Textination Newsline

Nature works often with fiber composites. The construction principles of nature require little material and energy and thus ensure the survival of animals and plant species. Examples include wood, plant stalks, chitinous shells, bones or tissues such as tendons and skin. Mussel shells or spider silk are also composite tissues. We can take advantage of these principles to design and manufacture bio-based, sustainable fiber reinforced composites, which are currently in high demand. Bio-based fiber reinforced composites consist of natural fibers or cellulose fibers embedded in a bio-based matrix. The bio-based components offer properties comparable to those of commonly used glass fiber composites. The German Institutes of Textile and Fiber Research (DITF), together with Arburg GmbH + Co KG, are developing an energy- and material-efficient 3D printing process for manufacturing of such lightweight bio-based fiber composites.

In fiber composites, which occur naturally, reinforcing fibers such as collagen or cellulose fibrils are embedded in a matrix of lignin, hemicellulose or collagen. The fiber strands align with the stress patterns. Tissues are formed mostly via solution-based physio-chemical processes that take place at ambient temperature. Similar to nature, new 3D printing processes with continuous fiber reinforcement also allow the deposition of fiber strands in the right place (topology optimization) and in the appropriate direction in accordance to the load. However, natural fibers such as cellulose fibers are sensitive to higher temperatures. Therefore, they cannot be processed in the commonly employed thermoplastic 3D printing process.

The result of the research work is 3D-printed fiber composite components consisting of cellulose continuous fibers embedded in a cellulose-based matrix. Newly developed 3D-printing process enables to manufacture the composites at ambient temperature. This means that - as in nature - the material and component can be produced simultaneously in a single operation at ambient temperature.

The cellulose fiber strand is first stabilized with a binder for processing in the printer. The specially designed print head transforms the binder into a matrix with which the cellulose continuous fibers are encased. Since the cellulose fibers and the matrix have similar chemical structures, the composite component is particularly stable. The mechanical properties, such as breaking strength, are exceptionally good. The solution-based and energy-efficient manufacturing method developed by the research team can also be used in other composite materials manufacturing processes. It is particularly suitable for processing temperature-sensitive materials that are in high demand, such as natural or cellulose fibers.

The " CellLoes-3D-Druck" research project is funded by the German Federal Ministry of Education and Research as part of the "Biologisierung der Technik" ideas competition.

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

• The “Bioconcept-Car” moves ahead

In automobile racing, lightweight bodies made from plastic and carbon fibers have been standard for many years because they enable drivers to reach the finish line more quickly. In the future, lightweight-construction solutions could help reduce the energy consumption and emissions of everyday vehicles. The catch is that the production of carbon fibers is not only expensive but also consumes considerable amounts of energy and petroleum. In collaboration with Porsche Motorsport and Four Motors, researchers at the Fraunhofer WKI have succeeded in replacing the carbon fibers in a car door with natural fibers. This is already being installed in small series at Porsche. The project team is now taking the next step: Together with HOBUM Oleochemicals, they want to maximize the proportion of renewable raw materials in the door and other body parts - using bio-based plastics and paints.

Carbon fibers reinforce plastics and therefore provide lightweight components with the necessary stability. Mass-produced natural fibers are not only more cost-effective but can also be produced in a considerably more sustainable manner. For the “Bioconcept-Car” pilot vehicle, researchers at the Fraunhofer WKI have developed body parts with 100 percent natural fibers as reinforcing components.

“We utilize natural fibers, such as those made from hemp, flax or jute. Whilst natural fibers exhibit lower stiffnesses and strengths compared to carbon fibers, the values achieved are nonetheless sufficient for many applications,” explained Ole Hansen, Project Manager at the Fraunhofer WKI. Due to their naturally grown structure, natural fibers dampen sound and vibrations more effectively. Their lesser tendency to splinter can help to reduce the risk of injury in the event of an accident. Furthermore, they do not cause skin irritation during processing.

The bio-based composites were successfully tested by the Four Motors racing team in the “Bioconcept-Car” on the racetrack under extreme conditions. Porsche has actually been using natural fiber-reinforced plastics in a small series of the Cayman GT4 Clubsport since 2019. During production, the researchers at the Fraunhofer WKI also conducted an initial ecological assessment based on material and energy data. “We were able to determine that the utilized natural-fiber fabric has a better environmental profile in its production, including the upstream chains, than the fabric made from carbon. Thermal recycling after the end of its service life should also be possible without any problems,” confirmed Ole Hansen.

In the next project phase of the "Bioconcept-Car", the researchers at the Fraunhofer WKI, in collaboration with the cooperation partners HOBUM Oleochemicals GmbH, Porsche Motorsport and Four Motors, will develop a vehicle door with a biogenic content of 85 percent in the overall composite consisting of fibers and resin. They intend to achieve this by, amongst other things, utilizing bio-based resin-hardener blends as well as bio-based paint systems. The practicality of the door - and possibly additional components - will again be tested by Four Motors on the racetrack. If the researchers are successful, it may be possible to transfer the acquired knowledge into series production at Porsche.

The German Federal Ministry of Food and Agriculture (BMEL) is funding the “Bioconcept-Car” project via the project-management agency Fachagentur Nachwachsende Rohstoffe e. V. (FNR).

Background
Sustainability through the utilization of renewable raw materials has formed the focus at the Fraunhofer WKI for more than 70 years. The institute, with locations in Braunschweig, Hanover and Wolfsburg, specializes in process engineering, natural-fiber composites, surface technology, wood and emission protection, quality assurance of wood products, material and product testing, recycling procedures and the utilization of organic building materials and wood in construction. Virtually all the procedures and materials resulting from the research activities are applied industrially.

 

• EU Project ALMA: Thinking Ahead to Electromobility

E-mobility and lightweight construction are two crucial building blocks of modern vehicle development to drive the energy transition. They are the focus of the ALMA project (Advanced Light Materials and Processes for the Eco-Design of Electric Vehicles). Nine European organizations are now working in the EU project to develop more energy-efficient and sustainable vehicles. Companies from research and industry are optimizing the efficiency and range of electric vehicles, among other things by reducing the weight of the overall vehicle. The Fraunhofer Institute for Industrial Mathematics ITWM is providing support with mathematical simulation expertise.

According to the low emissions mobility strategy, the European Union aims to have at least 30 million zero-emission vehicles on its roads by 2030. Measures to support jobs, growth, investment, and innovation are taken to tackle emissions from the transport sector. To make transport more climate-friendly, EU measures are being taken to promote jobs, investment and innovation. The European Commission's Horizon 2020 project ALMA represents one of these measures.

Offshore expansion and onshore repowering ensure growth

• Wind theme day with guided tour November 29th
• Lectures about material trends

With an investment volume of EUR 14 billion in the offshore sector alone, the European wind power industry has set a new record high in the first half of 2016. This figure and the view on the still open approval procedures in this segment as well as the onshore upcoming generational change from existing to modern facilities (repowering) show that the potential for growth is far from being exploited. Also in America as well as in Asia and the Pacific area a new emerging wind energy sector is also driving demand for fiber composites. The COMPOSITES EUROPE exhibition will be showing in Dusseldorf from November 29th to December 1st 2016 the latest trends and developments.

Theme Day: Wind meets Composites

Sector specialists such as Gaugler & Lutz, DD Compound, 3D Core, LAP and Power & Composite Technology will be showing current technologies at the COMPOSITES EUROPE, latest machine tools and manufacturing processes for the wind power industry. A highlight for all wind experts: On November 29th will be the theme day „Wind meets Composites" at the fair. This day will be sponsored by GUNNAR International, Weissenberger, Hexion and SAERTEX. Engineers of aerodynamics, materials science, lightweight construction and production technology will be able to exchange ideas with purchasers, exhibitors and wind energy specialists in the composite sector. The focus will be, among other things, on topics such as the influence of material selection, on design, weight, stability, processing or production processes as well as on certification, standardization and automation in rotor blade construction.
 
Guided theme walks

An optimal overview of exhibitors' offer on the topic wind is given to visitors by the opportunity of taking part at guided tours. Here they will specifically directed to various exhibitors from the wind segment, where they can get within 10 minutes information about their products and innovations. There will be two guided tours on November 29th: tour 1 will take place between 12:00 AM and 01.00 PM and tour 2 in the afternoon between 02:00 and 03:00 PM. Participating exhibitors include Airtech, GUNNAR International, Agilent Technologies, RH Cutting Technology, Granta Design, DD Compound and Armacell Benelux. The lecture is in English. Participation is free, but the number of participants is limited. Between the two round trips the participants have the opportunity to strengthen themselves at the "Wind Lunch" at the booth of Hexion (Hall 8a / booth G31).
Click here to register for the guided tours: www.composites-europe.com/guided-tours

 
Lectures at COMPOSITES Forum

On the afternoon of the wind theme day the COMPOSITES Forum provides an overview of the latest challenges in research, design, quality management, transportation and production of rotor blades. Starting at 3:00 PM Sinoi will discuss "Challenges and approaches in the construction of large onshore blades". Euros will hold a lecture on "Potentials and limits of composites in rotor blade construction" and the Fraunhofer Institute for Wind Energy and Energy System Technology will be presenting "Composite trends for wind turbine blades". Pontis Engineering also has a slot in the lecture program. From 04.00 PM it will be about "Challenges in design and manufacturing of large wind turbine blades". Access to the lecture area is free of charge for visitors. The COMPOSITES Forum is located in Hall 8, Booth B45.

Click here for a complete overview on the topic wind:
https://www.composites-europe.com/windenergie_527.html

About COMPOSITES EUROPE:
350 exhibitors from 30 countries will attend the COMPOSITES EUROPE, European Trade Fair and Forum for Composite Materials, Technology and Applications from November 29th to December 1st in Dusseldorf. The exhibition shows the entire range of fiber-reinforced plastics, from raw materials to manufacturing processes, to lightweight construction innovations in automotive engineering, aviation, boat building, wind power industry and construction. COMPOSITES EUROPE is organized by Reed Exhibitions in cooperation with the European sector association EuCIA and the economic association Composites Germany, a consortium of branch associations and clusters AVK, CCeV, CFK-Valley Stade and VDMA AG Hybrid Light Construction Technologies.