AUTEFA Solutions offers automated production line for FFP2/ N95 mask

AUTEFA Solutions, leading manufacturer of
nonwoven machines and automation solutions, has developed HiPerMask, a fully
automated production line for the production of protective/face masks.
HiPerMask produces protective masks in accordance with the EU FFP2 and FFP3
standards as well as the US N95 and N98 standards. The first machines were put
into operation in Germany and Switzerland in May 2020. The first customers were
Univent in Germany and Flawa in Switzerland, the market leaders in mask
production in their respective countries. Both companies were also among the
first to be able to handle the corresponding federal orders in Switzerland and
Germany. AUTEFA Solutions has already sold a double-digit number of the
machines. All the machines stand out due to their high process reliability and
high level of productivity. 

The mechanical and electrical design,
production and assembly, software programming and in-house tests take place in
Friedberg, Bavaria and Frauenfeld, Switzerland. All parts and components used
in the machines are from well-known German and European manufacturers. This
means that all production processes are subject to the ISO 9001-2015 certified
quality standards of the machine manufacturer. AUTEFA Solutions Germany will be
the supplier of the additional machines and production lines. In addition to
the DACH region, the target countries for sales are all of Europe and the USA.

Christian
Egger, CEO AUTEFA Solutions Germany GmbH said,
“The unique combination of knowledge at AUTEFA in mechanical engineering,
nonwovens technology and automation has enabled us to provide customers with a
complete solution that leaves nothing to be desired. We provide customers not
only with mask production line, but also with access to premium material,
camera-based quality control and a fully automated packaging solution for the
final product. These added values offered by AUTEFA allow an economic mask
production. 

HiPerMask
– state-of-the-art technology for FFP / N protective masks 

The new fully automated HiPerMask
production line offers numerous advantages for successful FFP/N protective mask
production, for which AUTEFA Solutions stands as a leading machine manufacturer
with the requisite expertise and know-how. Particularly noteworthy is the high
process reliability with reproducible product quality and a production output
of over 50,000 masks/day. 

The HiPerMask production line consists of a
material feed, nose clip feed and positioning, ultrasonic welding units, ear
loops or headband stations, mask folding, punching, and dispensing of the masks
into a collection container. Numerous state-of-the-art individual units are
joined together into a unique machine solution in the HiPerMask. Among other
things, an unwinder with 6 stations ensures a warp-free synchronised material
feed. The respirator/ mask shape welding is done with EMERSON Branson ultrasonic
assembly technology.  Other units include
a nose clip unit with precise feeding of the nose clips, a printing unit for
affixing the labelling on both sides, including individual numbering and the
company logo, and a mask folding unit that is equipped with automatic centering
by means of a vision sensor and linear unit. As an option, the mask strip
welding can be carried out as an ear loop station or as a headband station with
band length adjustment.  Another outstanding
feature is the shaping and welding of the protective mask contour for different
mask sizes and protective mask shapes. The automation continues on the
HiPerMask up to the integration of the packaging machines. In this way, the
masks can also be automatically packaged in individual bags. The entire process
is monitored by an integrated quality control, which is controlled by cameras
and carried out with the help of artificial intelligence.

Full
service for ultra-fast time-to-market

The production line is topped off with
comprehensive full-service packages for starting production and procuring
consumables for meltblown and spunbond nonwovens as well as other accessories.
AUTEFA also offers companies assistance with certification. The resulting short
delivery times and the fast “time-to market” guarantee a successful
entry into manufacturing FFP2 and FFP3 masks.

One of the first development partners and
now a completely satisfied customer for the fully automated HiPerMask
production line is univent Medical GmbH in Villingen-Schwenningen, Germany. Managing Director Thomas Vosseler is
very satisfied with the system and the collaboration: “Mask production is
a new business in Europe, and we spoke to various machine manufacturers who
wanted to build the machines. In the end, AUTEFA convinced me as a global
acting specialist for nonwoven machines and lines. That has already created a
lot of trust. In addition, everything that we had in our future plans, such as
automated  packaging, automated control
and head loop stations, children’s masks, i.e., everything we wanted having
to  do with producing masks, was never a
problem for AUTEFA, which always said that it was doable. The message was that
we can manage to do everything together, and it is working really well now.
That’s why I would definitely choose AUTEFA again. “

Upgrade
of existing production technology for FFP / N masks possible

Thanks to the extensive know-how that
AUTEFA Solutions has in the area of mask production, many FFP/N  mask machines from other manufacturers that
are available on the market can also be expanded and  modernised. Examples of such upgrades are the
upgrading around ear loop and head band welding stations,  mask shape stamping (for different mask
shapes) and mask folding (here the centering is sensor-controlled),  and of course quality control of the
processes and the entire production. André
Imhof, CEO AUTEFA Solutions  Switzerland
has this to say: “The production of FFP /N protective masks is about
quality, efficiency and  output. At
AUTEFA Solutions, we are happy to help wherever possible to improve production
quickly and sustainably with our know-how and flexible solutions in order to be
able to produce more masks faster and 
better.”