From the Sector

INDA, the Association of the Nonwoven Fabrics Industry, announces the three finalists competing for the 2024 Hygienix Innovation Award™. Harper Hygienics, Hello Hazel, and HIRO Technologies will present their absorbent hygiene products at Hygienix™, taking place November 18-21 at The Renaissance Nashville Hotel, Nashville, Tennessee.

• Harper Hygienics S.A.: Cleanic Naturals Hemp – Sanitary Pads (Day & Night), Pantyliners
  Cleanic Naturals Hemp by Harper Hygienics S.A. is an innovative femcare line, crafted with sero™ regenerative hemp fibers produced by Bast Fibre Technologies and processed on our unique Hemplace™ technology platform. These sanitary pads and pantyliners are designed for women’s comfort throughout their cycle. Hemp’s antibacterial and hypoallergenic properties make it a natural solution for sensitive skin, ensuring all-day safety and comfort. Plus, sero™ hemp fibers are 100% natural, offering an eco-conscious approach to personal care.
• Hello Hazel, Inc.: Hazel High & Dry Briefs
  Hazel’s High & Dry Briefs – the first and only disposable briefs for leaks designed to look, fit, and feel like real underwear. Engineered with a novel, ultra-thin, highly absorbent core seamlessly integrated beneath a unique elasticated cover that moves naturally with her body, offering unparalleled comfort, discretion, and reliable protection. Purposefully developed to reduce stigma and address both physical and emotional needs, the Briefs successfully attracted many new consumers who previously opted out of the category.
• HIRO Technologies, Inc.: World’s First MycoDigestable™ Diapers
  Introducing the world’s first MycoDigestible™ diapers, powered by HIRO’s frontier fungal technology. HIRO’s MycoDigestible™ solution introduces plastic-eating mushrooms in a safe, user-friendly way that seamlessly integrates into everyday life. The HIRO Diaper combines exceptional absorbency with natural materials like unbleached TruCotton™ and Kraft softwood fluff pulp, offering 12-hour protection while being gentle on both baby and planet.

The 2024 winner will be revealed on Thursday, November 21st at 11:00 am.

The 2023 Hygienix Innovation Award went to Sequel Spiral™ Tampon, which features a unique spiral design engineered for enhanced fluid absorption and leak prevention. This breakthrough product received FDA clearance as a medical device and is available online and in a growing number of retail outlets.

The ZEBRA (Zero wastE Blade ReseArch) project marks a significant leap forward in the recycling and circular economy for wind turbine blades. This collaborative effort demonstrates a breakthrough in the complete recycling of thermoplastic blades achieving significant environmental and economic benefits.

The ZEBRA project is a unique partnership led by the French Institute for Technological Research, IRT Jules Verne. Joining forces are industry leaders Arkema (resin supplier), Owens Corning (glass fiber supplier), LM Wind Power (blade manufacturer), SUEZ (dismantling and waste processing), CANOE R&D center (recycling technology), and ENGIE (life cycle analysis).

Each company played a crucial role in the development of the closed-loop recycling process:

• Arkema developed and validated the generation of recycled Elium® monomer through thermolysis, and, together with its subsidiary Bostik, an innovative adhesive for the blade assembly that is recycled together with Elium® paving the way for industrial-scale implementation.
• Owens Corning successfully recovered glass fiber at pilot scale, enabling its reintroduction into the production process for their Sustaina® product line.
• LM Wind Power manufactured two wind turbine blades with Arkema’s Elium® resin and Owens Corning’s Ultrablade® fabrics; one blade including a large structural element made with recycled Elium® resin.
• SUEZ provided cutting and grinding expertise for processing the blades.
• CANOE R&D center optimized recycling for production and carbon blade waste, additionally developing methods for repurposing waste streams through mechanical recycling.
• ENGIE conducted a comprehensive life cycle analysis demonstrating the environmental benefits of closed-loop ZEBRA blades and validated their economic viability.

A Sustainable Future for Wind Energy
The ZEBRA project successfully recycled Elium® resin and Ultrablade® fabrics from wind turbine blades and manufacturing waste, reformulating them back into usable materials. This closed-loop process addresses the growing challenge of end-of-life blade management within the wind energy industry.

• Recycled Elium® Monomer: Arkema achieved a yield of over 75% in the thermolysis process, paving the way for industrial-scale production of recycled resin.
• Recovered Glass Fiber: Owens Corning successfully retrieved glass fiber for remelting and reintegration into their Sustaina® product line.
• Life Cycle and Cost Analysis: ENGIE's study confirmed the significant environmental benefits and economic viability of ZEBRA blades when assuming a closed-loop recycling system from production to end-of-life.

ZEBRA blade using Elium® thermoplastic resin, Bostik’s highly compatible adhesive and Ultrablade® fabrics is bringing the best closed-loop recycling solution compared to traditional thermoset system. The operating cost and investments for recycling facility are significantly lowered. The CO2 emission linked to the recycling operations is reduced as well. All those results are making the closed-loop recycling solution of ZEBRA blades a viable option both on economic and environmental standpoints.

By demonstrating the feasibility of full wind turbine blade recycling, the ZEBRA project paves the way for a more sustainable future in the wind energy sector.

The Lenzing Group, a supplier of regenerated cellulose fibers for the textile and nonwovens industries, acquired of a minority share in TreeToTextile AB, joining the existing shareholders H&M Group, Inter IKEA Group, Stora Enso, and LSCS Invest. The group of owners is united by the strong belief that sustainably produced fibers will have the power to change the textile industry to the better.

TreeToTextile was established as a joint venture in 2014 with the objective of developing a more sustainable process for cellulosic fiber production. The company has operated pilot lines since 2015 and invested in a demonstration plant in 2021. The next step in the company's evolution will be to scale up the production and make its fibers available on the market.

Lenzing Group has produced sustainable regenerated cellulosic fibers and dissolving wood pulp for over 85 years. “We are excited about TreeToTextile’s award-winning technology and production process, which further reduces environmental impact, promotes the transition to a more sustainable future and is fully in line with our corporate strategy,” says Rohit Aggarwal, CEO of the Lenzing Group.

Dr. Roxana Barbieru, CEO of TreeToTextile, adds: “Now with the additional expertise and sustainability leadership of our new shareholder Lenzing Group, our speed to market will increase significantly, to reach our ambitious goals and become an important player in the textile industry.”

On the occasion of World Cotton Day 2024, Cotonea presented comprehensive CO2 and energy analyses of a total of 460 fabrics for the first time. Unlike conventional life cycle assessments, the brand analyzes its entire value chain from the cotton plant to the finished fabric and measures energy consumption and associated CO₂ emissions in detail. This enables comprehensive transparency and creates comparability.

“Our analyses and the consistent use of renewable energies along the entire supply chain show that some of our fabrics still act as CO2 sinks even after finishing. This is a clear signal of our commitment to environmental protection,” says Roland Stelzer, Managing Director of the long-established company Elmer & Zweifel and founder of the Cotonea brand.

Precise data
Cotonea examined the CO₂ and energy footprint for a total of 460 different fabrics so precisely that even differences in colors, such as yellow or black, could be determined exactly. Only the energy consumption for the yarn dyeing required for a few fabrics and means of transportation such as trucks, ships and trains as well as the assessment of primary energy sources are based on average values. “Instead of blanket CO₂ footprints or LCAs, we at Cotonea document exactly how our fabrics are manufactured and how much CO₂ and energy are consumed in the individual production stages,” emphasizes Stelzer.

Some fabrics act as CO₂ absorbers even after finishing. This is partly due to the natural CO2-binding properties of cotton fibers in organic cultivation and partly due to the use of hydropower and solar systems in the production facilities.

Advanced technology for comprehensive sustainability
For the analysis, Cotonea, with the support of the Industrieverband Veredelung - Garne - Gewebe - Technische Textilien e.V. (IVGT), used the “Umberto” life cycle assessment software, in which all relevant steps of the production process have been modeled and mapped. The calculations comply with ISO standards 14040 and 14044 for life cycle analysis (LCA). Since the end of 2012, Cotonea has provided items with a product passport that shows the individual production steps. In 2020, the organic cotton brand contributed its supply chain expertise to the “Textile Trust” blockchain project by IBM and Kaya & Kato, which was supported by the German Federal Ministry for Economic Cooperation and Development.

Teijin has teamed up with Germany's herone GmbH and the UK's Envision Racing to develop a composite wishbone which has the capability be used in a Formula E racing car using Tenax™ ThermoPlastics.

The new component is specifically designed to maximize performance while minimizing weight. By utilizing recycled materials from the aerospace industry and implementing herone's innovative pressing process, the partners are setting an example of environmental consciousness and technological excellence.

Multiple demonstrator parts were produced utilizing Tenax™ ThermoPlastic UniDirectional (TPUD) tapes. The material was braided to form the rod structure of the component. Recycled offcuts from part manufacturing in the aerospace industry were used for the functional elements. Those offcuts were injection molded to sockets which are needed for load introduction into the rod structure. herone’s innovative pressing process then compression molded the braids and at the same time co-consolidated the sockets into the rod structure to form the final part. All materials in this study were based on PPS polymer - thus making it attractive for further end-of-life recycling.

The use of these advanced materials makes it possible to reduce weight, minimize emissions, and increase performance at the same time. The combination of design and functionality opens new possibilities for future developments in the field of motorsport and beyond. We look forward to continuing to develop innovative solutions based on thermoplastic composites together with our partners and customers.

At this year's CINTE Techtextil fair in Shanghai, DILO received the innovation award for its intensive needling technology “MicroPunch”. Recent developments in energy costs, particularly for electricity and gas, and given the increasing shortage of water resources, have led to a shift in thinking over the past few years. Together with economic efficiency, the evaluation of the environmental impact of production has become increasingly important.

For DILO, this meant focusing on needling technology for the fine and lightweight nonwoven sector over the last years. The individual elements of the intensive needling technology underwent a complete revision. It became clear that the high production rates could only be achieved using the two-dimensional kinematics of the needle beam of "HyperPunch" or "CycloPunch." The necessary high feed rates of around 50 mm per stroke, coupled with the highest stitching densities to achieve good abrasion resistance, led to a need of a significant increase of the number of needles and needle density—almost doubling from approximately 20,000 needles/meter/board to around 45,000 needles/meter/board. It also became obvious that ensuring a high efficiency rate in production also required the careful attention to a quick assembly of the needle boards with needle modules. A completely new approach was needed in the design and construction of the needle boards to enable rapid module exchange and achieve a very high mechanical precision.

Previously, needling technology was primarily used for a surface weight range starting at 100 g/m² up to several kilograms per m². The expansion into the range below 100 g/m², and potentially down to 30 g/m², now completes the applicability of needling technology. The intensive needling technology "MicroPunch" opens up an economical field for a wide variety of lightweight nonwoven fabrics that can be produced by a pure mechanical processes. The product characteristics achieved, such as abrasion resistance, are comparable to those of hydroentangeld nonwovens. Needled fabrics tend to have more volume and more stretch while offering similar tensile strength values. These special quality characteristics are particularly interesting for applications in hygiene, medicine, cosmetics, and for technical products.

With this new development, the energy required to produce lightweight nonwoven fabrics has been reduced up to approximately 75% compared to other bonding technologies of this segment.

OUTLOOK™ 2024 took place on 24-26 September 2024 in Rome, gathering a record of 549 delegates from 212 companies and 37 countries across the nonwovens personal care, hygiene & wipes products value chain.

OUTLOOK24 Conference
The conference, structured across five key sessions, featured 26 speakers covering a diverse array of critical topics impacting not only the nonwovens industry but society at large. These topics included cutting-edge innovations and eco-design, evolving market dynamics, navigating new EU regulations, the future of absorbent hygiene products, sustainability, retail strategies, and the challenges posed by China's influence on European commerce.

The event's first day opened with a compelling presentation by Joachim De Vos, Managing Partner and Founder of Living Tomorrow & TomorrowLab. As an expert in strategic innovation and scenario planning, he shared valuable insights on guiding organizations towards future-readiness. He highlighted the emerging success factors, emphasizing how Generative AI can be leveraged to develop scenarios for the nonwovens industry, serving as a powerful roadmap for future innovation.

On the second day, James Kynge, the Europe-China correspondent for the Financial Times, delivered a keynote address., "The China Challenge", emphasizing China's rapid rise as a global tech superpower, noting that the country produced more than half of the world's robots last year. He explored the far-reaching impact of this growth on European commerce, highlighting the challenges and outlined strategies for European companies.

The final day of OUTLOOK™ Jack Stratten, Director of Insider Trends. highlighted in his presentation, “The polarization of choice: How retailers and brands are responding to market and product saturation,” in an unprecedented market saturation that leaves 64% of consumers feeling overwhelmed by choices. He discussed how massive retail platforms drive product saturation, influencing both quality and variety and concluded that differentiation in this crowded landscape occurs by focusing on high-quality, curated selections.

OUTLOOK24 Exhibition
As part of its commitment to fostering connections within the industry, OUTLOOK™ 2024 continued its tradition of offering extensive networking opportunities to its delegates. This year’s event featured a tabletop exhibition, where 20 companies had the chance to showcase their expertise over the 3 days.

The next edition of OUTLOOK™ will take place from 23-25 September 2025, in Budapest, Hungary at the Marriott Hotel, Budapest.

International technology group ANDRITZ supplied and recently commissioned a tearing line at Sealy Australia’s mattress manufacturing plant in Brisbane. Versatile technology enables Sealy to recycle post-consumer and post-industrial textile waste in one line.

Sealy is a leading Australian manufacturer of high-quality mattresses, producing 1,000 mattresses per day at its Brisbane plant. To replace some of the virgin fiber feedstock with more sustainable recycled fibers, the company installed an ANDRITZ tearing line at the plant.

The ANDRITZ reXline tearing can process up to 1,200 kg/h of cotton denim waste and up to 800 kg/h of quilt waste. The 6-cylinder Exel module allows flexible switching between the two types of material. The combination of the reXline and the ANDRITZ airfelt line, which has been in operation at the Brisbane plant since 2008, enables Sealy to process large amounts of waste into new mattresses ready for sale around the world.

“With our new line, we are taking a significant step towards circularity by making new mattresses from textile waste that would otherwise be burnt or landfilled,” says Shaun Guest, Fiber Plant Factory Manager of Sealy Australia.”

Haelixa has partnered with Italian fashion brand OVS for the second consecutive year. This collaboration aims to mark and trace cotton grown in Italy, ensuring trust throughout the supply chain.

Haelixa has integrated its DNA markers into the existing operations for OVS's cotton. The cotton is grown in Italy and marked with the DNA markers at the gin, close to the farm. The fibers are tested during the entire manufacturing process, ensuring that the cotton used in this OVS collection is ethically and sustainably sourced. This partnership is a testament to their commitment to promoting responsible and transparent practices in the fashion industry, providing customers with the assurance of the cotton's origin.

Traceability has become crucial in the fashion industry, with consumers demanding more information about the products they purchase. By partnering with Haelixa, OVS continues to meet this demand and set a new standard for cotton in the industry. This alliance will benefit customers and the farmers in Italy, giving them fair recognition for their work.

Simone Colombo, Head of Corporate Sustainability, says, “In 2024, we have continued with Swiss DNA Traceability supplier Haelixa in marking and tracing our OVS Cotone Italiano for the second year. Our goal is to approach 5% of our cotton requirements from cultivation in Italy within a few years.”

The collaboration between Haelixa and OVS has boosted the transparency of their supply chain. With the help of traceability provided by Haelixa, OVS is working towards improving its products' social and environmental impacts. OVS is firmly committed to sustainable and ethical practices and aspires to enhance its operations yearly. The partnership with Haelixa is a testament to their dedication to improving traceability in the fashion industry.

INDA, the Association of the Nonwoven Fabrics Industry, announces the release of the International Fiber Journal’s (IFJ) special sustainability issue dedicated to nonwovens. This special edition, which was sponsored by INDA, is a key piece of the association’s 2024 strategic sustainability initiative, launched at the beginning of 2024 in response to feedback that sustainability remains one of the nonwovens industry’s highest priorities.

The IFJ special issue features exclusive content from industry leaders, including Kimberly-Clark Corporation, Glatfelter, Lenzing Fibers, NatureWorks LLC, Hollingsworth & Vose, MANN+HUMMEL, Nexus Circular, Henkel Corporation, and INDA. This edition explores key sustainability topics, structured around three core pillars vital to the industry’s future: Responsible Sourcing, Innovations in Sustainability, and End-of-Life Solutions. Featured topics include:

• Environmentally sustainable nonwoven materials
• Circularity in single-use plastics
• Potential of post-consumer recycled (PCR) materials in nonwovens
• Navigating regulatory challenges
• Advances in bio-based nonwovens
• The role of plastics and polymers in sustainability

“This special issue of the International Fiber Journal is a vital part of our multi-faceted sustainability initiative aimed at providing new and enhanced offerings to INDA members and the nonwovens industry. We are excited to see the industry come together to share insights on the sustainability challenges we face,” said Tony Fragnito, President of INDA.