From the Sector

Rester Oy, which is developing the plant in Paimio, recycles companies' end-of-life textiles, and Lounais-Suomen Jätehuolto Oy (LSJH), which will hire a production area at the same facility, processes households' end-of-life textiles. The plant will process 12,000 tonnes of end-of-life textiles every year, which represents about 10% of Finland’s textile waste.

The textile industry’s end-of-life textile problem is intolerable. Natural resources are increasingly used to manufacture products, but these materials are lost at the end of their life cycle. About 100 million kilograms of textile waste are generated annually in Finland alone. Reusing this material could reduce the textile industry’s carbon footprint and significantly reduce the use of natural resources.

Rester Oy and LSJH will drive the textile sector towards a circular economy and begin processing textile waste as an industrial raw material. The Nordic countries’ first industrial end-of-textile refinement plant will open in Paimio in 2021. The 3,000-square-metre plant is being developed by Rester Oy, which recycles companies' end-of-life textiles and industrial waste materials. LSJH, which processes households’ end-of-life textiles on its production line, will hire part of the plant.

Outi Luukko, Rester Oy’s board chair, says, “The processing plant will begin a new era of textile circular economy in Finland. As industry pioneers, we are launching a system change in Scandinavia. The transition of the textile industry from a linear model to a circular economy is essential, as virgin materials cannot sustain the current structure of the textile industry. And why should it, when there is so much recyclable material available?”

From the perspective of Rester Oy’s main owner, work clothing supplier Touchpoint, the circular economy plant not only represents resource efficiency, but is also necessary from the perspective of the entire life cycle of a responsible work clothing collection.

Luukko adds, “Finding a local solution to a global problem is a huge leap in the right direction and raises Finland's profile as a pioneer of circular economy."

The future plant will be able to process 12,000 tonnes of end-of-life textiles annually, which represents about 10% of Finland’s textile waste. Both production lines produce recycled fibre, which can be used for various industrial applications, including yarn and fabric, insulating materials for construction and shipping industries, acoustic panels, composites, non-woven and filter materials, and other technical textiles, such as geo-textiles.

LSJH is piloting a full-scale refinement plant

LSJH has launched a pilot production line for processing households' end-of-life textiles. Unfortunately, consumers' end-of-life textiles are heterogeneous, making them a challenging raw material for further processing. Before processing, the textiles are sorted by material into various fibre classes using optical identification technology developed by LSJH and its partners. This ensures the quality of the raw material and the resulting fibre products.

Jukka Heikkilä, managing director for Lounais-Suomen Jätehuolto, explains: “On the basis of the experiences gathered from the pilot project, Lounais-Suomen Jätehuolto is preparing a full-scale refinement plant in the Turku region. As soon as 2023, the plant will process Finnish households' end-of-life textiles. The project involves all waste treatment plants owned by Finnish municipalities.”

Paimio has ambitious goals for circular economy companies

Rester’s initiative aims to create a circular economy cluster in Paimio that combines the processing and reuse of end-of-life textile fibres. Paimion Kehitys Oy, which is owned by the City of Paimio and the local association of enterprises, supports the development of circular economy companies in Paimio.

Mika Ingi, managing director for Paimion Kehitys Oy, says, “We want to step out of our traditional municipal role and create significant added value for everyone taking part. That is why we are involved in the development of a new modern service model based on ecosystem thinking. We are piloting the textile cluster, followed in the coming years by clusters focusing on plastic, construction, and energy. The aim of our service is to support and help develop new profitable business by bringing circular economy companies and their potential customers to innovate together."

The foundation stone of the processing plant was laid today (18 August 2020). The processing plant will begin operations in February 2021.

Following the successful commissioning of two new Monforts Montex wide-width stenter lines and additional environmental management equipment at its plant in Germany, GtA – Society for Textile Equipment GmbH – is aiming to be the first textile finishing company to become entirely CO2-neutral in the manufacture of all of its products by 2025.

GtA is a partner company to Germany’s large-format digital printing fabric leader, Georg and Otto Friedrich GmbH, which has has this year been able to considerably expand its portfolio due to the new Monforts lines.

Headquartered in Gross-Zimmern, close to Frankfurt, Georg and Otto Friedrich GmbH and its partners in Germany have an annual production of 37 million square metres of warp knits for a range of end-use applications, including garments, automotive interiors and technical textiles, but increasingly with a concentration on digital printing substrates.

Fault-free textiles

A new standard in pure white, 100% clean and fault-free textile substrates has been demanded by this market in recent years due to the rapid growth in digitally-printed banners and billboards – often referred to as ‘soft signage’.

The substrates of choice for digital printing are 100% polyester warp knits which are resilient and allow excellent take-up of inks, and vibrant colours and clear and precise images to be achieved with digital printing techniques. The knitted construction also has the advantage of elasticity, which is a plus in terms of flexibility for installers.

Critically, the warp knitted fabrics have extremely smooth surfaces which is becoming increasingly important due to the general move away from PVC coatings which were the standard in the past.

It was to finish these fabrics for Georg and Otto Friedrich GmbH as well as providing such services for many other customers, that the GtA plant in Neresheim, Baden-Württemberg, was established in 2015.

The purpose-built plant on a greenfield site was initially equipped with a fully-automated, 72 metre long Monforts installation comprising a washing machine integrated with a 3.6 metre wide, seven-chamber Montex stenter. The line quickly went from single to double shift production and then to 24/7 operation  to meet demand.

Expanded widths

Building on the success of this installation, GtA has now installed two more Montex stenter lines – both in expanded working widths of 5.6 metres and purpose-built at Montex GmbH in Austria.

A six-chamber Montex unit is combined with a washing machine to guarantee the purity of the substrates, while a five-chamber line is integrated with a wide-width coating machine. This new coating capability at GtA has led to a number of new additions to the Georg and Otto Friedrich DecoTex range for digital printing, including wide width fabrics with flame retardant, antimicrobial and non-slip finishes.

The new Montex stenter lines benefit from all of the latest innovations from Monforts, including the Smart Sensor system for the optimised maintenance planning of key mechanical wear components on the stenters. A comprehensive overview of the condition of all parts at any time is now available for operators within the highly intuitive Qualitex visualization software.

With Qualitex, all article-specific settings can be stored and the formulations for thousands of treatment processes called up again at any time. Individual operators can also personalise their dashboards with the most important machine functions and process parameters.

Environmental commitment

GtA is run by a seasoned team of textile professionals led by Managing Director Andreas Niess.

“We have received excellent service from Monforts from the outset and we were happy to place the order for these two new lines as part of our ongoing cooperation,” he says. “With all of the latest Monforts advances in technology we are fully in control of all production and quality parameters with these lines, as part of our significant commitment to innovative environmental technology.”

The GtA plant, which operates in near-cleanroom conditions, has also been equipped with proprietary technology to fully exploit the Monforts air-to-air heat recovery systems that are now standard with Montex stenters.

“Around 30 per cent of our investment volume at the site goes to energy-saving measures and we are sure that this commitment is worthwhile,” Mr Niess says. “As an example, our integrated heat recovery system fully exploits the waste heat from the process exhaust air and the burner exhaust gases of the Monforts stenters, allowing us to achieve an exhaust air temperature of  between 30 to 34°C, compared to what would conventionally be between 140 to 160°C. Another focus has been on exhaust air purification technology and here too, the latest technology has been installed with integrated heat recovery elements.”

This, he adds, saves 52% of the energy that would normally be used – equating to 5,800,000 KwH per year. The necessary audits for energy-efficient companies are also carried out annually.

In addition, GtA has purpose-designed the automatic chemical mixing and dosing systems that feed the padders for the key treatments that are carried out on the fabrics through the stenters.

The company is going further, however, in its pursuit of clean production and raw materials.

"We want to be an asset and not a burden on our immediate environment and therefore do not use any additives containing solvents," Mr Niess says. “We were the first to use fully halogen-free flame retardant chemistry, and we use bio-based, finely ground alumina products for the washing process instead of surfactants. PES polyester yarns made from recycled material are also increasingly used and the latest additions to our raw materials portfolio, the RC-Ocean products, are made from recycled sea plastic.

“We are now planning a combined heat and power plant for the production of electrical energy and heat and we will also build a photovoltaic system that converts solar radiation into electrical energy. GtA wants to be the first textile finishing company to be CO2-neutral in the manufacture of all of its products by 2025. The complete heat supply and heating for the 13,000 square metre production hall, as well as the office building and the hot water supply for the domestic water, is already energy-neutral. We are convinced that this commitment will pay off in the long term and our positive business development proves that sustainability and business profitability are perfectly compatible.”

In addition to the products for Georg and Otto Friedrich GmbH, GtA  offers its manufacturing capacities for other customers as a contract service.

All products are manufactured in accordance with Öko-Tex Standard 100, product class 1 and the company is also involved in the research and development of new sustainable manufacturing processes, in cooperation with many regional universities and funding project partners.

Shanghai - Sateri has signed the Fashion Industry Charter for Climate Action, becoming the first viscose producer in China to support this global fashion agenda. An initiative convened by the United Nations Framework Convention on Climate Change (UNFCCC), this charter calls on the fashion industry to support the goals of the Paris Agreement in limiting global temperature rise to well below two degrees Celsius above pre-industrial levels, by achieving 30 per cent aggregate reduction in greenhouse gas (GHG) emissions by 2030, including the supply chain.

Niclas Svenningsen, Manager of Global Climate Action, UNFCCC, said, “UNFCCC is excited to have Sateri joining the Fashion Industry Charter on Climate Action and committing towards global climate action as the first Chinese viscose producer to do so. We hope that it will inspire more textile companies from China to join and take action.”

As a signatory of the Charter, Sateri looks forward to participating in relevant Working Groups which bring together stakeholders and experts in the fashion and textile sectors. In recent months, Sateri has joined several other leading industry multi-stakeholder associations. These include the Sustainable Apparel Coalition (SAC), China Association of Circular Economy (CACE), and the European Disposables and Nonwovens Association (EDANA).

Allen Zhang, President of Sateri, said, “Sateri is committed to growing our business as sustainably as we can. Our adoption of the Fashion Charter goals is a bold leap but we believe that pushing the boundaries is necessary. We are also stepping up on our engagement with industry partners to be part of the collective action to accelerate efforts against climate change.  As we formulate Sateri Vision 2030 for a sustainable business, carbon reduction will be one of our key focus areas”.

In addition to stepping up greenhouse gas emission reductions in its own operations, the company will continue to support decarbonisation efforts of the downstream textile value chain. Late last year, in collaboration with the China National Textile and Apparel Council (CNTAC), a Climate Leadership Whitepaper was published. The paper analysed how innovation in Sateri’s EcoCosy® fibre products help reduce carbon emission during yarn and fabric manufacturing stages, and also proposed next steps in achieving industry-wide emission reduction goals.   

Sateri attained an ‘A-‘ score in CDP (formerly Carbon Disclosure Project) for Climate Change in 2019;  a score which is higher than the ‘C’ average globally, in Asia, as well as in the Textiles and Fabric Goods sector. 

• Bemberg™ presents a great deal of novelties with a true key-statement for sustainability: Let’s Make it Circular!
• The lifespan of Bemberg™’s regenerated cellulose fiber Cupro derived from cotton is fully circular: from the source to manufacturing.

“Sustainability is the founding pillar of our company,” says SHUNSUKE SATO, sales manager of Bemberg™ by Asahi Kasei. “Indeed, the smart fiber is made from a cotton linter which is pre-consumer material, a natural derived source, that doesn’t deplete forestry resources”.

In Bemberg™’s production the whole sustainable closed-loop process is supported by the LCA study, signed by ICEA (Istituto per la Certificazione Etica e Ambientale) and validated by President of Ecoinnovazione Paolo Masoni ex Research Director of ENEA (Ente per le Nuove tecnologie, l’Energia e l’Ambiente).

While recyclability is granted by the Global Recycle Standard - GRS certification by the renown Textile Exchange (an influential guarantee that involves the whole production process and supply chain behind the company’s smart yarns), Bemberg™ yarns are also entirely biodegradable and ecotoxicity-free - meaning that at the end of their life circle they break down into the environment leaving no trace in terms of toxic substances as attested by the Innovhub-SSI report.

A special focus deserves Velutine™ Evo, the new fibrillation finishing technology for Bemberg™ fabrics only that guarantees another level of sustainable benefits without sacrificing the Bemberg™ amazing and unique touch. As part of the company’s continuous innovation, Velutine™ Evo brings better environmental, energy and water profiles for the benefit of Bemberg™ partners in the manufacture of their ranges.
The sustainable achievements of the new finishing technology have been measured by LCA - Life Cycle Assessment study by ICEA and proved to guarantee environmental benefits such as -16.5% of greenhouses gas emissions and -21% of overall consumption of energy resources. On top of that Velutine™ Evo means also -20.5% of electricity savings, -15.9% of steam production and -19.5% of water consumption.

The first Bemberg™ partner to present a commercial collection enriched by Velutine™ Evo is the Portuguese Matias & Araújo. With an innovative spirit, dynamism and a determined entrepreneurial spirit, the company is a leading knitwear producer for the textile industry.

Bemberg™ collaborated also with the premium brand CAALO that is making its mark in the outerwear market with its Sustainably produced Functional-Luxury proposal. For SS20, CAALO uses Bemberg™ lining because of the sustainability properties and it’s unique colour.

CAALO uses as much eco-friendly and sustainable materials as possible without compromising on design or quality. This Bemberg™ lining was a perfect fit. This versatile blazer features a removable hood, hidden welt pockets, button closure, and removable cargo pockets.

ISKO presented its 100% responsible platform, R-TWO™.

The denim ingredient brand hosted a special panel to discuss some of the advancements in technology that are making the fashion industry more responsible: from R-TWO™ to automated laser technology.

With the fashion industry being considered one of the world’s most polluting businesses-sectors, collaborating and knowledge sharing are key in finding solutions for a better future. Fully aware of this scenario, ISKO was the headline sponsor at The Drapers Sustainable Fashion Forum brings together responsible players to discuss what can be done to tackle the industry’s environmental and social issues through innovation and creativity.

Sharing knowledge, collaborating for change.
As evidence of its Responsible Innovation™ approach, ISKO presented the R-TWO™ program, its latest
responsible achievement. Stemming from the mill’s holistic vision, R-TWO™ represents a great example of how reducing, reusing, and recycling strategies can be implemented in a textile business to improve its  environmental performance.
The R-TWO™ reduces the amount of raw material sourced by using a blend of reused cotton and recycled polyester – both certified –, improving sourcing efficiency throughout the entire field-to-fabric production.
Reused cotton is certified with the Content Claim Standard – or CCS – from the Textile Exchange. As for recycled polyester, it can be either Recycled Claim Standard (RCS) or Global Recycled Standard (GRS) certified, depending on the content percentages. Together with this cutting-edge and fully responsible program, ISKO also uses automated laser
technology developed in partnership with Jeanologia.

“How technology can help make the fashion industry more sustainable”:
On March 11th, ISKO hosted a discussion about ways, to make the fashion industry more responsible
The panel was moderated by David Shah, consultant on design and marketing development, Publisher and CEO at Metropolitan Publishing BV and Associate Professor at ARTez (Arnhem, the Netherlands) and Associate Professor at Renmin University, (Beijing, China). The talk involved Keith O’Brien, ISKO Marketing & Business Development Manager, Victoria Soto, Jeanologia Custom Technology Consultant and Filippo Ricci, Fashion Open Studio Program & Partnership Manager.

And finishings of the E.C.O. KOSMOS cross-collection, continuing its ethical and sustainable path and having also exclusives collaborations with international brands
Italian Converter, a leading manufacturer of innovative fabrics for fashion, footwear and accessories, expands E.C.O. Kosmos, the fully traceable, transparent and 100% Made in Italy cross-collection. The acronym E.C.O. - Ecologic, Conversion, Optimization perfectly reflects the founding values of the Italian Converter philosophy and represents a further step in the company's responsible path. E.C.O. Kosmos has also been selected to be part of C.L.A.S.S. (Creativity Lifestyle and Sustainable Synergy) and also welcomed with enthusiasm the proposal to support C.L.A.S.S. Smart Materials Bank, the educational platform and e-shop of C.L.A.S.S. designed for young designers who want to discover and experiment with innovative and sustainable textile solutions from the best manufacturers in ways suitable for their reality.

Here are some highlights of the collection:

• E.C.O. Alba – E.C.O. Aurora, fabrics made of 50% casual cotton combined with AMNI SOUL ECO ® technology.
• E.C.O. Sonica is a semi-shiny satin with an elegant and refined appearance. the textile sector at an international level.
• E.C.O. Aly is a vintage effect raffia, a very trendy theme right now.

Empowering sportwear and athleisurewear with a sustainable imprint

Bemberg™ products including its now-iconic cupro fiber are made from a cotton linter pre consumer material, a natural derived source, and a truly unique one in the smart fiber arena that doesn’t deplete forestry resources.

In Munich, the company is pleased to announce its ultimate collaborations with　Sidonios Malhas, SA. They have created Jacquard jersey with a very interesting look and graceful touch for the athleisure solutions.

Matias & Araujo which has developed, using ZUE’s Bemberg™/Polyamide intermingle yarn, a unique beautiful touch and physical property that suit the athleisure markets; and leading manufacturer of smart jersey TINTEX Textiles created a delicate and luxurious 100% Bemberg™ interlock with silky touch guaranteed by Plummy Technology®, GOTS certified light, fluid and soft Jersey that combine Bemberg™ with organic cotton enriched by the Naturally Clean® technology.

Bemberg™ also presents unique fabrics made in Japan with a special technology of combined yarn through texturizing process and blended yarn.

Bemberg™ by leading materials manufacturer Asahi Kasei is the sole maker of one-of-a-kind, matchless, high-tech natural fibers with a unique touch and feel as well as unique performances such as moisture control and is antistatic.

Atop the exquisite and precious touch, Bemberg™ fabrics are imbued with circular economy - from its source, manufacture and end-of-life. It is all supported by the LCA study, signed by ICEA and validated by Paolo Masoni, confirming a new quality profile and standard with a more responsible and unique position today. Full GRS certification, Oeko-Tex 100, ISO 14001, & Eco-Mark. Bemberg™ also has a new Compostability Certification.

The Lenzing Group completed the second pilot production plant announced in May 2018 for its innovative filament yarn TENCEL™ Luxe. Construction of the facility at the Lenzing site involving investments of EUR 30 mn could be concluded on schedule and within budget after 20 months of intensive work. The new pilot production line, which was put into operation in the middle of December 2019, gives Lenzing sufficient capacity for commercial programs and further application development.

Innovation in the eco-couture segment
Thanks to TENCEL™ Luxe, Lenzing is able to embed the issue of sustainability in the premium luxury market in combination with superior aesthetics. The properties of the fine filament yarn can be compared to those of silk due to its airy feeling on the skin and the matte finish. At the same time, TENCEL™ Luxe also stands out because of its extensive strength and high level of environmental compatibility. It is perfectly suited for very fine fabrics and as a blending partner for silk, cashmere and wool. “TENCEL™ Luxe opens up new markets for Lenzing and thus contributes to the successful implementation of their sCore TEN corporate strategy.

The integrated sustainable network making fashion circular, Made in Italy and 100% traceable

World leading textile manufacturer Manteco presents its sustainable path for a better future: The Manteco System. A strategy and a vision shaping the company’s sustainable imprint since 1943. The system consists in the development and engineering of a production network involving 100 partner-companies from the whole supply chain “We all team up responsibly to create premium collection based on transparent , traceable  circular economy practices,” comments Matteo Mantellassi, co-CEO of Manteco.
 
To achieve meeting the demand for fair and sustainable fashion that consumers believe in, and is expected  from our clients, the company and its partners have created and accomplished to a Protocol of Sustainable Values and Commitments in line with the highest standards of the global market.

“On a hand, the protocol preserves the unique ‘genius loci’ of our territory – it respects the heritage of all our partners, from the smaller businesses to the more structured ones - on the other hand, it works like a shared compass of sustainable values, allowing the whole supply chain behind Manteco products to stand out and be competitive on the global stage” adds Mantellassi.
 
The protocol and its monitored and traceable system cover virtuous management of resources – e.g. Water, energy and chemical products - waste management and low production impact on the environment but also responsible standards in terms of employment, quality of the working environment, equal rights and anti-discrimination policies.

One of the key  results of such commitment and sustainable development is the creation of an upgraded version of the recycled wool  MWool™: a top ingredient made from premium recycled wool process guaranteed by the Manteco System.The System works like a symphony where management, measurement and controls  are not there just to test  the quality of each single phase of processes or  products , but to make sure and offer the complete traceability of Manteco production.  From raw material, to yarn, spinning, finishing, testing and final fabric.

Some productions tips about Manteco:

•  5.3 million kg of raw materials processed annually.
•  6.860 tests on raw material per year.
•  34.400 tests on finished products.
•  100% made in Italy system completely based in the Prato district since 1943.
•  Total transparency and traceability thanks to a highly skilled management system.

With a turnover of over 91m Euro in 2019 and an annual growth of 17,80% since 2012, Manteco SpA is the 4th textile company in Italy, listed in the TOP30 companies of the Italian fashion system. “The unique Manteco system adds value to our products while highlighting the sustainable path we share with all our partners both upstream and downstream”.

Sateri has scored ‘A-‘ in CDP (formerly Carbon Disclosure Project) for Climate Change in 2019, placing it at Leadership band and the top 27% of companies in its sector, for implementing current best practices. And making Sateri World’s First Viscose Producer to Reach Leadership Band

This is the first time Sateri has participated in this annual voluntary reporting. It is also the first time that a viscose producer has reached Leadership band. Sateri attained an ‘A’ for more than half of the 11 categories that it was assessed for, including value chain engagement, Scope 1,2,3 emissions, and governance. Its ‘A-‘ overall score is higher than the ‘C’ average globally, in Asia, and in the Textiles and Fabric Goods sector; no companies in the same sector scored ‘A’.

Allen Zhang, President of Sateri, said, “We are very pleased to achieve such a commendable score on our first attempt at CDP reporting. It is a validation of our efforts and actions to combat climate change and our contribution towards decarbonising the textile industry. The CDP platform not only helps us measure and benchmark our sustainability performance against more than 8,400 companies globally, but also serves as a management tool for continuous improvement.”

Sateri has made great strides in the last year on emission reduction work. In June 2019, Sateri and the China National Textile and Apparel Council (CNTAC) jointly launched the EcoCosy® Climate Leadership Programme. The programme invites Sateri’s value chain partners to participate in the Climate Stewardship 2030 Initiative to set a decarbonisation pathway for the fashion industry to reduce the industry’s GHG emissions by 30% by 2030. Results of the first phase of the programme were published in the EcoCosy® Climate Leadership Whitepaper 2020, which was shared at COP25 in Madrid last year.