From the Sector

• Monomaterial solution contains renewably-sourced polypropylene from the Bornewables™ portfolio of circular polyolefins
• Trexel employs its proprietary MuCell® technology to deliver a range of lightweighting benefits
• EverMinds™ in action: reuse and design for recycling are focus of value chain collaboration

Borealis and Trexel, an expert in foaming injection and blow moulded parts, announce that they have co-developed a new plastic bottle based on a grade from the Bornewables™ portfolio of polyolefins made using renewable feedstocks derived 100% from waste and residue streams. The lightweight bottle – which will be showcased at the Borealis stand at the K 2022 (from 19 to 26 October 2022 in Düsseldorf) – is reusable and fully recyclable. It boasts a significantly lower overall CO₂ footprint because it is composed of renewably-sourced feedstock and produced in the foaming process.

The Bornewables™ portfolio of circular polyolefins helps reduce the carbon footprint while offering material performance equal to virgin polymers. Using Bornewables grades allows for design freedom and colour flexibility, and helps retain a premium look and feel. The grades – which are commercially available in Europe – help conserve natural resources because they are derived solely from waste and residue streams, for example from used cooking oil. Reusing waste already in circulation instead of fossil fuel-based feedstocks enhances the sustainability of applications made using the Bornewables grades.

The reusable new bottle developed by Borealis and Trexel retains its value over many life cycles thanks to the use of Trexel’s proprietary technology in tandem with Bornewables grades; as a material solution, the new bottle minimises the use of valuable raw materials. Moreover, converters consume less energy in the production process when using the MuCell® technology. The bottle thus helps close the loop on plastics circularity by way of design for recycling, the use of renewable feedstocks, and excellent material performance across multiple life cycles.

• An innovative European project to process and recycle plastic textile waste
• A partnership to reach the objectives set by the European Union in reducing CO2 emissions by 2030
• A unique consortium rallying 16 public and private European organizations working together for more circular economy

Carbios joined WhiteCycle, a project coordinated by Michelin, which was launched in July 2022. Its main goal is to develop a circular solution to convert complex^[1] waste containing textile made of plastic into products with high added value. Co-funded by Horizon Europe, the European Union’s research and innovation program, this unprecedented public/private European partnership includes 16 organizations and will run for four years.
 
WhiteCycle envisions that by 2030 the uptake and deployment of its circular solution will lead to the annual recycling of more than 2 million tons of the third most widely used plastic in the world, PET^[2]. This project should prevent landfilling or incineration of more than 1.8 million tons of that plastic each year. Also, it should enable reduction of CO2 emissions by around 2 million tons.
 
Complex waste containing textile (PET) from end-of-life tyres, hoses and multilayer clothes are currently difficult to recycle, but could soon become recyclable thanks to the project outcomes. Raw material from PET plastic waste could go back into creation of high-performance products, through a circular and viable value chain.
 
Public and private European organizations are combining their scientific and industrial expertises:

• industrial partners (Michelin, Mandals, KORDSA);
• cross-sector partnership (Inditex)
• waste management companies (Synergies TLC, ESTATO);
• intelligent monitoring systems for sorting (IRIS);
• biological recycling SME (Carbios);
• product life cycle analysis company (IPOINT);
• university, expert in FAIR data management (HVL);
• universities, research and technology organizations (PPRIME – Université de Poitiers/CNRS, DITF, IFTH, ERASME);
• industry cluster (Axelera);
• project management consulting company (Dynergie).

 
The consortium will develop new processes required throughout the industrial value chain:

• Innovative sorting technologies, to enable significant increase of the PET plastic content of complex waste streams in order to better process them;
• A pre-treatment for recuperated PET plastic content, followed by a breakthrough recycling enzyme-based process to decompose it into pure monomers in a sustainable way;
• Repolymerization of the recycled monomers into like new plastic;
• Fabrication and quality verification of the new products made of recycled plastic materials

 
WhiteCycle has a global budget of nearly 9.6 million euros and receives European funding in the amount of nearly 7.1 million euros. The consortium’s partners are based in five countries (France, Spain, Germany, Norway and Turkey). Coordinated by Michelin, it has an effective governance system involving a steering committee, an advisory board and a technical support committee.

^[1] Complex waste: multi materials waste (Rubber goods composites and multi-layer textile)
^[2] PET: Polyethylene terephthalate

• Exceptional achievement of research work on the use of Nuclear Magnetic Resonance (NMR) spectroscopy for understanding PET depolymerization enzymes

Carbios (Euronext Growth Paris: ALCRB), a pioneer in the development of enzymatic solutions dedicated to the end-of-life of plastic and textile polymers, announces the publication of an article entitled “An NMR look at an engineered PET depolymerase” in the scientific journal Biophysical Journal.

The article describes the use of Nuclear Magnetic Resonance (NMR) spectroscopy to study the thermal stability of PET depolymerization enzymes and the mechanism of adsorption of the enzyme on the polymer. This innovative approach, which required months of development, is a world first and opens up new ways of improving these enzymes. This publication confirms Carbios' international lead in the development of the most efficient enzymes for the depolymerization and recycling of plastics.

Prof. Alain Marty, Chief Scientific Officer of Carbios and co-author of the article, explains: “ Nearly 25 researchers are currently working on our unique enzymatic technology. It is based on academic collaborations with the world's leading experts in their fields..”

Dr. Guy Lippens, CNRS Research Director and co-author of the artcle, adds: “Nuclear Magnetic Resonance (NMR) is an extraordinary biophysical technique for visualizing an enzyme directly in solution. Our study is the first to use NMR as a complementary technique to crystallography and molecular modeling to observe a PETase. This gives new perspectives to better understand the functioning of these enzymes and it makes it possible to imagine new ways of improving these enzymes. ”

Indorama Ventures Public Company Limited (IVL) announced that construction of an integrated PTA-PET plant in Corpus Christi, Texas, will resume in August this year. Corpus Christi Polymers LLC (CCP), a partnership between three companies, is expected to begin production in 2025 and ensure continued cost-competitive production to support the growth of IVL’s global PET operations into the next decade.

CCP was formed in 2018 as a joint venture between Indorama Ventures Corpus Christi Holdings LLC, a subsidiary of Indorama Ventures; DAK Americas LLC, a subsidiary of Alpek S.A.B. de C.V.; and APG Polytech USA Holdings, Inc, a subsidiary of Far Eastern New Century, following the purchase of a partially constructed facility of M&G Resins in Corpus Christi. Each partner will procure its own raw materials and receive one third of the PTA and PET produced at the facility to sell and distribute independently.

Construction of the plant is resuming following a period of pandemic-related disruptions. Through the pandemic, the partners firmly resolved to continue planning amid continued robust demand for PET packaging and the need for shorter supply chains. As the impact of the pandemic eased in 2022, the management team was strengthened in preparation for the resumption in activities.

CCP is expected to be the largest vertically integrated PTA-PET production plant in the Americas, and IVL’s biggest greenfields project in the U.S. since the development of the AlphaPet production facility at Decatur, Alabama in 2009. The new Texas facility is a significant addition to IVL’s leading global footprint, and will expand its coverage to customers across the U.S. The plant’s vertical integration optimizes PTA-PET production and, together with the availability of raw materials Paraxylene and Mono Ethylene Glycol in the U.S., ensures long-term competitive-cost supply for IVL’s locally integrated polyester value chain.

The facility will have nominal annual capacities of 1.1 million metric tons of PET and 1.3 million metric tons of PTA, shared between the partners. It will employ three state-of-the-art technologies: PTA: IntegRex®, PET melt: Invista, and PET solid state: Easy Up (HCIRR – Horizontal Continuous slightly Inclined Rotary Reactor).

CCP is adding to its leadership team to prepare for the new growth opportunities. Mr Russell Wilson will leave his role with IVL as Head of Manufacturing Americas, Combined PET, to take up a new role as Chief Executive Officer of CCP from 18 July. He brings 30 years of Aromatics and PET leadership experience including prior roles with Amoco and BP before joining IVL. Mr Todd Hogue, IVL’s Global Head of EH&S, replaces Mr Wilson as IVL’s representative on CCP’s Board. Mr Michael Day joined CCP as Project Director in June and brings 34 years of construction leadership experience including senior roles with Bilfinger, KBR, and CB&I.  Mr Jeff Shea will assume the role of Chief Operating Officer on 18 July.  Mr Shea has been in the PET industry for the last 22 years and has managed PET sites for the last 17. 

New ideas were exchanged, brainstormed, and discussed freely at members’ booths at the Swiss Textile Machinery Pavilion during the recent Techtextil in Frankfurt. “Customers and researchers met Swiss textile machinery companies to explore the possibility of the not-yet-invented. “We regard our Pavilion as the place where future innovations catch a spark,” says Cornelia Buchwalder, Secretary General of the Swiss Textile Machinery Association. Further developments in the field of hybrid yarns were a hot topic. One example of this involves producing a yarn which has all the typical characteristics and advantages of carbon – but which also prioritizes careful use of resources, combining carbon fibres with thermoplastics.

Technical textiles cover a vast range of applications, and it’s still growing thanks to intensive research by specialist institutes and universities. Many members of the Swiss Textile Machinery Association maintain long-standing partnership with such bodies. Innovations are often joint efforts.

Feel-good technical fabrics
Some technical textiles feel like a second skin. A well-known example is activewear from the ‘sport tech’ field. Activewear includes breathable clothing, usually consisting of a three-layer-laminate: an inner lining, a breathable membrane in the center, and an outer fabric. The challenge is to bond the individual layers without losing breathability or softness, while meeting technical requirements such as resistance to a number of wash cycles.

Bonding solutions meeting top quality requirements, as well as ambitious standards for environmental protection and sustainability, were reinvented by the Cavitec brand from the Santex Rimar Group. This company’s hotmelt technology uses one-component polymers applied to textiles in a hot, molten state. Bonding based on hotmelts is both water- and solvent-free. Drying and exhaust air cleaning are not necessary, which is an ecological advantage. Energy consumption is also significantly lower. Cavitec hotmelt technology is also developed for laminated medical protection fabrics which are safe, high-quality and sustainable. These fabrics can be washed, sterilized, and used again.   

A second skin with added value is the result of Jakob Müller Group’s cooperation with an institute for an established outdoor fashion brand. They have devised a heating mat applied as an inner jacket. Outdoor gear with a heated inlay offers the wearer a comfortable feeling even in a cold climate. The heating mat is particularly light, breathable, flexible and adjustable to three temperature levels.

Fabrics with these advantages are now possible thanks to multi direct weaving (MDW) technology from the Jakob Müller Group. A lacquer-insulated heating strand is inserted into the base textile as a ‘meander’ using MDW technology. The technology is offered with both label weaving machines and the latest generation of ribbon weaving machines. The textile pocket calculator is another MDW based future-oriented application developed in cooperation with a textile research institute.

Safety and health
Life-saving reliability is a must for vehicle airbags. They have to fulfil high security aspects, and must remain inflated for several seconds when an accident occurs. Airbags made of flat-woven fabric – cut and seamed – can show weakness at seams during the inflation phase. Latest Jacquard technology by Stäubli enables one-piece-woven (OPW) airbags to be produced, creating shape and structure in a single process. The final product is an airbag consisting of a sealed cushion with woven seams. OPW airbag weaving reduces the number of production steps, and increases the security aspects.
Another big advantage of Stäubli’s new weaving technology is the flexibility in formats required in today’s mid- and upper-range cars, where lateral protection (in the seat or in the roof over the door) has become standard and is designed in line with the car shape. Safe airbags are woven on modern high-speed weaving machines. The warp material, the variety of fabric patterns, and the importance of precisely shaped airbags require the use of a robust and reliable Jacquard machine.

A revolution for orthopaedic patients is a knitting machine from Steiger Participations, which uses compressive yarns developed to meet the needs of the specific health market. This machine model was exclusively designed for production with inlaid elastic yarns and offers optimum performance with guaranteed final product quality.

In the orthopaedic field, many Steiger flat knitting machines have already been operating as automatic, custom-made production systems. For example, the dimensions of an injured limb are taken by the doctor and fed into a web-based application. The doctor selects the compression class in the various sections of the item and a data file created by the software automatically applies a preconfigured program. With no human intervention required, the program is generated and produced on the machine, precisely matching the patient’s dimensions. Each product is different, and generally available within 48 hours.

• The Borvida™ portfolio introduces sustainable base chemicals to Borealis’ range of product offering
• The range will initially be based on non-food waste biomass, and chemically-recycled waste; in the future it will also draw from atmospheric carbon capture
• The traceability of the content will be based on Mass Balance, which is ISCC PLUS certified
• This is the next step in an ambitious sustainability journey, which will see Borealis move away from traditional fossil-based feed

Borealis is strengthening its EverMinds™ circular product offering with Borvida™, a range of sustainable base chemicals.

The Borvida portfolio will offer base chemicals or cracker products (such as ethylene, propylene, butene and phenol) with ISCC Plus-certified sustainable content from Borealis sites in Finland, Sweden and Belgium. The move is part of Borealis’ broader commitment to a Future-Positive Revolution, in which the unrivalled benefits of base chemicals and polymers can be enjoyed at minimal impact to the planet.   

The portfolio will initially comprise Borvida B, from non-food waste biomass, and Borvida C, from chemically-recycled waste. In the future, the range will evolve to include Borvida A, sourced from atmospheric carbon capture. Borvida is complementary and is the building block to Bornewables™, a portfolio of polyolefins based on renewably-sourced second generation feedstocks, and Borcycle™, which offers circular polyolefins produced from mechanically- and chemically-recycled plastic waste.

Borealis produces a wide range of base chemicals for use in numerous industries based on various feedstock, such as naphtha, butane, propane and ethane. Through its olefin units (steam cracker and propane dehydrogenation), it converts these into the building blocks of the chemical industry: ethylene, propylene and C4 hydrocarbons (butylenes, ethyl tertiary-butyl ether (ETBE) and butadiene), and C5-6 hydrocarbons (pygas, phenol) among others.

The basis of the Borvida portfolio is Mass Balance, a Chain of Custody model that enables sustainable content to be tracked, traced, and verified through the entire value chain, offering sustainability-assured products from feedstock to end product. Using this model, circular alternatives can be offered in a cost-effective and environmentally-conscious way, which can be scaled up quickly without compromising on quality or efficiency.

Borvida can be used for a wide range of different polymer and chemical applications, also beyond polyolefins (PO). Non-PO polymers, such as polycarbonates, acrylonitrile butadiene styrene (ABS), super absorbant polymer (SAP) and other chemicals, are utilised for various end applications including coatings, plasticizers, adhesives, automotive, electronics, lubricants, detergents, appliances and sports equipment.

Together with key strategic partners, including Neste and Covestro, Borealis strives to provide a long-term solution in order to allow value-chain partners to meet their sustainability goals. Borvida will enable our customers to increase the sustainability of their products, keeping them ahead of forthcoming legislative changes, and meeting their customers’ demands for climate-conscious products.

Introduced on a smaller scale in early 2020, early renewable base chemicals customers include Covestro. “The use of alternative sustainable raw materials is one important pillar of our strategic ambition to become fully circular”, comments Frank Dörner, Managing Director Covestro Procurement Services GmbH & Co. KG. “The new product line is a good example for joint solutions, another strategic pillar, in order to establish new and reliable supply chains creating benefits for our customers.”

Stahl announced the launch of its Integra^® portfolio, a versatile toolbox that provides tailor-made, customer-orientated solutions under the umbrella of flame-retardant technology, protective surfaces, and protective coatings. The integrated, polymer-driven approach behind Integra® offers customers greater flexibility in terms of product development, helping them to achieve regulatory and environmental compliance while ensuring superior product quality and fabric integrity.

The market for flame retardants and performance coatings is increasingly complex and subject to extensive – and often conflicting – demands and requirements. This includes increasingly stringent chemical industry legislation that limits flexibility regarding chemical and additive usage as well as growing expectations from stakeholders regarding environmental, social, and governance (ESG) factors.
 
With Integra^®, Stahl offers a polymer-driven solution that builds upon the flame-retardant technology offered through Stahl’s Eagleban™ brand, which is enhanced by Stahl’s expertise in polymer-based technologies for protective coatings and surfaces. By using the proven polymer technology as its “backbone” while harnessing the other technologies in its toolbox, including specialty crosslinkers and other additives, Integra® can help customers solve complex challenges in a flexible, integrated way that goes beyond traditional additive-driven approaches.

With an annual report entitled 'Here.We.Go' and a sustainability report 'Shaping sustainable living, together', B.I.G. is also publishing a strong ambition for a sustainable future.

Offering sustainable flooring and material solutions will be the number one priority for the coming years.

The Group's first sustainability report is built around a self-designed sustainability model - "Route 2030" - which is based on achievable commitments, covers the main priorities and reflects B.I.G.'s vision in a sincere way.

Their vision for the B.I.G. change is to actively build a better future by their our carbon footprint to zero and doing business in a transparent, integer way. In this sense, it is the translation of the Group's purpose defined in 2021: shaping sustainable living, together.

Pol Deturck adds “By 2030, together with a broad group of suppliers, stakeholders and partners, we want to be the leader in sustainable flooring and material solutions. Specifically, our future value proposition is based on products and services that are environmentally & climate friendly, circular and offered by talented, innovative people with an emphasis on integrity and respect for values. This results more in a recurring value proposition for the future.”

Clear growth ambitions
As a 100% family-owned international Group with a clear long-term vision, B.I.G. stayed true to their plans and kept on investing in all areas of their business.
“The ambition for 2021 was to invest over 100 mio euro. But we were held back by external, unforeseen factors: from delays on quotes and execution to the lack of availability and resources due to the pandemic. If all goes as planned, we’ll make up for it in 2022 with an investment budget well over 100 million euro. The main areas of interest will be sustainability, innovation and Industry 4.0.” says Pieter-Jan Sonck, CFO of B.I.G.

Adding to the gradual top-line growth of recent years, the Group can look back on an unprecedented financial boom. The driving forces: favorable market conditions, a revitalized growth strategy and a team of nearly 5.000 first-class employees.

B.I.G. reported a turnover of EUR 2,5 billion, an increase of 45 % compared to 2020. The Group ebitda amounted to EUR 451 million, an increase of 120 % compared to 2020 and a net result of EUR 274 million, a growth of 215% compared to 2020.

Fruitful year for all Business Units
It was a fruitful year for all 3 business units, but the Group's business unit Polymers stood out. Exceptionally strong demand in Europe and North America, combined with raw material shortages and unplanned shutdowns of competitors, pushed prices and margins up to highs. The Polymers facilities ran at full capacity to meet the customers’ needs and hit all-time profit records during several months.

The Group's business unit Flooring Solutions also fared well. Most divisions and regions outperformed amid surging energy prices, disrupted supply chains, cost volatility in transport and raw materials, and other challenges. Their sustained focus on innovation, design and product differentiation led to an improved operating result at the end of 2021.

The achievements by Engineered Solutions echo those of the other two business units, from volume increases to budget increases. B.I.G. took big leaps forward in all its key markets, including the automotive sector, geotextiles and filtration.

• Sustainable infrastructure solutions, road safety and health protection

At this year’s Techtextil, Oerlikon Polymer Processing Solutions will be presenting the trade audience with new applications, special processes and sustainable solutions focusing on the production of industrial textiles. Among other things, the company will be showcasing new technology for charging nonwovens that sets new standards with regards to quality and efficiency. Between June 21 and 24, the discussions will be concentrating on airbags, seat belts, tire cord, geotextiles, filter nonwovens and their diverse applications.

More polyester for airbags
Airbags have become an integral part of our everyday automotive lives. The yarns used in them are made predominantly from polyamide. As a result of increasingly diverse airbag applications and also the increasing size of the systems used, polyester is today used as well, depending on the application requirements and cost-benefit considerations. Against this background, the Oerlikon Barmag technologies make an invaluable contribution. In addition to high productivity and low energy consumption, they particularly excel in terms of their stable production processes. Furthermore, they comply with every high quality standard for airbags, which – as in the case of virtually all other textile products used in vehicle construction – must provide the highest level of safety for vehicle occupants. And all this without any loss of function in any climate and anywhere in the world for the lifetime of the vehicle.

Buckle up!
Seat belts play a decisive role in protecting vehicle occupants. They have to withstand tensile forces in excess of three tons and simultaneously stretch in a controlled manner in emergencies in order to reduce the load in the event of impact. A seat belt comprises approximately 300 filament yarns, whose individual, high-tenacity yarn threads are spun from around 100 individual filaments.

Invisible, but essential – road reinforcement using geotextiles
But it not just inside vehicles, but also under them, that industrial yarns reveal their strengths. Low stretch, ultra-high tenacity, high rigidity – industrial yarns offer outstanding properties for the demanding tasks carried out by geotextiles; for instance, as geogrids in the base course system under asphalt. Normally, geotextiles have extremely high yarn titers of up to 24,000 denier. Oerlikon Barmag system concepts simultaneously manufacture three filament yarns of 6,000 denier each. Due to the high spinning titers, fewer yarns can be plied together to the required geo-yarn titer in a more cost- and energy-efficient manner.

hycuTEC – technological quantum leap for filter media
In the case of its hycuTEC hydro-charging solution, Oerlikon Neumag offers a new technology for charging nonwovens that increases filter efficiency to more than 99.99%. For meltblown producers, this means material savings of 30% with significantly superior filter performance. For end users, the consequence is noticeably improved comfort resulting from significantly reduced breathing resistance. With its considerably lower water and energy consumption, this new development is also a future-proof, sustainable technology.

New high-tech Staple Fiber Technology Center
Extending to around 2,100 m2, Oerlikon Neumag in Neumünster is home to one of the world’s largest staple fiber technology centers. As of now, these state-of-the-art staple fiber technologies are also available for customer-specific trials.

The focus during the planning and the design of the Technology Center was on optimizing components and processes. Here, special attention was paid to ensuring the process and production parameters in the Technology Center system could be simply and reliably transferred to production systems. Here, the fiber tape processing line is modular in design. All components can be combined with each other as required. And comprehensive set-up options supply detailed findings for the respective process for various fiber products.

The Technology Center is also equipped with two spinning positions for mono- and bi-component processes. The same round spin packs are used for both processes, characterized by excellent fiber quality and properties and meanwhile very successfully deployed in all Oerlikon Neumag production systems. Furthermore, the spinning plant is complemented by automation solutions such as spin pack scraper robots, for example.

SANITIZED AG, a specialist for hygiene function in textiles, is expanding its Sanitized® Odorex™ portfolio for odorneutralizing technologies. The new OX20 product is usable on cotton, viscose, or synthetic fibers. It does not contain any biocides, it is highly wash-resistant, and it can be combined well with other effects.

Sanitized® Odorex™ is the product of several years of experience with environmentally friendly textile treatments. SANITIZED focuses heavily on the causes of, the production of, and the fighting of unpleasant sweat odor in textiles. The basis for the newly introduced biocide-free OX20 product is a metal-free polymer that neutralizes odors. It meets market requirements regarding wash-resistance with excellent results after up to 50 household washes.

Versatile and highly cost-efficient
The new product can be applied in extraction, pad, and spray. It can be used on all common substrates and is compatible with other textile effects. These properties increase the flexibility and efficiency during product design, and they reduce production costs. As one of the first technologies worldwide, OX20 can be applied to synthetics in the dye bath.

Feel and wearing comfort
Binders and particle systems negatively affect the textile’s feel and moisture management. OX20 is a particle-free product with a long-lasting effect that does not change how the textile feels, nor does it affect the textile’s moisture management.