Manufacturing base Aschersleben, Germany
Masterplast Nonwoven GmbH in Germany has been operating as part of the Group since 1 July 2020, where nonwoven manufacturing looks back on more than 25 years. The acquired plant specializes in nonwoven fleece product manufacturing from PE and PP raw materials, and during its decades of operation significant know-how and experience have accumulated; therefore, the factory is considered an expert in its field. Nonwoven fleece is a commonly used material type, and several industries such as construction, healthcare, hygiene, vehicle, agriculture, air technology, food and home textile broadly use the different properties of the fleece materials produced in our factory.
Nonwoven fleece manufacturing
The Aschersleben plant builds on a spunbond-based nonwoven manufacturing platform matured over decades. Complemented by inline film extrusion and a separate lamination unit, the fleece line is able to serve an exceptionally wide range of industrial demand, in constant quality.
- BICO spunbond technology — bicomponent fibre forming, in which the core and the sheath of the fibre are made of different polymers; products can be fine-tuned through the coordinated operation of two extruders and targeted additives.
- Two spinning beams, 2.4 m manufacturing width — greater capacity and even quality; the fibres are laid on the conveyor belt by vacuum, then reach the 2.4 metre width as they pass through the calender rollers.
- Inline film forming and lamination — in multi-layer materials the film layer is extruded directly onto the fleece, bonded at the level of the material, in a single process.
- Biaxial stretching up to 5.2 m width — simultaneous stretching lengthwise and crosswise significantly increases the mechanical strength of multi-layer products and makes extra-wide rolls possible without bonding.
- Additives and an inline kiss-roll surface — additives at the level of the raw material allow product properties to be controlled between wide limits, while the kiss-roll unit sets the vapour permeability of the film layer.
- LINOPORE® / LINOBARRIER® — internationally trademarked product families, vapour-permeable and vapour-barrier respectively.
- Online quality control and a laboratory of our own — continuous monitoring, full batch traceability, and laboratory support for development and certification.
In the German plant hydrophobic PP and PE spunbond is made in the 15–120 g/m² weight range and in roll widths of 2.1–2.4 m, and can be ordered in flame-retardant, UV-resistant, hydrophilic, mite-resistant, antibacterial, antiviral, antistatic or custom-coloured versions on request. It is this flexibility that lets the same raw material serve industries from construction membranes to hygiene, furniture, automotive, agricultural and filtration applications.
Roof underlay manufacturing
Because of Masterplast's roots in construction, roof underlay and membrane manufacturing is the field in which the Aschersleben plant has the most experience. The LINOPORE®-based two- and three-layer membranes give watertightness, controlled vapour permeability and high tensile strength at once, for pitched roofs and wall structures.
The plant produces three-layer vapour-permeable membranes, together with two- and three-layer vapour-control layers and vapour-barrier films. The special material composition and the manufacturing technology together give the premium roof underlay films and wall insulation (windproof) membranes their high tensile strength, UV resistance and flame-retardant properties. On request the membranes are also made with an integrated self-adhesive strip, which makes installation on site and precise sealing easier.
Beside the standard Mastermax branded products we also manufacture custom, own-brand roof underlays — with one- or two-colour logo printing, in custom roll sizes and colours. The roof underlay range is certified in accordance with the European construction certifications: CE, BBA, CSTB, SINTEF and CCMC.