The"DOUBLE-SUPERLOOPER" brings multi-layered benefits

The intensive co-operation between Fehrer and the Linz fibre producer ASOTA, involving the manufacture of multi-layer velour products on the NL 21/SRV-D "DOUBLE SUPERLOOPER", has once again produced some highly interesting solutions.

One possible application for such multi-layer products is the self-laying carpet tile, which is an ideal solution to the problem of flooring at trade fairs. The manufacture of such products generally involves mechanical web bonding and unfavourable chemical finishing using latex. Moreover, chemically finished needle felts have recently encountered increasing scepticism due to the environmental loads caused by production and the lack of possibilities for recycling.

The multi-layer velours provided by the FEHRER"DOUBLE-SUPERLOOPER" represent an elegant possibility for the production of very stable, environment-friendly and recyclable carpet tiles. The first machine creates a velour surface on a preneedled felt using a balanced ratio of PP fibres of differing diameters and PE fibres, which both come from ASOTA.

Between the first and second machine, an additional layer is fed consisting of PP, PE and PP/PE bi-constituent fibres from ASOTA, and then needled onto the first layer in the second machine. Initially, extensive tests were carried out to find the appropriate needle type for this purpose, as well as the ideal penetration density and depth. A task that proved a challenge even to the experienced FEHRER engineers.

As the basic layer remains on the brush transport during the second needling procedure, its velour is undamaged. Subsequent thermal bonding at moderate temperatures results in the melting of the PE components, the high thermal shrinkage of the PE fibres employed providing extremely efficient melt bonding. Furthermore, the addition of bi-constituent fibres ensures a considerable improvement in end product stability and volume retention. Something of special importance to self-laying tiles.

The fact that the PP and PE fibres both stem from the polyolefine family ensures that the needled carpet produced in this manner can be entirely recycled. In this connection, ASOTA has patented a production process, which offers the following main advantages:
  - 100% product recycling
  - shorter drying times due to the removal of the latex layer with a resultant reduction in energy     consumption.
  - no latex residues during production and laying.

The trials carried out with ASOTA clearly indicate that the FEHRER"DOUBLE-SUPERLOOPER" is the ideal answer to the increasing ecological demands being made on needled carpeting.