Textination Newsline

Neo-ecology through innovative paper technology

To reduce the CO2 footprint, the Fraunhofer Institute for Casting, Composite and Processing Technology IGCV Augsburg research with a state-of-the-art wetlaid nonwoven machine for recycling carbon fibers. The production processes are similar to those of a paper manufacturing machine. The crucial difference: we turn not paper fibers into the paper but recycled carbon fibers into nonwoven roll fabrics. The carbon fiber thus gets a second life and finds an environmentally friendly way in nonwovens, such as door panels, engine bonnets, roof structures, underbody protection (automotive), and heat shields (helicopter tail boom), as well as in aircraft interiors.

“Wetlaid technology for processing technical fibers is currently experiencing a revolution following centuries of papermaking tradition.”
Michael Sauer, Researcher at Fraunhofer IGCV

The wetlaid technology used is one of the oldest nonwoven forming processes (around 140 BC - 100 AD). As an essential industry sector with diverse fields of application, wetlaid nonwovens are no longer only found in the classic paper. Instead, the application areas extend, for example, from adhesive carrier films, and packaging material, to banknotes and their process-integrated watermarks and security features. In the future, particularly sustainable technology fields will be added around battery components, fuel cell elements, filtration layers, and even function-integrated material solutions, e.g., EMI shielding function.

Fraunhofer IGCV wetlaid nonwovens line is specifically designed as a pilot line. In principle, very different fiber materials such as natural, regenerated, and synthetic fibers can be processed, mainly recycled and technical fibers. The system offers the highest possible flexibility regarding material variants and process parameters. In addition, sufficiently high productivity is ensured to allow subsequent scaled processing trials (e.g., demonstrator production).

The main operating range of the wetlaid line relates to the following parameters:

• Processing speed: up to 30 m/min
• Role width: 610 mm
• Grammage: approx. 20–300 gsm
• Overall machinery is ≥ IP65 standard for processing, e.g., conductive fiber materials
• Machine design based on an angled wire configuration with high dewatering capacity, e.g., for processing highly diluted fiber suspensions or for material variants with high water retention capacity.
• Machine modular system design with maximum flexibility for a quick change of material variants or a quick change of process parameters. The setup allows short-term hardware adaptations as well as project-specific modifications.

Research focus: carbon recycling at the end of the life cycle
The research focus of Fraunhofer IGCV is primarily in the field of technical staple fibers. The processing of recycled carbon fibers is a particular focus. Current research topics in this context include, for example, the research, optimization, and further development of binder systems, different fiber lengths and fiber length distributions, nonwoven homogeneity, and fiber orientation. In addition, the focus is on the integration of digital as well as AI-supported methods within the framework of online process monitoring. Further research topics, such as the production of gas diffusion layers for fuel cell components, the further development of battery elements, and filtration applications, are currently being developed.

• Off-price becomes a growth machine for the fashion industry
• Off-price segment grows five times faster than regular offer
• Growth of online sales in the off-price segment tripled - market share 40%
• Future growth almost exclusively online

Fashion consumers in Germany appreciate bargain hunting. The off-price segment, in which high-end fashion brands are offered at lower prices in online and offline outlets, was already growing faster than the entire fashion industry before 2020 and has shrunk less during the pandemic. Between 2025 and 2030, the segment is expected to grow five times faster than the entire fashion industry. One reason for this is the strong online presence of this product offering, which benefited from the boom in online shopping during the pandemic.

"Online accounts for 40% of the market in the off-price segment and is growing rapidly at an average of 13% per year. Almost all of the growth in off-price will take place online in the next three years," says Katharina Schumacher, digital expert and author of the study entitled "Mastering off-price fashion in an omnichannel world". "This opens up opportunities for fashion companies to reach new consumers with their brand who would not normally consider a full-price purchase."
          
For the study, global data on the off-price market was analysed and 11,000 consumers in ten countries were surveyed. German shoppers are particularly interested in bargains. In the past year, many consumers in Germany have increasingly shopped online. In the off-price segment, the growth of the online market has tripled: from 9% compound annual growth rate (CAGR) in 2020 to 27% in 2021.

By 2025, growth in Germany as well as in Austria could amount to 16% per year. The average in the EU lies at 13%. In addition, offprice offers fashion brands the opportunity to sell their surplus goods in a sustainable way.

Typical online off-price consumers, so-called enthusiasts, are particularly interested in luxury, affordable luxury and premium products and buy on specialised platforms such as dress-for-less, BestSecret, brands4friends or Scarce. They value style and usually start without a specific brand in mind. They enjoy comparing prices and spend 2.3 times more than other fashion consumers. In Germany, 30% of off-price shoppers who spend more than 1,000 euros per year account for 70% of total fashion spending. "However, these shoppers are generally willing to pay full price for premium and luxury brands," says Achim Berg, fashion industry expert at McKinsey. "Fashion suppliers should therefore carefully consider which goods they offer off-price."

Offline purchases with increasing expectations
Off-price shoppers who shop in stores are often younger and have a higher purchasing power than other fashion consumers. They like to shop in outlet centres, while they often shy away from going to a regular luxury shop on a shopping mall.
"Outlets therefore offer luxury fashion companies the opportunity not only to increase their profitability but also to reach new groups of shoppers without cannibalising their full-price assortment and damaging their brand," says Felix Rölkens, McKinsey expert for the fashion industry and co-author of the study. "However, shoppers expect more and more from outlets: comparable shop layouts as in regular brick-and-mortar retail, multilingual shoppers, restaurants and a good shopping experience."
          

A bandage that releases medication as soon as an infection starts in a wound could treat injuries more efficiently. Empa researchers are currently working on polymer fibers that soften as soon as the environment heats up due to an infection, thereby releasing antimicrobial drugs.

It is not possible to tell from the outside whether a wound will heal without problems under the dressing or whether bacteria will penetrate the injured tissue and ignite an inflammation. To be on the safe side, disinfectant ointments or antibiotics are applied to the wound before the dressing is applied. However, these preventive measures are not necessary in every case. Thus, medications are wasted and wounds are over-treated.

Even worse, the wasteful use of antibiotics promotes the emergence of multi-resistant germs, which are an immense problem in global healthcare. Empa researchers at the two Empa laboratories Biointerfaces and Biomimetic Membranes and Textiles in St. Gallen want to change this. They are developing a dressing that autonomously administers antibacterial drugs only when they are really needed.

The idea of the interdisciplinary team led by Qun Ren and Fei Pan: The dressing should be "loaded" with drugs and react to environmental stimuli. "In this way, wounds could be treated as needed at exactly the right moment," explains Fei Pan. As an environmental stimulus, the team chose a well-known effect: the rise in temperature in an infected, inflamed wound.

Now the team had to design a material that would react appropriately to this increase in temperature. For this purpose, a skin-compatible polymer composite was developed made of several components: acrylic glass (polymethyl methacrylate, or PMMA), which is used, for example, for eyeglass lenses and in the textile industry, and Eudragit, a biocompatible polymer mixture that is used, for example, to coat pills. Electrospinning was used to process the polymer mixture into a fine membrane of nanofibers. Finally, octenidine was encapsulated in the nanofibers as a medically active component. Octenidine is a disinfectant that acts quickly against bacteria, fungi and some viruses. In healthcare, it can be used on the skin, on mucous membranes and for wound disinfection.

Signs of inflammation as triggers
As early as in the ancient world, the Greek physician Galen described the signs of inflammation. The five Latin terms are still valid today: dolor (pain), calor (heat), rubor (redness), tumor (swelling) and functio laesa (impaired function) stand for the classic indications of inflammation. In an infected skin wound, local warmth can be as high as five degrees. This temperature difference can be used as a trigger: Suitable materials change their consistency in this range and can release therapeutic substances.

Shattering glove
"In order for the membrane to act as a "smart bandage" and actually release the disinfectant when the wound heats up due to an infection, we put together the polymer mixture of PMMA and Eudragit in such a way that we could adjust the glass transition temperature accordingly," says Fei Pan. This is the temperature, at which a polymer changes from a solid consistency to a rubbery, toughened state. Figuratively, the effect is often described in reverse: If you put a rubber glove in liquid nitrogen at –196 degrees, it changes its consistency and becomes so hard that you can shatter it like glass with one blow.

The desired glass transition temperature of the polymer membrane, on the other hand, was in the range of 37 degrees. When inflammation kicks in and the skin heats up above its normal temperature of 32 to 34 degrees, the polymer changes from its solid to a softer state. In laboratory experiments, the team observed the disinfectant being released from the polymer at 37 degrees – but not at 32 degrees. Another advantage: The process is reversible and can be repeated up to five times, as the process always "switches itself off" when it cools down. Following these promising initial tests, the Empa researchers now want to fine-tune the effect. Instead of a temperature range of four to five degrees, the smart bandage should already switch on and off at smaller temperature differences.

Smart and unsparing
To investigate the efficacy of the nanofiber membranes against wound germs, further laboratory experiments are now in the pipeline. Team leader Qun Ren has long been concerned with germs that nestle in the interface between surfaces and the environment, such as on a skin wound. "In this biological setting, a kind of no man's land between the body and the dressing material, bacteria find a perfect biological niche," says the Empa researcher. Infectious agents such as staphylococci or Pseudomonas bacteria can cause severe wound healing disorders. It was precisely these wound germs that the team allowed to become acquainted with the smart dressing in the Petri dish. And indeed: The number of bacteria was reduced roughly 1000-fold when octenidine was released from the smart dressing. "With octenidine, we have achieved a proof of principle for controlled drug release by an external stimulus," said Qun Ren. In future, she said, the technology could be applied to other types of drugs, increasing the efficiency and precision in their dosage.

The smart dressing
Empa researchers are working in interdisciplinary teams on various approaches to improve medical wound treatment. For example, liquid sensors on the outside of the dressing are to make it visible when a wound is healing poorly by changing their color. Critical glucose and pH values serve as biomarkers.

To enable bacterial infections to be contained directly in the wound, the researchers are also working on a polymer foam loaded with anti-inflammatory substances and on a skin-friendly membrane made of plant material. The cellulose membrane is equipped with antimicrobial protein elements and kills bacteria extremely efficiently in laboratory tests.

Moreover, digitalization can achieve more economical and efficient dosages in wound care: Empa researchers are developing digital twins of the skin that allow control and prediction of the course of a therapy using real-time modeling.

Further information:
Prof. Dr. Katharina
Maniura Biointerfaces
Phone +41 58 765 74 47
Katharina.Maniura@empa.ch

Prof. Dr. René Rossi
Biomimetic Membranes and Textiles
Phone +41 58 765 77 65
Rene.rossi@empa.ch

• Exhibition in Hamburg Museum für Kunst & Gewerbe: 25/02/ - 28/08/2022

Our wardrobe is among our most personal possessions. Nothing is closer to our bodies. Alongside its purely practical function, clothing is also a nuanced means of communication and self-expression. The exhibition DRESSED. 7 WOMEN – 200 YEARS OF FASHION presents seven fashion-conscious women and their wardrobes, ranging from the nineteenth century to the present day.
The spotlight is on the personalities and biographies of the wearers, who reveal themselves to be both performers and consumers of fashion. Whether haute couture, daywear, protest gear or avant-garde trends – what they chose to wear is every bit as diverse as their lifestyles. Their wardrobes tell of the status-consciousness of high-society wives, of an existence marked by illness, of “power dressing” for projecting confidence in the executive suite, of Hamburg’s punk scene, and of the aesthetics embraced by an art and design collector.
 
Rather than basing the selection on status or celebrity, the protagonists cover the greatest possible variety of women’s lifestyles and their expression through fashion. Around 150 garments and accessories from the Fashion and Textiles Collection at the Museum für Kunst und Gewerbe Hamburg (MK&G) illuminate seven different walks of life and 200 years of fashion, women’s liberation and contemporary history. The fashion items were produced by famous designers, couturiers/couturières and fashion ateliers such as Maison Worth, Elsa Schiaparelli, Yves Saint Laurent, Yohji Yamamoto, Rei Kawakubo and Martin Margiela as well as by anonymous tailors and seamstresses. They are supplemented by biographical testimonies, photographs and documents.

„The idea of approaching not only fashion history but also the former wearers through the seven wardobes on display immediately excited me”, remarks Tulga Beyerle, director of the Museum für Kunst und Gewerbe Hamburg. “The narrative also goes beyond that and deals with a topic that is still relevant today: the changing role of women in society.”
 
Senator Dr Carsten Brosda says of the exhibition:” The history of clothing is the history of man. The history of fashion is the history of our social self-image. “Dressed” tells both the story of individual lives and the spirit of the times. The exhibition traces our understanding of aesthetics, the relationship between no-go’s and avant-garde, do’s and don’ts and as a whole is a symbol of possibilities. With the exhibition „Dressed”, the MK&G once again sensitises us to the social value of clothing in a time of material hyperconsumption.”
               
SEVEN PERSONALITIES – SEVEN WARDROBES
The earliest apparel ensemble, which once belonged to ELISE FRÄNCKEL (1807 – 1898), consists mainly of accessories and reveals the up to date fashion sense of the senator’s wife from Oldenburg in Holstein around 1820. The wardrobe of the diplomat’s wife EDITH VON MALTZAN FREIFRAU ZU WARTENBERG UND PENZLIN (1886 – 1976) includes elegant daywear and exquisite afternoon and evening attire from the years 1895 to 1950. The life and clothing of ERIKA HOLST (1917 – 1946) were shaped by war and her illness with tuberculosis. Dating from 1935 to 1945, her wardrobe contains mostly daywear. The Hamburg gallery owner and museum founder ELKE DRÖSCHER (b. 1941) wore almost exclusively pret-à-porter models by Yves Saint Laurent between 1968 and 1986, opting for a form of “power dressing”. INES ORTNER (b. 1968), active in Hamburg’s punk scene since the mid-1980s, combines an interest in fashion with a socio-critical stance in her ”self-constructed”, in some cases anarchic clothing objects. ANGELICA BLECHSCHMIDT (1942 – 2018), editor-in-chief of German Vogues from 1989 to 2002, clad herself in high-end products from international fashion houses as befitting position. Her “work uniform” consisted of little black dresses in combination with chunky costume jewellery. The art and design collector ANNE LÜHN (b. 1944) has over the years donated individual pieces from her wardrobe to MK&G. The often asymmetrical garments created by an international design avant-garde display an aesthetic of resistance.

THE DEVELOPMENT OF FASHION
The seven wardrobes selected for the show shed light on the development of fashion since the early nineteenth century. The items on view can be seen in one sense as an abstract succession of generations. The Second World War marked a clear turning point in terms of women’s opportunities, as revealed by the marital status and occupation of the carious women portrayed. Women born after 1940 were no longer confined to the role of mother, wife and house wife but were able to pursue their own professional goals. The garments also tell of contemporary political and social developments. The rigid corset disappeared after the First World War, roughly concurrently with the rise of women’s suffrage. The proliferation of trousers in women’s fashion from the 1970s onwards went hand in hand with the women’s liberation movement. And in the 1980s, an increasing plurality of clothing styles reflected developments in society at large.
          
CLOTHING AS AN ARCHIVE
The design of the exhibition is inspired by the concept of an archive. Reference is thus made to the museum’s mission of collecting and research but also to the archival function of clothing itself, which serves as a material but also to the archival function of clothing itself, which serves as a material witness to the history of design, technology and trade. At the same time, garments perpetuate the traces of individual bodies, movement and use, providing immaterial clues to the wearer’s aura and calling to mind notions of femininity, beauty and chic as well as personal and collective memories.
 
CLOTHING AS OBJECT OF DAILY USE
Garments are everyday items inscribed with signs of their use and of the body that wears them and bearing the marks of material wear and tear and of storage. These visible marks are just as unwelcome in private wardrobes as they are in museum collections – and yet they prove to be extremely valuable as evidence for object-based research. The exhibition therefore also shows objects with clear signs of wear and provides information about their state of preservation.

CLOTHING AS A MEANS OF SOCIAL COMMUNICATION
Clothing norms and dress codes depend on factors such as age, gender, body shape, occasion, location, status and social group. We already start learning in childhood how to navigate this maze of rules and find the right mix for ourselves between conformity and individuality. As demonstrated by the biographies recounted here, fashion and a preoccupation with how we look is even today primarily a topic for women and people who read as female. Women are judged more by their appearance that their male counterparts and
are held to account more harshly for ostensible “mistakes” in how they present themselves. The role dress plays in social communication cannot be overestimated. Its effect is immediate. Whether consciously or unconsciously, we send and receive signals with our clothes bodies – not to communicate is impossible.

FASION HOUSES AND DESIGNERS REPRESENTED
The exhibition provides a detailed look at high-quality items of clothing in the MK&G collection along with glimpses of the creative work of a wide range of both anonymous makers and famous national and international fashion designers, couturiers/couturières and ateliers, including Georges Doeuillet, Romeo Gigli, Rei Kawakubo/Comme des Garçons, Alice Lanot, Emilienne Manassé, Maison Martin Margiela, Issey Miyake, Rick Owens, Prada, Yves Saint Laurent, Elsa Schiaparelli, Worth, Yohji Yamamoto and others.

CATALOGUE
The exhibition is accompanied by a catalogue of the same name, published by Hirmer Verlag Munich, edited by Turga Beyerle and Angelika Riley, and with essays by Claire Beermann, Turga Beyerle, Joanne Entwistle, Birgit Haase, Peter Kempe, Ingrid E. Mida, Angelika Riley and Maria Stavel, and photographs ny Anne Schönharting. In German with two essays in English, ca. 250 pages, ca. 475 colour illustrations, 90 of them full-page plates, 49.90 Euro.

Ingo Offermanns (Hamburg) is responsible for the graphic design of the catalogue and exhibition. The exhibition architecture is the work of designer and scenographer Katleen Arthen (Berlin).

EDUCTAIONAL PROGRAMM
As part of the exhibition, the MK&G is organising numerous analogue and digital guided tours, including the exhibition tour “With Pen and paper” – a drawing workshop on the seven wardrobes on display with the artist Anne Pflug. You can participate in the exhibition via MK6G’s social media channels: Which favourite piece of clothing should be preserved for posterity? The best photos and stories that are shared with MK&G links can be seen digitally in the exhibition shortly afterwards. More information on the event programme on the website under CALENDAR.

The exhibition is made possible by funds from the Exhibition Fund of the Free and Hanseatic City of Hamburg, the Hubertus Wald Foundation and the Ernst von Siemens Art Foundation.

Global supply chains comprise complex networks, making them particularly vulnerable. The UK is a prime example of this, where logistics problems are currently resulting in empty supermarket shelves and closed gas stations. Fraunhofer experts provide IT solutions that counteract supply bottlenecks in international goods traffic and maintain robust supply chains.

Earthquakes in South America, floods in Germany or political unrest in Asia: all compromise supply chains. A research team at the Fraunhofer Institute for Industrial Mathematics ITWM is developing mathematical methods that can be used to calculate how to minimize risks to supply chains. “Mathematically speaking,” explains Dr. Heiner Ackermann, Deputy Head of Optimization – Operations Research, “these disruptive events create a multidimensional decision problem.”    

Cushioning risks without additional costs
Ackermann’s team of experts analyze the properties of supply chains using mathematical models. The failure scenarios simulated on the basis of these calculations show at which points there is a greater need for action. In the second step, the researchers focus on holistic optimization – for a more robust supply chain that can cushion risks without incurring major costs. The experts package all variables into a multicriteria optimization problem. In this way, they determine the best possible solution for the triad of resilience, cost and risk. Algorithms calculate the optimum balance and with it various options for raw materials, suppliers and warehousing. Even the use of alternative materials is considered. The top priority: as few assumptions as possible. “Our work has set the ball rolling – companies that previously relied on Excel spreadsheets and their gut feeling are now engaging in very fruitful discussions,” explains Ackermann, adding: “Whether you are dealing with supply chains or supply networks, mathematics is a universal and very effective tool.”

Early detection of potential supply shortages
The Fraunhofer Institute for Material Flow and Logistics IML also offers highly effective support for testing and optimizing supply chains with its Order-To-Delivery-NETwork (OTD-NET) simulator. Thanks to this tool, planning and material flow processes from order to delivery can be continuously assessed. “OTD-NET maps even highly complex supply chains in full and at all levels, including the planning and information flow processes. Using various parameters, it is possible to accurately model cooperation between supply chain partners on the computer,” specifies Marco Motta, Head of Supply Chain Engineering at Fraunhofer IML.
 
Combining digital twins of supply chains with simulations
The tool set examines networks particularly with regard to customer promises in terms of delivery reliability and quality, etc., costs, environmental considerations and, in the analysis of alternative scenarios, resilience. “In the simulation, I can easily play around with demand peaks, a slump in the respective market or scenarios in which production is disrupted,” explains the Fraunhofer IML expert. In this way, forecasts can be made about how a supply chain will react in a state of emergency. Logistics assistance systems that combine a digital twin of the supply chain with simulations show dispatchers which cargo ships have loaded which parts, where these are located and when the consignment will be available at the required location. Supply for the next 20–30 weeks can thus be depicted for global networks, enabling potential bottlenecks to be detected early on. Tracking is also a distinguishing feature of the solution for demand and capacity management. Not only is the number of parts affected displayed but planners can also directly see the impact of this on the whole of production.
 
Most recently, both the automotive and medical sectors have suffered from supply bottlenecks. Saskia Sardesai, Senior Scientist at Fraunhofer IML, is leading different research projects in which OTD-NET is being used to increase resilience in value creation networks for medical supplies. “Especially smaller and medium-sized companies were addressing this problem using existing spreadsheet analysis tools. However, this approach does not identify dynamics.” This is where OTD-NET comes into play: The simulation dynamically shows over a long period whether all parts will be at the right location at the right time. “If all parts are available except for those from my transatlantic supplier and there is no alternative supplier in Europe, I will quickly have a break in my chain lasting over a month,” outlines the specialist.

Increasing the European manufacturing sector’s resilience to future pandemics In the European research project “CO-VERSATILE”, overseen by Sardesai, participants are doing everything in their power to increase the European manufacturing sector’s resilience to future pandemics. The supply chain should be able to react quickly and effectively to a sudden spike in demand for strategic medical supplies. To that end, experts at Fraunhofer IML have developed a simulation model that takes into account future peaks and fluctuations in demand as well as supplier risks. Companies are immediately given an overview of which effects they will have to face. “We have created very simple models to facilitate rapid feedback and implementation for a variety of companies,” explains the project manager. Particular attention was paid to capacities, lead times, transportation frequency and possible supply restrictions. Users can see how individual factors interplay – an invaluable advantage compared to the long-standing Excel solution.

FESPA has kick-started business recovery in the speciality print and signage communities with the successful return of FESPA Global Print Expo and European Sign Expo 2021 (12 – 15 October 2021) after a two-year gap.

The first live FESPA events in Europe since Spring 2019 attracted a strong audience dominated by business leaders, who came with an appetite to update their industry knowledge with a view to short- and medium-term investment.

International audience of senior decision-makers
Visitors came from more than 100 countries, with a strong emphasis on the Benelux region and Germany which accounted for 49% of the audience, in line with expectations given the location in Amsterdam. Other strongly represented countries were Italy, France, the United Kingdom, Spain and Poland. As anticipated, the challenges for long-haul travellers due to COVID-related restrictions resulted in fewer visitors from outside Europe than usual for a Global Print Expo event. In total, the events attracted 7,850 unique visitors, 42% of whom attended for more than one day, bringing total visits to 11,130.

Close to half of all visitors (44%) were owners or managing directors, reinforcing the significance of the event as a springboard for business recovery and forward planning. Two in three visitors influence or make final purchasing decisions in their business.

54% of visitors stated that they were visiting FESPA for the first time, indicating a thirst for market knowledge, insight and inspiration following the commercial challenges of the pandemic.

Sources of inspiration
Printeriors was once again a popular attraction for visitors. Inspired by nature and curated by FESPA’s Textile Ambassador, Debbie McKeegan, the feature highlighted digitally printed applications targeted at printers operating in or looking to expand into interior décor. In collaboration with industry suppliers including Imageco, Kornit Digital, PONGS, swissQprint and TTS, the products displayed were produced using a series of high-end technologies, print processes and materials.

The World Wrap Masters Europe 2021 competition was also a key area of interest. In addition to a series of demonstrations and workshops from wrap experts, visitors saw competitors battle it out for the title of the “World Wrap Master of Europe 2021”. On day four, Norman Brübach from Germany was crowned the winner and will go on to compete against regional champions in the World Wrap Masters Final 2022 at FESPA Global Print Expo 2022 in Berlin.

For members of the community unable to attend the event in person, FESPA and its exhibitors provided an array of live-streamed and virtual content. The FESPA Live sessions involved conversations with key exhibitors, printers and print experts on the latest trends and innovations and these attracted 5,125 views throughout the four-day event. The recordings of the sessions are also still available to watch on demand.

Neil Felton, FESPA CEO comments: “Feedback from exhibitors was effusive, with many commenting on the upbeat mood among visitors, the unmatched value of face-to-face conversations with senior decision-makers, the enthusiasm for the new technologies and consumables on display, and the overriding sense of optimism for the future. The buzz in the halls was energising and the impression was that delegates felt very confident and happy to be in a live event environment again after such a long time.”

Neil Felton concludes: “The past two years have undoubtedly been challenging for everyone in our community. To move forward, printers and signmakers need to unearth new opportunities, explore the latest technologies and meet with peers to share ideas. This year’s events were an important milestone in our collective recovery and we hope that our next Global Print Expo and European Sign Expo, which will return to Messe Berlin, Germany, from 31 May – 3 June 2022, will finally put our whole global community back in motion.”

Nonwovens are an important component of different products of several uses, e.g. transport of humidity in sanitary products, insulation materials or filters. Nonwovens are usually produced on large engineering facilities. For this, experimental studies of design with regard to the optimization of these nonwoven-structures prove to be very difficult.

Influence Design Parameters
There are so many parameters of design, as for example fibers, surface weight or type of nonwoven bonding and finishing that are affecting the properties of nonwovens. For the change of one single parameter, e.g. the material of fiber, it is necessary to adapt the whole process of fabrication from the spinning of the fibers via their stacking to the nonwoven hardening.

Following the production of such a prototype a time consuming and cost-intensive characterization of the properties of nonwovens carried out experimentally has to be done.  Therefore, for this reason detailed studies considering several parameters of design are uneconomic.

Thus, micromechanical models of simulation are developed at Fraunhofer ITWM in cooperation with Procter & Gamble Service GmbH (P & G). By means of these models it is possible to forecast numerically the effective properties of nonwovens for diverse parameters of design. To virtually modify and optimize individual parameters in this connection it is only necessary to adapt the corresponding inputs of the model.

Fast Predictions Possible
In this case, the focus of the numerical predictions is primarily lying on the time-dependent behavior of the nonwovens.  The dynamic properties can be determined by means of numerical simulation of cyclic measurements. In doing so, a good correspondence of simulation and measurements is obtained.

Compared to experiments the required time of simulation for the behavior in case of low frequencies does not change. Therefore, we can obtain rapid forecasts for the long-term behavior (month till years) and the corresponding resilience of nonwovens using numerical models. A lot of alternatives can be simulated and studied within a few hours.

The fact that not only effective (macroscopic) properties of nonwovens can be computed, but also local physical values such as distribution of tension in binding agents and fibres is a further advantage of this micromechanical  approach. So, the simulation contributes to a better understanding of the properties of nonwovens.

Future designs deal with an extension of the models with regard to simulation of the productionv processes. By this, a fully digitalized layout design of nonwovens, from the manufacturing process till the optimization of functionality is possible.

Nonwoven production received more attention than ever before from the general public in Corona times, because the technical textile is crucial for infection protection. The ultra-fine nonwoven products are manufactured in so-called meltblown processes. A cross-departmental team at the Fraunhofer Institute for Industrial Mathematics ITWM in Kaiserslautern is optimizing the entire production chain in the »ProQuIV« project. Simulations help to guarantee the product quality of the filter material despite fluctuations in production.

The abbreviation »ProQuIV« stands for »Production and Quality Optimization of Nonwoven Infection Protection Clothing«. This is because bottlenecks in the production of these materials were particularly evident at the beginning of the Covid 19 crisis. For the meltblown nonwovens, this optimization of the product quality is also particularly difficult because the textiles react very sensitively to fluctuations in the manufacturing processes and material impurities.

Digital Twin Keeps an Eye on the Big Picture
»Meltblown« is the name of the industrial manufacturing process whose ultra-fine fiber nonwovens are responsible for providing the crucial filtering function in face masks. In this process, the molten polymer is forced through nozzles into a forward-flowing, high-speed stream. It is stretched and cooled in a highly turbulent air flow.

»The overall process of filter media production – from the polymer melt to the filter medium – presents a major challenge in simulation,« explains Dr. Konrad Steiner, head of the »Flow and Materials Simulation« department. »In the project, we kept the big picture in mind and developed a completely integrated evaluation chain as a digital twin. In doing so, we take several key components into account at once: We simulate the typical production processes of nonwovens, the formation of the fiber structures and then the material properties – here, in particular, the filter efficiency. This allows us to quantitatively evaluate the influences of the manufacturing process on the product properties.« In each of these individual areas, Fraunhofer ITWM and its experts are among the leading research groups internationally.

Homogeneity of the Material – Fewer Clouds in the Simulation Sky
In the meltblown process, a key factor is the behavior of the filaments in the turbulent, hot and fast air flow. The properties of the filaments are strongly influenced by this air flow. The quality of the filaments – and thus the quality of the nonwovens – is influenced by many factors. Dr. Dietmar Hietel, head of the »Transport Processes« department, knows what this means more precisely in practice. His team has been working at Fraunhofer ITWM for years on the simulation of various processes involving filaments, threads, and fibers. »The focus of the project is the so-called cloudiness, i.e. the non-uniformity of the fiber distributions in the nonwoven,« explains Hietel. »We are investigating the question: How homogeneous is the fabric? Because the quality of the products can be greatly improved if we increase the uniformity. Our simulations help figure out how to do that.«

Objective Evaluation of the Homogeneity of Nonwovens
The researchers also use appropriate image analysis techniques to quantify this cloudiness. The power spectrum plays a special role here. »The cloudiness index (CLI) describes homogeneity complementary to local basis weight and its variance,« describes Dr. Katja Schladitz. She brings her expertise in image processing to the project. »Our CLI ensures a robust assessment of the homogeneity and can thus be used for different material classes and imaging techniques to be used as an objective measure.« The frequencies that go into the CLI calculation can be chosen so that the CLI is meaningful for the particular application area.

Filtration: How Efficient Are the Filters?
For the upscaling to industrial processes such as mask production, the ITWM expertise in filters is also included in the project. The »Filtration and Separation« team led by Dr. Ralf Kirsch has been working for years on the mathematical modeling and simulation of various separation processes.

»What's special about this project is that we calculated the efficiency of the filters for fluctuations of varying degrees in the fiber volume fraction,« emphasizes Kirsch. »This allows us to specify up to what level of cloudiness the required filter efficiency can be achieved at all.« As a current example of this, the figure depicts in the graphic the efficiency of a filter material for N95 masks as a function of the inhomogeneity of the nonwoven.

ITMW Methods Support Across the Entire Process Chain
In »ProQuIV«, digital twins and calculations from Fraunhofer ITWM support a holistic view and better understanding of the processes. The production of technical textiles thus not only becomes more efficient, but the nonwovens can be developed virtually without having to realize this in advance in a test facility. In this way, production capacities can be increased while maintaining or even increase the quality. Together with long-term partners from industry, the research can be put into practice quickly and efficiently.

Simulations save textile companies experiments, allow new insights, enable systematic parameter variations and solve upscaling problems that can otherwise lead to bad investments during the transition from laboratory plant to industrial plant. However, virtual implementation of nonwoven production also opens up new opportunities for optimization at other levels. For example, acoustic insulating nonwovens or even hygiene nonwovens can also be optimized in terms of their product quality precisely with regard to the material properties to be achieved – while taking into account the process fluctuations that occur.

The project is part of the Fraunhofer-Gesellschaft's »Fraunhofer versus Corona« program and was completed in April 2021. The results will flow into several follow-up projects with the nonwovens industry.

How can the major sustainability challenges in the textile industry be met? The textile services industry, whose business model has always been based on durability and re-use, has an important role to play here as ambassador. In the run-up to Texcare International, Elena Lai, Secretary General European Textile Services Association (ETSA), talks about these challenges and her expectations for Texcare International from 27 November to 1 December 2021.

The textile sector was identified as a priority sector in the European Green Deal and in the Circular Economy Action Plan. What are the implications for the European textile services industry?
Elena Lai: We are in a truly historic and exciting time for the textile services industry. We are all well-aware that our industry is the key to providing sustainable solutions and ecofriendly best practice. We had a series of webinars at ETSA dedicated to sustainability and circular economy being key elements of the Green Deal and our larger companies such as industrial laundries, key textile manufacturers and innovative machinery companies, are all up to the task and providing effective solutions. Our national associations too, members of ETSA, are all working synergistically to exchange their best ways forward, in Europe and beyond as we have also partners from the US. These efforts within ETSA’s value chain make us really proud and eager to go the extra mile, guiding our members also towards those areas which seem to be the most challenging. For instance, the new EU Climate Law, which calls for 55% CO₂ reductions by 2030: this means that European industries will all have to do better to make us reach these targets in less than nine years. We know ETSA could represent the right network to identify the best way forward on this issue and truly perform and deliver what the EU is advocating for.

How can the textile services industry contribute to achieving circular economy in the textile industry?
Elena Lai: The business model of textile services is inherently circular. By having a business model which is focused on renting and reusing textiles we can see a litany of benefits that it can offer to the EU’s Circular Economy Action Plan. Firstly, in renting textiles. Through rented textile services, textile service companies can extend the lifecycle of products and thus reduce the amount of production that is necessary to occur in the first place, while also reducing the amount of wastewater and energy needed in the laundry process. Secondly, through re-use and repair textile products can remain in consumer hands for longer, which is paramount as our industry is one that battles against planned obsolescence. Both of these are important pillars to our industries that will help both consumers and the planet. Lastly, by continuing to expand recycling and upcycling we can minimise waste, ensuring that a product stays inside the European economy as long as possible. These are all important steps and help us do our part to help Europe reach its emissions and sustainability goals.

Textile recycling is a very important point. How do you think the textile recycling rate can be increased?
Elena Lai: The Commission will mandate separate waste sorting of textiles by the year 2025, thus recycling, upcycling and end of life re-use must be improved. A ban on the burning of unused textiles will also soon take effect, this will incentivise further recycling and waste reduction. Fundamentally what we in textiles services need to do is to continue to reduce, re-use and recycle. We can increase the rate of recycling by making consumers aware of rented textiles and textile services so to increase the public demand for such services.

How can sustainability in textile services be further improved?
Elena Lai: In order to boost sustainability in our industry we need to build on the existing culture of innovation and entrepreneurship where exciting, new, out-of-the-box ideas can be developed and refined. EU programs like Horizon Europe, which emphasise green and digital solutions to common problems are an excellent way to empower citizens, textile service firms and local communities to take the initiative and take matters into their own hands. The EU’s Due Diligence legislation is one example of somewhere we can see both consumers and firms come together and take proactive action to improve sustainability, not only in textiles and textile services, but in European industry more broadly. To put it clearly, we have to strengthen our technological innovation while also empowering consumers, authorities and textile service firms, we believe our work at the EU level helps to make this a reality.

How does ETSA promote new projects in the field of sustainability?
Elena Lai: We at ETSA have been hard at work lobbying EU policymakers for responsible legislation, while also spreading awareness of the industry’s best practice to the public. Recently ETSA has also become an EU Commission Climate Pact Ambassador. This is an exciting opportunity which will allow ETSA to work closely with European Institutions to inform and inspire real climate action amongst our members, national associations and the industry as a whole. ETSA is a platform where stakeholders, citizens, industries and European Union representatives can come together and have a dialogue on the best ways to improve Europe’s sustainability. Furthermore, we have been hard at work disseminating information on the best practice that will help Europe get to 55% emissions reductions, as well information on chemicals, waste-water, microplastics and other salient environmental issues. Our work is far from being done but we look forward to continuing to strive and advance via our focused Working Group on Environment and our webinars to make the world green and sustainable again.

What role will circular economy/sustainability play at Texcare?
Elena Lai: A central role, several European and World Leaders have underlined, is that Climate Change is the most important issue of our time and it is imperative we act now. Climate Change is also an issue with a global spill over and therefore we all have a clear incentive to find solutions and work in synergy with each other. We need future-oriented dialogue which understands the urgent need for sustainability across the entire textile value chain. ETSA in synergy with one of our members, DTV, is working hard to put together a panel at Texcare dedicated to the sustainability debate, with lots of members and participants to get engaged.

What does ETSA expect from this year's Texcare?
Elena Lai: We at ETSA are excited to be at Texcare, we think it’s a great opportunity to not only network and converse with other relevant actors in the industry but also to share best practice, concerns and most of all opportunities. Due to the pandemic we had a difficult year 2021 and this event will really enhance a stronger engagement of key actors in this sector. The need for green, sustainable and digital solutions is nonetheless imperative. We are looking forward to hearing of ways that the industry across the world not only continues to adapt to the evolving COVID situation, but also how it is embracing the green and digital transition that has been emphasised as being the futuristic approach by our EU policymakers. We at ETSA wholeheartedly look forward to this event.

Texcare International will take place from November 27 December 1, 2021 in Frankfurt am Main.

Fraunhofer Institutes pave new ways in plastics recycling

A sustainable society, the renunciation of fossil raw materials, climate-neutral processes - also the chemical industry has committed itself to these goals. For the industry, this means a huge challenge within the next years and decades. This structural change can succeed if all activities - from the raw material base to material flows and process technology to the end of a product's life cycle - are geared towards the goal of sustainable value creation. The key to this is innovation.

Plastics such as polyethylene (PE), polypropylene (PP) or polystyrene (PS), which are currently produced almost entirely from fossil raw materials, are fundamental to many everyday products and modern technologies. The carbon contained in plastics is an important resource for the chemical industry. If it is possible to better identify such carbon-containing components in waste, to recycle them more effectively, and to use them again to produce high-quality raw materials for industry, the carbon can be kept in the cycle. This not only reduces the need for fossil resources, but also pollution with CO₂ emissions and plastic waste. At the same time, the security of supply for industry is improved because an additional source of carbon is tapped.

The "Waste4Future" lighthouse project therefore aims to create new opportunities for recycling plastics in order to make the carbon they contain available as a "green" resource for the chemical industry. "We are thus paving the way for a carbon circular economy in which valuable new base molecules are obtained from plastic waste and emissions are largely avoided: Today's waste becomes tomorrow's resource," says Dr.-Ing. Sylvia Schattauer, deputy director of the Fraunhofer Institute for Microstructure of Materials and Systems IMWS, which is heading the project. "With the know-how of the participating institutes, we want to show how the comprehensive recycling of waste containing plastics without loss of carbon is possible and ultimately economical through interlocking, networked processes." The outcome of the project, which will run until the end of 2023, is expected to be innovative recycling technologies for complex waste that can be used to obtain high-quality recyclates.

Specifically, the development of a holistic, entropy-based assessment model is planned (entropy = measure of the disorder of a system), which will reorganize the recycling chain from process-guided to material-guided. A new type of sorting identifies which materials and in particular which plastic fractions are contained in the waste. Based on this analysis, the total stream is separated and a targeted decision is then made for the resulting sub-streams as to which recycling route is the most technically, ecologically and economically sensible for this specific waste quantity. What cannot be further utilized by means of mechanical recycling is available for chemical recycling, always with the aim of preserving the maximum possible amount of carbon compounds. Burning waste containing plastics at the end of the chain is thus eliminated.

The challenges for research and development are considerable. These include the complex evaluation of both input materials and recyclates according to ecological, economic and technical criteria. Mechanical recycling must be optimized, and processes and technologies must be established for the key points in the material utilization of plastic fractions. In addition, suitable sensor technology must be developed that can reliably identify materials in the sorting system. Machine learning methods will also be used, and the aim is to link them to a digital twin that represents the properties of the processed materials.

Another goal of the project is the automated optimization of the formulation development of recyclates from different material streams. Last but not least, an economic evaluation of the new recycling process chain will be carried out, for example with regard to the effects of rising prices for CO₂ certificates or new regulatory requirements. The project consortium will also conduct comprehensive life cycle analysis (LCA) studies for the individual recycling technologies to identify potential environmental risks and opportunities.

For the development of the corresponding solutions, the participating institutes are in close exchange with companies from the chemical industry and plastics processing, waste management, recycling plant construction and recycling plant operation, in order to consider the needs of industry in a targeted manner and thus increase the chances of rapid application of the results achieved.

The following Institutes are involved in the Fraunhofer lighthouse project "Waste4Future":

• Fraunhofer Institute for Microstructure of Materials and Systems IMWS (lead)
• Fraunhofer Institute for Non-Destructive Testing IZFP
• Fraunhofer Institute for Materials Recycling and Resource Strategy IWKS
• Fraunhofer Institute of Optronics, System Technologies and Image Exploitation IOSB
• Fraunhofer Institute for High Frequency Physics and Radar Techniques FHR
• Fraunhofer Institute for Structural Durability and System Reliability LBF
• Fraunhofer Institute for Process Engineering and Packaging IVV