From the Sector

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

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

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

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

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

At ITMA 2023, EFI™ Reggiani is presenting its sustainable Reggiani ecoTERRA pigment printing line up, the high-speed EFI Reggiani HYPER and Reggiani BOLT XS direct-to-fabric printing solutions, and EFI Inèdit end-to-end digital textile workflows.

The EFI Reggiani ecoTERRA solution is an all-in-one solution for water-based pigment printing that requires no ancillary equipment for pre- and post-treatment. By reducing water, energy and chemicals consumption in the overall process, customers can now obtain a sustainable, direct-to-fabric printing solution. For the first time at ITMA, EFI Reggiani is presenting its full ecoTERRA line up of four models, including a 340 printing width, with speeds ranging from 150 to 600 sqm/hour. This allows customers to choose the best TCO/ROI based on output volume and speed range.
 
Reggiani ecoTERRA water-based pigment inks deliver excellent wet and dry fastness properties, sharpness in detail, and durability while also ensuring printhead longevity with reduced maintenance costs. Thanks to the enhanced polymerisation and finishing unit, EFI Reggiani ecoTERRA also provides an enhanced tactile experience and fabric softness.
 
In addition to highlighting EFI Reggiani’s sustainable product offering, the company will also demonstrate the significant productivity and efficiency advantages offered by its portfolio of high-speed, high-performance digital textile printers at ITMA 2023. Attendees will discover how mass production can transition to a digital, on-demand workflow with the high speeds and high print quality of the EFI Reggiani HYPER scanning printer and the next-generation EFI Reggiani BOLT XS single-pass textile printer.

Visitors to the booth also will see EFI Reggiani’s new proprietary end-to-end digital printing workflow and the latest enhancements to EFI Inèdit digital textile software. Inèdit, now part of EFI Reggiani, is one of the leading developers of raster image processors (RIPs) and related software for digital industrial textile printing. The EFI Reggiani end-to-end workflow with Inèdit integration boosts productivity and production capabilities for digital textile print operations while ensuring maximum security for customer’s designs thanks to two-level encryption.
 
EFI Reggiani QUERY, the user-friendly, advanced data analysis tool to measure printer performance, keep track of real costs per metre, and monitor water and energy consumption, will also be demonstrated.

Mimaki Europe, a provider of industrial inkjet printers, cutting plotters, and 3D printers, is debuting the new Tiger600-1800TS, Mimaki’s most productive sublimation transfer printer, on its stand at ITMA 2023. This latest high-speed, compact and robust roll-to-roll inkjet printer has been designed to accelerate the analogue to digital transformation within the textile printing industry.

The Tiger600-1800TS boasts a maximum printing speed of 550 m2/h (143% faster than the previous model) owing to the renovated high-speed printhead and Mimaki’s proprietary image quality enhancement technologies. The printer’s size has also been halved compared to the previous system, with the paper mounting and winding system both located at the back of the machine. This smaller footprint enables customers to easily install multiple units to meet fluctuating demand, whilst also increasing overall production capacity.

A further environmental benefit of the Tiger600-1800TS will be the bluesign® certification of its MLSb510 series sublimation transfer inks. This certificate, expected to be awarded in June 2023, will provide assurance that these inks are of highest quality combined with due consideration for the safety of consumers and print operators, and environmental conservation, and therefore, contributing to the sustainability of the textile industry.

Mimaki’s expertise in developing reliable, easy-to-use and efficient solutions has also not faltered in the development of the Tiger600-1800TS. The printer’s ink tanks can be replaced without interrupting the printing process, minimising down time. Maintenance of the printer is also reduced with its roller paper feeding method eliminating the need for the application of adhesives onto a belt.

Following their entry into the fibres and textiles sector, as announced at K 2022, recycling machine manufacturer EREMA launches the INTAREMA® FibrePro:IV - which has been specially developed for PET fibre-to-fibre recycling - at ITMA in Milan from June 8 to 14. Thanks to its especially gentle material preparation and efficient removal of spinning oils, the rPET produced can be reused in proportions of up to 100 percent for the production of very fine fibres.

PET is regarded as a key material for the production of synthetic fibres. Around two thirds of the total volume of PET goes into the production of PET fibres for the textile industry. This highlights the importance of high-quality recycling solutions for the circular economy. By combining proven INTAREMA® technology with a new IV optimiser, EREMA succeeds in processing shredded PET fibre materials heavily contaminated by spinning oils in such a way that the finest fibres can be produced again from the recycled pellets. The system, which now joins EREMA's machine portfolio as the INTAREMA® FibrePro:IV, is characterised by a longer residence time of the PET melt. This is an essential factor for achieving high quality recycled pellets, as it allows the spinning oils and other additives used to improve the handling of the fibres during manufacturing to be removed more efficiently than in conventional PET recycling processes. Following extrusion, by polycondensation the intrinsic viscosity (IV) of the PET melt is increased in the new IV optimiser and under high vacuum to the precise level that is needed for fibre production. "Including filtration the output quality that we achieve with this recycling process is so high that ultra-fine fibres of up to 2 dtex can be produced using these rPET pellets, with an rPET content of 100 percent," says Markus Huber-Lindinger, Managing Director at EREMA. Waste PET fibre from production processes can therefore be further processed into rPET filament fibre, carpet yarn and staple fibre.

While the focus of the fibre and textiles application is currently still on PET fibre recycling, EREMA is committed to driving forward the recycling of mixed fibre materials from classic textile recycling collection in a next project phase. In order to accelerate development work, the EREMA Group opened its own fibre test centre, where a cross-company team is working on recycling solutions for fibre-to-fibre applications. The centre also operates a fully equipped and variable industrial-scale recycling plant. It includes the peripheral technology required and is available to customers for trials.

KARL MAYER GROUP will be presenting a WEFTTRONIC® II G at the ITMA with new features and upgrades for greater efficiency. This warp knitting machine with weft insertion produces lattice structures from high-strength polyester, which are firmly established in the construction industry in particular. With a working width of 213", it offers productivity and further advantages through design innovations. New features include weft thread tension monitoring, management and the new VARIO WEFT laying system. The component for the weft insertion aims at maximum flexibility. It allows the patterning of the weft yarn to be changed quickly and easily electronically, without mechanical intervention during yarn insertion and without limits on repeat lengths. In addition, there is less waste.

The KARL MAYER GROUP also supports its customers with well thought-out Care Solutions. The new support offers include retrofit packages for retrofitting control and drive technology for weft insertion and composite machines, and service packages that bundle various services. These include machine inspections and the replacement of all drive belts. The customer benefits from fixed prices that cover the costs of technician assignments, various discount options and transparent services.

A new solution for the vertical greening of cities is presented from the field of application for technical textiles. The core of the innovation is a grid textile produced on warp knitting machines with weft insertion by KARL MAYER Technische Textilien GmbH. The knitted lattice fabric is made of flax. It is used as a climbing aid for fast-growing plants, and after the greening phase, in autumn, it can be recycled together with these plants as biomass in pyrolysis plants to produce electricity and activated carbon. In summer, the planted sails lower the ambient temperature through evaporation effects. In addition, photosynthesis creates fresh air and binds CO2. Other important advantages are low soil requirements and flexible placement in public spaces. The greening system was developed by the company Micro Climate Cultivation, OMC°C, with the support of KARL MAYER Technische Textilien.

The KARL MAYER GROUP will also be exhibiting a sustainable composite solution made from natural fibres. The reinforcing textile of the innovative lightweight material is a multiaxial non-crimp fabric, which was also produced from the bio-based raw material flax on a COP MAX 4 from KARL MAYER Technische Textilien. The boatbuilding specialist GREENBOATS uses natural fibre composites to achieve sustainable products. The fact that it succeeds in this is shown, for example, by the Global Warming Potential (GWP): 0.48 kg of CO2 per kilogram of flax reinforcement compares with 2.9 kg of CO2 per kilogram of glass textile.

ERCA, Patagonia® and YKK announce the implementation of ERCA’s REVECOL®, a sustainable, innovative chemical agent, in YKK’s dyeing processes at their Vietnam production sites transforms common waste material, such as exhausted vegetable cooking oil, into an upcycled, certified high performance, safe textile chemical. ERCA has invested in circular practices to take waste material and use them as feedstocks to create new responsible chemical products.

Always searching for new sustainable innovations, REVECOL® caught the attention of Patagonia®. Driven by the goal to utilize non-extractive chemistry in their supply chain wherever possible, the brand teamed up with ERCA and trim supplier YKK to deploy REVECOL®.

REVECOL® LV-TS has a carbon footprint that is 72% lower* than the more conventional chemical auxiliaries produced by ERCA. Today ERCA produces a wide range of high-performance chemical auxiliaries made from used vegetable oil that are ZDHC, bluesign® approved and GRS certified.

ERCA is one of the first companies to have GRS certified chemical products, opening the door to circular chemical auxiliaries.

As part of their Sustainability Vision 2050, YKK is constantly working to deploy more sustainable chemical processes in their production. The ability to replace a commonly used dye chemical with a lower impact version was a no-brainer for YKK’s Vietnam management. REVECOL® is not only more sustainable, it is also more efficient, reducing the use of the dyeing auxiliary by 20% to 30%, thus  helping to lower YKK’s overall chemical usage.

* bluesign® Product Carbon Footprint Report

B.I.G. Yarns unveils its new “SustainableYarns” platform, with Clerkenwell Design Week visitors the first to be invited to get on board and focus on what matters most for the design and manufacture of sustainable soft floorings.

The expert in polyamide (PA) 1 step 3 ply yarns offers a range of options for manufacturers to introduce sustainable yarns into carpet solutions and reach sustainability targets faster and more efficiently.

The Sustainable Yarns range creates opportunities to design with recycled content yarn (EqoCycle), to work with renewable resources (EqoBalance), and, following the launch of new polyamide 6 (PA6) EqoYarn at Clerkenwell Design Week, to also leverage the low-impact value chain.

New addition EqoYarn is a new low-impact PA6 carpet yarn based on the most recent innovations in polymer production, which enable yarn manufacturers to lower their carbon footprint by nearly 50% and give carpet manufacturers more options to reduce their impact.

For its EqoYarn Bulk Continuous Filament (BCF) production process, B.I.G. Yarns has selected the few best-in-class partners that have made major steps forward in terms of sustainability, and reduced their greenhouse gas emissions thanks to continuous investments in process efficiency, green energy, heat optimization and waste reduction. The result is EqoYarn with a carbon footprint of 4 kg CO2 eq/kg yarns, which is a CO2 reduction of up to 50% compared to conventional PA yarns.

EqoBalance PA6 yarns enable customers to reach an even higher CO2 reduction of up to 75%. Manufactured with polymers made from renewable resources such as organic waste from cooking oil instead of virgin or fossil feedstock, these yarns have a carbon footprint of 1.98 kg CO2 eq./ kg yarns. They help carpet manufacturers to create products with an extremely low carbon footprint.

EqoCycle PA6 yarns are fully recyclable and incorporate 75% recycled content originating from recycled and regenerated PA6 granules. With a carbon footprint of 4.64 kg CO2 eq./ kg yarns, they deliver the same high-quality performance of virgin PA6 yarn with the benefit of 37% CO2 reduction. EqoCycle yarns offer carpet manufacturers a sustainable alternative to help reduce the ecological footprint of their products and move towards a circular economy without jeopardizing the end-product quality.

In addition to the different CO2-reducing options, B.I.G. Yarns’ customers can access an unlimited colour range to elevate their designs. Its BCF technology for polyamide yarns, twisted and heat-set yarns, one-colour to multi-colour, between 650 and 15000 dTex, along with its colour studio, are available to support their creation of customised collections.

Indorama Ventures Public Company Limited, a global sustainable chemical producer, was upgraded to "A" from "BBB" in MSCI’s ESG rating, reaffirming the company’s effective management of sustainability related risks and opportunities.

MSCI (Morgan Stanley Capital International), an independent provider of research-based indices and analytics, ranked Indorama Ventures among the top 14% of 65 companies worldwide in the commodity chemicals industry. The rating has placed it in the top quartile for opportunities in clean tech, water stress, corporate governance, and corporate behavior.

Indorama Ventures is committed to reducing water intensity by 10% by 2025 and 20% by 2030. It developed a Water Risk Assessment Report on its contributions to achieving sustainable management of water targets and the United Nations Sustainable Development Goals (UN SDGs). For improved corporate governance, the company provides whistleblowers with protection from retaliation, and has policies on business ethics and anti-corruption. Relating to opportunities in clean tech, Indorama Ventures’ is investing in recycling technology and biomass feedstock under its Vision 2030, and is also investing in operational efficiencies, carbon capture technology, renewable energy, and phasing out coal to reduce Scope 1 and Scope 2 greenhouse gas emissions.

MSCI ESG Ratings aim to measure a company’s resilience to long-term ESG risks. Companies are scored on an industry-relative AAA-CCC scale across the most relevant key issues based on a company’s business model. Investors, including pension funds, sovereign wealth funds, endowments, and asset managers, commonly consider the ratings to assess financial risks in the investment process.

• Carbios has developed an ultra-high throughput microfluidic screening of PET-depolymerizing enzymes in partnership with the Paul Pascal Research Center^[1], a joint research unit of the CNRS^[2] and the University of Bordeaux
• Microfluidics enables millions of enzymes to be screened in a day, compared with a few thousand a week with conventional technologies
• Future polymers of interest will benefit from this acceleration of the R&D phase, enabling Carbios to develop its portfolio of innovations on different types of plastic more rapidly

Carbios has accelerated its enzyme screening process with a microfluidic technology developed in partnership with the Paul Pascal Research Centre (a joint research unit of the CNRS and the University of Bordeaux, which specializes in microfluidics). This technology enables the screening of millions of enzymes in just one day, speeding up the process to optimize enzymes breaking down PET. This competitive advantage enables Carbios to reduce the time between the R&D phase and the production of its proprietary enzymes, and therefore to develop concrete solutions to plastic pollution even faster.

Microfluidics
Microfluidics allows the production of devices handling very small amounts of liquid. Each droplet generated can be considered as an independent microreactor having a volume in the picoliter range (10-12 liters) and containing a particular enzyme whose PET depolymerization activity will be screened. These droplets move through analysis units the size of a microchip allowing ultra-high throughput screening of 150 enzymes per second.

Previously, conventional robotic systems allowed screening in microplate format with a volume in the milliliter range (10-3 liters) and with rates of around one enzyme per minute.

The use of microfluidics to screen for more efficient or new enzymes will become widely adopted in the coming years, therefore accelerating the development of bioprocessing. Currently used by Carbios for the development of its PET depolymerization process, microfluidics should be used to accelerate the development of new enzymes for other types of plastic such as polyamide.

Carbios researchers specialized in microfluidics
Microfluidic processes require special expertise. At present, two researchers at Carbios are dedicated to microfluidics and based in the cooperative laboratory with TBI^[3] hosted by INSA^[4] Toulouse.  Alexandra Tauzin, Researcher in Enzyme Engineering and Microfluidics, and Alexandre Gilles, Engineer specialized in robotics, work in partnership with the Paul Pascal Research Center.

^[1] Centre de Recherche Paul Pascal (CRPP)
^[2] Centre National de la Recherche Scientifique (CNRS) = National Center for Scientific Research
^[3] Toulouse Biotechnology Institute
^[4] National Institute of Applied Sciences

Jedes Unternehmen hat individuelle Bedürfnisse, wenn es darum geht, Wissen zu den Themen Digitalisierung und Ressourceneffizienz aufzubauen. Mit einem themenspezifischen Zugang zum umfangreichen Informationsangebot des VDI Zentrums Ressourceneffizienz (VDI ZRE) unterstützt der neue Online-Baukasten „Ressourceneffizienz 4.0“ bei der zielgerichteten Suche – je nach digitalem Reifegrad des Unternehmens.

Zielgerichteter Zugang zu Informationen
Je nach individueller Fragestellung und digitalem Reifegrad erhalten Unternehmen einen zielgerichteten Zugang zu Online-Tools wie Ressourcenchecks, zu Publikationen oder Weiterbildungsangeboten. Während eine umfangreiche Sammlung zu Technologien im Entwicklungsstadium einen Blick in die Zukunft gibt, zeigen zahlreiche Gute-Praxis-Beispiele, wie Digitalisierungsprojekte bereits zu mehr Ressourceneffizienz in Unternehmen geführt haben.

Der Online-Baukasten ist in die Bausteine Wissensaufbau, Strategie, Analyse und Entwicklung unterteilt. Entsprechend dem digitalen Reifegrad, d.h. abhängig davon, ob sich ein Unternehmen z.B. noch in der Erkundungsphase befindet oder schon fortgeschritten ist, werden verschiedene Arbeitsmittel vorgeschlagen.

Das vom Bundesumweltministerium beauftragte Online-Tool wird regelmäßig aktualisiert und erweitert. Es richtet sich vorrangig an kleine und mittlere Unternehmen aus dem verarbeitenden Gewerbe.