Textilwerke Todtnau Bernauer invests in
leading stenter technology
Well-established textile company plans with a tailor-made
Brückner line for technical textiles, brand name BERATEX ® far
into the future.
The origins of company Bernauer can be traced back as far as
1829. At that time already coloured yarn and woven fabric were
produced in several factories. Since the early 1970s, the
company is active in the field of technical textiles and
developed together with a leading tyre producer a special woven
release/separation liner for the tyre industry. This fabric
serves as release liner/textile for the production of tyres
reducing the long the process costs of the processing costs.
The BERATEX® fabric as such is woven with special
polyethylene ribbons, made of a polyethylene film produced by
the company itself. Depending on the quality it can be used up
to more than 20 years without interruption. To increase the
dimensional stability of this product, a heat-setting process is
indispensable. For several years this had been made by different
german commission finishers.
Brückner heat-setting stenter at Textilwerke Todtnau
Hanspeter Bernauer, owner of Textilwerke Todtnau
Bernauer KG is aware that the key to company sustainable success
is the quality of the products. Therefore, aiming at a further
control and optimisation of the products it was for Mr Bernauer
a logical conclusion to integrate the final finishing of the
fabric into the company. With the new heat-setting line made by
Brückner the company reached now a 100% value-creating chain:
from the granulate to the woven high-quality PE fabric and to
the international marketing in more than 46 countries.
Textilwerke Todtnau Bernauer KG decided to buy a
state-of-the-art Brückner stenter because only a line with the
alternatingly arranged thermo zones, which is typical for
Brückner machines, ensures the required temperature accuracy
across the entire length and width of the dryer. Temperature
differences of a few degrees Celsius have an enormous influence
on the heat-setting result and thus to the technical
characteristics of the final product.
In the conceptual design of the line, the project team TWT
Bernauer & Brückner turned the highest possible attention to an
accurate fabric flow of the rigid and thus delicate articles,
and an operation which is not to be interrupted by batch
changes. Given the firmly installed unwinding unit with two
positions, a generously dimensioned fabric accumulator allows
connecting the batch ends by sewing without interrupting the
production process. An automatic width control of the entering
fabric controls the centred entry into the stenter and protects
the transport system from critical mechanical loads. The use of
sensitive traction measurement systems for an accurate tension
control between the individual draw rollers and a sophisticated
tension control software prevent too high fabric tensions in
each individual production step.
The stenter with a horizontal low-lubrication roller chain
and a maintenance-free chain rail system has a direct gas
heating system which allows adjusting the process temperatures
exactly every 1.5 metres.
Mr. Hanspeter Bernauer and Mrs. Regina Brückner.
Another fabric accumulator with following two-position winder
is located at the stenter exit and allows to change the batches
without machine downtime. This optimised installation makes it
in addition possible to operate the line with a minimum number
of operators and increases thus the economic efficiency of the
line. The service personnel which never before had worked with a
stenter was trained during the start-up period as machine
operators. After two weeks already they were able to handle this
complex machine and finish technically sophisticated fabric.
Already now Textilwerke Todtnau Bernauer KG made all
arrangements to allow on short notice an integration of further
finishing units, e.g. a coating unit or a calender in case the
market requirements change.
Mr. Bernauer opted in this process for Brückner because of
the following points:
- Competent advice before submission of the offer.
- Extensive test facilities and trials in Brückner’s
- Training and education of the operators until the
acceptance of the line.
- Intensive support service during the warranty period.