Zero-tolerance contamination control from Uster

Uster – The latest contamination control solution from Uster is designed to give nonwovens producers total confidence in when it comes to the initial inspection and removal of contamination in drylaid fabrics.

Nonwovens applications such as medical, hygiene and cosmetics demand two non-negotiable rules - zero-tolerance and reliability with producers operating to the most stringent quality levels. This means zero-tolerance standards for defects bigger than 1 mm.

In this nonwovens segment, end-product quality depends absolutely on the efficiency of contamination sorting early in the process with the Jossi Vision Shield N designed to master this essential job whether the end-product is made of natural or synthetic fibres.

Bio-cotton is a trend growing from the sustainability movement. Customers are willing to pay higher prices for ‘all natural’ products. It’s a promising business scenario, says Uster, but also a complex one. Bales of cotton typically contain various kinds of contamination – none of which should get into the final product, and ideally should be removed at the earliest stage of production.

Eliminating contamination during fibre preparation – and before the contaminants are shredded into smaller particles by the further processes – absolutely improves the quality of the raw material and reduces waste. According to Uster, the Jossi Vision Shield N contamination sorter ensures the best possible detection and removal of contamination, right after the fibre opener.

A key element of the system is the performance of the top-level spectroscope technology from Uster which, the company says, cannot be matched by conventional camera-based systems. The high-end Imaging Spectroscopes in Jossi Vision Shield N can find contamination even within the ‘invisible’ range of IR and UV light.

The same expertise also works with bleached cotton. Fragments of contamination in light pastel colors and white are also no problem. The ‘Quick Teach’ feature automatically learns the correct colour of each new raw material, to prevent false ejections when material lots are changed.

Synthetic and clean

Nonwovens producers also expect high quality and no contamination when purchasing synthetic fibres. Control is the only secure method when operating a business in highly sensitive applications such as medical textiles and as such, durable or non-durable, the product must be super clean.

Contamination is not acceptable, and snow-white colour generally a must. Producers have the security they need with Uster Jossi Vision Shield N with the system capable of detecting the tiniest contamination fragments, even in light pastel colours and whites.

The Uster Jossi Vision Shield N is the result of surveys, close collaboration with international nonwovens companies and countless hours of field tests. Installation is said to be easy, since the fibre cleaner’s slim design fits perfectly into existing lines. The system readily copes with the pace of standard production environments – up to a capacity of 2,000 kg per hour. Stainless steel inserts, in areas which come into contact with the fibres, guarantee unmatched durability, the company says, noting that the future-oriented graphical user interface gives a quick overview of running performance in real time, on a large high-resolution touchscreen, showing the most relevant data at a glance. User-friendly, quick and intuitive navigation makes data handling easy.

"Managing quality with Uster Jossi Vision Shield N at the fibre preparation stage gives manufacturers the total confidence that only contamination-controlled products are delivered," says Uster. "The paramount need is to prevent defects from the production processes reaching the end-product – and the Uster system simply does that. Uster Technologies has built experience and technological know-how over nearly three decades of fibre cleaning in spinning. Contamination is unwelcome in yarn, just as it is in nonwovens!"