From the Sector

The current European Football Championships 2024 in Germany will be played on natural turf, which is very costly to maintain, does not tolerate high frequency of use and has a limited service life of only 6 months in some cases. Artificial turf is easier to maintain and correspondingly popular. In Germany, there are estimated to be more than 5,000 artificial turf pitches and as many as 25,500 across the EU. The drawback: the enormous annual emission of microplastics in the form of infill material, the high CO2 impact and the not environmentally friendly disposal. Researchers in Aachen presented a sustainable alternative: BioTurf is a new artificial turf system made from bio-based polymers that no longer requires polymer infill material!

"Every year, around 500 kilograms of plastic granules are produced per artificial turf pitch, which have to be refilled as infill. This also corresponds to the amount that potentially enters the environment as microplastics per sports pitch," explains Dr Claudia Post from TFI. With an estimated 25,000 artificial turf pitches in the EU, artificial turf in Europe alone produces 12,750 tonnes of microplastics that end up in the environment every year! The TFI - Institut für Bodensysteme an der RWTH Aachen e.V., Institute for Research, Testing and Certification in Europe for Indoor Building Products, has developed the innovative artificial turf system together with the ITA (Institute for Textile Technology at RWTH Aachen University) and in collaboration with the company Morton Extrusionstechnik (MET), a specialist in artificial turf fibres.

"New artificial turf pitches will be phased out by 2031 at the latest due to the ban on plastic granules. Even now, artificial turf pitches with infill material are no longer being subsidised," says Dr Claudia Post. For grassroots sports, clubs, cities and local authorities, converting their existing artificial turf pitches will be a mammoth task in the coming years, as artificial turf pitches have to be replaced every 10-15 years. With BioTurf, an environmentally friendly alternative is now available! The surface can be played on like any other, whether running, passing or kicking. Short, heavily crimped blades support longer blades and this simple approach increases playing comfort. BioTurf fulfils all quality requirements and standards for the highest footballing demands.

"BioTurf is an innovative, holistic solution," emphasises Dirk Hanuschik from TFI. "We use rapeseed oil and agricultural waste that does not compete with food production. BioTurf is also almost completely recyclable".
This is in stark contrast to conventional artificial turf, which can currently only be thermally utilised, i.e. burned to generate heat.

As BioTurf does not require the traditional latex process at all, the energy-intensive drying process can be dispensed with, which has a positive effect on the price. Latex is also difficult to recycle. In contrast, BioTurf uses the new thermobonding technology. Here, the thermoplastic pile yarns are thermally fused to the backing. Further development steps still need to be taken in the endeavour to develop a 100% mono-material artificial turf, as a few percent polypropylene still needs to be processed in the backing in addition to the polyethylene fibre material in order to protect it during thermobonding. However, this does not hinder its recyclability.

The German Institutes of Textile and Fiber Research Denkendorf (DITF) are coordinating the research project, which is funded as part of the European Union's Horizon Europe research and innovation program. The aim of BioFibreLoop is to develop recyclable outdoor and work clothing made from renewable bio-based materials. The kick-off event took place in Denkendorf on June 26 and 27, 2024.

The textile industry is facing two challenges: on the one hand, production must become more sustainable and environmentally friendly and, on the other, consumers are expecting more and more smart functions from clothing.

In addition, the production of functional textiles often involves the use of chemicals that are harmful to the environment and health and make subsequent recycling more difficult.

Intelligent innovations must therefore ensure that harmful chemicals are replaced, water is saved and more durable, recyclable bio-based materials are used, thereby reducing the usually considerable carbon footprint of textile products. Digitalized processes are intended to ensure greater efficiency and a closed cycle.

For example, the BioFibreLoop project uses laser technology to imitate natural structures in order to produce garments with water and oil-repellent, self-cleaning and antibacterial properties. At the end result of the research work will be affordable, resource and environmentally friendly, yet high-performance and durable fibers and textiles made from renewable sources such as lignin, cellulose and polylactic acid will be available. All processes are aimed at a circular economy with comprehensive recycling and virtually waste-free functionalization based on nature's example. In this way, greenhouse gas emissions could be reduced by 20 percent by 2035.

The technology for the functionalization and recycling of bio-based materials is being developed in three industrial demonstration projects in Austria, the Czech Republic and Germany. At the end of the project, a patented circular, sustainable and reliable process for the production of recyclable functional textiles will be established.

The BioFibreLoop project has a duration of 42 months and a total budget of almost 7 million euros, with 1.5 million going to the coordinator DITF.

The consortium consists of 13 partners from nine countries who contribute expertise and resources from science and industry:

• German Institutes of Textile and Fiber Research Denkendorf (DITF), Coordinator, Germany
• Next Technology Tecnotessile Società nazionale di ricerca R. L., Italy
• Centre Technologique ALPhANOV, France
• G. Knopf’s Sohn GmbH & Co. KG, Germany
• FreyZein Urban Outdoor GmbH, Austria
• BEES - BE Engineers for Society, Italy
• BAT Graphics Vernitech, France
• Interuniversitair Micro-Electronica Centrum, Belgium
• Idener Research & Development Agrupacion de Interes Economico, Spain
• Teknologian tutkimuskeskus VTT Oy, Finland
• Det Nationale Forskningscenter for Arbejdsmiljø, Denmark
• Steinbeis Innovation gGmbH, Germany
• NIL Textile SRO, Czech Republic

For the third time, the GoodTextiles Foundation is realising a WASH community project together with Cotton made in Africa (CmiA). In cooperation with the CmiA-verified cotton company Sofitex, hand-operated pumps were installed in two villages in Burkina Faso/Africa to improve the drinking water supply. The three partners have also trained the villagers in the use of water, particularly with regard to disease prevention, hygiene and healthcare.

For the people in the villages of Sidi and Moukouma, daily life was a challenge: they had to walk between four and ten kilometres to get access to clean drinking water. They were often forced to resort to unsafe water sources such as rivers, which resulted in significant hygiene and health problems.

Following a comprehensive assessment of water scarcity at the project sites, two boreholes were drilled and hand-operated pumps installed. These are located in communal areas that are freely accessible to all and free of any private property and rights. Now the 3,000 inhabitants of both villages have unrestricted access to clean drinking water at all times - a real lifeline for the communities.

A water management committee was set up in each village. In the WASH training sessions, the participants were familiarised with the tasks and functions of the water committee. In addition, the villagers were given a better understanding of WASH practices and principles. They were also taught how to promote hygiene at the water points to ensure water quality. Finally, they were given the necessary maintenance tools for their work.

A total of 115 committed people, including 61 men and 54 women, took part in the training courses. They will now act as multipliers for WASH initiatives, water, sanitation and hygiene measures in their communities and pass on their knowledge. Each committee also received a toolkit for the maintenance of boreholes - so that this project is not just short-term help, but a sustainable improvement in living conditions.

The GoodTextiles Foundation is supporting the project with around €17,000.00.

Etliche Textil-, Schuh- und Modehändler sind von den neuen Nachhaltigkeitsberichtspflichten der Corporate Sustainability Reporting Directive (CSRD) bzw. des deutschen Umsetzungsgesetzes (CSRD-UG) betroffen. Sie müssen ab dem Geschäftsjahr 2025 jährlich eine Nachhaltigkeitserklärung über ihre wesentlichen Themen und die EU-Taxonomie in einem Lagebericht veröffentlichen.
 
Die berichtspflichtigen Unternehmen müssen dabei u.a. folgende Fragen beantworten: Welche der 37 Themenfelder des European Sustainability Reporting Standards (ESRS) sind für sie wesentlich? Welche Daten müssen sie sammeln und veröffentlichen? Und welche IT-Tools können hier Hilfestellung bieten?
 
Zur Unterstützung der Branche veranstaltet der BTE einen praxisorientierten Intensiv-Kurs, der die Umsetzung der CSRD in den einzelnen Unternehmen erleichtern soll. Die Teilnehmer erhalten darin branchenspezifische Informationen, Vorlagen, Leitfäden und Hilfestellungen. Dazu gehört beispielsweise eine Bewertung der Auswirkungen, Risiken und Chancen für die Nachhaltigkeitsthemen des ESRS aus Sicht eines fiktiven Beispiel-Unternehmens inklusive einer Vorlage zur Durchführung der doppelten Wesentlichkeit für den Textil-, Schuh- und Modehandel. Ergänzt werden die Unterlagen um eine Vorlage zur Erstellung der Nachhaltigkeitserklärung für alle wesentlichen Themen, die mit den Anforderungen der Wirtschaftsprüfer abgeglichen werden. Die Unternehmen erhalten zudem Empfehlungen für mögliche IT-Tools für die Datensammlung.
 
Der dreitägige Kurs startet am 12. September in Köln, weitere Termine sind der 26. November (online) und der 21. Januar 2025. Als besondere Serviceleistung gibt es einen wöchentlichen Jour fixe, bei dem auftretende Fragen zeitnah diskutiert und geklärt werden können. Referentin und Kursleiterin ist Unternehmensberaterin Marion Sollbach, die über 17 Jahre bei Metro und Galeria Kaufhof für den Bereich Nachhaltigkeit verantwortlich war und über ein umfassendes Praxiswissen verfügt.
 
Die Teilnahmegebühr beträgt bis 11. August 2024 (Frühbucher) 1.950 Euro für EHV-Mitglieder und 3.450 Euro für Nicht-Mitglieder, jeweils zzgl. MwSt. Bei einer Buchung nach dem 11. August 2024 erhöht sich die Gebühr um 500 Euro. Die Zahl der Teilnehmenden ist auf maximal 16 Personen begrenzt. Weitere Informationen und Anmeldung unter https://www.bte.de/bte-veranstaltungen/.
 
Rechtliche Details zu CSRD
Das CSRD-UG verpflichtet ab dem Geschäftsjahr 2025 auch große mittelständische Unternehmen dazu, jährlich Auskunft über ihre nicht-finanziellen Chancen und Risiken zu geben. Betroffen sind alle Kapitalgesellschaften, die mindestens zwei der folgenden drei Kriterien erfüllen: Umsatz von mehr als 50 Millionen Euro, Bilanzsumme von über 25 Millionen Euro oder mehr als 250 Beschäftigte.
 
Die CSRD ist ein wichtiges Instrument des Sustainable Finance-Paketes der EU und soll vor allem Investoren vor möglichen Anlagerisiken bewahren. Die betroffenen Unternehmen müssen im Lagebericht eine Nachhaltigkeitserklärung nach ESRS abgeben, die nach ESG-Kategorien (Environmental, Social, Governance) unterteilt ist.
 
In die Nachhaltigkeitserklärung integriert werden muss die Berichtspflicht nach EU-Taxonomie, worüber die EU nachhaltigeres wirtschaftliches Handeln definiert. Banken, Versicherungen, Kreditgeber und Investoren müssen danach den Anteil von Investitionen in nachhaltigere Unternehmen in ihrer Nachhaltigkeitsberichterstattung berücksichtigen. Nachhaltigkeitskriterien werden damit Teil der Risikobewertung bei Krediten und können dazu führen, dass Unternehmen keine Kredite mehr bekommen oder einen Risikoaufschlag zahlen müssen. Dies kann auch mittelständische Textil- und Schuhhändler treffen, die unterhalb der CSRD-Grenzwerte liegen!
 
Auch die Berichtspflichten nach Lieferkettensorgfaltspflichtengesetz (LkSG) oder in Zukunft nach der Corporate Sustainability Due Dilligence Directive (CSDDD) sollen in die Nachhaltigkeitserklärung integriert werden.
 
In Deutschland erfolgt die Überwachung der Einhaltung des CSRD-Umsetzungsgesetzes (CSRD-UG) durch qualifizierte Wirtschaftsprüfer. Ein Verstoß gegen das Gesetz führt dazu, dass nur ein eingeschränktes Testat erteilt wird und Maßnahmen zur Verbesserung getroffen werden müssen.

CARBIOS and TOMRA Textiles, a tech venture set up by the sorting technology company TOMRA, announce the signing of an agreement to collaborate on establishing an efficient stream in Northern Europe from textile waste collection, sorting and preparation to recycling using CARBIOS’ enzymatic depolymerization technology at its first commercial plant currently under construction in Longlaville, France

The monomers obtained will be used to produce recycled polyester (r-PET) fiber, closing the loop for polyester textile circularity.

The innovations from both TOMRA Textiles and CARBIOS contribute to addressing critical gaps in the value chain and significantly increase textile-to-textile recycling from its current rate of 1%¹. By accelerating a circular economy for polyester, a sustainable alternative to incineration or landfill is made available.

TOMRA Textiles is on a mission to close the gap in textile circularity, by contributing to designing and scaling textile sorting plants. Under this partnership agreement, TOMRA Textiles will explore specific, tangible measures to enable the preparation of post-consumer polyester waste for biorecycling according to CARBIOS’ specifications.

CARBIOS' biorecycling technology involves breaking down polyester fibers into their basic components using enzymes, which are then used to produce high-quality recycled PET materials such as fibers for the textile industry. The breakthrough collaboration with TOMRA will redirect the challenging PET fraction of polyester textile waste towards biorecycling, showcasing a mutual dedication to pioneering recycling solutions for a circular economy.

¹ Ellen MacArthur Foundation, 2017

Im Zuge der steigenden Nachhaltigkeitsanforderungen in der Textilbranche kündigt das Technikum Laubholz eine Partnerschaft mit TEXOVERSUM und Neo.Fashion. an. Das Technikum Laubholz bringt die Textilfaser WDBSD TX® ein, die aus regionalem Buchenzellstoff hergestellt wird und eine umweltfreundliche Alternative zu herkömmlichen Textilfasern bietet. Die Zusammenarbeit mit TEXOVERSUM, der Plattform für textile Ausbildung und Innovation, sowie Neo.Fashion., einer Bühne für aufstrebende Designer*innen, verspricht wegweisende Entwicklungen für eine nachhaltige Modeproduktion.

Ein zentraler Aspekt dieser Kooperation ist die gemeinsame Realisierung einer besonderen Kollektion – WDBSD TX® Endless Fiber. Infinite Possibilities. – im Rahmen der Semesterarbeit der Designstudierenden der Hochschule Reutlingen. Die Kollektion dient als Inspirationsquelle für die nächste Generation von Designer*innen und ist gleichzeitig ein Beispiel für die innovative Kraft regionaler Ressourcen und akademischer Expertise. Für die Studierenden stellt dieses Projekt eine Gelegenheit dar, als die weltweit ersten Designer*innen mit diesem innovativen Material arbeiten zu können. Durch ihre Beteiligung erhalten sie Einblicke in nachhaltige Produktionsprozesse und vor allem die Gelegenheit, an der Entwicklung umweltbewusster Mode mitzuwirken.

Die Präsentation dieser Kollektion bei der Berlin Fashion Week am 3. Juli, im Rampenlicht der Neo.Fashion. Show, ist die Weltpremiere. Noch vor der großen Enthüllung auf der Berlin Fashion Week gibt es eine exklusive Preview dieser Kollektion an den Laubholztagen 2024 – einer Konferenz, die vom Technikum Laubholz veranstaltet wird.

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.

The Western Development Commission (WDC) announces the successful funding of the THREAD project. Supported by the Interreg Northern Periphery and Arctic Programme, THREADs (Textile and Habiliment Reuse for the Environment and NPA Area Development) is set to launch a transformative three-year initiative starting in September 2024, focusing on innovative textile waste management.

THREADs aims to significantly reduce textile waste in the Northern Periphery and Arctic region. With a total budget of €1.5 million, the project will implement a range of innovative approaches across the textile lifecycle—from design to disposal. This initiative includes trialling smart waste collection methods, enhancing circular practices, and integrating social inclusion initiatives in circularity efforts. Additionally, the project will explore new business models to support sustainable practices.

The project unites a diverse group of partners from across Europe, reflecting a collaborative effort to tackle an urgent environmental issue. The lead partner, Kajaani University of Applied Sciences from Finland, is joined by other key stakeholders including the Municipality of Kittilä, Kiertokaari Ltd, Remiks Husholdning AS from Norway, Technological University of the Shannon – Forge Design Factory from Ireland, University of Boras and Lulea Miljoresurs AB from Sweden, and the Icelandic Textile Center.

The funding announcement marks a crucial step towards implementing effective solutions that address both the environmental impact of textile waste and the challenges posed by fast fashion in sparsely populated areas. By focusing on sustainability and efficient resource use, THREADs is poised to create meaningful change in the way textile management is approached in the NPA region.

A new type of pure synthetic leather meets the requirements of the European Ecodesign Regulation. Made from a bio-based plastic, it is biodegradable and meets the requirements for a closed recycling process.

Many synthetic leathers consist of a textile substrate to which a polymer layer is applied. The polymer layer usually consists of an adhesive layer and a top layer, which is usually embossed. The textile backing and the top coat are usually completely different materials. Woven, knitted, or nonwoven fabrics made of PET, PET/cotton, or polyamide are often used as textile substrates. PVC and various polyurethanes are commonly used for coatings. The use of these established composite materials does not meet today's sustainability criteria. Recycling them by type is very costly or even impossible. They are not biodegradable. The search for alternative materials for the production of artificial leather is therefore urgent. In 2022, the EU adopted the Sustainable Products Initiative (SPI) ("Green Deal"). It includes an eco-design regulation that considers a product's life cycle in the conservation of resources. For textile and product design, this means incorporating closing the loop or end-of-life into product development.

In an AiF project carried out in close cooperation between the DITF and the Freiberg Institute gGmbH (FILK), it has now been possible to develop a synthetic leather in which both the fiber material and the coating polymer are identical. The varietal purity is a prerequisite for an industrial recycling concept.

The aliphatic polyester polybutylene succinate (PBS) was recommended as the base material because of its properties. PBS can be produced from biogenic sources and is now available on the market in several grades and in large quantities. Its biodegradability has been demonstrated in tests. The material can be processed thermoplastically. This applies to both the fiber material and the coating. Subsequent product recycling is facilitated by the thermoplastic properties.

In order to realize a successful primary spinning process and to obtain PBS filaments with good textile mechanical properties, process adjustments had to be made in the cooling shaft at the DITF. In the end, it was possible to spin POY yarns at relatively high speeds of up to 3,000 m/min, which had a tenacity of just under 30 cN/tex when stretched. The yarns could be easily processed into pure PBS fabrics. These in turn were used at FILK as a textile base substrate for the subsequent extrusion coating, where PBS was also used as a thermoplastic.

With optimized production steps, PBS composite materials with the typical structure of artificial leather could be produced. Purity and biodegradability fulfill the requirements for a closed recycling process.

KARL MAYER GROUP has developed a sophisticated system for considerable energy savings when operating the cylinder dryers in its PROSIZE® sizing machines and BLUEDYE dyeing plant.

Saving costs with inline energy recycling
The innovation is called CASCADE and focuses on steam as a heating medium in cylinder dryers. And for good reason: according to the IPCC report by ITMF Zurich, one tonne of steam cost between USD 20 and just under USD 27 internationally in 2021. The new solution relies on reuse to reduce the amount of process energy required.
"CASCADE recirculates parts of the process steam in cylinder dryers, enabling genuine, efficient energy recycling within the machine," explains Karl-Heinz Vaassen, Head of Textile Drying at KARL MAYER.
The customer benefits from significantly lower energy costs and CO2 emissions. With a view to the Asian market, a dryer with 14 cylinders and a running time of 7,000 working hours can achieve cost savings of up to USD 17,000 per year.

Precise, real savings values are available when looking at the machine dashboard. A sensor provides real-time data on the amount of steam circulating in the circuit, from which the corresponding reduction in CO2 equivalents can be calculated.

Utilizing the pressure drop
CASCADE reuses part of the invested process energy and uses the flash-steam in conjunction with the pressure ratios, which - nomen est omen - decrease in cascades in the different zones of the cylinder dryer.
The highest working pressure prevails in the first cylinder section. The heat transfer medium steam emits large amounts of energy for yarn drying and condenses without temperature loss.

The resulting hot condensate is not immediately discharged from the machine, but is instead fed into a flash tank, where vapor exhaust is formed as a result of the pressure reduction. In conventional systems, the carrier medium for gases is only created in the return line towards the boiler house and is eliminated as undesirable. Instead of being utilised in the process, it escapes into the environment. With the CASCADE system, this "freshly recycled steam" is used for the heat supply in the second cylinder section, but not without prior treatment.

In the system patented by KARL MAYER, the recycled steam is intelligently mixed with live steam and thus raised to the level of the required process conditions for use in the cylinder section at the end of the dryer. Here, the fabric moisture is reduced to the desired residual value at medium pressure and temperature conditions.

Market launch is underway
CASCADE was filed for patent by the KARL MAYER GROUP. It was published in September 2023.
The innovative solution at no extra charge was presented at ITM 2024 in Istanbul and was a visitor highlight at the KARL MAYER GROUP stand.

From January 2024, CASCADE will be part of the PROSIZE® as standard. The first sizing machine with the upgrade for greater energy efficiency will be delivered in the second quarter of this year. It will go to a manufacturer in Europe. In the next step, CASCADE will be integrated into other dryer types and will also be available for the BLUEDYE.