RF5 Technology: Future. Flow. Fascination.

RF5 Technology

Setting the New Standards for Spunbond, Meltblown and Composite Nonwovens

Forward-looking ideas, a flow of ongoing development and fascination for perfect nonwovens – that’s RF5.

Future.

What will producers and processors wish for in the future? In which direction will end products and raw materials develop? Which mega trends will influence our industry tomorrow? When developing new technologies, we pay attention to a far wider range of issues than just questions regarding the ideal filament speed or the diffusor geometry. As a technology provider, it is our aim to help you keep all your options open for the best possible future. We are convinced that digitalization offers us the greatest potential in this respect. Can you imagine that the production lines of the future will automatically know how to manufacture the perfect nonwoven? We can see it happening.

Venture into the digital world where intelligent machines guide you to best qualities and the most reliable process.

Flow.

Our industry is continually evolving. To us this means staying open to changes developments, criticism and fresh impulses – even in the middle of a development process. We are thinking in different directions – always searching for challenges that require a solution and for partners who are able to support us in the realization of their ideas. There is one thing that we have learned in all our years of industry experience: Large achievements are possible only with the correct data flow, information flow, knowledge flow and mind flow.

Benefit from enhanced production processes and innovative solutions by ongoing joint developments.

Fascination.

When we develop technologies we think about the perfect nonwoven and have a sense of fascination for design, process engineering, polymer chemistry and aerodynamics. We are constantly searching for new possibilities to take nonwoven manufacturing to the next level. Our passion for the subject helps us to transform ideas into measurable benefits.

Experience progress that arises when people with passion work on technical solutions for perfect nonwovens.

Benefits at a glance

RF5 Technology

Our latest machine generation delivers nonwoven quality never seen before. It is the most productive, most reliable and most efficient line technology we have ever engineered. And above that: with its all new digital tools it paves the way for intelligent production.

Bye bye hardpieces

Another step toward the perfect nonwoven

We cannot guarantee a hardpiece-free nonwoven. But with the new RF5 technology we are getting close. For production using standard raw materials, hardpieces are reduced by up to 90 percent in comparison to RF4 nonwovens.


Up to
less hardpieces

More Output

Faster production even for higher fabric weights

True to the motto more is more, we have significantly raised the output bar. Up to 270 kg per hour and meter width for spunbonded fabric and up to 70 kg per hour and meter width for meltblown is the measure of things to come. Take advantage of maximum speed even for higher grammages.


Up to
spunbond throughput per hour per meter width
Up to
meltblown throughput per hour per meter width
Up to
increase of output

Higher Speed

Previously unheard production speeds

The RF line is getting even faster: 1200 m/min is our new record. And even better: This value is the actual speed on the conveyor belt and can therefore be fully utilized in production. Effectively this means a 30 percent increase in line production speed.


Max. production speed on the belt
Increase of production speed

More Uptime

Anything but downtime

Almost all the improvements to RF5 have a positive effect on uptime, both directly or indirectly. In addition to this, we took another close look at maintenance time: Quench chambers and secondary air gaps can now be cleaned much faster. The result is decreased downtimes and increased productivity.

Increased Hydrohead

Keep it flexible

RF5 Meltblown offers the biggest process window ever available on our platform. Immediately enjoy greater flexibility when it comes to quality and productivity. You can decide whether to use the maximum output capacity and increase productivity by up to 35 percent, or to produce absolute premium quality at the present throughput levels.


Up to
higher meltblown quality

Energy Efficiency

Better performance and efficiency

Right from the start of our company history we set ourselves the goal of reducing the specific energy consumption for each new line generation. It is a promise that we have kept for composite lines of the new RF5 generation.


Up to
less composite energy comsumption

Smaller Filament Diameters

Increased spunbond properties

With RF5 Technology we enable you for the first time ever to produce filament diameters smaller one denier. And compared to the RF4s technology the same titers can be achieved with higher outputs or finer titers are feasible with the same outputs, but can provide for better uniformity, strength and softness.

RF5 Technology

Machine Intelligence

In the future, it won‘t be just line operators and process engineers who know our machines inside and out. The system will become an expert on itself. It will know its status, it will be able to predict the effects of parameter changes, it will communicate with other systems, learn and act autonomously to fulfill the production targets. With our RF5 technology we are offering and further developing hands-on solutions that pave the way for intelligent production.

Human Machine Interface

Easy and intuitive as never before

Our new developed web-based, context-related user interface simplifies system control and reduces complexity. Create your own individual dashboards showing the information most relevant for you, make use of remote control if helpful and benefit from a visualization that guides and supports you.

Digital Assistant

Bye bye searching

Our digital assistant provides all the information that could be relevant for your staff – such as line documentation, product descriptions, technical drawings, step by step instructions for maintenance or even training videos. The best: All the information is stored centrally, accessible by a mobile device from anywhere. No more searching.

Anomaly Detection

Monitor your line components

Your line will be able to predict anomalies before they occur – much earlier as humans could ever do. You will benefit from a more stable process and maximum uptime as you can act instead of react. Be informed about upcoming leakages or contaminations.

Virtual Sensors

Monitor your process

By measuring and evaluating process parameters, virtual sensors provide valuable indications on the best possible line set-up for high quality production. In the future, your line may tell you that you are on the way to produce drops and it may also tell you how to avoid this.

Reicofil Nonwoven Grading

Predicting what your customers think

Our nonwoven grading considers subjective evaluation in addition to objective measurement values, and predicts how your customers will perceive the nonwoven. Utilize the new possibilities to produce nonwovens individually tailored to your customers – e.g. based on their geographical location.

Predictive Maintenance

Avoid unplanned downtime

Your intelligent line will be able to inform you about upcoming wear and the failure of parts. You will be able to replace components before they will affect your productivity or product quality. With some more development effort it will also be possible to make exact predictions on the remaining life expectancy.

Profitability

“The output-cost-ratio for RF5 composite lines will be much more attractive than it was for previous line generations.”

Markus Müller, Sales Director Reicofil
Digitalization

“Customers using digital solutions in their line will always win, because they benefit from new features and still rely on the productivity and quality level of the even improved technology.”

Dr. Bernd Kunze, Managing Director Reicofil
Contamination

“Contamination was one of the main areas we focused on in the development of RF5. One result of our efforts is the significant reduction of hard pieces.”

Martin Neuenhofer, Development Lead RF5 Spunbond
Digitalization

“If I had one wish, the next big thing that would come to reality would be a fully automated spunbond line.”

Jens Mager, Reicofil Project Lead Digitalization
Digitalization

“We consider collaborations with our customers as key success factor for further developments in the field of machine intelligence.”

Jens Mager, Reicofil Project Lead Digitalization
Next Level Nonwovens

“It is time for the next level of nonwovens and I am really happy to see how RF5 will perform in the future.”

Markus Müller, Sales Director Reicofil
Performance

“One highlight of RF5 spunbond is the wider window of operation. We could increase output, speed and quality at the same time.”

Martin Neuenhofer, Development Lead RF5 Spunbond
Digitalization

“Speed becomes much more essential when developing digital solutions.”

Dr. Bernd Kunze, Managing Director Reicofil
Market Requirements

“In the market there was a tendency to go down in fabric weight but there was also the tendency to go up in fabric weight. For everything we will have answers on the RF5 platform.”

Markus Müller, Sales Director Reicofil
Uptime

“Maintenance will be easier and faster with RF5. One more advantage regarding high uptime.”

Martin Neuenhofer, Development Lead RF5 Spunbond
Digitalization

“In the world of digitalization you can risk more, because in the software industry it’s usual to test and beta-test with your customers. This is new for the machinery equipment industry.”

Dr. Bernd Kunze, Managing Director Reicofil
Upgrades

“It’s always difficult to introduce a new technology by a big bang. But we did not forget our current customers and offer very interesting upgrade packages for RF3 and RF4 lines.”

Markus Müller, Sales Director Reicofil
Digitalization

“Digitalization enables us to develop more custom tailored solutions and to support operators better than ever before.”

Jens Mager, Reicofil Project Lead Digitalization
RF5 Highlights

“I think most of our customers will rate the significant reduction of hard pieces as biggest benefit of RF5.”

Markus Müller, Sales Director Reicofil
Digitalization

“Customers working together with us in the field of digitalization will be among the first ones in the market to benefit from our new technologies.”

Jens Mager, Reicofil Project Lead Digitalization
RF5 Meltblown

“We made ourselves free from what we have done in the past – even this was successful. The result is an all new meltblown approach with great advantages.”

Markus Wuescht, Reicofil Development Lead RF5 Meltblown
RF5 Development

“It was a big challenge to develop something that could outperform our RF4 Technology. But I am very happy with the result now.”

Martin Neuenhofer, Development Lead RF5 Spunbond
RF5 Meltblown

“With RF5 meltblown we break with the contradiction of high output and high quality. Now customers can increase both.”

Markus Wuescht, Reicofil Development Lead RF5 Meltblown
Digitalization

“With digitalization we strengthen all the existing advantages of the Reicofil technology such as quality, productivity and reliability.”

Jens Mager, Reicofil Project Lead Digitalization
RF5 Meltblown

“For the RF5 meltblown platform we will continue offering our multirow concept to enhance flexibility and to widen the potential product portfolio of our customers.”

Markus Wuescht, Reicofil Development Lead RF5 Meltblown
RF5 Development

“It’s very encouraging to see your ideas evolving from a sketch on a piece of paper to a working prototype and the final product.”

Martin Neuenhofer, Development Lead RF5 Spunbond
Facts & Figures

All data at a glance

With RF5 technology you will produce next level nonwovens – as productive as never before. Check the facts.

RF4 RF5 RF5 Plus
Configurations S, SS, SSS, SSSS, SMS, SMMS, SMMMS, SMMMMS, SSMS, SSMMS, SSMMMS, SSMMMMS, SSMMSS, SSMMMSS, SMMMMSS S, SS, SSS, SSSS, SMS, SMMS, SMMMS, SMMMMS, SSMS, SSMMS, SSMMMS, SSMMMMS, SSMMSS, SSMMMSS, SMMMMSS S, SS, SSS, SSSS, SMS, SMMS, SMMMS, SMMMMS, SSMS, SSMMS, SSMMMS, SSMMMMS, SSMMSS, SSMMMSS, SMMMMSS
Line Width 1000
1600
2400
3200
1000
1600
2400
3200
4200 Plus (+200)
5200 Plus (+200)
Max. Production Speed 910 m/min 1200 m/min 1200 m/min
Hard Piece Reduction
Basement
Spunbond Technology RF4 RF5 RF5
Meltblown Technology RF4 MB RF5 MB
RF4 MB as option for multi-row
RF5 MB
RF4 MB as option for multi-row
Specific Throughput SB (kg/h/m) 120 - 200 150 - 270 150 - 270
Specific Throughput MB for Composite Lines (kg/h/m) 15 - 50 15 - 70 15 - 70
Titer Range znPP (den) 1,5 - 1,8 1,2 - 1,8 1,2 - 1,8
Titer Range mPP (den) 1,0 - 1,5 0,9 - 1,1 0,9 - 1,1
Production Speed on the Belt (m/min) 910 1200 1200
Specific Throughput @ 1.8 den (kg/h/m) 200 270 270
Specific Throughput @ 1.5 den (kg/h/m) 175 230 230
Specific Throughput @ 1.3 den (kg/h/m) 150 170 170
Specific Throughput @ 1.2 den (kg/h/m) 140 160 160
Specific Throughput @ 1.1 den (kg/h/m) 130 160 160
Specific Throughput @ 1.0 den (kg/h/m) 120 150 150
Specific Throughput @ 0.9 den (kg/h/m) N/A 140 140
Digital Assistant optional yes yes
RF5 Human Machine Interface optional yes yes
Virtual Sensors optional yes yes
Reicofil Nonwoven Grading optional optional optional
Condition Monitoring / Predictive Maintenance optional future joint development optional future joint development optional future joint development
Cloud Analytics optional future joint development optional future joint development optional future joint development
Download ”RF5 Technology - Technical Data”
Contact

We look forward to welcoming you!

You want to learn more about our technologies and meet us face to face? We will be pleased to hear from you.