In Herzebrock-Clarholz in East Westphalia, Germany, VETEX, a hidden champion, produces tufted and woven carpets as well as carpet tiles under the brand “Infloor Girloon”. Everything that the East-Westphalians sell to their customers, such as SAP, Daimler, Ford, Porsche, hotels or cinema chains like Cinemaxx and Cinestar, is produced in-house. In addition to weaving and tufting, the fully integrated production chain also includes coating, continuous dyeing, printing and finishing. All products are tested and certified according to the criteria of the German certificates Blue Angel and TÜV Premium. Customers particularly appreciate the fact that special designs can be produced in digital printing from as little as 100 m2. In addition, VETEX has the world’s only tufting line for 1/20” fine velour. Carpet tiles and modules in sizes (50 x 50, or 25 x 100 cm), which are unique in the world in that they are self-adhesive and can be laid again at any time, are bitumen and PVC-free. With the help of a special punching or cutting technique, a perfect seam is achieved.
Contrary to the general trend in the area of floor coverings – away from carpeting – the demand for the high-quality products from VETEX is so great that the management has set itself the goal of doubling production output in the area of coating tufted carpets in 2021. The bottleneck here was an existing 10 compartment stenter, which was installed in the coating line on two floors and fitted exactly into the hall. The capacity of the line to the required production quantity was no longer sufficient.
BRÜCKNER’s experts took measurements and other space restrictions and discussed different concepts to increase the production capacity with VETEX. After analyzing the key data, they were confident to reach the target of double the production capacity with a new dryer with only one dryer compartment more than before. This was confirmed by tests in BRÜCKNER’s modern technology center in Leonberg, where these assumptions were fully confirmed.
The new BRÜCKNER stenter with integrated DUO-THERM dryer works with a horizontal pin chain and direct gas heating. The exact and separately adjustable temperature for upper and lower air with a possible difference of up to 60° C is perfectly suitable for carpet coatings. Venturi mixing nozzles for mixing the extremely hot burner gases with the circulating process air as well as the alternating arrangement of the thermal zones every 3 m ensure optimum temperature distribution and thus maximum drying performance with low energy consumption.
The on-time production and installation of the dryer was significantly complicated by the interruption of the supply chains due to Corona and the accident of a vessel in the Suez Canal. The schedule was tight enough as it was. Within half a year, the dryer including control cabinets and control system had to be produced, the existing dryer had to be dismantled, and the stenter had to be installed and commissioned. In addition, the existing heat-recovery system was to be connected to the new DUO-THERM dryer.
In spite of these many challenges, delivery, installation and commissioning could be carried out in time and after the start-up phase and process optimization, the given target was reached: the new BRÜCKNER DUO-THERM allows with only one compartment more than before a doubling of the production speed compared to the old 10 compartment stenter. In short: “bottleneck eliminated”.
VETEX continues to look confidently ahead. Also the next project in the field of cutting the carpet tiles has already been realized. Thus, another necessary step has been taken to increase efficiency and quality at VETEX. Throughout the company, from the top management to each of the more than 100 employees, the passion for textile floor coverings is perceptible. In this way, an innovative and entrepreneurial team, with the participation of the right suppliers, can continue to write success stories in Germany.