Sia iCotton
Increasing basis weight, expanding production capabilities
SIA iCotton is a fast-growing international company specializing in the production of nonwoven materials for hygiene and cosmetic applications.
In a highly competitive market that demands increasingly high-performance and diversified products, the ability to increase fabric basis weight and expand the production range is a key strategic asset. To support the company’s growth and help unlock new business opportunities, Marzoli developed a tailor-made solution designed to enhance production flexibility, extend the achievable basis weight range, and significantly improve overall line efficiency.
Our intervention went far beyond a simple technological upgrade: it enabled SIA iCotton to access new application areas and laid the foundations for a more versatile, high-performance, and competitive nonwoven production process.
In a highly competitive market that demands increasingly high-performance and diversified products, the ability to increase fabric basis weight and expand the production range is a key strategic asset. To support the company’s growth and help unlock new business opportunities, Marzoli developed a tailor-made solution designed to enhance production flexibility, extend the achievable basis weight range, and significantly improve overall line efficiency.
Our intervention went far beyond a simple technological upgrade: it enabled SIA iCotton to access new application areas and laid the foundations for a more versatile, high-performance, and competitive nonwoven production process.
The challenge
As the only manufacturer in the Baltic States capable of offering a complete nonwoven production cycle, SIA iCotton operates in a highly competitive environment marked by rapid growth and increasingly specific market demands. The company therefore needed to address two closely connected requirements:
- Increase product basis weight to meet the growing demand for more structured, durable, and high-performance materials.
- Boost plant productivity and versatility in order to expand the product portfolio and quickly adapt to new trends in the nonwoven industry.
The requirements to be met were diverse but deeply interconnected: increasing the value and performance of the final product without compromising production speed and continuity, while at the same time ensuring maximum operational flexibility to respond quickly to market demands.
Marzoli Srl
The solution
To support SIA iCotton in this qualitative leap, we integrated condenser rollers into the four C701 cards dedicated to nonwoven production.
This targeted intervention transformed the way the company manages web formation and basis weight control. Designed to enhance process efficiency and stability, the solution now enables SIA iCotton to achieve superior performance in terms of product quality and production continuity.
Thanks to this advanced application:
This targeted intervention transformed the way the company manages web formation and basis weight control. Designed to enhance process efficiency and stability, the solution now enables SIA iCotton to achieve superior performance in terms of product quality and production continuity.
Thanks to this advanced application:
- The web basis weight can reach up to 60 gsm, ensuring greater structure and strength for nonwoven products;
- The condenser rollers, equipped with independently driven motors, provide extremely precise and customizable drafting control, optimizing every stage of the process;
- Fully adjustable line speed allows real-time production adaptation, maintaining uniformity and consistent quality even when materials or market requirements change.
The advantages of the solution
The results
“Thanks to this innovative solution applied to the cards of our plant, we were able to double the basis weight of the final product, reaching 280 gsm and significantly expanding the range of products we can offer our customers” the company states.
The developed layout introduces a strategic added value for SIA iCotton: the ability to broaden its product portfolio thanks to greater flexibility in raw material management.
Different fiber types - such as absorbent cotton, viscose, hemp, and cottonized flax - can now be processed both individually and in combination, enabling the production of multilayer nonwoven products made from two different raw materials.
This approach effectively meets the growing demand for nonwoven products that combine high structural strength, consistent quality, and maximum skin-friendliness - key requirements for hygiene and cosmetic applications.
The developed layout introduces a strategic added value for SIA iCotton: the ability to broaden its product portfolio thanks to greater flexibility in raw material management.
Different fiber types - such as absorbent cotton, viscose, hemp, and cottonized flax - can now be processed both individually and in combination, enabling the production of multilayer nonwoven products made from two different raw materials.
This approach effectively meets the growing demand for nonwoven products that combine high structural strength, consistent quality, and maximum skin-friendliness - key requirements for hygiene and cosmetic applications.
Thanks to its expertise and in-depth knowledge of a wide range of fibers, Marzoli immediately understood our requirements and translated them into a customized, versatile solution optimized for the available space.
SIA iCOTTON
