Textination Newsline

2 results
Photocredits: Hohenstein

Research Projects of the Zuse Community: Think about Recycling when Designing …

How applied research in cooperation with industry can lead to high-quality recycling solutions is explained by the Zuse community with its "Design for Recycling" series.

How applied research in cooperation with industry can lead to high-quality recycling solutions is explained by the Zuse community with its "Design for Recycling" series.

Artificial Turf of the Future
Textiles are much more than just clothes. The industry is a key customer for both synthetic and natural fibers. However, their textile products are often close to the consumer - this applies, for example, to the leisure industry or sports field construction, as is the case with artificial turf.
On sports fields, textiles are, so to speak, trampled underfoot, namely when playing on artificial turf. In Germany alone there are around 5,000 artificial turf pitches registered for football. But under the green stubble hides a heavy burden - for clubs and the environment. According to information from the IAKS Germany trade association, around 5 kg of granulate per square meter of artificial turf is infilled in Germany, and this figure is likely to be considerably higher in other countries. "In the case of artificial turf with a fiber length of 42 mm, only 12 mm look out of the mass of infill materials that have been applied to the surface," Dr. Ulrich Berghaus of Morton Extrusionstechnik GmbH, a leading manufacturer of artificial turf, explains. Nowadays, a new pitch is calculated to contain almost 50 percent of the old pitch - as infill material. But as a microplastic this can cause problems - alternatives have to be found. Together with the Aachen Institute for Floor Systems (TFI), Morton Extrusionstechnik is working on the artificial turf of the future, which can do without problematic infill materials.

The researchers at the TFI are now called upon to ensure that the nubs of the artificial turf will hold well in the carrier material in future, even without polyurethane and latex. "Ideally, artificial turf would be made of just one polymer," TFI project manager Dirk Hanuschik says. Because, similar to food packaging, inseparable material composites are poison for high-quality recycling. Hanuschik and his team are therefore researching with their industrial partner into an artificial turf design that does not require any polyurethane or latex for the backing of the carrier material. In a thermobonding facility, the artificial turf nubs are to be melted directly onto the base material, not glued on. Nevertheless, a durability of around 12-15 years is the goal - as with artificial turf laid today. He can test the new materials on the industrial coating plant, which is on a smaller scale at the TFI. The first production plant is scheduled to go into operation as early as the middle of next year.
"The practical project of the TFI is an excellent example of how industrial research from the Zuse community creates concrete benefits for people through sustainable recycling management. Research on 'Design for Recycling' is the focus of many of our institutes. Their close cooperation with companies and their interdisciplinary approach offer the best conditions for further innovations," explains the President of the Zuse Community, Prof. Martin Bastian.

Recycling in the Fashion Industry
Recycling is more than just a trend. In the future, fashion should increasingly include useful recycling: People in Germany buy an average of 26 kg of textiles per capita per year, including 12-15 kg of clothing. Given these large quantities, high-quality recycling is a major challenge. Improved recycling includes a circular economy that thinks about the "life after", i.e. the next or renewed product, already when designing products. A current research project of the Zuse community shows how this can work for clothing.
Beverage bottles made of the plastic PET are already ideally suited for recycling, and not only for packaging, because of their purity of type. Under the motto "From the fiber to the fiber", this is what the applied research in the joint project DiTex is using for rental linen. The fibers used come from recycled PET bottles, and the rented linen itself is to be recycled back into linen after its first life cycle.

"Rented linen is also well suited to the 'Design for Recycling' concept because its use can be precisely tracked, which provides optimum conditions for recycling," project manager Dr. Anja Gerhardts from the Hohenstein Research Institute explains. The institute from Baden-Württemberg is responsible for textile testing and product specifications in the project initiated and coordinated by the Institute for Ecological Economic Research (IÖW). For benefit rather than ownership, the partners in the alliance are developing a recyclable line of bed linen, as well as polo and business shirts. The shirts will serve as uniforms for police and rescue services.

Intelligent label stores information
The laundry is equipped with a digital tracking ID throughout the entire usage cycle. This "intelligent" label stores information such as fiber origin, material composition and composition of the textile. This enables recycling companies to sort the products better, increase the recycling share and upgrade them. Numerous washing trials are now being carried out at Hohenstein to test how well the tracking tool is performing and what the tensile strength, degree of whiteness, color quality, durability and wearing comfort of the textiles are when they are washed, spun and dried up to 200 times in commercial textile services. "In DiTex we bring users, procurers and recyclers of textiles to one table to make recyclable product design a reality", Anja Gerhardts explains.

"Practical research on fibers and textiles is one of the core competences of many of our institute, be it for industrial technical products or consumer-oriented products. Projects like DiTex show innovative solutions for design for recycling. Thanks to the interdisciplinary approach in our association, other industries can also learn from such solutions," explains Dr. Annette Treffkorn, managing director of the Zuse community.





  • 2015 Sales reached eight-year high
  • Particularly manufacturers of technical textiles successful

Prague (gtai) - The Czech textile and clothing industry is still on the upswing. Particularly in niche segments and with technical textiles the manufacturers achieve rising revenues since years. The investment climate in the sector therefore has been improved, the equipment suppliers are benefitting. German manufacturers of machinery for the textile and clothing industry were able to expand their exports to the Czech Republic in 2015 by one fifth.

  • 2015 Sales reached eight-year high
  • Particularly manufacturers of technical textiles successful

Prague (gtai) - The Czech textile and clothing industry is still on the upswing. Particularly in niche segments and with technical textiles the manufacturers achieve rising revenues since years. The investment climate in the sector therefore has been improved, the equipment suppliers are benefitting. German manufacturers of machinery for the textile and clothing industry were able to expand their exports to the Czech Republic in 2015 by one fifth.

With Czech Crowns 52.4 billion (Kc; EUR 1.9 bn) the Czech textile industry achieved so much revenue in 2015 as not anymore in the last eight years. According to the statistics office the clothing manufacturers output rose by 11%, that of textile manufacturing by 3%. Very good filled are the order books. For companies in the clothing industry the volume of new orders rose by over 13% in 2015, in the textile factories
by 4%.

According to the announcement of the professional association ATOK, the sector would have developed even better, if the growth markets in Asia and Africa would have not weakened. But fortunately the loss became offset by the traditional markets Germany, Italy, Poland, Slovakia, Austria and France. According to ATOK the textile segment of the Czech Republic exported goods worth equivalent of almost EUR 2.5 billion in 2015, corresponding to a trade surplus of almost EUR 30 million. In clothing, the country recorded a negative balance. Here goods were imported for Euro 2 billion and exported of EUR 1.3 Billion.

Sales Development of the Czech Textile and Clothing Industry
Year Sales in Kc bn. Change to previous year (in %)
2007 55.0 1.5
2008 46.1 -16.2
2009 41.1 -10.8
2010 41.3 0.5
2011 46.2 11.9
2012 45.9 -0.6
2013 47.1 2.6
2014 51.0 8.3
2015 52.4 2.7
2007 55.0 1.5

Source: Association of Textile, Garment and Leather Industry (ATOK, http://www.atok.cz)

Particularly in niche segments the clothing manufacturers can maintain themselves in their position. For example Triola from the northern Bohemia Horni Jiretin specializes in lingerie and successfully with oversizes. Also manufacturers like Timo, Pleas, Upavan or Linia can exist with underwear products on the market. According to reports from the business paper Hospodarske noviny Timo sells 200.000 pc. per year. The company offers among others prosthetic lingerie against breat tumors.In the next two years the family operation will invest more than EUR 700,000 in new technologies at the production site Litomerice (North Bohemia).

Hats and hoods are demanded in 30 countries

Another family company, Kama from Prague, specializes in headwear. With hats, scarves, headbands, gloves or hoods it makes now more than EUR 1 million per year and delivers to 30 countries. In Moravia-Silesia Sky Paragliders from Frydlant nad Ostravici invests around EUR 4 million in a weaving mill including a research center to develop new materials. The company produces emergency parachutes and rescue systems and belongs with annual revenues of EUR 2.7 million (2014) to the top ten manufacturers worldwide. It processes 200 kilometers of fabrics annually.

Thanks to favorable wages and the proximity to areas with good purchasing power smaller suppliers of made to measure products developed well. The company Janek from Roznov in Zlin produces,for example, 30,000 individually tailored shirts per year. Also suits and costumes belong to the assortment. Janes buy the yarn from a German yarn manufacturer which produces in the Czech Republic.

Czech Republic's largest textile and clothing manufacturers (selection, sales in million Kc) 1)
Company/location Product portfolio Sales
Borgers CS/Plzen Nonwovens for
5.038 10.879 115,9 http://borgers.cz
Juta/Dvur Kralovenad Labem Nonwovens for
5.568 6.618 18,8 http://www.juta.cz
Nova Mosilana /Brno Fancy dress fabrics 2.952 3.285 11,3 http://www.novamosilana.cz
Pegas Nonwovens/Znojmo Nonwovens 2.273 2.388 5,1 http://www.pegas.cz
Kordarna Plus/Velka nad Velickou Corduroy fabrics
Technical Textiles
for conveyors
2.195 2.287 4,2 http://www.kordarna.cz
Veba, textilni zavody/Broumov Home – and Clothing
fabrics, Brocat
2.124 2.160 1,7 http://www.veba.cz/cs/
Johnson Controls/
Strakonice 2)
Seatcovers for
1.722 1.865 8,3 http://www.johnsoncontrols.cz
Fibertex Nonwovens/
Nonwovens 958 1.128 17,7 http://www.fibertex.com
Pleas / Havlickuv
Under – and Nightwear 1.073 1.123 4,6 http://www.pleas.cz
Mehler Texnologies/
Lomnice nad
Popelkou 3)
Fabrics for tents,
boats, canvas, sunumbrellas
895 975 8,9 http://www.mehlertexnologies.
Nejdecka cesarna
vlny/Nejdek 4)
Processing of rawwool 800 692 -13,5 http://www.ncv.cz
Lanex/Bolatice Ropes, threats,
artificial turf
627 670 6,7 http://www.lanex.cz
Trevos/Kostalov Polypropylen-
576 639 10,9 http://www.monticekia.cz
Tessitura Monti Cekia/
Borovnice u Stare
Cotton shirt fabrics 609 568 -6,7 http://www.monticekia.cz
Svitap J.H.J./Svitavy Tents, canvas, Microfibers,
497 436 -12,3 http://www.svitap.cz

1) Change 2014 / 113 in%; 2) Fiscal year October 2012, 2013 till September 2013, 2014; 3) December 2012, 2013 till November 2013, 2014; 4) April 2013, 2014 till March 2014, 2015
Sources: Annual company reports, Trade register, Hospodarske noviny, Magazine Ekonom, CzechInvest, Association ATOK

The most actively trading companies in the textile sector are producing mostly for industrial consumers. Largest industry representative is the automotive supplier Borgers from Bocholt, which produces textile moldings, paneling, insulation and curtains for vehicles at four locations near Plzen. The second largest textile company Juta achieves half of its revenue from construction materials such as drainage mats, erosion control fabric or roof insulation. Moreover Juta makes a good business with packaging nets for potatoes or Christmas trees. One other growth area is artificial turf. The company invests nearly EUR 20 million every year, mainly in new production equipment.

Textile Machinery ordered for 250 m Euro

Other companies are expanding too. The manufacturer of workwear Waibel has expanded its site in2015. In Zdar nad Sazavou near Jihlava own collections and custom made programs are being manufactured. Clothing manufacturer Pleas invests annually over EUR 1 million in its equipment. The company belongs to the top 10 of the sector and produces annually 15 million pieces nightwear for the brands Schiesser and Pleas. The German machinery manufacturer Mayer & Cie. builds a factory for knitting machines in Vsetin. The production is expected to comence in summer 2016. The machines are designed for large manufactures particularly in Asia.

Import of important textile machinery to the Czech Republic ( EUR 1,000)
Maschinery group / HS-Position 2014 2015 Veränderung in %
Jet-spinning machines / 8444 177 15.369 8.583,1
..from Germany 59 9.829 16.559,3
Spinning machines / 8445 12.780 8.838 -30,8
..from Germany 6.591 5.017 -23,9
Weaving machines / 8446 13.357 12.778 -4,3
..from Germany 7.498 2.166 -71,1
Knitting machines / 8447 10.556 11.332 7,4
..from Germany 2.872 6.092 112,1
Auxiliary machines / 8448 75.082 72.178 -3,9
..from Germany 48.245 51.765 7,3
Machines for felting and nonwovens / 8449 3.349 16.306 386,9
..from Germany 949 6.741 610,3
Cleaning-, dying and ironing machines / 8451 83.874 105.825 26,2
..from Germany 44.671 50.234 12,5
Sewing machines / 8452 14.718 17.834 21,2
..from Germany 4.780 6.319 32,2
Machines for leather and fur processing resp. footwear production /
2.867 3.704 29,2
..from Germany 278 347 24,8
Total 216.760 264.164 21,9
..from Germany 115.943 138.510 19,5

Source: Czech Statistical Office