From the Sector

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. 

Archroma will introduce its new Super Systems+ concept and highlight product innovations at Techtextil 2024, being held in Frankfurt, Germany from April 23 to 26.

A highlight of Archroma’s participation in Techtextil, Super Systems+ are powerful end-to-end systems that combine fiber-specific processing solutions and intelligent effects. The Super Systems+ suite encompasses wet processing solutions that deliver measurable environmental impact from sizing to finishing; durable colors and functional effects that add value and longevity to the end product; and cleaner chemistries that eliminate harmful or regulated substances.

For textile partners to the automotive industry, Archroma is introducing DOROSPERS® KHF, a new range of high-lightfast disperse dyes that provide optimum build up on polyester microfiber, including artificial suede for car interiors.

For nonwoven applications in fields such as healthcare, hygiene and filtration, Archroma recommends APPRETAN® FFX6750, a new addition to its range of high-performance zero-formaldehyde acrylic copolymers, and APPRETAN® FFX1540.

APPRETAN® FFX1540 is a new APEO free and formaldehyde free self-crosslinking polymer, medium soft with very low tackiness, and strongly hydrophobic, developed for the chemical bonding of nonwovens and for the coating of technical textiles, where low water absorption and high-water tightness are required, combined with high durability in severe environment.

For workwear and uniforms that protect people under adverse conditions, Archroma solutions include HELIZARIN® ULTRA-FAST, for printing with pigment dispersions and metallic pigments, and the new ALBAFIX® ECO Plus wet fastness improver. Archroma’s PFC-free PHOBOTEX® R-ACE durable water repellent delivers excellent water repellence while preserving fabric quality and ensuring sustainability. Archroma has also expanded the revolutionary AVITERA® SE GENERATION NEXT range of resource-saving dyes with new colors.

Further solutions for active wear and workwear include the newly launched bio-based PHOBOTEX® NTR-50 durable water repellent product, which is PFAS free, formaldehyde free and crosslinker free, as well NYLOFIXAN® HFS, a new fixing agent for polyamide and blends that is fully compliant with the latest restrictions on bisphenol compounds.

Archroma is also launching ARKOPHOB® NTR-40 at Techtextil 2024. The company’s first crosslinker with an improved sustainability profile, its monomers are partially derived from renewably sourced, plant-based raw materials. Another new innovation is biocide-free OX20, an odor-neutralizing technology launched by Archroma in partnership with SANITIZED AG.

For home textiles, mills and brands can select ARKOFIX® NZW formaldehyde-free* resin for high whiteness and extraordinary product stability, with no yellowing during storage at elevated temperatures, even over a prolonged period of time. For a super-soft handle, the SILIGEN® EH1 is a vegan silicone macro-emulsion softener with 35% plant-based active content.

RadiciGroup announced the appointment of Stefano Pigozzi to the Board of Directors of Radici Partecipazioni SpA, the parent company overseeing all the Group's business activities in the chemicals, engineering polymers and advanced textile solutions sectors.
 
A professional with proven experience in the chemical industry, Mr. Pigozzi will complement the Board with his strategic vision acquired in international organizations.
 
Stefano Pigozzi graduated from the University of St. Gallen in Switzerland with a degree in Business Administration and started his work experience in the finance division of BASF in the late 1980s. Since then, chemistry has remained at the centre of his career: over the years, he has held marketing and sales positions of increasing responsibility in various business sectors (plastics and inorganics), moving up to more strategic and managerial roles within BASF, including president of the Monomers Division and, most recently, head of the Group Global Purchasing Division at the Ludwigshafen headquarters.
 
During his more than 30-year career at BASF, Mr. Pigozzi has consistently demonstrated his leadership capability, his financial analysis skills and his dedication to corporate business success. He has also contributed significantly to the positioning of BASF as a global leader in the chemical industry.
 
Mr. Pigozzi’s appointment to the Board of Directors of Radici Partecipazioni is aimed at strengthening RadiciGroup's presence in the market and helping to guide the company towards new goals.

Fibre Extrusion Technology Ltd (FET) of Leeds, UK is celebrating a year of achievements since its new Fibre Development Centre was first opened. This period has shown a marked acceleration in the number of client technical trials conducted, involving the ever-increasing development of new polymers.

FET designs, develops and manufactures extrusion equipment for a range of high value textile material applications worldwide, offering melt spinning, wet spinning and spunbond/meltblown options. Since its inception in 1997, a major part of FET’s service portfolio has always been to collaborate with industrial and research establishments in testing, evaluating and developing high value materials with diverse, functional properties. FET’s previous Process Development Laboratory presided over the development of about 60 new polymer types in multifilament, monofilament and nonwoven formats.

Since the new Fibre Development Centre came on stream, this process has accelerated and the number of new polymers has now increased to over 70, with considerably enhanced facilities more than doubling capacity and increasing efficiency. Clients frequently spend several days on site participating in development trials and technical sales meetings, so the new Centre is designed to make their stay even more efficient and comfortable.

With more new trials booked for the rest of the year and well into 2024, it is expected that many more new polymers will be developed, with sustainable fibres leading the way.

To reach its goal of being the world’s leading supplier of enhanced recycled polyethylene terephthalate (PET), gr3n is signing a binding Memorandum of Understanding (MOU) with its shareholder Intecsa Industrial to set up a Joint Venture.

gr3n together with Intecsa Industrial will join forces and build a “First-of-a-Kind” manufacturing facility able to produce 40.000 tons of virgin-like PET, commencing EPC phase in Q4-2024 and aiming to be operational in 2027. gr3n’s chemical recycling technology is capable of processing PET from various industries including textile waste, closing the loop for hard-to-recycle PET applications.

The world’s first industrial-scale MADE PET recycling plant will have the capability to process post-industrial and post-consumer PET waste including hard-to-recycle waste, to produce approximately 40.000 tons of virgin PET chips from the recycled monomers saving nearly 2 million tons of CO2 during its operating life. The post-consumer and/or post-industrial polyesters will be both from bottles (colored, colorless, transparent, opaque) and textiles (100% polyester but also mixtures of other materials like PU, cotton, polyether, polyurea, etc. with up to 30% of presence in the raw textile).

The technical concept of the MADE plant is to break down PET into its main components (monomers) so they can potentially be re-polymerized endlessly to provide brand new virgin PET or any other polymer using one of the monomers. Polymers obtained can be used to produce new bottles/trays and/or new garments, essentially completely displacing feedstock material from fossil fuels, as the recycled product has the same functionality as that derived traditionally. This means that gr3n can potentially achieve bottle-to-textile, textile-to-textile, or even textile-to-bottle recycling, moving from a linear to a circular system.

gr3n’s process has the potential to change the way PET is recycled worldwide, enabling huge benefits for both the recycling industry and the entire polyester value chain. Many efforts have been made in the past to transfer enhanced recycling from research laboratories to the manufacturing industry, but the economics and skepticism of the first adopters have constantly blocked the progress of the proposed solutions. Thanks to the MADE technology developed by gr3n, this approach is now feasible and makes gr3n one of the few companies with the potential to provide a reliable enhanced recycling solution that closes the life cycle of PET, and also offers food grade polymer material, processes a large variety of waste and reduces the carbon footprint of these materials usually destined for incineration or landfill.

With total sales of EUR 1,543 million, generated by over 30 production and sales units in Europe, Asia, and America, Radici Group closed its 2022 financial year with slight growth over 2021. EBITDA reached EUR 157 million in 2022, and net income for the year was EUR 80 million.

“We are moderately pleased with the 2022 figures,” Angelo Radici, president of RadiciGroup, commented. “Despite an unpredictable and challenging year, we were able to achieve positive results. Although the rise in energy costs began to be felt in January, we managed to maintain our position in the first three months of the year due to a significant increase in demand. From the second quarter onwards, the European market experienced a significant slowdown due to the outbreak of war in Ukraine, which exacerbated the already soaring costs of energy and raw materials. The situation was completely out of hand and made worse by the fact that some raw materials were not available. This created significant challenges for us, especially in the chemical sector. We even had to stop operations at our Novara plant in the latter part of the year. Products similar to ours in the nylon supply chain from China and the US were being sold at a price lower than our variable cost.”

The president continues: “At Group level, our internationalisation strategy helped us mitigate geopolitical risks in various countries. As a result, we were able to offset the challenges in the European chemicals and textile markets by leveraging our global presence in High Performance Polymers, where our numbers have held strong. As we began 2023, we regained our footing. However, the global economic and industrial scenario for the rest of the year remains highly uncertain, and forecasts are notably cautious.”

Even in these difficult times, the Group has continued to invest. In 2022, the High Performance Polymers Business Area completed the acquisition in India of the engineering plastics branch of Ester Industries Ltd, a listed company. Additionally, it began installing two new production lines in Mexico and Brazil, and confirmed plans to install a new extrusion line at the Villa d’Ogna production site in the province of Bergamo. These choices align with the Group’s goal of enhancing its worldwide presence and boosting competitiveness in high-potential growth markets. In a year where energy and raw material costs were certainly problematic, operating in geographically diverse markets and with varied applications proved to be an important tool in addressing the challenges. In this vein, a new production site spanning over 36,000 square metres has recently been inaugurated in China. The move is aimed at doubling the production capacity in line with the market’s growth expectations.

Extending the time horizon to 2018-2022, the Group has invested over EUR 277 million to enhance the competitiveness of its companies, implement Best Available Techniques, improve energy efficiency, reduce emissions, and conduct research and development activities aimed at introducing sustainable processes and solutions. These efforts include the research and development activities of Radici InNova, which are heavily focused on the circular economy.

DyStar, a specialty chemical company with a heritage of more than a century in product development and innovation, is announcing the sale of its auxiliary manufacturing site located at Pietermaritzburg, South Africa.

Oakland Polymers Pty Ltd, a local manufacturer, has acquired DyStar’s manufacturing facility and will take over the site to expand their polymer business. Under the sale and purchase agreement, DyStar divested the entire facility, which is approximately 12,000 sqm, to Oakland Polymers and Oakland Properties. DyStar Africa’s operations will continue to lease part of the premises from Oakland for office and warehousing use.

Mr. Xu Yalin, Managing Director, and President of DyStar Group said, “The sale of the manufacturing site at DyStar Africa is part of our ongoing efforts to reconsolidate our business resources in Turkey, Africa & Middle East (TAME) region, with a focus on improving productivity and utilization rates.”

As a result of the acquisition, all employees at the manufacturing site have already been informed. Compensation packages are offered to affected colleagues as well.

Customers have also been informed of undisrupted supply to their orders during the transition period and are further assured of a seamless customer journey going forward when the acquisition is completed.