose fibres.

During the next weeks we will be showing the first samples of nonwoven fabrics made using Olea fibre to our customers. At the same time we will continue to optimise the fibre for its respective end applications in nonwovens, textile, paper and short cut products. 

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In wetlaid nonwovens or paper applications, good bonding properties of the fibres bring advantages for the strength of the web. Due to their large surface area and their high flexibility, fibres with flat cross-sections display very good bonding properties - our Bellini fibre is an excellent example.

pic1The extremely flat and smooth structure of our Leonardo fibre with its width to thickness ratio of 40:1 and its extremely regular and flat fibre surface not only facilitates good fibre-fibre bonding; it also makes the fibre highly transparent, allowing for the production of wetlaid nonwovens and papers with improved transparency.

By the choice of the appropriate fibre cross-section, by chemical modification and by the selection of the right cut-length, our customers can achieve improvements in tensile strength, folding properties and other nonwoven parameters - and by adding Leonardo to our range of products we made the choice even wider for you. Don't forget: only small amounts of viscose fibres can improve your product significantly!

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Different "Leonardo-Papers" were tested to ascertain the influence of the fibre's linear density (with a constant width to thickness ratio) on the physical properties of a paper.
 
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Papers with 5% viscose fibres were tested to determine the influence of different fibre cross sections on the physical properties of papers.
 
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What influence does the chemical modification of the fibre have on paper properties? The comparison of fibres with the same physical structure has shown, that the anionically activated fibre (Verdi) improves the tensile strength of the paper even more than the "normal" viscose fibre. 
 
 
Published in Featured Products

kel logo2Three of Kelheim Fibres’ new viscose fibre specialities have been assessed by a panel of creative professionals and have been accepted into Material ConneXion’s library of innovative materials – the world’s largest library of this type.

The fibres Verdi, Danufil® Deep-Dye and Microfine as well as product samples made of these fibres are now displayed in Material ConneXion’s nine locations around the world.

In this library, which features more than 7,000 cutting-edge materials, including the largest selection of sustainable materials, designers and manufacturers from all disciplines and market segments, from industrial design to textile specialists, find solutions to their specific material challenges.

The fibres from Kelheim fit perfectly into Material ConneXion’s range of advanced materials:
each one delivers an additional benefit for the user:

Microfine, Kelheim’s finest viscose fibre, creates outstanding wearer comfort in high quality textiles and helps to enhance the physical properties of all types of speciality papers. Microfine is especially soft – an additional benefit for wipes.

Danufil® Deep-Dye is a chemically modified viscose speciality with a dye absorption capacity up to 40 times higher than standard viscose – ideal for optimising the dyeing process of textiles made out of viscose and PET, but also perfect for colour catcher fabrics which prevent colour staining in domestic wash cycles.

The the viscose fibre Verdi has been ionically activated in order to deliver a higher level of intrinsic absorbency and excellent dispersability in water – the fibre is ideally suited for paper applications where it improves the physical properties of speciality papers such as the paper’s strength.

Currently, Kelheim Fibres is preparing applications for further fibre innovations for the Material ConneXion Library.

Published in European News

kel logo2This was the title of the paper given to approximately 280 attendees at the third Cooperation Forum Biopolymers in Straubing by Dr. Haio Harms, CEO of Kelheim Fibres GmbH. The paper illustrated impressively the versatility of viscose fibres made in Kelheim and presented future-oriented applications possibilities for their use.

“Cellulose- and lignocellulose-based materials and composites” was one of the main topics of the Forum organized by Bayern Innovativ in collaboration with the Centre of Excellence for Renewable Resources in Straubing – and Kelheim’s viscose fibres are a prime example of such materials.

Speciality fibres from Kelheim are high-performance materials which can substitute oil based synthetic materials in certain applications and deliver equal or even better performance; filters and speciality papers are examples of end products which can benefit from Kelheim’s fibres – and even carbon fibres are made from viscose fibre precursors. In addition to this, viscose fibres are made from 100% renewable cellulose as a raw material and are therefore completely biodegradable.

As a result, the field trip to the speciality fibre manufacturer’s headquarters at Kelheim, which was offered as part of the additional programme of the cooperation forum, was met with great interest. Around 50 visitors were given the opportunity to see the production plant and Kelheim’s R&D pilot plants.

Published in European News

Man-made Fibres Congress, Dornbirn: new studies & our latest developments

Every year, we present our latest research results and our new fibre developments at the Man-made Fibers Congress at Dornbirn. This year, Kelheim Fibres made four presentations - as you see, our R&D team has been very busy! Here is a short summary of two of the presentations - more next time!

  • Dr. Roland Scholz, R&D Kelheim Fibres and
  • Ina Sigmund, Saxony Textile Research Institute (STFI): Viscose Fibers for Improved Dispersibility of Wet Wipes

kel optWipes for personal hygiene applications are frequently flushed into toilets - and risk blocking the waste water system. In the course of the study nonwovens based on 100% viscose fibres were tested for flushability according the demands of EDANA/-INDA’s “Guidance Document for Assessing the Flushability of Nonwoven Consumer Products”.

The results: the two crucial factors for dispersability and transportability through sewer pumps are the fibre-length and the strength of the nonwoven web. Both factors have to be sensitively balanced to achieve sufficient web strength, easy break-up of the nonwoven and a complete dispersion of the fibres.

Nonwoven fabrics based on 20mm viscose fibres with round cross-sections and with the letter shaped cross section of our new “Umberto” fibres achieved the best test results for flushability.

Statement from : Matthew North, Commercial Director Kelheim Fibres

A Specialist specialises

We are proud to hold an excellent position in an increasingly competitive global market - what are the reasons for our success? First of all, we understand the challenges we face - and how to turn them into advantages.

As a medium-sized company in a high cost area we have skilled and reliable workforce and easy access to R&D resources. Our location on the banks of the Danube near a residential are means high environmental costs - yet at the same time it forces us to maintain the state-of-art technology of our plant. With eleven relatively small spinning lines our production capacity is limited - but we are highly flexible and can manufacture small lot sizes of speciality fibres competitively.

To guarantee our future success, our strategy focuses on four key elements: The effective and efficient use of available equipment and technology is the first important step. Based on that, we build leading positions in key markets and maintain them by continuous improvement of our products and production processes. To name just one example: We hold the number one position as supplier for short cut fibres for wet laid applications - 70% of viscose fibres used world wide in the manufacture of speciality papers are produced in Kelheim.

Forming strong partnerships with universities and research institutes and using the versatile viscose fibre process to our advantage, we adapt existing technologies for innovation. And last but not least, we establish new business in new applications, in the paper industry or filtration for example, where our speciality fibres offer benefits for an enhanced performance of the end product.

Our success is therefore not based on coincidence but solidy and strategically planned. With us, our customers have a reliable partner not just short-term, but also in the long run.

 

Published in European News

The shareholders of Kelheim Fibres GmbH have approved the first stage of a new, 4-stage investment package. This was announced by the C.E.O. of Kelheim Fibres GmbH, Dr. Haio Harms, during festivities to mark the 75th anniversary of the fibre manufacturer.


At the festivities, staged under the motto “75 years – a bridge from yesterday to tomorrow,“ which were intended to focus particularly on the future development of the Kelheim fibre-producing location, amongst other issues, Harms emphasized those positive signals seen on the site in the past few years: the willingness to invest in new processes, in innovation and new products, had made it possible to continue to expand the company’s technological edge and to strengthen its market position.


He confirmed that more than 100 million Euros had already been invested in the location between 2004 and 2009.


In the first stage of the so-called UEK Programme („Umweltverbesserung (environmental improvement), effizienz-steigernde Erneuerung (efficiency-enhancing renewal) and Realisieren von Kapazitätsreserven“ (realization of capacity reserves) an investment volume of around 25 million Euros are to be spent on refurbishing an existing spinning line with state-of-the-art technologies. This will allow removal of the majority of process exhaust air directly at source.


An additional environmental measure includes investing in a new, combined evaporation and calcination plant, which will cut consumption of steam currently needed in this area by 75%.


At the same time, these improvements also eliminate certain bottlenecks in production, enabling an increase in production capacity at Kelheim Fibres as of the second quarter of 2012 to an annual fibre capacity of 91,000 tons.


In the following years, three further stages “UEK 2 to 4“ – each involviing an investment of around 25 million Euros – are planned for modernisation of the remaining spinning lines, thus enabling a capacity of around122,000 tons/annum to be reached.


This increase in production volume will enable Kelheim Fibres to alleviate the competitive disadvantage resulting from producing in Germany with the increased infrastructure costs this entails (such as energy, safety, incidental wage costs, environment, administration, etc.) via higher quantities – to maintain the competitive edge of Kelheim’s Fibres in an international environment.

Published in Press Releases
Monday, 23 May 2011 13:37

Fibre Solutions for Recycling Paper

Worldwide there is an expected rapid growth of paper as in the past paper demand grew more rapidly than Gross National Product and has been unaffected by the often predicted “paperless office”. Covering this huge demand only by using fresh fibre pulp would lead to en overexploitation of forest resources. Therefore it has mainly to be covered by recycling of used paper products.


Even though 80% of used paper is collected still only 70% of it is recycled even though recycling is economically very attractive. 30% of paper is still made out of virgin fibres.


Why don′t we recycle all of the paper we collect? During the recycling process paper is ground. Its fibres are shortened and hence the stability of the paper is reduced making it unsuitable for many applications. We have to consider that “70% recycled” also means 50% has been recycled more than once, leading to a further deterioration in performance. To compensate this 30% of fresh fibres are added to the paper. Particularly graphical papers have a very low content of recovered material.


With our viscose fibres we were able to achieve an increase of paper quality demonstrated by e.g. higher double fold numbers and tear lengths by adding only 2–3% of our short cut viscose fibres to the pulp. With these short cut fibres it is possible to use nearly 100% of the cheaper recycled pulp. Instead of adding 20–30% of fresh fibre pulp there is only a need to add 2–3 % of viscose fibres such as Bellini.


This means that resource consumption can be reduced by up to 90%. Furthermore savings can be made on the raw material price because adding 2–3 % of viscose fibres is still cheaper than adding 20–30% of virgin pulp.

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Published in Press Releases

Kelheim Fibres is already the sole manufacturer of short cut viscose fibres for paper applications in Europe – and improving the properties of speciality papers is now the target of the range of new fibres which Kelheim presented at this year’s Zellcheming meeting in Wiesbaden.

Offering tailor-made solutions for the specific needs of different paper applications, Kelheim has secured a position as an established supplier to the paper industry. Although existing paper types can be improved and modified by the use of short cut viscose fibres, the R&D team in Kelheim is developing new fibres with even more functionalities which are specially designed to meet the needs of the paper industry.

Kelheim produces around 75.000 tonnes of fully biodegradable viscose fibres for a wide range of end uses every year, all made of 100% environmentally friendly wood pulp, but the fibres remain a high-tech product with a consistent level of quality 365 days a year. Furthermore the composition of the fibre is exactly the same as the composition of wood pulp as traditionally used in paper making - nature's most abundant polymer, cellulose.

By the modification of specific parameters in the fibre making process, three properties of the individual fibres can be designed to meet the demands of the fibres' end use: cross section, the dimensions of the fibre, as well as its functionality.

Kelheim currently offers five different fibre cross sections (round, flat/crenulated, flat/smooth, y-shaped, and hollow) which each deliver specific benefits in a range of end uses. The fibre dimensions can be exactly designed to suit the further processing of the fibre and deliver the paper properties required. Kelheim offers fibre linear densities from 0,5-28 dtex (g/10.000m) and fibre lengths for wet processes from 3 to 12mm.

Finally, by the addition of coating, anionic or cationic modification of the fibres or by the inclusion of additives in the fibre matrix, Kelheim’s experts are able to create fibres with additional functionality.

Using this tool box, Kelheim has successfully created four new fibres particularly suited for the use in the manufacture of speciality papers:

-        The structure of the viscose fibre Verdi has been modified to deliver a higher intrinsic absorbency level. Linked to this are a gel effect on the fibre surface, self-extinguishing properties and an excellent dispersability in water.

-        The viscose fibre Bramante is characterised by its segmented hollow structure which delivers significantly increased absorbency in comparison to a standard viscose fibre.

-        The viscose fibre Dante proves that combining properties can deliver more than the sum of two parts. A combination of Verdi and Bramante fibre, Dante’s liquid absorption capacity is four times that of a standard viscose fibre. The gel effect, high dispersability and self-extinguishing properties are all inherent in the fibre.

-        The special structure of the Bellini fibre with its extremely flat cross section and its very smooth surface profile delivers a fibre with a very high self-bonding capacity – a fibre ideally suited for paper and wet laid applications. As a result of the high self-bonding capacity of these fibres Kelheim’s R&D has successfully produced a paper made from 100% viscose fibres – which has previously not been possible with standard viscose fibres.

Using its own in-house technical centre for paper development, Kelheim Fibres has been able to intensively test all of these products during their development. The results of this work and of a study conducted in close cooperation with the Institute for Paper, Pulp and Fibre Technology (part of the Graz University of Technology) were presented to the public at this year’s ZELLCHEMING General Meeting for the first time.

The work carried out has shown that speciality papers can benefit in a number of ways from the incorporation of these new fibres.

By the choice of the appropriate viscose fibre cross section the density of the paper can be precisely controlled: the density of the paper sheet decreases in proportion to the surface area of the fibre added.

In the same way, viscose fibres are used to improve and control the porosity of a paper – a crucial point for example in the production of tea bag or cigarette papers – or to modify the double fold properties of a sheet, an important factor for currency papers.

Even small quantities of viscose fibres can enhance the tear resistance of speciality papers: by the incorporation of 10% viscose fibres, the tear resistance of the paper can be increased on average by 40%! At the same time viscose fibres can improve the tear strength of the paper. In this manner an improvement in tear strength with a simultaneous increase of tear resistance is possible – which cannot be achieved by simply increasing the level of refining.

As well as this, papers incorporating viscose fibres generally exhibit better dewatering properties and, depending on the additive incorporated in the fibre, improved retention properties.

Furthermore, modified viscose fibres can add specific functionality to a paper.

Examples of Kelheim's products with added functionality are the fibres Poseidon and DeepDye. Poseidon is a viscose fibre with inherent ion exchange properties. In contrast to loose ion exchange granulates, it is possible to incorporate Poseidon fibres in papers or nonwoven fabrics and design filtration cartridges of any shape. Poseidon can be used for water softening, for example in tea bags or coffee pads or for the filtration of heavy metals for recycling purposes. Poseidon can remove destructive acids from all kinds of liquids and it can be used to generate an antimicrobial effect in a product by charging the fibres with metal ions such as silver or copper.

Deep-Dye is a chemically modified viscose speciality fibre with a dye absorption capacity up to 40 times higher than that of standard viscose products. Originally developed to optimise the dyeing process of textiles made out of viscose and PET, a wider range of possible applications has since been discovered - the fibre can be used in all areas which require fast and effective dye absorption, for example in filtration cartridges for the decolouration of the waste water.

With this wide range of products Kelheim Fibres is an ideal partner for the paper industry. The already impressive list of fibres developed and optimised for the paper industry is completed by the ability to create individual, tailor-made solutions for the different needs of the various paper manufacturers.

Kelheim Fibres GmbH is one of the world’s leading producers of viscose speciality fibres, combining more than 70 year’s of expert knowledge, the technical know-how of their staff and expertise in the practical application of cellulose chemistry.

Kelheim Fibres continuously uses its capability to innovate and develop new products coupled with the flexibility of its production plant to focus on the manufacture of viscose fibres for highly demanding end uses and niche markets. While the company remains the most important supplier for the world's tampon industry, the focus of its product portfolio shifts more and more in the direction of new speciality fibres.

Matthew North
Commercial Director
Kelheim Fibres GmbH
Tel: +49 (0)9441 99-368
Email: This email address is being protected from spambots. You need JavaScript enabled to view it.

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Kelheim Fibres GmbH, leading producer of viscose speciality fibres, will showcase their new products at this year’s Zellcheming for the first time.

In addition to the well-known brands Danufil®, Galaxy® and Viloft® nonwoven Kelheim presents an impressive number of speciality fibres which are specifically designed to meet the needs of the paper making industry.

Through the incorporation of Kelheim’s speciality fibres, paper properties can be adjusted according to the individual requirements of the end product. Tear strength and tear resistance, porosity, retention, dewatering or bulk are all properties which can be influenced in this manner.
Beyond this, these viscose specialities can also generate additional functionality in the end product. By the incorporation of each of the fibres Verdi, Bramante, Dante or Bellini, for example, a significantly increased level of absorbency can be achieved. In speciality papers or filters, the viscose fibre DeepDye delivers a high dye absorption capacity and is therefore ideally suited for the incorporation in filters for the decolouration of the waste water from dye houses.

Poseidon is a fibre with ion exchange properties – integrated in papers or wet laid fabrics, it too serves its purpose mainly in filters: when used in tea or coffee bags, it can be used to soften drinking water, for example. By loading the fibres with metal ions such as silver or copper, it is possible to deliver an antimicrobial effect for medical applications.

The advantage of all these fibre specialities: they are manufactured from wood pulp - the same basic raw material used in the paper industry – and can therefore be easily incorporated in the papermaking process.

Kelheim Fibres has been a regular supplier to manufacturers of speciality papers for many years. Kelheim offers short cut fibres with a linear density 0.75dtex to 9dtex in cut lengths from 4mm to12mm and is therefore able to fulfil the needs of a wide range of customers and production processes. Fibres with engineered cross sections offering different functionalities as well as dry short cut fibre for the airlaid industry complete Kelheim’s range of products.

With their own in-house technical centre for paper development, Kelheim Fibres is able to intensively test these products during development and present the results as part of the product launch. In addition to this, close cooperation with the professionals of the Institute for Paper, Pulp and Fibre Technology (part of the Graz University of Technology), allowed the positive influence of viscose fibres on paper properties to be independently tested and proven.

A detailed report of the results of this research will be presented to the public by Dr. Ingo Bernt, a member of Kelheim’s R&D team, at this year’s ZELLCHEMING general meeting.

At the same time, a team from Kelheim Fibres is looking forward to your visit to our stand at ZELLCHEMING expo – visit us in Hall 2, Stand 207!

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