From the Sector

At Chinaplas 2025, the Reifenhäuser Group will present its latest technological innovations for the efficient and sustainable production of plastic films. The extrusion specialists will showcase at Shenzhen World Exhibition & Convention Center from April 15 – 18 solutions that address the key challenges of today’s plastic industry: reducing resource consumption, increasing recyclability, and making production more autonomous and efficient. Meeting these demands requires advanced production technologies that Reifenhäuser already offers today.

A central focus at the show will be the use of Machine Direction Orientation (MDO) technologies for producing fully recyclable mono-material films with performance and cost-effectiveness equivalent to conventional multi-material structures.

Marcel Perrevort, CSO of the Reifenhäuser Group, explains: “In the flexible packaging sector, we are currently seeing a huge trend away from conventional and non-recyclable mixed material laminates towards fully recyclable mono-material composites, both for blown and cast films. Our state-of-the-art MDO stretching units enable enhanced mechanical properties for all-PE or all-PP films. Thus, PET films commonly used in material composites can be replaced. By downgauging, we also reduce production costs to a competitive level, making recyclable films a profitable choice.”

MDO for blown film lines
With the EVO Ultra Stretch MDO unit for Reifenhäuser’s blown film lines manufacturers produce all-PE mono films for applications such as high-barrier food pouches. Due to the stretch process film thicknesses of 18μm (with properties of a 25μm product) and less can be achieved, keeping production costs within the range of conventional films. With the patented integration of the MDO unit directly into the haul-off, the film is stretched in the ideal phase of the process – using the first heat – for maximum efficiency and film stability. Furthermore, the all-PE film achieves the required barrier effect with an EVOH content of less than five percent, fully meeting the criteria for recyclability. At the same time, Ultra Stretch enhances the performance of the EVOH barrier layer while reducing material usage, delivering cost and sustainability benefits.

Beaulieu Fibres International is exhibiting its next-generation sustainable fibre solutions for high performance nonwovens in various industries at IDEA25 in Miami Beach end of April.

“IDEA25 is at the intersection of nonwoven materials and sustainability, with a focus on innovation and research to address environmental challenges and new opportunities. With our Sustainable Fibres Program, we offer low carbon, recyclable and circular solutions where performance and sustainability go hand in hand, bringing value in co-design and TCO performance,” said Maria Teresa Tomaselli, General Manager, Beaulieu Fibres International.

Self-reinforced PP fibres for fully recyclable automotive composites
The company will be presenting its comprehensive range of polypropylene (PP) bonding fibres designed for thermoplastic lightweight composites and automotive interior fabrics. These fibres assist car manufacturers and OEMs in meeting stringent performance, cost-efficiency, and sustainability standards. Beaulieu’s PP fibres are engineered to enhance the mechanical, thermal, and functional properties of composites while reducing vehicle weight.

Fibres for high performance liquid and air filtration
Beaulieu has set new performance standards for the fast-growing air and liquid filtration industry rolling out its full range of MONO and BICO fine-medium count fibres, as an outcome of its investment into R&D efforts to promote staple fibres in the field of high efficiency filtration.

In addition to its existing portfolio of PP fibres for liquid filtration, compliant with FDA and European food contact regulations, Beaulieu is launching a new bicomponent fibre range in PET/PE, PP/PE for high loft filtration media and fine count mono PP fibres for tribo-electric charged air filter media.

The fine count mono fibres are customized according to the line specifics of the nonwoven producer and guarantee up to 20% higher filtration efficiencies for nonwovens in combination with state-of-the-art acrylic counter fibre compared to standard PP fibres used in this application. Typical applications are air handling units in larger buildings and residential furnaces.

Premium outdoor PP fibres for resilient, weather-resistant crop protection solutions
Engineered for superior mechanical strength and resistance to environmental stress factors, these fibres enhance durability in needle-punched fabrics, ensuring long-lasting protection in the field. Their advanced UV stabilization prevents degradation from prolonged sun exposure, extending the lifespan of crop covers, while their hydrophobic properties repel water, reducing moisture-related damage and maintaining breathability.

Ultrabond, design for recycling
Discover UltraBond innovative bonding staple fibres that replace the need for chemical binders. They open a path to create 100% polypropylene (PP) needlepunched fabrics which meet the same performance requirements as traditional constructions, while reducing end-of-life environmental impact.

The 100% polyolefin-based needlepunched fabrics are fully recyclable, reducing waste generation and creating high value PP recycled products as new materials. Furthermore, the sustainable fabrics are produced with an improved Total Cost of Ownership and with a significant ecological footprint reduction.

Beaulieu strengthening its position in the hygiene market
With a full portfolio already serving the hygiene sector, Beaulieu is focusing on next-generation speciality bicomponent solutions designed to enhance softness, processability, and sustainability in absorbent hygiene products.

Hypersoft fibres are specifically engineered for topsheet applications in direct contact with the skin: 25% improvement in softness compared to standard reference fibres while maintaining optimal processability has been achieved.

Meralux is a bicomponent trilobal fibre that improves nonwoven materials by providing better opacity, comfort, and absorption. It also promotes sustainability by saving raw materials and reducing carbon emissions by up to 60%.

Indorama Ventures exhibited the Trevira CS® brand together with 17 Trevira CS partner companies at the Heimtextil trade fair in Frankfurt, Germany, from January 14-17, 2025.

This year Trevira CS is celebrating its 45th anniversary! In 1980 Trevira CS® was launched on the market, at that time a pioneer for permanently flame retardant textiles whose flame retardant properties neither wash out nor are lost through ageing or use. They are characterized by the fact that they meet all essential fire protection standards without the need for a chemical finish. Fabrics made from specially produced flame-retardant polyester can be labeled as Trevira CS after passing a brand test. Samples, brochures, pictures and short anecdotes from 45 years of Trevira CS will be on display in a special area of the exhibition stand, inviting visitors to browse and smile.

In the anniversary year the focus of the Trevira CS® joint stand will be on permanent flame retardancy and the sustainability approaches of Trevira CS fabrics, which are known for their outstanding properties and versatility in the textile industry. Not only will the latest yarn and fabric developments from the 17 partners be presented, the three sustainability approaches from 1. pre-consumer recycling, 2. the Trevira CS take-back concept in cooperation with the company ALTEX Textil-Recycling GmbH & Co. KG in Gronau, Germany and 3. developments from chemically recycled raw material, but also all submissions to the Trevira CS Fabric Competition 2025. This encouraged Trevira CS participants to explore the interfaces between permanent flame retardancy, textile design, functionality and safety and to submit articles for five different categories.

The BREATHAIR® brand, a 3D upholstery material, was also be presented at the trade fair. This innovative and recyclable product has been specially developed for the upholstery industry and offers new possibilities for sustainable and comfortable furniture designs. Thanks to the nature of BREATHAIR®, it can be recycled at the end of its life cycle . Visitors to the trade fair will have the opportunity to experience the unique comfort of BREATHAIR® up close in a seating lab.

The Deja™ brand is an integral part of Indorama Ventures' commitment to long-term sustainability through recycling and bio-based materials. The product portfolio includes chips, as well as various staple fibers and filament yarns in multiple titer and yarn specifications.

In cooperation with Auping and TWE, Indorama Ventures and Deja™ developed an innovative mattress consisting of two basic components. This new design allows for easier disassembly and therefore more efficient recycling. The partnership aims to promote the circular economy and reduce the environmental impact of mattresses. By using recyclable materials and reducing waste, the companies are actively contributing to a more sustainable future.

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

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

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

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

eVent Fabrics, a company in waterproof and breathable technologies, is looking to the future and offering their partner brands eVent BIO and eVent alpineST technologies. Both are made without PFAS and are compliant with regulations requiring the removal of PFAS chemicals from many consumer products.

eVent BIO
eVent BIO is a bio-based membrane technology that uses sustainable materials to provide all-weather protection and performance. At the laminate technology’s core are renewable plant-based and biomass elements paired with smartly-sourced or recycled face and backer fabrics. Light, tough and flexible, eVent BIO has a reduced carbon footprint and is recyclable when it reaches the end of its lifecycle.

alpineST
alpineST is a sustainable alternative to ePTFE products that provides waterproofness, breathability, and protection in the harshest environments. Created with the planet in mind, alpineST products are built around a fluorine-free membrane laminated to recycled face fabrics. With an initial waterproofness of 25K, alpineST maintains a water column of 20K after dozens of washes.

CARBIOS and SASA, a manufacturer of polyester, fiber, filament yarn, polyester-based polymers, specialty polymers and intermediates, have signed a Letter of Intent (LOI) to cooperate through SASA’s potential acquisition of a license for CARBIOS’ unique PET biorecycling technology. This licensing agreement would allow SASA to construct and operate an enzymatic depolymerization plant in Adana, Turkey, with a capacity of 100,000 tons per year of prepared PET waste, and would give access to a circular recycling technology, enabling the production of polyester pellets, fibers and textiles from various waste sources, including polyester textile waste. With CARBIOS' biorecycling technology, SASA would diversify its offering to meet the growing global demand for sustainable materials in the textile industry, primarily catering to the European market.

Less than 1% of textile waste is currently recycled into new textile fibers^[1].  With European regulations moving towards the incorporation of more recycled content (at least 20% of recycled fibers by 2030), demand for recycled polyester in the EU is anticipated to increase, naturally positioning Turkey as a major producer alongside Asian countries.  In this context, SASA is striving to become the largest supplier of high value-added polyester in the region and beyond. To achieve this, SASA aims to introduce recycling as part of its activities, which already encompass the whole value chain from PET production to fiber and textile conversion. CARBIOS’ PET biorecycling technology plays an important part in SASA’s ongoing transformation strategy, which includes back integration, capacity expansion, even higher competitiveness, as well as circularity.

CARBIOS has developed a enzymatic depolymerization technology that enables efficient and solvent-free recycling of PET plastic and textile waste into virgin-like products. CARBIOS has ambitious plans to become a leading technology provider in the recycling of PET by 2035. After the recent announcement of a joint Letter of Intent with Zhink Group in China, this new Letter of Intent for a potential licensing agreement in Europe confirms global traction for CARBIOS biorecycling technology, and marks another significant step in the international roll-out of its licensing model. In addition to the world’s first industrial-scale enzymatic PET recycling plant which is currently under construction in Longlaville, France, this potential plant in Turkey would process PET waste that is currently not recyclable using conventional recycling technologies.

[1] System Circularity and Innovative Recycling of Textiles | Circular Cities and Regions Initiative (europa.eu)

With the fully recyclable 100% polyester trunk side trim, Autoneum is putting the rear of the vehicle at the center of its efforts for a more circular economy in the automotive industry. The latest addition to Autoneum’s growing portfolio of sustainable monomaterial products made entirely from polyester is based on the existing Pure technology Propylat PET. The component demonstrates an excellent environmental performance in terms of recycled content, waste-free manufacturing and end-of-life recyclability.

New regulations such as the revised End-of-Life Vehicles Directive in Europe are accelerating the automotive industry’s transition from a linear to a circular economy. In this context, the recyclability of vehicles at the end of their service life is becoming increasingly important. This in turn raises the demand for automotive components that have an excellent environmental performance across the product life cycle and at the same time meet the highest standards of material quality and technical performance. Autoneum’s new 100% polyester trunk side trim helps customers achieve their ambitious sustainability targets while offering optimum durability, design flexibility and aesthetics.

As with Autoneum’s environmentally friendly monomaterial carpet systems, the new 100% polyester trunk side trim is fully recyclable. Production cut-offs can be reclaimed, processed and reused, ensuring a closed material loop. Thanks to Autoneum’s high-value recycling concept, the recycled fibers can also be granulated and spun into new fibers, which reduces the need for virgin raw materials and thus conserves natural resources. The carrier material is based on the lightweight Autoneum Pure technology Propylat PET and contains at least 50% recycled fibers. Like all variants of Propylat, the technology features a high proportion of recycled material and can be produced waste-free thanks to its complete vertical integration. In addition, Propylat PET consists of 100% PET and is therefore fully recyclable. The new monomaterial trunk side trim made exclusively from polyester is also available under the Autoneum Blue sustainability label. Blue products feature at least 30% recycled PET that was collected from coastal areas, thus making an important contribution to preventing plastic pollution in the oceans.

Autoneum’s sustainable concept for 100% polyester trunk components is not limited to side trim but can also be applied to tailgate and other trunk trim. Thanks to their unique material composition, the Propylatbased trunk trim parts are lightweight and sound-absorbing, thus contributing to the attenuation of tire and rear e-motor noise. In addition, their geometry can be tailored to individual customer needs while the textile surface improves the overall aesthetic of the parts and at the same time offers a high resistance to scratches. Autoneum’s eco-friendly 100% polyester trunk trim is available in Europe, North America and China.

Beaulieu International Group is investing €5 million to transition the fossil based energy supply of its Cushion Vinyl production plant in Wielsbeke, Belgium, to bio mass generated steam supply. A transition to renewable energy. To this end, B.I.G. is collaborating with A&U Energie, a company that converts non-recyclable wood waste into green energy and heat. This strategic move aligns with B.I.G.'s commitment to reach ‘net zero’ for their operations by 2030.

The transition from fossil energy to green steam and the switch to waste gas treatment without direct fossil energy brings significant benefits. First, the switch in technology will lead to 88% reduction in their Belgian Cushion Vinyl carbon footprint related to heat supply and waste gas treatment, compared to the current emissions. Second, the use of steam heating and electric energy provides improved energy efficiency. In addition, the use of steam systems is known for its safety and reliability, providing a safer and more stable heating solution for the Belgian Cushion Vinyl facility. Moreover, the switch to steam and electric energy allows for the use of green electricity in the future, if available.

In addition to transitioning to 100% green energy, Beaulieu International Group is also dedicated to advancing the circular economy. These efforts encompass various initiatives, including increasing the use of recycled and reused materials. For example, 50% of B.I.G.'s PVC floor coverings are already fully recyclable. Additionally, they are actively working to reduce the environmental impact of their solutions by 42% at the end of their life cycle, striving to minimize product emissions to nearly zero, and eliminating pollutants. Recently at the Belgian Flanders Flooring Days, Beauflor launched its Twilight collection, a cushion vinyl floor created with PVC from 100% bio and circular sources resulting in a 40% reduced CO₂ footprint compared to their conventional heterogeneous CV flooring for residential applications

Furthermore, their cushion vinyl brand Beauflor launched the ReLive concept, a specialized program designed for a circular future, ensuring the collection, sorting, and recycling of PVC flooring cutting waste. Currently, this program focuses on post-installation waste and is exclusively available in France, with the goal of expanding its reach to other EU countries.

Through the establishment of strategic partnerships dedicated to finding innovative ways to repurpose waste materials previously slated for incineration, B.I.G. underscores its commitment to sustainable solutions and collaboration with like-minded organizations. 75% of B.I.G.'s post-industrial waste is now being successfully recycled.

Breaking new ground in plastics recycling means assessing the value chain from end to end. The big opportunities for the future are in fine-tuning the individual process steps; from the collection of recyclable materials to the recycling process and the end product. This is where the cooperation of Lindner and the EREMA Group comes in, officially launched following the 50/50 founding of the holding BLUEONE Solutions in August 2023 to which shares of Lindner Washtech were contributed. The expertise of EREMA, a manufacturer of extruders and filtration solutions for plastics recycling and the largest company within the EREMA Group, has now been combined with the expert know-how from Lindner Washtech, a leading provider of all-in-one solutions for shredding, sorting and washing plastic feed materials.

Data transfer ensures more efficient recycling processes
Process control is an especially important aspect of plastics recycling, which is why standardising the process control system was what the two companies focused on first. "Together, we have developed a platform that allows data to be exchanged between the extruder and the washing system," says Manfred Hackl, CEO of the EREMA Group at IFAT in Munich. "This enables us to analyse the data more precisely so that effective improvement measures can be deduced." All key parameters are taken into account and monitored via a digital interface. For example, it is possible to use information relating to the current throughput of the EREMA Pre Conditioning Unit to optimise the washing process as soon as possible so that it can compensate for fluctuations in capacity and achieve a significant increase in output. This data transfer represents a new step on the roadmap to digitalization.

High efficiency due to smart energy management
"To ensure sustainable recycling, it is necessary to find the right process for each application and to make sure that the individual process steps are perfectly coordinated," emphasizes Michael Lackner, Managing Director of Lindner. Coordinating the process steps has already achieved initial success in energy management, and a clear example of this is heat recovery. "We use the latent heat generated during the extrusion process as an energy source for the washing and drying process," explains Lackner. "This enables our customers to sustainably reduce their energy costs and carbon emissions".

Making the most of synergies along the value chain
Synergies need to be used to establish the quality standards specified for each end application. "The key question is how we can improve the end product and increase the overall efficiency of the recycling process at the same time," agree Manfred Hackl and Michael Lackner. This will only work if companies work together along the value chain. The industry leaders can already point to several examples where together they have improved recycling processes and made it possible to move away from downcycling. "An example of this is the recycling loop of HDPE starting material, which is processed into high-quality, food-safe rHDPE pellets using our two technologies," says Lackner. Lindner Washtech and EREMA continue to work intensively together to develop strategies for upcycling plastics and increase recycling rates.

To expand its support for high-end and luxurious automotive interiors, B.I.G. Yarns has completed its first industrial production runs of virgin polyester BCF yarns for automotive carpet to complement its line of polyamide PA6 superior yarns.

There is a growing market in PET for automotive interior applications, with polyester allowing automotive OEMs and Tier 1 to develop products that, from the outset, consider eco-design by building MONO-polymer carpets and flooring that are 100% recyclable at End of Life (EOL ). These materials are helping to ensure improved and more sustainable EOL recycling of electric vehicles that are driving the future of the car industry.

The new PET BCF Yarns offer high-performance for automotive carpets, including abrasion and stain resistance, and durability, passing all stringent automotive tests including the Taber test for abrasion performance, compressibility and recovery ability test, light fastness in automotive (DIN EN ISO 105-B06) and VOC (fogging) according the VDA 278 test on VOC and FOG emission. The yarns can be color solution dyed, have a dTex between 1300 – 1500, 81 filaments and are ideally for mats with a composition of 400 to 800 gram per m², while the yarns for molded carpets have a dTex of 1200, 144 filaments for 380 gram per m².

With the addition of PET BCF yarns, B.I.G. Yarns is now a one-stop-shop for 3 types of Solution Dyed BCF carpet yarns for the automotive industry: nylon (PA6), polypropylene (PP) and polyester (PET), and the Eqo-range of PA6 yarns – the sustainability focused EqoBalance, EqoCycle and EqoYarn.

The automotive carpet market is expected to grow strongly in the coming decade with the increased demand for vehicle customization and personalization driven by owners looking to upgrade and enhance interiors, including the flooring area.
A growing awareness around car hygiene is also boosting the market as consumers become more conscious of maintaining cleanliness in their vehicles, including the floors. Automotive carpets provide an effective solution by trapping dirt and preventing it from spreading to other areas.