Kohan Textile Journal presents an exclusive interview with Jutta Stehr, Head of Marketing at Trützschler Nonwovens, exploring the company’s latest advancements in recycling, circularity, AI-driven digitalization, and sustainable nonwoven technology. As global demand for recycled fibers accelerates—and as regions like Africa prepare to scale textile waste management—Trützschler shares its strategic insights, technological innovations, and long-term vision for building a smarter, greener, and more resilient textile future.
Recycling Innovation and Technology
Trützschler Nonwovens has been a pioneer in developing recycling solutions for textile waste and post-consumer materials. Could you share the latest innovations your company has
The main challenge in regard to recycled fibers lie in collecting, sorting, and recycling post-consumer textiles, as consistent, homogeneous raw materials are essential for stable production and product quality results.
While R-PET fibers from PET bottles are easy to process with our equipment due to their uniform properties, fibers reclaimed from mixed textiles are more difficult. Mechanical recycling shortens these fibers and affects their strength, limiting their use to lower-grade nonwovens like airlaid, thermobonded plaster or buffer fleece. These nonwovens usually are thrown away to go to incineration or landfill.
Currently, our own solutions for processing post-consumer recycled fiber materials are still under development. Our NCTC Technical Center can process various fiber types and blends, and we encourage customers to test their recycled materials and to develop stable and efficient production processes.
Circular Economy and Global Demand
With growing demand for recycled fibers worldwide, how does Trützschler support manufacturers in adapting their production lines to meet circular economy standards without compromising quality or productivity?
Our machinery processes recycled fibers such as R-PET and also cotton comber noils. These waste fibers from the combing process can be used with our NCR random and NCA airlaid cards to produce high-quality cotton wipes or pads.
Innovations in this regard are our latest X-series cards. Both the NC-X and the NCT-X card feature a separate good fiber suction system, which recycles unconsolidated web edges back into the blending bin after web formation.
Africa’s Rising Potential in Recycling
The African continent is gaining attention for its growing textile sector and its need for sustainable waste management. How do you evaluate the potential for recycling and nonwoven production in Africa, and is Trützschler planning any partnerships or initiatives in this region?
As previously mentioned, the real challenges lie in creating textiles designed from the outset for recycling. Mixed materials or fast-fashion items, for instance, pose particular difficulties in recovering high-quality fibers.
The export of used textiles from Europe to Africa tends to be problematic: it can provide short-term social and economic benefits by creating informal jobs and offering affordable clothing. But second-hand textile exports ultimately hinder the development of sustainable local textile industries and worsens waste issues, as much fast fashion items cannot be reused.
Currently, nonwoven production in Africa is very limited. For years, we have sought to encourage potential manufacturers to establish local nonwoven production, especially for technical applications like road construction or other local industry branches, as well as hygiene products such as diapers and wipes.
AI and Digitalization in Nonwoven Machinery
Artificial Intelligence is transforming machinery monitoring and maintenance. How is Trützschler integrating AI, IoT, and digital analytics into its nonwoven lines to enhance performance, predict maintenance needs, and reduce operational downtime?
Our digital solution is called T-ONE. This modular software system centrally collects all product and production-relevant data. There are already solutions available for many applications, such as quality control, recipe management, process monitoring and documentation, as well as AI-based plant optimization.
A key advantage is that T-ONE can be seamlessly integrated into the customer’s existing IT landscape – including their ERP and MES systems, as well as any digital solutions they may already use for instance for recipe management.
T-ONE is continuously developed further. Our customers have a direct say in which new features are implemented next. Currently, additional functionalities are being tested, scheduled for launch in 2026.
This customer-driven approach is what makes T-ONE so successful, enabling its use not only in the production of polymer and staple fiber-based nonwovens, but also in other industries.
Sustainability and Energy Efficiency
Energy consumption remains a major cost factor in nonwoven production. What energy-saving or eco-efficient technologies has Trützschler developed to help customers reduce both environmental impact and production costs?
Our main objectives for our customers’ success are: a) to minimize fiber usage in each product, thereby saving costs and valuable resources; b) to maximize machine availability, ensuring customers achieve the highest possible output; and c) to ensure our machines consume as little energy as possible.
Our production line concepts are meticulously tailored to the customer’s product range and processes. For example, our new NC-Xe card is a streamlined version specifically adapted to the lower requirements of standard needle-punching lines.
In our new MPD (Modular High-Performance Dryer) we have further reduced energy consumption. Especially cotton lines or high-speed spunlacing lines for viscose or wet-laid nonwovens require a high drying capacity. The MPD dryer’s thoughtful design reduces energy by more than 10% compared to other solutions. Additionally, this dryer is equipped for operation with hydrogen or biogas, providing our customers with a forward-looking, future-proof solution.
Future Outlook and Industry Vision
Looking ahead, how do you see the future of the nonwoven and recycling industry evolving globally — and what role will Trützschler Nonwovens play in leading the transition toward smarter, greener, and fully circular textile manufacturing?
Both single-use and durable nonwovens will continue to serve an important function within the textile industry. These materials offer a broad range of applications designed to improve safety and health (for instance geotextiles and filter media) and convenience, such as baby and adult diapers, femcare and wipes.
To promote sustainability, the expanded use of recycled fibers is necessary; however, supply chain challenges must first be addressed. The role of machinery in this context is comparatively minor.
Trützschler remains at the early stages of this transition, but our machines are frequently suitable for processing recycled fibers. We recognize that each customer’s fiber material and final product requirements are unique. Our Nonwovens Customer and Technology Center (NCTC) is available for testing fibers, developing reliable production processes, and producing all varieties of fiber-based nonwovens incorporating recycled materials.
