From the Sector

• Organic cotton project with thriving prospects

Dibella is participating in a joint project to promote organic cotton cultivation in India. The project aims to protect organic cultivation through targeted training measures and by paying premiums to small farmers, to support the conversion from conventional to organic cotton, to increase crop yields and at the same time to achieve better fibre quality.

The demand for organically grown organic cotton is growing rapidly, but crop yields are lagging well behind global demand. The Alliance for Sustainable Textiles (Berlin), initiated by Development Minister Dr. Gerd Müller, therefore wants to increase organic cotton volumes for its member companies with practical solutions. In cooperation with the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ), it is now promoting a forward-looking project for which Dibella provided the impetus.

"In India, it is mainly micro-farms and village cooperatives that are active in organic cotton cultivation. Conversion of additional land and sustainable management could increase yields and fibre quality of organic cotton. The Chetna Organic initiative, with which we have been working successfully for many years, advises the farmers in these processes. It supports the farmers and village communities with targeted education, training and practical assistance in organic farming, thus preparing the ground for better income and living conditions for the families," says Ralf Hellmann, Managing Director of Dibella.

Several alliance partners - Dibella, Fairtrade Germany, GIZ, Organic Cotton Accelerator (OCA) and Tchibo - have taken the exemplary initiative as an opportunity to promote the cultivation and expansion of organic cotton in India. In cooperation with Chetna Organic, they focus on supporting Indian women's cooperatives, women farmers and families in the production of organic cotton as part of the "Organic Cotton Pilot Project". Tchibo and Fairtrade subsidise micro-farms during the conversion phase of the fields (the fibres are only recognised as organic cotton four years after conversion) and contribute to the provision of GMO-free seeds, which have become a scarce commodity in India. Together with Dibella, they finance training courses that teach the optimal use of natural rainfall as well as efficient, ecological cultivation methods, which subsequently lead to improved fibre quality. In addition, they commit to purchasing Fairtrade organic cotton for many years.

Ralf Hellmann: "The pilot project enables us to expand our Dibella Good Textiles collection because it guarantees us long-term access to fair-trade organic cotton. At the same time, it improves the living conditions of the small-scale farmers and their families. We therefore hope that "Organic Cotton" will also set a precedent in other cotton growing regions and bring organic farming forward in India."

There are good reasons why narrow textiles are used so frequently in the fitness and rehabilitation sector: they are flexible, safe, light, durable, skin-friendly and have a low injury potential. Essential components are JUMBO textiles: Elastics can be used to convert kinetic energy into potential energy. This is why elastic cords and cables are some of the essential components of almost all fitness equipment and tools. After all, it is the elasticity of the trampoline cords that gives the jumping-sheet its necessary force. Only elasticated expander cords create the desired resistance of the classic strength training equipment.

The force-elongation ratio of elastic cords and cables – like all other properties – is specified individually and optimally for the respective application. Depending on the specific requirements of the narrow textiles in the respective product, expert teams develop cords and cables made of high-tech fibres and on high-tech equipment: technical textiles that are a perfect fit for the equipment and its functions.

Furthermore, non-elastic cords – depending on type and design – are essential as tension and connection elements for the functionality of fitness equipment. Textile components are often also an integral part of the equipment technology as fastening or fixing systems.

Wie zentral die Themen Digitalisierung und Datenarbeit inzwischen für fast alle mittelständischen und großen Unternehmen in Deutschland geworden sind, zeigt die branchenübergreifende, groß angelegte Studie „the factlights 2020“, deren Ergebnisse das Datenanalyse-Unternehmen QUNIS mit Unterstützung von Optimal Systems jetzt vorgelegt hat. Rund 1000 Führungs- und Fachkräfte aus rund 700 Unternehmen hatten im Rahmen einer Online-Befragung den Input dazu geliefert. Die Auswertung zeigt, dass große Unterschiede schon in der Haltung zum Fortschritt bestehen: Unternehmen mit geringem Digitalisierungsgrad haben ganz andere Erwartungen an die Digitalisierung als jene, die in Bezug auf neue Technologien bereits zu den Vorreitern gehören.

Zur Auswertung wurde das Unternehmen jedes Befragten nach seinem digitalen Reifegrad bewertet und einer von drei Gruppen (Adopter, Discoverer, Frontrunner) zugeordnet. Die meisten Umfrageteilnehmer (51 Prozent) arbeiten in Unternehmen mit durchschnittlichem Reifegrad, während je ein Viertel in einem wenig oder einem besonders weit digitalisierten Betrieb arbeitet. Aber auch dort sind die neuen Anforderungen längst angekommen: Knapp zwei Drittel (64 Prozent) der Befragten gaben an, ihr Arbeitsalltag würde von Digitalisierung, Datenarbeit und Analytics mindestens zu 50 Prozent beeinflusst. Knapp ein Drittel der Umfrageteilnehmer erkennen den Einfluss der Digitalisierung sogar an vier von fünf Tagen ihrer Arbeitswoche.
 
Digitalisieren, um zu sparen?
Interessant ist die Einschätzung der Befragten zu Nutzen und Potenzial digitaler Technologien: Diese unterscheiden sich je nach digitalem Reifegrad ihres Unternehmens deutlich. So erhoffen sich Unternehmen, die in Sachen Digitalisierung noch am Anfang stehen, vor allem Einsparungen durch technologischen Fortschritt, während Frontrunner scheinbar erkannt haben, dass hier nicht das größte Potenzial schlummert (drei Prozent).
 
Deutlich zeigt sich mit zunehmendem Reifegrad auch eine Abnahme der Erwartungen an eine verbesserte Unternehmenssteuerung: 21 Prozent der Adopter versprechen sich von der Digitalisierung entsprechende Vorteile, während die digitalen Vorreiter ihre Erwartungen auf nur noch fünf Prozent heruntergeschraubt haben. Sie dagegen sehen die wahrhaft lohnenden Möglichkeiten der Digitalisierung überwiegend in der Realisierung digitaler Geschäftsmodelle, der Produktindividualisierung und der Steigerung des Umsatzes. Dafür sind sie auch eher bereit, ihre Produkte und Dienstleistungen entsprechend der technologischen Möglichkeiten zu verändern (99 Prozent gegenüber nur 40 Prozent Bereitschaft unter Adoptern) und beispielsweise smarte Zusatzservices zu bieten (87 gegenüber 51 Prozent bei den Adoptern).
 
Mehr analysieren, besser umsetzen
Ein genereller Befund der Studie: Unternehmen erkennen den Wert qualitativer Daten, nutzen ihn jedoch zu wenig. So schöpfen Handel, ITK und Banken dieses Kapital am ehesten aus und betrachten es als wertvolles Wirtschaftsgut (voll oder teilweise: Informations- und Telekommunikationsbranche: 94 Prozent, Handel 95 Prozent, Banken 94 Prozent), während die Automobilbranche (87 Prozent), die Verwaltung (75 Prozent) und das Baugewerbe (80 Prozent) die Schlusslichter der Skala darstellen, wenn auch noch auf relativ hohem Niveau.
 
Kritisch für das Gelingen des Wandels ist eine entsprechende Strategie im Unternehmen: Digitalisierung ist nicht mit dem Einkauf von ein paar Software-Programmen erledigt – sie bedeutet einen regelrechten Transformationsprozess, der auch ein entsprechendes Mindset bei den Beteiligten braucht sowie planvoll und strategisch umgesetzt werden sollte. Allerdings gibt immerhin fast ein Viertel (23 Prozent) der Befragten an, die entsprechende Roadmap werde in ihrem Unternehmen nicht eingehalten.
 
„Die Umfrage macht deutlich, dass es in Sachen Digitalisierung noch viel zu tun gibt“, kommentiert Sven Kaiser, Director Marketing & Brand Strategy beim Studien-Sponsor Optimal Systems die Ergebnisse. „Aber die Ergebnisse zeigen auch: Wer eine Strategie verfolgt, die auf einer klaren, realistischen Zielsetzung aufbaut, und diese konsequent umsetzt, vermeidet nicht nur mittelfristig den Anschluss zu verlieren. Er generiert auch nachhaltige Vorteile: Nicht umsonst zeigen gerade die bereits weit entwickelten Frontrunner eine fast viermal so hohe Bereitschaft, in Datenmanagement und Analyse zu investieren, als Unternehmen mit geringem Reifegrad.“

Since the outbreak of the coronavirus pandemic, the worldwide demand for protective masks and apparel has resulted in a record number of new orders in the high double-digit millions of euros at Oerlikon Nonwoven. The meltblown technology from Neumünster is recognized by the market as being one of the technically most efficient methods for producing highly-separating filter media made from plastic fibers.

Protective equipment demands high-end nonwoven products
The rising demand for protective masks and other medical protective equipment since the start of the coronavirus pandemic and the associated global ramping up of production capacities has also resulted in an increase in the demand for nonwovens for the production thereof. Initially, this resulted in bottlenecks in the provision of meltblown filter nonwovens. To this end, there had until this point be very few producers of medical filter nonwovens outside China. Meanwhile, the demand for spunbond systems is also rising. “Due to the structure of our group, we are in the fortunate position to swiftly reallocate and free up our production capacities. This means that we are able to relatively quickly deliver not only meltblown systems, but also spunbond equipment”, explains Dr. Ingo Mählmann, Head of Sales & Marketing at Oerlikon Nonwoven, talking about the positive situation at the company.

The capacities for respiratory masks available in Europe to date are predominantly manufactured on Oerlikon Nonwoven systems. “Our machines and systems for manufacturing manmade fiber and nonwovens solutions enjoy an outstanding reputation throughout the world. Ever more manufacturers in the most diverse countries are hoping to become independent of imports”, comments Dr. Mählmann. The Oerlikon Nonwoven meltblown systems are being delivered to Germany, China, Turkey, United Kingdom, South Korea, Italy, France, North America and – for the very first time – to Australia until well into 2021.

Quality and efficiency in demand
Depending on the purpose of the application, medical PPE (personal protection equipment) should be breathable and comfortable to wear, protect medical staff against viruses, bacteria and other harmful substances and form a barrier against liquids. For these reasons, they are often made of either pure spunbond or of spunbond-meltblown combinations. Here, the meltblown nonwoven core assumes the barrier or filter task, while the spunbond has to retain its shape, while being tear-resistant, abrasion-proof, absorbent, particularly flame-resistant and nevertheless extremely soft on the skin.

All masks are not created equal – thanks to the ecuTEC+
Protection against infections such as coronavirus can only be guaranteed with the right quality.

The nonwovens can be electrostatically-charged in order to further improve the filter performance without additionally increasing breathing resistance. Here, Oerlikon Nonwovenʼs patented ecuTEC+ electro-charging unit excels in terms of its extreme flexibility. Nonwovens manufacturers can freely choose between numerous variation options and set the optimal charging method and intensity for their specific applications. In this way, even the smallest particles are still attracted and reliable separated by a relatively open-pored nonwoven. Nevertheless, mask wearers are still able to easily breathe in and out due to the comparatively loose formation of the fibers. To this end, it comes as no surprise that all meltblown systems currently destined for the production of mask nonwovens are equipped with the ecuTEC+ unit.

Belgian textile innovator Devan Chemicals was lauded by Frost & Sullivan for its antimicrobial technology with proven quaternized silane chemistry, known under its trade name as BI-OME®.

RONSE, BELGIUM – The non-leaching attributes of the technology coupled with its ability to reduce microbial mutation make it a potential candidate for textiles where durability and safe human contact are highly valued.

Based on its recent analysis of the European antimicrobial technology for the textile market, Frost & Sullivan recognizes the Belgium-headquartered Devan Chemicals NV (Devan) with the 2020 European Technology Innovation Leadership Award. Devan’s highly relevant antimicrobial technology addresses issues concerning the contamination of PPE and textiles, including the spread of drug-resistant bacteria, viral transmissions, and hospital-acquired infections (HAIs). Its quat-silane technology, due to its non-migrating behaviour, physically punctures the microorganism cell to destroy it without interfering with cell DNA. Notably, it eliminates the adverse effects of leaching antimicrobials while providing high efficiency in the range of 99.9 percent to 99.99 percent, even after multiple washes.

"By providing non-migrating antimicrobial technology for the textile industry, Devan plugs the safety and performance gaps inherent in current inorganic and organic antimicrobial agents. Its antimicrobial technology, unlike silver- or triclosan-based technology, comprises non-migrating monomers and prepolymers such as organo-functional silane," said Monami Dey, Industry Manager, Frost & Sullivan. "The organo-silane polymers are covalently bonded and polymerized to the textile surface as a coating via padding, exhaust, and spraying techniques. The coating forms a non-leaching reactive surface and destroys the microbes on contact, without releasing harmful components into the environment."

Devan CEO Sven Ghyselinck is very happy with the award: “The best practice award is a nice recognition of the hard work we did in the last 6 months to evaluate the performance against viral activity. It’s great to see our efforts didn’t go unnoticed.”

Earlier this month Devan published new test results confirming the high performance virus-reducing capabilities of its BI-OME fabric coating technology on both unwashed and intensely washed fabrics. The Belgian company has worked closely with a series of international third party laboratories to test different fabric substrates against a wide range of enveloped viruses. Before washing, samples treated with Devan BI-OME score very good to excellent (99% and higher according to ISO 18184) results on virus reduction. Different substrates, like polyester, cotton and polycottons, were exposed to enveloped viruses like SARS-COV-2 (known to cause COVID-19), Feline Corona, Vaccinia (the EU standard for enveloped viruses) and Porcine Respiratory viruses. After 30minutes, BI-OME already reduced 99.96% of the activity of SARS-COV-2.

After washing, a decrease in virus reduction performance of coating technologies is normal and expected. However, BI-OME is confirmed to deliver only a minimal reduction, retaining up to 98.5% virus reduction even when the fabric is washed 25 times.

"Devan is working towards sustainability and green chemistry. For instance, its technology does not contain any harmful solvents such as formaldehyde or polychlorinated phenols and fulfills the regulatory obligations of the EU BPR," noted Dey. "Its commitment to promoting sustainability in textile finishes with a strong focus on GMO-free, kosher, as well as halal certifications, and recyclability has given the company an edge in launching new products at an accelerated pace to match customers’ most pressing concerns and demands."

One of those innovations is BI-OME NTL (natural), a natural, bio-based antimicrobial solution that guarantees an optimal freshness and hygiene for textiles. The active ingredient is the well-known Linseed oil, obtained from the dried, ripened seeds of the flax plant. The active ingredients in BI-OME NTL are GMO free, Halal, Kosher and recyclable.

The RX circular loom series is produced at the Starlinger plant in Taicang/China specifically for the Southeast Asian market. This series is now extended with the RX 8.1, a circular loom that is particularly suited to the production of lightweight fabrics for 1-loop FIBCs, tarpaulins as well as geo- and agrotextiles made of PP, HDPE, and PET. In combination with the RX 6.0, RX 6.1, and RX 8.2, Starlinger Taicang now offers the ideal circular loom for every fabric width.
The new Starlinger circular loom RX 8.1 produces fabric with a width of 1,200 – 1,700 mm, which is an ideal match for 1-loop FIBCs, tarpaulin fabrics as well as geo- and agrotextiles. The model completes the RX series, which now covers every working width between 300 and 2,250 mm.

Like all models of the RX series, the RX 8.1 is equipped with numerous technological advantages. Due to its special reed and shuttle design, the machine does not have any sliding parts that would require lubrication, and thus leaves no traces of oil on the fabric. This property allows for the optimal adherence of the coating to the fabric and eliminates concerns regarding the use of the fabric in food applications. Moreover, the RX 8.1 produces fabric of highest quality at lowest production cost per square meter, as the production speed of 800 picks/minute is high while the number of warp breaks is low.
Other advantages are the machine’s user-friendliness, the energy-saving motors as well as a low noise level.

The machine will give its official debut at the plastics exhibition Chinaplas in 2021, as this year’s event has been cancelled due to COVID-19. In the meantime, the RX. 8.1, can bes visited in the Starlinger factory in Taicang. The standard execution of the machine with single inlet will show the production of tarpaulin fabric with a double flat width of 1,500 mm and a weight of 70 g/m².
A second machine will be equipped with double inlet and a gusseting device, which are available as options, and will produce fabric for 1-loop FIBCs with the same width, but twice the fabric weight (140 g). Another machine in Taicang, which can be visited is the RX 6.0 L: On this 6-shuttle circular loom, a PE liner is inserted into the woven fabric tube and attached to the plastic fabric. This process is performed fully automatically in the production process and allows the use of the fabric in sensitive applications such as food packaging.

For the sixth time now, Oerlikon Nonwoven will be showcasing market- and customer-oriented solutions for hygiene, medical, filtration and other technical applications at the globally-leading nonwovens trade fair INDEX in Geneva, Switzerland. Between March 31 and April 3, 2020, visitors to the trade fair can convince themselves of the Neumünsterbased systems constructor’s extensive product and process know-how.

Comprehensive spunbond portfolio – always the right solution
Oerlikon Nonwoven meanwhile has a very broad range of spunbond technology products and services. The process for manufacturing geotextiles from polyester or polypropylene has been optimized; it is characterized by high production capacities and yields, with simultaneously low energy consumption for producing benchmark nonwoven products.

For the manufacture of hygiene nonwovens, Oerlikon Nonwoven offers its new QSR (Quality Sized Right) systems. Here, the benefits of the Chinese machine construction partner’s nonwoven formation are integrated into the complete solution. The advantage for nonwovens producers: highly competitive solutions at attractive prices with comparably low investment.

Cost-efficiently manufacturing meltblown nonwovens
New, unique and highly sophisticated filter media can be easily and efficiently manufactured thanks to Oerlikon Nonwoven’s optimized meltblown technology. Whether as a stand-alone system with one or several positions, as ‘plug & produce’ installations for already existing systems or in conjunction with other technologies: the Oerlikon Nonwoven meltblown process already enables the cost-efficient manufacture of meltblown nonwovens with the quality requirements of tomorrow. Ever more producers are choosing the meanwhile extensively tried-and-tested and consistently further-developed Oerlikon Nonwoven meltblown solutions.

Airlaid technology for the nonwovens of tomorrow
Pulp or cellulose fibers as raw material for manufacturing nonwovens are currently virtually unrivaled with regards to sustainability and environmental compatibility. The Oerlikon Nonwoven airlaid process is the ideal solution for processing this raw material into high-end products for a wide range of applications. Today, there is huge demand for manufacturing solutions for high-quality, lightweight airlaid nonwovens with economically attractive production speeds and system throughputs. In this area, the patented Oerlikon Nonwoven formation process – which also permits the homogeneous mixing of the most diverse raw materials, while simultaneously guaranteeing superb evenness and homogeneous fiber laying – is setting standards even for nonwovens with low running meter weights. And the benefits of this technology are also increasingly gaining significance in sustainable recycling applications.

P&G patented PHANTOM technology from Teknoweb Materials
Also being showcased at the trade fair stand is the P&G patented PHANTOM technology from Teknoweb Materials, Oerlikon Nonwoven’s strategic partner for hygiene products and wipes. The PHANTOM technology is released to Teknoweb Materials by P&G in worldwide exclusive license. The PHANTOM technology is the superior dry laid alternative technology for manufacturing wet wipes from pulp and polymer fibers, for example. Compared to conventional, known processes, this technology offers superior performances with cost advantage in much more eco-friendly products. Dispensing with hydroentanglement renders subsequent drying of the material redundant. Targeted process management allows the optimal setting of the relevant product parameters such as softness, tenacity, dirt absorption and liquid absorption.

In diesem Sommer werden sich zum ersten Mal die besten Sportkletterer_innen im Rahmen der Olympischen Spiele in Tokyo messen. prAna hat für diesen besonderen Anlass zwei neue Kletterhosen entworfen: Wakeen Pant für Frauen und Kragg Pant für Herren. Beide Hosen punkten mit ausgeklügelten Details sowie mit dem weichen, robusten und nachhaltigen RipStop-Material aus Biobaumwolle.

Die Wakeen Pant ist für kletterbegeisterte Frauen designt. Die Kniepartie ist vorgeformt und aus verstärktem Material – so ist sie nicht nur extra robust, sondern liefert auch optimale Bewegungsfreiheit. Mit Freiheit und Tragekomfort überzeugt auch der flach anliegende Stretch-Bund, der mit einem versteckten Kordelzug ausgestattet ist. Zwei große, umlaufende Vordertaschen mit seitlichem Reißverschluss und eine elastische Schlaufe eignen sich prima, um Bürste etc. unterzubringen.

Die Kragg Pant für Männer aus Biobaumwoll-Canvas kommt mit viel Stretch. Der Hosenbund lässt sich dank Kordelsystem individuell anpassen – sorgenfreier Sitz garantiert. Der verstärkte Zwickel hält auch großer Belastung stand. Die abgeschrägte Gesäßtasche sowie die hintere Sicherheitstasche mit Reißverschluss verschaffen Stauraum. Abnäher an den Kniepartien sorgen für bessere Bewegungsfreiheit und durch Kordelzüge lässt sich die Hose immer auf die gewünschte Beinlänge bringen.

• Glass fiber textiles for helicopter type H145
• First ever material supply for primary structural components in the aerospace segment

Since August of this year, SGL Carbon delivers two special glass fiber textiles, so-called non-crimped fabrics, for the new version of helicopter model H145 from Airbus Helicopters. These materials are used in the new, especially efficient five-blade rotor. Developed in close collaboration with Airbus Helicopters, the material has been qualified for the application for the next years to come.  

Thanks to their unidirectional fiber orientation, the fabrics are extremely resistant, providing optimal support for the new geometry of the especially long H145 rotor blades. The fabrics are manufactured at the SGL Carbon site in Willich near Düsseldorf in a multi-stage process and delivered to Airbus Helicopters in Paris.  

“The order emphasizes our growing presence in the aerospace business. With the fabrics for Airbus Helicopters, we have realized, qualified, and started serial production for a material concept for primary structural components for the first time,” underscores Dr. Andreas Erber, Head of the Aerospace segment in the business unit Composites – Fibers & Materials at SGL Carbon.

The current deliveries are part of a framework contract with Airbus Helicopters, intended to gradually intensify collaboration. Besides the current development of materials for helicopter components, Airbus Helicopters and SGL Carbon have worked together in the area of component material processing for Airbus group aircraft doors for years. In addition, Airbus and SGL Carbon are jointly involved in various associations and research projects in the area of components, such as Carbon Composites e.V.

Chomarat Group, expert in composite reinforcements for the marine market developed a high performing C-PLYTM reinforcement for the hull and deck of Arcona 435 and 465. Both cruiser-racer are a unique combination of comfort onboard and performances, for fast family cruising and high-level races thanks to their specific design, and the use of C-PLY™. The carbon NCF reinforcement allows structural design benefits, premium surface quality and overall parts cost saving.

“With 45 years of expertise, Chomarat is a pioneer in developing solutions to achieve weight reduction, improved surface appearance and stronger structure.

C-PLY™ makes it possible to meet these specifications, while ensuring stable quality and cost-effectiveness” explains Vincent Cholvy, Marine market Manager at Chomarat.

THE CUTTING-EDGE TECHNOLOGY FOR SERIAL PRODUCTION OF CARBON BOATS
A study was led to determine the optimal construction to develop a high performing C-PLY™ range for a better permeability in infusion process. The result is a carbon NCF that achieves high mechanical performances, multi resins compatibility and cost efficiency. “Chomarat is the best choice for supplying the product our factory prefers to work with: stable quality and cost effectiveness are the key benefits” explains Nicolas Broberg, Managing Director Arcona Yacht.

Infusion technology for hull and deck with up to 70% level of carbon in the laminate gives the greatest possible strength.