From the Sector

• New product initiatives and a system solution.

In the year of its 100th birthday RUDOLF will be at TECHTEXTIL to present its latest innovations and process solutions. Since 1922, RUDOLF offers a wide portfolio of specialty chemicals aiming to increase innovation and sustainability along the entire value chain, from fiber to finish.

At TECHTEXTIL, RUDOLF will present four new product initiatives and one system solution. The Company will hold “Conscious Performance” short seminars at its booth to present them.

New product initiatives
BIO-LOGIC® - Performance products with bio-carbon at core. Textile functionality is ensured through natural, renewable raw materials that are neither chemically nor genetically modified and that are not competing as food, feed or fuel.

CYCLE-LOGIC® - A new path: the upcycling of post-consumer, disposable and non-returnable plastics into valuable textile chemistry. Recycled PET bottles are now raw material for the manufacturing of some of our textile auxiliaries without attacking new, virgin resources.

PRISTINE® - Hygiene and freshness from continuous R&D advances. RUDOLF’s new ingredient brand that groups all high-performing technologies for textile hygiene, protection and freshness.

BIONIC FINISH® ECO - An idea borrowed from Mother Nature. Based on proprietary dendrimer technology, RUDOLF presents an extended family of unique fluorine-free DWR formulations suited for different materials and designed for different applications and needs.

New system solution
ECO-LOGIC® - Two-steps process designed and managed by RUDOLF’s specialists in textile process chemistry. It simulates, analyses and measures the environmental impact of a given industrial textile process to then provide insights into the optimization of resources, costs and CO₂ emissions..

SHIMA SEIKI MFG., LTD. of Wakayama, Japan, along with its Italian subsidiary SHIMA SEIKI ITALIA S.p.A., will be participating in the Techtextil exhibition in Frankfurt, Germany from the 21st till the 24th of June 2022.

On display will be SHIMA SEIKI’s latest innovation in flat knitting technology as applied to the field of technical textiles—a prototype weft knitting machine capable of multi-axial yarn insertion. Fabrics produced on this machine use inlay technique for the production of hybrid textiles that combine the stretch characteristics of knitted fabrics with the stability of woven textiles, suited to various technical applications. To this, warp yarn is inserted to further expand its capability to produce 3D-shaped carbon fiber and composite preforms directly on the machine. This is made possible by taking advantage of the fact that flat knitting as a textile production method is capable of producing end products that are shaped-to-form and with added thickness. Compared to current methods of preform production, savings in post-processing time, material, labor and associated costs are immense, realizing efficient and sustainable production. SHIMA SEIKI’s own yarn unwinding technology is also used for optimum yarn feed and tension for use with technical yarns that are otherwise difficult to knit. Industrial textile samples knit on the multi-axial machine will also be available for examination on-site.

SHIMA SEIKI's SDS®-ONE APEX4 3D design system will be available for demonstrations as well. Of particular interest should be its ultra-realistic simulation capability that realizes Virtual Sampling. When countless variations must be evaluated before arriving at a final design, virtual product samples can be used to streamline the decision-making process by minimizing the enormous amount of time, cost and material normally associated with producing actual samples for each variation. When approved, the same data can be converted to machine data for immediate knitting, significantly reducing lead times.

• Hexcel Composite Innovations for Aerospace Applications on Display at JEC World 2022: Hall 5, Stand J41

In late 2021, Hexcel announced an agreement with Fairmat, a deep technology startup, to build the capability to recycle carbon fiber prepreg from Hexcel European operations for reuse in composite panels sold into commercial markets, giving a second life to recovered carbon fiber. To do so, Fairmat has developed a virtuous recycling process, and a sample of its newly recycled material will be available to view at JEC World 2022. Hexcel will present an array of product innovations for aerospace and urban air mobility customer applications during JEC World 2022 in Paris on May3-5. These latest innovations demonstrate the company’s leadership in developing advanced composites technology for the aerospace market.

• Sustainability Focus on Recycling and Reuse
• HiTape® and HiMax® Reinforcements for OoA Processing
• Innovative HiFlow™ Resins for Continuous and Shorter Cycle Injection Processes
• HexPly® Prepregs for Primary Structure and Engine Applications
• HexTow® High Modulus Fibers HM63 and HM54
• Thermoplastics and Processing Innovations for Primary and Secondary Structures
• Lightweight PrimeTex® Reinforcements Solutions for Urban Air Mobility (UAM)

At Techtextil from 21-24 June in Frankfurt, Mahlo will be demonstrating how manufacturers of technical textiles can optimise their production even further using measuring and control technology.

Special straightening technology for technical textiles
Mahlo's range also includes solutions for straightening distorted goods. Best suited for technical textiles are, for example, the symbol of the straightening machine, the Orthopac RVMC-15 and the reinforced version Orthopac GRVMC-15. Frame, bearings, and rollers are designed for high loads and allow large working widths of up to 5,400 mm. As the latest development from Mahlo, the experts present the Orthopac CRVMC-15 automatic straightener, which is particularly interesting for the glass & carbon fabric industry and some special applications.

The Mahlo team will present the wide portfolio of intelligent scanners and sensors that record product and process parameters, such as distortion, fabric temperature, dwell time, basis weight, coating weight, thickness, moisture content, residual moisture, exhaust moisture, air permeability, etc. online. Among other things, visitors can expect to see the Famacont PMC-15 weft density measurement system in live operation. The system measures the weft or course density on the running web and compares it with the target value stored in the recipe data management system. The detected deviation from the target value is used to fully automatically control the overfeed during the needling process at the stenter frame and to ensure a constant weft/course density over the full width of the product.

Hexcel will present a wide range of high-performance composite innovations for the Automotive, Marine, Wind Energy and Recreation markets during JEC World 2022 in Paris on May 3 – 5.

G-Vent Technology for Marine Structures
Hexcel has developed a new technology for out-of-autoclave (OoA) processing that delivers a game-changing reduction in process time and cost for marine manufacturers without compromising mechanical performance. Hexcel has leveraged its experience in aerospace and wind energy to develop its new G-Vent technology for OoA processing of highly loaded, thick section marine structures such as masts, foils, and wind-assisted ship propulsion (WASP) components. A full range of Hexcel marine prepregs are now available with integrated G-Vent technology, reducing the requirement for debulking steps and ensuring extremely low porosity (<1%) regardless of the laminate thickness. Leading marine non-destructive testing specialists Q.I. Composites recently confirmed that the thick section G-Vent panels they had evaluated had void contents and laminate quality in line with state-of-the-art autoclaved prepreg components. Visitors to the Hexcel stand will see a unique 400mm carbon cube cured in a single stage using 695 layers of HexPly M79 carbon fiber UD600 prepreg with G-Vent technology.

New HexPly® Nature Range Sustainable Prepregs
HexPly® Nature Range prepregs feature proven resins such as HexPly M49, M78 and M79 with bio-derived epoxy resin content. Created for use in all industrial markets, HexPly Nature Range materials can be seamlessly integrated into existing production processes, maintaining consistent mechanical performance and processing properties. A dedicated sustainability corner of the Hexcel stand will detail Nature Range products optimized for automotive, marine, wind energy and winter sport applications. The display will include an alpine ski produced by leading manufacturer Tecnica Group Ski Excellence Center which produces skis for Blizzard and for Nordica using HexPly Nature M78.1 UD flax prepreg material. In addition to the reduced environmental impact of the sustainably grown reinforcement, the flax fiber laminates also improve impact resistance and vibration damping in the ski.

HexPly® XF Surface Technology for Improved Part Surface Finish Quality
HexPly XF is a lightweight, semi-preg material that replaces traditional in-mold gel coat. It eliminates time-consuming refinishing work typically required to obtain a paint-ready surface and produces lighter, more consistent parts with shorter cycle times and a cleaner working environment. Visitors to the stand will see a composite panel illustrating a high-quality painted surface enabled with XF technology in a diverse range of industrial applications such as super yacht roof parts, Class A surface automotive panels, and both prepreg and infused wind turbine blades.

HexPly® M49 Prepreg for Automotive Visual Carbon Parts
HexPly M49 is easy to process and is especially suitable for visual carbon fiber-look applications such as the Brabus hood scoop on display on the Hexcel stand at JEC.

HexPly® Prepregs and HiMax® Reinforcements for Performance Marine Structures
Using a scale model of a Gunboat 68 performance sailing catamaran, Hexcel will illustrate how its HexPly and HiMax materials provide manufacturers with a complete set of lightweight composite solutions for high-performance marine structures. HexPly prepreg was selected for critical structural parts of the Gunboat 68 and provides very high mechanical performance including high dry and wet Tg.

Heavyweight HiMax reinforcements offer high deposition rates and remain easy to handle after cutting, making them highly suitable for industrial applications. In combination with a lightweight PrimeTex® woven fabric, the package of carbon fiber HiMax materials developed for the Gunboat 68 enabled consistent resin flow during infusion with reduced surface print-through.

Hexcel Fibers and Reinforcements for Lightweight Sporting Equipment
Sporting equipment manufacturers rely on Hexcel composite materials to deliver the ultimate performance at the lowest possible weight. Hexcel will exhibit a number of the latest high-performance sporting equipment applications such as a Bauer hockey stick featuring PrimeTex 98 gsm AS4C 3K fabric and a Corima tri-spoke cycling wheel made with lightweight Hexcel carbon fiber UD tape. Hexcel will also demonstrate how its HexTow® carbon fibers are used in key leisure and marine applications by displaying an AEROrazr solid carbon rigging component manufactured by spar and rigging manufacturer Future Fibres for the 36th America’s Cup.

ISKO did not miss the opportunity to be a driver for change as the community of fashion leaders gathered at the event “Drapers Sustainable Fashion 2022” on April 21st, in London. Specifically, ISKO’s presence at the event took place through a stand dedicated to the company’s commitment to the development of new processes for better industry practices, and through the participation of ISKO’s head of sustainability, Ebru Ozkucuk Guler, in the panel “Leading the way: exploring denim’s approach to responsible and sustainable manufacturing”.

The company’s technology R-TWO™50+ played a great role in showing how the innovative soul of the company matches its sustainable one. R-TWO™50+ is the driving force behind ISKO’s efforts to reduce the industry’s impact on the planet. The fabrics are made with a minimum of 50% pre- and post-consumer recycled blend that is entirely Global Recycled Standard (GRS) certified. This results in less use of natural resources and a reduced carbon and water footprint of up to 45% and 65% respectively.
Held at main Stage, the panel was a chance to delve into the great strides that the industry has taken to dramatically reduce its carbon footprint through ground-breaking technology, with the speakers stating that “sustainability strategies are essential for the health not only of the planet but also of the industry itself.”

• Focus on the embossing technique applied to the recycled fabrics collection of the NATIVE Sustainable Textiles line

Performance Days, the leading trade fair on the latest trends in the development of fabrics for the functional textile industry, has as main focus the PERFORMANCE FORUM, where the most recent innovations and developments are presented with a prize awarded to the winner of the category chosen for the current year, which for 2022 will be “The Journey to Carbon Neutrality - CO₂ Reducing Technologies and Measuring Tools”.

Protagonists are therefore all those materials that contain carbon in reduced form and the strategies/technologies that companies implement to ensure the reduction of CO₂ emissions during production and how these reductions are actually measured (through energy saving, careful use of resources, use of more sustainable materials, local production and other technological and production measures).

In this sense, Sitip’s strategy for reducing CO₂ emissions and maximizing the use of resources is based on consolidating and optimizing the layout and logistics of the production plants, installing a cogeneration plant and a new generation smoke smoke abatement system and the transition to an energy-saving lighting system.

Regarding products, at Performance Days Sitip brings its latest innovations with an absolute focus on the embossing technique, a particular system of mechanical processes that can also be used on the recycled items from the NATIVE Sustainable Textiles line, a technology that is applied to fabrics produced with recycled yarns and chemicals with low environmental impact, implementing the GRS standard (Global Recycle Standard), result of the journey towards sustainability implemented by the company.

The collection of embossed designs combines performance, style and sustainability: thanks to special mechanical processes that combine heat and pressure, the fabric is embossed with geometric and design motifs for a more structured and palpable texture.

• Hypetex® to Showcase Coloured Carbon and Flax Fibre Solutions
• Hypetex, London, April 20 2022, Booth R52, Hall 6

Hypetex, the market leaders in colouring carbon and natural fibre materials, will demonstrate both the processing and sustainability benefits of its patented colourisation technology when it exhibits for the first time at JEC World 2022.

Exhibiting as part of the Composites UK stand (Booth R52), Hypetex will display its portfolio of uniquely coloured carbon fibre materials including 3K woven styles, ultra-lightweight spread tow fabrics, UD, and 3D materials. Hypetex will also present details of its latest eco-friendly coloured flax materials  which combine sustainably grown natural flax with sustainable colouring technologies. Hypetex patented colouring technology, available in an extensive palette of standard and bespoke colours and shades, can be applied to traditional woven fabric constructions, non-woven UDs, spread tow and bespoke fabric designs. The technology replaces a traditional coloured painted finish, providing an exceptional depth of colour to any composite part, improving thermal conductivity and reducing heat absorption ,whilst reducing the overall weight and processing time with no compromise to the mechanical performance of the composite structure.

By removing the need for painting, and the associated preparation steps, Hypetex technology provides manufacturers with a repeatable straight out of the mould coloured finish, that is not only easy to integrate into all composite processes, but also takes additional materials, consumables, and process time out of the component cost. As part of its continued commitment to leading the drive for more sustainable composite solutions, and its focus on improvements based on the ESG framework. Hypetex will also display its new range of coloured flax fibre textiles. The advanced colouring technology used protects the natural flax fibres throughout the high temperature processes required for composite production, avoiding burning or any discolouration issues common to natural fibres. In addition, Hypetex colouring solution is an ecofriendly sustainable alternative to traditional dyeing processes which are a significant cause of global water pollution.

The Hypetex team will be on hand throughout the show to provide additional details on Hypetex materials and their integration into the manufacturing process. Visitors to the Hypetex stand will be able see Hypetex carbon and flax products in raw fabric, and how its unique colour palette translates into the most distinctive finished moulded components. Hypetex partners SHD Composites, Textreme, Sigmatex and Angeloni will also have materials and components on display at JEC World 2022, including sporting equipment such as racquets, sticks, and skateboards, which highlight the massive range of processing options and potential applications for this novel technology. One such application, the adidas Kromaskin field hockey stick, with a unique Hypetex coloured Textreme spread tow carbon finish, will also be part of the JEC Innovation Planets feature.

High-performance yarns now offer almost unlimited possibilities for replacing traditional raw materials in a vast range of technical applications. Often tailor-made, these filament yarns go way beyond the conventional idea of ‘textiles’ – finding new uses in sectors such as automotive, aviation, maritime, medical and construction, among many others.

Technical textiles are everywhere in our daily lives today, even if we may not always realize it. Some are in more obviously textile products, from sewing threads to artificial turf. But then, take cars as an example: modern vehicles are stuffed with parts made from sophisticated yarns. It’s common for producers of automotive parts now to send template material and requirement lists to Swiss Textile Machinery members, trusting their expertise and experience. Members operate development and testing centers with latest machine installations, where their experts devise customized solutions, as well as calling on the pure innovative spirit which is part of their DNA.

At the extremes
Technology drives applications beyond our current imagining in the case of Heberlein air splicers. Developed for a wide range of uses with high-strength technical fibers, they have no problems splicing aramid fibers up to 16’100 dtex, carbon up to 30’000 dtex, Dyneema up to 5’500 dtex, and glass up to 4’800 tex. Using compressed air, the splicers produce a tear-resistant, homogeneous splice of material without interfering knots.

Retech has the technology to achieve specifications for filament yarns, drawing and stretching fibers to perfection. Top heated godet rolls – many customized – are developed for high-performance fibers. Temperatures up to 400 °C can be achieved. Combining the right settings and wide speed ranges for each specific process results in unique end-products.

Fabric producers of high-end applications must avoid any quality risk. Yarn producers are well aware of this responsibility, so they use precision package winders for technical yarns, developed by Rieter’s subsidiary SSM. Taking yarns from ring twisting bobbins, its specialist finish winders can produce coarse-count technical yarns up to 50’000 dtex, offering a new level of flexibility and winding quality.

Lifestyle essentials
At first glance, motorists might fail to notice many of the technical yarns ‘hidden’ inside their cars. These products have functions such as providing stability with hardly any weight, or absorbing tensile forces at defined elongation. This kind of controlled elongation behaviour, for example, arises from the choice of textile material and the special construction of the yarns used.

Such specifications make twisting and cabling machines essential for the automotive industry. Saurer offers machines for the production of technical yarns made from a variety of feed materials in a very wide yarn count range. They are needed for vehicle products such as tire carcasses, toothed engine belts, seat belts, airbags and lorry tarpaulins.

Technical yarns also play a surprising role in our mobile devices. Tapping, scrolling and swiping are second nature for billions, with our phones and a plethora of other lifestyle essentials. Yet, how many people would know that the touch-sensitivity we take for granted on these screens is largely made possible by twisted glass fibers. Bräcker, part of Rieter’s components business, offers a selection of vertical sinter metal rings and nylon travelers for glass fiber twisting, so that mills can achieve high levels of productivity and quality.

Future unlimited
Automotive and communication technology are already important industries for Swiss Textile Machinery members, along with well-known technical textiles markets in sectors such as medical, transport and construction. Smart-wear is already noted as a field with significant potential. Naturally, members are constantly investigating other possibilities. Swiss textile machinery is already applied in energy (batteries), and plastics.

The Swiss Textile Machinery Pavilion will be at the Techtextil exhibition in Frankfurt, Germany, taking place from 21 to 24 June 2022.

• Complete fibre portfolio for geotextiles, hygiene & wipes, floor coverings, automotive, upholstery, filtration, RTM and construction
• Increasing nonwoven & engineered fabric performance with new fibres that reduce carbon footprint & support design for recycling
• Exploring new possibilities for collaboration using BFI’s expertise, pilot line and equipment

 Beaulieu Fibres International, the largest and most differentiated European staple fibre producer, turns the spotlight on future-focused solutions for nonwovens & engineered fabrics at IDEA®22, 28-31 March. A key priority is innovation in polyolefin and BICO fibres to advance sustainable design, end-of-life recyclability, and resource and carbon footprint reduction for industrial and hygiene applications.

Sustainability is key to Beaulieu Fibre International’s long-term strategy, and the company is heavily focused on defining its green portfolio to support evolution in diverse market applications.

Bio-based fibres
From June 2022, Beaulieu Fibres International will offer ISCC+ certification on mono-PP and BICO PP/PE fibres. The fibres will be offered in 1,3-8,9 dtex and will be available with all the main available finish classes (ie. hydrophilic, hydrophobic, etc.) suitable for the main carding and consolidation technologies. These drop-in solutions with no loss in quality will support customers looking to reduce reliance on virgin fossil carbon in their nonwoven and engineered fibre applications. The bio-based fibres enable customers to contribute to the transition towards a circular economy.

Achieving material savings
For customers in industrial segments like geotextiles, high-tenacity HT8 staple fibres enable customers to achieve nonwovens for construction projects with high mechanical performance but with 15% less weight. The durability of the fibres means that customers can use less raw material for a longer service lifetime, supporting more sustainable design in addition to resource reduction.
For hygiene nonwovens, the Meralux fibres provide significant sustainable design advantages. Meralux fibres deliver substantial sustainability benefits including around 55% savings in raw materials, with equivalent carbon emission savings. These emission savings are thanks to weight reduction in nonwovens with the same coverage level and also the higher recyclability of PP/PE compared to BICO materials.