Nonwovens / Paper / Films / Textiles / Healthcare / Composites
Softness, Bulk, Shrinkage Control, Stretch & Extensibility
Drape & Hand, Decorative Effects, Absorbency
  OverviewApplicationsProduct Development & TechnologyTrialsContract ConvertingAbout Micrex


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Learn more about current Micrex applications by reviewing recent issues of our Technical Newsletter


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Product Development & Technology:

Micrex is focused on helping our customers develop new products utilizing Micrex technology. Our development process has been refined over the last decade of work with R&D teams from leading global roll good manufacturers and product goods companies.

Micrex’s development methodology is built around four principles:

  • Quick response and rapid prototyping as a requirement
  • Ability to rapidly go from a lab-scale prototype to global sourcing of Microcreped product
  • Understanding the importance of cost at all stages of a development
  • A rigorous respect for the IP and confidentiality of our customers

 

How We Work:

The Micrex Process has a minimum of 27 different points of adjustment.  Each of these "points" has from two to almost infinite levels of adjustment.  Simply put, this allows for potentially millions of different sets of process settings.  Further complicating matters is the reality that the recipe of the incoming material is probably more critical to the performance of the process than the adjustments to the machine itself. 

This means that there is no reliable predictive model on how a particular substrate will process on a Micrex/Microcreper.  For this reason, Micrex technology is applied using an empirical model based on trials.  In our production facility we have three lab scale machines on which we can produce all nine configurations of Micrex/Microcreper.  This allows us to efficiently test a wide range of  conditions to quickly arrive at a go / no go gate toward further development.

Based on success of these initial "screening trials", we are configured to seamlessly move through developmental and then production trials, all the time using our knowledge of the technology to optimize the final product constant with our customer's objectives.

Very often we are able to suggest modifications to the base substrate which while geared toward improving performance on the Micrex/Microcreper,  will actually result in system-wide lower costs.

Critical to success is a close working relationship with our customers. Successful firms have learned that even when one round of product development is completed, it is crucial to continue to integrate Micrex in subsequent generation of products. 

Almost without exception -- no company has been able to successfully innovate new Microcreped products on their own production equipment.

 
New Technology:

Micrex technology is always advancing.  Whether by inventing new configurations of Micrex/Microcreper, or by expanding the operating envelope of an existing configuration, we are committed to expanding the usefulness of Micrex technology. 

Screening trials - even unsuccessful ones help guide our research work.  While in 1988 there were only two versions of the Micrex/Microcreper, now there are nine.

Current technology

 

Micrex/Microcreper Configurations:

There are five base configurations of the Micrex/Microcreper, and four advanced configurations (which are only available in-plant to our contract converting customers).

The basic configurations are Comb Roll, Rigid Retarder, Bladeless, Flat Blade and Two Roll.  

The Two Roll cavity illustrated above is the most recent commercial development by Micrex.  This system -- utilizing two drive rolls and two retarding blades, is at the core of the Micrex/Mark II technology.

Designed to minimize damaging heat at high speed, this system processes low melting point substrates such as polypropylene or polyethylene.

 

The Comb Roll configuration is widely used to soften hydro-entangled nonwovens, and crepe high basis weight substrates.

 

The Bladeless configuration is widely used to soften light weight nonwovens, bulk gauze, and a wide range of shrink proofing applications. Designed to compact less structured materials, the bladeless cavity is used in a wide range of applications that could not withstand the forces of the Rigid Retarder cavity.  

Picture of the underside of the package

The Rigid Retarder configuration is widely used to soften wet laid products, crepe paper, and process a wide range of nonwovens.

 

The Micrex/Microcreper equipped with a Flat Blade Cavity is designed to give the textile finisher maximum flexibility to respond to a competitive style-driven marketplace.

A poly/cotton material can be made into a whole series of rich decorative styles. Many decorative styles are possible, plisse, crepe, and seersucker all can be accomplished on the same basic material within minutes.

The process utilizes a notched blade made from spring steel, which selectively compacts the fabric. New styles can be configured by the operator using scissors, simply by cutting patterns in a steel blade. The spacing is limitless and is solely up to the finisher. The Micrex/Microcreper is able to impart a myriad of patterns with a relatively short changeover time, typically 2-3 minutes. In one case of a shower curtain manufacturer, the customer specified a 5 inch wide "pucker" with a 1/4 inch compacted width. 

A wide range of woven fabrics can be processed on the Microcreper. Materials that contain 50% or more synthetic fiber (polyester or nylon) can have the patterns set right on the machine. An external hot oil system provides the necessary heat to the main roll to "set" the patterns into the fabric to hold up through home laundering. 100% cotton fabric and material with high amounts of natural or cellulosic fibers need pre and post treatment with the use of resin to stand up to washing.

 

To learn more about the machinery.