From the Sector

International technology group ANDRITZ has successfully started up the new carding machine and opening/blending line it delivered to Albis in Roasio, Vercelli, Italy.

With its large working width of 5.10 meters, the machine allows for the production of nonwoven fabrics tailored to specific customer requirements while maintaining excellent properties and consistent quality. One example is Albis Curacell ®, a multilayer composite nonwoven fabric in a weight range between 35 and 70 gsm that is produced with a fully water-free patented process and is able to absorb liquid flows of over seven times its own weight. The production line also includes an advanced upstream opening and blending system from ANDRITZ.

Albis, a privately owned group founded in Italy in 1995 by Gianni Boscolo, has been a major player in the nonwoven market for over three decades. Through continuous research and development, the company offers innovative, high-quality nonwoven solutions across various sectors, including hygiene, medical, personal care, textiles, filtration, and agriculture.

•    First production supercar created with Hypetex coloured carbon fibre
•    Paint-replacement technology reduces weight to enhance performance

British car manufacturer Briggs Automotive Company (BAC) has created a unique Hypetex coloured carbon fibre version of its Mono R, reducing the weight by removing the need for paint.  

The original BAC Mono R was created to be lighter and more powerful than the standard model, with 343bhp and 555kg total weight, equating to a power-to-weight ratio of 618bhp-per-tonne. By removing the need for paint coatings in this version, the net weight of the exterior is reduced compared to a painted shell, resulting in a further improved overall performance.

The car’s body was created using Hypetex’s titanium carbon fibre twill, and finished with a crystalized lacquer, offering a unique aesthetic finish. The ultra-lightweight supercar can accelerate from zero to 60mph in less than 2.5 seconds.  

Hypetex’s paint-replacement technology retains the visible weave, allowing for a bold design and a choice of colours without technical compromises, perfectly aligning with BAC’s initiatives to maximise performance whilst creating bespoke supercars. Paint generally adds 138 grams per metre squared, whereas Hypetex adds just 17 grams for the same area, offering an 8x weight saving.
This bespoke version of BAC’s single-seater Mono R was subject to BAC’s renowned BAC Bespoke programme, which ensures that no two Monos are the same. The client, a US-based collector, worked with BAC’s design team to design the car to their personal taste.   

Born out of Formula 1 technology, Hypetex offers manufacturers sustainable aesthetic materials with technical and efficiency benefits. This collaboration is an all-British success story, with the Hypetex carbon fibre body built by Formaplex, a leading UK-based manufacturing company who manufacture lightweight engineered solutions for top tier customers in Automotive, Aerospace and Defence markets. BAC’s supply chain is 95% UK-based.  

Hypetex continues to expand its growing portfolio of the use of coloured carbon fibre to add personalisation to the automotive field, with its material recently featured on the 2024 Ford Mustang Dark Horse.  

Technological progress often results from close collaboration, and industries that rely on continual improvement stand to benefit from the return to in-person business. Cinte Techtextil China’s first edition since eased pandemic measures is set to reflect a 27.9% increase in exhibitor numbers, with a rejuvenated international contingent further supplemented by the return of the European Zone. Taking place from 19 – 21 September across 40,000 sqm at the Shanghai New International Expo Centre, the platform is expected to welcome buyers from across Asia, Europe, and beyond. Pre-registrations have doubled compared to the previous edition, and international buyers account for over 20% of the total.

The new zone, Marine Textile Zone, will be comprised of multiple Chinese green marine and nautical rope netting exhibitors, while also hosting the Technology Exchange Forum, and the awards ceremony of the Top 10 Suppliers in the China Rope Net Industry. Prominent exhibitors in this zone include Ropenet Group, Hunan Xinhai, and Zhejiang Four Brothers Rope.

Other domestic exhibitors, such as Shanghai Shenda Kebao New Materials, SIJIA New Material (Shanghai), Zhejiang Hailide New Material, and Zhejiang Jinda New Materials, will showcase products for applications in outdoor advertising, tents, boats, vehicles, environmental engineering, and much more.

Supplementing the fairground’s wide variety of domestic suppliers will be a much-increased showing of international exhibitors, with many to be found within hall E1’s European Zone. Several global industry leaders are featured in their categories below:

Nonwovens equipment

• Autefa Solutions, Germany: solutions provider for nonwovens lines and machines for carded-crosslapped needlepunching lines, spunlace lines and thermobonding lines.
• Dilo, Germany: in addition to offering general services, Dilo supplies opening and blending equipment, carding and airlay machines, and crosslapping and needling machines.
• Groz-Beckert, Germany: provider of industrial machine needles, precision parts and fine tools, as well as systems and services for the production and joining of textile fabrics.
• Reifenhäuser Reicofil, Germany: provider of innovative technologies and components for plastics extrusion, producing blown films, cast films, sheets as well as nonwovens.

Weaving equipment

• Itema, Italy: provider of advanced weaving machines, spare parts, and integrated services, specifically for rapier, air jet and projectile weft insertion technologies.
• Lindauer DORNIER, Germany: the company manufactures weaving machines, film stretching lines, and composite systems, also offering technical support and spare parts supply.
• Picanol, Belgium: producer and servicer of high-tech air jet and rapier weaving machines, with around 2,600 weaving mills utilising their systems worldwide.

Coating and lamination

• BRÜCKNER Textile Technologies, Germany: manufacturer of machines and lines for the coating and finishing of apparel fabric, technical textiles, nonwovens, glass fabrics and floor coverings.
• ROWA Lack, Germany: developer of high-quality materials and product solutions for the polymer industry, with applications including automotive, electrical engineering, construction, technical textiles, and medical technology.
• Stahl, the Netherlands: the Dutch company provides high quality coatings, dyes and process chemicals for leather, flexible coated substrates, textiles, films and foils, paper, and related products.

Fibre

• Monosuisse, Switzerland: with production sites in Switzerland, Poland, Romania, Mexico, and Germany, Monosuisse manufactures various precise, high-quality polymer monofilaments from 19µm to 3.00 mm in diameter.
• Perlon, Germany: specialised in the manufacture of synthetic filaments in diverse application areas, including paper machine clothing, dental care, and advanced technical textiles for agriculture, 3D printing, sports and leisure, home, and more.

Meanwhile, first-time exhibitors include Rökona (Germany), showcasing RE:SPACE, their range of recycled technical textiles; Testex AG (Switzerland), the official OEKO-TEX® representative in multiple countries including China; Hohenstein (Germany), the renowned testing laboratory and research institute; and zwissTEX (Germany), the knitted fabrics and lamination specialists. In addition, the returning Taiwan Pavilion is set to feature the debut of Shinih Enterprise Co Ltd (Taiwan China).

Beyond the innovation displayed at the booths, the fair’s programme is set to welcome global experts from various technical textile and nonwoven sub-sectors to offer specific insights and unveil innovations. Highlighted events include:

The 11th China International Nonwovens Conference
14 sessions cover topics such as the quality control of medical supplies; green development in technology and applications in the nonwovens industry; and the development and application of flashspun nonwovens in China.

Marine textiles and rope netting events
Events specific to this zone include the Top 10 Suppliers in the China Rope Net Industry; Conference on Textile Applications for Marine Engineering and Fisheries; and the China Nonwovens & Industrial Textiles Association (CNITA) Rope Net Branch Council Meeting

"Nonwovens, Creating a Better Life” Innovation Showcase
Product display area showcasing around 100 nonwovens products with applications in five areas: medical and health, quality of life, human habitat, sustainable development, and innovative design.

Advanced Technical Textiles Industry Chain Synergistic Innovation Development Forum
Includes presentations from multiple key players in the technical textile industry, including Mr Steven Liu, Commercial Manager of Polymer Additives Business of Sanitized (China) Ltd.

Spinnova has decided to evaluate its existing strategy to prioritise areas that in the short- to medium-term deliver the fastest time to positive cashflow generation and that create the most value for the company’s stakeholders.
 

The company expects to conclude the assessment of its strategy in the coming months, after which the results will be presented in more detail including key actions and any changes to medium- and long-term business targets. Financial guidance for full year 2023 is unchanged.

Spinnova’s unique sustainable technology is a key differentiator. To recognize the value of its technology offering, the company has decided to review opportunities to expand the licensing of its technology to new customers. In the future, Spinnova sees great potential in developing circular raw materials such as textile waste and agricultural waste, as well as recycled SPINNOVA® fibre. Initial tests show that refining these raw materials into micro fibrillated cellulose (MFC) may be more efficient than refining other raw materials Spinnova has worked with. The company has received significant interest from customers wanting to build plants that convert multiple circular raw materials into SPINNOVA® fibre.

Together with Suzano, Spinnova is gathering the learnings from the first Woodspin plant to support the decision making for the next Woodspin factory investment. At the same time Spinnova continues to further develop the technology concept to reduce capital expenditure per tonne of fibre produced compared to the first Woodspin plant. While Suzano develops its MFC process it is expected that the first Woodspin facility will mainly be used for R&D to test new MFC batches and that commercial production volumes will be limited in the short term. The market opportunity and ambition level with Suzano to scale Woodspin’s production capacity remains unchanged

Spinnova will continue to have the option to invest into all future Woodspin and Respin plants, as per the respective joint venture agreements. The company will evaluate whether it participates in these investments based on the value it creates for Spinnova’s shareholders compared to other opportunities to invest Spinnova’s capital. Regardless of whether Spinnova invests its own capital into future plants, Spinnova will continue to be the exclusive technology provider to Woodspin and Respin, and they will continue to be important technology customers of Spinnova.

INDA, the Association of the Nonwoven Fabrics Industry, announced the conference program for Hygienix™ 2023, November 13-16 to be held at The Roosevelt New Orleans Hotel, New Orleans, LA.

The program details can be found on the Hygienix website.

The keynote speaker is Courtney Scharf, Chief Client Officer, Trend Hunter. Trend Hunter leverages big data, human researchers, and AI to identify consumer insights, and deep dive opportunities for the world’s most innovative companies, such as Unilever, Colgate-Palmolive, Georgia-Pacific, Kroger, Johnson & Johnson, Reckitt Benckiser, Samsung, and Bacardi. Trend Hunter utilizes Artificial Intelligence and research to identify and curate top insights and trends to advise brands and businesses in their pursuit of innovation.

The Hygienix program will feature thought leaders in consumer-centric innovations, the circular economy, raw material advancements in sustainability, opportunities for advanced recycling in absorbent hygiene, optimizing the packaging footprint, new approaches for odor control, and market trends and drivers.

Experts presenting at Hygienix include:

• Aquapak Polymers Ltd. – “Creating Sustainable Nonwovens for Hygiene Applications with Thermally Processable Polyvinyl Alcohol; A Water Soluble, Environmentally Friendly and High-Performance Polymer”
• Asahi Kasei Advance Corporation – “Continuous-Filament Cellulose Nonwovens”
• Confitex Technology – “Reusables Production: It’s Not All Green”
• Egal Pads, Inc. – “Closing the Circularity Gap One Used Pad at a Time”
• Essity – “Diaper Collection & Recycling in Australia”
• ExxonMobil Chemical Company – “Innovate New Levels of Strong Comfort with Hygiene Solutions”
• Henkel Corporation – “Reducing the Packaging Waste from Personal Hygiene Products”
• INNOVATEGRN – “Accelerating Innovation / Embracing a Consumer-Centric Approach”
• Kuraray Europe GmbH – “Safe and Eco-friendly Elastics for Absorbent Hygiene Products”
• Nexus Circular – “Increasing Plastics Circularity for the Hygiene Segment Through Advanced Recycling”
• W. Pelz GmbH –“Disposable Pads Meet Reusable Underwear”
• Price Hanna Consultants – “Squaring the Circle: Why Demonstration Projects = Good Sustainability Strategy” and “Wellness and Natural Materials”
• Rem Brands, Inc. – “Effective Reduction of Material Odors, In-use Odors, and Post-use Odors”
• Sequel – “Spiraling into Business: How a Dramatic Innovation to the Tampon Met the World’s Largest Manufacturer of Feminine Hygiene”
• Sparkle Innovations Inc. – Sustainability and Circularity in the Absorbent Hygiene Products Industry”

The Hygienix program will offer a hands-on workshop as well as two pre-conference webinars. Jim Robinson, Principal, Absorbent Hygiene Insights, LLC, will lead the in-person workshop on AHP Absorbent Hygiene Systems, Monday afternoon, November 13th. This workshop evaluates SAP absorption for different SAPs and participants have the opportunity to deconstruct and examine several hygiene products including infant, adult, and period care products to increase the understanding of these systems.

To reach its goal of being the world’s leading supplier of enhanced recycled polyethylene terephthalate (PET), gr3n is signing a binding Memorandum of Understanding (MOU) with its shareholder Intecsa Industrial to set up a Joint Venture.

gr3n together with Intecsa Industrial will join forces and build a “First-of-a-Kind” manufacturing facility able to produce 40.000 tons of virgin-like PET, commencing EPC phase in Q4-2024 and aiming to be operational in 2027. gr3n’s chemical recycling technology is capable of processing PET from various industries including textile waste, closing the loop for hard-to-recycle PET applications.

The world’s first industrial-scale MADE PET recycling plant will have the capability to process post-industrial and post-consumer PET waste including hard-to-recycle waste, to produce approximately 40.000 tons of virgin PET chips from the recycled monomers saving nearly 2 million tons of CO2 during its operating life. The post-consumer and/or post-industrial polyesters will be both from bottles (colored, colorless, transparent, opaque) and textiles (100% polyester but also mixtures of other materials like PU, cotton, polyether, polyurea, etc. with up to 30% of presence in the raw textile).

The technical concept of the MADE plant is to break down PET into its main components (monomers) so they can potentially be re-polymerized endlessly to provide brand new virgin PET or any other polymer using one of the monomers. Polymers obtained can be used to produce new bottles/trays and/or new garments, essentially completely displacing feedstock material from fossil fuels, as the recycled product has the same functionality as that derived traditionally. This means that gr3n can potentially achieve bottle-to-textile, textile-to-textile, or even textile-to-bottle recycling, moving from a linear to a circular system.

gr3n’s process has the potential to change the way PET is recycled worldwide, enabling huge benefits for both the recycling industry and the entire polyester value chain. Many efforts have been made in the past to transfer enhanced recycling from research laboratories to the manufacturing industry, but the economics and skepticism of the first adopters have constantly blocked the progress of the proposed solutions. Thanks to the MADE technology developed by gr3n, this approach is now feasible and makes gr3n one of the few companies with the potential to provide a reliable enhanced recycling solution that closes the life cycle of PET, and also offers food grade polymer material, processes a large variety of waste and reduces the carbon footprint of these materials usually destined for incineration or landfill.

• ITA Master's graduate wins Hanns Voith Foundation Award 2023

In his Master's thesis, Flávio André Marter Diniz, a graduate of the Institut für Textiltechnik of RWTH Aachen University (ITA), developed ultra-thin polyethylene (PE) carbon fibres with a filament diameter 2-3 times smaller than usual. In addition, the use of PE-based precursors will make it possible to reduce the price of carbon fibres by 50 per cent in the future, thus opening up a wide range of other possible applications in key industries such as wind power, aerospace and automotive. For this groundbreaking development, Marter Diniz was awarded the Hanns Voith Prize with the Hanns Voith Foundation Award in the category "New Materials". The prize is endowed with € 5,000 in prize money.

Flávio André Marter Diniz won the prize in the category "New Materials" for his master thesis entitled "Investigation of the stabilisation and carbonisation process for the production of ultra-thin polyethylene-based carbon fibres".

The use of carbon fibres in highly stressed lightweight construction solutions, such as today's growth applications of wind turbines or pressure tanks, has become indispensable due to their excellent mechanical properties and low density. High manufacturing costs of conventional PAN precursor-based carbon fibres make the material very cost-intensive. In addition, it is not sufficiently available. New manufacturing approaches that develop alternative raw materials and manufacturing processes can be a key and growth engine for further industrial composites applications.

The aim of the work was to develop a new and cost-effective manufacturing process for high-quality ultra-thin carbon fibres using a polyethylene precursor. For this purpose, the sulphonisation process, which is time-consuming today, was to be significantly shortened. As a result, Mr. Marter Diniz produced novel ultra-thin polyethylenebased carbon fibres with a filament diameter < 3 μm with an excellent surface quality of the fibres without detectable structural defects. The fibre diameter is 2-3 times smaller than that of conventional PANbased CF. This provides the basis for mechanically high-quality material properties. At the same time, Mr. Marter Diniz was able to reduce the sulphonisation time by 25 percent. The developed material and technology set important milestones on the way to cheaper carbon fibres. With PE-based precursors, the price of CF can be reduced by 50 percent compared to conventional PAN-based CF.  

A total of five other young scientists were awarded in six categories (Drive Technology, Innovation & Technology/Artificial Intelligence, New Materials, Paper, Hydropower and Economic Sciences. This year, for the 10th time, the Hanns Voith Foundation awarded the Hanns Voith Prize to outstanding young scientists.

The EPTA – European Pultrusion Technology Association organizes in cooperation with the ACMA – American Composites Manufacturers Association - the 17th World Pultrusion Conference on 29th February – 1st March 2024 in Hamburg, Germany. The conference is one of the leading pultrusion events in the world. The event takes place just before the JEC World 2024 in Paris (5th – 7th March 2024).

The presentations are to document innovations in the following subject areas of
pultruded reinforced plastics:

• Market development in Europe, USA, Asia
• Innovative applications
• New Markets: Ideas for potential new applications with pultruded shapes or
• systems
• Sustainability: Technical possibilities, recycling, etc.
• Raw materials
  ○ Development of fibres
  ○ Development of resins
• Construction / Testing / Calculation
• Processes

The presentation language will be English. Deadline for paper submission (title, short abstract, speaker name and address) until 15th September 2023 to info@pultruders.com.

Spinnova has entered into a yarn development cooperation agreement with the Portuguese company Tearfil, where Tearfil will operate Spinnova’s R&D yarn-spinning line. The yarn-spinning line is intended for product development and will be located in Guimarães, Portugal at Tearfil's facilities.  

The rationale behind the yarn-spinning line is for research and development into using Spinnova's fibre in commercial scale yarn production and to streamline development work with industry partners.   
Spinnova has decided to locate the line in Guimarães in Portugal, at Tearfil’s facilities. Spinnova will benefit from the industry know-how of a strong partner and from the proximity of one of Europe’s most significant textile industry hubs in Portugal. This will improve Spinnova’s access to global textile markets.   

Spinnova’s yarn-spinning line will be installed at Tearfil's premises. The technology delivery and installations are expected to take place in the fall of 2023, and the spinning line is intended to be operational by the end of the year. Tearfil is responsible for the yarn-spinning line's operations, and Spinnova will use a part of the line capacity for its product development.  

In 2021, Spinnova announced that it would establish an R&D yarn-spinning line in Jyväskylä, Finland. The decision to change the location was made during the feasibility planning and discussions with potential partners. This change in location and operational model will slightly decrease the capital expenditure and will lead to lower operational expenses.  

The technology supplier for Spinnova's new spinning mill line is the Swiss-based company Rieter. Rieter is a leading supplier of systems for manufacturing yarn from staple fibers in spinning mills. The company develops and manufactures machinery, systems and components used to convert natural and man-made fibers and their blends into yarns in the most cost-efficient manner.

Nylon 6, nylon 6,6, polypropylene, PET and calcium carbonate are available through the company’s proprietary carpet recycling process

Circular Polymers by Ascend, a market-leading recycler of post-consumer carpet, today the launch of Cerene™, a line of recycled polymers and materials made from the company’s proprietary carpet reclaiming technology. Cerene is available as polyamide 6 and 66, PET, polypropylene and calcium carbonate as a consistent,
sustainable feedstock for many applications, including molding and compounding.
Recycling experts from Circular Polymers will be showcasing Cerene at Compounding World Expo on June 14-15 at the Messe Essen in Germany.

Ascend Performance Materials, a fully integrated producer of durable high-performance materials and the majority owner of Circular Polymers by Ascend, is known for its innovations in nylon 6,6. Cerene will continue that legacy with offerings in nylon 6,6 while also bringing to market recycled polymers such as nylon 6, PET and PP.

“Customers around the globe are seeking consistent and reliable post-consumer recycled materials,” said Maria Field, business director of Circular Polymers by Ascend. “Cerene is mechanically recycled using a process that minimizes our carbon footprint and environmental impact.”

Circular Polymers by Ascend converts post-consumer carpet into fiber and pellets. The company uses a proprietary process in its California-based facilities to achieve high efficiency in recycling, successfully providing a new life for virtually every component of the carpet and backing. The company has redirected 85 million pounds of carpet from landfills into new goods since 2018.