From the Sector

A new research project links some of Denmark's leading researchers in PFAS remediation with artificial intelligence. The goal is to develop and optimise a new form of wastewater and drinking water treatment technology using artificial intelligence for zero-pollution goals.

In a new research and development project, researchers from Aarhus University aim to develop a new technology that can collect and break down perpetual chemicals (PFAS) in one step in a purification process that can be connected directly to drinking water wells and treatment plants.

The project has received funding from the Villum Foundation of DKK 3 million, and it will combine newly developed treatment technology from some of Denmark's leading PFAS remediation researchers with artificial intelligence that can ensure optimal remediation.

"In the project, we will design, construct and test a new, automated degradation technology for continuous PFAS degradation. We’re also going to set up an open database to identify significant and limiting factors for degradation reactions with PFAS molecules in the reactor," says Associate Professor Xuping Zhang from the Department of Mechanical and Production Engineering at Aarhus University, who is co-heading the project in collaboration with Associate Professor Zongsu Wei from the Department of Biological and Chemical Engineering.

Ever since the 1940s, PFAS (per- and polyfluoroalkyl substances) have been used in a myriad of products, ranging from raincoats and building materials to furniture, fire extinguishers, solar panels, saucepans, packaging and paints.

However, PFAS have proven to have a number of harmful effects on humans and the environment, and unfortunately the substances are very difficult to break down in nature. As a result, the substances continuously accumulate in humans, animals, and elsewhere in nature.

In Denmark, PFAS have been found in drinking water wells, in surface foam on the sea, in the soil at sites for fire-fighting drills, and in many places elsewhere, for example in organic eggs. It is not possible to remove PFAS from everything, but work is underway to remove PFAS from the groundwater in drinking water wells that have been contaminated with the substances.

Currently, the most common method to filter drinking water for PFAS is via an active carbon filter, an ion-exchange filter, or by using a specially designed membrane. All of these possibilities filter PFAS from the water, but they do not destroy the PFAS. The filters are therefore all temporary, as they have to be sent for incineration to destroy the accumulated PFAS, or they end in landfills.

The project is called 'Machine Learning to Enhance PFAS Degradation in Flow Reactor', and it aims to design and develop an optimal and permanent solution for drinking water wells and treatment plants in Denmark that constantly captures and breaks down PFAS, while also monitoring itself.

"We need to be creative and think outside the box. I see many advantages in linking artificial intelligence with several different water treatment technologies, but integrating intelligence-based optimisation is no easy task. It requires strong synergy between machine learning and chemical engineering, but the perspectives are huge," says Associate Professor Zongsu Wei from the Department of Biological and Chemical Engineering at Aarhus University.

From Resource-efficient and Recycled Fibres for Textiles and Building Panels to Geotextiles for Glacier Protection: Six award nominees present innovative and sustainable solutions for various industries in the cellulose fibre value chain. The full economic potential of the cellulose fibre industry will be introduced to a wide audience that will vote for the winners in Cologne (Germany), and online.

Again nova-Institute grants the “Cellulose Fibre Innovation of the Year” award in the context of the “Cellulose Fibres Conference”, that will take place in Cologne on 13 and 14 March 2024. In advance, the conferences advisory board nominated six remarkable products, including cellulose fibres from textile waste and straw, a novel technology for dying cellulose-based textiles and a construction panel as well as geotextiles. The innovations will be presented by the companies on the first day of the event. All conference participants can vote for one of the six nominees and the top three winners will be honoured with the “Cellulose Fibre Innovation of the Year” award. The Innovation award is sponsored by GIG Karasek (AT).

In addition, the ever-growing sectors of cellulose-based nonwovens, packaging and hygiene products offer conference participants insights beyond the horizon of traditional textile applications. Sustainability and other topics such as fibre-to-fibre recycling and alternative fibre sources are the key topics of the Cellulose Fibres Conference, held in Cologne, Germany, on 13 and 14 March 2024 and online. The conference will showcase the most successful cellulose-based solutions currently on the market or those planned for the near future.

The nominees:

The Straw Flexi-Dress: Design Meets Sustainability – DITF & VRETENA (DE)
The Flexi-Dress design was inspired by the natural golden colour and silky touch of HighPerCell® (HPC) filaments based on unbleached straw pulp. These cellulose filaments are produced using environmentally friendly spinning technology in a closed-loop production process. The design decisions focused on the emotional connection and attachment to the HPC material to create a local and circular fashion product. The Flexi-Dress is designed as a versatile knitted garment – from work to street – that can be worn as a dress, but can also be split into two pieces – used separately as a top and a straight skirt. The top can also be worn with the V-neck front or back. The HPC textile knit structure was considered important for comfort and emotional properties.

HONEXT® Board FR-B (B-s1, d0) – Flame-retardant Board made From Upcycled Fibre Waste From the Paper Industry – Honext Material (ES)
HONEXT® FR-B board (B-s1, d0) is a flame-retardant board made from 100 % upcycled industrial waste fibres from the paper industry. Thanks to innovations in biotechnology, paper sludge is upcycled – the previously “worthless” residue from paper making – to create a fully recyclable material, all without the use of resins. This lightweight and easy-to-handle board boasts high mechanical performance and stability, along with low thermal conductivity, making it perfect for various applications in all interior environments where fire safety is a priority. The material is non-toxic, with no added VOCs, ensuring safety for both people and the planet. A sustainable and healthy material for the built environment, it achieves Cradle-to-Cradle Certified GOLD, and Material Health CertificateTM Gold Level version 4.0 with a carbon-negative footprint. Additionally, it is verified in the Product Environmental Footprint.

LENZING™ Cellulosic Fibres for Glacier Protection – Lenzing (AT)
Glaciers are now facing an unprecedented threat from global warming. Synthetic fibre-based geotextiles, while effective in slowing down glacier melt, create a new environmental challenge: microplastics contaminating glacial environments. The use of such materials contradicts the very purpose of glacier protection, as it exacerbates an already critical environmental problem. Recognizing this problem, the innovative use of cellulosic LENZING™ fibres presents a pioneering solution. The Institute of Ecology, at the University of Innsbruck, together with Lenzing and other partners made first trials in 2022 by covering small test fields with LENZING™ fibre-based geotextiles. The results were promising, confirming the effectiveness of this approach in slowing glacier melt without leaving behind microplastic.

The RENU Jacket – Advanced Recycling for Cellulosic Textiles – Pangaia (UK) & Evrnu (US)
PANGAIA LAB was born out of a dream to reduce barriers between people and the breakthrough innovations in material science. In 2023, PANGAIA LAB launched the RENU Jacket, a limited edition product made from 100% Nucycl® – a technology that recycles cellulosic textiles by breaking them down to their molecular building blocks, and reforming them into new fibres. This process produces a result that is 100% recycled and 100% recyclable when returned to the correct waste stream – maintaining the strength of the fibre so it doesn’t need to be blended with virgin material.
Through collaboration with Evrnu, the PANGAIA team created the world’s first 100% chemically recycled denim jacket, replacing a material traditionally made from 100% virgin cotton. By incorporating Nucycl® into this iconic fabric construction, dyed with natural indigo, the teams have demonstrated that it’s possible to replace ubiquitous materials with this innovation.

Textiles Made from Easy-to-dye Biocelsol – VTT Technical Research Centre of Finland (FI)
One third of the textile industry’s wastewater is generated in dyeing and one fifth in finishing. But the use of chemically modified Biocelsol fibres reduces waste water. The knitted fabric is made from viscose and Biocelsol fibres and is only dyed after knitting. This gives the Biocelsol fibres a darker shade, using the same amount of dye and no salt in dyeing process. In addition, an interesting visual effect can be achieved. Moreover, less dye is needed for the darker colour tone in the finished textile and the possibility to use the salt-free dyeing is more environmentally friendly.
These special properties of man-made cellulosic fibres will reassert the fibres as a replacement for the existing fossil-based fibres, thus filling the demand for more environmentally friendly dyeing-solutions in the textile industry. The functionalised Biocelsol fibres were made in Finnish Academy FinnCERES project and are produced by wet spinning technique from the cellulose dope containing low amounts of 3-allyloxy-2-hydroxypropyl substituents. The functionality formed is permanent and has been shown to significantly improve the dyeability of the fibres. In addition, the functionalisation of Biocelsol fibres reduces the cost of textile finishing and dyeing as well as the effluent load.

A New Generation of Bio-based and Resource-efficient Fibre – TreeToTextile (SE)
TreeToTextile has developed a unique, sustainable and resource efficient fibre that doesn't exist on the market today. It has a natural dry feel similar to cotton and a semi-dull sheen and high drape like viscose. It is based on cellulose and has the potential to complement or replace cotton, viscose and polyester as a single fibre or in blends, depending on the application.
TreeToTextile Technology™ has a low demand for chemicals, energy and water. According to a third party verified LCA, the TreeToTextile fibre has a climate impact of 0.6 kg CO2 eq/kilo fibre. The fibre is made from bio-based and traceable resources and is biodegradable.

adidas unveils its SS24 Melbourne collection to mark the start of the 2024 Grand Slam season. AIRCHILL technology – a first for adidas in tennis – works in tandem with HEAT.RDY material technology to support players performing in the heat of the moment.

AIRCHILL material technology supports cooling through thermally zoned, raised pattern motifs and mesh layers. The lightness of AIRCHILL helps skin breathe – deliberately placed in high sweat and evaporation zones – under the armpits, chest and back. The raised patterns and open mesh fabrics are designed to optimize airflow during high-intensity workouts and matches.

The 26-piece range for men and women also boasts a tranquil color palette and pattern scheme, specially crafted to help evoke a sense of calm. The spectrum of greens – including the key colorway ‘Green Spark’, inspired by the natural phenomena of bioluminescence – were carefully chosen for their soft, glowing shades, meanwhile prints adorning the fabric emulate recurring fractal shapes in nature.

The apparel collection is made from 100% recycled materials and comes in sizes XS-2XL for men and 2XS-2XL for women.

The collection will be worn by athletes including Caroline Wozniacki, Elina Svitolina, Xinyu Wang, Dana Mathewson, Jessica Pegula, Karolína Muchová, Maria Sakkari, Stefanos Tsitsipas, Felix Auger Aliassime, Jason Wu and Martin de la Puente.

INDA, the Association of the Nonwoven Fabrics Industry, announced that nominations are open for the 2024 World of Wipes Innovation Award^®. This Award recognizes a product or technology in the wipes sector that creatively uses nonwovens. The Award will be presented at the World of Wipes^® (WOW) International Conference, June 17-20 at the Hyatt Regency Minneapolis, Minneapolis, MN.

Nominations will be accepted online through Monday, April 15^th via www.inda.org/awards/wow-innovation-award.html. Nominees will be selected from a range of products and technologies that have been commercially available two years prior to WOW 2024. Products and technologies may include end product components, fabrication techniques, or end-products that use a nonwoven technology. Award categories include dry or wet wipes, institutional or industrial wipes, raw materials, and equipment. Three finalists will present their innovations to industry leaders attending WOW on Tuesday, June 18^th. The winner will be announced Thursday, June 20^th.

B&B Italia unveiled a special edition Camaleonda, the iconic sofa system by Mario Bellini, adorned in a brand-new fabric designed by Stella McCartney – platforming her S-Wave monogram. Marking the second chapter of the partnership between the British conscious luxury pioneer and the Italian design house, the collaboration was launched at Art Basel Miami Beach on 6th December 2023 as part of an installation at B&B Italia Design Studio’s grand opening. The Camaleonda is crafted from nearly entirely sustainable materials, materialising both brands’ nature-positive visions.

The partnership between B&B Italia and Stella McCartney was born of Stella’s long-time personal passion for Bellini’s works and started in 2022 with the Le Bambole armchair. It evolves now with the new version of Camaleonda, the sofa system originally designed in 1970, which made its comeback 50 years later in 2020 - speaking a contemporary language between structural solutions and sustainable choices.

The brand-new Stella McCartney X B&B Italia Camaleonda introduces the latest printed fabric “S-Wave”, which is the result of a next-generation sustainability innovation introduced by the design company’s R&D team. The S-Wave upholstery, available in two different colours, is based on OceanSafe naNea yarn, which is verified to be biodegradable, Cradle to Cradle Certified® Gold and does not contain harmful substances. The material does not shed persistent microplastics into the environment, however, performs like conventional materials.

ITMF (International Textile Manufacturer Federation) has published its International Textile Industry Statistics (ITIS) on productive capacity and raw materials consumption in the short-staple organized (spinning mill-) sector in virtually all textile-producing countries in the world.

The global number of installed short-staple spindles has grown from 225 million units in 2021 to 227 million units in 2022. The number of installed open-end rotors increased from 8.3 million in 2021 to 9.5 million in 2022. This constitutes the strongest growth ever recorded in this market with investment disproportionally targeting Asia. The number of installed air-jet spindles continued to increase in all regions in 2022.

The substitution between shuttle and shuttle-less looms continued in 2022. The number of installed shuttle-less looms increased from 1.72 million in 2021 to 1.85 in 2022 while installed shuttle looms reached 952 thousand. Total raw material consumption in the short-staple organized sector slightly decreased from 45,6 million tons in 2021 to 44,26 million tons in 2022. Consumption of raw cotton and synthetic short-staple fibers decreased by -2.5% and -0.7%, respectively. Consumption of cellulosic short-staple fibers increased by 2.5%.

A collaboration between Deakin University researchers and Australia’s largest commercial linen supplier Simba Global is tackling a critical global issue, the spread of harmful microplastics through our laundry.

Clothing and textiles are estimated to generate up to 35 per cent of the microplastics found in the world’s oceans, making them one of the biggest contributors. But there is still a lot to be learnt about the characteristics of these microplastics and exactly how and why they are generated.

Researchers at the ARC Research Hub for Future Fibres in Deakin’s Institute for Frontier Materials (IFM) have teamed up with Simba Global, a global textile manufacturing and supply company, to better understand the extent and type of microplastics shed when their products are laundered. Simba Global wants to lead the charge to reduce the environmental impact of textiles.

Lead scientist IFM Associate Professor Maryam Naebe said working with an industry partner on the scale of Simba Global meant the research could have a huge real-world impact.

Simba Global is the major linen supplier to Australia’s hospitals, hotels and mining camps, resulting in 950,000 tonnes of textile products – including bedsheets, bath towels, scrubs and much more – going through the commercial laundering process each year. It also supplies international markets in New Zealand, Singapore and the US.

“As part of our research, we will investigate potential solutions including the pre-treatment of textiles to reduce the shedding of microplastics, or even increasing the size of the plastics that break down so they can be better captured and removed by filtration during the laundering process,” Associate Professor Naebe said.

“Microplastics are now ubiquitous in the environment, they’re in the air we breathe, the food we eat and the earth we walk on. The magnitude of the problem is bigger than previously thought.

“Of serious concern is the mounting evidence that microplastics are having a negative impact on human and animal health. There are not just physical, but chemical and biological impacts.”

Associate Professor Naebe’s team have taken the first steps in the project, analysing wastewater samples from commercial laundries with high-powered electron microscopes in their Geelong laboratory, part of the largest fibres and textiles research facility in Australia.

The team recently presented a new scientific paper at the Association of Universities for Textiles (AUTEX) Conference 2023, which started the important process of formally categorising these types of microplastics, as well as developing standard terminology and testing methods.

“Because our understanding of microplastics is still in its infancy, we needed to start right at the beginning,” Associate Professor Naebe said.

“We need to have a standard definition of what is a microplastic. Up to this point that has been lacking, which makes it difficult to compare and incorporate other studies in this area.

“We are now developing a systematic method for sampling and identifying microplastics in laundry wastewater. It has been tricky to measure the different sizes, but this is important information to have. For example, there are studies that suggest some sizes of microplastics are causing more issues in certain animals.

“The next step will be establishing an essential method to prevent the release of microplastics from textile laundering. This may involve a coating on the surface of the textile or better ways to collect the waste during the washing process.”

Simba Global Executive Chair Hiten Somaia said the company had a strong focus on sustainability, driven by the business’ purpose statement.

“We are proud to partner with Deakin University in what is the first significant research into textile microplastic pollution in Australia. What we are most excited about is sharing the results of this research with all other textile markets in Australia – including clothing – and putting an end to microplastic pollution from textiles.”

ALLIED Feather + Down, global leaders in high performance, ethically sourced down, and MN Inter-Fashion, manufacturers of high performance luxury outerwear, announced that the ALLIED Feather + Down outerwear collection will be available to the European market.  

Originally released only in Japan, the exclusive collection will be available to select European boutique retailers for the fall 2024 season. Limited to a few hundred pieces, this line will showcase the breadth of ALLIED’s down offering, from their industry-leading ExpeDRY down insulation to their exceedingly high performance 1000 fill power down. It will also include MN Inter-Fashion’s experience delivering quality design and craftsmanship to some of the best known fashion houses in the world.

Designed, cut, and sewn by MN Inter-Fashion in Japan using materials from ALLIED and Pertex, the jackets shall represent a collision between cutting edge fashion aesthetics and materials normally reserved for highly technical outerwear. The result is a unique garment with a sophisticated urban look blended with performance that rivals the most technical outdoor apparel available. 

The kick-off meeting for the "Trends and Design Factors for Hydrogen Pressure Vessels" project, recently held at AZL Aachen GmbH, was a successful event, bringing together more than 37 experts in the field of composite technologies. This event laid a solid foundation for the Joint Partner Project, which currently comprises a consortium of 20 renowned companies from across the composite pressure vessel value chain: Ascend Performance Materials, C evotec GmbH, Chongqing Polycomp International Corp. (CPIC), Conbility GmbH, Elkamet Kunststofftechnik GmbH, F.A. Kümpers GmbH & Co. KG, f loteks plastik sanayi ticaret a.s., Formosa Plastics Corporation, Heraeus Noblelight GmbH, Huntsman Advanced Materials, Kaneka Belgium NV, Laserline GmbH, Mitsui Chemicals Europe GmbH, Plastik Omnium, Rassini Europe GmbH, Robert Bosch GmbH, Swancor Holding Co. Ltd. Ltd., TECNALIA, Toyota Motor Europe NV/SA, Tünkers do Brasil Ltda.

The project follows AZL´s well proven approach of a Joint Partner Project, aiming to provide technology and market insights as well as benchmarking of different material and production setups in combination with connecting experts along the value chain.

The kick-off meeting not only served as a platform to foster new contacts and get informed about the expertise and interests of the consortium members in the field of hydrogen pressure vessels, but also laid the groundwork for steering the focus of the upc oming project's ambitious phases. As a basis for the interactive discussion session, AZL outlined the background, motivation and detailed work plan. The central issues of the dialogue were the primary objectives, the most pressing challenges, the contribut ion to competitiveness, and
the priorities that would best meet the expectations of the project partners.

Discussions covered regulatory issues, the evolving value chain and the supply and properties of key materials such as carbon and glass fibres and resins. The consortium defined investigations into different manufacturing technologies, assessing their matu rity and potential benefits. Design layouts, including liners, boss designs and winding patterns, were thoroughly considered, taking into account their implications for mobile and stationary storage. The group is also interested in cost effective testing m ethods and certification processes, as well as the prospects for recycling into continuous fibres and the use of sustainable materials. Insight was requested into future demand for hydrogen tanks, OEM needs and strategies, and technological developments to produce more economical tanks.

The meeting highlighted the importance of CAE designs for fibre patterns, software suitability and the application dependent use of thermoset and thermoplastic designs.

The first report meeting will also set the stage of the next project phase, which will be the creation of reference designs by AZL's engineering team. These designs will cover a range of pressure vessel configurations using a variety of materials and production concepts. The aim is to develop models that not only re flect current technological capabilities, but also provide deep insight into the cost analysis of different production technologies, their CO₂ footprint, recycling aspects and scalability.

AZL's project remains open to additional participants. Companies interested in joining this initiative are invited to contact Philipp Fröhlig.

Toray Industries, Inc. announced the successful development of recycled carbon fiber (rCF) derived from the production process of the Boeing 787 components using Toray’s advanced carbon fiber, TORAYCA™. The rCF, which is based on pyrolysis recycling process, has been integrated into the Lenovo ThinkPad X1 Carbon Gen 12 as reinforcement filler for thermoplastic pellets. Toray and Lenovo will continue to collaborate to expand the usage of rCF in other Lenovo products.

Toray rCF is the outcome of Boeing and Lenovo’s shared commitment to minimize their environmental impact. Boeing’s objective is to reduce solid waste going to landfill and produce recyclable materials, while Lenovo has been exploring materials to reduce the carbon footprint of their products. Toray rCF connects these visions by repurposing Toray’s high-performance carbon fiber from the Boeing aircraft production process into Lenovo’s ultra-light laptop PC.

TORAYCA™ is an established aerospace material known for its high strength, stiffness, and lightweighting properties. These qualities have led to its adoption in other applications such as electrical and electronic equipment housings, sports equipment, and other industrial applications.

A key advantage of carbon fiber is the ability to retain its primary mechanical properties even after the recycling process. Toray is actively advancing recycling technologies and establishing a strategic business model for rCF. Given that the carbon footprint of rCF is lower than that of virgin carbon fiber, Toray is proactively recommending the adoption of rCF to reduce the environmental impact of customers’ products. This commitment aligns with Toray’s dedication to fostering a circular economy, thereby reducing landfill waste.