Döhler S.A., one of Brazil’s leading home textile producers, has increased production speeds and significantly reduced energy costs with wider fabric widths, since installing the new Montex 6500 stenter, produced by Monforts Textilmaschinen, a leading textile machinery manufacturer.

Brazil’s Döhler S.A. has installed a first Monforts stenter at its 22O,000m² facility in Joinville, Santa Catarina, to ensure increased production and significant energy savings whilst offering new business opportunities with new products – not previously possible with its older range of 10 locally-made stenters.

Doubling production

Currently producing 1500t/month – predominately home textiles for the domestic market – Döhler has ambitious plans to double production within five years, according to Ingo Döhler, the Managing Director.

“We are constantly seeking new technology and solutions to further improve our production techniques,” he said. This includes the recent installation of the first Monforts stenter, a Montex 6500. “With a finishing department comprising 10 older, locally produced stenters, we recognised the need to look at the latest technology in the marketplace.”

“We therefore placed the order for an 8-chamber Montex 6500 through local representative Euro-Texteis. Installed in a line incorporating a coating and flocking arrangement at the stenter infeed, the Montex has introduced wider fabric working at faster speeds. It has already provided energy saving of around 18% and increased production by as much as 30% with fabric widths of up to 3.20m.”

Family-run

Döhler was founded in 1881 by Ingo’s great grandfather Carl Gottlieb Döhler, a German immigrant.  Today, the company remains a family concern, with 10 family members – six as directors and four in production roles.

Led by President, Udo Döhler and Ingo Döhler as Managing Director, as the fourth generation, the newest fifth generation members are already working in the company.  

Home textiles specialist

Some 60 years ago the company opted to specialise in home textiles, today producing a comprehensive range of curtains, upholstery, table cloths, bed linen, terry towels, kitchen towels, vertical blinds and mattress covers.

“This wide range allows us the flexibility to meet, for example, seasonal high demands for certain products,” said Ingo Döhler.

In the finishing department, the fully integrated vertical operation purchased its first stenter in 1958, a Brazilian Texima.  Today with 10 units, the management recognised the need to modernise its facility and recently installed the first Montex 6500.

Montex line

“By incorporating the coating and flocking units into the inlet feed of the Montex 6500 we are able to carry out virtually every application required,” explained Ingo.  “The older stenters are virtually only able to finish one particular product.

“The Montex therefore makes us very flexible. For example, one of the older stenters also includes a coating and flocking unit, but it only accepts widths of up to 1.50m. The Montex with a working width of 3.20m opens new market opportunities for us.”

Another new product made possible for Döhler, thanks to the new Montex, is a 2.80m wide blackout curtain fabric, soon to be introduced into the market. “Currently a blackout curtain this wide must be imported,” claimed Ingo, “We will be the first Brazilian company to offer this product.”

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