From the Sector

From 6 – 8 March 2024, the Spring Edition of Intertextile Shanghai Home Textiles will make its  return to the National Exhibition and Convention Center in Shanghai. Showcasing home textile products, encompassing everything from floor to ceiling, exhibitors will be prepared to capture buyers’ attention during China’s traditional peak sourcing season. Suppliers can further benefit from a wider visitor scope, with many buyers crossing over from the co-located fairs Intertextile Shanghai Apparel Fabrics – Spring Edition, Yarn Expo Spring, CHIC, and PH Value. The comprehensive textile platform provides key opportunities for industry players to connect and explore new possibilities.
 
While the growth rate of the global economy remains slow, the domestic market in China has shown promising figures after the Chinese government implemented measures to encourage household consumption. These include providing support to both the home industry and consumers, to develop sustainable, intelligent and healthy living environments. Loan procedures for home refurnishing and funding for related industry sectors have also been optimised. Against this backdrop, for the first eight months of 2023, China Customs recorded a 7% year-on-year increase in consumables retail sales, reaching a total of RMB 3 billion (around USD 410 million). Homing in on the textile sector, profitability is regaining momentum, driven by both the local market and the success of international trade agreements such as Regional Comprehensive Economic Partnership (RCEP).

Across three days, the 2023 spring edition attracted 26,538 trade visitors and 283 exhibitors from five countries and regions. The upcoming fair in March will showcase a full range of home textiles to meet buyers’ needs, including bedding & towelling, rugs, table & kitchen linen, home textile technologies, textile design, and many more. Exhibitors, meanwhile, are set to benefit from the concurrent textile fairs, with the apparel fabrics, yarns and fibres on offer to attract additional segments of the textile value chain, and facilitate sourcing on a wider scale.

The adoption of composite parts based on flax fibres by the Marine Industry continues to grow, with major OEMs as well as smaller shipyards now aiming to take advantage of the reduced carbon impact and impressive mechanical properties they can provide.

“Over the last ten or fifteen years, several innovative flax fibre boats have been built and the fibre has started to gain significant traction,” says Julie Pariset, Innovation & CSR Director at the Alliance for European Flax-Linen and Hemp. “In addition to the environmental benefits, manufacturers are realising significant technical and processing gains with flax fibre composites.”

“Flax is a very low-density fibre, with a high specific stiffness,” she explains. “It can be used to manufacture composite laminates with mechanical properties not dissimilar to typical E-glass composites and the coefficient of thermal expansion of a flax fibre epoxy part is also quite close to that of a carbon fibre part.” This allows the materials to work well in combined assemblies with carbon fibre composites and the flax parts are also highly impact resistant.

Flax fibres also provide acoustic and vibration damping in composite applications, as well as providing a warm and aesthetically pleasing appearance below decks.

ecoRacer30
As a member of the Alliance for European Flax-Linen and Hemp, Bcomp, headquartered in Fribourg, Switzerland, has this year been working with Northern Light Composites (nlcomp), based in Monfalcone, northern Italy, on the creation of what is billed as the first fully recyclable nine-metre-long sailing boat – the ecoRacer30.

The boat is based on nlcomp’s proprietary rComposite technology – a combination of thermoplastic resins and BComp’s ampliTex high-performance natural fibre reinforcement fabrics and patented powerRibs technology.

It was built in a collaborative effort with the help of Barcelona-based Magnani Yachts, which took care of the composite manufacturing, and Sangiorgio Marine, which provided technical assistance as the boat was being assembled at its shipyard in Genova, Italy.

Magnani Yachts has subsequently become the first shipyard to hold an rComposite license and others are now being encouraged to adopt the technology.

The second ecoracer30 is currently under construction and has already been sold and nlcomp is planning to build a fleet of eight of these boats in time to enter a series of regattas in the summer of 2025.

Flax 27 Daysailer
Greenboats, based in Bremen, Germany, is another specialist in building boats from natural fibre composites and has this year launched the Flax 27 daysailer.

The lower hull of this vessel is also made from Bcomp’s ampliTex technical fabrics in combination with a sandwich core of recycled PET bottles. Using a vacuum infusion process, the fibres were integrated with a plant-based epoxy resin in order to further reduce the CO₂ footprint of the vessel.

The light structure and modern shapes of the lower hull of the boat result in very fast, sharp and agile handling on the water.

Greenboats has also recently announced significant new backing from alliance member Groupe Depestele, which manages 13,000 hectares of flax land in Normandy, France.

Blue Nomad
A project in Switzerland has meanwhile proposed the use of flax fibre composites in solar-powered habitats designed for comfortable living on the oceans – as the world grapples with the frightening implications of climate change and rising sea levels.

As envisaged by students from Institut auf dem Rosenberg in St Gallen, Switzerland working with Denmark-based SAGA Space Architects, Blue Nomad structures would form modular blocks to establish large communities and oceanic farms.
 

Carbios and L’Oréal have won the “Pioneer Awards” in the Industry category, presented by the Solar Impulse Foundation at the first World Alliance Summit. This prize was awarded to Carbios for its enzymatic PET recycling solution, labeled “Efficient Solution” by the Solar Impulse Foundation since 2019, and to L’Oréal for using this technology for the first time in a cosmetics bottle prototype. Carbios’ solution offers brands an alternative to petro-sourced plastic that helps them meet their sustainability commitments. This advancement paves the way for future applications in other sectors such as packaging, food and beverage, and textiles.

Carbios and L’Oréal: a long-term collaboration
Since 2017, Carbios and L’Oréal have been working together with a shared vision of accelerating the transition to a circular economy for plastic. In 2017, both companies created a Consortium to improve the recyclability and circularity of PET packaging.  Nestlé Waters, PepsiCo and Suntory Beverage & Food Europe joined this Consortium in 2019 to scale up Carbios’ innovation. The world’s first enzymatically recycled PET packaging was made in 2021 using Carbios’ biorecycling process. The world’s first PET biorecycling plant is scheduled to be commissioned in 2025. In parallel, Carbios is rolling out its technology internationally through licensing agreements.

The environmental benefits of biorecycling developed by Carbios
Recent life-cycle analyses^[1] show a 57% reduction in CO₂ emissions compared with the production of virgin plastic^[2], and for every tonne of recycled PET produced, 1.3 tonnes of petrol are avoided. Compared with conventional recycling, enzymatic recycling is 4 times more circular (calculated according to the Ellen MacArthur Foundation’s Material Circularity Indicator). Thanks to its highly selective enzyme, optimized for efficient PET degradation, Carbios’ depolymerization process can process all types of PET waste, including colored, multilayer or textile waste that cannot be recycled using current technologies. Furthermore, the two monomers produced (PTA and MEG) make it possible to recreate recycled PET products of identical quality to virgin ones, and suitable for food contact.
 
 
^[1] Database ecoinvent 3.8
^[2] French scenario, taking into account the detour of 50% of PET waste from conventional end-of-life. Virgin PET: 2.53 kg CO₂/kg (cradle to gate)

Hologenix® is an honoree on the second annual Power Partner Awards list by Inc. Business Media. Inc.’s 2023 Power Partner Awards feature B2B organizations across the globe that have proven track records supporting entrepreneurs and helping startups grow. There were 389 companies in all who achieved top marks from clients for being instrumental in their success and made the final list. Hologenix was recognized in the Health & Wellness category, which focuses on companies that provide health and wellness products or services. In order to achieve this status, customers provided written testimonials detailing their experience in working with Hologenix as a partner.

“Our business is set up to succeed when our partners succeed, so we are grateful that our partners have affirmed the superior level of support we aim to provide,” said Seth Casden, Hologenix CEO and Co-Founder. “CELLIANT offers something unique to world-class brands looking to deliver health and wellness benefits. Our proprietary technology offers a key textile differentiator for their products, from apparel, bedding and furnishings to medical-use fabrics, bandages and wraps, transportation seating and even saunas.”

In its latest evaluation, adidas ranked the suppliers of chemical products and auxiliaries used in the manufacture of its products. With 98 % ZDHC Level 3 auxiliaries and colorants in its portfolio CHT is supplier of choice in this ranking. On the one hand, this pays off the innovative strength of CHT's research and development, and on the other hand, it shows that CHT is the preferred partner for the sustainable chemical treatment of certifiable brand products.

CHT invests in sustainable textile value chains
In 2022, the CHT Group generated 77 % of its total sales with sustainably classified products. The company's own research and development is working ceaselessly to make the entire textile value chain more sustainable.
Customers from the manufacturing textile industry benefit from CHT’s know-how and technical expertise in machine application.

CHT and textile standards
In this regard, CHT has already been active as a ZDHC Contributor since 2019 with a comprehensive range of more than 2200 certified products. Of these, 70 % are textile auxiliaries and 30 % are dyes in the portfolio that are certified to Level 3 ZDHC, bluesign® or C2C standards.
CHT supports its customers and business partners and invests in compliance and regulatory measures. Especially in the textile sector, the group of companies cooperates with all renowned standards and labels. Among others bluesign®, C2C or GOTS. Especially in the context of the ZDHC program, CHT is one of the global leaders. More than 2200 products certified by CHT currently reach LEVEL 3, the highest possible level for safe textile chemistry. It is particularly noteworthy that this includes textile auxiliaries (70 %) as well as dyes and pigments (30 %).

CHT Group is involved in several ZDHC task teams and is also a member of the ZDHC internal Chemical Industry Advisory Group (CIAG).

The mission of Accelerating Circularity is to create new supply chains and business models to turn textile waste into mainstream raw materials. Accelerating Circularity has created a working group, the Alliance of Textile Chemical Recyclers (ACTR), to meet and address the textile industry with a common voice to facilitate accurate information on textile chemical recycling.

“We formed this collective to move chemical recycling technology forward, share common definitions, and address policies in a collaborative way to maximize the elimination of textile waste to landfills and incineration” explained Karla Magruder, Founder and President of Accelerating Circularity. “Chemical recycling technology has many benefits, including quality more similar to virgin fiber and the ability to recycle multiple times.”

ACTR plans to provide the industry with information on how textile chemical recycling can:

• offer solutions for diverting textile waste to landfill
• enable textile to textile recycling versus incineration/landfill
• provide sustainably sourced/circular materials
• support brand/retailers/producers in achieving their CO2 reduction targets
• provide long term price stability and consistent supply of raw materials versus virgin

Members of the Alliance include founding members Eastman, Lenzing, and The LYCRA Company, as well as key innovators Circ®, Sappi, Renewcell, Infinited fiber, Worn Again Technologies, Gr3n, CuRe Technology, and OnceMore® from Sodra.

As a first step, the ACTR (Alliance of Chemical Textile Recycling) is introducing a dictionary of common terms developed to educate the industry on the chemical recycling of textiles.

After four decades in the packaging industry, the Manjushree Group is entering the Indian nonwovens market. The entrepreneurs rely on a flexible RF Smart Composite line from Reifenhäuser Reicofil to meet very different customer requirements.

The Manjushree Group operated a blown film line for packaging materials for the tea industry in the eastern part of India as early as 1983. In the years that followed, Manjushree Technopack Ltd. developed into one of the largest suppliers of solutions for rigid plastic products in South Asia - and the family business grew into a group with several business segments. In 2018, the entrepreneurial family repositioned itself: it sold its previous core business to a financial investor and established Manjushree Ventures with footholds in start-up financing, real estate business, and manufacturing - the largest of which is Manjushree Spntek as a producer of high-quality spunmelted fabrics.

Since February 2023, Manjushree Spntek has been producing high-performance spunmelts on an RF Smart Composite line from Reifenhäuser Reicofil - benefiting both from many years of experience in the packaging industry and from experience with Reifenhäuser's blown film lines. "We know a lot about plastic extrusion, for example when it comes to line operating parameters such as temperature and pressure. Processing is similar in both industries," explains Rajat Kedia. "The main difference is the distribution of the products: In plastic packaging, we had an established customer base and sold a lot of material to the big consumer goods manufacturers. The nonwovens market in India, on the other hand, is still forming, with thousands of small companies currently getting involved." These serve customers in their regions, such as hospitals.

The RF Smart Composite line is a standardized spunmelt line for smaller and emerging markets. The line produces nonwovens of the highest Reicofil quality with appropriately adapted throughput. This makes it ideally suited for applications in hygiene and medical technology and, with typically 8,200 annual production hours, it is extremely reliable. In addition, operators can start production quickly because in many cases the line can be integrated into existing buildings.

Before production could start, Manjushree built a new production building in Bidadi, a town an hour's drive from Bangalore International Airport. The building is designed to be sustainable: It uses natural light and fresh air, has comprehensive contamination control, and obtains almost all of its energy from renewable sources. Reifenhäuser Reicofil then installed, commissioned and tested the RF Smart Composite line.

Since February 2023, Manjushree Spntek has been producing high-quality spunmelted nonwovens, including ultra-soft fabrics and fabrics with special coatings for customers in the hygiene and medical industries. The material can be used, for example, for baby diapers and feminine hygiene products, but also for medical articles ranging from surgical gowns to surgical drapes.

In August 2023, Australian Research Council (ARC) Chief Research Officer Professor Christina Twomey officially launched the ARC Research Hub for Functional and Sustainable Fibres.

Through collaboration with 16 domestic and international Partner Organisations, the team at the ARC Research Hub will be conducting research across three core themes – Sustainability, Circular Economies, and Extraordinary Functionality.

Led by Deakin University, the ARC Research Hub aims to harness Australia’s research capacity in fibre, textiles, and composite materials to develop materials with enhanced functionality, meeting Australian consumer and industrial demand for advanced fibre capabilities including recycling and re-purposing textile waste.
 
Professor Twomey said that the ARC Research Hub is fundamental to increasing collaboration between Australia’s most innovative researchers and vital industries.

“The ARC has a proud history of supporting outstanding research that benefits the Australian community, and the ARC Research Hub for Functional and Sustainable Fibres is a great example of this,” Professor Twomey said.
 
“In collaboration with industry partners, the research team are building on the work undertaken by the ARC Research Hub for a World-class Future Fibre Industry which ended in 2021 – this continued success is no easy feat.

“This new ARC Research Hub will strengthen productivity and competitiveness of the advanced manufacturing sector and will place Australia at the forefront of a global shift towards functional and sustainable materials.”
 
The ARC is investing $5 million over 5 years under the ARC Industrial Transformation Research Program.

It is expected that the ARC Research Hub will address the immediate need to reduce industry’s reliance on petroleum-derived materials and to reduce the environmental impact of supply chains.

•    First production supercar created with Hypetex coloured carbon fibre
•    Paint-replacement technology reduces weight to enhance performance

British car manufacturer Briggs Automotive Company (BAC) has created a unique Hypetex coloured carbon fibre version of its Mono R, reducing the weight by removing the need for paint.  

The original BAC Mono R was created to be lighter and more powerful than the standard model, with 343bhp and 555kg total weight, equating to a power-to-weight ratio of 618bhp-per-tonne. By removing the need for paint coatings in this version, the net weight of the exterior is reduced compared to a painted shell, resulting in a further improved overall performance.

The car’s body was created using Hypetex’s titanium carbon fibre twill, and finished with a crystalized lacquer, offering a unique aesthetic finish. The ultra-lightweight supercar can accelerate from zero to 60mph in less than 2.5 seconds.  

Hypetex’s paint-replacement technology retains the visible weave, allowing for a bold design and a choice of colours without technical compromises, perfectly aligning with BAC’s initiatives to maximise performance whilst creating bespoke supercars. Paint generally adds 138 grams per metre squared, whereas Hypetex adds just 17 grams for the same area, offering an 8x weight saving.
This bespoke version of BAC’s single-seater Mono R was subject to BAC’s renowned BAC Bespoke programme, which ensures that no two Monos are the same. The client, a US-based collector, worked with BAC’s design team to design the car to their personal taste.   

Born out of Formula 1 technology, Hypetex offers manufacturers sustainable aesthetic materials with technical and efficiency benefits. This collaboration is an all-British success story, with the Hypetex carbon fibre body built by Formaplex, a leading UK-based manufacturing company who manufacture lightweight engineered solutions for top tier customers in Automotive, Aerospace and Defence markets. BAC’s supply chain is 95% UK-based.  

Hypetex continues to expand its growing portfolio of the use of coloured carbon fibre to add personalisation to the automotive field, with its material recently featured on the 2024 Ford Mustang Dark Horse.  

Members of TMAS – the Swedish Textile Machinery Association – will be taking part in the forthcoming ITMA Asia + CITME exhibition, taking place from November 19-23 2023 at the National Exhibition and Convention Centre in Shanghai, China.

Weaving
In the area of weaving, 93% of the 114,000 new looms delivered in 2022 went to Asia, according to the latest figures from the International Textile Manufacturers Federation (ITMF), with China the top destination, followed by India.
As a result, TMAS members like Vandewiele Sweden AB and Eltex have a huge market to address that has been established over many decades.

Vandewiele Sweden AB benefits from all of the synergies and accumulated know-how of the market-leading Vandewiele Group, supplying weft yarn feeding and tension control units for weaving looms to the majority of weaving machine manufacturers. It also retrofits its latest technologies to working mills to enable instant benefits in terms of productivity and control.

Yarn and sewing thread monitoring
With nearly 70 years of expertise in yarn sensor technology, Eltex of Sweden AB has been at the forefront of new product development. Its EYE and EyETM systems are capable of accurately and efficiently monitoring the movement and tension of more than 1,000 yarns simultaneously. These systems are suitable for various applications and fibre types, including warping, winding, multiaxial weaving and new material applications.

Eltex sewing tension monitors, such as the ETM422, have been well-received by customers. This device can monitor the tension of sewing threads in real time, effectively improving the quality and safety of sewn products. Particularly in China's rapidly growing automotive manufacturing sector, the ETM422 has seen widespread use to meet the industry’s escalating demands for product safety and quality.

Dyeing and finishing
“Digitalisation, automation and AI have become the key enablers for sustainable gains across the entire textile industry and so much has been achieved in the past few years, especially in terms of automation,” says TMAS secretary general Therese Premler-Andersson. “One area in which TMAS members are really making a difference right now, is in replacing water and energy-intensive technologies for the dyeing and finishing processes with new digital technologies.”

The TexCoat G4 non-contact spray technology for textile finishing and remoistening, for example, will be showcased in Shanghai by Baldwin. It not only reduces water, chemicals and energy consumption, but also provides the flexibility to adapt to a customer’s requirements in terms of single and double-sided finishing applications. The TexCoat G4 can reduce water consumption by as much as 50% compared to traditional padding application processes.