From the Sector

The EU's planned ban on the entire group of per- and polyfluoroalkyl substances (PFAS) would endanger many industrial processes, states VDMA Textile Machinery. Textile manufacturing would be affected twice – by missing important chemicals for technical textile production and by the lack of indispensable textile machine components. The latter would affect the whole supply chain from textile machinery manufacturers and its suppliers to the textile industry in the EU.

Solid PFAS parts are widely used in textile machinery production, especially where extreme conditions prevail. Verena Thies, Managing Shareholder Thies GmbH & Co. KG, explains: “Our textile dyeing machines are world leaders and set standards in efficiency and sustainability. They work under pressure at temperatures of up to 140° C using highly acidic, highly basic and/or oxidative or even reductive chemicals. This is precisely why PFAS is needed, for example, in seals and rings, flaps as well as valves for a long-lasting and high-quality machine concept – because there are no alternatives with qualitatively equivalent properties. In addition, PTFE semi-finished products enable a sliding and gentle contact with the textile fabric in ecologically important techniques in the transformation of textile wet finishing."

PTFE and also FKM are fluoropolymers (fluoroplastics and fluoroelastomers), a group within the broad PFAS range of about 10,000 substances which would be banned for production, use and sale in the EU. They are high-tech materials, and as so-called "polymers of low concern" are not a danger to the environment, according to the OECD. Furthermore, these components are installed inside a machine and exchanged or disposed of properly. PFAS such as PTFE and FKM must be exempted from the ban, demands the VDMA in its position paper.

"In this way, the association also supports the approach taken in Great Britain. With the 10,000 substances, everything is lumped together, although the various PFAS groups are very different," warns Dr Sarah Brückner, Head of VDMA Environmental Affairs and Sustainability. "We should take our cue from the UK and look at the substance groups in a differentiated way."
Apart from several types of dyeing machines, PFAS components are indispensable in textile drying machines (e.g., conveyor dryers, tumblers and stenters) and damping machines. They are also used in fully automatic chemical dispensing systems and pressure vessels for thermochemical treatment of textile recycling material, heat recovery systems and wastewater treatment technology. This means that a lot of machines needed for a sustainable textile production would be affected by the PFAS ban.

VDMA Textile Machinery will take part in the ongoing EU public consultation. The association will describe indispensable key functionalities and conditions of use in the textile machinery sector as well as the consequences for the companies and the customers in the EU if the ban is imposed. The consultation ends on September 25, 2023, and VDMA urged its members affected by the planned restriction to participate in the consultation at an early stage. This is the only way to ensure that the broad scope of the mechanical and plant engineering sector is represented.

On Monday, December 19 2022, the European energy ministers reached an agreement on a price cap for natural gas wholesale prices.

Despite welcoming the adoption of the instrument and the prospect to limit gas price speculations on the stock market, EURATEX considers the cap at 180 €/MWh to be still too high. Also, the complexity of the conditionalities triggering the cap may weaken its effectiveness and implementation: according to the legal proposal, the price level must be reached for three working days and European wholesale gas prices must remain, for the same length of time, at €35 above the global price of liquefied natural gas. Therefore, EURATEX urges the Council of the EU to improve this market correction mechanism.

Furthermore, EURATEX insists on the need to provide the industry with support measures to counteract competition from the US and other countries. Dirk Vantyghem, Director General of EURATEX, affirms: “The Industry is at the heart of the European way of life and the fundament of our social market economy. The European textile industry is 99.8% composed of SMEs, which struggle with tight margins while being at the upstream part of the supply chain: the EU must do more to save its industrial structure, its competitiveness and its capacity to provide essential products to European citizens”.

The associations published a joint European textiles industry statement on the energy package claiming incisive actions with no further delay.
Here is the statement in full:

Last month, when gas wholesale prices reached the record level of 340€/MWh – triggering also sky-high electricity prices – the European textiles industry called on the European Union to adopt a wholesale price cap for gas, the revision of the merit-order principle in the electricity market, support for SMEs and a single European strategy. On 14 September 2022, on the occasion of the State of the Union address by President Von der Leyen, the Commission announced initiatives aimed at tackling the dramatic energy crisis that the Europe is facing.

We, the European associations representing the whole textiles’ ecosystem,  welcome these proposals by the Commission to change the TTF benchmark parameters and decouple the TTF from the electricity market and the revision of the merit-order principle for the electricity market, which is no longer serving the purpose it was designed for.

We also welcome the proposal to amend the state-aid framework that, in our view, should include the textiles finishing, the textiles services and the nonwoven sectors as well as a simplification of the application requirements. Furthermore, we call for a uniform implementation across the EU.

However, we acknowledge that the Commission proposal lacks in ambition and – if confirmed – it will come at the cost of losing European industrial capacity and European jobs. Ultimately, Europe will remain without its integrated textiles ecosystem, as we know it today, and no mean to translate into reality the EU textiles strategy, for more sustainable and circular textiles products.

An ambitious and meaningful European price cap on the wholesale price of natural gas is absolutely necessary. Europe is running out of time to save its own industry. It is now time to act swiftly, decisively in unity and solidarity at European level. We understand a very high price cap has been so far discussed among Ministries and that is not reassuring for companies across Europe: if any cap is, as expected, above 100/MWh, these businesses will collapse.

Already in March 2022, with EU gas wholesale prices at 200€/MWh, the business case for keeping textiles production was no longer there. To date, natural gas wholesale prices have reached the level of 340€/MWh, more than 15 times higher compared to 2021! Currently, many businesses have suspended their production processes to avoid the loss of tens of thousands of euros every day. We hope this will not become the new normal and – to reduce the likelihood of such a scenario – we call on the Commission, the EU Council and the Parliament to swiftly adopt decisive, impactful and concrete actions to tackle the energy crisis and ensure the survival of the European industry.

Given the dire international competition in which the EU textiles industry operates, it is not possible to just pass on the increased costs to consumers. Yet, with these sky-high prices, our companies cannot afford to absorb those costs. The EU textiles companies are mainly SMEs that do not have the financial structure to absorb such a shock.  In contrast with such reality in Europe, the wholesale price of gas in the US and China is 10€/MWh, whereas in Turkey the price is 25€/MWh. If the EU does not act, our international competitors will easily replace us in the market, resulting in the de-industrialisation of Europe and a worsened reliance on foreign imports of essential products.

Specific segments of the textile industry are particularly vulnerable:

• The man-made fibres (MMF) industry for instance is an energy intensive sector and a major consumer of natural gas and electricity in the manufacturing of its fibres. Not only is it being affected by higher energy process, it is also experiencing shortages and sharply rising costs of its raw materials.
• For the nonwovens segment, production processes – which use both fibres and filaments extruded in situ – are also highly dependent on gas and electricity. Polymers melting and extrusion, fibres carding, web-forming, web-bonding and drying are energy-intensive techniques. Nonwoven materials can be found in many applications crucial to citizens like in healthcare (face masks) or automotive (batteries).
• It also is to be noted that for some segments the use of gas has no technological substitute: for example, the dyeing and finishing production units make very intense use of gas. These production units are mainly composed by boilers and driers, which only work on gas and there is no alternative technology.
• The textile services sector is also struggling: with the critical nature of the service they provide, they require a considerable amount of energy to keep services, particularly hospitals and care homes stocked with lifesaving material as well as clothing and bed linens for the patients themselves. Losing these businesses would cause a lack of clothing for healthcare professionals, including protective sanitary gowns for surgeons, nurses and doctors, uniforms including other forms of personal protective equipment.

With its current position paper, the Industrievereinigung Chemiefaser e.V. takes a stand on the intense discussions about an embargo against Russian natural gas supplies. The association believes that Germany's economic and global political future can only be secured with a strong industrial base and therefore, weighing up all positions and influencing factors and assessing the consequences for labour and the market economy, cannot support a short-term natural gas embargo on Russia.

An interruption of the continuous supply of natural gas would result in immense losses for the chemical fibre companies, which could even lead to the destruction of the industry in Germany. The losses are made up of technical damage caused by an uncoordinated shutdown of plants on the one hand and market-related consequential damage caused by lost production and a lack of product sales on the other.

Depending on the location and size of the plants, a short-term outage due to a lack of natural gas would result in average losses of EUR 5 million/plant. In addition, an ongoing daily loss would have to be expected which could be in the order of e.g. 250 000 EUR/day/plant, depending on the location. Furthermore, restarting the plants is questionable if supply chains could no longer be serviced and customers globally look for other suppliers in the meantime. Thus, entire sites would be at risk. With China's global market share in man-made fiber production already exceeding 70 %, a scenario is more than realistic that China will also take over these supply chains, thus leading to an even greater dependence on China.

The vast majority of power plants used for the production of man-made fibers, especially the highly efficient combined gas-and-steam power plants based on the principle of cogeneration with efficiencies of 90 %, are designed exclusively for the use of natural gas. Quite often, there are no technical facilities for operating gas turbines or steam boilers with fuels other than natural gas. Only in exceptional cases could a switch be made to mineral oil. However, even in these cases, the necessary stockpiling of mineral oil is designed only for a short-term failure of the gas burners. A change to base-load supply with mineral oil could take a time window of between 3 and 56 months, depending on the type of plant and taking into account licensing requirements. The use of hydrogen as an energy source is only possible in the very long term. In the few cases where natural gas can be substituted, investment costs of EUR 250 million/plant can be incurred, depending on the emission level of the converted plant.

A natural gas embargo imposed by the European Union on the Russian Federation would not only mean the cessation of production and the end for man-made fiber producers, but also for other industries such as basic chemicals, paper, metal production and glass and ceramics manufacturing, as well as their related sectors. As the German economic institute Institut der Deutschen Wirtschaft Köln e. V. (IW Köln) concluded in its summary report 40/2022 of April 2022: "No one can accurately predict what future these businesses would then still have in Germany. That would be an unprecedented development."

On the occasion of releasing its 2021 Spring Report, EURATEX calls the European Institutions to implement a new Industrial Strategy which will effectively support the European textiles industry. EURATEX welcomes the fact that Textile and Clothing industry is recognised as one of the 14 essential ecosystems of the European economy, but we need to take effective measures to support these sectors, and take into consideration the global dimension.

Economic data for 2020 in EURATEX Spring Report show preoccupying trends. Figures reflect a dramatic contraction in demand and production: EU turnover contracted by -9.3% in textiles (which is in line with the general manufacturing average) and by -17.7% in clothing, compared with 2019. Furthermore, supply chain disruptions and substantial price increases of some raw materials are putting significant pressure on the T&C industries across Europe. The trade deficit for European textiles and clothing jumped from € -47 bln in 2019 to € -62 bln in 2020, an increase of more than 30%, which is almost entirely due to the import of Chinese face masks and related products. Fortunately, more recent figures from the 1st quarter of 2021 indicate some signs of recovery.

That figure illustrates very well today’s political discussions on the future of the European industry. Many European companies have made considerable efforts to adapt their production to the pandemic, but clearly this was not enough. Whether the production cost in Europe is too high or the EU should adapt its procurement rules, the industry needs have a coherent long-term plan to become more competitive and conquer new markets.

EURATEX General Assembly highlighted the critical role of the new EU Industrial Strategy. The inclusion of textiles and clothing in the fourteen ecosystems is a step in the right direction to consolidate the industrial base but we should look also at the global challenges. European companies should continue investing in innovation, design and quality, in combination with a structural move towards more sustainable textiles. At the same time, the EU should create an environment - both inside the Single Market and globally - where everybody plays by the same rules.

• Technology webtalk on sustainable denim production

The next VDMA technology webtalk is scheduled for 12th November 2020 (2 pm - 4 pm CET). The topic will be “Sustainable denim production: latest finishing technologies”.

The presenters and their topics at a glance:

Volker Kunzmann, FONG’S EUROPE, will present highly efficient and innovative wet finishing solutions for denim by combining modular systems adapted to the product and customer’s and local specifications.

Hans Wroblowski, A. Monforts Textilmaschinen, will speak about advanced denim finishing technologies with a focus on ecological and economical energy consumption. Furthermore, a new yarn dyeing process will be presented.

Dr. Jürgen Thoms, PLEVA, will present online measuring and control devices for sustainable and cost-effective denim finishing. Latest technologies in straightening, preskewing, moisture management and quality reporting are shown.

After the presentations, the three experts will be available to answer the participants' questions. Free registration is still possible.

In May 2017, Jochen Adler, Vice-President and Chief Technology Officer at Oerlikon Textile GmbH & Co. KG, presented a Oerlikon Barmag take-up winder as a partial gift to Prof. Dr Thomas Gries, head of the Institut für Textiltechnik (ITA) at RWTH Aachen University. The new Type ASW602 winder, which is equipped with modern control software and user interface, replaces the former institute’s Barmag take-up winder.

Due to this modernisation, ITA has access to a latest generation take-up winder which is used for various research projects. The new winder is applied at ITA’s two pilot melt spinning plants and ensures the transfer of new research and development insights into the pilot scale. Furthermore, this winder has two winding positions and operates with winding speeds between 2500 m/min and 5500 m/min. The new winder is suitable for all kinds of polymers, from polypropylene to polyethylene, polyester, polyamide etc. as well as for the production of several types of yarn, such as industrial yarn, pre-oriented yarn and fully-drawn yarn.
“We thank Oerlikon Barmag for the generous partial gifting and the support during the set-up of the new take-up winder”, says Prof. Dr Thomas Gries. “The new equipment will keep the institute’s machine park on a high and powerful level.” The head of ITA’s chemical fibre department Dr Thorsten Anders adds: “This winder is designed for the needs of chemical yarn research. It allows state of the art technology research and development and pilot-scale production. We will use it for the melt spinning plants in the single- and bi-component spinning process. This way, we can access a wide variety of producible yarn types.“