From the Sector

• Latex-free: UltraBond allows 100% recyclable thermal bonded nonwovens
• Sustainability & cost-efficiency: significant reductions in CO2 emissions and energy and water consumption for manufacturers of needlepunched exhibition & contract flooring
• UltraBond debuts at Domotex 2019 Stand B56 Hall 11

Beaulieu Fibres International (BFI) unveils a unique opportunity for carpet manufacturers to create fully recyclable needlepunch carpets, and benefit from production and resource savings, without influencing performance.

Launched at Domotex 2019, new UltraBond is a patented polyolefin bonding staple fibre that eliminates the need for latex or other chemical binders to bind nonwovens. It opens up a new path for creating 100% polypropylene (PP) needlepunch carpets which meet the same performance requirements as traditional latex-bonded carpets while reducing the end-of-life environmental impact. Functional properties such as pilling resistance, resistance to wear and abrasion, and also UV resistance are guaranteed.

Using UltraBond manufacturers finally gain the potential to cost-efficiently produce 100% recyclable carpets. In addition to the general benefits of making recycled PP available for the plastics production chain and reduced waste generation, environmental advantages and financial savings arise from a total lack of water and less energy use. As a 100% dry process, thermal bonding uses no water and results in a total absence of waste water. There is also a reduction in the VOC level of the carpet. This all leads to a significant reduction in a needlepunch carpet’s ecological footprint.

The sustainability benefits are quantified through lifecycle analysis (LCA) of an exhibition carpet application – among the primary applications for needlepunch carpets. Evaluations show that the absence of water consumption directly translates into a large energy saving of 93% when using UltraBond compared to a latex bonding solution, and also a potential annual water saving of over 20 million litres for 100 million m2 of exhibition applications in the EU. Without the addition of any other bonding agent, CO2 emissions are reduced by 35% over the full production process.

Karena Cancilleri, Vice President Beaulieu Engineered Products, Beaulieu International Group, commented, “Recyclability and achieving a greener, more cost-effective production process without compromising on current performance levels are significant unsolved topics within today’s carpet industry. By eliminating the need for latex and chemical binders through UltraBond, we offer needlepunch manufacturers a breakthrough they have been looking for that boosts environmental and economic sustainability. We see textile flooring as just the beginning. Together with our customers, we look forward to exploring the potential of this unique thermal bonding fibre in other applications such as laminated nonwovens or as an alternative to dry powders.”

Discover more about UltraBond from the Beaulieu Fibres International team at Stand B56 Hall 11, Domotex 2019 in Hannover, Germany from January 11-14, 2019.

New products for photopolymer and laser sinter printing methods from BASF 3D Printing Solutions GmbH (B3DPS) are on show from November 13 to 16 at Stand F20 in Hall 3.1 at this year’s formnext fair in Frankfurt. The BASF subsidiary is also announcing several new partnerships for the development and distribution of groundbreaking 3D printing solutions and products.

B3DPS has entered into a strategic partnership with the US company Origin, San Francisco, California for the further development of photopolymer printing processes. “Within the framework of an open business model, we are combining BASF’s material know-how with Origin’s expertise in printer software programming and the manufacture of the corresponding hardware,” explained Volker Hammes, Managing Director BASF 3D Printing Solutions GmbH. The collaboration has already shown the first signs of success. Origin has developed a new printing method where BASF’s new Ultracur3D photopolymers can be processed particularly well. The technology offers an optimal combination of a good surface finish and high mechanical stability, while also allowing for high material throughput.

B3DPS is working together with Photocentric, a manufacturer of 3D printers and their corresponding software and materials, on the development of new photopolymers and large-format photopolymer printers for mass production of functional components. Based in Peterborough, UK and Phoenix, USA, Photocentric has developed and optimized the use of LCD screens as image generators for its own printing systems. The two partners plan to offer the industry 3D printing solutions that replace parts of traditional manufacturing processes such as injection molding for small series, as well as enabling the production of large components.

The objective of the cooperation with Xunshi Technology, a Chinese printer manufacturer headquartered in Shaoxing, and operates in USA under the name Sprintray, will be opening new fields of application in 3D printing for the Ultracur3D product range of B3DPS.

Ultracur3D specialties for photopolymer printing processes
B3DPS has grouped well-established and new photopolymers designed for the respective 3D printing processes under the brand name Ultracur3D. BASF has developed unique raw materials for its new products that enable special part properties.
“Our Ultracur3D portfolio enables us to offer customers various UV-curable materials for 3D printing that provide far better mechanical properties and higher long-term stability than most available materials,” explained András Marton, Senior Business Development Manager at B3DPS. He added: “These materials have been developed for functional components that are subject to high stress.”

Expansion of distribution network for filaments
Innofil3D, a subsidiary of B3DPS, is entering into a partnership with Jet-Mate Technology, based in Tjanjin, China, for the distribution of plastic filaments in China. In parallel, a distribution agreement has been concluded with M. Holland in Northbrook, USA for the distribution of filaments in USA. “Since the USA is the largest market for filaments, we intend to strengthen our activities there,” said Jeroen Wiggers, Business Director 3DP Solutions for Additive Extrusion at B3DPS, adding: “Asia is another important market for us. We will be developing further distribution channels there and putting our Ultrafuse filaments on the Asian market in 2019.”

BASF’s portfolio of filaments for 3D printing are comprised of two categories; the well-established Innofil3D filaments based on generic polymers for conventional applications and polymer-based Ultrafuse filaments for advanced formulations used in demanding technical applications. One of the broadest filament selections on the market, this portfolio covers customer requirements ranging from prototype to industrial-scale production.

SLS: new 3D printing material with fire protection classification
New flame-resistant Ultrasint Polyamide PA6 Black FR meets UL94 V2 fire protection standards and is a new material class for use in selective laser sintering (SLS) processes, distinguished by high stiffness and thermal stability. In cooperation with one of the global leaders of public transportation vehicles, B3DPS has developed new components that meet vehicle fire protection requirements. “Together with our partner, we are currently producing prototypes, spare parts, and small series components, and are working to further improve flame resistance to meet additional certification specifications,” explained Hammes.
BASF introduced Ultrasint Grey PA6 LM X085 at AMUG this spring and now is followed by another product on show at formnext. Ultrasint PA6 Black LM X085 is based on polyamide 6, and can be processed at 175-185 degrees Celsius therefore making it suitable for most current SLS machines.

B3DPS adds polypropylene to its 3D printing portfolio
Through the acquisition of Advanc3D Materials GmbH in July 2018, B3DPS has expanded its range with numerous materials for use on laser sinter machines, including polyamide Adsint PA12, Adsint PA11, Adsint PA11CF and Adsint TPU flex 90.
Ultrasint PP is a special highlight. This polypropylene-based product exhibits outstanding mechanical properties and is frequently used in standard industrial production as it offers a good balance between price and performance. Ultrasint PP is distinguished by excellent plasticity, low moisture uptake, and resistance to liquids and gases. Prototypes and small batches can now be produced from the same material as used for traditional serial production. Post treatments such as thermoforming, sealing, and dyeing can be performed after printing.

Asia’s largest biennial event for the entire technical textiles and nonwovens sector will feature some of the industry’s biggest overseas machinery brands. Held on the earlier date of 4 – 6 September this year, the fair will feature an expected 500-plus total exhibitors from around 20 countries & regions.

As the world’s largest producer of technical textiles and nonwovens, China’s demand for production machinery is insatiable. As such, this September’s Cinte Techtextil China has attracted some of the world’s leading machinery brands, particularly in the nonwovens and sewing machinery sectors, ensuring a wide range of sourcing options for both domestic and international buyers.

Overseas producers respond to strong Chinese demand
As the Chinese domestic and export markets’ demand for quality technical textiles and nonwovens products continues to increase, overseas machinery brands continue to enter the country, using Cinte Techtextil China as their starting-out platform. ANDRITZ Nonwoven is just one of those who see the growing potential. “Chinese nonwovens manufacturers are increasingly requiring higher capacities and top-class quality for their nonwovens products for local and export markets,” Mr Laurent Jallat explained. “China is the biggest market in terms of installed capacity, and shows quite promising potential for the future. In the past years, we’ve seen rapid growth in products such as disposable face masks.” ANDRITZ responds to this demand with their neXline spunlace eXcelle line which features state-of-the-art TT card web forming and JetlaceEssentiel hydro entanglement units for high capacity and speed.

The DiloGroup also report an increase in demand for their products in China. “China is one of our biggest markets,” explains Mr Dominik Foshag. “We have procured huge orders from China, as Chinese customers are considering German technology more frequently nowadays. The visitor quality of Cinte Techtextil has been very good in this past, and we think this year’s fair will be also successful as we know many of our customers are going to visit.”

Oerlikon will introduce its spunbond technology to the Chinese market this year, and is expecting to conclude initial contracts at the fair due to increased demand for overseas products. “The Chinese market for nonwovens products is by far the largest and fastest growing national market. Chinese manufacturers are no longer satisfied with lower product quality, but want to exceed Western quality levels, for example. The products must now meet stricter customer requirements and legal standards, some of which are significantly higher than other international standards,” Ms Lena Kachelmaier said.

Truetzschler Nonwovens has also noticed this trend. Ms Jutta Stehr commented: “In the last two or three years, China became one of the pacemakers in the field of nonwovens used in beauty, skin care and hygiene applications. Asian markets have set new standards concerning quality in nonwovens. For instance, making disposable wipes from cotton fibres is a trend originating in Asia. The luxurious feeling of cotton combined with the requirement for eco-friendly products will further drive demand in China and elsewhere. Accordingly, Truetzschler Nonwovens anticipates more inquiries at Cinte Techtextil for its proven carding and spunlacing solutions for cotton nonwovens.”

Weaving machine supplier Itema has also noticed strong demand in China for products made in Italy. “Generally speaking, and especially for technical fabrics, imported machinery is highly evaluated and appreciated by Chinese customers. In recent years, Itema experienced significant growth in the sale of its Made-in-Italy weaving machines in China, and in other APAC countries. Imported machines are synonymous with quality and reliability, and we believe this positive trend will be constant in the future,” Mr Matteo De Micheli outlined.

Weaving machinery exhibitor highlights

• ANDRITZ Nonwoven: their specialty is technologies for drylaid, wetlaid, spunbond, spunlace, needlepunch and textile calendering. At Cinte Techtextil, they will highlight their aXcess product portfolio, which has been especially designed for medium-capacity production. ANDRITZ has developed this range to fit the demands of producers with medium-capacity requirements, particularly in emerging markets. It includes lines and individual machines for needlepunch, spunlace, wetlaid and calendering processes.
• Autefa Solutions: visitors to their booth will experience the company’s expertise as a full line supplier for carded- crosslapped needlepunch lines, aerodynamic web forming technology, spunlace and thermobonding lines. Their nonwovens lines meet customers’ requirements for quality web formation, bonding, active weight regulation and minimal maintenance.
• DILO Systems: a leader in the field of staple fibre nonwoven production lines, DiloGroup will present their latest developments at the fair, including staple fibre production lines, card feeding and cards and crosslappers & needlelooms.
• Oerlikon: they will showcase spunbond solution lines for the production of polypropylene geotextiles. According to the company, spunbond geotextile applications are on the rise as the market is increasingly demanding more efficient processes and products, which means the product requirements are often the same or greater, but with a lower raw material input. Spunbonds are progressively replacing classical carded nonwovens due to their technical and commercial benefits.
• Truetzschler Nonwovens: concentrating on solutions for producing a broad range of hygiene nonwovens including wipes at the fair, they will focus on thermobonding & spunlacing processes and the respective machinery, from fibre preparation down to winding.

Sewing machinery exhibitor highlights

• Itema: making their debut at Cinte Techtextil, they are a leading supplier of weaving machines for technical fabrics production. According to the company, they are the only weaving machine producer to offer technical textile manufacturers the top three technologies for weft insertion: Rapier, Projectile and Airjet.
• Picanol: they use their leading position as producers of weaving machines for other textile products to expand into machines for woven technical textiles by investing heavily in state-of-the-art technology, as well through the modular design of their machine platforms which allow them to serve different industry sectors effectively.
• Lindauer Dornier: featuring in the German Pavilion this edition, they offer a number of weaving machine varieties including rapier, air-jet, open reed weave (ORW) and more. Their rapier weaving machines have set the technological standard in the high quality wool textiles market for decades, and this quality will be on display at their booth with the DORNIER P1 rapier weaving machine.

Domestic brands to watch out for

In addition to these leading overseas brands, a strong line-up of Chinese machinery producers will also feature at the fair, including Changshu Weicheng Non-Woven Equipment and Shijiazhuang Textile Machinery.

• Additives, pigments and masterbatches for transportation, packaging, textiles & fibers
• Support to “future-proof” medical applications
• Contributing towards more sustainable engineering plastics

Clariant, a world leader in specialty chemicals, turns the spotlight on its increasing on-the-ground support and innovation focus for North America’s four key plastics application segments at NPE 2018 Booth S18155.

Clariant is pushing forward with plans for growth in the region by advancing R&D competencies, and increasing its manufacturing footprint and technical capabilities across its 50+ sites, 3 R&D and 6 technical innovation centers. Clariant’s innovations for the plastics industry include advanced additives, masterbatches and pigments which support the packaging sector in engaging consumers via differentiated, convenient solutions. At NPE, it will also highlight solutions for enhancing and protecting healthcare products, as well as its contribution to stronger and colorful textiles and fibers for everything from e-mobility to industrial applications.

Deepak Parikh, president of region North America, Clariant comments: “Clariant’s product innovation for the US and wider North American plastics industry embraces the region’s fastest growing end-use areas of automotive and construction. It also addresses the impact of trends driven by changing consumer lifestyle preferences and market regulations on other important segments such as packaging and healthcare.”

Transportation
Clariant brings color and protection to support the increasing use of engineering plastics and high temperture resins in automotive interiors, exteriors and under-the-hood. Halogen-free Exolit® OP 1400 provides outstanding flame retardancy to polyamide parts, enhances safety with UL 94 V0 performance down to 0.4 mm and enables the molding of complex parts with no mold deposits and blooming. Exolit OP 1400 has been awarded the Clariant EcoTain®label for outstanding sustainability and performance. At the same time, Clariant offers low-halogen controlled high-performance PV Fast® pigmentswith excellent migration and weather fastness properties to meet the high requirements of today’s transportation and automotive industry. Easy processing Renol® compounds and masterbatches for engineering and high temperature resins provide heat and light stability, and flame retardancy, while maintaining critical flow properties in parts like SMT connectors. Importantly, they are available as small lots which enables customers to purchase only what they require and contribute to a reduction in their carbon footprint.

Packaging
As US packaging manufacturers explore more consumer-friendly, lighterweight and appealing solutions, Clariant is on hand to support their functionality, sustainability-related and color desires. Clariant Pigments has an innovative cooperation with Konica Minolta and matchmycolor to enable fast, precise and efficient color matching of HDPE products, using select organic PV Fast and Graphtol® pigments that comply with FDA regulations. The ColorWorks®center in Chicago is dedicated to US brand managers and designers with teams of color design experts to create color formulations faster than ever before for bottles, caps, closures and films.

According to market reports, plastic pouches are gaining share from traditional pack types in packaged food and are mainstream in home care. To support smoother and more environmentally-compatible processing especially for film applications, Clariant offers an FDA-compliant, vegetable-based powder amide wax, Licolub® FA 1, which acts as a slip and anti-block agent. It is suitable for polyolefins and PVC.

Textiles & Fiber
At NPE 2018, Clariant puts the focus on strong and colorful textiles, carpets and industrial fibers. New AddWorks® TFB 117 offers a number of benefits to help stabilize and smoothen fiber production processes, protect color, and improve heat stability and mechanical properties of fibers. AddWorks TFB 117 ensures smooth spinnability with less filaments breakage, even at low processing temperatures and at high speed spinning up to 5,500 m/min. Clariant also offers a broad range of colorants for polypropylene, polyester, polyamide and acrylic fibers, featuring migration fastness, chemical stability, light- and weather-fastness.

Healthcare
Clariant supports risk control and regulatory compliance for medical polymer and pharmaceutical packaging solutions. Its Mevopur® color and performance masterbatches and compounds include a USP Class 6 line of compliant products and multiple global ISO, 87, 88, and 661.1 certifications ahead of the market deadline. Clariant also offers selected FDA-compliant organic pigments and polymer soluble dyes that meet purity migration fastness as well as toxicological properties for medical devices and pharmaceutical packaging.

• Oerlikon integrates automation solutions for largescale plants in technology portfolio

Remscheid, Germany / Pfäffikon, Schwyz, Switzerland - Oerlikon announced today that it has acquired Germany-based AC-Automation GmbH & Co. KG, an engineering company specializing in large-scale plant automation solutions for the textile and packaging industries. The two companies have been partnering since the early 1980s. The integration of AC-Automation in Oerlikon expands the market-leading technology portfolio of its Manmade Fibers Segment. It also marks a milestone in Oerlikon’s ongoing quest to offer innovative, fully automated and digitally networked Industry solutions in the manmade fiber industry.

The 60 employees at AC-Automation’s Bernkastel-Kues and Augsburg locations will become part of Oerlikon’s Manmade Fibers Segment, which includes the leading brands Oerlikon Barmag and Oerlikon Neumag. The move will expand the Segment’s business model, adding another key core component to its current offering of production plants and technology solutions from melt to yarn, fibers, andnonwovens. Ultimately, Oerlikon will be able to offer customers a total solution from a single source, including automation logistics for packaging, high-bay storage, and other areas, which complement its current market-leading spinning and process technologies for the textile industry.

"We see our expanded overall offering as an Industry solution, reflecting the future of an even more efficient, digitized and profitable chemical fiber industry, especially for large-scale plants with daily production capacity of several hundred tons of polyester, nylon, polypropylene, or other manmade fibers,” explains Georg Stausberg, CEO of the Manmade Fibers Segment. Manmade fiber producers from China — the world’s most important market, generating more than 70 % of worldwide manmade fiber production — as well as companies from other fast-growing markets such as India, Turkey and the USA are also relying on automated and networked Industry total solutions.

"The acquisition and integration of AC-Automation’s automation solutions will provide new opportunities for our manmade fiber business. It enables the Segment to increasingly position itself as an Industry solution provider in combination with our own digitization solutions,” says Oerlikon Group CEO Dr. Roland Fischer. “As a leading provider of advanced materials, surface solutions and materials processing including the engineering and production of polymer plants, this acquisition marks another milestone in Oerlikon’s strategy to strengthen its businesses and thus sustain profitable growth.”

"After such a long partnership, we are excited to be able to benefit even more in the future as part of a global player in the textile industry. Our market access will further improve with the help of the Oerlikon
Group's sales and service network. For my employees, I am very pleased to be able to bring them into an international Group, in which there would be new opportunities and perspectives for them personally,”
said Rolf Gänz, AC-Automation’s Managing Director.

For buyers that prioritise having the widest range of sourcing options in one place, their best bet is March’s Intertextile Shanghai Apparel Fabrics. Boasting pavilions from Japan, Korea, Pakistan and Taiwan, individual exhibitors from Hong Kong, India, Indonesia and Vietnam, not to mention 2,800-plus Chinese exhibitors, the fair is the largest gathering of Asian suppliers under one roof for the spring / summer sourcing season. To ensure convenience for buyers, international exhibitors are grouped by country or region, while Chinese exhibitors are located in product halls including fabrics for casualwear, functional wear / sportswear, ladieswear, lingerie & swimwear, shirting and suiting, as well as for accessories and denim.

In total, around 3,300 exhibitors will showcase their apparel fabrics and accessories at the fair, with the SalonEurope zone hosting premium suppliers from Europe – including pavilions and zones from France, Germany, Italy and Turkey – while the International Hall also houses other overseas exhibitors from the likes of Argentina, Australia, Peru the US and elsewhere.

Japan Pavilion keeps ‘Banshu-Ori’ tradition alive
Organised by the Japan Fashion Week Organization (JFW), the Japan Pavilion will house 22 exhibitors and also feature a Japan Trend Corner. After the immense popularity of this pavilion with buyers in previous editions, the organisers are in a good position to comment on the trends in the local market. “The now mature Chinese market tends to seek out very different types of products and purchase in smaller batches, which is a world away from the mass-production focus of the past,” JFW commented.

Included in this edition’s Japan Pavilion are three companies from the Nishiwaki region, which is famous for its ‘Banshu-Ori’, or Banshu weave. Banshu-Ori is a yarn-dyed fabric, woven into various patterns, such as checks and stripes, with yarns that are dyed before being woven by weaving machines. This tradition dates back to 1792, and will be showcased by Bon Co Ltd, Ueyama Orimono Corp and Kuwamura Co Ltd at the fair. Bon will showcase a range of new products using this traditional technique, including organic cotton fabrics, paper yarn fabrics and indigo items. Ueyama Orimono, which boasts Japan’s largest dyeing factory in Nishiwaki, designs its own fabrics in Tokyo, and will present cotton, cotton / linen and medium-thin yarn-dyed fabrics at the fair. Kuwamura will showcase fabrics based on 100% yarn-dyed cotton, as well as cotton and cotton-blend materials.

Taiwan Pavilion the place to find innovation
The Taiwan Pavilion, with over 40 participating companies, is a guaranteed source of innovation at the fair, with a number of exhibitors also offering eco-friendly options. Some of the highlights include:

• Keen Ching Industrial: they will have a number of their patented KCC-branded zippers at the fair including a durable double-coil zipper, an invisible zipper with a movable retainer box, a track type water-repellent zipper, a curved metal zipper and more.
• Handseltex Industrial: will showcase a wide range of products including lace, jacquard and mesh, made with the likes of organic cotton and recycled polyester with an eco-friendly production process.
• Paltex: the company’s ‘From Waste to Yarn’ regeneration system involves turning waste fishing nets and plastic bottles from the ocean into polyester and nylon fabrics, membranes and trimmings.
• Superwill: their unique gradient fabric combines specialty yarns and a special knitting process, and features a thickness that decreases from top to bottom. This design allows the fabric to be tailored to different garments.
• Tri Ocean Textile: will feature its own DreamFel® high-performance filament polypropylene yarn which is lightweight, durable and environmentally friendly, and used in sports & outdoor apparel and outdoor furniture.

The Taiwan Pavilion will be full of innovative textile solutions again this edition
The Korea and Pakistan Pavilions round out the Asian offerings. Nearly 60 Korean exhibitors will showcase predominantly manmade, fancy, knitted, acetate woven, tricot, jacquard, faux leather and printed fabrics, as well as lace and embroidery, for ladieswear, while other members will feature fabrics for sportswear and outdoor wear. Those from Pakistan, meanwhile, will feature in the Beyond Denim hall and offer a wide range of denim products.  

In addition to Intertextile Shanghai Apparel Fabrics, four other textile fairs also take place at the National Exhibition and Convention Center: Yarn Expo Spring, Intertextile Shanghai Home Textiles – Spring Edition, fashion garment fair CHIC and knitting fair PH Value.

In May 2017, Jochen Adler, Vice-President and Chief Technology Officer at Oerlikon Textile GmbH & Co. KG, presented a Oerlikon Barmag take-up winder as a partial gift to Prof. Dr Thomas Gries, head of the Institut für Textiltechnik (ITA) at RWTH Aachen University. The new Type ASW602 winder, which is equipped with modern control software and user interface, replaces the former institute’s Barmag take-up winder.

Due to this modernisation, ITA has access to a latest generation take-up winder which is used for various research projects. The new winder is applied at ITA’s two pilot melt spinning plants and ensures the transfer of new research and development insights into the pilot scale. Furthermore, this winder has two winding positions and operates with winding speeds between 2500 m/min and 5500 m/min. The new winder is suitable for all kinds of polymers, from polypropylene to polyethylene, polyester, polyamide etc. as well as for the production of several types of yarn, such as industrial yarn, pre-oriented yarn and fully-drawn yarn.
“We thank Oerlikon Barmag for the generous partial gifting and the support during the set-up of the new take-up winder”, says Prof. Dr Thomas Gries. “The new equipment will keep the institute’s machine park on a high and powerful level.” The head of ITA’s chemical fibre department Dr Thorsten Anders adds: “This winder is designed for the needs of chemical yarn research. It allows state of the art technology research and development and pilot-scale production. We will use it for the melt spinning plants in the single- and bi-component spinning process. This way, we can access a wide variety of producible yarn types.“