From the Sector

A much more sustainable, cost effective and very flexible process for manufacturing critical fibres based on ultra high molecular weight polyethylene (UHMWPE) is being launched by the UK’s Fibre Extrusion Technologies (FET).

UHMWPE is prized in many industries due to its extraordinary properties. The fibre is, for example, ten times stronger than steel by weight, while exhibiting outstanding abrasion resistance, low friction and high impact strength. UHMWPE fibres are also chemically inert, resistant to most chemicals and UV light and do not absorb water. They maintain performance in a wide range of temperatures and despite their toughness are extremely lightweight.

As a result, they are unbeatable in demanding applications such as high-performance ropes in maritime industrial and rescue applications. In addition, they are invaluable in ballistic protection, cut-resistant clothing and high-performance sports gear – and increasingly in medical implants.

Biomedical market
“FET has supplied many extrusion systems to the biomedical market, most notably for the production of both resorbable and non-absorbable sutures,” says FET Managing Director Richard Slack. “In exploring what else we could do in assisting these customers, it became clear that there was a need for smaller quantities of UHMWPE fibres in bespoke sizes.”

“The current systems for manufacturing UHMWPE filament yarns are on a huge scale, with very complex processing routes,” adds Research and Development Manager Jonny Hunter. “This means the supply chain is currently very inflexible with minimal opportunity for new product development. These disadvantages have been fully addressed in the development of our new FET-500 series lab and small scale gel spinning system.”

Solvent extraction
A major FET innovation is the introduction of a patented batch system for solvent extraction exploiting supercritical carbon dioxide (CO2).

UHMWPE production, until now, has involved the use of large volumes of hazardous solvents such as dichloromethane (DCM) or hexane. The UHMWPE powder is mixed with mineral oil to form a gel which is subsequently extruded, cooled and solidified. The oil is then extracted from the fibres using DCM or hexane and the solid fibres are then drawn at high temperature to further align the polymer chains, resulting in final strong and tough fibres. Typically, it takes 10 kg of Hexane to extract 1 kg of oil. 

“Solvent reclamation using extraction baths and hot air drying chambers is not practical for the scale of our system,” explains FET’s Senior Material and Process Scientist Kris Kortsen. “The current baths employed can be up to 200 metres long and the waste volumes are considerable. Expertise is needed in dealing with such dangerous chemicals and overall the process has an immense environmental impact.

“CO2, by contrast, is a cheap and abundant sustainable solvent that is non-toxic, non-flammable and leaves no residue.” 

Closed loop
FET’s closed-loop system can achieve more than 95% solvent recovery without loss of performance, resulting in residue-free UHMWPE filament yarns via a vastly improved route in terms of both safety and logistics.

A further innovation is the highly modular drawing system based on heated godet rollers, enabling flexible temperature and drawing control for new product development and the ability to be expanded at any time to meet customer needs.

A comprehensive LCA study detailing the full savings potential is currently being prepared and will be published shortly.

“Having processed over 130 separate polymers in the development of our extrusion systems, we believe the FET-500 is a game changer,” concludes Richard Slack. “We believe there is a big gap in the market for smaller quantities of UHMWPE, and our first line is now fully operational at the FET Fibre Development Centre in Leeds. We look forward to demonstrating it and discussing its full potential with interested companies from around the world.”

The winners of the 2025 IDEA® Achievement Awards and FiltXPO™ Innovation Awards were announced during special ceremonies held April 29 and 30 at the Miami Beach Convention Center in Miami Beach, Florida. Presented at the co-located IDEA®25 and FiltXPO™ 2025 events, the awards celebrate outstanding innovations driving progress in nonwovens and filtration. INDA, the Association of the Nonwoven Fabrics Industry, collaborated with International Filtration News for the FiltXPO™ Awards and Nonwovens Industry magazine for the IDEA® Achievement Awards.

IDEA® Equipment Achievement Award
Dilo Systems GmbH – MicroPunch
The rising energy costs and water shortages have led to a re-evaluation of production methods, with a stronger focus on environmental impact. With MicroPunch, it is possible to reduce energy consumption by approximately 75 percent compared with other consolidation techniques that produce lightweight nonwovens. This technology enhances efficiency and reduces the manufacturing costs and the environmental footprint.

IDEA® Nonwoven Products Achievement Award
Innovatec Microfibre Technology GmbH & Co. KG – InnovaWipe® Water-Soluble Nonwoven
This water-soluble nonwoven is completely biodegradable under both aerobic and anaerobic conditions. It offers excellent resistance to oils, greases and chemicals. It does not leave any microplastics behind, breaking down into carbon dioxide, water and biomass. It also has no ecotoxic effects, is safe for the marine environment and does not cause fatbergs or blockages in wastewater systems – flushable and home compostable.

IDEA® Raw Materials Achievement Award
Woolchemy NZ Ltd. – neweFibre
Woolchemy’s neweFibre is the world’s first hygiene-grade wool, engineered for high-performance, sustainable hygiene products. This fully traceable, renewable fiber enhances moisture management, thermal comfort, and odor control. Seamlessly integrating into production, neweFibre powers innovations like neweFlex ADL for exceptional fluid distribution and skin dryness.

IDEA® Short-life Achievement Award
Egal Pads, Inc. – Egal™ Pads on a Roll
At Egal, we believe pads should be as common as toilet paper.  Our vision is that “pads on a roll” will be put in every toilet stall – where they are needed most – to ensure privacy and dignity to all who menstruate.  Egal pads are manufactured in roll form, 40 individually wrapped on each roll, so they can be mounted on existing toilet paper dispensers or in Egal’s custom-designed dispensers.

IDEA® Long-life Achievement Award
Magnera – Sontara® EcoRE Bag
EcoRE bags are produced entirely from cellulosic fibers, presenting a sustainable alternative to traditional synthetic materials. Made with Sontara fabric certified by OK compost HOME, these bags maintain their durability and strength without the need for added binders, addressing a common concern with compostable goods. With plastic bag bans now in place in many states, Sontara offers a timely and eco-friendly solution for the retail and shopping market.

IDEA® Sustainability Advancement Award
KINDCLOTH™ – PURA HEALTH Insect Repellent – Water Dissolvable Wipes
This wet wipe combines water-dissolvable Hydropol™ technology with a natural formula featuring lemongrass and citronella. Designed for eco-conscious consumers, this innovative wipe provides effective insect protection while leaving no waste behind. Certified biodegradable, flushable, and designed not to create harmful microplastics, it safeguards fragile ecosystems and supports sustainability goals.

IDEA® Entrepreneur Award
Dude Products, Inc.
In less than a decade, the Dude Wipes brand has grown from an entrepreneurial concept conceived in a bachelor’s post-college apartment to a more than $200 million global brand. These flushable wipes have flourished in flushable wipes industry, successfully going head to head against multinational consumer product companies Kimberly-Clark, S.C. Johnson, and Procter & Gamble.

FiltXPO Air/Gas Filtration Award
Greentech Environmental LLC – Greentech Filters with ODOGard®
ODOGard® technology deeply integrates odor-neutralizing polymers into nonwoven and nanofiber filters, offering an innovative, non-toxic approach to indoor air quality. ODOGard® significantly enhances filtration durability and performance.

FiltXPO Water/Liquid Filtration Award
Ahlstrom – BioProtect™
Ahlstrom’s sustainable BioProtect™ material offers superior dye-catching performance for laundry applications. Manufactured from 100 percent naturally derived fibers and OC-Biobinder®, BioProtect™ is both biobased and home compostable, combining premium performance with environmental responsibility.

FiltXPO Filtration Equipment Award
Filtration Advice Inc. – FA-TCO Software
This cutting-edge software provides comprehensive Total Cost of Ownership (TCO) analysis and predictive modeling for air filtration systems. FA-TCO enables data-driven decisions, extending filter lifespans, reducing operational costs, and enhancing overall sustainability in filtration management.

The fine filament nonwoven technology from Freudenberg Performance Materials is made from a wide variety of polymers and blends using mono or bico fibers. The high flexibility and broad customization options provide benefits in a wide range of markets and applications – from roofing membranes to liquid filtration, as well as specific applications such as dehumidification products and artificial turf.

Freudenberg’s innovative fine denier spunbond materials rely on flexible manufacturing capabilities, which enable a high level of customization. They can be made of PET, PE or PP, not only as 100% composition but also in many different combinations, e.g. PET/PE, PET/coPET or PET/mPP, using mono or bico fibers with titer ranging from 2.5 to 3 dtex. The material weight spans 17 to 140gsm. The nonwovens are strongly bonded thanks to thermal bonding provided either by flat calendering or point sealing. The technology enables lightweight solutions with high tensile and tear strength, as well as a smooth and uniform surface.

Advantages for the construction industry
Suited for construction applications such as roofing & facade membranes, vapor barriers and house wrappings, Freudenberg lightweight fine denier nonwovens complement the well-known Terbond®, Texbond® and Colback® solutions for the construction market. They deliver mechanical strength and, in particular, a high nail tear strength as required by the market. Moreover, they have high UV and temperature resistance and stability thanks to the PET composition.

Filtration applications
The fine denier technology is also marketed under the Filtura® brand, specifically suited for liquid filtration, e.g. coolants & lubricants. The technology provides high efficiency and a regular surface, as well as new capabilities with PET-PA and PET-PE nonwovens. Support media applications for glass fiber, nano and activated carbon also benefit from the lightweight fine denier nonwovens as protective layers.

Packaging and coating: Efficient converting and high durability
The fully synthetic PET/PE fine denier materials are ideal for packaging applications such as desiccant bags and other dehumidifier products. They enable the efficient and fast production of such pouches due to their exceptional hot sealing capabilities, with no need for chemical binders or additional treatments. Freudenberg’s technology provides high strength, high abrasion resistance and high durability, allowing for long-lasting desiccant bags.

In the coating industry, too, Freudenberg’s fine denier spunbonds contribute to enhanced process efficiency. The materials are chemically resistant and have good thermal stability. High-quality coating results can be achieved by using these materials as coating substrates, thanks to their smooth and even surface. The material properties can be customized for coating, laminating and concealing applications thanks to different combinations of polymers, fiber types and bonding technologies. For example, a specific very lightweight flat bonded variant of the material is an ideal coating substrate for cold wax depilatory strips, providing the necessary high mechanical strength and material flexibility.

Other applications for Freudenberg’s fine filament technology are crop covers in agriculture, decoration applications and other industrial or consumer applications.

Fibre and fabric production technologies – especially in the area of composite reinforcements – have played an as-yet largely unheralded role in the development of the UK’s Formula One industry, but the British Textile Machinery Association (BTMA) aims to change that.

Motorsport Valley
“If there’s one thing the UK does well, it’s Formula One, with seven of the ten F1 teams located within just an hour of each other in the midlands region known as Motorsport Valley,” explains BTMA CEO Jason Kent. “They are all linked to a national network of around 4,500 companies involved in a motorsport and high-performance engineering industry worth around £9 billion annually and employing 40,000 people. This network draws on the services of a significant number of our member companies.”

“With the exception of the engine, virtually every part of a Formula One racing car now starts from a textile, including the bodywork, the tyres and many of the latest fuel systems,” says Richard Kirkbright, project manager at Leeds-based Roaches International. “This has influenced developments in the broader automotive sector, in addition to the aerospace industry.”

Show cars and memorabilia
While best known as the developer of textile testing systems, Roaches has over the years also supplied advanced autoclaves to the UK’s composites industry, including a recent delivery to Northampton-based Memento Exclusives, a specialist in the production of show cars working directly with F1 and its leading teams.

Each major F1 team sponsor is supplied with one or two show cars for use at exhibitions and a wide range of other promotional activities arranged around the racing event calendar. These cars have no engine and their bodies may be made of fewer carbon fibre plies, but they are otherwise identical to the latest cars being raced by the F1 teams.

Memento Exclusives has its own in-house carbon fibre parts manufacturing facility and the integration of the Roaches autoclave has significantly expanded its capabilities in show car production.

Master bakers
“Composite materials undergo a metamorphosis in the autoclave which subjects them to both mechanical and chemical processes,” explains Richard Kirkbright. “Trapped air and volatiles are expelled and plies are consolidated under precise pressure. Heat cycles are then introduced, curing the resin systems and yielding flawlessly crafted components. Autoclave specialists are a little like master bakers, knowing exactly how to treat their ingredients at every stage of the process, to achieve the desired final product.”

“The Roaches autoclave now enables us to cure large components with full control and achieve a swift turnover of parts while ensuring the highest quality finish,” adds Terry Wasyliw, Head of Build for Memento Exclusives.

McLaren’s influence
Woking, UK-headquartered McLaren was the very first F1 team to introduce a car chassis manufactured entirely from carbon fibre composites back in 1981, setting the ball rolling for the creation of a completely new and global supply chain.

McLaren has this year unveiled a world-first in supercar engineering – aerospace-derived Automated Rapid Tape (ART) carbon fibre, developed at the dedicated McLaren Composites Technology Centre (MCTC) facility in Sheffield. This is being employed to create the active front wings of the W1 hypercar which has a starting price of $2.1 million.

A rear floor component was also developed for McLaren as part of the recently-completed £39.6 million ASCEND programme involving a range of UK partners, including BTMA member Cygnet Texkimp.

Handling, converting and decarbonisation
A wide range of handling and converting machines are supplied to the composites industry by Cygnet Texkimp, including bespoke creels, prepreg, coating, slitting and filament winding machines.

Its technologies are employed in the construction of composite components for aerospace and automotive, as well as in the production of tyre cord and more recently in the advanced construction of hydrogen storage vessels which are largely viewed as the future of F1 propulsion, along with advanced batteries for electric vehicles.

Cygnet Texkimp has been involved in the F1 supply chain for over 20 years and most carbon fibre used in the industry has been processed on one of its VHD creels. The company is also the largest independent manufacturer of prepreg machines in the world and is currently leading the design and build of the UK’s first carbon fibre research lines for a project led by NCC (National Composites Centre) to accelerate the development of more sustainable carbon fibres.

In addition, Cygnet is licensed to design and build the DEECOM® composite recycling system developed by new BTMA member Longworth Sustainable Recycling Technologies, the first of which was recently commissioned by the Henry Royce Institute in Manchester. DEECOM® is a zero emission, low carbon pressolysis solution using pressure and steam to reclaim pristine condition fibres and resin polymers frocm production waste and end of life composites.

“Decarbonisation is a major priority for manufacturers globally,” says Cygnet CEO Luke Vardy. “At Cygnet Texkimp, we’re developing the capability to process technical fibres in ways that enable lightweighting, hydrogen power and electrification, reduce waste and revolutionise the end-of-life management of composite materials and parts. In collaboration with our industry partners, we’re bringing to market some of the most innovative new fibre processing technologies ever developed to deliver real-world benefits that support the sustainability agenda.”

Prepregging
Another new BTMA member, Emerson & Renwick (E+R), a specialist in print, forming, vacuum and coating technologies, also supplies technology for the production of carbon fibre prepregs, which are integrated rolls of fabrics and resins.

Its most recent 1.7-metre-wide line supplied to a customer in Italy operates at speeds of 40+ metres per minute for web coatings or prepreg fibre and resin consolidation, or a combination of both processes. It is distinguished by an ultra precise three-roll reverse roll coater for the processing of high viscosity thermo-activated resins and enables the automatic changeover of sensitive woven fabric materials at zero tension, with three high precision calendaring nips with hot/cool plates. Multiple unwind and rewind systems for intermediate lamination steps include side loading and reliable lap splicing and zero speed splicing with a web accumulator for the main product rewind.
 
 E+R has also been part of a consortium working on the development of lithium-sulphur (Li-S) batteries within the £540 million UK Faraday Battery Challenge. Once commercially viable, Li-S batteries promise to provide relatively high energy density at low cost for sustainable electric vehicles of the future – inevitably starting with F1.

Strong links
“In addition to our powerful base of textile testing and control companies, many other BTMA members are working on further F1 and advanced composite projects,” says Jason Kent in conclusion. “We are also forging strong links with the UK’s key research hubs such as Sheffield University’s Advanced Manufacturing Research Centre, the Northwest Composites Centre in Manchester, the National Centre for Motorsport Engineering in Bolton and the National Composites Centre in Bristol.

“The BTMA recently became an associate member of Composites UK too, because this sector is the crucible of innovation for tomorrow’s textiles.”

Fibre Extrusion Technology Ltd (FET) of Leeds, UK enjoyed a highly successful exhibition at COMPAMED 2024 in Düsseldorf. This was the first time that FET had exhibited at this leading international trade fair for the medical technology supplier sector, a reflection of the company’s growing role in the global medical sector. In 2023-24, over 60% of FET’s turnover was derived from the medical market.

“It is never certain whether a new exhibition will prove to be a successful venture until it is tested in practice” commented FET’s Managing Director Richard Slack, “but we are delighted to report that COMPAMED 2024 exceeded all expectations. In fact, we have already booked a stand for next year’s exhibition in November, albeit in a slightly different location”.

COMPAMED 2024 attracts suppliers of a comprehensive range of high-quality medical technology components, services and production equipment for the medical industry. FET’s expertise in this sector therefore proved to be a perfect fit. With almost 40 serious customer leads taken at the show from both existing and previously unidentified clients, the initial outlook is for a very successful exhibition which will be followed up by future participation at this annual event.

FET’s established expertise lies in laboratory and pilot melt spinning equipment for a vast range of applications, especially precursor materials used in high value medical devices and specialised novel fibres from exotic and difficult to process polymers. In cases where melt spinning solutions are not suitable, FET provides a viable alternative with pilot and small scale production wet spinning systems.

Central to FET’s success has always been its ability to provide customers with advanced testing facilities and equipment at its Fibre Development Centre in Leeds, complemented by unrivalled knowledge and expertise in research and production techniques.

FET has successfully processed over 100 different polymer types and its systems can melt spin resorbable polymers in multifilament, monofilament and nonwoven formats, collaborating with specialist companies worldwide to promote greater sustainability through innovative manufacturing processes.

On December 4, 2024 Borealis proudly announced the winners of the Borealis Scientific Innovation Award 2024 (BSIA) at the Borealis Innovation Day in Linz, Austria.

As a global industry leader, Borealis is rewarding pioneering ideas since 2008 with the Borealis Scientific Innovation Award, celebrating groundbreaking innovations with the potential to impact the world. This year’s focus was on new solutions for the environmentally sustainable production and use of plastics.

Innovative thinkers from the professional and academic scientific communities, entrepreneurs, start-ups, and university researchers were invited to submit their ideas. The winners were selected by a panel from Borealis' research team, who meticulously evaluated all submissions.

This year, submissions were accepted in the following key areas:

• New catalysts for sustainable production
• Energy-efficient polymerization processes
• Recycling of polymers
• Polymeric materials for energy transition

Winners of the 2024 Borealis Scientific Innovation Award 2024:

• First place: Clement Collins Rice (University of Oxford, UK) “Towards designer polyolefins: highly tuneable olefin copolymerisation using a single permethyl-indenyl post-metallocene Catalyst”
• Second place: Elisabetta Carrieri (Ghent University, Belgium) “Development of a solvent based recycling process for agricultural film”
• Third place: Esun Selvam (University of Delaware, USA) “Recycling polyolefin plastic waste at short contact times via rapid joule heating”

In addition to receiving monetary prizes, the winners were invited to the Borealis Innovation Headquarters in Linz, Austria, where they participated in the award ceremony during the Borealis Innovation Day 2024.  

The next call for applications for the BSIA will start in spring 2025.

The Oerlikon Polymer Processing Solutions Division of the Swiss Oerlikon Group is expanding its customer services and spare parts business in the area of machines and systems for the production of carpet yarns (BCF) and industrial yarns (IDY). To this end, the company concluded an agreement with the Truetzschler Group, based in Moenchengladbach, Germany, in August. Technology experts and service staff from Oerlikon Neumag are now the new contacts for customer services and the spare parts business for Truetzschler's BCF and IDY technologies installed in the market. The Moenchengladbach-based textile machinery manufacturer is withdrawing from this business segment in order to concentrate on the spinning, card clothing and nonwovens businesses in future.

Oerlikon Polymer Processing Solutions offers complete solutions for the manmade fiber industry. They range from extrusion and polycondensation plants to texturized yarn, and are accompanied by automation and digital solutions. The supply of all process steps from a single source ensures a harmonized technology that guarantees high quality of the yarns produced.

Based in Neumuenster, Germany, Oerlikon Neumag, a branch of Oerlikon Textile GmbH & Co. KG and a brand of the Oerlikon Polymer Processing Solutions Division, has been an established and broadly positioned international supplier with proven expertise in the field of BCF for decades. The division's sister company Oerlikon Barmag from Remscheid, Germany, contributes its expertise in the field of IDY systems.

CARBIOS and SASA, a manufacturer of polyester, fiber, filament yarn, polyester-based polymers, specialty polymers and intermediates, have signed a Letter of Intent (LOI) to cooperate through SASA’s potential acquisition of a license for CARBIOS’ unique PET biorecycling technology. This licensing agreement would allow SASA to construct and operate an enzymatic depolymerization plant in Adana, Turkey, with a capacity of 100,000 tons per year of prepared PET waste, and would give access to a circular recycling technology, enabling the production of polyester pellets, fibers and textiles from various waste sources, including polyester textile waste. With CARBIOS' biorecycling technology, SASA would diversify its offering to meet the growing global demand for sustainable materials in the textile industry, primarily catering to the European market.

Less than 1% of textile waste is currently recycled into new textile fibers^[1].  With European regulations moving towards the incorporation of more recycled content (at least 20% of recycled fibers by 2030), demand for recycled polyester in the EU is anticipated to increase, naturally positioning Turkey as a major producer alongside Asian countries.  In this context, SASA is striving to become the largest supplier of high value-added polyester in the region and beyond. To achieve this, SASA aims to introduce recycling as part of its activities, which already encompass the whole value chain from PET production to fiber and textile conversion. CARBIOS’ PET biorecycling technology plays an important part in SASA’s ongoing transformation strategy, which includes back integration, capacity expansion, even higher competitiveness, as well as circularity.

CARBIOS has developed a enzymatic depolymerization technology that enables efficient and solvent-free recycling of PET plastic and textile waste into virgin-like products. CARBIOS has ambitious plans to become a leading technology provider in the recycling of PET by 2035. After the recent announcement of a joint Letter of Intent with Zhink Group in China, this new Letter of Intent for a potential licensing agreement in Europe confirms global traction for CARBIOS biorecycling technology, and marks another significant step in the international roll-out of its licensing model. In addition to the world’s first industrial-scale enzymatic PET recycling plant which is currently under construction in Longlaville, France, this potential plant in Turkey would process PET waste that is currently not recyclable using conventional recycling technologies.

[1] System Circularity and Innovative Recycling of Textiles | Circular Cities and Regions Initiative (europa.eu)

Fibre Extrusion Technology Ltd (FET) of Leeds, UK has continued the ongoing process of strengthening its Research & Development team. The latest addition is Charlotte Witts, who is currently studying for a degree in Chemistry at Nottingham University and will work at FET for a 12-month period. She will continue her studies in chemistry as distant learning modules whilst also working at FET. FET designs, develops and manufactures extrusion equipment for a wide range of high value textile material applications worldwide.

“I’m really excited to be joining the team at FET and getting stuck in to the role. Sustainability is a big passion of mine, so I’m looking forward to learning how FET develops new technologies that support the textile industry in this endeavour. I hope that my previous studies within this area will help to foster new ideas.”

Furthermore, FET has a development policy of bringing young people into the industry and has invested heavily in recent years to this end, helping to address the skills gap in the UK textile industry. The company’s R&D department comprises ten scientists and engineers who work closely with customers on process development and new product trials.

Charlotte Witts will be focusing on the wet spinning process which is fortuitous as FET has just finished commissioning their own in-house low viscosity wet spinning system. Over the coming year she will focus on spinning a number of bio-sourced polymers (e.g. alginate, chitosan, gelatin, recombinant proteins). These materials require a strong scientific understanding of the underlying chemistry to successfully produce a high-quality yarn. Furthermore, FET regularly gets customer requests to conduct trial work on these materials to de-risk the equipment purchase process.

Stahl has joined the Global Organization for PHA (GO!PHA), a non-profit platform that advocates and advances the use of polyhydroxyalkanoates (PHAs), a naturally occurring polymer that offers a lower-impact, bio-based alternative to traditional fossil-based plastic feedstocks.  

GO!PHA is a coalition of over 60 stakeholders ranging from producers and formulators to users as well as universities and research institutes. The members, all early adopters of PHAs, work together to increase understanding of this relatively new PHA technology and advance the science behind these renewable, compostable and biodegradable materials. As a member of the network, Stahl will have the opportunity to join forces with the wider PHA value chain to help move PHAs beyond the testing phase and accelerate the potential application of the technology in the coatings market.