T-ONE: The digital future of nonwoven production

T‑ONE is Trützschler Nonwovens’ modular software solution for smart production processes and sustainable efficiency improvements.

Based on a single source of truth, T‑ONE unifies all data, functions and best practices – regardless of machine type, line age or IT infrastructure.

Whether needle-punching, air-through bonding, hydroentangling, spunlacing, spunbond or meltblown processes: T‑ONE establishes the foundation for production excellence, streamlined workflows and long‑term competitiveness.

More time for what really matters

We call T‑ONE a “digital working environment” because it supports a wide range of tasks – from quality control and recipe management to KPI analysis, process optimization, continuous line monitoring, and energy and data management.

Your benefits at a glance:

Centralized data management and complete transparency
Digitized routine tasks (e.g. quality control)
AI‑assisted optimization and continuous improvement
Scalability and easy integration into existing systems
Support for sustainability goals through energy and CO₂ management
Knowledge retention within the company

Table of content

Proven successes of T‑ONE
Which modules and features are available?
Which are the benefits of digitalizing with T‑ONE?
The path to T-ONE - structure, approach and collaboration
Why do customers value working with T‑ONE?

What proven successes have been achieved with T‑ONE?

Up to 100% higher production speeds

Up to 30% less waste

Up to 15% better product properties

Up to 50% shorter product development time

General questions about T-ONE

Is T‑ONE only available for Trützschler equipment?

No. T‑ONE is manufacturer‑independent and can be used on all nonwoven production lines – regardless of age, type or manufacturer. Machines from other suppliers can usually be integrated without issues; in special cases, interfaces may need to be programmed.

What prerequisites are required for T‑ONE?

T‑ONE works with all production technologies and machine types, regardless of age or existing interfaces. You only need a server (local or cloud‑based).
The software can operate with or without SCADA/OPC – and you do not need to connect your line to T‑ONE immediately. Either way, after implementation you receive a fully functional T‑ONE system.

Is T‑ONE a stand-alone system?

No. For efficiency reasons, T‑ONE should be connected directly to the production line. However, even without direct machine connectivity, T‑ONE can already capture, document and analyze production‑relevant data.
In addition, the software offers flexible interfaces to ERP and MES systems, SCADA/PLC, OPC servers and measurement devices, enabling data exchange with existing IT systems.

Is T‑ONE capable to communicate with existing IT systems?

Yes. T-ONE offers flexible interfaces to ERP and MES systems, SCADA/PLC, OPC servers and measurement devices, enabling data exchange with existing IT systems.

How quickly will measurable improvements appear?

Initial measurable effects – such as more stable processes or increased A‑grade output – typically appear after a few months, usually toward the end of our support phase.

Are there examples or references from companies successfully using T‑ONE?

Yes. There are more than a dozen T‑ONE installations worldwide that have been running successfully for years. These customers have achieved proven, significant performance improvements in their lines. If you want details about specific references or concrete results, feel free to contact us directly.

Which modules & features does T‑ONE offer?

Each software module supports a mission‑critical task within nonwoven production and enables intelligent, streamlined workflows. T‑ONE increases efficiency across the production line and within the team, while enabling transparent and future‑proof production processes. Currently, eight modules are implemented:

Interfaces & historization (long-term data storage)
Quality Control
Recipe Management
Production Documentation
KPIs and Continuous Improvement
Process Monitoring and Energy Management
Process Optimization
Anomaly Detection

Every module is designed to enable smart production processes, increase efficiency, and make production transparent and future‑proof.

Interfaces & historization

Connection to the production line, external systems and data storage

Compatible with ERP, SCADA, PLC and measurement systems.
Flexible integration into existing IT landscapes.
Assured data storage - even when expanding the system, for example by adding new modules or extending it to additional production lines.

Digital quality control

Foundation for fast decisions

Digital recording, monitoring and documentation of all quality data.
Automated creation of certificates and reports.
Visualization of trends and key figures.

Smart recipe management

Consistency across all shifts

Central management of all production recipes and parameters.
Fast adjustment and transfer of recipe changes.
Direct upload of recipes to the production line.

Production documentation

Foundation for optimization and root‑cause analysis

Complete documentation of all settings and changes.
Linking with quality data to create the “digital twin” of each nonwoven roll.

KPI analyses & continuous improvement

Consistency across all shifts

Automatic generation and evaluation of performance indicators.
Root‑cause analysis for efficiency losses.
Planning and implementation of improvement measures.

Process monitoring & energy management

Achieving quality and sustainability targets

Real‑time monitoring of all production data and alarm limits.
Calculation of energy consumption, costs and CO₂ footprint per kg or running meter of product, job or per roll.

AI‑assisted process optimization

Reliable suggestions for better products and processes

Self‑learning algorithms analyze machine settings and product quality.
Simulations and optimization suggestions for operators.
Reduction of waste and energy consumption.

Detection of anomalies

Camera‑based monitoring of critical machine areas

Early detection of deviations and automated warnings.
Protection against waste and machine damage.

Frequently asked questions about modules and functions of T‑ONE

Which tasks does T‑ONE automate?

T‑ONE automates data acquisition, documentation, evaluation and alarm handling, creates user‑specific visualizations and reports, and supports optimal machine settings – helping to improve quality while reducing cost.
Control always remains with the operator – T‑ONE supports but does not intervene directly in machine control.

How flexible can T‑ONE be adapted to our workflows?

T‑ONE adapts to processes, lines and user groups. User rights, dashboards, visualizations and evaluations can all be configured individually.

Can T‑ONE calculate and optimize the CO₂ footprint of my products?

Yes. The module “Process Documentation & Energy Management” shows energy consumption and – if desired – CO₂ footprint in real time per job or roll. With the “Process Optimization” module, energy and material consumption can be reduced in a targeted manner.

Where are the advantages of digitalizing with T‑ONE?

The T‑ONE modules combine all relevant data and processes in a central working environment. Systematic workflows based on implemented, proven routines—so‑called best practices—provide decisive advantages for sustainable production excellence.

Specific advantages of T‑ONE

Single-source-of-truth:
T‑ONE users have access to all relevant production data via the central T‑ONE database – ranging from customer specifications, measurement plans and CoA (Certificate of Analysis) templates to process parameters, KPIs and measurement data for every nonwoven roll produced. This ensures that all teams work with the same consistently up‑to‑date information and make data‑driven decisions, increasing overall performance and aligning results across different shifts.

Digital twin for every nonwoven roll:
Complete data is the foundation of everything: T‑ONE fully documents all relevant information – recipe, machine settings, quality measurements. They are accessible at any time.

Advantages of a digitalized production

More efficient. More transparent. More competitive.

Digitalized production processes connect machines, materials and data in real time. This results in stable workflows, less waste and optimally used resources. Continuously available production and quality data enable faster, better‑informed decisions and measurably reduce downtime and costs. At the same time, flexibility increases: product changes, adjustments and optimizations can be executed faster and more reliably – a critical foundation for high delivery performance and sustainable growth.

Digitalization helps companies reduce costs, accelerate innovation and adapt flexibly to changing market conditions.

AI-based optimization:
Active support and therefore reduced risk during process adjustments: AI‑assisted suggestions and simulations help your teams identify optimal machine settings.

Support for the production team:
T‑ONE embeds best practices directly into the system: the software guides users through each step, minimizes sources of error and enables new team members to get started quickly and safely.

Securing and leveraging knowledge:
Support extends beyond daily tasks: recipes and their history remain centrally stored. Changes and their effects are fully traceable.

Develop products faster:
Combining intelligent recipe management, digital documentation and line simulation significantly accelerates product development.

Continuously improve processes:
Custom KPIs, systematic data evaluation and integrated root‑cause analysis increase efficiency, process stability and sustainability step by step.

Increase sustainability & resource efficiency:
T‑ONE helps reduce energy consumption, CO₂ footprint and material usage – while maintaining consistently high product quality.

Frequently asked questions about system and software

How does T‑ONE differ from classic SCADA or MES systems?

T‑ONE was developed by nonwoven experts for nonwoven experts. That’s why the software consistently reflects typical data structures, KPIs and workflows of the industry. It combines proven best‑practice workflows in recipe, quality and documentation management with AI‑assisted optimization of domain‑specific data. In T‑ONE projects, you always work with specialists in fiber‑ and polymer‑based nonwoven production.

Is there a smartphone app for T‑ONE?

T‑ONE is an industrial software solution designed for large data volumes, real‑time analytics, simulations and guided workflows – this requires a powerful, secure IT environment. Use is possible via Windows‑based laptops or tablets; smartphones are not recommended.

Which data does T‑ONE capture – and how is it protected?

T‑ONE records, among others: product specifications, production and quality data, machine settings, sensor data and energy/consumption data. All data is stored in a secured database within your IT infrastructure (local or cloud). Access rights can be controlled granularly, backups run automatically, and the architecture follows common security and compliance standards.

How long is data stored, and how is traceability ensured?

Storage intervals and retention periods are configurable. Every manual change and comment is logged. For every produced roll, a complete ‘digital twin’ is created with recipe, machine settings and quality measurements – fully traceable.

The path to T-ONE - structure, approach and collaboration

Introducing T‑ONE is not a traditional IT project, but a structured path toward greater transparency, stability and continuous improvement in nonwoven production. From the initial assessment through step‑by‑step implementation to ongoing optimization, Trützschler supports customers with a clear methodology, defined project phases and close collaboration between all participating teams.

Frequently asked questions about T-ONE projects

How does a typical T‑ONE project work?

It begins with an on‑site visit to analyze your processes and goals. After that, you receive a tailored implementation plan. Basic installation usually takes 1–3 weeks (depending on modules/interfaces). Afterwards, we support your team until they can operate T‑ONE independently and confidently.

What IT environment is recommended for T‑ONE?

Recommended are secured Windows servers (on‑premises or cloud) with regular backups, role‑based access rights and standardized interfaces (e.g., OPC UA).

Can we start with individual modules?

Yes. You can freely choose the modules per line. Starting with a streamlined configuration is possible; expansion happens step by step as needed.

Is T‑ONE scalable?

Yes. T‑ONE is modular and can be expanded at any time with functions, lines or sites – without changing systems.

Which training and support services are provided?

We train all employees who work with T‑ONE – from operators and quality engineers to product developers and managers. During commissioning, we provide targeted on‑site coaching. After go‑live, we remain available and offer needs‑based support packages.

Our customer love working with T-ONE. Why?

Customers value T‑ONE because it helps them truly understand their processes—rather than relying on experience or gut feeling.

Production speeds can be increased in a targeted manner because settings, cause‑and‑effect relationships and process limits become transparent. Process stability improves, variation in product properties is reduced, and production speeds can therefore be raised step by step. In many cases, fiber consumption can also be reduced, as more stable processes and lower variability make it possible to reliably achieve the required mechanical properties—such as strength, elongation or nonwoven thickness—even with less material.

At the same time, scrap rates and the share of B‑quality products decrease: operator teams can apply validated machine settings from standardized recipes, detect deviations from target quality at an early stage, and systematically analyze and eliminate their causes. Beyond this, T‑ONE opens up new possibilities in product development. Existing recipes provide a defined starting point, while self‑learning algorithms offer guidance on how product properties can be adjusted in a targeted way. As a result, stable processes for new nonwoven qualities are established at an early stage—shortening development times because results are comparable and progress is transparently documented.

For many customers, T‑ONE is therefore more than just a digital tool: it becomes a shared point of reference for production and development—and an integral part of a data‑driven, learning organization.

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