From the Sector

International technology group ANDRITZ has received an order from the Uzbek cotton spinning specialist Texygen Textile LLC to supply a complete neXline spunlace line. Start-up is scheduled for the first quarter of 2023.

This will be the first spunlace line ever installed in Uzbekistan. The equipment will process high-quality cotton fibers in a fully integrated production line, from bleaching to winding. With this new line, Texygen Textile LLC will be able to produce top-class spunlace wipes made of 100% cotton, thus opening up new market opportunities.

The ANDRITZ equipment will minimize fiber loss and enable Texygen to produce a high-end spunlace fabric that will allow the company to serve the international medical industry with spunlace wipes.

Established in 2010, Texygen is a frontrunner in the Uzbekistan textile industry, especially in cotton spinning. The company has its headquarters in Tashkent, Uzbekistan.

Over the past 14 days, the wholesale cost of natural gas in Germany has risen by more than 50%. This increase presents an extraordinary challenge for industry, and there is no sign of support or intervention from the Government. Indeed, recent statements are destined to provoke a worsening of the situation.

Kelheim Fibres is entirely dependent on natural gas for the generation of electrical energy and steam and has no viable short-term alternatives. In addition, the raw materials used by the company often consume high levels of energy in their production and are also increasing significantly in cost. These increases in cost jeopardise the future of the business if they cannot be passed on though the supply chain.

Kelheim Fibres is calling on the Government of Germany to take immediate steps to mitigate the impact of the cost increases for natural gas and is committed to work to implement alternative sources of energy in the medium term.

In parallel, the disruption to global logistic networks that has been seen throughout 2021 is now expected to continue throughout 2022. Massive increases in shipping rates – in some cases in excess of 80% – are being imposed without notice and with no opportunity for negotiation. These costs must also be passed on though the supply chain if businesses are to remain viable.

To address these issues, Kelheim Fibres is implementing the following measures with immediate effect:

• The increased cost of energy and freight will be passed on in prices to customers at the soonest opportunity;
• If necessary, changes or adjustments to existing agreements will be negotiated to reflect the increased cost levels;
• If the necessary increase in fibre prices cannot be secured, cuts to production will be implemented with the objective of minimising losses until the cost increases can be mitigated.

As the drivers for the increases in natural gas prices appear to be temporary in nature, we will maintain any price adjustments under review and pass on any relief to customers.

Craig Barker, CEO of Kelheim Fibres, describes the current situation as critical. “The cost increases we are facing are unprecedented and call for swift and decisive action. We are determined to take the necessary steps to preserve the future of our business and provide security of supply for our customers. At the same time, we are relying on the support of our customers to help us conquer the challenges our business is facing.”

The AVK – Industrievereinigung Verstärkte Kunststoffe – has once again presented its Innovation Awards to companies, institutes and their partners. Three composites innovations were recognised in each of the three categories – “Innovative Products/Applications”, “Innovative Processes” and “Research and Science” – at the new event JEC Forum DACH on 23 November 2021, the first edition of which was held in Frankfurt.

“As usual, the submissions included a lot of very interesting and promising products and processes this year. The Innovation Awards highlight the outstanding efficiency, cost-effectiveness and sustainability of fibre-reinforced plastics as well as the companies and institutes operating in the sector,” explains Dr. Elmar Witten, Managing Director of the AVK. The jury of leading experts from the industry honoured the following innovations this year:

Category “Research and Science”
First place in the “Research and Science” category was awarded to the German Aerospace Center (DLR) for its Bondline Control Technology (BCT). This innovative process is used for quality control and assurance of bonded joints. The core element is a porous fabric which is applied to a joining surface using an epoxy adhesive or matrix resin. Peeling away the fabric creates a chemically reactive and undercut surface and can also be used as a test to check adhesion to the substrate. BCT has potential in a variety of possible applications. For example, peel ply can be replaced by BCT fabric to produce composite components with an optimised joining surface. The cost-effective BCT peel test is suitable for coupon testing and process control. In addition, the combined adhesion test and surface pre-treatment can be used for quality assurance of bonded repairs on fibre composite structures.

Second place was taken by the Institute of Textile Technology (ITA) at RWTH Aachen University and its partners AEROVIDE GmbH, Altropol Kunststoff GmbH, Basamentwerke Böcke GmbH, TechnoCarbon Technologies GbR with “StoneBlade – Lightweight construction with granite for the wind industry”. This innovation enables manufacturers to reduce the amount of non-recyclable materials used in rotor blade construction. At the same time, it reduces the weight of these components and improves the mechanical properties relating to the stability of wind turbines. The innovative approach replaces glass-fibre reinforced plastic in the blade components with hard rock – a natural, cost-effective and recyclable lightweight material. The slabs of rock are cut and ground to a thickness of just a few millimetres and embedded in a fibre composite laminate with carbon fibre, which stabilises them for alternating load cases. The pre-stressed material is pressure-stable in the composite and can absorb tensile forces in the event of continuously alternating loads without any loss of stiffness.

Third place went to the Dresden University of Technology – Institute for Lightweight Construction and Plastics Technology (ILK) with its partner Mercedes Benz AG for the interdisciplinary development of a highly integrated inductive charging module for electric vehicles. The ultra-thin charging module was designed to make optimum use of space in the vehicle underbody without reducing ground clearance. An interdisciplinary approach was adopted for the development process. This involved the electrical, mechanical and process characterisation of high-frequency Litz wires, ferromagnetic foil and metal wire cloth as well as the creation of a simulation model. The result is a demonstrator for a charging system with a structural height of 15 mm and a total weight of 8 kg. It achieves a transmission efficiency of up to 92 percent at 7.2 kW nominal power and active air cooling. The hardware demonstrator was fabricated in a 3-step process using RTM and VARI techniques.

Overview of all the winners in the three categories:
Category “Innovative Products/Applications”
1st Place: “Traffic signs from Nabasco (N-BMC)” – Nabasco Products BV and Lorenz Kunststofftechnik GmbH, partners: Pol Heteren BV and NPSP BV
2nd Place: “Novel, ultratough vinyl ester resin for the construction of large marine vessels” Evonik Operations GmbH
3rd Place: “Air intake housing with a multi-material design for gas turbines” – MAN Energy Solutions SE, Leichtbau-Zentrum Sachsen GmbH and Leichtbau-Systemtechnologien KORROPOL GmbH.
Category “Innovative Processes”
1st Place: “In-mould wrapping” off-tool, film-coated, fibre composite components for exterior applications – BMW Group, Partner: Renolit SE
2nd Place: “Adaptive automated repair of composite structural components in the aviation sector” – Lufthansa Technik AG, Partner: iSAM AG
3rd Place: “Automated surface pre-treatment using VUV excimer lamps” – CTC GmbH
Category “Research and Science”
1st Place: “Bondline Control Technology (BCT)” – German Aerospace Center (DLR)
2nd Place: “StoneBlade – Lightweight construction with granite for the wind industry” – Institute of Textile Technology at RWTH Aachen University, Partners: AEROVIDE GmbH, Altropol Kunststoff GmbH, Basamentwerke Böcke GmbH, TechnoCarbon Technologies GbR
3rd Place: “Interdisciplinary development of a highly integrated inductive charging module for electric vehicles” – Dresden University of Technology – Institute for Lightweight Construction and Plastics Technology (ILK), Partner: Mercedes Benz AG

Submissions for the next Innovation Award can be made from the end of January 2022.

The Crypton Companies (Crypton LLC and Nanotex LLC), leaders in high-performance fabrics for contract and residential interiors, has partnered with Hologenix®, LLC, whose CELLIANT® infrared technology is an ingredient in world-class brands across many categories. The two have collaborated to create a new textile innovation, Crypton® CELLIANT®, the first woven upholstery fabric with CELLIANT.

CELLIANT, ethically sourced minerals embedded into fibers, reflects natural body heat back to us as infrared energy. It has been clinically tested and proven to increase cellular oxygenation for improved energy, stronger performance, faster recovery, better sleep and overall enhanced wellbeing. With the tagline “easy care meets self-care,” the new Crypton CELLIANT fabric additionally offers Crypton’s performance characteristics. These include moisture-resistance, stain-resistance, spill-repellence, odor-resistance and cleanability. Both Crypton’s contract fabrics and its Crypton Home lines will offer collections of this innovative blend of Crypton performance along with CELLIANT’s energy-enhancing properties.

Crypton CELLIANT is exclusively woven at The Crypton Mills at Broad River, the firm’s own mill in Cliffside, North Carolina, and enhanced with performance technology in its research and manufacturing facility in Kings Mountain, North Carolina, to the highest environmental standards. Like all Crypton products, Crypton CELLIANT is GREENGUARD® Gold Certified. Crypton CELLIANT will be introduced to market through distributors in early 2022.

• Order intake of CHF 698.6 million in third quarter 2021
• Order intake of CHF 1 673.9 million after nine months
• Acquisition of the three Saurer businesses on schedule
• Credit lines renewed early
• Outlook 2021

The positive market dynamics, which Rieter has already reported on several occasions, continued in the third quarter of the current year. Rieter recorded an order intake of CHF 698.6 million in the third quarter of 2021 (2020: CHF 174.4 million).

The order intake of CHF 1 673.9 million after nine months corresponds to an increase of 294% compared to the prior year period (2020: CHF 425.1 million).
 
The market development is broadly supported at the global level and is based on a catch-up effect from 2019 and 2020 in combination with a regional shift in demand. Rieter believes that a major reason for this regional shift in demand is the development of costs in China. This is leading to increased investments outside the Chinese market. The orders came primarily from Turkey, Latin America, India, Pakistan and China. Overall, Rieter is benefitting from its innovative product range and the global positioning of the company.

The Business Group Machines & Systems achieved an order intake totaling CHF 1 281.6 million in the first nine months of 2021 (+447%).*

In the first nine months of 2021, the Business Group Components recorded an increase of 95% to CHF 227.0 million, while the Business Group After Sales posted an order intake of CHF 165.3 million, an increase of 123% compared to the prior year period.*

Acquisition of the three Saurer businesses on schedule
The acquisition of the three businesses from Saurer, which Rieter announced on August 16, 2021, is proceeding according to plan. The incoming orders for these businesses are not taken into account in this trading update.
 
Credit lines renewed early
The Rieter Group arranged the early renewal of the existing committed credit lines (five-year term, totaling CHF 250 million).
 
Outlook 2021*
The first nine months of 2021 were characterized by a rapid market recovery combined with a regional shift in demand. Rieter expects the demand for new systems to gradually return to normal in the coming months.  
 
For the full year 2021, Rieter anticipates sales of around CHF 900 million.

* See attached document for more information.

The Hygiene Fibers Group of Indorama Ventures (IVL) came together at the Index Show to present an all-inclusive range of recycled and biodegradable solutions for Hygiene Fiber and Nonwoven applications.

The combination of polymers, technologies, processes and global reach supported by the Hygiene Fibers Group – one of three business segments that make up Indorama Ventures – positions it within the Hygiene industry to meet increasingly challenging market demand for innovative sustainable solutions within the hygiene sector. Across the six brands and companies that make up Hygiene Fibers Group – Auriga, Avgol, FiberVisions, Indorama Asia, Trevira and Wellman International – sustainability and supporting customers to achieve circular objectives is integral to all efforts and fundamental to the ethos of the Hygiene business segment.

At the Index Show, the Hygiene Fibers Group launched CiCLO®, a textile technology which allows polyester and other synthetic materials to biodegrade like natural materials do in wastewater treatment plant sludge, sea water and landfill conditions, reducing synthetic microfiber pollution generated during washing, and minimizing plastic accumulation in landfills caused by discarded textiles.

In line with the company’s commitment to support customers with high performance products, while also reducing the impact on the environment, several of the  Hygiene Fibers brands, including Wellman International, Trevira GMBH and Auriga, have been working closely over the last 12 months with the IAM team and the CiCLO® technology. Developments have focused on PET and rPET staple fiber and filament sustainable solutions for applications where recycling is particularly challenging, such as Hygiene, Home Textiles and Automotive applications.

Strengthening the profile of biodegradable offerings within the Hygiene Fibers Group’s sustainability portfolio, Trevira introduced a new range of bicomponent fibres based on PLA and PBS (polybutylene succinate) at the Index show. Both biopolymers offer an exceptional technological opportunity in terms of environmental care and sustainability, while delivering optimum performance. Equally to PLA, PBS is recyclable and up to 100% biodegradable under industrial conditions.

Efforts towards supporting customers to achieve circular objectives are a priority within the Hygiene Fibers Group. This is reflected in the recycled fibers expertise deployed across the segment. Four Hygiene Fibers Group brands, IVL Asia, Auriga, Trevira and Wellman International offer an extensive range of 100% recycled, accredited PET fibers, across a multitude of fiber and nonwovens applications.

The development and evolution of sustainable technologies is central to activity across IVL’s Hygiene Fibers Group, with particular focus on sustainable polyolefin solutions. FiberVisions and ES-FIBERVISIONS, leading Polyolefin mono and bico fiber brands and sister company Avgol, have partnered with UK-based Polymateria to commercially harness the innovative ‘biotransformation’ technology pioneered by Polymateria. The patented technology alters the properties of polyolefins to make them biodegradable in a natural process.  Other polyolefin sustainable innovations within the Hygiene Fibers Group were featured at Index include biosurfactant and biocolourant developments being undertaken by the Avgol team with FiberVisons progressing sustainable design solutions, including lightweight, high performance, reduced carbon solutions.

Due to soaring natural gas and ammonia prices, Röhm GmbH announces a price increase for MERACRYL™ MMA (methyl methacrylate) and other methacrylate monomer products in Europe with immediate effect.

As agreements allow, the increase is:

MERACRYL™ MMA: 130 EUR/mt
MERACRYL™ GMAA: 130 EUR/mt
MERACRYL™ n-BMA: 95 EUR/mt
MERACRYL™ i-BMA: 95 EUR/mt
MERACRYL™ HEMA 98: 110 EUR/mt
MERACRYL™ HPMA 98: 110 EUR/mt

Lenzing presented at FILO its sustainable approach and on a selection of key innovations such as TENCEL™-branded specialty fibers.

As part of the space dedicated to Cittadellarte – Fondazione Pistoletto and Fashion B.E.S.T., the first Italian collective of responsible fashion designers, a selection of TENCEL™’s key technologies were under the spotlight:

• TENCEL™ x REFIBRA™, using cotton textile waste and wood pulp as the feedstock for cellulosic fibers, creating a circular solution;
• TENCEL™ x Indigo Color, infusing pigment into fibers directly during the spinning process;
• TENCEL™ Luxe, providing superior aesthetics, performance and comfort to be the perfect partner of other noble fibers such as silk, cashmere or wool;
• TENCEL™ Carbon Zero, offering carbon-zero CarbonNeutral®-certified products by Natural Capital Partners;
• TENCEL™ x Eco Clean, bringing totally chlorine-free-bleached TENCEL™ Modal fibers to the textile industry.

Lenzing's priority has been to produce fibers for many sectors (fashion, beauty care, cleaning, hygiene and home textiles) in a sustainable way. Each Lenzing product is made of cellulose from wood, a renewable natural resource, coming only from certified sustainable sources.
The Lenzing Group operates two commercial-scale biorefineries with 100% wood utilization, which ensure that the totality of wood constituents are used to produce fibers, biobased chemicals, and bioenergy, thus maximizing value creation from an economic and environmental perspective. This concept was illustrated by Carlo Covini, Lenzing Business Development Manager Italy & Switzerland, in his presentation “Lenzing’s biorefinery concept”.

Lenzing will be at the 56th edition of FILO, taking place on September 29 and 30, in Milan, with its TENCEL™ fiber. Sustainability and ethical values will be the main focus of the event.

Furthermore, to delve deeper in the sustainable approach that drives Lenzing's production processes, on September 30, at 3.00 PM, a presentation with the title "Lenzing's biorefinery concept" will be held by Carlo Covini, Lenzing – Business Development Manager Italy & Switzerland. This will be part of the Dialoghi di Confronto segment set near the Networking Area.

Korteks, one of the world’s biggest yarn producers based in Bursa, Turkey, has started the production of recycled polyester filament yarn in its production facility using a Starlinger recycling line.

With the new recycling facility, which comprises a total closed area of 17,000 m² and has a monthly production capacity of 600 tons, Korteks was able to reduce the production waste at its virgin PES yarn site to zero.

The Starlinger recoSTAR universal 165 H-VAC iV+, which is part of Korteks’ 10 million dollars investment in a new polymer recycling facility, took up operation in May 2021. It has a production capacity of 7,200 tons per year and currently processes clean in-house polyester fibers from production scrap together with washed post-consumer PET flakes at a ratio of 50/50. Korteks uses the polyester regranulate at a share of 100 % for its new polyester filament yarn line it is going to market under the name “TAÇ Reborn”. With this investment, the company has made an important step towards establishing a circular economy in the Turkish textile industry.

The Starlinger recycling line is the first of its kind in Turkey and is equipped with special components for filament yarn recycling. A RSC (Rapid Sleeve Changer) candle filter developed by Starlinger ensures finest melt filtration down to 15 μm. It has been specially designed for polyester recycling and reaches an output of 1000 kg/h. For continuous operation the filter elements are changed “on the fly” without interrupting production, which significantly limits melt loss.

The viscoSTAR SSP unit at the end of the recycling process guarantees consistent IV increase according to the first-in-first-out principle. This makes sure that the produced regranulate has the ideal properties required for filament yarn production. The technical configuration of the line does not only allow the processing of a polyester fiber/PET flake mix as input materials, but also 100 % polyester filament scrap or 100 % PET bottle flakes.

Korteks expects the recycling market in general to grow as there is increased acceptance for recycled products in the society, and predicts the need for recycling solutions also for other synthetic and natural fibers.