From the Sector

International technology group ANDRITZ has established a new inline Wetlace™ CP pilot line with an original design at its center of competence in Montbonnot, France. The line combines both spunlace and wetlaid technologies.

From now on, partners will be able to conduct trials and test all options available for wipes production – from carded staple fibers to pulp and various combinations thereof. The combination of both spunlace and wetlaid technologies offers to move forward to more sustainable options while maintaining a high level of product quality, in particular by achieving high CD strength and good linting properties.

Over the past few decades, ANDRITZ has continued to innovate with various nonwoven processes, like spunlace, WetlaceTM and Wetlace™ CP, with the aim of optimizing the use of raw materials and focusing on sustainability by reducing the synthetic fiber content. Facing the growing demand for bio-wipes in parallel with enforcement of the EU’s single-use plastics directive last year, ANDRITZ has decided to support its customers making their investment decisions.

The Montbonnot pilot line has been rebuilt to integrate the new headbox inside the spunlace line. Pulp can be fed in directly and entangled with carded staple fibers to produce unique nonwoven fabrics designed for end uses as bio-wipes.

With the goal of making recycling of lightweight, high-volume fiber and flake recyclate much more economical and, in some cases even possible, Coperion has developed a new version of its ZS-B side feeder. Using the innovative ZS-B MEGAfeed, plastic recyclate with a bulk density under 200 kg/m³, long considered intake-limited and thus not worth recycling, can be reliably fed in large quantities into Coperion’s ZSK twin screw extruder and be concurrently recycled and compounded.

The ZS-B side feeder’s novel design makes it possible to feed very high rates of fiber and flakes, such as PA, PE, PET, and PP. As a result, the ZSK twin screw extruder’s high capacity can be fully exploited when the ZS-B MEGAfeed is used. Very high throughputs in both mechanical and chemical recycling of post-industrial and post-consumer waste are achieved.

Increased Throughput in Numbers
With a ZSK 58 Mc18 twin screw extruder, the throughput increase and thus the potential of the new ZS-B MEGAfeed becomes very clear. When recycling PA fibers with a bulk density of ~40-50 kg/m3, throughputs of 70 kg/h were previously achieved using conventional equipment. When the PA fibers were fed into the ZSK extruder using the ZS-B MEGAfeed, throughputs increased about fourteenfold to 1,000 kg/h. Similar results were achieved recycling carbon fibers with a bulk density of ~50-70 kg/m3; in this case, throughputs increased from 50 kg/h to 2,500 kg/h using the ZS-B MEGAfeed. When recycling PCR (Post-Consumer Recycled) flakes, throughputs increased from 50 kg/h to 700 kg/h, and from 80 kg/h to 1,300 kg/h with multilayer film flakes.

Key to Economical Recycling of A Wide Variety of Plastics
Plastics previously considered not recyclable are becoming a valuable raw material using the new Coperion ZS-B MEGAfeed. For example, PCR flakes or recyclate from carbon fiber-reinforced plastics can now be fed into the ZSK extruder at high feed rates and recycled economically.

In the case of mechanical upcycling, upstream processes necessary for compounding, such as compacting, melting and agglomeration, are completely eliminated using the ZS-B MEGAfeed technology. In this recycling process, flakes and fibers can be fed directly into the ZSK extruder, where they are melted, compounded, devolatilized, and filtered in a single step. In so doing, both investment costs and energy consumption drop. The production process becomes significantly more efficient. Moreover, the thermal product stress is reduced and recyclate quality increases.

Even when recycling PET, the feed rate is no longer a limiting factor. With the ZS-B MEGAfeed, PET flakes and fibers can be fed into the ZSK twin screw extruder in large quantities with no pre-drying or crystallizing, where they can be processed with the highest degree of profitability.

The ZS-B MEGAfeed can also feed large quantities of post-consumer waste, adding appreciable value to the chemical recycling process with the ZSKs. ZSK throughput rates are very high with the ZS-B MEGAfeed. Preheating of the recyclate via mechanical energy input of the twin screws thus becomes even more economical for further processing in the reactor.

Existing Coperion extruders can be retrofitted with ZS-B MEGAfeed technology to greatly expand their spectrum of applications and increase their throughput rates.

SHIMA SEIKI MFG., LTD. of Wakayama, Japan, along with its Italian subsidiary SHIMA SEIKI ITALIA S.p.A., will be participating in the Techtextil exhibition in Frankfurt, Germany from the 21st till the 24th of June 2022.

On display will be SHIMA SEIKI’s latest innovation in flat knitting technology as applied to the field of technical textiles—a prototype weft knitting machine capable of multi-axial yarn insertion. Fabrics produced on this machine use inlay technique for the production of hybrid textiles that combine the stretch characteristics of knitted fabrics with the stability of woven textiles, suited to various technical applications. To this, warp yarn is inserted to further expand its capability to produce 3D-shaped carbon fiber and composite preforms directly on the machine. This is made possible by taking advantage of the fact that flat knitting as a textile production method is capable of producing end products that are shaped-to-form and with added thickness. Compared to current methods of preform production, savings in post-processing time, material, labor and associated costs are immense, realizing efficient and sustainable production. SHIMA SEIKI’s own yarn unwinding technology is also used for optimum yarn feed and tension for use with technical yarns that are otherwise difficult to knit. Industrial textile samples knit on the multi-axial machine will also be available for examination on-site.

SHIMA SEIKI's SDS®-ONE APEX4 3D design system will be available for demonstrations as well. Of particular interest should be its ultra-realistic simulation capability that realizes Virtual Sampling. When countless variations must be evaluated before arriving at a final design, virtual product samples can be used to streamline the decision-making process by minimizing the enormous amount of time, cost and material normally associated with producing actual samples for each variation. When approved, the same data can be converted to machine data for immediate knitting, significantly reducing lead times.

TEXAID with its Spanish subsidiary PERCENTIL enable Springfield to put its commitment to sustainability into action through implementing a circularity pilot project with the aim of giving a second life to second-hand garments. As part of the Tendam Group, who operates more than 2000 stores in 79 countries, Springfield partners with the TEXAID group, leading in the industry of collecting, sorting, reselling and recycling used garments, to launch the R[ECO]LLECT initiative.

Take-Back Program R[ECO]LLECT
With "the future is circular" as their call to action, the project is called R[ECO]LLECT and refers directly to the collection of all second-hand garments in good condition, to meet three clear sustainability objectives of Springfield: reduce the pressure on natural resources, reduce CO2 emissions and reduce the amount of textile waste.

R[ECO]LLECT was launched in May 2022 as a pilot project in 16 Springfield stores in Spain across different cities and provinces.

TEXAID’s Spanish subsidiary PERCENTIL is a strategic partner of Springfield in this step towards sustainability. The motto of PERCENTIL is that "there is nothing more sustainable than what you already have in your closet", and it is an intermediary between people who want to get rid of clothes and those who are looking to buy almost new clothes from brands recognized for their design and quality, but at a much lower price. In this way, textile overproduction is reduced, and the environmental impact is reduced. In addition, PERCENTIL receives the clothes, sorts them and takes care of giving them a second life.

Focus on eccentric screw pumps and pumps for shear-sensitive materials

Improved productivity and increased lifespan and tailored solutions also for the most demanding applications within the chemicals and plastics industries and in PUR applications – these are the convincing arguments with which Oerlikon Barmag is showcasing its precision metering pumps at this year’s ACHEMA between August 22 and 26, 2022 in Frankfurt. The focus is on the new pump for shear-sensitive conveying media and the new eccentric screw pump.

Eccentric screw pumps – robust all-rounders convey any medium
The requirements for pumps are considerable, as the demand for customized solutions for increasingly complex processes is rising. This is particularly true for Oerlikon Barmag’s new eccentric screw pump range. High wear-resistance, increased durability and robust operation – the new pump is tailor-made for conveying highly-filled, high-viscosity and abrasive media, such as filled adhesives, filled silicones and filled casting compounds, for example. The is the multi-stage seal system, which considerably increases the pump’s lifespan. The upstream shaft sealing ring protects the slide ring seal against excessively-fast wear caused by challenging media. In turn, the optimum alignment of the drive shaft – ball bearing-supported and centrally-guided through the shaft sealing ring – prevents any metal debris caused by friction and hence ensures considerably greater durability. Producers benefit from considerably greater productivity, as the pumps’ maintenance intervals and hence machine downtimes are significantly reduced.

New pump for shear-sensitive materials
For increasingly complex customer-specific process solutions, Oerlikon Barmag is now expanding its GA series, developed especially for the challenging conveying of high-viscosity media, to include the GAB51F for shear-sensitive conveying media. The newly-developed pump with its viscosity range of max. 300 Pas is tailored to conveying high-viscosity, shear-sensitive materials such as adhesives and silicones, for example. “The shear forces impacting the medium within the pump are reduced to a minimum as a result of a specially geometry”, explains Thorsten Wagener, Senior Sales Manager within the Pump Construction business unit. The material is conveyed through the pump in an as gentle and low-pulsation manner as possible and metered precisely at the outlet – ensuring it retains its characteristic properties.

High-speed metering pump with sealed product space
The high-speed metering pump has been especially developed for metering poorly-lubricating media. Here, the main benefit is the sealed product space, which extends the pump’s lifespan considerably. The space that comes into contact with the media is limited to the area around the gears. “As a result, the high-speed pump is particularly suited for applications in the chemicals industry, which frequently involve aggressive acids”, comments Thorsten Wagener.

GM series for low-viscosity media
The pumps in the GM and GA series provide precision metering with low-pulsation feeding of the conveying medium. The multi-stage GM pump conveys low-viscosity media (i.e. 250 bar, 100 mPas) even under high pressure and in the most challenging conditions. The square design from the proven GM series is the standard pump for many metering tasks. The development of the multi-stage pump expands the applications range for the GM series considerably. The round 2-stage GM pump has been developed especially for use in high-pressure technology. It masters the particular challenge of conveying small throughputs with low viscosities. The pump is perfect for 0.05 through 20 cm³/rev feed sizes and is excellently suited for use in high-pressure machines for PUR molded parts, foam slab stock, refrigeration unit insulations and sandwich panels, for example.

GA series pumps for high-viscosity media
The Oerlikon Barmag GA range has been especially developed for the challenging conveying of media with higher viscosities. The GA series pumps are available for conveying volumes of between 1.25 and -30 cm³/rev (0.6-144 l/h). They have been designed for pressures of up to 200 bar, for viscosities of up to 1.500 Pas as well as for temperatures of up to max. 225 °C. With this range of pumps, Oerlikon Barmag offers its customers tailor-made solutions for many technical processes in which high-precision and even metering is of paramount importance.

The drum pump – conveying and metering using a single unit
With the drum pump, the Oerlikon Barmag pump specialists have created a pump designed specifically for conveying and metering high-viscosity materials such as adhesives, silicones and other high-viscosity materials from drums and other large containers and for pressures of up to 250 bar. Its special features not only include the fact that it removes high-viscosity materials from the drum, but that it also meters the medium directly without any additional interim stops.

International textile producers meet again in Istanbul, Turkey, from June 14 – 18, 2022 on the occasion of the ITM + Hightex Exhibition. In Hall 9 (Hightex) the exhibitors will present the complete industry value chain from nonwovens raw materials, production machines and accessories to the endproduct. The related industries covered include hygiene, filtration, fabrics and apparel, medical, automotive, wipes, home furnishings and upholstery. DiloGroup offers tailor-made production systems from one supplier and will inform about its portfolio and the latest equipment developments from fibre opening to the finished felt.

DiloGroup will inform about complete lines as well as high speed needlelooms for spunbonds. A new, simplified elliptical needle beam drive makes Hyperpunch technology also attractive for standard application. Hyperpunch HαV allows a more uniform stitch distribution in the preneedling process especially in combination with the new needle pattern 6000X. In a complete needling line this felt homogenization process can be improved further. The new needle pattern 8000X is a milestone in the needle pattern development process and results in endproduct surfaces with low markings over a wide range of advances/stroke.

Another strong pillar of the sales program over decades has been fibre preparation and high speed webforming equipment for other nonwoven technologies. The further development of the high-speed layering principle “Hyperlayer” made progress for better CD strength through a combination of inline cards and crossline card with crosslapper. Particularly, carding machines in a working width above 3.5 m up to 5.1 m have been supplied by DiloSpinnbau as complete high speed carding systems, comprising two or even three cards in a line to directly feed the hydroentangling units of various suppliers. Together with DiloTemafa not only have high throughput rates been achieved in the fibre preparation section of the line but also dedusting filtering and air-conditioning systems have been successfully engineered and integrated.

Together with Sicam, Dilo has combined know-how for hydroentangling technology and therefore can provide complete lines as general contractor including equipment for cutting, winding and packaging.

Another interesting machine is the 3D-Lofter, first presented during ITMA 2019 in Barcelona, which offers a wider range of nonwovens applications by exploring the third dimension. A series of single web forming units which work according to the aerodynamic web forming principle deliver defined fibre masses in varied patterns on a base needlefelt. A stress oriented production of technical formed parts resulting in fibre savings or patterned DI-LOUR or DI-LOOP felts with or without repeat are two examples for this technology which explores new application areas for needlefelts.
The 3D-Lofter technology may also be used “inverted” as “IsoFeed” for filling up bad spots in web mats and thus achieves a better homogeneity of spunlace or airlay products.

The DiloLine 4.0 concept offer I4.0 modules which not only support the user but also facilitate quality control and maintenance by a maximum data transparency in production and control of operation. The Dilo solutions “Smart Start” for a fully automatic start of the production line or “DI-LOWATT” for energy savings are accompanied by Siemens solutions which can be selected via App or Data Cloud “MindSphere”.

Stahl, an active proponent of responsible chemistry, has published its 2021 Environment, Social, and Governance (ESG) Report. The report outlines the company’s sustainable development ambitions and its achievements over the year. It also features Stahl’s ambitious climate mitigation targets for 2030, such as the transition to more renewable feedstocks.

The 2021 Stahl ESG Report is a cornerstone of Stahl’s commitment to reporting transparently on its progress toward a more sustainable chemicals value chain. This acknowledges the important role that industry must play in tackling climate change while enabling a higher quality of life for more people. A key focal point of the new report is a progress update on Stahl’s ESG Roadmap. Introduced last year, this ten-year plan outlines the company’s ESG commitments and targets for 2023 and 2030.
 
Climate action
Stahl is focused on mitigating climate change by reducing greenhouse gas (GHG) emissions from all activities over which it has influence. This includes investing in renewable energy and process efficiencies to lower the GHG emissions caused directly by Stahl’s own operations and the energy used to power them. On this point, progress was made toward the 2023 and 2030 targets in 2021, including a reduction in Scope 1 and 2 CO2 emissions of 15%. Also covered are Stahl’s indirect value-chain impacts, for example, from the raw materials it buys. Looking beyond Stahl’s direct environmental impacts and fostering greater supply-chain transparency will be vital for tackling emissions on a wider scale.

Creating responsible chemistry, together
In 2021, advances were made regarding the company’s diversity and safety targets, which are areas of continuous improvement. Stahl is committed to ensuring a safe working environment, as well as nurturing a diverse and inclusive workplace to continuously improve employee skills.

EcoVadis Gold rating
Fostering ethical behavior through exemplary leadership and governance is key to Stahl’s ambitions. Achieving the EcoVadis Gold rating was an important milestone in this respect. This well-established award reflects the company’s ongoing commitment to supply chain transparency and working with partners to improve the sustainability of its products and operations.

Leading Japanese textile solutions provider SHIMA SEIKI MFG., LTD. of Wakayama, Japan will exhibit at the upcoming JEC World 2022 exposition to be held in Paris, France next month.

On display will be the P-CAM®131 multi-ply computerized cutting machine (NC cutting machine). SHIMA SEIKI's fast, efficient and reliable P-CAM® series computerized cutting machines are known for their innovative functions and Made-in-Japan quality, and boast the largest market share in Japan. At JEC World P-CAM®131 is shown in its most compact form, featuring a cutting area of 1,300 mm x 1,700 mm, with option for expansion. Its multi-ply cutting capability allows up to 1 inch (33mm) of fabric or material to be cut. A knife sharpening system produces a sharp, strong blade every time. Strong, robust components permit quicker response times for knife movement and more accurate cutting composites and other industrial materials. The P-CAM® lineup is ideally suited to global production in a wide range of industrial applications in addition to apparel and textiles.

Also available for video display will be SHIMA SEIKI’s latest innovation in flat knitting technology as applied to the field of technical textiles—a prototype weft knitting machine capable of multi-axial yarn insertion. Fabrics produced on this machine use inlay technique for the production of hybrid textiles that combine the stretch characteristics of knitted fabrics with the stability of woven textiles, suited to various technical applications. To this, warp yarn is inserted to further expand its capability to produce 3D-shaped carbon fiber and composite preforms directly on the machine. This is made possible because flat knitting as a textile production method is capable of producing end products that are shaped-toform and with added thickness. Therefore, savings in post-processing time, cost, material and labor as compared to current methods of preform production are immense, realizing efficient and sustainable production. SHIMA SEIKI’s own yarn unwinding technology is also used for optimum yarn feed and tension for use with technical yarns that are otherwise difficult to knit. Industrial textile samples knit on the multi-axial machine will also be available for examination on-site.

Chemistry plus creativity” is Officina39’s new tagline expressing the most important values at the core of the company’s approach, founded on a deep understanding of sustainability. Embracing the “plus” that used to feature as part of the Officina39 logo, it now takes the shape of a true formula of innovation that echoes throughout the renovated brand look that the company is introducing for the first time at Kingpins.

The latest addition to the Trustainable™ collection is Aqualess Fade, a technology that recreates the bleaching effect of chlorine on fabrics, a waterless special compound for the discoloration of denim on indigo/black garments which is reducing resource consumption and environmental impact. This innovation completes and integrates Aqualess Mission, a combination of technologies that allows garment laundry processes to reduce 75% of the water use.

Traditional systems usually use about 52 liters of water for a pair of jeans, while Officina39’s cutting-edge technology employs only 12.5 liters without affecting the quality of the final product. Until now, the process included three eco-friendly technologies: Novascraper Indigo, a laser finishing technique that adds a natural, vintage look to denim garments; OZ-ONE Powder, an advanced product to give garments a bleached yet eco-friendly treatment, for a worn and distressed look; and Aqualess Aged, a waterless compound to give denim abrasion effects.

“In our field, the word “less” is to be found pretty much everywhere you look: less water, less energy, less impact and the list goes on. So I asked myself if we could work on implementing the word “plus” in this collection.” stated Stefano Parrotta, Officina39 Technical Manager. “And the answer, of course, was yes: we thought of all the ways in which the idea of more (plus) best represents what we do – more passion, more creativity, more collaboration, more inspiration, more Officina39. I think it is important to look for what the industry needs more of and the word “plus” perfectly embodies that!”

ISKO has signed the Dutch Denim Deal for circular denim. The Denim Deal, a public-private initiative, was launched by the Dutch government following the EU Green Deal and the Circular Action Plan and includes agreements to make the denim textile chain more circular. In the deal, more than 40 parties, such as Scotch & Soda, PVH and Soorty, are working together to improve post-consumer textiles in the denim industry and make fiber recycling the new norm. The signatories cover a wide range of manufacturing companies, brands and stores, collectors, sorters, cutters, and weavers.

The main objective is to collectively produce a total of 3 million jeans with (a minimum of 20%) post-consumer recycled cotton (PCR) by the end of 2023. In addition, all parties have agreed that they will work together towards the standard of at least 5% recycled textiles in all denim garments as quickly as possible. The Denim Deal is also an opportunity to set up a 'reverse supply chain' for recycled cotton and create a systemic change to close the denim cycle.

Although the denim industry still has a negative image due to its high carbon footprint, in recent years many good steps have been taken in the field of recycling. But these steps are on a small scale, limiting the overall impact.
"The Dutch Denim Deal fits perfectly into ISKO's circular strategy," says Marc Lensen, ISKO Head of Global Communication. "Our scale and knowledge of sustainable technological solutions will increase the overall impact and accelerate circularity in the denim chain.”