From the Sector

Over 600 delegates from 58 countries subscribed to the latest VDMA textile machinery webinar on sustainable dyeing held on February 3rd, 2022 – a record since the monthly online series started in June 2020. The webinar, entitled ‘Resource-saving in Textile Processing – Continuous Dyeing and Washing’, involved the three companies Monforts, DyStar® and Goller.

In outlining the capabilities of Monforts Thermex hotflue lines for the Econtrol® continuous dyeing process, the company’s Textile Technologies Engineer Jonas Beisel observed that the current industry focus is very much on cleaner processes and products in accordance with the Corporate Social Responsibility (CSR) commitments of the major fashion brands, and with further regulations to be expected.

Cellulosics
Econtrol® is a continuous process for the dyeing of woven cellulosic fabrics that has already been well proven on the market, with over 150 Monforts Thermex lines already in operation at mills worldwide.

Reactive dyestuffs are fixed into the fabric in a one-step dyeing and drying process with a controlled combination of steam and air. The entire pad-dry process takes just two-to-three minutes at a temperature of between 120-130°C and a relative humidity volume of 25-30%.

Benefits
The Econtrol® pad-dry process has a number of immediate benefits. Compared to the common pad-dry-pad-steam process, no salt is used and no steamer is required for a separate fixation step.

Compared to the pad-dry-thermofix process, no urea is used and no smoke or deposits are generated, and unlike with the cold pad batch process, direct feedback of the dyeing results ensures no batching time is necessary and guarantees good reproducibility from the lab to bulk production.

Complementary services and systems
Complementing the Monforts presentation during the webinar, Bertram Seuthe, Global Business Development Manager at DyStar, outlined the importance of specific Levafix® /Remazol® reactive dyes and Dianix® disperse dyes for sustainable dyeing processes such as Econtrol®, Cadira® Continuous and CPB knit. In these processes Sera® auxiliaries are also employed for optimised wash-off results.

Guido Seiler, Area Sales Manager at Fong's Europe, also introduced the latest developments of the Goller brand for the washing process, which can reduce water consumption by between 10 to 20%, as well as reductions in both heating energy and waste generation, depending on the specific fabric construction and required shade.

For more than 70 years BRÜCKNER has been in the construction of drying and finishing lines for the textile and nonwovens industry. In the nonwovens sector, the company supplies worldwide thermofusion ovens, dryers, coating and heat-setting lines. On the IDEA 2022 trade fair in Miami, USA, BRÜCKNER presents together with its American representation FI-TECH new machine concepts and solutions for different applications in the mentioned fields.

The production of nonwovens always requires a bonding process after the nonwovens formation, where the loosely laid fibers are bonded to a resilient fiber composite. For this purpose, depending on the process, different ovens and dryers are used. BRÜCKNER supplies the necessary lines for all applications. The production program is completed by different impregnation and coating units as well as slitting and winding equipment. BRÜCKNER's customers produce geo nonwovens, filter media, hygiene and medical textiles or different fabrics for the automotive and transport industry

For the production of highloft nonwovens the double-belt thermofusion oven SUPRA-FLOW BX is used. This oven system operates according to the air-through principle and can be perfectly adapted to the product requirements in terms of flow speed, flow direction and temperature on a field-by-field basis.  
The SUPRA-FLOW BX can produce nonwovens up to a thickness of 280 mm and a basis weight of max. 8 kg/m². The available working widths vary between 2400 and 5200 mm at production speeds of up to 100 m/min.  
For geotextile projects, the POWER-FRAME stenter is usually used, which impresses with its uniformity in terms of temperature distribution as well as productivity. In addition, the fabric can be stretched in a targeted manner by transporting it in the stenter chain. This has a controlled influence on fabric width, fiber orientation and fabric shrinkage. Working widths of up to over 7 meters are not uncommon with geotextile finishing systems.

After thorough consultation with the exhibitors and partners of the event, JEC Group has decided to postpone the 2022 edition of JEC World. The world’s leading composites event will now take place from May 3rd to 5th, 2022, at the same venue Paris Nord Villepinte, as well as online via the JEC World Connect digital platform.

JEC World gathers the whole value chain of the composite materials industry in Paris, France every year and is “the place to be” for composites professionals from all over the world. The event brings together not only all major global companies, but also innovative startups in the field of composites and advanced materials, experts, academics, scientists, and R&D leaders. JEC World is also the “festival of composites”, offering a unique showcase of what composites can offer to various application sectors, from aerospace to marine, from construction to automotive, and an unlimited source of inspiration for participants from these industries.

“We are fully dedicated to supporting the composites industry and to fostering its development via our events and media activities. Exhibitors and partners are strongly supporting JEC World, their leading event and want to meet in person in 2022 to activate business, share knowledge and highlight innovations. Postponing from March to May is a way to offer improved conditions to satisfy the industry requirements for such a trade fair as JEC World”, says Eric Pierrejean, CEO of JEC Group.

The JEC World team has decided to postpone the event after conducting a survey of its exhibitors and partners, confirming that a large majority is in favour of the new dates in May. As already planned, for three days, the event will offer for the first time a digital platform, JEC World Connect, in parallel to the in-person event in Paris for an augmented digital experience. Even after the show, via the JEC Web TV, unique content will be available to extend the reach of the event.

“Our main concern is to create the best possible conditions for our participants for successful networking, inspiration and business success. With a postponement of eight weeks we can enable this and offer to the industry the event it deserves. Taking the decision now, after consultation of all exhibitors, was necessary to give them planning and preparation visibility,” adds Thomas Lepretre, VP Events, Sales and Operations.

Freudenberg Performance Materials Apparel Europe started construction work on its competence center for finishing and coating base material for the apparel industry at its site in Sant´Omero (Italy) as scheduled in December. Further processing of base material is to begin in Italy in early 2023. The Weinheim site will then become the competence center for interlining base material.

In January 2021, Freudenberg Performance Materials Apparel Europe (Freudenberg) announced plans to set up two competence centers. In future, the company will concentrate on manufacturing base material for interlinings at the Weinheim location. Base material finishing and coating is to be bundled at Sant´Omero. For this purpose, production plant will be relocated from Weinheim to Sant´Omero and recommissioned in a newly-built production hall.

The traditional groundbreaking ceremony with senior representatives from local authorities and Freudenberg management was cancelled due to the high number of coronavirus cases in the area.

• Second Session of the International Conference on Cellulose Fibres 2022

Cellulose fibers are a true material miracle as they offer a steadily expanding, broad range of applications. Meanwhile markets are driven by technological developments and policy frameworks, especially bans and restrictions on plastics, as well as an increasing number of sustainability requirements. The  presentations will provide valuable information on the various use-opportunities for cellulosic fibers through a policy overview, a special session on sustainability, recycling and alternative feedstocks, as well as the latest developments in pulp, cellulosic fibers and yarns. In addition, examples of non-wovens, packaging and composites will offer a look beyond the horizon of conventional application fields.

The second session of the conference: "New Opportunities for Cellulose Fibres in Replacing Plastics", will focus on questions such as: "What is the impact of the ban on plastics on single-use products?" and "What are the latest regulatory issues and policy opportunities for cellulose fibres?".  This section presents new opportunities for replacing fossil-based insulating materials with cellulose-based technologies that can be used for a variety of applications, from aerospace to mobility, as well as in construction. For the program just click here.

Speakers of the Session "New Opportunities for Cellulose Fibres in Replacing Plastics":

• Nicolas Hark - nova-Institut (DE): Opportunities in Policy for Cellulose Fibres
• Paula Martirez - Stora Enso (SE): Last years Winner Papira® – an Eco-revolution in Foam Packaging
• Stefanie Schlager - Lenzing (AT): LENZING™ Fibres for Sustainable Single use Products
• Sascha Schriever - Institut für Textiltechnik der RWTH Aachen University (DE): Cellulose Aerogel Non-wovens – Sustainable Insulators of Tomorrow

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.

Royal Golden Eagle (RGE) has released its 2021 progress report on its commitment to invest USD200 million in next-generation textile fibre innovation and technology over a ten-year period which started in 2019.

The annual report provides an update on the activities undertaken by RGE and its business groups (Sateri, APR, APRIL, Bracell) involved in the fashion value chain to advance its ambition towards closed-loop, circular and climate-positive cellulosic fibre.

In 2021, Sateri achieved full compliance with the emission limits set out in the European Union Best Available Techniques Reference Document (EU-BAT BREF) for all of its five viscose mills in China, two years ahead of schedule. Bracell completed construction of the world’s largest and greenest new generation pulp mill in São Paulo which uses cutting-edge technology for fossil fuel-free generation.

Amid the COVID-19 pandemic continuing to restrict travel and collaboration, RGE persisted in building upon existing partnerships, while entering into new agreements. Sateri strengthened its strategic collaboration with Infinited Fiber Company, participating in the company’s EUR30 million funding round, which attracted new and existing investors such as H&M Group, Adidas, BESTSELLER and Zalando.

New partnerships formed by RGE included a five-year textile recycling research collaboration with Nanyang Technological University Singapore, and a three-year strategic partnership with the Textile and Fashion Federation Singapore which seeks, among others goals, to advance research and innovation in circular economy approaches to fashion waste in Asia.

RGE’s in-house R&D team has made good progress in advancing its textile-to-textile project, focusing on producing quality viscose using recycled cotton textiles as feedstock. To support plans to build a textile recycling facility in Indonesia, and as part of commercial feasibility analysis, studies examining the availability of textile waste and textile recycling landscapes in China, Indonesia, Sri Lanka and Bangladesh were completed.

Sateri remains on track in developing a product with 50 per cent recycled content by 2023, and to reach 100 per cent by 2030. It also aims for 20 per cent of its feedstock to contain alternative or recycled materials by 2025. In this similar vein, APR will source 20 per cent of its feedstock from alternative or recycled materials by 2030.

The Chairman of the Walter Reiners-Stiftung foundation of the VDMA Textile Machinery Association, Peter D. Dornier has awarded prizes to three successful young engineers. The award-winning works provide practical solutions on the topic of circular economy. For example, the recycling of carbon fibres, which are used to produce lightweight components for the automotive industry. Or the environmentally friendly production of yarns from crab shells. Another topic was medical applications: The processing of ultra-fine yarns into stents for aortic repair. The award ceremony took place online on 9 November as part of the Aachen-Dresden-Denkendorf International Textile Conference.  

With a creativity prize, endowed with 3,000 euros, the foundation honoured the diploma thesis of Irina Kuznik, TU Dresden. She used a creative approach to realise solutions for processing chitosan into fibre yarn.

Mr Kai-Chieh Kuo was awarded the diploma/master's thesis promotion prize of 3,500 euros. With his master's thesis, which was written at RWTH Aachen University, Mr Kuo contributes to the production of vital components used in medicine. The stents made of ultra-fine yarns are made possible by an innovative modification of the classic tube weaving process.

The Walter Reiners Foundation rewarded the doctoral thesis of Dr. Martin Hengstermann with the promotional prize in the dissertation category, endowed with 5,000 euros. The thesis deals with the production of recycled carbon fibres. These can be used to produce lightweight components for motor vehicle and aircraft construction or the wind energy sector.

New Prize Sustainability / Circular Economy
The environmental conditions of the textile industry and machine construction are changing. Topics such as climate protection and the circular economy are becoming central. From this perspective, the board of the Walter Reiners Foundation has decided to further develop the foundation's prize system.

In 2022, the foundation will for the first time offer a prize with a focus on design / sustainability. Peter D. Dornier, Chairman of the Foundation, explained: "Already in the design phase, one can set the parameters so that a textile product can be reintroduced after use into the economic cycle for a high-quality application. For example, through the appropriate use of materials and finishing. We are looking for solutions for resource-saving design, technology and manufacturing processes."   

Teijin Limited announced today that its carbon fiber subsidiary Renegade Materials Corporation, a leading U.S.-based supplier of highly heat-resistant thermoset prepregs, resins and adhesives for the aerospace industry, will expand its prepreg production by 2.5 times approximately. The increased capacity, which aligns with Renegade’s capacity expansion strategy at the Miamisburg, Ohio location, is the result of a USD 4 million investment made in December 2019 and the construction was started in March 2020. Operation of the new production lines will commence January 2022.

Renegade Materials' heat-resistant thermoset prepregs, resins and adhesives are well trusted by U.S. and European aircraft manufacturers and aircraft engine suppliers.

Renegade Materials will showcase its high heat-resistant thermoset prepreg at the Composites and Advanced Materials Expo (CAMX), one of the largest, most comprehensive composites and advanced materials event in North America, at the Dallas Convention Center in Dallas, Texas, from October 19 to 21.

• Composites in the construction industry - The lightweight construction material of the future

Building with fibre-reinforced materials opens up completely new possibilities. In terms of engineering, design, and organisation. This is due, on the one hand, to the excellent properties of fibre-reinforced materials (FRM) and, on the other hand, to the fact that the material – unlike wood or brick, for example – is not machined or processed for its use, but custom-produced.

Excellent properties – in terms of engineering, design, and organisation
Fibre-composite materials offer a whole range of technical properties for innovative and sustainable building:
•    High mechanical rigidity
•    Low weight
•    High corrosion resistance
•    Low material fatigue
•    Low heat transfer coefficient of the plastic matrix
•    Resistance to frost and de-icing salt
•    Good draping capability

In addition, fibre composites offer numerous design options for novel and exceptional new building and maintenance projects:
•    Unique variety of shapes
•    Different structures of the textiles
•    Large spectrum of colours and colour combinations
•    Translucency of the plastic matrix
Thanks to these properties, composites can be used to produce coloured, phosphorescent, thermochromic or – through the use of LEDs or light-conducting fibres permanently integrated into the matrix – luminescent components.

In addition, there are organisational benefits for planning, construction and maintenance work with fibre-reinforced materials:
•    Easier handling and assembly of the far lighter and more flexible components – compared with steel, concrete or wood
•    Faster installation
•    Shorter construction site times in road and bridge maintenance
•    Shorter delivery times
•    Ability to integrate electronic monitoring systems

Individual composite textiles – for every lightweight engineering project
The composites experts at vombaur develop and manufacture woven tapes and seamless round or shaped woven textiles from carbon, glass, flax or other high-performance fibres on special weaving lines for individually specified round and shaped woven textiles – and can therefore offer you the best possible fibre base for every lightweight construction project.

"Regardless of whether it's a new construction or a renovation project, a façade design, a bridge or a staircase – as your development partner for composite textiles, we have plenty of experience with composites for demanding tasks," emphasises Dr.-Ing. Sven Schöfer, Head of Development and Innovation at vombaur. "We develop, create samples and manufacture woven tapes and seamless round or shaped woven textiles – in collaboration with the customer enterprise development teams and individually for the respective projects." This is how novel and unique lightweight components made of high-performance textiles are created for visionary projects.