From the Sector

• Fraunhofer, SABIC, and Procter & Gamble join forces
• The Fraunhofer Cluster of Excellence Circular Plastics Economy CCPE and its Institute for Environmental, Safety and Energy Technology UMSICHT have developed an advanced recycling process for used plastics.
• The pilot project with SABIC and Procter & Gamble serves to demonstrate the feasibility of closed-loop recycling for single-use facemasks.

Due to COVID-19, use of billions of disposable facemasks is raising environmental concerns especially when they are thoughtlessly discarded in public spaces, including - parks, open-air venues and beaches. Apart from the challenge of dealing with such huge volumes of essential personal healthcare items in a sustainable way, simply throwing the used masks away for disposal on landfill sites or in incineration plants represents a loss of valuable feedstock for new material.

“Recognizing the challenge, we set out to explore how used facemasks could potentially be returned into the value chain of new facemask production”, says Dr. Peter Dziezok, Director R&D Open Innovation at P&G. “But creating a true circular solution from both a sustainable and an economically feasible perspective takes partners. Therefore, we teamed up with Fraunhofer CCPE and Fraunhofer UMSICHT’s expert scientists and SABIC’s Technology & Innovation specialists to investigate potential solutions.”

As part of the pilot, P&G collected used facemasks worn by employees or given to visitors at its manufacturing and research sites in Germany. Although those masks are always disposed of responsibly, there was no ideal route in place to recycle them efficiently. To help demonstrate a potential step change in this scenario, special collection bins were set up, and the collected used masks were sent to Fraunhofer for further processing in a dedicated research pyrolysis plant.

“A single-use medical product such as a face mask has high hygiene requirements, both in terms of disposal and production. Mechanical recycling, would have not done the job”, explains Dr. Alexander Hofmann, Head of Department Recycling Management at Fraunhofer UMSICHT. “In our solution, therefore, the masks were first automatically shredded and then thermochemically converted to pyrolysis oil. Pyrolysis breaks the plastic down into molecular fragments under pressure and heat, which will also destroy any residual pollutants or pathogens, such as the Coronavirus. In this way it is possible to produce feedstock for new plastics in virgin quality that can also meet the requirements for medical products”, adds Hofmann, who is also Head of Research Department “Advanced Recycling” at Fraunhofer CCPE.

The pyrolysis oil was then sent to SABIC to be used as feedstock for the production of new PP resin. The resins were produced using the widely recognized principle of mass balance to combine the alternative feedstock with fossil-based feedstock in the production process. Mass balance is considered a crucial bridge between today’s large scale linear economy and the more sustainable circular economy of the future, which today is operated on a smaller scale but is expected to grow quickly.

“The high-quality circular PP polymer obtained in this pilot clearly demonstrates that closed-loop recycling is achievable through active collaboration of players from across the value chain”, emphasizes Mark Vester, Global Circular Economy Leader at SABIC. “The circular material is part of our TRUCIRCLE™ portfolio, aimed at preventing valuable used plastic from becoming waste and at mitigating the depletion of fossil resources.”

Finally, to close the loop, the PP polymer was supplied to P&G, where it was processed into non-woven fibers material. “This pilot project has helped us to assess if the close loop approach could work for hygienic and medical grade plastics”, says Hansjörg Reick, P&G Senior Director Open Innovation. “Of course, further work is needed but the results so far have been very encouraging.”

The entire closed loop pilot project from facemask collection to production was developed and implemented within seven months. The transferability of advanced recycling to other feedstocks and chemical products is being further researched at Fraunhofer CCPE.

• Digital Pioneer Awards ceremony at the digitalCHURCH
• ITA Academy GmbH was honoured to receive the Digital Pioneer Award at the Digital Summit Event in Aachen on June 09, 2021.

The Digital Pioneer Award is given to companies that drive digitalisation with digital business models, processes or digital products. ITA Academy GmbH was honoured with the Digital Capability Center (DCC) Aachen and its support of companies in their digital transformation.

Using the latest didactic methods, sophisticated solution concepts and state-of-the-art technologies, the DCC Aachen supports people in keeping up with the digital future and becoming pioneers in digital transformation. In order to make innovative solutions such as AI and digital assistance systems tangible, the ITA Academy founded the Digital Capability Center (DCC) Aachen together with McKinsey & Company in 2017. The DCC is a model factory 4.0 in which digital applications are demonstrated and taught using the example of a realistic factory. The DCC thus offers a learning environment for companies in which participants are supported in building up competencies in the field of digital transformation in the form of practical work-shops.

The digital pioneers are to be publicised as best-practice examples in order to sensitize regional SMEs to the topic of digitisation. Around the award of the digital pioneers, the digitalHUB Aachen e.V. rolls out effective marketing activities. The pioneers achieve high visibility through the various planned campaigns and advertising opportunities.

International technology Group ANDRITZ has received a repeat order from Zhejiang Saintyear Textile Co., Ltd., based in China, to supply a second, complete neXline spunlace line for the production of premium-quality nonwoven roll goods. The line is scheduled for start-up during the third quarter of 2022.

No later than nine months after placing a first order for a complete high-speed spunlace line, Zhejiang Saintyear Textile has decided to rely on ANDRITZ once again by purchasing another complete line dedicated to the production of first-class wipes. The production capacity will be up to 2,800 kg/h for lightweight fabrics.

ANDRITZ will provide a full line with state-of-the-art equipment – from web forming to drying. The scope of supply includes the precise opening and blending machinery from Laroche – newly acquired by the ANDRITZ GROUP, two inline TT cards, a proven JetlaceEssentiel unit for hydroentanglement, and the efficient neXdry through-air dryer.

Avgol, a subsidiary of global petrochemical producer Indorama Ventures Public Company Limited (IVL),  appointed Mr. Tommi Bjornman as its new CEO, replacing Mr. Shachar Rachim who takes up a broader role as CEO leading the Hygiene vertical of IVL’s Fibers business.

Mr. Bjornman’s new position with Avgol took effect on 1 June, 2021. The Hygiene business is one of 16 integrated verticals under Indorama Ventures, and comprises brands including Avgol, Auriga, FiberVisions, ES FiberVisions, Trevira and Wellman. The Hygiene vertical provides fibers and filaments used in hygiene, medical, personal protective equipment (PPE) and industrial disposable applications as well as durable textile applications used for automotive interiors, furnishings, wall and window coverings and related goods. Mr. Bjornman continues to report to Mr. Rachim who retains his role as an Avgol Board member.

ISKO presents 2022 Collection Vol. 2, a forward-thinking collection with responsibility, creativity, authenticity and comfort engrained into every fiber of every fabric to provide solutions for all denim lovers’ dreams and needs across the world.

2022 Collection Vol. 2 has been created using the company’s principles of Responsible Innovation™ and is made entirely with ISKO’s revolutionary R-TWO™ technology. Certified to Textile Exchange credentials, the R-TWO™ fabrics in 2022 Collection Vol. 2 ensure complete traceability of raw materials from field to final product. Using a blend of reused and recycled materials, they help decrease the usage of raw materials and improve sourcing efficiency, while preserving all the properties and benefits of each product. R-TWO offers a simple way for companies to switch from virgin to reused and recycled materials for all products in ISKO’s collection.

The 2022 Collection Vol. 2 further explores the four lifestyles introduced in ISKO’s Vol. 1 collection -Denim Lovers, Simplify, ISKO™ Comfy and Euphoria – building on a collection to provide further inspiration for designers and brands to suit different vibes and moods.

Montalvo, an international specialists in web tension control, has been awarded the 2021 Exporter of the Year Award from the Maine International Trade Center for outstanding commitment to strengthening Montalvo’s businesses through international markets.

Montalvo Corporation CEO Robin Goodwin. "This award feels like a validation of our strategy and the teamwork we have at Montalvo. This is huge for us. We are a small, family-owned company, and all of us here are excited as this award is something every single one of our employees shares in.  We have some great product development going, new industry’s we are getting into, and expanding our capabilities and solutions offering, so it’s a very exciting time for the company and our employees, and this award has only energized us further."

Montalvo sells to over 70 countries across the globe, with their headquarters in Maine, USA, and with operations in China and Europe.

• New capacity brought online to meet growing demand

Ascend Performance Materials has expanded production capacity for HiDura long-chain polyamides in its Greenwood, S.C., plant. The multi-million dollar expansion will help the company meet growing demand for its new product line.

Launched in Nov. 2020, Ascend’s HiDura PA610 and 612 products are used in a variety of consumer goods, industrial, renewable energy, automotive and electric vehicle applications. “Exceptional ductility, UV weatherability and hydrolysis resistance give HiDura resins and engineered plastics reliable, long-term performance in some of the harshest conditions,” said Kaan Gunes, business manager for HiDura at Ascend. Gunes cited applications in solar photovoltaic supports, battery seals and brush bristles to illustrate the versatility and durability of HiDura. “Each of these parts faces extreme conditions, whether the 25 years a solar PV installation will be exposed to the elements or the constant contact with corrosive chemicals inside a battery cell. The various grades we developed are designed to improve the reliability of our customers’ products.”

Ascend, which is the largest fully integrated producer of polyamide 66 resin, used its extensive polymerization knowledge to expand capacity at its Greenwood facility. “We have been polymerizing PA66 in Greenwood for decades,” said Michael Walters, senior site director for Ascend in Greenwood. “Our people understand how to consistently produce high-performance, high-quality materials safely and were excited to see the success of HiDura build off their work.” Ascend continues to expand its HiDura grades to meet the growing needs of its customers.

There are good reasons why narrow textiles are used so frequently in the fitness and rehabilitation sector: they are flexible, safe, light, durable, skin-friendly and have a low injury potential. Essential components are JUMBO textiles: Elastics can be used to convert kinetic energy into potential energy. This is why elastic cords and cables are some of the essential components of almost all fitness equipment and tools. After all, it is the elasticity of the trampoline cords that gives the jumping-sheet its necessary force. Only elasticated expander cords create the desired resistance of the classic strength training equipment.

The force-elongation ratio of elastic cords and cables – like all other properties – is specified individually and optimally for the respective application. Depending on the specific requirements of the narrow textiles in the respective product, expert teams develop cords and cables made of high-tech fibres and on high-tech equipment: technical textiles that are a perfect fit for the equipment and its functions.

Furthermore, non-elastic cords – depending on type and design – are essential as tension and connection elements for the functionality of fitness equipment. Textile components are often also an integral part of the equipment technology as fastening or fixing systems.

• The Techtextil and Texprocess trade fairs have a positive view of the future and invite the sector to take part at Frankfurt Fair and Exhibition Centre from 21 to 24 June 2022.
• Exhibitors who register well in advance benefit from an early-booking discount.

The dates for the next editions of Techtextil and Texprocess have been set and the leading international trade fairs for technical textiles and nonwovens and for the processing of textile and flexible materials are set to attract exhibitors and trade visitors from all over the world to Frankfurt am Main from 21 to 24 June 2022. Thus, the fairs are shifting the biennial cycle of events from odd to even years, which fits in perfectly with the sector’s international event calendar. Companies that book exhibition space at one of the two trade fairs no later than 31 August 2021 benefit from an early booking discount. “We see the future in a positive light and are confident that we will finally be able to give the sector the opportunity to meet and exchange ideas and information in June 2022. The desire for personal encounters, direct communication and new impressions is growing from day to day”, says Olaf Schmidt, Vice President Textiles and Textile Technologies.

Elgar Straub, Managing Director, VDMA Textile Care, Fabric and Leather Technologies, emphasises that, “Texprocess and Techtextil are the world’s foremost trade fairs for our innovative sector by a large margin. Both events offer customers an unrivalled overview of state-of-the-art innovations and technological developments – and beyond. Particularly when it comes to the latest trends for sustainability and digitalisation, Texprocess and Techtextil in Frankfurt represent the most important, future-oriented market. This makes it all the more important for both the exhibitor and visitor sides of the sector that we have the opportunity to obtain an overview of the latest market developments, to exchange ideas and information and to initiate new business. We are very relieved about this and hope that, next year, we will once again have the chance to generate new momentum for our sector in the international market.”

For the first time, Techtextil and Texprocess will occupy the western sector of Frankfurt Fair and Exhibition Centre with a total of four exhibition halls and, with a hybrid format, offer the best of both the physical and immaterial worlds: personal communication, virtual networking opportunities and maximum digital coverage. With a comprehensive hygiene and safety concept, Messe Frankfurt will ensure that all visitors and exhibitors can take part safely and with a good feeling.

Winding technology offers simplicity, productivity and product control for premium tissue products

Paper Converting Machine Company (PCMC)—a division of Barry-Wehmiller and a global supplier of high-performance converting machinery for the tissue, nonwovens, package-printing and bag-converting industries— is pleased to announce the launch of its Paragon tissue rewinder.

Paragon features a patent-pending center-surface design that produces superior caliper, bulk and diameter flexibility. Log winding takes place in a new-concept nest, comprised of a winding drum, winding belt, compound-motion rider roll and center drives.

"Paragon offers a completely new method of tissue rewinding,” said Andrew Green, PCMC Vice President of Tissue and Folding. “It is radical only in the sense that we made the wind nest as simple as possible. Usually when you increase a machine’s speed, you sacrifice ease of use, but we know customers want both. With Paragon, we created a machine capable of higher speeds that is easier to operate. It’s remarkable.”

Many of Paragon’s subsystems are proven technology solutions in use on PCMC’s trusted Forte rewinder, with several upgrades. Paragon’s enhanced web handling and grade changes are mainly recipe-driven, and its specially designed tools guide fast calibrations. Like the Forte rewinder, Paragon has an intentional open-access design, plus, typical areas to clean require less frequent attention, and recovery and restart occur safely and quickly. Paragon also closes the gap between humans and machines with a new Smart Touch human-machine interface (HMI), which delivers Industry 4.0 tools that transform data to action. Following high-performance design principles, the clean and modern interface provides enhanced operator help, and new smart analytic features offer insights to improve overall equipment effectiveness. The Smart Touch HMI works much like today’s mobile devices with swipe functionality, enabling a short learning curve and improved productivity.

“While the focus is on the new wind nest, a Paragon line is more than that,” said Green. “We added elements like advanced web handling and a state-of-the-art HMI. At PCMC, we are not into hyperbole, but we believe that this machine has raised the bar and is what future tissue-converting machines will be judged against. And, that’s why we called it Paragon.”