From the Sector

The Hygiene Fibers Group of Indorama Ventures (IVL) came together at the Index Show to present an all-inclusive range of recycled and biodegradable solutions for Hygiene Fiber and Nonwoven applications.

The combination of polymers, technologies, processes and global reach supported by the Hygiene Fibers Group – one of three business segments that make up Indorama Ventures – positions it within the Hygiene industry to meet increasingly challenging market demand for innovative sustainable solutions within the hygiene sector. Across the six brands and companies that make up Hygiene Fibers Group – Auriga, Avgol, FiberVisions, Indorama Asia, Trevira and Wellman International – sustainability and supporting customers to achieve circular objectives is integral to all efforts and fundamental to the ethos of the Hygiene business segment.

At the Index Show, the Hygiene Fibers Group launched CiCLO®, a textile technology which allows polyester and other synthetic materials to biodegrade like natural materials do in wastewater treatment plant sludge, sea water and landfill conditions, reducing synthetic microfiber pollution generated during washing, and minimizing plastic accumulation in landfills caused by discarded textiles.

In line with the company’s commitment to support customers with high performance products, while also reducing the impact on the environment, several of the  Hygiene Fibers brands, including Wellman International, Trevira GMBH and Auriga, have been working closely over the last 12 months with the IAM team and the CiCLO® technology. Developments have focused on PET and rPET staple fiber and filament sustainable solutions for applications where recycling is particularly challenging, such as Hygiene, Home Textiles and Automotive applications.

Strengthening the profile of biodegradable offerings within the Hygiene Fibers Group’s sustainability portfolio, Trevira introduced a new range of bicomponent fibres based on PLA and PBS (polybutylene succinate) at the Index show. Both biopolymers offer an exceptional technological opportunity in terms of environmental care and sustainability, while delivering optimum performance. Equally to PLA, PBS is recyclable and up to 100% biodegradable under industrial conditions.

Efforts towards supporting customers to achieve circular objectives are a priority within the Hygiene Fibers Group. This is reflected in the recycled fibers expertise deployed across the segment. Four Hygiene Fibers Group brands, IVL Asia, Auriga, Trevira and Wellman International offer an extensive range of 100% recycled, accredited PET fibers, across a multitude of fiber and nonwovens applications.

The development and evolution of sustainable technologies is central to activity across IVL’s Hygiene Fibers Group, with particular focus on sustainable polyolefin solutions. FiberVisions and ES-FIBERVISIONS, leading Polyolefin mono and bico fiber brands and sister company Avgol, have partnered with UK-based Polymateria to commercially harness the innovative ‘biotransformation’ technology pioneered by Polymateria. The patented technology alters the properties of polyolefins to make them biodegradable in a natural process.  Other polyolefin sustainable innovations within the Hygiene Fibers Group were featured at Index include biosurfactant and biocolourant developments being undertaken by the Avgol team with FiberVisons progressing sustainable design solutions, including lightweight, high performance, reduced carbon solutions.

Autoneum carpet systems already meet high standards of sustainable mobility due to their high content of recycled fibers. Thanks to an alternative backcoating (ABC) process, Autoneum carpets are now becoming even more environmentally friendly: By replacing the latex commonly used in standard backcoatings with thermoplastic material, the recyclability of carpets at the end of product life is further  improved. In addition, the innovative manufacturing process greatly reduces water and energy consumption and thus CO2 emissions in production.

Lightweight, textile-based carpet technologies such as Di-Light or Relive-1 significantly improve the environmental performance of carpets. For example, Di-Light-based carpets consist of up to 97% recycled PET; aside from that, they are around 20% lighter than conventional needlepunch carpets, thus contributing to lower fuel consumption and CO2 emissions from vehicles. In addition, Autoneum needlepunch carpets are now even more sustainable thanks to the innovative ABC process, which uses a thermoplastic adhesive instead of latex in the backcoating: Unlike latex, thermoplastic adhesives can be heated and melted down together with the carpet components made of pure PET at the end of the product life cycle, which facilitates recycling considerably. Furthermore, since the fibers of the thermoplastic mono-material are easier to open, carpet cut-outs can be reclaimed more easily, thereby reducing the consumption of natural resources as well as waste volumes and thus CO2 emissions. The environmental  performance of Autoneum’s needlepunch carpets, which already contain a high proportion of recycled PET, is thus further improved.

Moreover, backcoatings without latex improve the sustainability of carpets not only thanks to better recyclability at the end of the product life cycle. Since the application of the thermoplastic adhesive using the innovative ABC process consumes significantly less energy than the production of latexbased backcoatings and does not require any water at all, the environmental impact can already be minimized in the manufacturing process. Additionally, thermoplastic adhesives developed in-house by Autoneum will open up new possibilities in the future for adapting backcoatings to the individual needs of vehicle manufacturers in terms of their acoustic performance, stiffness and abrasion resistance.

Models from various customers in Europe and North America are already equipped with latex-free needlepunch carpets from Autoneum. In the near future, backcoatings with thermoplastic adhesives will also be used for Autoneum’s tufted carpets. Production of the new, even more sustainable generation of tufted carpets is scheduled to start in early 2022.

• Mostafiz Uddin, Managing Director of Denim Expert Limited and Founder of Bangladesh Apparel Exchange (BAE) has won Sustainable Fashion Champion at the Drapers Sustainable Fashion Awards 2021, which took place virtually on 10 March.

On receiving the award, Mostafiz said he wants to be a game-changer in the apparel industry, leading by example to inspire others to behave responsibly and ethically.

He also dedicated the award to H&M which, he explained, supported his business, Denim Expert, through the pandemic by continuing to place orders He said the loyal support of the Swedish fashion giant almost certainly helped save the livelihoods of 2000 workers at his factory and their 10000 family members. “That’s true sustainability leadership,” he said.

The Drapers Sustainable Fashion Awards recognise steps being made in reducing the fashion industry’s environmental impact and creating fairer working conditions across the supply chain.
Judged by an independent panel of sustainability and fashion retail experts, the awards shine a spotlight on best practice within the global fashion industry.

Covid-19 has presented unforeseen challenges for fashion retailers and brands, but it has also given us all an opportunity to build back better. Forward-thinking fashion businesses know change is not optional, and are embracing their responsibilities and ability to make a difference.

Mostafiz Uddin has been recognised as the Sustainable Fashion Champion 2021 for setting examples in promoting sustainability during the Covid-19 pandemic which broke out worldwide in March last year.
Jill Geoghegan, Acting Editor of Drapers, said: “Despite the challenges thrown up by the Coronavirus pandemic, fashion brands and retailers increasingly recognise that sustainability is a business imperative.”  
“Many businesses continued to invest in cleaning up their supply chains and introducing new models of working, despite the unprecedented trading conditions.

“The Drapers Sustainable Fashion Awards highlight and celebrate these advancements, paving the way for a more responsible future for the industry.” Managing Director of Denim Expert Limited Mostafiz Uddin said: “In the pandemic, my factory Denim Expert Limited kept true to its commitment towards sustainability, despite an extremely difficult trading landscape.

“During the pandemic, I was vocal about the issue of buyer-supplier relationships and, in speaking out, I wanted to champion the cause of suppliers all over the world. Too often suppliers in garment supply chains do not have a voice because they fear that by speaking out, they will be treated unfavourably by brands.

“This was, of course, a risk on my own part but I like to think I stood up for what I think is right and ultimately, I believe progressive brands understood I was coming from a good place. Like them, all I want to see is a fair, ethical and sustainable industry where brands and retailers work in an environment of collaboration, not conflict.”

Mostafiz also had some special praise for H&M. He said: “It would have not been possible for me to support my workers during the pandemic, had my factory not received help from H&M during the unprecedented time. While Denim Expert suffered from huge orders cancellation and orders hold, H&M supported us by placing orders in the pandemic that saved thousands of lives and livelihoods. Therefore, I would like to dedicate this Award to H&M and its CEO Helena Helmersson.”

The judges of Drapers Sustainable Fashion Champion Award 2021 have been Kerry Bannigan, Founder, Conscious Fashion Campaign; Sarah Ditty, Global Policy Director, Fashion Revolution; Miriam Lahage, Founder, Aequip; Samata Pattinson, CEO, Red Carpet Green Dress; Caroline Rush, Chief Executive Officer, British Fashion Council; Lucy Shea, Group CEO, Futerra; Jane Shepherdson, Chairman, My Wardrobe HQ; and Dilys Williams, Director, Centre for Sustainable Fashion.

Technologies with an excellent environmental performance throughout the entire product life cycle – that is what “Autoneum Pure.” stands for. In future, components that meet the highest standards in terms of sustainability and eco-friendliness can be identified at a glance under this label. This also includes the innovation “Mono-Liner” for wheelhouse outer liners.

As innovation leader in acoustic and thermal management, Autoneum continuously invests in the development and production of resource-saving components that make cars lighter and thus more climate-friendly. In view of an increasing sustainability awareness and the correspondingly greater information needs on environmentally-friendly vehicle components, the Company has now launched Autoneum Pure. The label determines particularly sustainable technologies, thereby guiding car manufacturers in product selection for future models.

Autoneum Pure is based on a comprehensive set of criteria assessing the sustainability performance of a product in all four phases of its life cycle: material procurement, production, use and end of life. For example, components with a high content of recyclable materials or those that achieve significant weight savings compared to comparable standard components qualify for the “Autoneum Pure.” label. Autoneum already offers various multifunctional technologies that meet the high standards for Autoneum Pure products: Ultra-Silent for underbody systems or battery undercovers, Di-Light for carpet systems, Prime-Light and IFP-R2 for inner dashes and floor insulators as well as Hybrid-Acoustics PET for e-motor encapsulations and engine-mounted parts, which was launched in fall 2019.

With Mono-Liner, the latest innovation for wheelhouse outer liners is also included in the Autoneum Pure portfolio. Among other things, the Mono-Liner-based components convince thanks to their lightweight construction, thereby contributing to lower vehicle weight with correspondingly less fuel consumption and emissions. The excellent life cycle assessment is also based on their particularly resource-saving manufacturing: Production cut offs of the components, which consist to a large extent of recycled PET fibers, can be processed into pellets and completely returned to the manufacturing process as fibers. An SUV and a crossover model from a US vehicle manufacturer already benefit from Mono-Liner wheelhouse outer liners.

Anahid Rickmann, Head of Corporate Communications & Responsibility, explains: “With Autoneum Pure we are the first automotive supplier to establish a sustainability label in the field of acoustic and thermal management. Autoneum Pure is part of the Company's Advance Sustainability  Strategy 2025 and sets industry standards in product communication.”

• Latex-free: UltraBond allows 100% recyclable thermal bonded nonwovens
• Sustainability & cost-efficiency: significant reductions in CO2 emissions and energy and water consumption for manufacturers of needlepunched exhibition & contract flooring
• UltraBond debuts at Domotex 2019 Stand B56 Hall 11

Beaulieu Fibres International (BFI) unveils a unique opportunity for carpet manufacturers to create fully recyclable needlepunch carpets, and benefit from production and resource savings, without influencing performance.

Launched at Domotex 2019, new UltraBond is a patented polyolefin bonding staple fibre that eliminates the need for latex or other chemical binders to bind nonwovens. It opens up a new path for creating 100% polypropylene (PP) needlepunch carpets which meet the same performance requirements as traditional latex-bonded carpets while reducing the end-of-life environmental impact. Functional properties such as pilling resistance, resistance to wear and abrasion, and also UV resistance are guaranteed.

Using UltraBond manufacturers finally gain the potential to cost-efficiently produce 100% recyclable carpets. In addition to the general benefits of making recycled PP available for the plastics production chain and reduced waste generation, environmental advantages and financial savings arise from a total lack of water and less energy use. As a 100% dry process, thermal bonding uses no water and results in a total absence of waste water. There is also a reduction in the VOC level of the carpet. This all leads to a significant reduction in a needlepunch carpet’s ecological footprint.

The sustainability benefits are quantified through lifecycle analysis (LCA) of an exhibition carpet application – among the primary applications for needlepunch carpets. Evaluations show that the absence of water consumption directly translates into a large energy saving of 93% when using UltraBond compared to a latex bonding solution, and also a potential annual water saving of over 20 million litres for 100 million m2 of exhibition applications in the EU. Without the addition of any other bonding agent, CO2 emissions are reduced by 35% over the full production process.

Karena Cancilleri, Vice President Beaulieu Engineered Products, Beaulieu International Group, commented, “Recyclability and achieving a greener, more cost-effective production process without compromising on current performance levels are significant unsolved topics within today’s carpet industry. By eliminating the need for latex and chemical binders through UltraBond, we offer needlepunch manufacturers a breakthrough they have been looking for that boosts environmental and economic sustainability. We see textile flooring as just the beginning. Together with our customers, we look forward to exploring the potential of this unique thermal bonding fibre in other applications such as laminated nonwovens or as an alternative to dry powders.”

Discover more about UltraBond from the Beaulieu Fibres International team at Stand B56 Hall 11, Domotex 2019 in Hannover, Germany from January 11-14, 2019.