Berry Global Group Inc. has put the finishing touches on $15 million worth of improvements at the company's nonwovens production facility in Terno d'Isola, Italy.
A two-year effort has created improvements in production processes and innovation capabilities, according to Vincenzo D'Acchioli, director of product marketing for hygiene based in Italy.
"The transformation delivers enhanced production processes and innovation capabilities to respond to the changing market demands," D'Acchioli said in an email interview. "The new and upgraded manufacturing lines in Terno are designed for the production of all basis weights for air-through bonded carded nonwovens with both mono and multi-layers."
Carding, D'Acchioli explained, "is a drylaid mechanical process where mixed fibers are conveyed by air transport to be combed into a web by a carding machine."
A carding machine is made of a rotating drum or a series of drums covered in fine wires or teeth. Formed fibers can be bonded by hot air or pressure and temperature during the nonwovens production process on the machine.
The improvements also included new automated high-speed spooling machines.
"The upgrades provide significant capability in servicing critical areas of the hygiene product marketplace, including topsheets, backsheets and acquisition/distribution layers (ADL) through advanced air bond and thermal bond technologies," D'Acchioli said.
Upgrades also include a new research and development laboratory for hygiene material development.
"The site's new multi-layer capability specifically supports performance in addressing thinner product market trends, as well as advanced construction techniques targeting performance as well," D'Acchioli said in the email interview. "Additionally, the site's spooling capacity has been increased 100 percent in order to improve ultimate product quality by helping preserve material loft and bulk."
The project included a new production line as well as an upgrade of an existing product line, the company said. The facility now has three carded lines.