From the Sector

Mayer & Cie. presented an overview of its current portfolio in the circular knitting sector at the ITM in Istanbul. Two machine types – the SF4 3.2 III and the Relanit 3.2 HS II – and various smart solutions that make circular knitting more efficient were on display. knithawk, a tool for the optical detection of knitting defects, met with interest among the visitors. The same was true for knitlink, Mayer & Cie's hub for digital solutions. Spare parts packages and conversion kits are also in demand for the long-term value retention of Mayer & Cie. machines.

Relanit 3.2 HS II
The Relanit 3.2 HS mechanical single jersey machine offers high productivity, especially in the context of elastic plating. It processes a wide range of yarns and qualities reliably. It is suitable for processing recycled yarns. Their energy consumption is up to a third lower than that of a circular knitting machine with conventional technology.

In Istanbul, Mayer & Cie. presented an updated version of its flagship, the Relanit 3.2 HS II. The new open-width take down is the single component that attracted the most interest. It ensures a uniform pull-off tension of the knitted fabric over its entire circumference. The knitted hose is only opened below the take-down rollers. Furthermore, the take-dwon is equipped with two drives: one for tensioning, one for rewinding. Both can be controlled separately.

Another innovation of the Relanit 3.2 HS is aimed at reducing downtimes: The needle with predetermined breaking point, which was developed together with Groz-Beckert, prevents it from breaking uncontrollably and, in the worst case, breaking needle butt. The new spring sinker is also a joint development with Groz-Beckert. This makes the Relanit 3.2 HS II run more smoothly, produce less noise as well as with less wear and tear.

SF4-3.2 III for lightweight three-tread fleece knitted fabrics
With its SF4-3.2 III, Mayer & Cie. is addressing a trend in the clothing industry that is reflected beyond Turkey: lightweight, elastic three-thread knitted fabrics in both pure cotton and blends.

New Control 5.0 machine control system
Both ITM machine exhibits were on display with the new Control 5.0 machine control system. Control 5.0 is a prerequisite for using knitlink, the hub for Mayer & Cie's digital applications. In this function, the machine control system attracted interest from various large customers.

In the standard SmartControl version, as shown in Istanbul, a so-called Smart Knob is attached to each machine foot. From there, all the functions that the machine operator needs for his work are available. More in-depth settings, such as those made by the knitting manager, are only possible from a mobile device. Any number of Mayer & Cie. machines can be operated from this at the same time.

knithawk
knithawk, a tool for optical defect detection, inspects the knitted fabric as it is produced. It sits in the single jersey machine directly at the knitting point. If knithawk detects a serious or recurring error, the machine is stopped. The tool also creates an error log.

Machine-specific upgrade and conversion kits
With its upgrade kits, Mayer & Cie. brings technological innovations to existing machines. These range from machine-specific upgrades, such as the Performance Kit for existing Relanit 3.2 models to the Senso Blue RS lubrication system.

In addition to the upgrade kits, Mayer & Cie. offers conversion kits for popular machine types. Two are currently available: for the MV4 3.2 II/MBF 3.2 and the S4-3.2 II/ SF4-3.2 III.

Guangxi Baisheng Textile Co., Ltd. signed an agreement with Rieter to implement the world’s first complete spinning process using Rieter’s latest air-jet spinning technology J 70.

This move will enable the vertically integrated textile company based in Guangxi, China, to further ensure a steady yarn supply for its knitting operations. Rieter’s air-jet spinning machine J 70 features 200 individually automated spinning units that independently manage quality cuts and natural ends down quickly and efficiently. The J 70 also boasts delivery speeds of up to 600 meters per minute and supports up to four lots simultaneously. In addition, Rieter’s latest generation yarn clearer identifies weak yarn during production.

Beaulieu International Group is investing €5 million to transition the fossil based energy supply of its Cushion Vinyl production plant in Wielsbeke, Belgium, to bio mass generated steam supply. A transition to renewable energy. To this end, B.I.G. is collaborating with A&U Energie, a company that converts non-recyclable wood waste into green energy and heat. This strategic move aligns with B.I.G.'s commitment to reach ‘net zero’ for their operations by 2030.

The transition from fossil energy to green steam and the switch to waste gas treatment without direct fossil energy brings significant benefits. First, the switch in technology will lead to 88% reduction in their Belgian Cushion Vinyl carbon footprint related to heat supply and waste gas treatment, compared to the current emissions. Second, the use of steam heating and electric energy provides improved energy efficiency. In addition, the use of steam systems is known for its safety and reliability, providing a safer and more stable heating solution for the Belgian Cushion Vinyl facility. Moreover, the switch to steam and electric energy allows for the use of green electricity in the future, if available.

In addition to transitioning to 100% green energy, Beaulieu International Group is also dedicated to advancing the circular economy. These efforts encompass various initiatives, including increasing the use of recycled and reused materials. For example, 50% of B.I.G.'s PVC floor coverings are already fully recyclable. Additionally, they are actively working to reduce the environmental impact of their solutions by 42% at the end of their life cycle, striving to minimize product emissions to nearly zero, and eliminating pollutants. Recently at the Belgian Flanders Flooring Days, Beauflor launched its Twilight collection, a cushion vinyl floor created with PVC from 100% bio and circular sources resulting in a 40% reduced CO₂ footprint compared to their conventional heterogeneous CV flooring for residential applications

Furthermore, their cushion vinyl brand Beauflor launched the ReLive concept, a specialized program designed for a circular future, ensuring the collection, sorting, and recycling of PVC flooring cutting waste. Currently, this program focuses on post-installation waste and is exclusively available in France, with the goal of expanding its reach to other EU countries.

Through the establishment of strategic partnerships dedicated to finding innovative ways to repurpose waste materials previously slated for incineration, B.I.G. underscores its commitment to sustainable solutions and collaboration with like-minded organizations. 75% of B.I.G.'s post-industrial waste is now being successfully recycled.

Archroma introduces COLOR MANAGEMENT+, an enhanced color design and development solution that helps textile and fashion brands and mills work together for improved economic and environmental sustainability.

Archroma COLOR MANAGEMENT+ incorporates the industry’s largest off-the-shelf color atlas selection, design tools and customized services for fast color selection and creation. It combines these with engineered color standards created with Archroma’s SUPER SYSTEMS+ for reduced environmental impact and consistent and accurate color reproduction.

With these end-to-end capabilities, brands and designers can focus on their color inspiration and on the required functionality and sustainability for their end article, with the assurance that their inspiration can be precisely communicated and efficiently executed at the mill.

Within COLOR MANAGEMENT+, the Color Atlas by Archroma® offers access to a collection of more than 5,700 unique colors for cotton, polyester and blends, both as a physical library and searchable online library. Designers also have the option to create custom colors.

Ahievability criteria are available for each color standard, whether in the Color Atlas or provided as an Engineered Color, at the selection phase. This includes information about the technical and economic feasibility of the selected color, along with a commitment to sustainability build on the foundation of the Zero Discharge of Hazardous Chemicals (ZDHC) Manufacturing Restricted Substances List (MRSL) Level 3.

The COLOR MANAGEMENT+ color standards provide clear color communication to mill colorists, textile technologists and quality control specialists, helping them deliver the right color faster and achieving reproducible colors across countries and mills. Clear communications can also eliminate excessive lab dipping, shorten approval times and improve first-time-approval rates.

The color standards in COLOR MANAGEMENT+ are created with Archroma’s SUPER SYSTEMS+ solutions for bulk production in mind. Offering end article-specific processing solutions, durable colors and intelligent effects, the SUPER SYSTEMS+ suite allows brands to achieve measurable environmental impact, eliminate harmful or regulated chemicals, and add value and longevity to the end product.

The solution is further supported Archroma’s ONE WAY+ Impact Calculator and Sustainability Improvement Program (SIP), and SAFE EDGE+ compliance-data platform. Global technical support is provided to help the supply chain deliver the right colors with consistency and reduced environmental impact.

Polyurethane has become an integral part of our daily lives, whether in the construction industry, in leisure activities, in the manufacture of furniture or in numerous other applications. The precision gear pumps from Oerlikon Barmag, which will be presented at this year's UTECH Asia / PU China 2024 in Shanghai, impress with customised solutions for demanding tasks in the chemical industry. They increase the productivity of the often complex manufacturing processes for this wide range of applications.

Oerlikon Barmag pumps handle demanding processes in PUR applications, in the chemical, plastics or paint and lacquers industries. One of the greatest challenges lies in the accurate and reliable metering of toxic or low-viscosity media. With the GM and GA series and the associated components, Oerlikon Barmag presents the optimum equipment for these applications.

GM pump
Pumps in the GM series achieve precise dosing by feeding the flow with low pulsation. The multi-stage GM pump conveys low-viscosity media even under high pressure and the most difficult operating conditions (e.g. 250 bar, 100 mPas). The standard pump for many dosing tasks is the GM series in a square design. With the development of the multi-stage pump, the range of applications for the GM series has been significantly expanded. The round 2-stage GM pump has been specially developed for use in high-pressure technology. It fulfils the special challenge of pumping small flow rates with low viscosities. The pump serves flow rates from 0.05 to 20 ccm/rev and is therefore particularly suitable for the production of PUR moulded parts, block foam, refrigeration unit insulation or sandwich panels.  

GA series
Making products and processes more efficient is a constant challenge for manufacturing companies. This is why Oerlikon Barmag has added the GA series to the GM series especially for the demanding conveying of high-viscosity media. The GA series is available in delivery volumes of 1.25 - 30 cm³/rev (0.6-144 l/h). It is designed for pressures up to 200 bar, for viscosities up to 1,500 Pas and for temperatures up to a maximum of 225°C. With this pump series, Oerlikon Barmag offers customised solutions for process engineering processes where highly accurate and uniform metering is required.

The drum pump
The drum pump from Oerlikon Barmag is specially designed for conveying and dosing highly viscous materials such as adhesives, silicones and other highly viscous materials from drums and other large containers and for pressures of up to 250 bar. One of its special features is not only that it discharges highly viscous materials from the drum, but also that the medium can be dosed directly without an intermediate stop.

The gear pump and drum follower plate are synchronised so that the plate effortlessly reaches the bottom of the container, leaving behind only a very small residual quantity of < 1%. This reduces material costs and has a positive effect on the production process.

Breaking new ground in plastics recycling means assessing the value chain from end to end. The big opportunities for the future are in fine-tuning the individual process steps; from the collection of recyclable materials to the recycling process and the end product. This is where the cooperation of Lindner and the EREMA Group comes in, officially launched following the 50/50 founding of the holding BLUEONE Solutions in August 2023 to which shares of Lindner Washtech were contributed. The expertise of EREMA, a manufacturer of extruders and filtration solutions for plastics recycling and the largest company within the EREMA Group, has now been combined with the expert know-how from Lindner Washtech, a leading provider of all-in-one solutions for shredding, sorting and washing plastic feed materials.

Data transfer ensures more efficient recycling processes
Process control is an especially important aspect of plastics recycling, which is why standardising the process control system was what the two companies focused on first. "Together, we have developed a platform that allows data to be exchanged between the extruder and the washing system," says Manfred Hackl, CEO of the EREMA Group at IFAT in Munich. "This enables us to analyse the data more precisely so that effective improvement measures can be deduced." All key parameters are taken into account and monitored via a digital interface. For example, it is possible to use information relating to the current throughput of the EREMA Pre Conditioning Unit to optimise the washing process as soon as possible so that it can compensate for fluctuations in capacity and achieve a significant increase in output. This data transfer represents a new step on the roadmap to digitalization.

High efficiency due to smart energy management
"To ensure sustainable recycling, it is necessary to find the right process for each application and to make sure that the individual process steps are perfectly coordinated," emphasizes Michael Lackner, Managing Director of Lindner. Coordinating the process steps has already achieved initial success in energy management, and a clear example of this is heat recovery. "We use the latent heat generated during the extrusion process as an energy source for the washing and drying process," explains Lackner. "This enables our customers to sustainably reduce their energy costs and carbon emissions".

Making the most of synergies along the value chain
Synergies need to be used to establish the quality standards specified for each end application. "The key question is how we can improve the end product and increase the overall efficiency of the recycling process at the same time," agree Manfred Hackl and Michael Lackner. This will only work if companies work together along the value chain. The industry leaders can already point to several examples where together they have improved recycling processes and made it possible to move away from downcycling. "An example of this is the recycling loop of HDPE starting material, which is processed into high-quality, food-safe rHDPE pellets using our two technologies," says Lackner. Lindner Washtech and EREMA continue to work intensively together to develop strategies for upcycling plastics and increase recycling rates.

Monforts, which is celebrating its 140th anniversary this year, will exhibit a Montex stenter chamber with an integrated overhead heat recovery unit at the forthcoming ITM textile machinery exhibition in Istanbul from June 4-8.

The heat recovery unit on display at the stand of Monforts partner Neotek is just one of a range of energy saving options the company is now providing for both new and existing line installations.

Monforts Montex stenters and Thermex dyeing ranges are industry standard for the fabric finishing industry, providing many advantages in terms of production throughput and especially in energy efficiency and savings.

coaTTex
At ITM, Monforts will also introduce its latest coaTTex coating unit, dedicated to air knife and knife-over-roller coating. For single-sided application with paste or foam, the versatile coaTTex is suitable for both incorporation into existing finishing ranges as well as installation with new Monforts lines, especially Montex stenter systems.

A wide range of coatings can be applied to fabrics for providing functions such as waterproofing, liquid and gas protection and breathability, in addition to foam lamination and coating, including black-out coating.

Central location
“In Turkey we are very strongly supported by our representative Neotek, our solution partner on the ground for service, installation and commissioning, providing specialised and rapid help to all of our customers,” says Monforts Area Sales Manager Thomas Paeffgen. “ITM is always one of the most important exhibitions for Monforts, for meeting customers not just from Turkey, but across the Middle East and Central Asia, as well as Bangladesh, India and Pakistan.

“Istanbul’s centralised position makes it accessible to the majority of the major textile manufacturing hubs and as we mark our 140th anniversary in 2024, having been founded back in 1884, the ITM show will provide us with the ideal opportunity to celebrate with colleagues and customers all together in one location.”

Polartec, a Milliken & Company brand, underscores its dedication to building a more sustainable future as it pursues the 2025 People, Product and Planet Goals, including certified science-based net-zero targets.

The Milliken & Company 2023 Sustainability Report discloses performance against the diversified global manufacturer’s 2025 Sustainability Goals and Net-Zero Targets and details the company’s key impacts across its people, product, planet, and net-zero measures. It also includes updates on each of the key impact areas Milliken and Polartec adhere to, including:

• People: The company focused on protecting associates by reducing lost-time incidents, strengthened its commitment to an inclusive supply chain by hosting its inaugural Supplier Diversity Event, and surpassed its goal of serving 100,000 community volunteer hours one year ahead of schedule.
• Product: Milliken used sustainability assessments to analyze all new products and made measurable gains in its multi-year commitment to address end-of-life challenges for plastics.
• Planet: Investments in cogeneration, energy efficiency, and renewable energy procurement are keeping the company ahead of schedule relative to its 2025 Greenhouse Gas (GHG) and Renewable Energy Goal; however, paths to achieve its 2025 Landfill and Water Reduction Goals have proven more challenging.
• Net-Zero: Five years of progress on GHG and renewable goals have helped Milliken progress toward its 2030 scope 1 and 2 net-zero targets, and the company has improved its scope 3 accounting to allow for a more detailed and accurate perspective on value chain emissions.

TradeBeyond has announced an advancement in its traceability solution through the integration of artificial intelligence. This upgrade allows global brands and retailers to improve visibility and reduce risks in their supply chains.

TradeBeyond's latest platform enhancements incorporate artificial intelligence to automate documentary verification and document chain of custody. These improvements bolster efficiency, security, and reliability. Advanced AI verifies the authenticity and integrity of products, tracing their journey from raw materials to production and delivery in compliance with increasing ESG regulations and standards.

TradeBeyond’s enhanced traceability solution leverages AI to automatically scan all documents, including orders, invoices, bills of lading, and shipping advices. It compiles the chain of custody documentation and checks critical product and shipment documents against multiple databases of blacklisted entities for potential compliance risks. The AI also identifies gaps or missing documentation, alerting businesses and suppliers for resolution before shipping.

Recent global supply chain due diligence laws, including the Uyghur Forced Labor Prevention Act and others, have placed stringent requirements on brands and retailers to provide their goods' chain of custody. TradeBeyond’s AI simplifies compliance with these laws, while increasing the data accuracy, visibility, and transparency necessary for sustainable sourcing.

Graniteville Specialty Fabrics has set new standards by challenging the traditional pad finishing process. With Baldwin Technology’s spray finishing technology, Graniteville Specialty Fabrics has been able to increase production efficiency, and minimize chemical and water waste.
 
Based in Graniteville, South Carolina, Graniteville Specialty Fabrics produces coatings and coated fabrics that are resistant to water, fire, UV and weather for the military, marine and tent markets. The installation of Baldwin’s TexCoat™ G4 is part of a facility upgrade to maximize production efficiency and capacity in the durable water-repellent finishing and coating line to meet growing customer demand for advanced engineered products.

With sustainability benefits, tracking and process control, and Industry 4.0 integration, the TexCoat™ G4 provides high-quality fabric finishing, with no chemistry waste, as well as minimal water and energy consumption. This system utilizes non-contact precision-spray technology, ensuring precise finishing coverage with the exact amount of chemistry. Changeovers (pad bath emptying, cleaning and refilling) are reduced, resulting in substantial chemical conservation and increased productivity.