Producing a high-quality recycled fibre, free of neps (knots of tangled fibres) and with an excellent fibre effect, requires not only tearing but also carding. A textile tearing and carding system combines tearing with carding in an integrated flow: tearing breaks the material into fibre, and carding aligns and separates the fibres individually, producing a clean fibre, free of neps, ideal for high-quality nonwovens.
A textile tearing and carding system is a specialised solution for processing spunlace and air-through cloth waste, in particular the irregular edges (edge trim). The resulting fibre is free of neps and has a very good fibre effect, suitable for manufacturing new quality nonwovens. See the full range of recycling equipment and the solutions for textile recycling.
Key Advantages for Tearing and Carding Spunlace Waste
• Combined tearing and carding, a textile tearing and carding system combines the two processes for higher-quality fibre.
• Nep-free fibre, carding removes the neps (fibre knots), producing a clean and uniform fibre.
• Excellent fibre effect, the carded fibre has a very good fibre effect, valued in nonwoven applications.
• Specialised for spunlace and air-through, a dedicated solution for processing spunlace and air-through cloth waste.
• Processing irregular edges, ideal for the irregular edge trim of these materials.
• Fibre for new nonwovens, the resulting fibre is suitable for manufacturing new quality nonwovens.
• Closed loop for nonwoven manufacturers, recycling one's own waste into reusable fibre.
• Automatic control, integrated flow coordinated between tearing and carding.
Technical Specifications, Textile Tearing and Carding System
| Parameter | Value |
|---|---|
| Feedstock | Spunlace and air-through cloth waste, irregular edge trim |
| Process 1, Tearing | Opening: breaks the material into fibre |
| Process 2, Carding | Carding: aligns and separates the fibres individually |
| End product | Nep-free fibre, with an excellent fibre effect |
| Applications | Manufacture of new quality nonwovens |
| Specialisation | Processing spunlace and air-through waste |
| Control | Automatic, integrated flow |
| Components | CE marked where applicable |
| Capacity | Configurable according to the project |
Applications for Recycled Nep-Free Fibre
A textile tearing and carding system serves manufacturers of spunlace and air-through nonwovens who want to recycle their own waste (in particular the edge trim) into quality reusable fibre. These nonwoven manufacturing processes generate irregular edge waste which, recycled into a nep-free fibre, can be reintroduced into the production of new nonwovens.
Recycling nonwoven waste is encouraged at European level within the circular economy; a textile tearing and carding system delivered in Europe is designed in line with the requirements of the Waste Framework Directive 2008/98/EC. For complete textile recycling solutions, see also the complete industry solutions.
The role of carding in a textile tearing and carding system is crucial for fibre quality: after tearing, the fibre can contain neps (knots of tangled fibres) and unaligned fibres. Carding, through the action of cylinders fitted with card clothing, aligns the fibres individually, separates the neps and produces a clean, uniform fibre with an excellent fibre effect, far superior to fibre that has only been torn.
The specialisation for spunlace and air-through cloth of a textile tearing and carding system answers a specific need: these nonwoven materials have particular characteristics, and their waste (in particular the irregular edge trim) requires adapted processing. The system is designed to process this waste efficiently, producing a fibre suitable for reintroduction into the manufacture of new nonwovens.
The closed loop for nonwoven manufacturers is the major economic benefit of a textile tearing and carding system: a spunlace or air-through manufacturer who recycles their own edge trim into nep-free fibre simultaneously reduces the raw material cost and the waste disposal cost. The recycled fibre reintroduced into production replaces virgin fibre, improving the factory's economic efficiency and sustainability.
The quality of the nep-free fibre produced by a textile tearing and carding system opens up demanding applications: quality nonwovens (hygiene products, medical materials, premium wipes) require a clean fibre, free of knots. The carded fibre meets these requirements, allowing it to be reintroduced into the production of quality nonwovens, not just inferior applications.
Processable Materials
| Material | Notes |
|---|---|
| Spunlace edge trim | Irregular edges from spunlace production |
| Air-through edge trim | Edges from air-through cloth production |
| Spunlace waste | Nonwoven production offcuts |
| Air-through cloth waste | Thermal-bonded material offcuts |
| Discarded nonwovens | Materials of the same nature |
How It Works
1. The spunlace or air-through waste is fed into the tearing system.
2. Tearing (opening) breaks the material into fibre.
3. The torn fibre passes to the carding stage.
4. Carding aligns and separates the fibres individually, removing the neps.
5. The nep-free fibre, with an excellent fibre effect, is collected.
6. The recovered fibre is reintroduced into nonwoven production or sold.
The control system coordinates the integrated flow between tearing and carding. A correctly adjusted textile tearing and carding system produces nep-free fibre of consistent quality, suitable for reintroduction into the manufacture of new quality nonwovens.
Frequently Asked Questions
What are neps and why do they matter?
Neps are small knots of tangled fibres, which appear during tearing and reduce fibre quality. In quality nonwovens, neps are undesirable. A textile tearing and carding system removes the neps through carding, producing a clean and uniform fibre, suitable for demanding applications.
Why add carding to tearing?
Carding aligns the fibres individually, removes the neps and produces a fibre with an excellent fibre effect, far superior to fibre that has only been torn. A textile tearing and carding system produces a fibre suitable for reintroduction into the manufacture of quality nonwovens, not just inferior applications such as fillings.
Is the system specialised for certain materials?
Yes, a textile tearing and carding system is specialised for processing spunlace and air-through cloth waste, in particular the irregular edges (edge trim). These nonwoven materials have particular characteristics, and the system is designed to process them efficiently into reusable nep-free fibre.
Is the equipment delivered new?
Yes. We deliver new, unused equipment, made to order, not refurbished units. The construction uses components from established suppliers, CE marked where applicable, and each system undergoes a complete inspection before shipping. You receive the technical documentation and operating manuals in your language.
What makes URSTAG a premium brand?
European design, top-tier components and experience. Every machine is designed by our engineering teams in Europe and built from components by industry leaders such as Siemens, Schneider Electric, ABB, WEG, SEW-Eurodrive, NORD Drivesystems and Bonfiglioli. The result is reliable, energy-efficient and durable equipment, backed by over 15 years of experience and by delivery, installation, training and service included.
How long do installation and commissioning take?
Transport, commissioning and operator training are included and carried out by a local team, in your language. Before shipping, the system undergoes a complete inspection, so your unit becomes operational quickly, without hidden installation costs.
Can I recycle my own edge trim into nonwoven production?
Yes. A textile tearing and carding system allows spunlace or air-through manufacturers to recycle their own edge trim into nep-free fibre, reintroducing it into production. This closed loop simultaneously reduces the raw material cost and the waste disposal cost, improving the factory's efficiency and sustainability.
Why URSTAG?
URSTAG is a premium brand of recycling equipment, with over 15 years of experience. You don't just get a machine, you get a solution engineered by specialists, built from top-tier components and backed by a team that supports you from design through commissioning.
• European engineering, every machine and every complete line is designed by our engineering teams in Europe, with a focus on reliability, safety and energy efficiency.
• Premium components, we build on motors and automation from industry leaders: Siemens, Schneider Electric, ABB, WEG, SEW-Eurodrive, NORD Drivesystems and Bonfiglioli.
• Over 15 years of experience, we know how materials and machines behave in real-world operation, and we configure each solution for your flow and volume.
• New equipment, configured for you, we supply new units, made to order for your application, with complete technical documentation.
• Delivery, installation and training included, we handle transport, commissioning and operator training, with support throughout the equipment's life.
As a premium brand, URSTAG relies on European engineering, top-tier components and experience. You choose a partner that supports your production long term, with equipment built to run reliably in demanding industrial environments.
