From the Sector

A much more sustainable, cost effective and very flexible process for manufacturing critical fibres based on ultra high molecular weight polyethylene (UHMWPE) is being launched by the UK’s Fibre Extrusion Technologies (FET).

UHMWPE is prized in many industries due to its extraordinary properties. The fibre is, for example, ten times stronger than steel by weight, while exhibiting outstanding abrasion resistance, low friction and high impact strength. UHMWPE fibres are also chemically inert, resistant to most chemicals and UV light and do not absorb water. They maintain performance in a wide range of temperatures and despite their toughness are extremely lightweight.

As a result, they are unbeatable in demanding applications such as high-performance ropes in maritime industrial and rescue applications. In addition, they are invaluable in ballistic protection, cut-resistant clothing and high-performance sports gear – and increasingly in medical implants.

Biomedical market
“FET has supplied many extrusion systems to the biomedical market, most notably for the production of both resorbable and non-absorbable sutures,” says FET Managing Director Richard Slack. “In exploring what else we could do in assisting these customers, it became clear that there was a need for smaller quantities of UHMWPE fibres in bespoke sizes.”

“The current systems for manufacturing UHMWPE filament yarns are on a huge scale, with very complex processing routes,” adds Research and Development Manager Jonny Hunter. “This means the supply chain is currently very inflexible with minimal opportunity for new product development. These disadvantages have been fully addressed in the development of our new FET-500 series lab and small scale gel spinning system.”

Solvent extraction
A major FET innovation is the introduction of a patented batch system for solvent extraction exploiting supercritical carbon dioxide (CO2).

UHMWPE production, until now, has involved the use of large volumes of hazardous solvents such as dichloromethane (DCM) or hexane. The UHMWPE powder is mixed with mineral oil to form a gel which is subsequently extruded, cooled and solidified. The oil is then extracted from the fibres using DCM or hexane and the solid fibres are then drawn at high temperature to further align the polymer chains, resulting in final strong and tough fibres. Typically, it takes 10 kg of Hexane to extract 1 kg of oil. 

“Solvent reclamation using extraction baths and hot air drying chambers is not practical for the scale of our system,” explains FET’s Senior Material and Process Scientist Kris Kortsen. “The current baths employed can be up to 200 metres long and the waste volumes are considerable. Expertise is needed in dealing with such dangerous chemicals and overall the process has an immense environmental impact.

“CO2, by contrast, is a cheap and abundant sustainable solvent that is non-toxic, non-flammable and leaves no residue.” 

Closed loop
FET’s closed-loop system can achieve more than 95% solvent recovery without loss of performance, resulting in residue-free UHMWPE filament yarns via a vastly improved route in terms of both safety and logistics.

A further innovation is the highly modular drawing system based on heated godet rollers, enabling flexible temperature and drawing control for new product development and the ability to be expanded at any time to meet customer needs.

A comprehensive LCA study detailing the full savings potential is currently being prepared and will be published shortly.

“Having processed over 130 separate polymers in the development of our extrusion systems, we believe the FET-500 is a game changer,” concludes Richard Slack. “We believe there is a big gap in the market for smaller quantities of UHMWPE, and our first line is now fully operational at the FET Fibre Development Centre in Leeds. We look forward to demonstrating it and discussing its full potential with interested companies from around the world.”

Mit Hilfe der elektrochemischen CO₂-Reduktion lässt sich der Kohlenstoffkreislauf schließen: Unvermeidbare Emissionen aus Betonproduktion oder Abfallverbrennung werden zu CO – und somit zum Ausgangspunkt für Chemikalien oder Kraftstoffe. Bei der industriellen Anwendung dieser Technologie lauert allerdings eine Hürde: Sie ist (bislang) nicht kompatibel mit der bestehenden Infrastruktur. Eine mögliche Lösung haben Forschende von Fraunhofer UMSICHT und Ruhr-Universität Bochum entwickelt: ein neuer Reaktor, der CO₂ unter Verwendung von unter Druck stehendem CO₂ und reinem Wasser effizient umwandelt.

„CO₂ ist bereits fester Teil vieler industrieller Prozesse wie der Erdgasreformierung, der Ethylenoxid-Produktion und der Oxyfuel-Verbrennung“, erklärt Prof. Ulf-Peter Apfel, Leiter der Abteilung Elektrosynthese bei Fraunhofer UMSICHT und der Forschungsgruppe Anorganische Chemie an der Ruhr-Universität Bochum. „In diesen Prozessen steht das CO₂ entweder direkt im Anschluss unter Druck oder wird für die Speicherung und den Transport auf höhere Drücke komprimiert. Die Druckentlastung dieser CO2-Ströme für die Verwendung in der CO₂-Elektrolyse erschwert die Integration elektrolytischer Technologien und führt zu weiteren energetischen Einbußen.“

Um diesen Schritt zu umgehen, haben die Forschenden einen Zero-Gap-Reaktor für die CO₂-Elektrolyse entwickelt, welcher mit einem Differenzdruck von bis zu 40 bar betrieben werden kann. Er beruht auf einem neuen Design und umfasst u.a. eine neue mechanisch stabile Protonenaustauschmembran mit einer dünnen anionischen Deckschicht. Dieses neue System ermöglicht die Erzeugung von Kohlenstoffbausteinen bei Differenzdrücken von 40 bar(g) und vereinfacht gleichzeitig die Konstruktion des Elektrolyseurs, da an der Anode nur reines Wasser zum Einsatz kommt. Weitere Highlights:

• Der Differenzdruck erhöht die Produktselektivität von CO auf 81 Prozent bei einer Stromdichte von 500 mA cm-2.
• Der Reaktor kann mit einem sehr niedrigen CO₂-Überschuss betrieben werden, sodass aktuell bis zu 25 Prozent des eingesetzten CO₂ in einem Durchlauf zu CO reduziert werden können.
• Hohe Produktselektivität von CO bei dem Betrieb mit der modifizierten Protonen-austauschmembran und reinem Wasser als Anolyt – auch bei hohen Stromdichten über 300 mA cm-2

„Durch den Betrieb bei Differenzdrücken verbessert das System die Umwandlungsraten und die Stabilität erheblich, wodurch der Prozess nachhaltiger und effektiver wird«, fasst Ulf-Peter Apfel zusammen. »Diese Fortschritte ermöglichen die Integration der CO2-Umwandlung in bestehende chemische Industrien und fördern weitere Innovationen in der Katalysator- und Reaktortechnologie, wodurch umweltfreundlichere Methoden der chemischen Produktion gefördert werden.“

The prize in the ‘Building and Civil Engineering’ category was awarded for the development of Carbon Fibre Stone (CFS). Environmentally friendly CFS can save up to 40 % CO₂ in the construction of house walls. CFS is an innovative material that combines stone and bio-based fibres. It serves as an environmentally friendly replacement for CO₂-intensive concrete in house walls. Each square metre of a CFS wall binds 59 kg of CO₂, while conventional cement walls release 98 kg of CO₂.

The ITA won the second JEC award in the “Sports, Leisure & Recreation” category.

The Honey Roots technology is a sustainable surfboard construction realised through a 3D laminate that improves the mechanics and eliminates the need for consumables for the infusion process. The choice of materials is consistently bio-based or recycled to minimise the carbon footprint.

Project partners were Techno Carbon Technologies GbR and Kanoa Surfboards.

PhD student and project leader Lars Wollert summarises: "These awards are a recognition of our research activities and show what the ITA stands for the development of innovative products and processes together with a great network of industrial partners, openness for versatile application areas in which fibres of all kinds bring advantages and research in the context of sustainability."

Klopman, a European leader in the production of fabrics for workwear, and TDV Industries, a France-based company specializing in textiles for technical and military clothing, completed an innovative project for the creation of an advanced tool to calculate the Life Cycle Assessment of their fabrics. The tool has obtained the well-recognized EPD (Environmental Product Declaration) certification from Environdec.

The EPD certification validates the methodology and results of a product's Life Cycle Assessment (LCA), a rigorous methodology that evaluates the environmental impact of a given product throughout all phases of its life cycle: from raw material extraction to production, usage, and disposal. This approach provides a comprehensive and accurate overview of environmental impacts, and the production processes involved. LCA allows for the measurement of parameters such as greenhouse gas emissions, energy consumption, water usage, and other environmental indicators, offering a scientific basis for improving efficiency and reducing the ecological footprint of products.

The Environmental Product Declaration (EPD) is a certified verification system that ensures a transparent and reliable assessment of a product's environmental impact. This certification follows international standards and enables companies to demonstrate their commitment to sustainability, improving transparency with customers and business partners.

Thanks to the new tool, Klopman and TDV Industries can now accurately calculate the environmental impact of each stage of their fabric production. This allows both companies to generate complete EPD certifications in compliance with international regulations, ensuring greater transparency and credibility for their products.

"Our Group has always been committed to sustainability projects, both within the company and regarding the products we bring to the market. Today, with this tool, we want to provide our customers with clear answers about the impact of our fabrics in terms of CO2 emissions, water, and land consumption, but also beyond that," says Amaury Sartorius, Group Commercial Director and Managing Director of Klopman. "The textile industry is undergoing a transition toward more sustainable production processes, and this project fits perfectly within this evolution. With this tool, we aim to produce fabrics with an increasingly lower environmental impact, thereby helping our customers in their sustainability and decarbonization journeys (such as SBTi).”

Elkem Silicones has been honored for its commitment to sustainable businesses, receiving awards in two categories of the SEAL Awards. This recognition underscores our comprehensive approach to our ESG strategy, from executing our climate roadmap to developing silicone solutions supporting circularity.
Environmental Initiative Award:

The innovative Industrial Symbiosis for Silicones value chain initiative has been recognized for the recycling of hydrochloric acid (HCl) waste into valuable raw materials for specialty silicones.

This approach not only reduces waste and CO2 emissions but aligns with the company’s ambition to develop and scale up new technologies and processes to maximize raw material value, starting with in-house industrial waste.
This closed-loop system has already delivered a carbon footprint reduction of up to 6.5% in one of our product ranges, with the potential to achieve up to 14% in the midterm.

Sustainable Product Award
SILCOLAPSE™ EASY 10, honored with the Sustainable Product Award, is the result of an intensive R&D program aimed at formulating an optimal solution for foam control in the plastic recycling sector.

This product addresses the critical issue of foam formation during the washing and wastewater treatment stages of recycling, which are essential for reducing environmental impact and improving process efficiency.

In industrial trials, SILCOLAPSE™ EASY 10 has shown up to a 50% reduction in antifoam usage, leading to lower CO2 emissions and enhanced productivity. This innovation aligns with Elkem's commitment to supply industries enabling the green transition.

Pili, a French pioneer in biobased dyes and pigments, partners with Orta, the Turkish denim mill and Citizens of Humanity, a California-based high-end denim brand known for its commitment to quality and sustainability.

They are beginning a transformative shift in the denim industry with the commercial launch of the first products dyed with Pili’s biobased indigo. The first products will debut in January in the Spring 2025 collections of Citizens of Humanity and AGOLDE.

A New Ecological Standard for the Denim Industry
In 2024, Pili achieved a major milestone by producing its first tons of biobased indigo, enabling the creation of sustainable denim articles, a turning point in the company's efforts to decarbonize the textile industry especially denim.

Pili has developed unique processes combining fermentation and organic chemistry to offer a high-performance, eco-friendly alternative to petrochemical dyes. Their ecological alternative significantly reduces the use of toxic chemicals and fossil resources, while aiming to cut CO2 emissions up to 50%. It meets the same performance as petrochemical indigo while seamlessly integrating into existing dyeing processes without requiring additional investment in commercial dyeing equipment.

Pili’s colors development is based on standardized Life Cycle Assessments (LCAs), ensuring a rigorous process to measure and minimize their environmental impact.

A Partnership Driving Sustainable Transformation in the Industry
Fiber and dye are the two main components of denim products and also the ones with the greatest impact on their production. The partnership between Citizens of Humanity, Pili, and Orta establishes one of the highest ecological standards in the market with the use of regenerative cotton and biobased indigo.

Pili biobased indigo will make its debut in Citizens of Humanity and AGOLDE’s Spring 2025 collections. This long-term partnership between Citizens of Humanity, Orta, and Pili will continue to expand in future collections. The launch will be exclusive on NET-A-PORTER on January 6, 2025, before being extended to agolde.com, citizensofhumanity.com, and other global retailers.

A Key Step Towards the Decarbonization of the Color Industry
Building on this first success, Pili is accelerating the development of coloring solutions for various industrial applications, particularly in the inks, paints, and polymers sectors. The aim is to decarbonize everyday products using high-performance biobased pigments, with the first applicative tests set to begin this year. Pili continues its mission to decarbonize the color industry, paving the way for a sustainable revolution.

Dibella‘s latest sustainability report covers the period from January 1st, 2023 to July 31st, 2024 and documents progress and future plans in the areas of environmental, social and corporate governance.

Dibella laid the foundations for corporate social responsibility back in the early 2010s. Since then, the company has been consistently committed to the implementation of socially and environmentally consciously produced textiles and has initiated and completed numerous lighthouse projects in the supply chain. Dibella presented its activities and goals for the first time in 2012 in its sustainability report. Since then, the company has documented its progress at regular intervals.

Environment
Particularly noteworthy are the constant proportion of GOTS and Fairtrade-certified products and a significant increase in the implementation of Cotton made in Africa cotton in the supply chain using the mass balance system: from 300 tonnes in 2023 to 750 tonnes in 2024. Another highlight is the reforestation project in Tamil Nadu, India, where over 4,000 trees have already been planted to offset CO₂ emissions. As a founding member of CIBUTEX, Dibella is also committed to the recovery of textile resources and the associated reduction of environmental pollution.

Social
Dibella has initiated and completed various social projects. One example is the improvement of working conditions in the supply chain by providing ergonomic seating for employees of a Pakistani clothing manufacturer. Dibella's own GoodTextiles Foundation also supports educational projects in India and drinking water initiatives in Africa. Measures have been introduced within the company to promote a good working environment.

Corporate Governance
99.5 per cent of textiles are now labelled with the Green Button, which confirms compliance with the Supply Chain Duty of Care Act. In addition, digital transparency tools such as the respect-code, which disclose the origin and production steps of the goods, have been further expanded. Following the coronavirus-related travel restrictions, business trips to India were also resumed in order to familiarise customers and interested parties with the positive ecological and social framework conditions of the supply chain.

Goals for the future
By 2030, company-related CO2 emissions are to be reduced by 45% and the proportion of organic Fairtrade cotton is to be increased to 20%. Overall, the proportion of sustainable cotton is to be increased to 70% of production. The company will continue to focus on sustainable innovation and transparency in the future.

Twenty years have in fact passed since the Group published its first Social Report in 2004, qualifying it as one of the pioneering companies in the realisation of voluntary non-financial reporting. The document measures the Group’s achievements and the actions it has taken to reduce its environmental impact, respect social values, and implement good business management practices.

Over the years, the Report has steadily evolved and is now a true sustainability report that considers all ESG (Environment, Social and Governance) aspects, showing how they are also central to the company's business strategy. Over time, many new topics have been covered, the accuracy of the data has improved and the scope has expanded to include all Group companies: over 30 sites across Asia, the Americas and Europe.

The information contained in the Sustainability Report shows RadiciGroup's strong commitment, starting with the investments made:

• between 2019 and 2023, €278 million were allocated to support the competitiveness of the Group's companies, of which €45 million in 2023 alone;
• the amount invested in the environment in 2023 and earmarked for the introduction of Best Available Techniques and performance efficiency reached €4.2 million.

Twenty years of reporting have also allowed RadiciGroup to measure the results of the investments it has made, to such an extent that in 2023 it already achieved the first goal of its "From Earth to Earth" Roadmap to 2030, i.e., a Group-wide reduction of 83% in direct CO2 equivalent emissions compared to 2011.

A significant contribution to this result came from the commissioning of an EnviNOx plant at the Radici Chimica plant in Germany, which, thanks to this technological innovation, greatly reduced its direct greenhouse gas emissions (- 92%).

The focus on responsible use of natural resources continues: In 2023, the share of electricity from renewable sources used for production processes was consolidated at 59%. The percentage of water resources saved through the practice of water recycling was also raised to 79%: some of our plants in fact reuse the same water up to 60 times and then return it to the environment. The theme of circular economy remains a cross-cutting one in many of the innovation projects, often also in a collaborative perspective with the rest of the supply chain. In particular, all Radicigroup companies work to contain the generation of scrap and waste through rigorous process management: 73% of all non-hazardous waste was recovered in 2023 and 56% of this was destined for internal recovery.

Even in the product area, measurement is fundamental, which is why RadiciGroup has long used Life Cycle Assessment studies to objectively calculate the environmental impact of its products and introduce environmental footprint mitigation solutions. This commitment is also evidenced by the numerous environmental certifications obtained by RadiciGroup plants.

With a view to promoting collaboration with customers, suppliers, scientific partners or independent experts in order to develop innovative and sustainable technologies or materials, RadiciGroup has strongly promoted open innovation projects: opportunities to stimulate a Group culture increasingly open to change and contamination with different fields of knowledge.

Regarding its employees, the Group has placed significant emphasis on training, particularly in fostering ESG awareness. In fact, in 2023, it organised its first large-scale training program focused on sustainability and circularity, engaging around 240 employees and delivering a total of 1,500 training hours. In addition, an internal human rights survey was launched, the results of which will form the basis for the formulation of a company policy on human rights and diversity.

The ZEBRA (Zero wastE Blade ReseArch) project marks a significant leap forward in the recycling and circular economy for wind turbine blades. This collaborative effort demonstrates a breakthrough in the complete recycling of thermoplastic blades achieving significant environmental and economic benefits.

The ZEBRA project is a unique partnership led by the French Institute for Technological Research, IRT Jules Verne. Joining forces are industry leaders Arkema (resin supplier), Owens Corning (glass fiber supplier), LM Wind Power (blade manufacturer), SUEZ (dismantling and waste processing), CANOE R&D center (recycling technology), and ENGIE (life cycle analysis).

Each company played a crucial role in the development of the closed-loop recycling process:

• Arkema developed and validated the generation of recycled Elium® monomer through thermolysis, and, together with its subsidiary Bostik, an innovative adhesive for the blade assembly that is recycled together with Elium® paving the way for industrial-scale implementation.
• Owens Corning successfully recovered glass fiber at pilot scale, enabling its reintroduction into the production process for their Sustaina® product line.
• LM Wind Power manufactured two wind turbine blades with Arkema’s Elium® resin and Owens Corning’s Ultrablade® fabrics; one blade including a large structural element made with recycled Elium® resin.
• SUEZ provided cutting and grinding expertise for processing the blades.
• CANOE R&D center optimized recycling for production and carbon blade waste, additionally developing methods for repurposing waste streams through mechanical recycling.
• ENGIE conducted a comprehensive life cycle analysis demonstrating the environmental benefits of closed-loop ZEBRA blades and validated their economic viability.

A Sustainable Future for Wind Energy
The ZEBRA project successfully recycled Elium® resin and Ultrablade® fabrics from wind turbine blades and manufacturing waste, reformulating them back into usable materials. This closed-loop process addresses the growing challenge of end-of-life blade management within the wind energy industry.

• Recycled Elium® Monomer: Arkema achieved a yield of over 75% in the thermolysis process, paving the way for industrial-scale production of recycled resin.
• Recovered Glass Fiber: Owens Corning successfully retrieved glass fiber for remelting and reintegration into their Sustaina® product line.
• Life Cycle and Cost Analysis: ENGIE's study confirmed the significant environmental benefits and economic viability of ZEBRA blades when assuming a closed-loop recycling system from production to end-of-life.

ZEBRA blade using Elium® thermoplastic resin, Bostik’s highly compatible adhesive and Ultrablade® fabrics is bringing the best closed-loop recycling solution compared to traditional thermoset system. The operating cost and investments for recycling facility are significantly lowered. The CO2 emission linked to the recycling operations is reduced as well. All those results are making the closed-loop recycling solution of ZEBRA blades a viable option both on economic and environmental standpoints.

By demonstrating the feasibility of full wind turbine blade recycling, the ZEBRA project paves the way for a more sustainable future in the wind energy sector.

INDA, the Association of the Nonwoven Fabrics Industry, has announced the finalists for the 2024 RISE® Innovation Award. On October 1-2, technology scouts, product developers, and business development professionals will gather at the James B. Hunt, Jr. Library, North Carolina State University, Raleigh, NC, to explore nonwoven research and advancements.

Finalists will present their innovations to RISE participants on Tuesday, October 1st. The Award winner will be revealed on Wednesday afternoon, October 2nd.

The 2024 Award Finalists:
Dual-Layer Filtration Media by Ahlstrom Italia S.p.A. – Ahlstrom’s new dual-layer filter media technology enhances engine air intake filtration performances, offering up to double the dust holding capacity and extending filter lifetime by over 50% compared to single-layer media. It also enables smaller, lighter filter designs, meeting current and future engine specifications, including fuel cells. Dual-layer filter media can be offered with flame-retardant functionality for various transportation and industrial applications, ensuring safety, improved performances and reduced environmental impact.

ENDURA™ rPP Spunbond & SMS by Berry Global – A pre-consumer recycled Spunbond and SMS product, recognized by SCS Recycled Content Certification. With Spunbond products containing up to 90% recycled content and SMS products containing up to 40% recycled content, customers/consumers are provided a product with greenhouse gas emissions benefits, validated with life cycle assessment tools assumptions based on the actual production.  ENDURA Spunbond products have the opportunity to reduce CO2 emissions per kilogram of production by 70%, versus previous generation of product.

PlantPanel X by Hempitecture Inc. – PlantPanel X is a rigid continuous insulation material used in exterior above-ground applications. With an R Value of R3.25 per inch, PlantPanel adds to thermal and acoustic comfort and performance. Engineered with a density to resist compression and deflection, PlantPanel is used in split-insulation wall and roof assemblies with either a rain screen cladding or roofing material, depending on the application. With 100% biobased and recycled content, PlantPanel is a sustainable, low carbon continuous insulation solution that’s easy to install and safe to handle.

2023 RISE Innovation Award winner:
TiHive won the 2023 RISE Innovation Award for their SAPMonit technology. TiHive’s innovation, SAPMonit, inspects millions of diapers weekly. SAPMonit delivers lightning-speed inline inspection of superabsorbents’ weight and distribution, optimizes resources, detects flaws, and accelerates R&D.