From the Sector

Fibre and fabric production technologies – especially in the area of composite reinforcements – have played an as-yet largely unheralded role in the development of the UK’s Formula One industry, but the British Textile Machinery Association (BTMA) aims to change that.

Motorsport Valley
“If there’s one thing the UK does well, it’s Formula One, with seven of the ten F1 teams located within just an hour of each other in the midlands region known as Motorsport Valley,” explains BTMA CEO Jason Kent. “They are all linked to a national network of around 4,500 companies involved in a motorsport and high-performance engineering industry worth around £9 billion annually and employing 40,000 people. This network draws on the services of a significant number of our member companies.”

“With the exception of the engine, virtually every part of a Formula One racing car now starts from a textile, including the bodywork, the tyres and many of the latest fuel systems,” says Richard Kirkbright, project manager at Leeds-based Roaches International. “This has influenced developments in the broader automotive sector, in addition to the aerospace industry.”

Show cars and memorabilia
While best known as the developer of textile testing systems, Roaches has over the years also supplied advanced autoclaves to the UK’s composites industry, including a recent delivery to Northampton-based Memento Exclusives, a specialist in the production of show cars working directly with F1 and its leading teams.

Each major F1 team sponsor is supplied with one or two show cars for use at exhibitions and a wide range of other promotional activities arranged around the racing event calendar. These cars have no engine and their bodies may be made of fewer carbon fibre plies, but they are otherwise identical to the latest cars being raced by the F1 teams.

Memento Exclusives has its own in-house carbon fibre parts manufacturing facility and the integration of the Roaches autoclave has significantly expanded its capabilities in show car production.

Master bakers
“Composite materials undergo a metamorphosis in the autoclave which subjects them to both mechanical and chemical processes,” explains Richard Kirkbright. “Trapped air and volatiles are expelled and plies are consolidated under precise pressure. Heat cycles are then introduced, curing the resin systems and yielding flawlessly crafted components. Autoclave specialists are a little like master bakers, knowing exactly how to treat their ingredients at every stage of the process, to achieve the desired final product.”

“The Roaches autoclave now enables us to cure large components with full control and achieve a swift turnover of parts while ensuring the highest quality finish,” adds Terry Wasyliw, Head of Build for Memento Exclusives.

McLaren’s influence
Woking, UK-headquartered McLaren was the very first F1 team to introduce a car chassis manufactured entirely from carbon fibre composites back in 1981, setting the ball rolling for the creation of a completely new and global supply chain.

McLaren has this year unveiled a world-first in supercar engineering – aerospace-derived Automated Rapid Tape (ART) carbon fibre, developed at the dedicated McLaren Composites Technology Centre (MCTC) facility in Sheffield. This is being employed to create the active front wings of the W1 hypercar which has a starting price of $2.1 million.

A rear floor component was also developed for McLaren as part of the recently-completed £39.6 million ASCEND programme involving a range of UK partners, including BTMA member Cygnet Texkimp.

Handling, converting and decarbonisation
A wide range of handling and converting machines are supplied to the composites industry by Cygnet Texkimp, including bespoke creels, prepreg, coating, slitting and filament winding machines.

Its technologies are employed in the construction of composite components for aerospace and automotive, as well as in the production of tyre cord and more recently in the advanced construction of hydrogen storage vessels which are largely viewed as the future of F1 propulsion, along with advanced batteries for electric vehicles.

Cygnet Texkimp has been involved in the F1 supply chain for over 20 years and most carbon fibre used in the industry has been processed on one of its VHD creels. The company is also the largest independent manufacturer of prepreg machines in the world and is currently leading the design and build of the UK’s first carbon fibre research lines for a project led by NCC (National Composites Centre) to accelerate the development of more sustainable carbon fibres.

In addition, Cygnet is licensed to design and build the DEECOM® composite recycling system developed by new BTMA member Longworth Sustainable Recycling Technologies, the first of which was recently commissioned by the Henry Royce Institute in Manchester. DEECOM® is a zero emission, low carbon pressolysis solution using pressure and steam to reclaim pristine condition fibres and resin polymers frocm production waste and end of life composites.

“Decarbonisation is a major priority for manufacturers globally,” says Cygnet CEO Luke Vardy. “At Cygnet Texkimp, we’re developing the capability to process technical fibres in ways that enable lightweighting, hydrogen power and electrification, reduce waste and revolutionise the end-of-life management of composite materials and parts. In collaboration with our industry partners, we’re bringing to market some of the most innovative new fibre processing technologies ever developed to deliver real-world benefits that support the sustainability agenda.”

Prepregging
Another new BTMA member, Emerson & Renwick (E+R), a specialist in print, forming, vacuum and coating technologies, also supplies technology for the production of carbon fibre prepregs, which are integrated rolls of fabrics and resins.

Its most recent 1.7-metre-wide line supplied to a customer in Italy operates at speeds of 40+ metres per minute for web coatings or prepreg fibre and resin consolidation, or a combination of both processes. It is distinguished by an ultra precise three-roll reverse roll coater for the processing of high viscosity thermo-activated resins and enables the automatic changeover of sensitive woven fabric materials at zero tension, with three high precision calendaring nips with hot/cool plates. Multiple unwind and rewind systems for intermediate lamination steps include side loading and reliable lap splicing and zero speed splicing with a web accumulator for the main product rewind.
 
 E+R has also been part of a consortium working on the development of lithium-sulphur (Li-S) batteries within the £540 million UK Faraday Battery Challenge. Once commercially viable, Li-S batteries promise to provide relatively high energy density at low cost for sustainable electric vehicles of the future – inevitably starting with F1.

Strong links
“In addition to our powerful base of textile testing and control companies, many other BTMA members are working on further F1 and advanced composite projects,” says Jason Kent in conclusion. “We are also forging strong links with the UK’s key research hubs such as Sheffield University’s Advanced Manufacturing Research Centre, the Northwest Composites Centre in Manchester, the National Centre for Motorsport Engineering in Bolton and the National Composites Centre in Bristol.

“The BTMA recently became an associate member of Composites UK too, because this sector is the crucible of innovation for tomorrow’s textiles.”

The Jakob Müller Group (JMG), a global leader in narrow fabric machinery, is pushing forward with the implementation of its JMG 2030 strategy. This strategy aims to solidify the company's market leadership, respond more agilely to the dynamic industry landscape, and align even more closely with customer needs. The current measures focus specifically on the company's core competencies and include, among other things, simplified corporate structures, adjustments and expansions of the product portfolio, a new acquisition, and targeted customer initiatives. With this, JMG strengthens its position in the market and lays the foundation for sustainable growth for the long-standing Swiss company.

The Swiss industrial landscape is changing – as is the global textile machinery industry, for which JMG manufactures machines and system solutions. As part of its JMG 2030 strategy, the world's leading machine manufacturer has now presented a series of measures designed to secure its market leadership and enable long-term growth.

JMG is investing specifically in strengthening customer focus and modernizing both its product portfolio and global internal processes. This includes the creation of innovative customer collaboration platforms, the expansion of the product portfolio in the volume segment, the optimization of the service offering, as well as the simplification of corporate and management structures.

Focus on core competencies and operational excellence
As part of its strategic realignment, JMG will increasingly focus on its core segments of Weaving, Label Production Systems, Warp Crochet Knitting, as well as Dyeing and Finishing. At the same time, the Winding & Making-up and Warping Systems segments at the JMG site in Schwelm, Germany, will be discontinued, with essential technologies and products being transferred to other areas. In addition, the Finishing segment will be relocated from Kadan, Czech Republic, to JMG’s sister company Benninger in Pune, India. These measures will lead to structural adjustments at the locations in Germany and the Czech Republic, where production will be gradually reduced.

"Even though these decisions were not easy for us, they are necessary to secure the future viability of the Jakob Müller Group. Our resources must be specifically directed where we see the greatest growth potential," says owner Stephan Bühler. Andreas Conzelmann, CEO of JMG, adds: "By focusing on our core segments, we are strengthening our innovative power and competitiveness – and ensuring that we can continue to offer our customers the best solutions in the future."

Unifying JMG’s brand identity and strengthening the global market position
COMEZ, the leading manufacturer of crochet and warp knitting machines in Italy, will be fully integrated into JMG and will operate under the name Jakob Müller Italy in the future. With investments in research and development – including the acquisition of MEI International, a renowned Italian manufacturer of label weaving machines – JMG will drive next-generation solutions and expand its product portfolio to include innovative air-jet technology. Further information regarding the acquisition of MEI will be provided in a separate announcement.

New Customer Center and Lab1887
Creating outstanding customer experiences is at the heart of the JMG 2030 strategy. The strategic investments in innovation and operational excellence enable JMG to offer state-of-the-art solutions, faster turnaround times, and an enhanced customer experience. A key element of this customer-centric approach is the opening of the new Customer Center and of the LAB1887 in Frick, Switzerland, in late summer 2025. This innovation factory serves as a development center where customers, together with JMG, can explore new technologies and develop novel applications for narrow fabrics.

On July 16, 2024, Rieter and Shanghai Digital Intelligence World Industrial Technology Group Co., Ltd. (DIW) have signed a purchase contract for more than 700 of the company’s winding machines Autoconer X6. This represents the largest order in the history of Rieter China. The agreement also strengthens the strategic partnership between the two companies that aims to develop spinning operations and achieve unprecedented levels of quality, productivity and efficiency.

DIW has placed an order for more than 700 of Rieter’s winding machines Autoconer X6. The winding machine serves as the final quality assurance in the ring spinning and compact-spinning process and is key to the performance of subsequent process steps. With its productivity, intelligent process automation, great splicing and winding quality, the Autoconer X6 is widely recognized in the market. The order will help DIW strengthen the vertical integration of its operations and accelerate its growth strategy in the cotton spinning industry, further underpinning its position in global markets. This order follows the initial batch placed in March 2024, when Rieter and DIW signed their first strategic partnership to develop intelligent yarn manufacturing technology that utilizes digitization and automation to minimize conversion costs and maximize value for customers.

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.

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

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

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

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

BTMA member Dent Instrumentation – a specialist in contactless yarn sensors – has become an employee-owned business following the formation of a new Employee Ownership Trust (EOT).

The company, based in Colne, Lancashire, has been family owned since its founder Geoffrey Dent secured a patent for the very first contactless yarn sensor in the 1960s. It has been successfully run by his son Andrew and the family for many years.
“This deal ensures a smooth succession as well as the preservation of the company’s core family values and the Dent Instrumentation name,” said Managing Director Colin Hull. “The EOT structure will maintain the integrity of the business for years to come.”

The liability of Dent sensors makes them integral to the yarn spinning and winding processes and they have become a standard throughout the textile industry, recognised for their quality, performance and value. They are used by major manufacturers of textiles and textile machinery under either Dent or OEM machine builder brands.

Rieter is moving its Kahramanmaraş service station to a larger location covering 2 000 m² in a bid to broaden its offering and strengthen its market position in Turkey. The station will house one of the region’s largest test-spinning facilities and provide know-how in sustainable yarn manufacturing.

The comprehensive portfolio covers both mechanical and electronic services, including the revision of gear units, servomotor adjustments, and suction drums. The station will also offer preventive maintenance and mill optimization. The service offering spans the entire Rieter product portfolio.

Highlights of the Kahramanmaraş Service Station include the setup of a fully automatic rotor spinning machine R 70 and the winding machine Autoconer X6. Three-quarters of the 2 000 m² service space is reserved for functional activities, which will feature one of the region’s largest test-spinning facilities. Customers can run yarn comparison tests and analyze the impact of different technology parts so they can optimize machine setups. In-depth yarn trials and access to Rieter textile technology expertise will allow customers to cater more effectively to the dynamic demands of textile brands regarding performance, quality and sustainability, such as recycling applications.

The Kahramanmaraş service station is strategically located at the heart of the region’s textile industry, with a large proportion of Rieter’s installed base located within a radius of around 200 kilometers. Turkey is a textile powerhouse, currently ranking fifth in global exports and poised for additional growth. The country’s industry is also implementing a green action plan to help it meet the growing demand for sustainable textiles, especially from Europe.

The new service station starts operations in September 2022 and will accelerate the growth of the company’s three stations in Turkey. Rieter has been operating service stations in Turkey since 2005 with a presence in the country dating back to the 1990s.

SHIMA SEIKI MFG., LTD. of Wakayama, Japan, along with its Italian subsidiary SHIMA SEIKI ITALIA S.p.A., will be participating in the Techtextil exhibition in Frankfurt, Germany from the 21st till the 24th of June 2022.

On display will be SHIMA SEIKI’s latest innovation in flat knitting technology as applied to the field of technical textiles—a prototype weft knitting machine capable of multi-axial yarn insertion. Fabrics produced on this machine use inlay technique for the production of hybrid textiles that combine the stretch characteristics of knitted fabrics with the stability of woven textiles, suited to various technical applications. To this, warp yarn is inserted to further expand its capability to produce 3D-shaped carbon fiber and composite preforms directly on the machine. This is made possible by taking advantage of the fact that flat knitting as a textile production method is capable of producing end products that are shaped-to-form and with added thickness. Compared to current methods of preform production, savings in post-processing time, material, labor and associated costs are immense, realizing efficient and sustainable production. SHIMA SEIKI’s own yarn unwinding technology is also used for optimum yarn feed and tension for use with technical yarns that are otherwise difficult to knit. Industrial textile samples knit on the multi-axial machine will also be available for examination on-site.

SHIMA SEIKI's SDS®-ONE APEX4 3D design system will be available for demonstrations as well. Of particular interest should be its ultra-realistic simulation capability that realizes Virtual Sampling. When countless variations must be evaluated before arriving at a final design, virtual product samples can be used to streamline the decision-making process by minimizing the enormous amount of time, cost and material normally associated with producing actual samples for each variation. When approved, the same data can be converted to machine data for immediate knitting, significantly reducing lead times.

International textile producers meet again in Istanbul, Turkey, from June 14 – 18, 2022 on the occasion of the ITM + Hightex Exhibition. In Hall 9 (Hightex) the exhibitors will present the complete industry value chain from nonwovens raw materials, production machines and accessories to the endproduct. The related industries covered include hygiene, filtration, fabrics and apparel, medical, automotive, wipes, home furnishings and upholstery. DiloGroup offers tailor-made production systems from one supplier and will inform about its portfolio and the latest equipment developments from fibre opening to the finished felt.

DiloGroup will inform about complete lines as well as high speed needlelooms for spunbonds. A new, simplified elliptical needle beam drive makes Hyperpunch technology also attractive for standard application. Hyperpunch HαV allows a more uniform stitch distribution in the preneedling process especially in combination with the new needle pattern 6000X. In a complete needling line this felt homogenization process can be improved further. The new needle pattern 8000X is a milestone in the needle pattern development process and results in endproduct surfaces with low markings over a wide range of advances/stroke.

Another strong pillar of the sales program over decades has been fibre preparation and high speed webforming equipment for other nonwoven technologies. The further development of the high-speed layering principle “Hyperlayer” made progress for better CD strength through a combination of inline cards and crossline card with crosslapper. Particularly, carding machines in a working width above 3.5 m up to 5.1 m have been supplied by DiloSpinnbau as complete high speed carding systems, comprising two or even three cards in a line to directly feed the hydroentangling units of various suppliers. Together with DiloTemafa not only have high throughput rates been achieved in the fibre preparation section of the line but also dedusting filtering and air-conditioning systems have been successfully engineered and integrated.

Together with Sicam, Dilo has combined know-how for hydroentangling technology and therefore can provide complete lines as general contractor including equipment for cutting, winding and packaging.

Another interesting machine is the 3D-Lofter, first presented during ITMA 2019 in Barcelona, which offers a wider range of nonwovens applications by exploring the third dimension. A series of single web forming units which work according to the aerodynamic web forming principle deliver defined fibre masses in varied patterns on a base needlefelt. A stress oriented production of technical formed parts resulting in fibre savings or patterned DI-LOUR or DI-LOOP felts with or without repeat are two examples for this technology which explores new application areas for needlefelts.
The 3D-Lofter technology may also be used “inverted” as “IsoFeed” for filling up bad spots in web mats and thus achieves a better homogeneity of spunlace or airlay products.

The DiloLine 4.0 concept offer I4.0 modules which not only support the user but also facilitate quality control and maintenance by a maximum data transparency in production and control of operation. The Dilo solutions “Smart Start” for a fully automatic start of the production line or “DI-LOWATT” for energy savings are accompanied by Siemens solutions which can be selected via App or Data Cloud “MindSphere”.

Each year, since its creation more than 20 years ago, the JEC Composites Innovation Awards celebrate successful projects and cooperation between players of the composites industry. The competition has especially shined a light on some 203 companies and 499 partners, awarding them for the excellence of their composite innovations.

The ceremony took place on April 26th in Paris. Highlighted by the presence of jury members, finalists and winners but most importantly, as it was livestreamed, the gathering of many people all around the world to watch the awaited results.

The enthusiasm for the Innovation Awards, exactly 7 days prior to JEC World, is a good sign of the industry’s eagerness to get back together and ensure the future of composites innovation.

• Aerospace Application
  Diab (Sweden): 100% thermoplastic panel for cabin interiors
• Aerospace – Process
  MTorres Disenos Industriales S.A.U. (Spain): Innovative Infusion Airframe Manufacturing System
• Automotive & road transportation – Structural
  Jaguar Land Rover Limited (UK): TUCANA
• Automotive & road transportation – Surfaces
  AUDI AG (Germany): Seamless Integration of Flexible Solar Film in FRP
• Building & Civil Engineering
  Windesheim (Netherlands): Structural Re-Use of Thermoset Composites
• Design, Furniture and Home
  Kairos (France): Kairlin®, a new recyclable & compostable material
• Equipment and Machinery
  Fibraworks GmbH (Germany): Winding the future – fibraforce technology
• Maritime Transportation & Shipbuilding
  Voith Composites SE & Co. KG (Germany): Marine Rotor Blades made of Voith ‘Carbon4Stack’
• Renewable Energy
  Siemens Gamesa Renewable Energy (Denmark): RecyclableBlade
• Sports, Leisure & Recreation
  Bcomp Ltd. (Switzerland): Eco-joint from thermoset race and thermoplast road