From the Sector

Mayer & Cie. CN Changzhou LLC, the Chinese subsidiary of the German circular knitting and braiding machine manufacturer Mayer & Cie., settled in Jiangsu Province at the beginning of the year. Until now, the Sales & Service subsidiary Mayer & Cie. China, founded in 2003 and later to become Mayer & Cie. China, had been based in Shanghai.

The new location within a Sino-German Innovation Park comprises a production hall of around 5,000 square meters. In the future, the circular knitting machines assembled for the domestic market will increasingly consist of locally sourced parts and components from various suppliers.

Since 2011, Mayer & Cie. has been assembling selected machine types for the domestic market at its Chinese plant in Shanghai. It started with a single jersey machine for the most common requirements. Today, China's domestic portfolio includes four types of machines. Until now, the knitting heads for these circular knitting machines had been pre-produced at the Mayer & Cie. plant in the Czech Republic and then transported to China.

The manufacturer is now saying goodbye to this "knitting head principle". It made perfect sense for the start of the assembly line, says Benjamin Mayer, managing partner of Mayer & Cie. However, it leaves little room for flexibility. He explains: "In the future, we will source all parts and components of the machines assembled in China from various local suppliers. This allows us to offer our local customers more attractive prices and faster delivery times with the same quality standards. We expect this change to improve the positioning of our products in the domestic market." In addition, the new plant will be connected to the parent company in Albstadt via an SAP connection. This was imperative to increase efficiency, transparency and quality.

The new headquarters of Mayer & Cie. CN is the German Chinese Innovation Park in Jintan in Jiangsu Province. The companies based there enjoy various advantages, including attractive location costs as well as proximity and exchange with other German companies on site. In addition, the administration of the SGIP supports companies in their search for employees, suppliers and service providers.

The 17th World-Pultrusion-Conference (WPC) took place in Hamburg from 29 February to 1 March. Pultrusion, also known as the extrusion process, is a highly efficient method for producing fibre-reinforced plastic profiles for various applications in the construction/infrastructure and transport sectors.

A record number of almost 150 participants from all over the world attended the event. An international audience of experts from Europe and the USA, as well as China, India and Japan was represented.

The lecture programme with a total of 25 specialist lectures was strongly characterised by the topic of sustainability. The process development of thermoplastic pultrusion and applications in wind energy, solar panels, bridge construction and the automotive industry were also discussed at length. Despite the difficult market environment, many opportunities and possibilities for the pultrusion industry were presented.

The conference takes place every two years in a European country of importance to the pultrusion industry and is organised by AVK for the European Pultrusion Technology Association (EPTA), in cooperation with the American Composites Manufacturers Association (ACMA).

Archroma and Browzwear, a company of 3D digital solutions for the fashion industry, have expanded their partnership to bring the complete Color Atlas by Archroma® library of colors to Browzwear’s VSticher, Lotta and Stylezone platforms.

Designers will now have access to a total of 5,760 color references, with 1,440 colors for polyester added to Browzwear’s existing color library of 4,320 Color Atlas colors for cotton poplin. This will support them to collaborate across the entire supply chain, ensuring color consistency from digital design to production for cotton, polyester and blends.

Crucially, the color references in the Color Atlas by Archroma® have been formulated to comply with leading international eco-standards, allowing designers to select dyes and finishes that meet their desired sustainability profile. Each color is available as a physical color standard that includes precise dyeing recipes and compliance data, as well as access to expert technical support from Archroma around the world.

The German Institutes of Textile and Fiber Research Denkendorf (DITF) have modernized and expanded their melt spinning pilot plant with support from the State of Baden-Württemberg. The new facility enables research into new spinning processes, fiber functionalization and sustainable fibers made from biodegradable and bio-based polymers.

In the field of melt spinning, the DITF are working on several pioneering research areas, for example the development of various fibers for medical implants or fibers made from polylactide, a sustainable bio-based polyester. Other focal points include the development of flame-retardant polyamides and their processing into fibers for carpet and automotive applications as well as the development of carbon fibers from melt-spun precursors. The development of a bio-based alternative to petroleum-based polyethylene terephthalate (PET) fibers into polyethylene furanoate (PEF) fibers is also new. Bicomponent spinning technology, in which the fibers can be produced from two different components, plays a particularly important role, too.

Since polyamide (PA) and many other polymers were developed more than 85 years ago, various melt-spun fibers have revolutionized the textile world. In the field of technical textiles, they can have on a variety of functions: depending on their exact composition, they can for example be electrically conductive or luminescent. They can also show antimicrobial properties and be flame-retardant. They are suitable for lightweight construction, for medical applications or for insulating buildings.

In order to protect the environment and resources, the use of bio-based fibers will be increased in the future with a special focus on easy-to-recycle fibers. To this end, the DITF are conducting research into sustainable polyamides, polyesters and polyolefins as well as many other polymers. Many 'classic', that is, petroleum-based polymers cannot or only insufficiently be broken down into their components or recycled directly after use. An important goal of new research work is therefore to further establish systematic recycling methods to produce fibers of the highest possible quality.

For these forward-looking tasks, a bicomponent spinning plant from Oerlikon Neumag was set up and commissioned on an industrial scale at the DITF in January. The BCF process (bulk continuous filaments) allows special bundling, bulking and processing of the (multifilament) fibers. This process enables the large-scale synthesis of carpet yarns as well as staple fiber production, a unique feature in a public research institute. The system is supplemented by a so-called spinline rheometer. This allows a range of measurement-specific chemical and physical data to be recorded online and inline, which will contribute to a better understanding of fiber formation. In addition, a new compounder will be used for the development of functionalized polymers and for the energy-saving thermomechanical recycling of textile waste.

Kelheim Fibres is showcasing recent research findings at this year's Cellulose Fibres Conference (13rd-14th of March). The development, led by Dr. Ingo Bernt, Project Leader of Fibre & Application Development at Kelheim Fibres, and Dr. Thomas Harter from Graz University of Technology, provides insights into the correlation between the geometry of viscose fibres and the liquid absorption of tampons.

Kelheim Fibres has long been engaged in the functionalization of viscose fibres, including the specific adaptation of fibre cross-sections. The trilobal Galaxy® serves as an example. The current study underscores the properties of the fibre, primarily rooted in its geometry. This involves taking a closer look at the underlying mechanisms. It has been confirmed that, in contrast to the traditionally round viscose fibres and despite similar chemical compositions and mechanical properties, Galaxy® enables significantly better liquid absorption.

While the higher specific surface area of trilobal fibres already promotes improved liquid absorption, this is not the main factor accounting for the difference in absorption. Instead, the geometric shape of the fibres proves to be crucial. Trilobal fibres create and maintain a more voluminous, extensive network within the absorbent body, providing a larger volume for liquid absorption.

Dr. Ingo Bernt emphasizes, "The results of our study are not limited to tampons—any application requiring increased absorbency can benefit from the properties of our Galaxy® fibres."

The lecture "Geometry Matters: Unveiling Tampon Absorption Mechanisms" by Dr. Ingo Bernt und Dr. Thomas Harter takes place on the 14th of March at 2:50pm.

Borealis is commemorating its thirtieth year of operations. Born of a merger between Statoil and Neste, Borealis has expanded from its early Nordic roots to become one of the top polyolefins players. Its dedication to value creation through innovation has produced proprietary and transformative technologies which benefit society and accelerate the transition to a circular economy. The company is regularly ranked as Austria's top innovator in the European Patent Index and holds an extensive patent portfolio of around 8,900 granted patents. In Europe in particular, Borealis has for decades bolstered the industrial landscape by investing in its capital assets, and by providing thousands of jobs.

Innovations
Borealis uses technological innovation to add value to polyolefin-based applications, ensure that production processes are made more resource efficient, and to accelerate plastics circularity. Borstar®, the multi-modal proprietary technology for the manufacture of polyethylene (PE) and polypropylene (PP), has been a mainstay of Borealis success since the start-up of the first Borstar PE plant in Porvoo, Finland in 1995. Borstar has since been joined by other technology brands, like Borlink™, an innovation for the power cable industry; Borstar® Nextension Technology, an innovation that among other benefits facilitates the production of monomaterial applications designed for recycling; or the Borcycle™ M technology for mechanical recycling, which breathes new life into polyolefin-based, post-consumer waste, transforming it into applications with a lower carbon footprint.

Global Expansion
With the strong support of its two majority shareholders OMV (Austria) and The Abu Dhabi National Oil Company (ADNOC, UAE), Borealis continues to expand its global footprint. The joint venture Borouge, established in 1998 in the UAE, and listed on the Abu Dhabi Securities Exchange (ADX) since 2022, is one of the largest integrated polyolefin complexes. It is currently the site of the company’s largest-ever growth project: Borouge 4, the new USD 6.2 billion facility in Ruwais, which will serve customers in the Middle East and Asia. In North America, the Baystar™ joint venture, founded in 2017 and operated with partner TotalEnergies, entailed the construction of a new ethane cracker as well as the most advanced Borstar plant ever built outside of Europe. The PE Borstar 3G plant in Pasadena, Texas was started up in late 2023 and has brought Borstar to this continent for the first time. Borealis’ commitment to Europe as a production location is evidenced by the new, world-scale propane dehydrogenation (PDH) plant currently under construction at Borealis operations in Kallo, Belgium.

Autoneum has established a new Business Unit Commercial Vehicles to expand its existing truck business and to increase revenue and profitability in this vehicle segment as part of the Group’s strategic focus on profitable growth. To begin with, the Business Unit will focus on the commercial vehicles business in Europe and South America, as these two regions have a comparable customer base. The Business Unit is responsible for the global commercial vehicles business development, while its financial results will be consolidated within the Business Groups.

The new Business Unit focuses primarily on the business with components for medium and heavy trucks as well as agricultural commercial vehicles. Following the acquisition of Borgers Automotive in April last year, Autoneum has significantly expanded its product and technology portfolio for these vehicle segments. In combination with the Company’s global presence and diversified customer structure, this provides an ideal basis for future profitable growth. Autoneum already operates plants which manufacture products for the exterior and interior of commercial vehicles in Belgium, Czech Republic, France, Germany and Poland, as well as in Brazil. With the creation of a dedicated Business Unit Commercial Vehicles, Autoneum aims to leverage its existing production footprint in order to further grow the business worldwide.

As with the product portfolio for light vehicles, Autoneum’s multifunctional, lightweight and sustainable systems and components are suitable for commercial vehicles of all drive types. Autoneum is therefore well positioned for the expected increase in electric models due to more stringent environmental regulations.

A new €26 million manufacturing plant with its own forest has been opened by AkzoNobel in Faisalabad – the company’s largest investment in Pakistan to date.

The 25-acre site, which has facilities for making decorative paint, wood finishes, automotive and specialty coatings, coil coatings and protective coatings, will help to meet increasing customer demand across a variety of markets.

Also incorporated into the Faisalabad location is a forest spanning an area of 5,450 square feet. More than 1,400 native trees and shrubs – planted using the Japanese Miyawaki gardening technique – are expected to grow into a flourishing self-sustaining ecosystem over the next two years.

The site, which employs nearly 200 people, has been constructed to comply with the company’s strict environmental standards and includes a series of sustainability features, such as renewable energy generation and energy efficient design.

CARBIOS and Landbell Group, a global operator of more than 40 producer responsibility organizations (PROs) and a provider of closed-loop recycling solutions, announce the signing of a non-binding Memorandum of Understanding for the sourcing, preparation and recycling of post-consumer PET waste using CARBIOS’ biorecycling technology at its first commercial plant in Longlaville from 2026.  

The partnership will leverage Landbell Group’s expertise and network in the sourcing of PET packaging and textile waste which will be prepared for biorecycling. Thanks to CARBIOS’ highly selective enzyme, less sorting and washing is required compared to current recycling technologies, offering future savings in energy and water use. From 2026, Landbell Group will supply CARBIOS with 15 kt/year of PET flakes, ensuring a steady supply chain for sustainable PET production. These flakes will serve as essential feedstock for CARBIOS’ production of food-grade PTA and MEG, further re-polymerized into PET.

Through the partnership with Landbell Group in Germany, the supply of multilayer trays through the CITEO tender in France  and the MoU with Indorama Ventures, CARBIOS will have sourced over 70% of its feedstock required for the 50kt/year capacity when its first commercial plant in Longlaville, France, will operate at full capacity. Close to the borders with Belgium, Germany and Luxembourg, the plant’s location is strategic for nearby waste supplies.

Through this partnership with CARBIOS, Landbell Group will ensure that the problematic PET fractions such as multilayered, colored and opaque trays from packaging waste and polyester textile waste are redirected towards recycling. In this way, Landbell Group strengthens its commitment to the development of recycling solutions to enable a circular economy.

The European Chemicals Agency (ECHA), between 2009 and 2023, has performed compliance checks of approximately 15 000 registrations, representing 21 % of full registrations.  The Agency has met its legal target for dossier evaluation, which was increased from 5 % to 20 % in 2019. While, for substances registered at quantities of 100 tonnes or more per year, ECHA has checked compliance for around 30% of them.  

In 2023, the Agency conducted 301 compliance checks, covering more than 1 750 registrations and addressing 274 individual substances. These checks focused on registration dossiers that may have data gaps and aim to enhance the safety data of these substances. As a result, 251 adopted decisions were sent to companies, requesting additional data to clarify long-term effects of chemicals on human health or the environment.

ECHA will now put more focus on following up the requests sent to companies. In the follow-up evaluation process, the Agency assesses the incoming information for compliance. The outcome of the incoming data is shared with the Member States and European Commission to enable prioritisation of substances. ECHA will work closer together with the Member States for enforcement of non-compliant dossiers.  

Compliance of registration dossiers will remain a priority for ECHA for the coming years. This year, the Agency will review the impact of the Joint Evaluation Action Plan, aimed at improving REACH registrations compliance, and, together with stakeholders, develop new priority areas to work on.