Unlocking more value from existing nonwoven production lines

Allied forces of experts of ANDRITZ and customer help to improve performance of line capabilities

Process optimization combines expert analysis, targeted actions and continuous follow-up to improve line performance without heavy capital investment

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Authors: Gersende Calatayud & Wenjie Wang

Marketing Manager/Aftersales Manager , ANDRITZ Nonwoven & Textile

Improving productivity, quality and resource efficiency does not always require a new production line. A focused analysis of the installed process can reveal practical ways to stabilize operation and unlock more value from existing assets.

Starting with the real operating conditions

During an on-site audit, ANDRITZ process specialists observe the line and review its actual operating conditions. The analysis can cover production stability, quality, energy and water use, fiber losses, automation, maintenance and equipment availability.

The findings are converted into a prioritized action plan. Immediate adjustments may be implemented during the visit, while other opportunities may involve process tuning, automation changes, maintenance measures or targeted upgrades.

From a one-time audit to continuous improvement

ANDRITZ SYNERGY™ service agreements provide a structured framework for continuous improvement. Regular expert visits generate and implement recommendations, review results and define next priorities, with online support available throughout the agreement period.

This follow-up turns individual observations into a tailored improvement roadmap combining the relevant process, mechanical, automation, maintenance and digital expertise.

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Process optimization using the example of an ANDRITZ Wetlaid line at a customer's site

Practical gains from existing assets

Efficiency and availability: more stable operation and fewer interruptions.
Energy and resource performance: reduced losses in drying, water circuits and raw-material use.
Quality and productivity: optimized parameters, smoother operation and less waste.
Extended line capability: focused retrofits or upgrades instead of full replacement.
Knowledge transfer: stronger process understanding within customer teams.

The project example in the chart above followed a clear progression: measure the current situation, locate losses, define the most relevant conservation measures, and validate the selected adjustments under real operating conditions. By making better use of water recirculation and recovering fine fibers, the customer achieved lasting gains through optimization of the existing process rather than major new equipment.

Adding digital insight where it creates value

ANDRITZ Metris digital solutions complement expert analysis by turning process data into operational insights. They support resource efficiency, consistent quality and reduced unplanned downtime.