From the Sector

• Kettelhack GmbH – a German leader in the dyeing and finishing of monochrome fabrics for high-quality and durable workwear and bed linen – has this year retired its existing Monforts sanforizing line after 35 years of daily service, replacing it with a new one.

The first line was installed in 1985 during a decisive time for the company.

Taking the helm in the early 1980s, Jan Kettelhack – the current CEO, owner and great grandson of Heinrich Kettelhack who founded the company back in 1874 – made a number of decisions that have secured its success over the following decades.

In 1982 Kettelhack had to vacate its existing plant in the city of Rheine due to urban development restrictions and despite a general sense of crisis in the European textile industry at that time, opted to relocate and build a new highly automated plant that was not reliant on mechanical and personnel-intensive processes. This was aligned with a greater focus on competitive international sales.

From 1986, the company’s proficiency as a specialist in solid-colour textiles led to workwear textiles becoming a bedrock of the business. Continuous investments in machinery and technical equipment have resulted in a fully integrated and rationalised single source site dedicated solely to what the company does best – the expert dyeing and finishing of textiles.

Crucial process steps

These stages in the textile value-added chain, Jan Kettelhack has observed, are crucial to the quality of a final product in workwear – whether it stands the test in everyday use, how comfortable it is, and how many washes it can withstand.

Central to this is the sanforizing process, which pre-shrinks a fabric by compressing it prior to washing. This limits any residual or further shrinkage in a made-up finished garment to less than 1%, to ensure perfect comfort and fit over an extended lifetime.

“We certainly can’t complain about the performance of the old Monfortex sanforizing line which gave us so many uninterrupted years of service, but certain spare parts for it were becoming increasingly hard to source, the control unit was becoming a little unstable and we couldn’t risk potential interruptions to our production schedule,” says Kettelhack plant manager Hendrik Pleimann. “In many ways, the new Monfortex sanforizer is much the same as the old one in terms of its mechanical reliability and robust construction, but of course today’s drives are much more efficient, and when it comes to the automation features and control units – and the data we can generate and analyse for increasing efficiency – that’s a whole new world.”

Qualitex 800

The two-metres-wide Monfortex line benefits from the latest Qualitex 800 control system which allows all parameters to be easily automated via the 24-inch colour touchscreen, including production speed, control of all fabric feed devices, rotation spray or steaming cylinder options, the width of the stretching field and the rubber belt pressure.

The integrated Compactomat system allows a continuous indication and control of the shrinkage values and the temperatures of the shrinking cylinder and felt calender. Up to 10,000 separate process parameter records can be generated and stored by the data manager.

Full line management can be optimised via the batch-specific calculation of all process material consumption and water and electricity use, with any standstill times analysed and immediately corrected for the future.

Any further assistance required is available via Monforts Teleservice, with direct connection to technicians and virtual access to machine analysis.

Professional

Commissioning of the new Monfortex line at Kettelhack commenced in January and it was fully operational in a relatively short time.

“This was a very professional installation provided by the Monforts team with whom we have a very good relationship dating back many years, and everyone knew what was required from both sides,” says Mr Pleimann. “Our operators have found the new line very user friendly and we are very pleased with how everything proceeded so smoothly. An unexpected benefit is that the new line is also a lot quieter, of course, which is something our operatives are appreciating.”

Key features of the Monfortex line are the proven fabric preparation, weft straightening and spreading units, prior to the compressive shrinkage machine with a 750mm shrinking cylinder, and a felt calender equipped with 2,000mm diameter drying cylinder. The line also features an integrated automatic grinding unit.

Customer service

Kettelhack is processing primarily cotton and polyester woven fabrics, with lyocell becoming increasingly popular in workwear for its softness and comfort.

As part of its customer service, the company stocks more than a million metres of grey fabric and at least 1.2 million metres of finished and rolled standard fabric in its warehouse at any one time, with a further 750,000 metres permanently in production.

While a significant cost, this commitment ensures Kettelhack customers can be fully flexible and rely on it as a partner.

“As a family-run company with around a hundred employees, Kettelhack operates very differently to bigger businesses which have to constantly consider their immediate quarterly profits,” Mr Pleimann concludes. “The thinking at Kettelhack is in terms of the next twenty years and ensuring that the business will be just as successful for the next generation as it is today. We also have a very flat organisational structure in which everyone is involved and takes an active part, which makes it a very nice place to work.”

Rester Oy, which is developing the plant in Paimio, recycles companies' end-of-life textiles, and Lounais-Suomen Jätehuolto Oy (LSJH), which will hire a production area at the same facility, processes households' end-of-life textiles. The plant will process 12,000 tonnes of end-of-life textiles every year, which represents about 10% of Finland’s textile waste.

The textile industry’s end-of-life textile problem is intolerable. Natural resources are increasingly used to manufacture products, but these materials are lost at the end of their life cycle. About 100 million kilograms of textile waste are generated annually in Finland alone. Reusing this material could reduce the textile industry’s carbon footprint and significantly reduce the use of natural resources.

Rester Oy and LSJH will drive the textile sector towards a circular economy and begin processing textile waste as an industrial raw material. The Nordic countries’ first industrial end-of-textile refinement plant will open in Paimio in 2021. The 3,000-square-metre plant is being developed by Rester Oy, which recycles companies' end-of-life textiles and industrial waste materials. LSJH, which processes households’ end-of-life textiles on its production line, will hire part of the plant.

Outi Luukko, Rester Oy’s board chair, says, “The processing plant will begin a new era of textile circular economy in Finland. As industry pioneers, we are launching a system change in Scandinavia. The transition of the textile industry from a linear model to a circular economy is essential, as virgin materials cannot sustain the current structure of the textile industry. And why should it, when there is so much recyclable material available?”

From the perspective of Rester Oy’s main owner, work clothing supplier Touchpoint, the circular economy plant not only represents resource efficiency, but is also necessary from the perspective of the entire life cycle of a responsible work clothing collection.

Luukko adds, “Finding a local solution to a global problem is a huge leap in the right direction and raises Finland's profile as a pioneer of circular economy."

The future plant will be able to process 12,000 tonnes of end-of-life textiles annually, which represents about 10% of Finland’s textile waste. Both production lines produce recycled fibre, which can be used for various industrial applications, including yarn and fabric, insulating materials for construction and shipping industries, acoustic panels, composites, non-woven and filter materials, and other technical textiles, such as geo-textiles.

LSJH is piloting a full-scale refinement plant

LSJH has launched a pilot production line for processing households' end-of-life textiles. Unfortunately, consumers' end-of-life textiles are heterogeneous, making them a challenging raw material for further processing. Before processing, the textiles are sorted by material into various fibre classes using optical identification technology developed by LSJH and its partners. This ensures the quality of the raw material and the resulting fibre products.

Jukka Heikkilä, managing director for Lounais-Suomen Jätehuolto, explains: “On the basis of the experiences gathered from the pilot project, Lounais-Suomen Jätehuolto is preparing a full-scale refinement plant in the Turku region. As soon as 2023, the plant will process Finnish households' end-of-life textiles. The project involves all waste treatment plants owned by Finnish municipalities.”

Paimio has ambitious goals for circular economy companies

Rester’s initiative aims to create a circular economy cluster in Paimio that combines the processing and reuse of end-of-life textile fibres. Paimion Kehitys Oy, which is owned by the City of Paimio and the local association of enterprises, supports the development of circular economy companies in Paimio.

Mika Ingi, managing director for Paimion Kehitys Oy, says, “We want to step out of our traditional municipal role and create significant added value for everyone taking part. That is why we are involved in the development of a new modern service model based on ecosystem thinking. We are piloting the textile cluster, followed in the coming years by clusters focusing on plastic, construction, and energy. The aim of our service is to support and help develop new profitable business by bringing circular economy companies and their potential customers to innovate together."

The foundation stone of the processing plant was laid today (18 August 2020). The processing plant will begin operations in February 2021.

The coronavirus pandemic and its massive impact on the automotive industry led to an un-precedented market slump in the first half of 2020 and a corresponding revenue decline at Autoneum. Revenue in local currencies fell by –32.7% compared to the prior-year period, and in Swiss francs by –36.8% to CHF 730.6 million. The turnaround program for the North American sites made further progress in the first six months and is showing the targeted results. However, they were clearly overcompensated by the massive impact of the corona-virus crisis, which led to a negative net result of CHF –54.9 million despite comprehensive cost flexibilization measures.

Like the entire automobile industry, Autoneum was massively impacted by the effects of the corona-virus pandemic in the first half of the year. The temporary plant closures at almost all customers in every region, especially in the second quarter of the year, not only led to an unprecedented market collapse, but also to a production stop at all 55 Autoneum sites. Starting in February in China and one month later in all other regions, vehicle manufacturers temporarily shut down production completely. The corresponding massive drop in global vehicle production led to a slump in revenue at Autoneum of –32.7% in local currencies. This reflects the development of the market in the first half of 2020, which contracted by –33.2% year-on-year. Revenue in Swiss francs at Autoneum fell by –36.8% to CHF 730.6 million (prior-year period: CHF 1 156.1 million). Revenue development in all Business Groups outperformed the respective markets, particularly in Asia and the SAMEA (South America, Middle East and Africa) region.

 Like the entire automobile industry, Autoneum was massively impacted by the effects of the corona-virus pandemic in the first half of the year. The temporary plant closures at almost all customers in every region, especially in the second quarter of the year, not only led to an unprecedented market collapse, but also to a production stop at all 55 Autoneum sites. Starting in February in China and one month later in all other regions, vehicle manufacturers temporarily shut down production com-pletely. The corresponding massive drop in global vehicle production led to a slump in revenue at Autoneum of –32.7% in local currencies. This reflects the development of the market in the first half of 2020, which contracted by –33.2% year-on-year. Revenue in Swiss francs at Autoneum fell by –36.8% to CHF 730.6 million (prior-year period: CHF 1 156.1 million). Revenue development in all Business Groups outperformed the respective markets, particularly in Asia and the SAMEA (South America, Middle East and Africa) region.

Autoneum promptly responded to the pandemic-related market slump by adopting extensive cost-cutting measures in all regions. These include the reduction of employee costs by, among other things, adjusting time accounts, introducing short-time work at eligible locations and temporary layoffs as well as headcount reduction, mainly among temporary workers. In addition, operating expenditures were limited to the absolutely necessary. The investment volume for 2020, already reduced from previous years, was downsized even further. Autoneum continues to benefit in this regard from the high level of investments undertaken in recent years.

 Although the coronavirus crisis and the measures taken to contain it dominated Autoneum’s course of business in the first half of 2020, the Company achieved necessary operational and financial im-provements during this period. The comprehensive turnaround program for the North American sites made further progress and is on track. Efficiency improvements already achieved there had a posi-tive effect on the figures of the first half-year, but were significantly overcompensated by the substan-tial impact of the COVID-19 crisis. Savings and cost flexibilization measures taken immediately and implemented worldwide in view of the revenue loss could not offset the ongoing, capacity-related fixed costs. This led at the Group level to a negative EBIT of CHF –31.8 million (prior-year period: CHF 16.4 million), which equates to an EBIT margin of –4.4% (prior-year period: 1.4%). The net result decreased because of the severe revenue shortfall to CHF –54.9 million (prior-year period: CHF –6.0 million).

Outlook
For 2020 Autoneum expects revenue to develop at market level. Although customers’ production volumes should increase again in the second half of 2020 compared with the first semester, latest fore-casts indicate that they will remain clearly below the level of the second half of 2019. Immediately implemented and ongoing cost reduction measures as well as further operational optimizations also within the turnaround program in North America will lead to improvements in the second half of the year. Due to the current uncertainties, a reliable statement on the net result for the full year 2020 thus cannot be made. With regard to the mid-term targets, a recovery of the profitability level is expected, but it will largely depend on the market development.

• With shop.hygiene-austria.at, quick access to MNS, FFP2 and child masks “made in Austria” is guaranteed.

Wiener Neudorf – Hygiene Austria LP GmbH has become known for its locally produced mouth-nose protective masks, FFP2 and children's masks during the COVID-19 crisis. The company is now well prepared for the reintroduction of the mask requirement. “Especially in times of a pandemic, it is important to us at Hygiene Austria to make a contribution to the security of Austrian supply”, said Stephan Trubrich, Managing Director of Hygiene Austria LP GmbH, confidently.

All interested parties who want to prepare for their purchases in the supermarkets or their visit to public facilities but also for their holiday trips can now purchase masks of different types at the following website: https://shop.hygiene-austria.at.

• Australian production of medical masks to commence from April 2021 with Oerlikon Nonwoven meltblown technology

Neumünster/Germany, Brisbane/Queensland/Australia – Queensland company OZ Health Plus will establish Australia’s first manufacturing plant to make the critical fine plastic material used in most protective face masks. OZ Health Plus has purchased a plant of the Swiss-based technology company Oerlikon to establish a Queensland-based production plant for spun-bond and meltblown nonwovens. These fabrics are essential for Australia’s face mask manufac-turers, who currently produce about 500 million medical and industrial masks per year. However the fabrics have to be imported from overseas and access to these materials has been severely disrupted during the COVID-19 pandemic.

Oerlikon’s German-based business unit Oerlikon Nonwoven has now executed legal and commercial arrangements to supply the specialised machinery which can manufacture the nonwoven material lo-cally. The same machinery is used to make almost all face masks material manufactured in Europe. The world-leading Oerlikon Nonwoven meltblown plant will commence operations in April next year, with a second stage planned for late 2021.

The Oerlikon Nonwoven plant can produce meltblown fabrics for 500 million masks per year, along with other medical and non-medical grade products, filtration products, sanitary items, antiseptic wipes and more. Rainer Straub, Head of Oerlikon Nonwoven said: “We are very proud that we can now for the first time supply our Oerlikon Nonwoven meltblown technology to Australia. Due to the short delivery time, we hope to make our contribution to the Australian population and their safe sup-ply of high-quality protective masks as soon as possible.”

Queensland company secures manufacturing plant for the only Australian production of critical face mask material

OZ Health Plus director Darren Fooks said: “Australia has access to raw polypropylene feedstock but lacks the plant to convert that raw material to specialised spunbond and meltblown fabrics. These fabrics are essential for local mask manufacturing. The Australian-based Oerlikon Nonwoven plant will fill the production chain gap for Australia by producing the fabrics we need for mask production and many other products – it will reduce Australia’s protective mask supply chain from thousands of kilo-metres, to tens of kilometres.”

“Our decision in favor of Oerlikon Nonwoven was a given once we had analyzed the material samples. It was a matter of course for us that the Business Unit of the Oerlikon Manmade Fibers segment could supply high-quality machines and systems”, added Darren Fooks.

OZ Health Plus’ new facilities will take up 15,000 m2 of manufacturing space and will employ 100 full-time roles once the second stage of the project is complete. OZ Health Plus continues to work with both Queensland and Federal Government stakeholders and values their support in bringing this vital capability to Queensland.

Leading meltblown technology

Oerlikon Nonwoven meltblown technology, which can also be used to produce nonwovens for protec-tive masks, is recognized in the market as the technically most efficient method of producing high-separation filter media from plastic fibers. Most of the protective mask capacities available in Europe to date are produced on Oerlikon Nonwoven equipment.

• Since the end of March 2020, COVID-19 has led to very low demand in all Business Groups
• Comprehensive crisis management implemented
• Loss in the mid double-digit million range expected in the first half of 2020
• Plans to introduce short-time working to adjust capacity in Switzerland and Germany
• Strategy will continue to be implemented

Due to COVID-19, a large number of spinning mills have stopped production worldwide. Since the end of March 2020, this has led to low demand for spare parts and wear & tear parts and delays in testing programs during the development of new machines. Customers are postponing investment projects or unable to implement them due to restrictions imposed by national governments. This results in low demand for new machines.

Comprehensive crisis management
Rieter has implemented comprehensive crisis management. Priorities are being given to protecting employees, fulfilling customer commitments and ensuring liquidity. The necessary measures to protect employees have been implemented worldwide.
The order backlog of well in excess of CHF 500 million is being processed largely according to plan, despite the existing bottlenecks in the supply chains. Less than 5% of the orders in the order backlog have been canceled.
Rieter has already implemented measures to ensure liquidity and reduce costs. The company has good net liquidity and undrawn credit lines in the mid three-digit million range.
Loss expected in the first half of 2020
As already reported, Rieter expects sales and earnings in the first half of 2020 to be significantly below the prior year level.

Loss expected in the first half of 2020
As already reported, Rieter expects sales and earnings in the first half of 2020 to be significantly below the prior year level. The effects of COVID-19 will place an additional burden on the first half of 2020. Rieter therefore expects sales in the first half of 2020 to be less than CHF 300 million. Despite the countermeasures implemented at the net profit level, this will lead to a loss in the mid double-digit million range.

Plans to introduce short-time working to adjust capacity
Rieter plans to apply for short-time working for the areas with forecasted low capacity utilization at the locations in Switzerland and Germany. The application will be for 40% short-time working in the third quarter of 2020. Talks with staff representatives will begin next week.
As a sign of solidarity, Rieter’s Board of Directors, Group Executive Committee and the senior management will waive 10%-20% of their salaries temporarily.

Implementation of the strategy
In recent years, Rieter has consistently implemented the strategy based on innovation leadership, strengthening the business in components, spare parts and services and the adjustment of cost structures. The company intends to forge ahead with the implementation of the strategy in the coming months, thus strengthening its market position for the time after the COVID-19 pandemic.
The next information on the course of business is planned with the publication of the half-year results on July 16, 2020
 

Center of competence for hygiene established in Wiener Neudorf to support Austria and the EU in the Covid-19 crisis for the industrial production of high-quality protective masks with a monthly capacity of 12 million pieces.

Lenzing AG and Palmers Textil AG found “Hygiene Austria LP GmbH”, in which Lenzing AG holds 50.1% and Palmers Textil AG 49.9%. The newly founded company will start producing and selling protective masks for the domestic and European markets from May 2020.

Over the past few weeks, Lenzing AG and Palmers Textil AG have invested several million euros in a modern production infrastructure at the Wiener Neudorf location and secured the corresponding raw materials for protective masks production. In a first step, the company produces so-called mouth-nose protective masks (MNS) and surgical protective masks of class EN14683. Hygiene Austria LP GmbH plans to increase its capacities to over 25 million masks per month over the next few weeks and to expand this business geographically as well.

The demand for high-quality MNS and respiratory masks for medical personnel is increasing rapidly, and there is real competition on the international market for these products. In order to sustainably secure domestic supply now and in the future and to strengthen the business location, the two companies Lenzing AG and Palmers Textil AG have now set a milestone with their own competence center for hygiene based in Austria.

Hygiene Austria LP GmbH thus makes a significant contribution to combating the Covid-19 pandemic and ensures the long-term supply of these critical goods in Austria in high quality.

• Antiviral properties of Sanitized® products on synthetics validated

Tests conducted by independent laboratories have now confirmed that a treatment with Sanitized® T 99-19 and Sanitized® T 11-15 reduces the viral load on PES textiles by
up to 99 %.

Swiss company SANITIZED AG announces the validation from impartial labs that Sanitized®T 99-19 and Sanitized®T 11-15 are also effective against viruses (in accordance with ISO 18184:2019). Tests were performed using a feline coronavirus with structures and mechanisms reminiscent of SARS-Cov2. Patented technology featuring an ammonium silicate compound  is employed in Sanitized®T 99-19 and Sanitized®T 11-15 utilizes tried and tested silver technology.

These additives are the perfect tool for an antiviral and antibacterial treatment of face masks, protective professional medical clothing, bed linens, or mattresses. The formulation of both products remains completely untouched, thus ensuring that it will continue to offer outstanding protection against bacteria.

Before a final product’s antiviral properties can be publicly promoted, viral tests must be performed in specialized laboratories. Compliance with local legal regulations is essential here. SANITIZED AG explicitly points out that this is standard procedure and has composed a preliminary Guide for Treating PPE (personal protective equipment) with biocide products.

Guide Link: https://campaign.sanitized.com/en/treatment-of-ppe-with-biocidal-products

Pinko is glad to announce that its Chinese subsidiary, Cris Conf Retail, received from the highest office in the Shanghai municipality the “Shanghai Multinational Company Headquarter” certification.

At the presence of Shanghai mayor, Gong Zheng, Cris Conf Retail obtained this status thanks to its investment projects for the creation of a central headquarter in the Chinese city, which will be the primary hub for the management and commercial development of Pinko’s operations across the Asian market. Through this important recognition, Pinko and its parent company Cris Conf confirm the strategic importance of the Chinese market in the brand’s global internalization process.

Thanks to the “Shanghai Multinational Company Headquarter” certification, Pinko will have access to a range of benefits in China, including facilitated import and custom procedures, as well as expedited clearance for the company’s staff upon arrival in China and a direct channel of communication with Chinese national offices.

Pinko currently operates 72 stores in China, located in the most important cities and at the most prestigious malls and department stores.

a leading Asian large-scale manufacturer of manmade fibers and polymers has invested in a new Oerlikon Nonwoven meltblown system. The recently-signed contract comprises a 2-beam system for manufacturing filtration nonwovens – predominantly for medical products such as face masks – with a nominal capacity of up to 1,200 tons of nonwovens a year. The commercial production launch has been scheduled for the fourth quarter of 2020.

The 2-beam system has an operating width of 1.6 meters and is equipped with the new patented Oerlikon Nonwoven electro-charging unit. The Oerlikon Nonwoven meltblown technology is recognized by the market as being the technically most efficient method for producing highly-separating filter media made from manmade fibers, particularly in conjunction with electrostatic charging and with extremely low-pressure loss. Electro-charging the filter nonwovens allows the manufacture of sophisticated EPA- and HEPA-class filter media as well as media that comply with the requirements of N95-, FFP2- and FFP3-class respiratory masks.

The demand for filtration nonwovens for medical applications has risen tremendously across the globe since the outbreak of the Sars-CoV-2 (coronavirus) epidemic, presenting all manufacturers with huge challenges. A meltblown system will be commissioning at the site of a leading Western European nonwovens producers as early as the second quarter of 2020. This system will be deployed exclusively in the manufacture of nonwovens for respiratory masks.

Due to the current state of emergency with regards to the local supply of face masks, Oerlikon Nonwoven is currently using its own laboratory system to produce electrostatically-charged filter media which are being sent to local small businesses and companies for the manufacture of face masks.