From the Sector

• New brand Trevira CS eco

After a challenging 2020 for Trevira CS®, a year in which the coronavirus crisis put pressure on the contract market, in particular on the hotel and event sector, and also on the cruise shipping industry, the market is starting to show some signs of improvement. Numerous new developments are seizing upon the trends that have emerged since the crisis began.

Although the coronavirus pandemic had a negative effect on individual business sectors, it also has the potential to open up new market opportunities for flame retardant Trevira CS fabrics in the long run. The increase in people working from home and the longer and more frequent stay within one’s own home have led to a change in perspective in terms of the relevance of interior design. The design of the living space has undergone a revaluation. Sustainability, durability, high quality, and the desire for safe products that contain little to no harmful substances are defining criteria for selecting a new textile interior. The colour range of the new Trevira CS developments is directed specifically towards this trend and often comes across as discreet and close to nature. After Trevira CS products have found their way more and more into private homes, the new Trevira CS collections include numerous attractive textiles not only for the contract sector but also for the residential sector.

In the contract sector, notably in the hotel industry, the trends towards sustainability and quality are likely to continue to grow. Moreover, there is an increase in awareness as far as hygiene requirements are concerned. Textiles that are easy to clean without losing their appearance or their functionality can excel here. Accordingly, products ordinarily used in the healthcare sector might start to be of interest to the hotel and catering industry, public spaces, the transport industry, and to offices. This will apply in particular to areas where there is a regular flow of visitors and where people come into direct contact with fabrics. Antimicrobial textiles provide additional protection in these situations. Besides their flame retardancy, many new Trevira CS products integrate additional functions such as noise or sun protection.

Trevira has launched the Trevira CS eco brand for flame retardant textiles that consist of recycled Trevira products.
The new Trevira CS eco brand unites sustainability and flame retardancy. Trevira offers products for this which have been manufactured through different recycling processes. The flame retardant filament yarns are based on the use of recycled PET bottles (post-consumer recycling). Textiles bearing the Trevira CS eco trademark consist of at least 50% recycled materials.

Trevira uses an agglomeration facility to recycle reusable waste materials from production to manufacture recycled fibres that, after further processing, retain the same quality and performance characteristics as the original products (pre-consumer recycling).

Zünd Connect compiles production data from integrated Zünd cutting systems into meaningful key performance indicators, such as cutter capacity, availability, and overall equipment effectiveness. Zünd Connect creates transparency and identifies areas in the digital cutting workflow with potential for optimization.

There are many ways to optimize digital cutting and ensure maximum productivity, which is the reason why Zünd now offers Zünd Connect, a monitoring tool that helps the user recognize this potential and increase productivity. Using Zünd Connect, the user can see at a glance when and, more importantly, why machine interruptions occur, how much time is spent in setup, and what the availability of each machine is.

The web-based monitoring tool gives the user access to cutter- performance data at a glance, any time of day. Reliable key performance indicators are available at all times to help users maximize productivity. The system records productivity levels over a freely definable period using Zünd Cut Center – ZCC (Version 3.4 or later) as data source. Data monitoring provides information users need in order to make informed decisions. This comprehensive overview of production data reveals connections that are often overlooked. Zünd Connect supplies valuable key performance indicators for assessing how efficiently cutting systems are working. To be able to improve cutter efficiency, potential areas of improvement must be uncovered and recognized. This potential lies primarily in the technology but also in the way it is being used.

Zünd Connect is available in a "Monitor" or an "Analyzer" version.

Swiss dairy company Emmi is partnering with Borealis and Greiner Packaging to produce iced coffed drinking cups using chemically recycled polypropylene.

The cups are produced by Greiner Packaging and the chemically recycled material comes from Borealis, one of the world’s leading providers of advanced and circular polyolefin solutions based in Vienna, Austria.

Emmi, Switzerland’s largest milk processor is committed to climate protection and the circular economy. The dairy company has the stated goal to make all of its packaging 100% recyclable and is committed to various measures to promote circularity such as packaging that contains at least 30% recyclate by 2027.

From September 2021 Emmi will use at least 100 tonnes of plastic based on the recycled material each year. Chemical recycling renews plastic back to plastic creating recycled materials with a level of purity equivalent to fossil-fuel based PP and hence, fit for protective, food-safe and other demanding applications. In this way, Emmi is utilizing difficult to recycle feedstock preventing plastic waste that would be likely landfilled or incinerated. In the future, depending on the availability of suitable material, the amount of recycled plastic in packaging is to be further increased.

The new technology to recover the polypropylene is currently still in its infancy, where Greiner Packaging and Borealis are leading the way. Only limited quantities of chemically recycled polypropylene are currently available, and Emmi is one of only a few food manufacturers to have secured a share of the chemically recycled polypropylene plastic through its early commitment and long-standing collaboration with the development companies.

The chemically recycled material used for the cups consists entirely and solely of ISCC (International Sustainability & Carbon Certification) material, on a mass balance basis. Mass balance is a methodology that makes it possible to track the amount and sustainability characteristics of circular and/or bio-based content in the value chain and through each step of the process. This provides transparency ultimately also to the consumers, enabling them to know that the product they are buying is based on this renewable material.

Originally conceived as a low-cost, high-volume alternative to knitting and weaving, nonwovens was already expanding its market boundaries by the 1970s with new applications in ‘disposables’ such as diapers, hygiene and teabags.

In the past five decades, the nonwovens business has exploded in all directions, reaching a global market worth USD 40.5 billion in 2020, projected to grow to USD 53.5 billion by 2025. This annual growth rate of 5.7% (MarketsandMarkets, Nonwoven Fabric Market Report) is based on countless new applications and expansion into durable, as well as additional disposable, products.

Major growth drivers include the hygiene sector, and filtration media for power plants and air conditioning systems. Especially during the peak of the COVID pandemic in 2020 and 2021, demand in the hygiene sector multiplied. Worldwide capacities for both meltblown and spunlace production rocketed compared to a normal business year. Swiss Autefa Solutions, for example, significantly benefited from this trend, notably with the launch of a fully-automatic machine for producing face masks.

The automotive industry is the second big growth area, with many new applications being pioneered. The trend to electric and hybrid vehicles has helped this, as nonwovens reinforced with carbon fibres are widely used as battery housings.

Swiss nonwovens competence
Innovative applications across all sectors have driven the rapid evolution of sophisticated nonwovens machinery. Today’s trends demand higher productivity, sustainability and Industry 4.0 compatibility – demonstrated by the full equipment portfolio of Swiss Textile Machinery member Autefa Solutions. With V-Jet Futura, the company recently sealed the link in its product range between web forming and drying technology. This latest Hydroentanglement Machine, together with the SQ-V Square Drum Dryer, embodies advanced technology combined with significant reductions in energy consumption compared to other process solutions.

A vital contribution to nonwovens production is offered by Rieter subsidiary Graf, a leading supplier of clothing and combs for carding and combing processes in spinning and nonwovens. Graf's Hipro card clothings – suitable for any man-made fibres in the nonwovens sector – are focussing on higher productivity. Their superior performance delivers up to 10% higher throughput and greater carding efficiency compared to conventional clothings. These reliable card clothing elements also ensure a consistently reproducible high web quality, as well as 20% fewer failures in the web, thanks to the precise fibre transfer to and from the cylinder.

Another constant trend in nonwovens today is the drive for better quality. Manufacturers want to take charge of contamination levels in their processes, as well as eradicating defects which may arise during production. Uster Technologies, a leading provider of quality management solutions from fibre to fabric, offers a combined solution to achieve both these required quality standards. At the fibre preparation stage, Uster Jossi Vision Shield N ensures the best possible initial inspection and removal of contamination. Then, at the end of the production sequence, Uster EVS Fabriq Vision N handles automated detection and marking of all the main defects caused during production. This combined solution avoids material waste and takes full advantage of the potential for process optimization.

To ensure product protection and prevent brand piracy, GRAFE has developed a simple and elegant solution that also offers a high level of security. The basis is special markers. "The highly complex pigments with special physical properties designed for this purpose are used in minute quantities within the plastic matrix. With an appropriately calibrated detector, products equipped with them can thus be read and authenticated," explains Business Development Manager Florian Ludwig. At the same time no changes in properties can usually be observed. The detectors can use an LED display to check within seconds whether the unique marker is contained in the product and whether this item is the original product.

In general, there are two options: x ray and light fluorescence, i.e. fluorescent X-rays or light. With the first option, the base color has no influence (not even black) and the customer benefits from low addition dosage and batch price, but this method requires higher investment. "With light fluorescence, on the other hand, detection is done by a measuring device, which is preconfigured by our partner or by us directly. Different types are available, from handy hand-held measuring devices to stationary office solutions to inline spectrometers, in order to have a control take place directly during production," Ludwig explains. With this method, the masterbatch dosage is based on the base color, among otherv things. The method of operation is fast and simple, and the necessary investment is also manageable.

From injection molding and extrusion to transparent and fiber applications, almost all areas of plastics processing come into question.

• Transformation program and improving order situation show first successes
• Sales up 8.8% to €496.7 million compared with first half of previous year
• Adjusted EBITDA improves by 70.7% to €71.7 million
• Positive business development led to forecast increase on July 13, 2021

While the past fiscal year 2020 was still characterized by a Corona-related slump in orders in many business areas of SGL Carbon, demand picked up again in the first six months of 2021. Accordingly, Group sales increased by 8.8% to €496.7 million in H1 2021 (H1 2020: €456.5 million).

The Carbon Fibers and Composite Solutions Business Units particularly contributed to the €40.2 million increase in sales. Carbon Fibers contributed €166.4 million to Group sales, especially benefiting from increased demand from the automotive market segment. In the Composite Solutions Business Unit, the increase in sales of 52.4% to €60.2 million was also primarily based on the recovering demand from the automotive industry.

With sales of €221.2 million, the Graphite Solutions business area contributed around 44.5% of SGL Group sales. The 3.8% increase in the division's sales was particularly due to the positive development in the important markets of the LED, semiconductor and automotive industries.

Transformation program:
The restructuring and transformation process initiated at SGL Carbon made a significant contribution to the Company's positive sales and earnings performance. In addition to leaner and more efficient structures as well as a reorganization of the business units with responsibility for results, a large number of improvements and cost initiatives in all business units and sites have contributed to the success of the ongoing transformation program.

Forecast increase:
Due to pleasing business development in the first half of the year as well as transformation successes, SGL Carbon raised its forecast for fiscal year 2021 on July 13, 2021. For the financial year 2021, the company now expects consolidated sales of around €1.0 billion (previously: €920 - 970 million). In line with developments in the first half of 2021 and the results from the transformation, adjusted EBITDA for 2021 is expected to be between €130 - 140 million (previously: €100 - 120 million). Accordingly, a slightly positive net profit is now forecasted for fiscal year 2021 (previously: €-20 million to €0).

Solid net profit and further strengthening of the balance sheet thanks to significant revenue and profitability increases

The automobile industry recovered significantly in the first half of 2021 compared to the prior-year period, which had been impacted by the effects of the coronavirus pandemic. Autoneum benefited from the market dynamics and managed to increase its revenue in local currencies by 24.3% in the first semester. EBIT rose to CHF 44.7 million thanks to higher revenues and further progress in the turnaround in North America, corresponding to an EBIT margin of 5.0%. The strong free cash flow of CHF 67.2 million has allowed for a further reduction in net debt.

In the first half of 2021, 29.2% more light vehicles were produced worldwide than in the coronavirus-hit first half of 2020. The market recovery, though significant, was hampered by the global semiconductor shortage, which led to temporary production stoppages and manufacturers producing lower vehicle volumes. Autoneum increased revenue in local currencies by 24.3% in the first six months. In Swiss francs, revenue climbed by 21.9% to CHF 890.3 million. Business Group SAMEA (South America, Middle East and Africa) grew clearly above market, while the shortage of semiconductors in North America in particular impacted the production of models supplied by Autoneum and the revenue development of Business Group North America.

Autoneum managed to improve its operating result (EBIT) considerably by CHF 76.5 million in the first six months compared to the prior-year period. In addition to higher revenues, this was mainly due to the immediate and sustainable adjustment of the cost structure in all Business Groups to the new market reality in 2020 as well as the improved earnings achieved in the turnaround program in North America. Higher material costs, however, had a negative impact on the operating result. EBIT in the amount of CHF 44.7 million (prior-year period: CHF –31.8 million) corresponds to an EBIT margin of 5.0% (prior-year period: –4.4%).

The development of global light vehicle production in the second half of 2021 remains uncertain due to the semiconductor shortage. Although there is a high demand from end customers in all regions, it can be assumed that the shortage of chips will continue to impact automobile production in the second half of the year, but not as severely as in the second quarter of the first half-year.

Revenue in the second half-year 2021 is expected to be higher than in the first semester. Based on the unfavorable allocation of semiconductors to vehicle models supplied by Autoneum in the first half of 2021, revenue development is likely to be slightly below market for the full year 2021. With an easing of the semiconductor shortage, this will normalize.

The 11^th edition of RISE®, Research, Innovation & Science for Engineered Fabrics Conference will be presented virtually on Sept. 28-30 with more than 150 professionals in product development, materials science, and new technologies.

The conference will culminate on Sept. 30 with the presentation of the 2021 RISE® Innovation Award recognizing problem-solving innovations that advance the nonwovens industry.

The program includes presentations from industry leaders, round-table discussions and question-and-answer sessions on the key themes of material science developments for sustainable nonwovens, sustainability, increasing circularity in nonwovens, and promising innovations in nonwovens, processes and materials:

• Promising Materials Development Using PLA
  presented by Behnam Pourdeyhimi, Ph.D., William A. Klopman Distinguished Professor and Executive Director, North Carolina State University, The Nonwovens Institute
• Phantom Platform: The Polyolefin-cellulose Coformed Substrates Technology at Its Best, featuring insights from Fabio Zampollo, CEO, Teknoweb Materials S.r.l.
• Biotransformation Technology in Polyolefin Fibers and Nonwoven Fabrics, Focus on Fugitive Used Articles
  with speakers, DeeAnn Nelson, Ph.D., Development Program Manager, and Nick Carter, Vice-President of Marketing and Business Intelligence, both from Avgol Nonwovens
• High-Loft, Ultra-Soft Hygiene Solutions,
  presented by Paul Rollin, Ph.D., Global Team Lead – Nonwovens, ExxonMobil Chemical Company
• Innovating a Sustainable Future for Nonwovens; A European Perspective
  given by Matthew Tipper, Ph.D., Operations Director, Nonwovens Innovation & Research Institute Ltd., (NIRI), UK
• Filtration Media Functionalized with Zinc Oxide
  by Wai-shing Yung, Ph.D., Technical Director, Ascend Performance Materials

Hexcel, a global leader in advanced composites technologies, confirms that its HexPly® M901 prepreg system has been selected by Rassini, a Mexico-based technology leader in composite vehicle suspension systems, to speed up prototype and new product development cycles, reducing overall time to market with an easy to process material solution that enables effective early-stage design screening and cost-effective production.  

As a specialist in the mass production of composite helper leaf springs for various leading OEMs, Rassini continuously develops innovative new suspension component designs. Due to cost and timing, however, these new products cannot easily be prototyped using conventional high-pressure resin transfer molding (HP-RTM) technology.

With more than 15 years of experience in delivering glass fiber prepregs for the serial production of composite leaf springs, Hexcel developed its high-performance HexPly M901 prepreg system specifically for this type of application. HexPly M901 combines the right level of structural performance required with simple processing, providing Rassini with a reliable material solution optimized for rapid development and fine-tuning iterations.

HexPly M901 is a high Tg epoxy resin prepreg system specifically developed for structural components that will be exposed to harsh thermal and environmental conditions.  With short cure cycles of 10 minutes and below producing excellent green, or handling, strength of the composite part for demolding and unidirectional glass fiber aerial weights up to 1,600gsm, HexPly M901 delivers a powerful combination of benefits for suspension component applications.

Schoeller Textil AG, the Swiss textile and technology company, announces a shift in leadership as Joachim Kath takes over as CEO. Following a 10-year career at the global textile solutions brand, CEO Siegfried Winkelbeiner is moving into his retirement later this month. Joachim Kath, who comes from the chemical industry, has been working closely with Winkelbeiner as COO at Schoeller for the past year and a half.

The transition comes after long-term planning. Since February 2020, and in close partnership with Siegfried Winkelbeiner, Joachim Kath (on the left) has been preparing as Schoeller COO to take over its management. Joachim Kath originally comes from Flensburg (DE) and, following his studies of Chemical Engineering in Karlsruhe, shaped his professional career in the chemical industry with Ciba (-Geigy) / BASF in Basel (CH). His career over 30 years has incorporated engineering, production and marketing & sales in diverse management functions – in a wide range of business segments for various industries and areas of application around the globe. Joachim Kath spent 12 years of his career dedicated to textile finishing, with a period of intensive travel in Asia and a 3-year stay in the USA.

Asked how he sees himself, Joachim Kath said: “The common thread running through all my assignments and business activities is process orientation, interest in new paths, and an instinct for what is feasible – with the goal of achieving customer benefits and satisfaction. Kath aims to ensure that Schoeller can continue to face the challenges of changing market requirements with outstanding and exceptional products, while evolving and innovating to stay ahead of consumer needs for the future. High performance capability, sustainable product development, premium quality, reliability, productivity, and keeping the customer as the central focus of all activities continue as essential keys to Schoeller’s continued business success.