From the Sector

Carbios has signed an agreement with On, Patagonia, PUMA, and Salomon, to develop solutions that will enhance the recyclability and circularity of their products.
 
An important element of the two-year deal will be to speed up the introduction of Carbios’ biorecycling technology, which constitutes a breakthrough for the textile industry. Carbios and the four companies will also research how products can be recycled, develop solutions to take-back worn polyester items, including sorting and dismantling technologies, and gather data on fiber-to-fiber recycling as well as circularity models.
 
The challenge the four brands share, is that their ambitious sustainable development goals can only partially be met by conventional recycling technologies which mostly target bottle-to-fiber recycling. Future regulations will require more circularity in packaging and textile. Yet the market consensus is that there will soon be a shortage of PET bottles, as they will be used for circular production methods in the Food & Beverage Industry.   
 
Carbios’ innovative process constitutes a technological breakthrough for the recycling of polyester (PET) fibers, which are widely used in apparel, footwear and sportswear, on their own or together with other fibers. PET polyester is the most important fiber for the textile industry with 52 MT produced, even surpassing cotton at 23MT. The biorecycling process uses an enzyme capable of selectively extracting the polyester, recovering it to recreate a virgin fiber. This revolutionary technology makes it possible to recover the PET polyester present in all textile waste that cannot be recycled using traditional technologies.
 
PET plastics and fibers are used to make everyday consumer goods such as bottles, packaging and textiles. Today, most PET is produced from fossil resources, then used and discarded according to a wasteful linear model. By creating a circular economy from used plastics and fibers, Carbios’ biorecycling technology offers a sustainable and more responsible solution.

DOMO Chemicals, a producer of engineered polyamide materials, and Hynamics, a 100% subsidiary of EDF Group specializing in the production of low-carbon hydrogen, have entered into a partnership project with the objective of achieving zero-carbon for 100% of the hydrogen used at the Belle-Étoile industrial site, in Saint-Fons (south of Lyon, France), in the heart of the French Vallée de la Chimie (“Chemistry Valley”).

For the first time in France, the “HyDom” project will enable the installation of an 85-megawatt (MW) hydrogen production plant using the water electrolysis process at the Belle-Étoile site, with a production capacity of 11,000 metric tons of low-carbon hydrogen per year. The plant will be powered by the French low-carbon electric power mix. By 2027, it will supply 100% of the annual production of hexamethylene diamine, a key component used in the production of plastics.

The project will eventually prevent the emission of 84 kilotons of carbon dioxide (CO2) each year. Hexamethylene diamine, and ultimately, durable and low-carbon polyamides, will be used in various applications in major industry sectors, such as automotive, electronics, and heating & cooling.
This project is a major step towards the decarbonization of industrial sites that use grey hydrogen (produced from fossil fuels). The location in the Vallée de la Chimie within the vicinity of major transport routes opens up opportunities for the creation of a more complete hydrogen ecosystem.

The first phase of the project will consist of building up and ascertaining technical concepts and integrating the low-carbon hydrogen production plant within the larger production process of hexamethylene diamine.

Considering the high-power scale of the future electrolytic hydrogen production facility, the HyDom project is being developed in close collaboration with RTE (an organization in charge of managing the French power grid), to solve connection issues. As a priority project for the industry's zero-carbon strategy and for the “France 2030” investment plan, HyDom is supported by the French government and has been presented to the European Commission for public funding.

Fiery®, the digital front end (DFE) and workflow business of EFI, announced that it has acquired CADlink® Technology Corp., a software company that delivers solutions for the high growth areas of digital direct-to-garment (DTG) and direct-to-film (DTF) printing; digital cutting and engraving; digital wide-format print; and vehicle wraps. CADlink’s products address increasingly important customer needs for customization and personalization, and for reducing the time spent moving work from design to production.

CADlink is a global software company that serves markets that require unique workflows involving different types of production devices. CADlink’s products are recognized leaders in design, RIP and workflow technology, and are sold globally to customers through OEM partners and an extensive network of resellers. CADlink’s products, partners and channels are a natural complement to what the Fiery business delivers for its global commercial, display graphics and industrial printing customer base.  

The CADlink software portfolio includes proven, advanced solutions that support the development and growth of e-commerce for custom-manufactured products.

“Becoming part of the EFI Fiery business will extend the geographic reach for our products and enhance our ability to support and drive greater value to customers and partners worldwide,” said CADlink Co-founder and CEO Gordon Reynen.

International technology group ANDRITZ has received an order from Yanpai Filtration Technology Co., Ltd. (YANPAI®), China, to supply batt forming equipment with an aXcess card and crosslapper for a needlepunch line producing PTFE filtration products at its site in Tiantai. The PTFE felts will be used as smoke filters in waste incineration plants. Start-up of the line is planned for the second half of 2022.

Yanpai is one of the leading Chinese producers of nonwoven filters for dust and air treatment and of woven filter fabrics used in solid/liquid separation. Established in 1990, Yanpai was at the forefront of development work on new industrial filtration fabrics. Today, Yanpai is a company with facilities in China and the USA.

• Printing Expo Online is expanding again by doubling the size of Zone 2 with new exhibitors and feature zones making it one of the largest virtual trade shows in the world.

Visitors will be able to visit the new Zaikio underground catacombs that are accessible from several portals around the show. Click on a New York taxi, a London Phone Box or a funky Hot Dog Van and you will be transported into the Zaikio cavern environment where visitors will be able to watch application videos, arrange demos and sign up to this amazing new cloud-based platform.

Another addition to Zone 2 is the new Software Technology Centre (STC). This feature area will grow over time to show a wide range of software solutions that are available on the market.

Joining Printing Expo Online in the STC for the launch is EFI Fiery, who are showing their full portfolio of software solutions.

Design’N’Buy are also a new exhibitor in the STC with their all-In-One Web2Print software solution that helps users leverage technology, people and processes for the multi-fold growth of your printing business.

Also moving into the STC will be PrintIQ who offer the modern print shop a solution for businesses that need to be able to grow and scale as needed without slowing down or sacrificing quality.

Another new addition to the show is the introduction of the Global Print Trade Club. This initiate is free to all Print Service providers around the world and offers the opportunity to network on a global scale.

New to the exhibition is Kornit Digital with their multi storey showroom which will shortly be opening its doors where visitors will be able to view Direct to Garment and Direct to Fabric printing equipment, technical data, case studies, clothing designs and applications as well as visit the Kornit dedicated auditorium where live streaming content will be shown of Kornit Digital’s Fashion weeks as they happen throughout the year.

Another addition is the new application journey added to the Xeikon Innovation Centre at Printing Expo Online. Visitors will now be able to experience a virtual tour of a living room, kitchen, bathroom, and garage where Xeikon will show applications for commercial, label and Wall Deco products that can be produced on their digital print engines.

Printing Expo Online is open 24/7 365 days a year and has now welcomed over 60,000 visitors from all over the world and continues to grow not only its footprint and total visitor numbers, but also its relevance as an important resource tool for Print Service Providers from around the world that, for whatever reason, are unable to attend live events.

• The Borvida™ portfolio introduces sustainable base chemicals to Borealis’ range of product offering
• The range will initially be based on non-food waste biomass, and chemically-recycled waste; in the future it will also draw from atmospheric carbon capture
• The traceability of the content will be based on Mass Balance, which is ISCC PLUS certified
• This is the next step in an ambitious sustainability journey, which will see Borealis move away from traditional fossil-based feed

Borealis is strengthening its EverMinds™ circular product offering with Borvida™, a range of sustainable base chemicals.

The Borvida portfolio will offer base chemicals or cracker products (such as ethylene, propylene, butene and phenol) with ISCC Plus-certified sustainable content from Borealis sites in Finland, Sweden and Belgium. The move is part of Borealis’ broader commitment to a Future-Positive Revolution, in which the unrivalled benefits of base chemicals and polymers can be enjoyed at minimal impact to the planet.   

The portfolio will initially comprise Borvida B, from non-food waste biomass, and Borvida C, from chemically-recycled waste. In the future, the range will evolve to include Borvida A, sourced from atmospheric carbon capture. Borvida is complementary and is the building block to Bornewables™, a portfolio of polyolefins based on renewably-sourced second generation feedstocks, and Borcycle™, which offers circular polyolefins produced from mechanically- and chemically-recycled plastic waste.

Borealis produces a wide range of base chemicals for use in numerous industries based on various feedstock, such as naphtha, butane, propane and ethane. Through its olefin units (steam cracker and propane dehydrogenation), it converts these into the building blocks of the chemical industry: ethylene, propylene and C4 hydrocarbons (butylenes, ethyl tertiary-butyl ether (ETBE) and butadiene), and C5-6 hydrocarbons (pygas, phenol) among others.

The basis of the Borvida portfolio is Mass Balance, a Chain of Custody model that enables sustainable content to be tracked, traced, and verified through the entire value chain, offering sustainability-assured products from feedstock to end product. Using this model, circular alternatives can be offered in a cost-effective and environmentally-conscious way, which can be scaled up quickly without compromising on quality or efficiency.

Borvida can be used for a wide range of different polymer and chemical applications, also beyond polyolefins (PO). Non-PO polymers, such as polycarbonates, acrylonitrile butadiene styrene (ABS), super absorbant polymer (SAP) and other chemicals, are utilised for various end applications including coatings, plasticizers, adhesives, automotive, electronics, lubricants, detergents, appliances and sports equipment.

Together with key strategic partners, including Neste and Covestro, Borealis strives to provide a long-term solution in order to allow value-chain partners to meet their sustainability goals. Borvida will enable our customers to increase the sustainability of their products, keeping them ahead of forthcoming legislative changes, and meeting their customers’ demands for climate-conscious products.

Introduced on a smaller scale in early 2020, early renewable base chemicals customers include Covestro. “The use of alternative sustainable raw materials is one important pillar of our strategic ambition to become fully circular”, comments Frank Dörner, Managing Director Covestro Procurement Services GmbH & Co. KG. “The new product line is a good example for joint solutions, another strategic pillar, in order to establish new and reliable supply chains creating benefits for our customers.”

Indorama Ventures Public Company Limited (IVL), a global sustainable chemical company, has signed a license agreement with Shandong Binhua New Material Co., Ltd. (Binhua), a subsidiary of Befar Group, a leading petroleum and chemical enterprise in China, to build, own and operate a propylene oxide (PO), t-Butanol (TBA) and t-Butyl methyl ether (MTBE) co-production unit.

Featuring the world’s only MTBE ‘single-step’ reaction technology, IVL’s proprietary innovation, the project is part of the ‘C3 and C4’ comprehensive utilization project in Shandong, China. It is one of the largest in the province, covering an area of over one million square meters.

Under the contract, IVL will provide a design package, technology, operational know-how and training to enable the construction and operation of a PO co-production with MTBE and TBA units for Binhua. The plant is part of a larger complex comprising propane dehydrogenation to propylene, butane isomerization, synthetic ammonia, and other installations.

Albstadt-based Mayer & Cie. has been named a Top 100 award-winner for the third time as one of Germany’s most innovative small and mid-range businesses. The jury made special mention of the circular knitting and braiding machine manufacturer’s innovative processes. At the centre of the family firm’s further digital development is on the aim to boost its customers’ productivity. Last Friday, 25 June, members of the Mayer & Cie. management received the award from the science journalist Ranga Yogeshwar at the SMB summit in Frankfurt am Main.

For some time now, the focus of development work at Mayer & Cie. has been on lean management in assembly processes, on optimisation of aftersales service, including setting up an online shop for spare parts, and on product lifecycle management, or PLM, which stands for a concept of seamless integration of all the information that arises during a product’s lifecycle. A clean data structure is the basis for these measures, it’s called the “digital backbone”. It means that all product data is processed in the same database and all information is available only once and can be downloaded immediately.

In all, 436 companies, including about ten per cent from machinery and plant engineering, competed for the Top 100 seal of innovation this year. Nearly 300 were successful and were congratulated in person by Ranga Yogeshwar at the SMB summit. He noted that the award winners set a role model example. “Innovators are thought leaders; they are always pioneers too,” said Yogeshwar, who mentors the competition. “They put their products to the test and ask themselves what an ecological society and a climate-oriented world will require of them. And they check the opportunities and challenges that increasing digitisation will bring for forms of cooperation, social relationships and, with them, for employee retention.”

With the goal of making recycling of lightweight, high-volume fiber and flake recyclate much more economical and, in some cases even possible, Coperion has developed a new version of its ZS-B side feeder. Using the innovative ZS-B MEGAfeed, plastic recyclate with a bulk density under 200 kg/m³, long considered intake-limited and thus not worth recycling, can be reliably fed in large quantities into Coperion’s ZSK twin screw extruder and be concurrently recycled and compounded.

The ZS-B side feeder’s novel design makes it possible to feed very high rates of fiber and flakes, such as PA, PE, PET, and PP. As a result, the ZSK twin screw extruder’s high capacity can be fully exploited when the ZS-B MEGAfeed is used. Very high throughputs in both mechanical and chemical recycling of post-industrial and post-consumer waste are achieved.

Increased Throughput in Numbers
With a ZSK 58 Mc18 twin screw extruder, the throughput increase and thus the potential of the new ZS-B MEGAfeed becomes very clear. When recycling PA fibers with a bulk density of ~40-50 kg/m3, throughputs of 70 kg/h were previously achieved using conventional equipment. When the PA fibers were fed into the ZSK extruder using the ZS-B MEGAfeed, throughputs increased about fourteenfold to 1,000 kg/h. Similar results were achieved recycling carbon fibers with a bulk density of ~50-70 kg/m3; in this case, throughputs increased from 50 kg/h to 2,500 kg/h using the ZS-B MEGAfeed. When recycling PCR (Post-Consumer Recycled) flakes, throughputs increased from 50 kg/h to 700 kg/h, and from 80 kg/h to 1,300 kg/h with multilayer film flakes.

Key to Economical Recycling of A Wide Variety of Plastics
Plastics previously considered not recyclable are becoming a valuable raw material using the new Coperion ZS-B MEGAfeed. For example, PCR flakes or recyclate from carbon fiber-reinforced plastics can now be fed into the ZSK extruder at high feed rates and recycled economically.

In the case of mechanical upcycling, upstream processes necessary for compounding, such as compacting, melting and agglomeration, are completely eliminated using the ZS-B MEGAfeed technology. In this recycling process, flakes and fibers can be fed directly into the ZSK extruder, where they are melted, compounded, devolatilized, and filtered in a single step. In so doing, both investment costs and energy consumption drop. The production process becomes significantly more efficient. Moreover, the thermal product stress is reduced and recyclate quality increases.

Even when recycling PET, the feed rate is no longer a limiting factor. With the ZS-B MEGAfeed, PET flakes and fibers can be fed into the ZSK twin screw extruder in large quantities with no pre-drying or crystallizing, where they can be processed with the highest degree of profitability.

The ZS-B MEGAfeed can also feed large quantities of post-consumer waste, adding appreciable value to the chemical recycling process with the ZSKs. ZSK throughput rates are very high with the ZS-B MEGAfeed. Preheating of the recyclate via mechanical energy input of the twin screws thus becomes even more economical for further processing in the reactor.

Existing Coperion extruders can be retrofitted with ZS-B MEGAfeed technology to greatly expand their spectrum of applications and increase their throughput rates.

The automotive industry currently faces a complex set of market dynamics: rising material and transport costs, reduced budgets, changing consumer expectations, increasing challenges related to CSR, etc. In this context, improving efficiency across the whole value chain has become a strategic priority for vehicle and equipment manufacturers. Lectra supports its customers by designing and developing cutting-edge solutions that combine software, equipment, data and services to make its offer the gateway to Industry 4.0.
 
With Industry 4.0, a new range of possibilities is opening up to businesses. The concept and its technologies bring in new value creation and cost control models based on synchronized, flexible and fast processes.
 
The Automotive Cutting Room 4.0 offer is a set of solutions connected to one other: Vector, the fabric cutting equipment offering the best performance in the market; Empower, a new generation of digital services to leverage Vector's capabilities; Valia, the heart of the new offer, a software for preparing and scheduling production; and Algopex, an application for exploiting and capitalizing on all the data generated by the cutting room, so you can make the best decisions as quickly as possible.
 
Connecting up all the elements of the Automotive Cutting Room 4.0 offer delivers this unprecedented value and enables an unparalleled level of performance to be achieved. Nicolas Favreau, Lectra’s Automotive Marketing Strategy Director, explains: “When the whole cutting room process is digitalized, the data generated are centralized and accessible in real time, helping our customers to make the best decisions at every step of the production process. The benefits are huge. For example, the key performance indicators from the offer’s first users show productivity gains of around 5% and a reduction in material consumption of nearly 2%. That’s unheard of! These results, combined with the agility that the Automotive Cutting Room 4.0 brings and the complete process control, demonstrate the offer’s maximum relevance.”