German finishing machinery maker Monforts is offering textile producers full-scale trials of new fabrics and finishing processes at its Advanced Technology Centre (ATC) in Mönchengladbach — a route to validating investments before committing capital to new lines.

The centre, first opened in 2013 and later expanded, now covers 1,200 square metres. It houses two full-scale MONTEX stenter lines, a THERMEX continuous dyeing system for denim and other woven fabrics, a fully equipped colour kitchen and a range of laboratory-scale systems for small-batch trials.

"The ATC allows our customers to test their own textile products and technical fabrics on Monforts dyeing and finishing machines under completely confidential, real production conditions," said Monforts Marketing Manager Nicole Croonenbroek. "Using the results from these trials, we can also make recommendations for developing many fabric finishes."

For sourcing and production planners, the model addresses a familiar risk: mills can evaluate new fabric and finish applications in genuine production conditions before investing in their own capacity. Monforts frames the centre's core value as enabling validation of new fabrics, finishes and production technologies not just in the lab but on the factory floor, allowing producers to set optimum process parameters and take technically and economically more reliable decisions ahead of capital spending.

Dedicated technical textiles line

The ATC operates a line dedicated to technical textiles, designed for materials with widely differing performance requirements. Equipment includes a four-chamber horizontal chain MONTEX stenter and an explosion-proof coating cabin rated for work with organic solvents and other volatile substances.

The system processes at up to 320°C and, in some applications, can treat the top and bottom fabric surfaces at different temperatures in a single pass. Monforts says this delivers advantages in flooring, where the textile surface and rubber layer have different processing requirements; in chemically foamed PVC upholstery; and in heavily coated blackout curtain fabrics. It also permits the highly precise temperature control required when processing organic solvents used in applications such as antiseptic treatments for the pharmaceutical sector.

Digital application cuts resource use

Monforts has integrated a Baldwin TexCoat G4 digital spray system onto the technical textiles line. Used with Archroma's new-generation sustainable finishing chemicals, it applies water-based chemistry — softeners, antimicrobial treatments, water repellents and flame retardants — with precision. According to Monforts, when the TexCoat G4 runs in combination with MONTEX stenters it can cut water, energy and chemical consumption by up to 50% versus conventional pad applications.

Knits line targets tension control

A second line at the ATC focuses on knitted fabrics. Built around a vertical-chain MONTEX stenter, it runs at low, precisely controlled tension to preserve the elastic structure of knits while delivering homogeneous heat treatment.

The line's Eco Applicator offers an alternative to conventional wet-on-wet padding. It reduces fabric moisture at stenter entry from 60% to 40%, cutting energy consumption, and can apply different chemicals to one or both faces of the fabric.

Continuous dyeing and heat recovery

The Econtrol process fixes reactive dyestuffs in a single-stage dyeing and drying operation using a controlled combination of steam and air, completing both steps in two to three minutes at 120-130°C.

A Monforts Universal Energy Tower, recently integrated into the THERMEX line, recovers heat from exhaust air leaving thermal processes and delivers energy savings of up to 25% depending on operating conditions.

With the TexCoat G4, Eco Applicator and Universal Energy Tower now all proven on-site at the ATC, Monforts is positioning the centre as the proving ground where mills can benchmark those savings against their own fabric portfolios before signing purchase orders.