From the Sector

RadiciGroup's sustainable Repetable yarn took to the field alongside Liverpool and Chelsea during the Emirates FA Cup final, which took place on 14 May at Wembley Stadium.
 
Over 47,000 plastic bottles were collected from previous events at Wembley stadium and transformed into Repetable, the innovative RadiciGroup yarn made from PET flakes, which was then used to make the red banner 105 meters long and 68 meters wide, unveiled during the opening ceremony of the event and decorated with the logos of the two teams.
 
Compared to virgin polyester, Repetable® allows lower CO2 emissions (-45%), lower water consumption (-90%) and lower energy consumption (-60%), guaranteeing high performance.

The red banner will be recycled again to make backpacks and sports bibs that the FA will donate to the local community to inspire the eco-players of the future: an initiative in the name of circularity!

Cobra International has launched an innovation report highlighting its key composite manufacturing innovations that have reshaped the Windsurfing industry.
Having first begun building windsurf boards in 1978, Cobra continues to drive technology development in the sport and 44 years later, manufactures approximately 80% of the world’s composite windsurf boards. Manufacturing for leading brands such as Fanatic, Starboard, Naish, RRD, JP and Quatro Goya, Cobra has consistently evolved and improved the construction and finishes of the boards that it builds, balancing stiffness, comfort, weight, strength, durability, and aesthetics.
Cobra’s report details key manufacturing innovations including:

• The introduction of its innovative vacuum moulding technique that Cobra perfected just as the popularity of the sport exploded.
• The manufacture of its own composite EPS forming moulds producing strong, watertight cores that are ready to use in production directly from the mould.
• The mass production of sandwich boards with thermoformed PVC foam wrapped around the rails, increasing the board’s strength whilst keeping weight to a minimum.
• Seamless rail construction
• High-volume manufacturing capacity optimized for the finest prepreg carbon foils satisfying the current demand for windsurf foiling equipment
• Development programs with on of the world’s leading carbon fibre fabric producers to create ever lighter biaxial fabrics.

“As we set aside time during the pandemic to upskill, innovate, and look to the future, it was also important that we referred back to our key technology successes. This got us thinking about so many of our developments which led us to create this innovation report. Customers can draw great confidence from the fact that the Cobra team is always working on tomorrow’s next generation product as well as building exceptional quality into each of today’s boards.” Bruce Wylie, CCO, Cobra International

Albini Group, historic manufacturer of high-end shirting fabrics, meets C.L.A.S.S. Eco Hub, international platform for the promotion and development of innovative and sustainable textiles. Two groundbreaking companies joining forces in the name of ethical and technological development through the C.L.A.S.S. Material Hub, the section dedicated to fibers, threads, yarns and fabrics that are changing the fashion and textile industry.  The values in which Albini Group believes and the strong sensitivity to environmental issues have led the company to also address the issue of the risk of toxic and harmful chemicals in a systemic way, integrating into the production cycles activities and controls aimed at gradually eliminating their presence, with the clear objective of protecting man and the environment.

Three main research areas - innovative fibers and yarns, sustainable dyes and green chemistry - united by the task of transferring cutting-edge technologies through open innovation. Among the new projects presented is "Off the Grain," born from the collaboration with Riso Gallo, a leading rice producer in Italy. It is a new type of dye derived from the processing of a particular variety of black rice: the boiling water of the rice, which can no longer be used for the food industry, is transformed into a natural dye, resulting in significant water savings during the dyeing process.

"Grounded Indigo" is a natural textile dyestuff, born from the search for dyeing practices that are more responsible to people and the environment. For this project, ALBINI_next chose to collaborate with Stony Creek Colors, an American producer of the world's only 100% plant-based indigo that is USDA BioPreferred certified.

The third project, called "HempFeel," is an innovative hemp oil-based finishing, tipically used for cosmetic products. ALBINI_next was the first company to apply it to fabrics of different weights, compositions and structures. HempFeel replaces silicones usually used in finishing, thus reducing the release of microplastics and giving fabrics a soft and durable hand.

"When discussing values related to creativity, next-generation production and commitment to ethics and traceability, Albini is an extremely important point of reference." says Giusy Bettoni, founder and CEO of C.L.A.S.S. "This is why we are delighted with its inclusion within our Material Hub, alongside its colleagues of the responsible innovation movement. Follow us on this new common path. Next- generation solutions and nice surprises will not be missed."

• Hexcel Composite Innovations for Aerospace Applications on Display at JEC World 2022: Hall 5, Stand J41

In late 2021, Hexcel announced an agreement with Fairmat, a deep technology startup, to build the capability to recycle carbon fiber prepreg from Hexcel European operations for reuse in composite panels sold into commercial markets, giving a second life to recovered carbon fiber. To do so, Fairmat has developed a virtuous recycling process, and a sample of its newly recycled material will be available to view at JEC World 2022. Hexcel will present an array of product innovations for aerospace and urban air mobility customer applications during JEC World 2022 in Paris on May3-5. These latest innovations demonstrate the company’s leadership in developing advanced composites technology for the aerospace market.

• Sustainability Focus on Recycling and Reuse
• HiTape® and HiMax® Reinforcements for OoA Processing
• Innovative HiFlow™ Resins for Continuous and Shorter Cycle Injection Processes
• HexPly® Prepregs for Primary Structure and Engine Applications
• HexTow® High Modulus Fibers HM63 and HM54
• Thermoplastics and Processing Innovations for Primary and Secondary Structures
• Lightweight PrimeTex® Reinforcements Solutions for Urban Air Mobility (UAM)

• Freudenberg presents liquid absorbers for lithium-ion battery packs

The experts from Freudenberg Performance Materials (Freudenberg) will be presenting battery pack liquid absorbers, an innovative solution that makes battery systems safer, at this year's Battery Show in Stuttgart. The absorbent pads capture and store unwanted liquids inside the packs quickly and reliably. With adjustable absorption capacity and geometries, battery pack liquid absorbers ensure long-lasting battery packs. Visitors will find Freudenberg at Stand C 36 in Hall 10 from June 28 to 30.

Battery packs are the core elements of mobile and stationary lithium-ion energy storage systems. They are used in automotive and industrial applications. The performance and lifespan of these components are largely responsible for the efficiency of the energy storage system. Moisture inside the packs, such as condensation water or leaking coolant, can considerably diminish both function and lifespan. Battery pack liquid absorbers act as a safety system: the special fleece quickly takes up condensate or coolant and stores it effectively.

C.L.A.S.S. has taken another strategic step with Training, an educational offer made of three moments aimed at sharing valuable and practical information concerning three main areas of sustainable development. Training will be adding value to the Smart Academy offer by C.L.A.S.S., a program of events and conferences, lectures or customized training services, united by an important goal: to educate, raise awareness and inspire professionals, students and even consumers with an eye to the values of responsibility.

There are three trainings offered:

1. Introduction to a new generation of fashion
   C.L.A.S.S. team will introduce and explain the new generation of value-driven fashion where the fusion of design, innovation, communication and responsibility shapes an informed and competitive business, able to play both at an economic and social level. Since 2007, at the base of our philosophy is a formula: Virtuous Fashion, the one with the capital F, is the product of an integration of design (D), innovation (I), sustainability (S) and communication (C). In brief: F = D x I x S x C.
    
2. Introduction to Smart Ingredients
   What is a responsible material? How to source responsibly? Which are the latest smart ingredients that can enrich with new generation fashion collections?
   During the session participant will be guided through materials available in the market, and will have the chance to have an “informed background“ of each one of the materials' journey. Conscious Choices can be made ONLY IF we have all the true full information in our hands. This training informd participant to make the best informed choice for their objectives. A simple but facts driven introduction to the key available innovative and sustainable materials: naturals, transformed and innovative where traceability, transparency, innovation, performance, responsible measurements are leading both the storymaking and the storytelling of each one of them.
    
3. Introduction to Sustainability Report
   The preparation of the company's sustainability report is a fundamental moment to define objectives, identify improvement actions, and measure its environmental and social impact. It is a job that involves the entire company team, which can transform the report into an opportunity for growth.
   The package offered by C.L.A.S.S., in collaboration with Silvia Gambi, sustainable fashion journalist and podcaster of Solo Moda Sostenibile, combines training with personalized consulting with a coaching action to guide the company team in the preparation of its sustainability report, offering the necessary support to create a document that tells about the company, its values, its commitment and also its objectives.

Following their merger, Freudenberg Performance Materials, Low & Bonar, Mehler Texnologies® and Filc will be presenting their innovative solutions at a joint stand for the first time at this year’s techtextil exhibition in Frankfurt. The focus is on sustainability. Among the highlights are Evolon® RE, a microfilament textile for a wide variety of applications and markets, FILFLEX, a sustainable padding material for car seat covers, and the truck tarpaulin POLYMAR® 8556 ECO CF. Customers will find the world's leading manufacturer of technical textiles at Stand C51 in Hall 12.1.

Evolon® textiles made from recycled PET
With Evolon® RE, Freudenberg Performance Materials is presenting an even more sustainable version of its high-performance microfilament textiles. Evolon® RE is manufactured from an average of 70% recycled polyester, which the company makes by cycling post-consumer PET bottles in-house. Evolon® RE products are available for various applications such as technical packaging, in weights currently ranging from 80g/sqm to 300g/sqm. For high-tech wiping, lightweight Evolon® RE is now available starting from 30g/sqm. The material meets the needs of cleaning specialists for more sustainable wiping solutions. Evolon® RE offers the same high quality and material performance as all other Evolon® textiles.

Tarpaulins made from recycled raw materials presented by Mehler Texnologies®
When it comes to tarpaulins on trucks, both protection of the transport cargo and advertising for the transport company place high demands on the material. Mehler Texnologies® tarpaulin material ranks among the premium products for truck tarpaulins. The company is a pioneer in sustainable development and is showcasing POLYMAR® 8556 ECO CF. This unique material has a 25% share of recycled raw materials in the coating mass. In addition, the material is made with 100% R-PES yarns. The input materials undergo a complex separation and filtering process.

Sustainable padding material for automotive and furniture seat covers presented by FILC
FILFLEX is a soft and flexible padding layer made from nonwovens for automotive and furniture seat covers. It prevents leather from creasing and improves the dimensional stability of the seat covers. In terms of sustainability, its benefit is its 100% PET composition, making FILFLEX easy to recycle. FILFLEX offers customers easier handling during sewing and the seat covering process. End users benefit from the high seating comfort.

• Innovation packages from STOLL - a company of the KARL MAYER Group

Optimizations, further developments and innovations are an integral part of STOLL's activities. The industry leader in flat knitting technology has recently launched a new offering in the form of defined innovation packages. The aim here is to make STOLL's high innovative strength even clearer and enable customers to benefit from it more quickly. "The demands made on flat knitting technology are changing all the time, whether in the case of technical textiles for transportation and furniture fabrics or medical solutions well as in the fashion sector, where new yarns - such as recycled yarns or innovative technologies, such as smart textiles - have to be taken into account all the time," knows Erhard Vöhringer, Sales Manager of the STOLL Business Unit in the KARL MAYER Group "Our customers always have to keep abreast of the latest developments. We are therefore continuously developing appropriate improvements, and with our innovation packages we are now offering even more detailed demand-oriented solutions."

Detail optimisations for more overall performance
The innovation packages have the benefits for customers in focus and were tailored to the respective target groups. Every optimization contained therein leads to a decisive improvement in production. All of the solutions developed can be easily integrated into existing STOLL machines.  

Innovation package Number One
Innovation package Number One will be launched on the market in a few weeks' time and is aimed explicitly at knitters who focus on technical textiles. The focus is on convenience and process acceleration. Simple network configuration, expansion of the number of NP values, extended functionality when loading and saving the pattern and also improvement of handling in connection with Production Management from PPS are just some of the features of the package. "The corresponding updates for the machine control system are available to our customers for download free of charge on Customer_Net. In the future, there will also be a cloud-based offering," explains Erhard Vöhringer.

Innovation package Number Two
Still in the pipeline, included in the Number Two innovation package, are improvements for the maintenance area – regarding the use of lubricants and the maintenance intervals (predictive maintenance) – as well as optimizations in terms of sustainability, for example when it comes to reducing consumption of oil and increasing reliability. These solutions will be suitable for all machine types and applications.
The focus here is on improvements in belt take-down, the import and export of data and support for additional storage feeders.
A physical improvement in handling is promised by the new lighting including mirror directly on the machine.
In addition, the development teams are currently working on optimizing various knitting qualities and increasing user-friendliness. So you can already be curious!

Concentrated innovative power
The STOLL development team, with several hundred engineers and technicians in the fields of electronics, software, patterning, and design, never runs out of topics. Questions like "What is the market looking for? What do customers want?  Which changes do the machines have to meet and which ones do the software control and design program have to meet?" are first discussed, evaluated and debated together as a team and then go into the development phase. "Our customers can be absolutely sure that all our innovations are meticulously tested before we go to market with them" emphasizes Erhard Vöhringer. This also applies to the solutions in the innovation packages.

Small solutions, big impact
STOLL flat knitting machines impress with their great application and production potential. Almost 150 years of extensive practical experience in flat knitting technology - the STOLL company was founded in 1873 - is unique in the industry. As a Business Unit of the KARL MAYER Group, STOLL continues to do everything in its power to inspire its customers with innovative strength. Productive, flexible and reliable - simply STOLL! This slogan has not lost any of its meaning today. Quite the contrary: With the new innovation packages, customers benefit not only from the latest high-tech flat knitting machines, but also from an always up-to-date performance upgrade of their existing machine park.
With its innovation packages, STOLL has found a flexible and very fast way directly to the customer. Anyone who wants to know more about this is cordially invited to this year's trade fairs. STOLL looks forward to seeing you at the KARL MAYER Group stand at ITM (Istanbul), Techtextil (Frankfurt), Techtextil India (Mumbai) and ITMA ASIA. (Shanghai).

Paper Converting Machine Company (PCMC), part of Barry-Wehmiller, welcomed 70-plus customers, suppliers and area supporters to its new Packaging Innovation Center on April 26 for a ribbon-cutting ceremony, tour and overview presentation.

Located at PCMC’s headquarters in Green Bay, the facility — focused on the printing and packaging industries — will serve as a resource for training, demonstrations and industry trials, along with research and development opportunities. The new center features the latest equipment for plate mounting, anilox roll laser cleaning, and central impression and inline flexographic printing.

PCMC’s current partners at the center include 3M, All Printing Resources Inc., AV Flexologic, Clean Planet, Fox Valley Flexo Services, Harper Corporation of America, Interflex Laser Engravers, INX International Ink Co., Miraclon, Rossini s.p.a., Sandon Global, tesa SE, Wikoff Color Corporation and XSYS, in addition to Hudson-Sharp, which is part of PCMC. In the future, PCMC will seek to expand the center’s capabilities by collaborating with additional innovative companies serving the flexographic printing industry.

Each year, since its creation more than 20 years ago, the JEC Composites Innovation Awards celebrate successful projects and cooperation between players of the composites industry. The competition has especially shined a light on some 203 companies and 499 partners, awarding them for the excellence of their composite innovations.

The ceremony took place on April 26th in Paris. Highlighted by the presence of jury members, finalists and winners but most importantly, as it was livestreamed, the gathering of many people all around the world to watch the awaited results.

The enthusiasm for the Innovation Awards, exactly 7 days prior to JEC World, is a good sign of the industry’s eagerness to get back together and ensure the future of composites innovation.

• Aerospace Application
  Diab (Sweden): 100% thermoplastic panel for cabin interiors
• Aerospace – Process
  MTorres Disenos Industriales S.A.U. (Spain): Innovative Infusion Airframe Manufacturing System
• Automotive & road transportation – Structural
  Jaguar Land Rover Limited (UK): TUCANA
• Automotive & road transportation – Surfaces
  AUDI AG (Germany): Seamless Integration of Flexible Solar Film in FRP
• Building & Civil Engineering
  Windesheim (Netherlands): Structural Re-Use of Thermoset Composites
• Design, Furniture and Home
  Kairos (France): Kairlin®, a new recyclable & compostable material
• Equipment and Machinery
  Fibraworks GmbH (Germany): Winding the future – fibraforce technology
• Maritime Transportation & Shipbuilding
  Voith Composites SE & Co. KG (Germany): Marine Rotor Blades made of Voith ‘Carbon4Stack’
• Renewable Energy
  Siemens Gamesa Renewable Energy (Denmark): RecyclableBlade
• Sports, Leisure & Recreation
  Bcomp Ltd. (Switzerland): Eco-joint from thermoset race and thermoplast road