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29.03.2022

The man-made fibers industry at the turning point of time

"You don't tear down a house before the new one is ready for occupancy."

Textination talked to the Managing Director of the Industrievereinigung Chemiefaser e.V., Dr. Wilhelm Rauch, about his assessment of the turning point that the man-made fibers industry is currently facing. What are the risks and threats, and what needs to change in order to remain a competitive player on the global market.

"You don't tear down a house before the new one is ready for occupancy."

Textination talked to the Managing Director of the Industrievereinigung Chemiefaser e.V., Dr. Wilhelm Rauch, about his assessment of the turning point that the man-made fibers industry is currently facing. What are the risks and threats, and what needs to change in order to remain a competitive player on the global market.

US President Joe Biden has called his Russian counterpart Vladimir Putin a war criminal in connection with the invasion of Ukraine. The United Nations' highest court, the International Court of Justice in The Hague, has ordered Russia to immediately end its war against Ukraine. How do you personally assess Russia's behavior?
Dr. Rauch:
With family roots in the Rhineland, Central and East Germany, I grew up at a time when, as a result of the division of Europe, families were separated and people were ruthlessly shot in the middle of Germany who wanted to cross the inner-German demarcation line towards the West. Since 1989, the fall of the Iron Curtain has led us into a period that lasted more than 30 years and allowed us, at least in Europe, to experience an era of peaceful coexistence between the great power blocs, intensive trade relations and prosperous states.

It is more than shocking to see today how Russia is trying to turn back the wheel of history in Europe with a brutality that the youngest generation growing up in Europe has fortunately not had to experience so far, and it brings back the worst memories of the Cold War, which everyone hoped would never return. If today in Ukraine even facilities for the peaceful use of nuclear energy are fired upon, a dimension has been reached that one does not want to extrapolate any further. In addition to the unspeakable human suffering caused, which we can only begin to alleviate by accepting Ukrainian refugees, in the long term all trust in political promises is being gambled away, which, however, is essential both for peaceful coexistence and for economic cooperation. We are facing a reordering of the world in which supply relationships and dependencies with or on autocratic states must be evaluated much more sensitively for each individual case.

The economic consequences of the Russia-Ukraine conflict are becoming increasingly clear. The Association of German Chambers of Commerce and Industry (DIHK) is correcting its forecast for 2022, but does not yet see a recession. What are your expectations for the industry in the current fiscal year?
Dr. Rauch:
The man-made fibers industry has been severely affected by the SARS-CoV-2 pandemic in the last two years. Planned investments were first postponed and then finally abandoned. By the end of 2022, three man-made fibers producers will close their doors in Germany compared to 2019. The industry started the current year on a very hopeful note, although previous issues such as REACH and, above all, energy costs were already increasing in severity before the Russia-Ukraine war. The economic consequences of the war will have a negative impact both directly in the form of increased energy prices and indirectly through changes in international competitive conditions.

What do the war in Ukraine and the economic sanctions against Russia entail for the upstream supply chains of the manmade fiber industry?
Dr. Rauch:
The immediate upstream supply chains will not be affected much by this war at first. However, we must expect supply chains in other industries to be disrupted. If, for example, certain raw materials or products are no longer available, this can have a noticeable impact, starting with logistics (mobility) and extending to components in production technology facilities. An example of this is the availability of cable harnesses, which were previously produced in Ukraine and are indispensable in many electronic components for man-made fibers production.

What is the relevance of Ukraine and Russia as sales markets for IVC member companies?
Dr. Rauch:
If we take the last year before the outbreak of the SARS-CoV-2 pandemic as the reference year, exports to Ukraine and the Russian Federation account for around 1.6% of total exports of man-made fibers from Germany. On average, a loss of sales to these countries can be tolerated, although it should not be forgotten that in individual cases - depending on a company's product portfolio - the impact can be quite significant. Looking beyond the horizon, it is not only the direct exports of man-made fibers to the war region that are of significance, but also deliveries of products in which man-made fibers are processed. Here, there are now interrupted supply relationships that result in order losses for the man-made fibers industry.

Certain industries are particularly affected by the consequences - what does this mean for the man-made fibers sector as a supplier industry?
Dr. Rauch:
Wherever production is cut back along the downstream value chain in which man-made fibers were used, the effects will be noticeable with a temporal delay. This applies, for example, to deliveries to the automotive sector, where the production of new vehicles comes to a standstill due to a lack of components originating from Ukraine.

How are exploding energy prices and the gas embargo affecting man-made fibers producers in the DACH region?
Dr. Rauch:
Even before the Russia-Ukraine war, European energy costs were already at a level that hit our members hard. For example, European gas costs currently rose by ten times from approx. 12 EUR/MWh to approx. 120 EUR/MWh as a result of the war, while in the USA they "only" rose by two and a half times from approx. 8 EUR/MWh to approx. 18 EUR/MWh. The situation is similar for electricity prices in Germany in particular, which have also risen by a factor of 10 from an already high level. Further price increases in Europe cannot be ruled out, but are more likely. Against this background, moderate adjustments in man-made fibers prices are only a drop in the bucket. A market development with virtually exploding energy costs cannot be reliably depicted by any company, nor can it be priced in such a way as to cover costs.

As the industry association of the man-made fibers industry, what do you think of "Freeze for Peace" or a stop to all Russian gas and raw material imports?
Dr. Rauch:
In Germany in particular, we have deliberately made ourselves dependent on Russian gas, contrary to all international warnings, by defining it as necessary for the bridge technology of electricity generation that we will need after the shutdown of coal- and nuclear-based power plants, before the availability of a sufficient amount of so-called "green" energy is assured. Gas is also needed for heating purposes and as a raw material, so it takes on the function of an all-rounder.

A boycott-related import stop would not only have serious negative consequences for the man-made fibers sector, but for the entire German industry and the majority of private households. As I mentioned at the beginning, it is the order of the day to help alleviate human suffering by taking in Ukrainian refugees. But this is not the end of the crisis. It must be assumed that the war situation will not be resolved in the near future. However, in order to cope with a protracted crisis situation, our economic strength must be maintained in order to be able to cope with the challenges ahead. An import freeze would be counterproductive in this respect. Since, due to the latest developments, gas deliveries are now to be paid for in rubles, there is rather a risk that Russia, for its part, will stop gas deliveries. In their effect, the two scenarios do not differ. The only thing that is certain is the fact that the availability of Russian gas to Europe is no longer guaranteed. Ultimately, the Russian demand to switch payments to rubles, which is not only aimed at revaluing the ruble, makes it clear that Russia is not dependent on Europe as a buyer of its gas. This would mean that a "freeze for peace" would lead to nothing. In the Far East, there is already a potential buyer of Russian gas to obtain it cheaply and safely, and which is also a major competitor of the European chemical fiber industry: China.

Are agreements with the United Arab Emirates and Qatar a good substitute solution for gas and oil supplies from Russia?
Dr. Rauch:
It is not a question of evaluating a measure in the sense of good or bad, but of whether it appears suitable in this particular situation to reduce unilateral dependencies on an aggressor before sustainable solutions are available in sufficient quantity. In this respect, there should initially be no ideological barriers in the measures to be examined for feasibility. The agreements concluded with the United Arab Emirates and Qatar after certainly careful political scrutiny are individual decisions and represent only one piece in the mosaic among many.

Does the saying "First we had bad luck, then we were not lucky at all" apply to the current economic performance of the industry - or: how do you assess the influence of the Corona pandemic and the war situation in this respect?
Dr. Rauch:
Both the SARS-CoV-2 pandemic and the Russia-Ukraine war are events with a global character. While the first event affected all countries equally sooner or later, the impact of the Russia-Ukraine war must be assessed in a more differentiated manner. The consequences of the war primarily affect companies in Europe, and there in particular those countries which - as mentioned above - have placed themselves in unilateral dependencies like Germany. This does not apply to the man-made fibers industry in particular. Although there are many fellow sufferers in other industries, this does not improve the situation, of course.

What does the industry expect from the political leaders in Berlin and Brussels in the future?
Dr. Rauch:
The wish list can be fixed to a few core elements:
In the long term, we need a supply of energy and raw materials that is not based on the dependence of a few autocratic states. On the way there, against the backdrop of the Russia-Ukraine war, previous exit scenarios from coal and nuclear energy must be reconsidered without prejudice with regard to their timeline. Or to put it more concisely: You don't tear down a house before the new one is ready for occupancy.

But energies from renewable raw materials must also be offered at prices that allow global competitiveness. According to a study by DECHEMA and FutureCamp, the chemical industry has calculated a price of 4 ct/kWh (including all taxes and fees). We are miles away from this today.

The revision of REACH must not lead to further bureaucracy and requirements that tie up capacity in companies. What we need in Europe is not dotting the i on Maslow's hierarchy of needs, but to ensure that we do not slide down the levels step by step and that the i dot floats in the air without an "i".

European economic policy must focus on the international competitiveness of European industry. It is not sufficient to consider and regulate the European Union only from the point of view of the internal market. The planned carbon border mechanism is such an example. It is intended to impose customs duties on imports that carry a high CO2 burden. This may protect the domestic market, but it does nothing at all to help export-oriented European industry such as the man-made fibers sector on the international world market, because European production costs remain too high by global standards despite the carbon border taxes.

The European Commission must increasingly recognize the European industry and with it the man-made fibers industry as problem solvers. Man-made fibers are indispensable as products for the energy turnaround (rotor blades for wind turbines), lightweight construction in mobility (lightweight car bodies in composite systems), sustainable road construction (geotextiles to reinforce the road surface and increase its service life), reduction of steel-reinforced concrete and thus cement, sand and gravel (reinforcement with high-tensile man-made fibers) and medical products (medical masks, bandaging materials, stents).

In Europe, we again need more market economy and no small-scale regulations that are adapted again and again and proliferate into an impenetrable thicket.

With all the wishes to politicians mentioned above, let me finally mention the following with regard to the current situation: In 1961, after the Berlin Wall was built, Russian and American tanks faced each other at Checkpoint Charlie at a distance of less than 50 meters, ready to fire.

A year later, in October 1962, nuclear-equipped American and Russian naval units met head-on in the Cuban Missile Crisis. Both John F. Kennedy and Nikita S. Khrushchev - bitter rivals in the contest of political systems - were sensible enough at the time not to let the situation escalate.

At present, I wish our national, European and transatlantic politicians’ unconditional determination in the defense of our free democratic values, but I also appeal to all politicians worldwide to take to heart one of Albert Einstein's fundamental perceptions: "I don't know what weapons will be used in the Third World War. But I can tell you what they'll use in the Fourth - rocks!"

Source:

Textination

The Interview was conducted by Ines Chucholowius, CEO Textination GmbH

(c) Toray
23.11.2021

Toray Industries: A Concept to change Lives

Founded in January 1926, Tokyo-based Japanese chemical company Toray Industries, Inc. is known as the world's largest producer of PAN (polyacrylonitrile)-based carbon fibers. But its overall portfolio includes much more. Textination spoke with Koji Sasaki, General Manager of the Textile Division of Toray Industries, Inc. about innovative product solutions, new responsibilities and the special role of chemical companies in today's world.

Toray Industries is a Japanese company that - originating in 1926 as a producer of viscose yarns - is on the home stretch to its 100th birthday. Today, the Toray Group includes 102 Japanese companies and 180 overseas. They operate in 29 countries. What is the current significance of the fibers and textiles business unit for the success of your company?

Founded in January 1926, Tokyo-based Japanese chemical company Toray Industries, Inc. is known as the world's largest producer of PAN (polyacrylonitrile)-based carbon fibers. But its overall portfolio includes much more. Textination spoke with Koji Sasaki, General Manager of the Textile Division of Toray Industries, Inc. about innovative product solutions, new responsibilities and the special role of chemical companies in today's world.

Toray Industries is a Japanese company that - originating in 1926 as a producer of viscose yarns - is on the home stretch to its 100th birthday. Today, the Toray Group includes 102 Japanese companies and 180 overseas. They operate in 29 countries. What is the current significance of the fibers and textiles business unit for the success of your company?

The fibers’ and textiles’ business is both the starting point and the foundation of Toray's business development today. We started producing viscose yarns in 1926 and conducted our own research and development in nylon fibers as early as 1940. And since new materials usually require new processing methods, Toray also began investing in its own process technology at an early stage. On the one hand, we want to increase our sales, and on the other hand, we want to expand the application possibilities for our materials. For this reason, Toray also began to expand its business from pure fibers to textiles and even clothing. This allows us to better respond to our customers' needs while staying at the forefront of innovation.

Over the decades, Toray has accumulated a great deal of knowledge in polymer chemistry and organic synthesis chemistry - and this know-how is the foundation for almost all of our other business ventures. Today, we produce a wide range of advanced materials and high-value-added products in plastics, chemicals, foils, carbon fiber composites, electronics and information materials, pharmaceuticals, medicine and water treatment. However, fibers and textiles remain our most important business area, accounting for around 40% of the company's sales.

What understanding, what heritage is still important to you today? And how do you live out a corporate philosophy in the textile sector that you formulate as "Contributing to society through the creation of new value with innovative ideas, technologies and products"?

Toray has consistently developed new materials that the world has never seen before. We do this by focusing on our four core technologies: Polymer chemistry, organic synthetic chemistry, biotechnology and nanotechnology. We do this by focusing on our four core technologies: Polymer chemistry, organic synthetic chemistry, biotechnology and nanotechnology. For textiles, this means we use new polymer structures, spinning technologies and processing methods to develop yarns with unprecedented properties. We always focus on the needs and problems of the market and our customers.

This approach enables us to integrate textiles with new functions into our everyday lives that natural fibers and materials cannot accomplish. For example, we offer sportswear and underwear that absorb water excellently and dry very quickly, or rainwear and outdoor clothing with excellent water-repellent properties that feature a less bulky inner lining. Other examples include antibacterial underwear, uniforms, or inner linings that provide a hygienic environment and reduce the growth of odor-causing bacteria. People enjoy the convenience of these innovative textiles every day, and we hope to contribute to their daily comfort and improve their lives in some way.

In 2015, the United Nations adopted 17 sustainable development goals – simply known as the 2030 Agenda, which came into force on January 01, 2016. Countries were given 15 years to achieve them by 2030. In your company, there is a TORAY VISION 2030 and a TORAY SUSTAINABILITY VISION. How do you apply these principles and goals to the textile business? What role does sustainability play for this business area?

Sustainability is one of the most important issues facing the world today - not only in the textile sector, but in all industries. We in the Toray Group are convinced that we can contribute to solving various problems in this regard with our advanced materials. At the same time, the trend towards sustainability offers interesting new business approaches. In our sustainability vision, we have set four goals that the world should achieve by 2050. And we have defined which problems need to be addressed to achieve this.

We must:

  1. accelerate measures to combat climate change,
  2. implement sustainable, recycling-oriented solutions in the use of resources and in production,
  3. provide clean water and air, and
  4. contribute to better healthcare and hygiene for people around the world.

We will drive this agenda forward by promoting and expanding the use of materials that respond to environmental issues. In the textile sector, for example, we offer warming and cooling textiles – by eliminating the need for air conditioning or heating in certain situations, they can help reduce energy costs. We also produce environmentally friendly textiles that do not contain certain harmful substances such as fluorine, as well as textiles made from biomass, which use plant-based fibers instead of conventional petrochemical materials. Our product range also includes recycled materials that reduce waste and promote effective use of resources.

The TORAY VISION 2030, on the other hand, is our medium-term strategic plan and looks at the issue of sustainability from a different angle: Toray has defined the path to sustainable and healthy corporate growth in it. In this plan, we are focusing on two major growth areas: Our Green Innovation Business, which aims to solve environmental, resource and energy problems, and the Life Innovation Business, which focuses on improving medical care, public health, personal safety and ultimately a longer expectancy of life.

Innovation by Chemistry is the claim of the Toray Group. In a world where REACH and Fridays for Future severely restrict the scope of the chemical industry, the question arises as to what position chemistry can have in the textile industry. How do chemistry, innovation and sustainability fit together here?

The chemical industry is at a turning point today. The benefits that this industry can bring to civilization are still enormous, but at the same time, disadvantages such as the waste of resources and the negative impact on the environment and ecosystems are becoming increasingly apparent. In the future, the chemical industry will have to work much more towards sustainability - there is no way around it.

As far as textiles are concerned, we believe there are several ways to make synthetic materials more sustainable in the future. One of these, as I said, is materials made from plants instead of petrochemical raw materials. Another is to reduce the amount of raw materials used in production in the first place – this can be achieved, for example, by collecting and recycling waste materials from production or sales. Biodegradable materials that reduce the impact of waste products on the environment are another option worth pursuing, as is the reduction of environmentally harmful substances used in the production process. We are already looking at all of these possibilities in Toray's synthetic textiles business. At the same time, by the way, we make sure to save energy in our own production and minimize the impact on the environment.

Toray's fibers & textiles segment focuses on synthetic fibers such as nylon, polyester and acrylic, as well as other functional fibers. In recent years, there has been a clear trend on the market towards cellulosic fibers, which are also being traded as alternatives to synthetic products. How do you see this development – on the one hand for the Toray company, and on the other hand under the aspect of sustainability, which the cellulosic competitors claim for themselves with the renewable raw material base?

Natural fibers, including cellulose fibers and wool, are environmentally friendly in that they can be easily recycled and are rapidly biodegradable after disposal. However, to truly assess their environmental impact, a number of other factors must also be considered: Primarily, there is the issue of durability: precisely because natural fibers are natural, it is difficult to respond to a rapid increase in demand, and quality is not always stable due to weather and other factors.

Climatic changes such as extreme heat, drought, wind, floods and damages from freezing can affect the quantity and quality of the production of natural fibers, so that the supply is not always secured. In order to increase production, not only does land have to be cleared, but also large amounts of water and pesticides have to be used to cultivate it – all of which is harmful to the environment.

Synthetic fibers, on the other hand, are industrial products manufactured in controlled factory environments. This makes it easier to manage fluctuations in production volume and ensure consistent quality. In addition, certain functional properties such as resilience, water absorption, quick drying and antibacterial properties can be embedded into the material, which can result in textiles lasting longer in use.

So synthetic fibers and natural fibers, including cellulose fibers, have their own advantages and disadvantages – there is no panacea here, at least not at the moment. We believe: It is important to ensure that there are options that match the consumer's awareness and lifestyle. This includes comfort in everyday life and sustainability at the same time.

To what extent has the demand for recycled products increased? Under the brand name &+™, Toray offers a fiber made from recycled PET bottles. Especially with the "raw material base: PET bottles", problems can occur with the whiteness of the fiber. What distinguishes your process from that of other companies and to what extent can you compete with new fibers in terms of quality?

During the production of the "&+" fiber, the collected PET bottles are freed from all foreign substances using special washing and filtering processes. These processes have not only allowed us to solve the problem of fiber whiteness – by using filtered, high-purity recycled polyester chips, we can also produce very fine fibers and fibers with unique cross sections. Our proven process technologies can also be used to incorporate specific textures and functions of Toray into the fiber. In addition, "&+" contains a special substance in the polyester that allows the material to be traced back to the recycled PET bottle fibers used in it.

We believe that this combination of aesthetics, sustainability and functionality makes the recycled polyester fiber "&+" more competitive than those of other companies. And indeed, we have noticed that the number of requests is steadily increasing as companies develop a greater awareness of sustainability as early as the product planning stage.

How is innovation management practiced in Toray's textile division, and which developments that Toray has worked on recently are you particularly proud of?

The textile division consists of three sub-divisions focusing on the development and sale of fashion textiles (WOMEN'S & MEN'S WEAR FABRICS DEPT.), sports and outdoor textiles (SPORTS WEAR & CLOTHING MATERIALS FABRICS DEPT.) and, specifically for Japan, textiles for uniforms used in schools, businesses and the public sector (UNIFORM & ADVANCED TEXTILES DEPT.).

In the past, each division developed its own materials for their respective markets and customers. However, in 2021, we established a collaborative space to increase synergy and share information about textiles developed in different areas with the entire department. In this way, salespeople can also offer their customers materials developed in other departments and get ideas for developing new textiles themselves.

I believe that the new structure will also help us to respond better to changes in the market. We see, for example, that the boundaries between workwear and outdoor are blurring – brands like Engelbert Strauss are a good example of this trend. Another development that we believe will accelerate after the Corona pandemic is the focus on green technologies and materials. This applies to all textile sectors, and we need to work more closely together to be at the forefront of this.

How important are bio-based polyesters in your research projects? How do you assess the future importance of such alternatives?

I believe that these materials will play a major role in the coming years. Polyester is made from purified terephthalic acid (PTA), which again consists of paraxylene (PX) and ethylene glycol (EG). In a first step, we already offer a material called ECODEAR™, which uses sugar cane molasses waste as a raw material for EG production.

About 30% of this at least partially bio polyester fiber is therefore biologically produced, and the material is used on a large scale for sportswear and uniforms. In the next step, we are working on the development of a fully bio-based polyester fiber in which the PTA component is also obtained from biomass raw materials, such as the inedible parts of sugar cane and wood waste.

Already in 2011, we succeeded in producing a prototype of such a polyester fiber made entirely from biomass. However, the expansion of production at the PX manufacturer we are working with has proven to be challenging. Currently, we are only producing small sample quantities, but we hope to start mass production in the 2020s.

Originally starting with yarn, now a leading global producer of synthetic fibers for decades, you also work to the ready-made product. The range extends from protective clothing against dust and infections to smart textiles and functional textiles that record biometric data. What are you planning in these segments?

In the field of protective clothing, our LIVMOA™ brand is our flagship material. It combines high breathability to reduce moisture inside the garment with blocking properties that keep dust and other particles out. The textile is suitable for a wide range of work environments, including those with high dust or grease levels and even cleanrooms. LIVMOA™ 5000, a high quality, also demonstrates antiviral properties and helps to ease the burden on medical personnel. The material forms an effective barrier against bacteria and viruses and is resistant to hygroscopic pressure. Due to its high breathability, it also offers high wearing comfort.

Our smart textile is called hitoe™. This highly conductive fabric embeds a conductive polymer – a polymer compound that allows electricity to pass through - into the nanofiber fabric. hitoe™ is a high-performance material for detecting biosignals, weak electrical signals that we unconsciously emit from our bodies.

In Japan, Toray has developed products for electrocardiographic measurements (ECGs) that meet the safety and effectiveness standards of medical devices. And in 2016, we submitted an application to the Japanese medical administrative authorities to register a hitoe™ device as a general medical device – this registration process is now complete. Overall, we expect the healthcare sector, particularly medical and nursing applications, to grow – not least due to increasing infectious diseases and growing health awareness among the elderly population. We will therefore continue to develop and sell new products for this market.

In 1885, Joseph Wilson Swan introduced the term "artifical silk" for the nitrate cellulose filaments he artificially produced. Later, copper, viscose and acetate filament yarns spun on the basis of cellulose were also referred to as artifical silk. Toray has developed a new innovative spinning technology called NANODESIGN™, which enables nano-level control of the fineness and shape of synthetic fibers. This is expected to create functions, aesthetics and textures that have not existed before. For which applications do you intend to use these products?

In NANODESIGN™ technology, the polymer is split into a number of microscopic streams, which are then recombined in a specific pattern to form a new fiber. By controlling the polymer flow with extreme precision, the fineness and cross-sectional shape of the fiber can be determined much more accurately than was previously possible with conventional microfiber and nanofiber spinning technologies. In addition, this technology enables the combination of three or more polymer types with different properties in one fiber – conventional technologies only manage two polymer types. This technology therefore enables Toray to specify a wide range of textures and functions in the production of synthetic fibers that were not possible with conventional synthetic fibers – and even to outperform the texture and feel of natural fibers. Kinari, our artificial silk developed with NANODESIGN technology, is a prime example here, but the technology holds many more possibilities – especially with regard to our sustainability goals.

What has the past period of the pandemic meant for Toray's textile business so far? To what extent has it been a burden, but in which areas has it also been a driver of innovation? What do you expect of the next 12 months?

The Corona catastrophe had a dramatic impact on the company's results: The Corona catastrophe had a dramatic impact on the company's results: In the financial year 2020, Toray's total sales fell by about 10% to 188.36 billion yen (about 1.44 billion euros) and operating profit by about 28% to 90.3 billion yen (about 690 million euros). The impact on the fiber and textile business was also significant, with sales decreasing by around 13% to 719.2 billion yen (approx. 5.49 billion euros) and operating profit by around 39% to 36.6 billion yen (approx. 280 million euros).

In the financial year 2021, however, the outlook for the fibers and textiles sector is significantly better: So far, the segment has exceeded its goals overall, even if there are fluctuations in the individual areas and applications. In the period from April to June, we even returned to the level of 2019. This is partly due to the recovering sports and outdoor sector. The fashion apparel market, on the other hand, remains challenging due to changing lifestyles that have brought lock-downs and home-office. We believe that a full recovery in business will not occur until the travel and leisure sector returns to pre-Corona levels.

Another side effect of the pandemic that we feel very strongly, is the growing concern about environmental issues and climate change. As a result, the demand for sustainable materials has also increased in the apparel segment. In the future, sustainability will be mandatory for the development and marketing of new textiles in all market segments. Then again, there will always be the question of how sustainable a product really is, and data and traceability will become increasingly important. In the coming years, the textile division will keep a close eye on these developments and develop materials that meet customers' needs.

About the person:
Koji Sasaki joined Toray in 1987. In his more than 30 years with the company, he has held various positions, including a four-year position as Managing Director of Toray International Europe GmbH in Frankfurt from 2016 to 2020. Since 2020, Koji Sasaki has been responsible for Toray's textile division and serves as acting chairman of Toray Textiles Europe Ltd. In these roles, he supervises the company's development, sales and marketing activities in the apparel segment, including fashion, sports and work or school uniforms.

The interview was conducted by Ines Chucholowius, Managing partner Textination GmbH

Photo: pixabay
06.07.2021

»Waste4Future«: Today's Waste becomes Tomorrow's Resource

Fraunhofer Institutes pave new ways in plastics recycling

A sustainable society, the renunciation of fossil raw materials, climate-neutral processes - also the chemical industry has committed itself to these goals. For the industry, this means a huge challenge within the next years and decades. This structural change can succeed if all activities - from the raw material base to material flows and process technology to the end of a product's life cycle - are geared towards the goal of sustainable value creation. The key to this is innovation.

Fraunhofer Institutes pave new ways in plastics recycling

A sustainable society, the renunciation of fossil raw materials, climate-neutral processes - also the chemical industry has committed itself to these goals. For the industry, this means a huge challenge within the next years and decades. This structural change can succeed if all activities - from the raw material base to material flows and process technology to the end of a product's life cycle - are geared towards the goal of sustainable value creation. The key to this is innovation.

Plastics such as polyethylene (PE), polypropylene (PP) or polystyrene (PS), which are currently produced almost entirely from fossil raw materials, are fundamental to many everyday products and modern technologies. The carbon contained in plastics is an important resource for the chemical industry. If it is possible to better identify such carbon-containing components in waste, to recycle them more effectively, and to use them again to produce high-quality raw materials for industry, the carbon can be kept in the cycle. This not only reduces the need for fossil resources, but also pollution with CO2 emissions and plastic waste. At the same time, the security of supply for industry is improved because an additional source of carbon is tapped.

The "Waste4Future" lighthouse project therefore aims to create new opportunities for recycling plastics in order to make the carbon they contain available as a "green" resource for the chemical industry. "We are thus paving the way for a carbon circular economy in which valuable new base molecules are obtained from plastic waste and emissions are largely avoided: Today's waste becomes tomorrow's resource," says Dr.-Ing. Sylvia Schattauer, deputy director of the Fraunhofer Institute for Microstructure of Materials and Systems IMWS, which is heading the project. "With the know-how of the participating institutes, we want to show how the comprehensive recycling of waste containing plastics without loss of carbon is possible and ultimately economical through interlocking, networked processes." The outcome of the project, which will run until the end of 2023, is expected to be innovative recycling technologies for complex waste that can be used to obtain high-quality recyclates.

Specifically, the development of a holistic, entropy-based assessment model is planned (entropy = measure of the disorder of a system), which will reorganize the recycling chain from process-guided to material-guided. A new type of sorting identifies which materials and in particular which plastic fractions are contained in the waste. Based on this analysis, the total stream is separated and a targeted decision is then made for the resulting sub-streams as to which recycling route is the most technically, ecologically and economically sensible for this specific waste quantity. What cannot be further utilized by means of mechanical recycling is available for chemical recycling, always with the aim of preserving the maximum possible amount of carbon compounds. Burning waste containing plastics at the end of the chain is thus eliminated.

The challenges for research and development are considerable. These include the complex evaluation of both input materials and recyclates according to ecological, economic and technical criteria. Mechanical recycling must be optimized, and processes and technologies must be established for the key points in the material utilization of plastic fractions. In addition, suitable sensor technology must be developed that can reliably identify materials in the sorting system. Machine learning methods will also be used, and the aim is to link them to a digital twin that represents the properties of the processed materials.

Another goal of the project is the automated optimization of the formulation development of recyclates from different material streams. Last but not least, an economic evaluation of the new recycling process chain will be carried out, for example with regard to the effects of rising prices for CO2 certificates or new regulatory requirements. The project consortium will also conduct comprehensive life cycle analysis (LCA) studies for the individual recycling technologies to identify potential environmental risks and opportunities.

For the development of the corresponding solutions, the participating institutes are in close exchange with companies from the chemical industry and plastics processing, waste management, recycling plant construction and recycling plant operation, in order to consider the needs of industry in a targeted manner and thus increase the chances of rapid application of the results achieved.

The following Institutes are involved in the Fraunhofer lighthouse project "Waste4Future":

  • Fraunhofer Institute for Microstructure of Materials and Systems IMWS (lead)
  • Fraunhofer Institute for Non-Destructive Testing IZFP
  • Fraunhofer Institute for Materials Recycling and Resource Strategy IWKS
  • Fraunhofer Institute of Optronics, System Technologies and Image Exploitation IOSB
  • Fraunhofer Institute for High Frequency Physics and Radar Techniques FHR
  • Fraunhofer Institute for Structural Durability and System Reliability LBF
  • Fraunhofer Institute for Process Engineering and Packaging IVV
Grafic: Gerd Altmann, pixabay
19.01.2021

IW Association Survey: Textile industry and Banks particularly pessimistic

Things can only get better

At the turn of the year, the German Economic Institute (IW) traditionally asked German associations about their economic expectations for the coming year. Most industries are reporting incisive difficulties and are hoping for an improvement in 2021. However, many companies will cut jobs - especially where there were have been already problems before the pandemic started.

Things can only get better

At the turn of the year, the German Economic Institute (IW) traditionally asked German associations about their economic expectations for the coming year. Most industries are reporting incisive difficulties and are hoping for an improvement in 2021. However, many companies will cut jobs - especially where there were have been already problems before the pandemic started.

At the end of the year, the German economy looked back on one of the most difficult years in recent history. The Covid-19 pandemic already hit many companies in spring 2020, and the current winter and the second wave have put struggling sectors under further strain. It is still not possible to predict when the situation will noticeably improve. This is also reflected in the traditional IW association survey: 34 of 43 associations interrogated reported a worse economic situation than the year ago. Those reporting an improved or unchanged position were often already in a difficult economic situation in the previous year. These include, the automotive and chemical industries respectively.

Four out of five companies in Germany at the turn of 2020/2021 judge the mood even worse than a year before. This crisis-prone initial position partly explains in general optimistic business expectations for 2021. According to the IW’s association survey, higher economic activity is expected in 26 of 43 sectors. By contrast, 13 associations expect a decrease in production in 2021. While there is a moderate recovery in investments overall, employment is expected to decline further in 23 sectors.

Looking ahead to 2021, the IW Association Survey is dominated by confidence. This is not surprising understanding this confidence as an improvement on the crisis year 2020. The expected increases can be explained having the massive drop in view as well as a poor starting point in 2020. For a number of companies and entire industries, this hopeful outlook for 2021 does not necessarily mean a return to pre-crisis production levels. The IW business survey with more than 2,200 companies conducted in November 2020 consistently shows, that around half of the companies surveyed still expect shortfalls in production by 2022 compared to the pre-crisis level (IW Research Group Macroeconomic Analysis and Business Cycle, 2020).

Textile industry and banks particularly pessimistic
After all, most associations are confident with a view to 2021, expecting their situation to improve - although the pre-crisis level is not yet in sight for many sectors. 26 associations are planning increased production for the coming year. 13 associations - including shipbuilding and marine technology, textile and fashion associations, and the food industry - predict lower production. Banks and construction companies also have subdued expectations for 2021, although the pandemic has had relatively little impact on these industries up to now.

Less jobs in the automotive industry
The outlook for the employment market is less optimistic: Only five of 43 associations surveyed expect their member companies to employ more people in the coming year. This includes the construction industry and handicraft businesses, which already suffered from a shortage of skilled workers before the crisis. 23 associations expect a reduction in employment, especially for industrial site. Particularly pessimistic are associations with member companies facing structural adjustment burdens in addition to the corona pandemic – like in the area of finance:

In the previous years, fewer and fewer customers used branches of banks. The automotive industry is also planning with fewer employees: In addition to the weak global economy, are strict exhaust emission limits and quotas for electric mobility put companies under pressure. Exports, which are extremely important for the industry, decreased by a similar amount.

The few industry associations whose members - on average across all enterprises and subsectors - are in the same or better position than at the previous turn of the year, are often sectors that were already in a difficult economic situation at the turn of 2019/2020. The automotive industry, segments of the metal and electrical industry as well as the chemical industry point to this. The Covid-19 crisis already records a negative history for parts of the industry. 2019 the downturn in business was partly the result of a cyclical normalization after a phase of high capacity utilization. Above all, protectionism and geopolitical uncertainties weighed on global investment activity, and hit the German industry, which is heavily involved in the international capital goods business. Technological challenges - due to digitization and climate change for example - also created adjustment burdens.

Source:

German Economic Institute, Prof. Michael Grömling Head of the Macroeconomic Analysis and Business Cycle Research Group

02.01.2018

THAILAND'S TEXTILE INDUSTRY ON NEW PATHS

  • Good chances for synthetic fibers and functional textiles

Bangkok (GTAI) - Thailand's textile industry is in transition and is increasingly positioning itself in new markets with higher added value. Synthetic fibers became an important foothold on the basis of innovative raw materials, while functional textiles are grateful to customers in a dozen sectors. In addition, there is the traditional silk craft, which can be marketed by international design and attractive fashion shows - and this at top prices.

  • Good chances for synthetic fibers and functional textiles

Bangkok (GTAI) - Thailand's textile industry is in transition and is increasingly positioning itself in new markets with higher added value. Synthetic fibers became an important foothold on the basis of innovative raw materials, while functional textiles are grateful to customers in a dozen sectors. In addition, there is the traditional silk craft, which can be marketed by international design and attractive fashion shows - and this at top prices.

The Thai textile industry is changing. As a part of the long-term national development strategy “Thailand 4.0” , new technologies are designed to help innovative products breakthrough in key emerging markets, backed by concerted efforts in design, fashion and marketing. The industrial foundation ensures the availability of a complete value chain from fiber production, yarn spinning, fabric weaving and processing to the production of clothing.
The long-term strategy has been outlined by the Thailand Textile Institute (THTI) in its "Thailand Textile and Fashion Industries Development Strategy 2015-2030". Three phases are planned from the regional center for textile and fashion retail, to the development of creative products for international brands, and finally the breakthrough as the global market leader in fashion design, including Thai components. The concrete catalog of measures includes an industrial fashion zone, a pilot fiber plant, a development center for yarn, fabrics and fashion products as well as a regional fashion academy.

Broad spectrum for innovations
A diversified petrochemical industry with high-quality downstream products provides a rich foundation for a wide variety of synthetic fibers. The main products are polyester, nylon, rayon and acrylic polymers. The range of applications is quite broad, including apparel, medical technique, hygiene and automotive manufacturing. For polyester, Thailand ranks ninth in the world with an annual production of 621,000 tons, the larger producers include Indorama Polyester, Teijin Polyester or Thai Toray.

Increased research and development efforts with both artificial and natural textile fibers are paving the way for functional textiles. There are a dozen applications in this broad future market: Agrotex, Mobiltex, Medtex, Hometex, Oekotex, Packtex, Buildtex, Clothtex, Indutex, Geotex, Protex and Sportex. The leaders in this branch are companies such as Asahi Kasei, Perma, Saha Seiren, PJ Garment or TP Corporation. Thailand also wants to play an active role in shaping the future market of "smart fabrics" - such as fabrics with UV protection or antibacterial and fire-resistant properties.

Renaissance of the silk
On elegant paths also the traditional over generations grown art of silk crafts is moving. Thanks to the rich raw material base, the kingdom is considered to be the world's fourth largest silk producer. In the preference of visitors from abroad, silk products are at the eighth place in the souvenir statistics 2015 with USD 149 mio.
The origins of silk were characterized by the craftsmanship weaving with regional origin characteristics such as at the Lumphun Broocade Thai Silk, the Phu Thai Praewa Silk or the Surin Hole Silk. The change to innovative products took place with the growing demands of customers. New technologies produced goods of higher value, which were also became promoted with new stronger marketing ideas.

Jim Thompson and Passaya are considered two major pioneers of world-class luxury silk brands. Jim Thompson generates USD 72 mio thanks to modern design and premium products. Passaya won international awards for outstanding innovations in design as well as in the production process. Public support has been provided by promotional events such as "Proud Pastra", which recently completed USD 1.5 mio  in trade surplus. The Ministry of Commerce also intends to establish a silk center in the northeastern Korat under the state-sponsored so-called OTOP scheme (One Tambon One Product).

The entire industry has currently  4,700 textile and garment manufacturers with over 500,000 workers, including 730 textile companies for technical textiles. The export value amounted to USD 6.45 billion in 2016, which represented about 3 percent of total exports. The national retail sector recorded steady growth rates averaging 3.5 percent per year over the period 2011-2016.

In addition to production, Thailand also tries to profile itself as a fashion hub for regional and international fashion shows. The most important events are the "Bangkok International Couture Fashion Week", "Elle Bangkok Fashion Week" and the "Bangkok International Fashion Fair". The first national designer brands have already made their debuts on the catwalk, such as Sretsis, Naraya, Dry Clean Only or Disaya. Sretsis, founded by three sisters, became successfully supported by some big names such as Beyoncé, Paris Hilton, January Jones and Zooey Deschanel.

More information:
Thailand
Source:

Waldemar Duscha, www.gtai.de

ISPO MUNICH 2017 © Messe München GmbH
23.08.2016

ISPO TEXTRENDS: TEXTILE TRENDS FOR FALL/WINTER 2018/2019

  • Trend preview for designers and product developers
  • Registration for ISPO TEXTRENDS 2017 available now
Together with trend experts, ISPO monitors influences, themes and colors that will shape fabric innovations for Fall/Winter 2018/2019. The textile trends are developed on the basis of these findings. They steer the work of designers and product developers and provide comprehensive predictions for future trend developments. Three megatrends focus on new market segments, the latest in functionality and the subject of sustainability. Companies wishing to showcase their products at ISPO TEXTRENDS can register now at www.textrends.ispo.com
 
ISPO is a renowned network for innovations. In combination with ISPO TEXTRENDS, it provides a platform for innovative fabrics and components in the textile sector.
  • Trend preview for designers and product developers
  • Registration for ISPO TEXTRENDS 2017 available now
Together with trend experts, ISPO monitors influences, themes and colors that will shape fabric innovations for Fall/Winter 2018/2019. The textile trends are developed on the basis of these findings. They steer the work of designers and product developers and provide comprehensive predictions for future trend developments. Three megatrends focus on new market segments, the latest in functionality and the subject of sustainability. Companies wishing to showcase their products at ISPO TEXTRENDS can register now at www.textrends.ispo.com
 
ISPO is a renowned network for innovations. In combination with ISPO TEXTRENDS, it provides a platform for innovative fabrics and components in the textile sector. Just recently the summer event was successfully launched for the first time at ISPO SHANGHAI. The well-established ISPO TEXTRENDS winter event will follow at ISPO MUNICH from February 5–8, 2017. Companies wishing to showcase their products at ISPO TEXTRENDS can register now at www.textrends.ispo.com. Which products can be entered in the race? Do they meet the expectations of the judging panel? The textile trends provide initial pointers and act as a guideline for participants when making their application. The textile trends consider various factors, from consumer behavior to the global economic situation. They also incorporate the influences of film, music and art on the industry and your products. The result is three megatrends, upcoming color trends and five detailed textile trends. As part of this, ISPO provides an exclusive initial glimpse of the sportswear market for Fall/Winter 2018/2019.
 
A quick look at textile trends for Fall/Winter 2018/2019
 
Megatrends – Opportunity Knocks, Perpetual Emotion, Infinite Act
The three megatrends will influence the textiles of Fall/Winter 2018/2019, crossing over into the sports market:
 
Opportunity Knocks calls for a focus on new market opportunities. The outdoor and activewear sector is no longer solely confined to a niche market. It is an opportunity to successfully expand product ranges.
 
With the Perpetual Emotion trend, positivity and confidence take a stand against the ever-increasing doom and gloom in the world. This trend is spearheaded by the desire to explore boundaries and provide the ultimate functionality without compromising style. Consumers expect the latest in functionality, enhanced comfort and a feeling like no other they’ve experienced when they wear the garment.
 
Infinite Act focuses on the message of sustainability combined with a strong corporate responsibility both to the environment and the workforce. Nanotechnology and biomimicry continue to make a mark, while the chemical industry and manufacturers of functional fabrics focus on their environmentally-friendly approach.
 
Color spectrum for Fall/Winter 2017/2018
 
The colors for the Fall/Winter season 2018/2019 are forward-looking, optimistic and focused. This season the active color spectrum is shifting to a slightly more powdery look compared to the traditionally bright best-selling tones. Deep reds and dark berry tones compliment envisaged shades of green and orange, presenting a warm but invigorating color spectrum inspired by nature.
 
Textile trends: Sensory, Allegiance, Myriad, Paragon, Transmutation
Five textile trends reflect numerous influences from consumer behavior to the global economic Situation.
 
Trend 1 – Sensory. This trend is about enhancing performance through fit, touch and visual appeal. The functionality on offer is manifested in fabrics, finishes, trims and accessories. This covers featherlight base layers to super soft insulation and multi-functional outer shells. Sensory pushes the boundaries of technology and textile manufacturing. 
 
Trend 2 – Allegiance. This trend teams the benefits of natural fibers with the guaranteed performance of advanced synthetic fabrics. The result is an increase in hybrid blends. From manufacturers of natural and synthetic yarn to textile suppliers and finishing producers, everyone is striving to deliver more environmentally sustainable products and manufacturing processes. This also influences the appearance. 
 
Trend 3 – Myriad. This trend is aimed at incredibly lightweight products crammed full of multi-functionality, enabling popular basics to be spruced up into new generation must haves. The developments in this section give rise to highly intelligent products that create new agility and improved functionality for the consumer. 
 
Trend 4 – Paragon. Paragon is geared toward everyone who strives to be the best in winter sports – the fabrics, trims and accessories make for a winning performance. Protective aspects also feature in this trend, from core stability and reflective elements to tear resistance and shock absorption. 
 
Trend 5 – Transmutation. This trend brings about fabrics and trims that adapt to different situations, especially through prints and yarn combinations inspired by metamorphism. Visually and structurally stimulating, products in this sector are screaming for attention in a whole host of scenarios, ranging from high-level performance and fun with a hint of glamour. 
 
Companies wishing to showcase their products at ISPO TEXTRENDS can register now at www.textrends.ispo.com . The application deadline is Sunday, October 30, 2016. An international expert judging panel will then assess all of the submissions. The selected materials will be exhibited at ISPO MUNICH 2017 in Hall C2.
 
The latest ISPO TEXTRENDS app reveals the best fabrics and components for making sportswear—get your copy from the ISPO SHOP.
 
More information on ISPO TEXTRENDS is available at www.textrends.ispo.com and on Facebook: www.facebook.com/ispomunich
 
More information on textile trends is available on request from: stephanie.ledru@pascher-heinz.com