From the Sector

With a clear focus on sustainability, Barmag, a subsidiary of the Swiss Oerlikon Group, is presenting comprehensive solutions from its product brands Oerlikon Barmag and Oerlikon Neumag for DTY and carpet yarn production at the Morocco Stitch & Tex Expo in Casablanca. From May 13 to 15, trade visitors can talk to experts from Barmag and the joint venture BB Engineering (BBE) at the Unionmatex booth (booth B4) to get an idea of the portfolio of the chemical fiber machine manufacturer.

Sustainable and efficient – the production of DTY yarns
Oerlikon Barmag offers a wide range of DTY machine configurations for the efficient and sustainable production of high-quality textured yarns made of various polymers – from polyester and polyamide to polypropylene, PLA and PTT. The modular machines – whether manual or automatic – produce yarns for excellent downstream processing at optimal OPEX costs.

Fancy yarns increasingly in demand
The demand for textiles with special characteristics is continuously increasing. For the production of these effect yarns, such as cotton-like DTY, linen-like DTY or wool-like DTY, Oerlikon Barmag offers a variety of processes and additional components. With its high-quality and flexible technology as well as its detailed knowledge of the yarn path and the required parameter settings, Oerlikon Barmag is the ideal partner for the successful and flexible production as well as the continuous further development of these specialty yarns.

Extended product range for carpet yarns
Thanks to its comprehensive knowledge of all relevant technologies in manmade fiber spinning, Oerlikon Barmag is the only manufacturer worldwide that can expand its range for the production of carpet yarns. The system concept, based on a POY and texturing process, is designed for the carpet and home textile sector and produces particularly soft and bulky polyester threads with BCF-like properties. The aim is to produce yarns with a titer of up to 1300dtex and over 1000 filaments, such as 1300dtex f1152, 660dtex f1152 and 990dtex f768. The machine concept includes the well-known WINGS HD POY winder and the eAFK Big-V texturing machine.

Innovative bicomponent BCF yarn for the carpet market
Quality, efficiency and performance – with its latest development in the field of bicomponent yarns for carpet production, Barmag's product brand Oerlikon Neumag is meeting the carpet market's demand for innovative BCF yarns. The new BICO-BCF yarn is characterized by a richer and higher volume and simultaneously significantly reduces the raw material consumption during carpet manufacturing.

VarioFil® – versatile compact spinning system for diverse applications and specialties
The VarioFil® system from BBE is ideal for a broad range of products, whether it be carpets, upholstery fabrics, fashion, sports, seat belts or airbags. This compact turnkey spinning line is particularly suitable for producers of small batches or specialized products. It flexibly processes various polymers such as PET, PP, PA 6, PA 6.6 and PBT. In combination with Oerlikon Barmag texturing machines, a wide range of textile standard yarns as well as textured yarns with BCF-like properties can be produced.

The VarioFil® R+ enables the direct recycling and processing of PET bottle flakes and PET waste from the start-up process into POY. This sustainable machine concept offers a high degree of product flexibility, including the production of spun-dyed yarn.

JeTex® air texturing offers a versatile product portfolio
BB Engineering also offers flexible solutions for the subsequent texturing of yarns. The JeTex® air texturing system perfectly complements the Oerlikon Barmag DTY systems and expands the product portfolio to include high-quality ATY based on POY and FDY for various textile applications. The centerpiece of the system is the texturing box developed by BB Engineering, which ensures gentle yarn treatment with reliable texturing effects and production efficiency.

“From waste to value” with VacuFil and Visco
BBE's VacuFil PET recycling system transforms textile waste into high-quality rPET melt. The technology is based on decades of experience in extrusion, filtration and spinning and combines gentle large-area filtration with targeted IV control. VacuFil processes various input materials, from bottle flakes to production waste and post-consumer waste. The patented Visco+ component removes volatile contaminants and automatically regulates the IV. The recycled melt can be added to the main melt stream, pelletized into chips or fed directly back into the spinning mill. The VacuFil system is modular and flexibly adaptable to customer needs.

The next-generation card TC 30i has earned popularity in main textile markets by achieving proven results in real-world operating conditions – for cotton yarn and for man-made fibers. It is suitable for a uniquely broad range of applications, including fine count (with the TC 30Fi model) and recycling (with the TC 30Ri model). All orders from the last few months are now being installed, so that the TC 30i can demonstrate ist positive impact on productivity and quality at many more mills worldwide

The TC 30i is designed to maximize process efficiency and product quality for spinning. Due to its intelligent, self-optimizing functions it achieves consistent results from any raw material while reducing or eliminating the demand for operator intervention. The machine has already proven up to 40 % higher productivity in man-made fiber applications. In recent trials with cotton applications, customers in Indonesia and Türkiye have achieved outstanding results, too.

The T-GO automated gap optimizer improves quality by enabling the smallest and most precise carding gaps – far beyond anything possible with manual settings. Second, the TC 30i maximizes quality and productivity by increasing the number of active flats without sacrificing flexibility in the pre- and post-carding areas due to the larger cylinder diameter. And third, the TC 30i minimizes cotton waste because it features a new and highly precise mote knife at the first licker-in. Customers can automatically optimize and adjust the mote knife settings to meet their specific needs. Combined with the impact of our WASTECONTROL feature, this significantly reduces material waste.

Big benefits for Budi Texindo Prakarsa
Budi Texindo Prakarsa is a leading spinning mill based in Indonesia, specialized in the production of premium cotton yarn with an annual capacity of 80,000 spindles. In their recent trials with the TC 30i, they produced 100 % cotton yarn (Ne 20 to Ne 30) via ring-combed processes. Compared to the previous benchmark, productivity increased by up to 30 % with the same IPI quality level. At the same time, energy and air consumption per kilogram have been reduced.

Measurable advantages for Mem Tekstil
In Türkiye, Mem Tekstil is one of the largest integrated manufactures in the textile sector. Their products range from knitting, dyeing, rotation and digital printing to ring spinning, open-end spinning and vortex spinning. With Trützschler's TC 30i they produced a yarn (Ne 20) made from 100 % cotton soft waste via open-end (OE) spinning. Its engineers tested the TC 30i because they are considering upgrading older card models from a Swiss competitor. Our machine has increased productivity from 70 kilograms per hour to 160 kilograms per hour with the same or better quality. This shows once again that modernization can be worthwhile.

Super results for SAFTEKS
SAFTEKS is another Trützschler customer located in Türkiye. The company produces cotton yarns with a monthly production capacity of 2100 tons. It uses OE spinning to manufacture 100 % cotton yarn (Ne 20) from 40 % virgin cotton and 60 % cotton soft waste. Swapping its cards for the TC 30i made it possible for SAFTEKS to increase its output capacity from 70 tons per day to 85 tons per day. That is a productivity boost of more than 20 %, with the same level of quality.

Promising results for PT Dhanar Mas Concern in man-made fiber applications
PT Dhanar Mas Concern (Danar Mas) is an Indonesian company dedicated to the production of high-quality textile products. The company specializes in spinning yarns and manufacturing greige fabrics. They use our TC 30Si card, which is specially customized for man-made fibers. In recent trials with the TC 30Si, Danar Mas produced a ring carded polyester yarn (Ne 20 to Ne 30) and a viscose yarn (Ne 30 to Ne 40) via vortex spinning. In both applications, the next-generation card produced 125 kg/h of material at the same IPI quality level, up to 40 % more than the company produces with its current benchmark.

Curtains will open next week for Intertextile Shanghai Home Textiles – Spring Edition 2025, taking place from 11 – 13 March, and offering the home and contract sectors a comprehensive selection of products with a strong emphasis on smart bedding and sustainability. Alongside innovative fringe events, over 350 exhibitors from four countries and regions are ready to convene in Hall 5.2 at the National Exhibition and Convention Center (Shanghai) to showcase an impressive range of products, including bedding, duvets, pillows, towelling, carpets, rugs, and more.

Intertextile Shanghai Home Textiles – Spring Edition 2025 will be held concurrently with Intertextile Shanghai Apparel Fabrics – Spring Edition, Yarn Expo Spring, CHIC and PH Value at the National Exhibition and Convention Center. The fair is organised by Messe Frankfurt (HK) Ltd; the Sub-Council of Textile Industry, CCPIT; and the China Home Textile Association (CHTA).

Key exhibitors to display extensive range of home textile advancements
Throughout the show floor, various exhibitors will showcase their innovations across the sector, including:

• 3M China Limited (USA) – as one of the first thermal material brands to emphasise thinness, its product 3M™ Thinsulate™ is an insulating fabric made from a blend of synthetic fibres, including polyester. Its fibres have a diameter of around 2 – 5 micrometres, making it much smaller than the other synthetic fibres used for insulation.
• CoolisT Life Technology Co Ltd (China)  – CoolisT Group specialises in bio-based biodegradable sponges, including bio-based Zero Foam and Hydrophilic Foam. Utilising advanced technology, its products are certified by USDA, OK bio-based, and TÜV AUSTRIA.
• Changzhou Huaji Wool Co Ltd (China) – the company produces wool and linen raw materials, with proprietary patented equipment and technology for shrink-resistant wool and wool strips. Its innovative wool products have received OEKO-TEX STANDARD 100 and RWS Responsible Wool certifications.
• Fujian Anran Textile Technology Co Ltd (China) – holding over 50 patents and multiple certifications, it specialises in 3D spacer materials, fabrics, and various products.
• Jiangyin Hongliu Bedsheet Co Ltd (China) – the company’s bedding set is crafted from high-quality nylon and spandex, offering a soft and comfortable texture. It features moisture-wicking and quick-drying properties while maintaining an elegant appearance.
• Shinwon Felt (Korea) – utilising a needle punching technique, the company regenerates plastic waste into felt products. Its sustainable product lines, certified by GRS, contribute significantly to addressing plastic waste issues.
• Tela's Design (Portugal) – a design studio specialising in home textile designs and decorations. Its core principles – colour, design, and detail – have established Tela as one of the leading and most successful textile design firms globally.

Uncovering trends driving change in home textiles
In addition to a robust lineup of exhibitors, Intertextile Shanghai Home Textiles will host various fringe events to keep attendees informed about emerging developments, trends, and key insights, including:

• Timeless and Transformative Colour Celebrating the Rich Diversity of Modern Living for 2026: held by Pantone Color Institute, participants can experiment with various styles, from industrial to rustic, and explore the vibrant colour palettes for home interiors in 2026.
• Sleeping Aid Summit 2025: one of the most vital yet often overlooked aspects of wellness is achieving quality sleep. At the summit, sleep technology will once again take centre stage, providing in-depth insights into sleep quality and exploring related business opportunities.
• Green and Low Carbon Forum: a growing number of individuals are opting for natural materials and sustainable textiles in their bedrooms and homes. The forum will highlight sustainability and the future direction of the industry.

Reju™, a textile-to-textile regeneration company, and Cibutex, a cooperative of companies dedicated to establishing a more sustainable textile supply chain, announced a partnership. Through this collaboration, Reju and Cibutex will work to establish an ecosystem among Cibutex member companies.

This partnership will deliver feedstock supply of secondary raw materials derived from post-consumer textile waste to Reju for the recycling and the production of regenerated Reju Polyester™. This provides circular regeneration opportunities using Reju’s innovative textile-to-textile recycling technology.

Reju is pioneering a global infrastructure for large-scale textile waste regeneration, starting with polyester. Reju Polyester™, will have a 50% lower carbon footprint compared to virgin polyester and can be regenerated infinitely. This partnership with Cibutex will see materials from the cooperative’s member companies processed at Reju’s Regeneration Hub Zero in Frankfurt, Germany, which will be fully operational in 2025 and at future Reju Regeneration Hubs.

Cibutex brings together companies from the textile service sector to collect and process post-use business textiles, creating a pathway for these materials to be reintroduced into the production cycle. It aims to close the loop on business textile production, ensuring that B2B post-use textiles are collected and transformed into valuable raw materials. By integrating Reju’s proprietary regeneration technology, this union ensures traceability and scalability, key components of a truly sustainable and circular textile supply chain.

The joint efforts of Reju and Cibutex highlight the strength of combined ingenuity and innovation in tackling the growing challenge of textile waste. With the European Union’s mandate for textile waste collection taking effect this year, along with pending regulations in the U.S., this initiative comes at a pivotal moment, ensuring scalable solutions to meet regulatory demands and achieve a more sustainable future.

Oerlikon Manmade Fibers Solutions recently hosted its highly anticipated Innovation and Technology Day at the Deltin Hotel in Daman by end of January 2025. The event attracted over 300 participants, including industry experts, partners, and stakeholders, who gathered to explore the latest advancements and trends in the manmade fibers industry in India.

Customer Event in Daman, India
The Innovation and Technology Day commenced with a warm welcome and introduction by Wolfgang Ernst, Chief Sales Officer (CSO) at Oerlikon Manmade Fibers Solutions, and Debabrata Ghosh, Head of Sales at Oerlikon Textile India. They provided an overview of the Indian market and its challenges.

“The Indian textile industry, particularly the chemical fiber sector, is experiencing significant growth and transformation. This development is driven by increasing production capacities, strategic investments, and a shift in global consumption patterns”, said Ghosh. India's production of manmade fibers (MMF) is robust, with annual outputs of 4.8 million tons of Polyester Filament Yarn (PFY), 1.7 million tons of Polyester Staple Fiber (PSF), 0.7 million tons of viscose, 0.2 million tons of Polyamide 6 (PA 6), and 25 thousand tons of acrylic. Additionally, the country boasts substantial capacities for PET bottles and films, growing at rates of 7% and 15% per annum, respectively. The Indian market is witnessing significant expansions in PTA (Purified Terephthalic Acid) capacity, with major projects underway by Indian Oil Corporation, GAIL, MCPI, Reliance Industries, and the Adani-Indorama joint venture. These expansions are set to increase the PTA capacity from the current 6.296 million tons to over 14 million tons by 2030.

Market Dynamics and strategic investments
“The global consumption landscape is shifting towards India and emerging Asia, driven by rising incomes and changing demographics. By 2050, India and emerging Asia are expected to account for 30% of global consumption at purchasing-power parity (PPP), up from 12% in 1997. This shift underscores the growing importance of these regions in the global economic landscape”, Ghosh continuous. Significant investments are being made to enhance production capacities and integrate advanced technologies. Indian Oil Corporation, in a joint venture with MCPI, is establishing a 900 TPD continuous polymerization unit in Odisha, supported by substantial government subsidies. Similarly, the Adani Group, in partnership with Indorama, is entering the petrochemical sector with a $3 billion PTA plant in Maharashtra.

Challenges and Opportunities
Despite the positive outlook, the industry faces challenges such as ensuring cost efficiency, scalability, and the seamless integration of new technologies into existing production processes. However, the sector is optimistic about improving profitability, driven by favorable supply-demand dynamics and strategic investments. “The Indian textile and chemical fiber industry is poised for significant growth, supported by strategic investments, capacity expansions, and a favorable global consumption shift. These developments position India as a key player in the global textile market, driving towards a sustainable and prosperous future”, said Ernst.

After the introduction about the current market situation, the event continued with numerous technical presentations in which Oerlikon and its partners presented their technological and solution expertise along the textile value production chain “From Melt to Yarn, Fibers and Nonwovens”.

“To spin an excellent yarn, you need the prefect melt”, said Moderator André Wissenberg, Head of Marketing, Corporate Communications, and Public Affairs at Oerlikon Manmade Fibers Solutions. How this can be produced using extrusion or continuous polycondensation technology was demonstrated by the keynote speakers Sven Streiber, Regional Sales Director at Oerlikon Barmag, Deepak Lokre, Head of Engineering at Oerlikon Textile India, and Matthias Schmitz, Head of Engineering Recycling Technology at BB Engineering (BBE).

The second session focused on Oerlikons technology partner for manmade fiber spinning mills. Presentations covered topics such as enhancing manmade fiber production with innovative air engineering, automatic handling solutions and quality inspections, as well as air texturizing solutions. Notable speakers included Praveen Kumar Singh, Managing Director of Luwa India, and Luca Lacitignola, Sales Director at Irico Gualchierani Handling (IGH), Simone Ducceschi, Sales & Project Manager at Thema Systems, as well as Ralf Morgenroth, Head of Engineering Textile Machinery at BBE.

The third session delved into solutions for producing the perfect fibers and yarns, with a focus on Oerlikon Barmag POY/DTY, FDY, IDY technologies as well as Oerlikon Neumag BCF and staple fiber line plants. Presentations were delivered by Philip Jungbecker, Head of R&D, and Guido Dresen, Regional Sales Director, both at Oerlikon Barmag, as well Chetan Bhagat, General Manager Sales, and Sameer Mehrotra, General Manager Service at Oerlikon Textile India. Ralf Morgenroth added further insights of the compact spinning solution VarioFil from BBE.

Environmentally friendly recycling solutions
The fourth session highlighted environmentally friendly recycling solutions, featuring insights from Sven Streiber and Sudipto Mandal, Sales and Marketing Manager at Oerlikon Textile India, and again Matthias Schmitz, BBE. They provided a detailed portfolio overview in the field of mechanical and chemical recycling. The new partnership between Oerlikon Barmag and Evonik was also presented to the audience. Finally, this was followed by a session on customer services and digital solutions, where Michael Ruebenhagen, Head of Global Service Sales and Ivan Gallo, Digital Solutions, both at Oerlikon Manmade Fibers Solutions discussed current upgrade and retrofit options, the Digital Academy, and the future of digitalization in manmade fiber spinning mills. Shared Kulkarnie, General Manager Service Sales & Workshops, as well as Chandru Gurbaxani, Digital Solutions, performed together with their German colleagues.

The event concluded with closing remarks again from Wolfgang Ernst, who provided a global market overview and outlook for 2025. Final remarks were given by Atul Vaidya, Managing Director of Oerlikon Textile India. Finaly the event ended with a gala evening with more than 500 participants featuring a fashion show, music, dancing, and excellent food, supported by Decathlon and Garden Vareli.

It is getting exciting again in Cologne on 12 and 13 March for the cellulose fibres industry. Six new products have been nominated for the popular innovation award.

Every year, the conference organisator nova-Institute together with award sponsor GIG Karasek honours companies that impress with their creativity, technological progress and ecological impact. The aim of the award is not only to recognise the winners’ innovative products, but also to set an example for the courage to innovate.

The nominees’ presentations, the voting and the winner ceremony will take place on 12 March at the Cellulose Fibres Conference 2025. Participants of the conference can vote live for the three winners. More than 220 people are expected to attend.

The Nominees

Fibers365 (DE): Hemp365 – Agricultural Decorative and Carrier Material
The solution “hemp365” is characterised by the development of a cost-effective, plant-based decorative and carrier material through the chemical-free processing of a regional agricultural fibre and the use of resulting short fibres in a wet-laid process, allowing for a massive reduction in the amount of fossil based binders required for strength and functionality. The non fibre content is less than 7 % and is also made from biogenic and biodegradable material. Hemp365 is 100% natural and vegan. It has been designed for consumer (fashion) and industrial applications in cooperation with an automotive OEM.

Releaf Paper France (FR): Releaf Fiber – Eco-Friendly Paper from Urban Fallen Leaves
Releaf Paper France transforms urban fallen leaves into sustainable cellulose fibres, offering an eco-friendly alternative to traditional hardwood pulp. Using proprietary low-temperature extraction, high-quality fibres with excellent paper-forming properties are isolated. With a cellulose content of 32-48 % and properties similar to hardwood, RELEAF fibres are ideal for packaging materials like corrugated paper, boxes, and bags. This innovative process, which requires minimal water and non-aggressive solvents, aligns with circular economy principles, repurposing millions of tons of urban leaf waste annually and supporting global brands in achieving sustainable packaging solutions.

SA-Dynamics (DE): Cellulose Aerogel Textiles – Next-Generation Insulation Materials
Cellulose Aerogel Textiles are revolutionary insulation materials made from 100 % biodegradable cellulose aerogel fibres. These combine the flexibility and ease of processing of traditional fabrics with the superior thermal insulation properties of aerogels by utilising a novel aerogel fibre process. Lightweight, highly efficient, and compatible with conventional textile machinery, they provide a sustainable alternative to fossil-based and animal-derived insulation materials. Fully recyclable and free from microplastic emissions, Cellulose Aerogel Textiles set a new benchmark for circular economy solutions in the textile and construction industries. Initial functional demonstrators were developed through two projects, funded by Biotexfuture and RWTH Innovation, respectively.

Sci-Lume Labs (US): Bylon® – Renewable Circular Fibres from Agricultural Waste
Sci-Lume Labs makes Bylon®, a scalable, circular, biosynthetic fibre. Using highly efficient chemistries to valorise agricultural waste, Bylon® seamlessly integrates into every step of the global value chain – from raw material production through textile manufacturing. Bylon® is distinct from incumbent and next-gen materials because it is simultaneously bio-based; waste-derived; degradable; recyclable; downstream-compatible; and melt-spinnable. Bylon® also offers a unique performance profile by combining the mechanical properties and tunability of traditional synthetics with the moisture properties and circularity of natural fibres. By not requiring changes to the supply chain, Bylon® empowers the industry to reduce its environmental impact – without compromising on quality, performance, or cost.

TMG Automotive (PT): REFIBER – Sustainable Automotive Surface Material
Textile-based composite solutions are a growing trend in the automotive sector, especially for decorative and functional interior applications. Innovative plant-based leather demonstrates this trend, combining sustainability with advanced performance. Developed from a biopolymer matrix combined with cellulose waste, this material transforms waste into a premium, eco-friendly solution. Its textile backing and non-woven laminate backing are also made entirely from cellulose fibres, creating a fully integrated bio-based composite. Designed for car interiors and more, this lightweight, durable and aesthetically versatile material sets a new standard for sustainable design, while satisfying the industry’s growing demand for circular and renewable alternatives.

Uluu (AU): Replacing plastic in textiles with natural, seaweed-derived materials
Uluu is an Australian start-up set to replace plastics with natural polymers called PHAs. Uluu materials are made from a regenerative feedstock: farmed seaweed, thus ending reliance on fossil fuels and land crops. Uluu, in partnership with Deakin University, is developing textiles that perform like synthetic polyester but are truly biodegradable and biocompatible, thus eliminating persistent microplastic pollution in fashion. Importantly, Uluu materials are reusable, recyclable, and most importantly, compostable. They are naturally produced through a unique fermentation process that uses seaweed, saltwater microbes and seawater. Uluu pellets can be directly substituted for plastic (e.g., polyester, nylon) in existing melt spinning equipment, creating yarns that can be knitted or woven into textiles. In addition to fibre-grade pellets, Uluu is also producing other grades of pellets to replace plastics used in e.g., buttons, sunglasses, hair clips and packaging.

The Middle East’s industrial sector is synonymous with high-risk environments, particularly in oil and gas production. Workers face hazards such as flash fires, chemical splashes and electric arcs—all within the context of demanding conditions, including sweltering heat and long shifts. In response to these challenges, flame-retardant (FR) fabrics with stretch properties are emerging as the next generation of protective workwear, delivering comfort, safety and durability.

Traditionally, FR fabrics prioritised protection over comfort. However, the increasing demand for ergonomic clothing has driven a shift towards stretch solutions. Thanks to innovations in textile engineering and the influence of modern fashion, these fabrics now combine unparalleled flexibility with the stringent safety standards required in high-risk industries.

Stretch fabrics such as Carrington Textiles’ Flametougher 290AS Flex and Flameflex 300AS demonstrate how this transition is not just a luxury but a necessity. Flametougher 290AS Flex, for example, incorporates 19.5% CORDURA® nylon 6,6 for exceptional durability and strength, blended with 78% cotton for lightweight comfort. At just 290gsm, it ensures workers maintain mobility without compromising on protection.

Meeting the needs of Middle Eastern workers, Flameflex 300AS, weighing 300gsm, provides a perfect balance of durability, flexibility and flame resistance. Its 83% cotton and 14% polyester composition ensures longevity, while 2% EOL fibres enable enhanced elasticity—critical for workers in physically intensive roles such as oil rig operations or refinery maintenance.

Flexibility in workwear isn’t just a matter of comfort, it’s a matter of safety. Restricted movement can lead to fatigue, reduced compliance with safety standards and accidents. Stretch FR fabrics excel in adaptability. Whether it’s a worker scaling scaffolding on an oil platform or handling maintenance in a petrochemical plant, garments made with stretch FR textiles allow for the unrestricted movement critical to performing tasks safely.

The rise of these type of fabrics also owes much to the fashion industry. Decades of innovation in stretch garments for everyday use have created a ripple effect in workwear. Workers increasingly expect the same level of comfort and fit in their protective clothing, and manufacturers are responding.

ZDHC announced the publication of the Recycled Polyester Guidelines V1.0 and Industry Standard Implementation Approach V1.0.

The use of recycled polyester has grown increasingly, growing by 3.5% to 8.9 million tonnes in 2023. In order to support the fashion industry with a framework for sustainable chemical management in the production process for bottle-to-textile and textile-to-textile recycling processes, ZDHC has developed these transformative guidelines.

Objective:
The document sets requirements, across three chapters, for recycled polyester manufacturers on key chemicals used in recycled polyester processes, the recovery and reuse of these chemicals, safe chemical storage and handling, worker safety and the environmental impacts of commercially viable processes on wastewater, air and sludge.

Chapter 1
Input management covers bottle/textile feedstock and chemicals used as inputs in recycled polyester production.

Chapter 2
Process management covers best practices, including chemical recovery, safe storage and handling of chemicals for worker safety.

Chapter 3
Output management covers emissions from wastewater, sludge and air from the production of recycled polyester fibre.
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‍Expectations by ZDHC:
Brands should share these guidelines with their relevant suppliers and build in the request to implement these guidelines into their strategy and policies.
Suppliers should study these guidelines and take relevant actions to ensure implementation.
Solution providers should review the test methods and limits detailed in the guidelines.

Autoneum has supported Renault Group in the development of Renault Emblème, a low-carbon demonstration car designed to reduce greenhouse gas emissions by 90 percent over its entire life cycle. As a key partner of the project, Autoneum further optimized the environmental performance of its sustainable Pure technologies, which were used for numerous components in the vehicle interior and exterior. Leveraging its proven expertise in the development of lightweight and fully recyclable monomaterials with a high recycled content, as well as in the areas of life cycle analysis (LCA) and product innovation, Autoneum was able to reduce the carbon footprint of its parts and contribute to a significant reduction in vehicle weight for Renault Emblème.

Increasingly stringent regulations to reduce greenhouse gas emissions on a global scale, new directives and the electrification of mobility require innovative approaches from the entire automotive industry. To support vehicle manufacturers in achieving their sustainability targets, Autoneum continuously optimizes the environmental performance of its products and processes: from further increasing the share of recycled content and the end-of-life recyclability of its lightweight technologies to reducing waste and shifting to renewable energy in its production facilities. In addition, the Company is working closely with customers and partners to validate data and products together. One of the most recent examples of such a successful collaboration is Autoneum’s contribution to Renault Emblème.

The Renault Emblème demonstration car emits 90% fewer greenhouse gases over its entire life cycle than a comparable vehicle produced today. To achieve these ambitious decarbonization targets, Renault Group assembled more than twenty suppliers from across the industry to participate in specialized projects in five different areas: eco-design, raw material selection, manufacturing, use and end of life. In addition to providing valuable expertise in the areas of LCA and product development, Autoneum’s contribution entailed the further optimization of its environmentally friendly Pure technologies, which already today are characterized by an excellent sustainability performance across the product life cycle and also include the Company’s growing portfolio of monomaterial technologies made of 100 percent polyester.

Autoneum’s innovative and lightweight materials were used for around thirty fiber-based components in the interior and exterior of Renault Emblème, including the carpet, the underbody panels and wheelhouse outer liners as well the front and rear trunk. Thanks to the high recycled content, the waste-free production process and the excellent recyclability of the materials at the end of their service life, Autoneum was able to reduce drastically the carbon footprint of the components. This outstanding achievement was made possible by further boosting the sustainability performance of existing technologies such as Ultra-Silent, Propylat PET, Hybrid-Acoustics and Autoneum’s monomaterial polyester carpet systems. In addition, the parts contributed to a weight reduction, which positively affected both the carbon footprint and the range of the electric car.

Aktuelle biobasierte Kunststoffe sind oft nur für kurzlebige Anwendungen, wie Verpackungen geeignet, da sie unzureichende Langzeiteigenschaften aufweisen. Das neue Projekt „Biobasierte Polyester für anspruchsvolle Langzeitanwendungen“ aus dem Fraunhofer-Institut für Betriebsfestigkeit und Systemzuverlässigkeit LBF soll die Langzeiteigenschaften von Biokunststoffen durch gezielte Additivierung verbessern, um deren Einsatz in technischen Anwendungen zu ermöglichen. Dafür suchen die Forschenden Unternehmen entlang der Wertschöpfungskette, die auch bei langlebigen Produkten petrobasierte Kunststoffe durch biobasierte Lösungen substituieren möchten.

In dem geplanten Projekt werden biobasierte Materialien durch gezielte Additivierung optimiert, um mit petrochemischen Kunststoffen vergleichbar zu sein. In zahlreichen Projekten haben Forschende aus dem Fraunhofer-Institut für Betriebsfestigkeit und Systemzuverlässigkeit LBF in den letzten Jahren auf dem Gebiet Kunststoff-Additive geforscht und können die Langzeiteigenschaften von Kunststoffen sowohl aus fossilen als auch aus nachwachsenden Rohstoffen verbessern. Ziel des Projektes ist die nachhaltige Substitution petrobasierter technischer Kunststoffe auf Basis bisher gewonnener Erkenntnisse zur Materialoptimierung sowie die Realisierung entlang der gesamten Wertschöpfungskette.

Minimale Veränderungen im Verarbeitungsprozess
Das Projekt adressiert die Herausforderungen der Langzeiteigenschaften von Biokunststoffen. In einer umfassenden Literaturrecherche werden zunächst bestehende Daten zur Langzeitstabilität und eingesetzten Stabilisatoren zusammengeführt. Gemeinsam mit den Projektpartnern wird ein Lastenheft erstellt, welches die zu erreichenden Materialeigenschaften festlegt. Marktverfügbare Biokunststoffe und Additive werden identifiziert und hinsichtlich ihrer Eigenschaften getestet. Die Modifikation der Biokunststoffe erfolgt durch die Entwicklung neuer Formulierungen im Technikumsmaßstab. Ziel ist es, die Materialsubstitution mit minimalen Veränderungen in den bestehenden Verarbeitungsprozessen zu ermöglichen.

Die Fraunhofer Wissenschaftlerinnen und Wissenschaftler suchen Partner aus Unternehmen entlang der Wertschöpfungskette beginnend mit Herstellern von Kunststoffen und Additiven bis hin zu Unternehmen, die einzelne Bauteile in ihren Konstruktionen substituieren wollen, mit besonderem Fokus auf Entwickler und Produzenten fertiger Bauteile.

Gemeinsam Wettbewerbsvorteile sichern: Nachhaltige anspruchsvolle Kunststoffprodukte
OEM und Hersteller von Kunststoffbauteilen aus dem Bereich Bau, Automotive, Sport und Freizeit, Elektro- und Elektronik Bauteile, Haushaltsgeräte, die petrobasierte Kunststoffe durch biobasierte Lösungen substituieren möchten, erhalten mit der Teilnahme an dem neuen Projekt »Biobasierte Polyester für anspruchsvolle Langzeitanwendungen« ausreichend Wissen, um ihre eigene Forschung und Entwicklung individuell und zielgenau zu optimieren. Sie profitieren direkt von neuesten Erkenntnissen und sichern sich dadurch Wettbewerbsvorteile. Rohstoff- und Additivhersteller können ihr bestehendes Produktportfolio um neue Anwendungsmöglichkeiten erweitern und Compoundeure wappnen sich für zukünftige Herausforderungen beim Einsatz von Biokunststoffen.