Nonwoven hygiene products
KARWEB NONWOVENS, based in Turkey, is one of the big global players in the sector of hygiene products with more than 270 product types made from nonwoven fabric. They export 80 percent of our production to 36 countries, like America, England and Italy. At their Spunlace plant, they can produce protective products against bacterial due to sophisticated technologies like Ozone Threatment and UV systems.
In the quality control process, which is of great importance in the hygiene sector, they rely upon the quality control system Qualiscan QMS-12 from Mahlo. With instant quality detection, they can continuously control the correct component mixture of their fibre products.
A traversing scanner (o-frame) of type Webpro M with two sensors for simultaneous measurement is used for the task. The infrared sensor Infralot IMF detects the moisture. The Gravimat DFI beta sensor measures the basis weight.
Pictures courtesy of Selçuk İplik, Turkey
Continuous control of the cross profiles of basis weight and residual moisture on spunlace nonwovens
Simultaneous measurement of residual moisture (Infralot IMF infrared sensor) and basis weight (Gravimat DFI beta sensor) on running web of spunlace nonwoven fabric
The Qualiscan QMS is displayed and operated via an ergonomic touchscreen. All important information is immediately visible. Operation is simple and intuitive.
Haartz Corporation, based in Action, Massachusetts, USA, is one of the world's leading suppliers of automotive upholstery fabrics and a leading manufacturer of soft trim automotive interiors. Haartz roll and film products can be found in almost every car brand worldwide, especially in convertible tops. At Acton, surface effects such as artificial leather are embossed into extruded PVC, TPO or other compounds to produce mouldable and handcrafted materials. These goods are processed into door panels, seats, console covers, instrument panels and more for models ranging from Nissan to BMW.
Haartz controls and monitors the quality of its coatings with the Qualiscan QMS-12 web gauging system from Mahlo. An automatic profile control system for the extrusion dies is also in use. This enables Haartz to meet the strict specifications of the car manufacturers.
Pictures courtesy of Haartz, USA
Haartz Corporation, headquartered in New England, USA, is a leading manufacturer of automotive flooring materials and uses Mahlo systems for quality control.
Thickness and basis weight measurement of an extruded TPO web. It is later processed into convertible tops.
Typical material thicknesses range from 0.5 - 1.3 mm and must be strictly adhered to by the automotive supplier Haartz.
Even very thin coatings are no problem for the Mahlo system. The Mahlo scanner measures basis weight on coated PVC film for the production of instrument panels in car dashboards.
The Gravimat DFI sensor from Mahlo provides an exact CD and MD profile of the web, improving fabric quality and reducing waste and defects.
Eric Reber from Mahlo (left) and process engineer John Gilbert from Haartz (right) discuss the intuitive software of the Qualiscan QMS-12 system.
Gravimat FMI/DFI
Measurement of basis weight (mass per unit area) / thickness /density
The beta sensor measures grammage and material thickness by means of isotope rays
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Transmission of beta rays
The weight monitoring and control system measures the weight continuously, without contact, destruction-free and on moving product. The measurement is based on the attenuation of rays from a radioactive isotope through the substrate located in the measuring gap. This attenuation in intensity is an indication of the weight of the product.
The Gravimat uses a target weight to reduce the range of different m2 weights and thereby ensure a more consistent product.
Product Highlights
- Intelligent sensor with ultrafast microprocessor for preprocessing measurements
- Precise measurements as a result of using extremely efficient beta radiation detectors
- Four temperature-compensation sensors along with air pressure compensation
Customer benefits
- Non-destructive, continuous determination of the weight per unit area of product webs
- Highly stable and accurate measurement along with a minimum need to calibrate
- The DFI allows wider measurement gaps and avoids damage to soft webs or wet coatings
The Mahlo Gravimat DFI (Dynamic Flutter Independent) beta sensor uses a revolutionary new sensing technique that allows:
- Complete insensitivity to web flutter throughout the entire measurement gap
- The smallest beta sources and the highest measurement performance
- Very fast scanning speeds with ultra-narrow web defect detection
- Long-term trouble free, cost effective operation in the harshest environments.
Problems with product flatness exist with almost all treatment methods for product webs. Cast and rolled film as well as rolled sheet metal exhibit ripples and flutter, triggered by tension changes, electrostatic charges or band vibration. Paper and coating converters must deal with faulty substrates, edge curl and unsupported product web areas. Manufacturers of nonwovens and fabric are facing fluctuations of degree of drying, density and thickness of their product webs, caused by changes in centre of gravity.
All of these conditions result in measurement errors with traditional transmission sensors like X-ray or beta gauges. Backscatter sensors like gamma or X-ray are even more sensitive to web movement and some are even required to contact the web!
The Mahlo patented DFI Beta Sensor is not affected by web flutter, passline change, ripples, sag or edge curl. The DFI measures accurately throughout changes in loft, density or thickness.
| Specification | Value | Unit | ||
|---|---|---|---|---|
| Type | DFI | FMI | ||
| Isotope | Krypton-85 (Kr-85) | Strontium-90 (Sr-90) | Promethium-147 (Pm - 147) | |
| Measuring range 1 | 10 - 1400 | 100 - 6000 | 2,5 - 160 | g/m² |
1) Referring to PET
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