From the Sector

• First fiber producer to have an approved science-based target – CO₂ neutrality by 2050
• Breakthrough in REFIBRA™ technology – worn textiles can also be used as fiber raw material
• Pioneer in the introduction of blockchain technology for fiber recognition
• On track to meet all sustainability targets

Lenzing – Just ahead of the “Day of Forests ” on March 21, which the FAO (Food and Agricultural Organization of the United Nations) introduced in the 1970s in response to global deforestation, the Lenzing Group presents its Sustainability Report 2019. This sets out how the company is actively dealing with the global challenges.

Lenzing produces fibers from the renewable raw material wood and is well known among its customers and partners in the global textile and nonwoven fabric industry for the clear position it takes as a sustainable producer. It is no accident that the new report is appearing on the International Day of Forests. Lenzing’s sustainable practices in procurement, especially for wood and pulp, were once again ranked as leading in the 2019 reporting year (Hot Button Report).

“Stand up! A gainst business as usual ”

Under the motto “Stand up! Against business as usual ”, Lenzing emphasizes its wider responsibilities over and above its products. Business - as - usual scenarios have to be overcome, in particular for climate protection. With a science-based target, Lenzing is taking action to master the problems caused by climate change. The Lenzing Group is committed to reducing its greenhouse gas emissions per ton of product by 50 percent by 2030 (baseline: 2017). The Science-Based Target s initiative has approved Lenzing’s climate target as science-based.

Breakthrough in REFIBRA™ technology

One of Lenzing’s strategic principles under its “Naturally positive” sustainability strategy and a focus in the 2019 Sustainability Report is the circular economy. To address the enormous textile waste challenges of industry and society, Lenzing has developed a unique recycling technology branded REFIBRA™. This technology enables garment production waste to be reprocessed into fibers. 

• Technology for dyeing polyester and its blends

TERASIL® BLUE W high wash fastness dye raises operational excellence of mills, providing right-first-time results leading to savings of water, energy and costs.

Huntsman Textile Effects introduces TERASIL® BLUE W, the latest addition to the TERASIL® W/WW range of wash fast disperse dyes. TERASIL® Blue W is designed to meet all major requirements for high performance sportswear and athleisure wear.

Polyester fiber has become the fiber of choice in the textile industry, the demand for polyester and man-made fibers is expected to rise over the long term, as sports and athleisure apparel markets expand around the world. At the same time, leading brands, retailers and mills are increasingly focused on achieving brilliant and deep shades, consistent shade reproducibility, as well as water, energy and cost savings.

TERASIL® BLUE W is developed by Huntsman Textile Effects to provide the leading solution for meeting industry’s wash fastness requirements. TERASIL® BLUE W offers an attractive shade and high build-up for deep blues which stays vibrant. TERASIL® BLUE W also provides quality assurance as products are bluesign® approved and suitable for STANDARD 100 by OEKO-TEX® certified textile products.

• Investment of Rp. 15 trillion (USD1,1 billion) in facility
• Supports development of national textile industry and ‘Making Indonesia 4.0’ roadmap

The President of Indonesia, Joko Widodo, today inaugurated Indonesia's largest integrated viscose rayon production facility, injecting a boost for the country’s textile sector and the Indonesian Government’s industrial 4.0 development strategy.

The new Asia Pacific Rayon (APR) facility is located in the same production complex as APRIL Group in Pangkalan Kerinci, Riau province, Sumatra. This co-location allows integrated operations where renewable plantation pulp supply from APRIL feeds directly to APR for viscose rayon production. The new operation represents a total investment of approximately Rp.15 trillion (USD1.1 billion).

The APR facility has an annual production capacity of 240,000 tons. The inauguration ceremony included the signing of a plaque by President Widodo and the symbolic sealing by the President of an export container with 10,190 tons of viscose rayon fibre for shipment to Turkey, one of APR’s key export markets, and another 12,000 tons to Central Java.

The ceremony was also graced by the Minister of Industry, Agus Gumiwang Kartasasmita, the Minister of Trade Agus Suparmanto, the Governor of Riau, Syamsuar, RGE Founder and Chairman Sukanto Tanoto, and Anderson Tanoto, Director, RGE.

Speaking at the inauguration, President Widodo welcomed APR's investment in the development of the national textile industry. The role of the private sector was influential in driving economic growth, alongside the stimulus provided by the Government, he said. “Our garment industry should be greater than Vietnam. We already have our own raw materials here, such as viscose rayon, to support the industry,” he said.

Economic Contribution
APR’s business aligns with President Jokowi's vision to encourage more value-added investment in the nation and the strengthening of the national textile and textile product (TPT) industry, as set out in the Making Indonesia 4.0 Road map. In addition, the production of viscose rayon will reduce dependence on the import of textile raw materials, particularly cotton, to meet domestic demand.

Agus Gumiwang Kartasasmita, Minister for Industry, said: “By optimising the availability and use of raw materials originating from Indonesia, we can boost the performance of our textile sector. This is just one of several steps we are taking to continue to improve the performance and competitiveness of the labour-intensive industry.”

Basrie Kamba, Director APR, said: “The presence of APR will have a positive impact on employment and business opportunities for small and medium-sized businesses in the upstream and downstream sectors of the textiles and textile products industry. We are honoured and grateful to President Jokowi for inaugurating our new facility”.

In addition to Turkey, APR’s products are exported to 14 other countries including key textile centres such as Pakistan, Bangladesh, Vietnam, Brazil, and various parts of Europe. The products also support an expanding Indonesia fashion industry.

It is estimated that APR may generate foreign exchange revenues exceeding Rp1.77 trillion (USD130 million) annually, and reduce dependence on imported raw materials by about Rp2.01 trillion (USD149 million) annually.

Sustainable Production
APR produces sustainable viscose rayon fiber from renewable, traceable and biodegradable raw materials. The company’s raw materials are supplied by APRIL Group, which is recognised as a responsible pulp producer through national (Timber Legality Verification System) and international (Program for the Endorsement of Forest Certification/PEFC) certifications.

APR is the first viscose rayon manufacturer in Indonesia to receive the internationally recognised STeP certification from OEKO-TEX ®, an independent Swiss-based certification organisation, for the responsible manufacturing of viscose staple fibre.

APR has launched the ‘Everything Indonesia’ campaign to promote the sustainable sourcing and production of fashion from Indonesia. The aim is to support Indonesia’s resurgence as a global centre for textile manufacturing, and catalyse home-grown fashion design and creativity.

In the latest technology innovation from members of TMAS (the Swedish textile machinery association), ACG Kinna and ACG Nyström have teamed up with Juki Corporation – the world’s leading sewing machine manufacturer – in the development of a new automated line concept that can considerably speed up the production of finished filter bags.

Woven or nonwoven filter bags employed in a wide range of industrial processes may be under the radar as products, but they represent a pretty significant percentage of technical textiles production.

According to a recent report from BCC research, a leading US analyst covering this sector, industrial filtration represented a $555 million market in 2019 and some of the key areas where such filter bags are employed include:

• Metal fabrication, with effective filtration required for manual and automated welding, thermal cutting, blasting and machining, especially for coolant filtration.
• The process and energy industries, including foundries, smelters, incinerators, asphalt works and energy production plants.
• Other key manufacturing fields – often where dust is generated – including the production of timber, textiles, composites, waste handling and minerals, in addition to chemicals, food production, pharmaceuticals, electronics and agriculture.

Line integration
The new SFL-2000 line is the result of a four-year development project between Juki Central Europe, headquartered in Poland, and the two ACG companies.

It is capable of handling a wide range of different filter media, and as an all-in-one solution, can produce high quality and accurate seams to pre-defined parameters, with optional modules allowing for customised constructions.

At the Swiss-Egyptian Investment Forum which took place on February 3 in Cairo (Egypt), the Cotton & Textiles Holding Company and Rieter signed additional contracts related to the modernization program for the Egyptian textile industry.

Further Orders from Egypt:

• Contracts for additional projects signed in Cairo
• Order volume is around 30 million Swiss francs
• Order intake in the first half year of 2020 expected

The total volume of the contracts sums up to around 210 million Swiss Francs, including the contracts which had been signed at ITMA 2019 in Barcelona and which represent a volume of around 180 million Swiss Francs.

Rieter expects the full amount of orders to be booked as order intake in the first half year of 2020. So far, 165 million Swiss Francs have been booked.

Bemberg™ gears up for Première Vision - February 11th-13th, Paris, France; with a great deal of novelties and a key statement on sustainability: Let’s Make it Circular! That’s why the Japanese brand of regenerated cellulose fibers joins the fair with two booths, one in the yarn-focused sector – Hall 6 C52 6D53 – the other one in the Smart Creation area, the curated district showcasing cutting-edge sustainable innovation for the textile and fashion business. Hall3 S14.

“We simply could not miss out on the Smart Creation Area as sustainability is the founding pillar of our company,” says SHUNSUKE SATO, sales manager of Bemberg™ by Asahi Kasei. “Indeed, the smart fiber is made from a cotton linter which is pre-consumer material, a natural derived source, that doesn’t deplete forestry resources. The strategy beyond our double presence is to highlight our deep commitment to responsible innovation to a larger target of professionals.”

Let’s take it circular! is the motto at the Smart Creation booth. The lifespan of Bemberg™’s regenerated cellulose fiber derived from cotton is fully circular: from the source to manufacturing. The whole sustainable closed-loop process is supported by the LCA study, signed by ICEA and validated by Paolo Masoni. Recyclability is granted by the Global Recycle Standard - GRS certification by the renown Textile Exchange. An influential guarantee that involves the whole production process and supply chain behind the company’s smart yarns. Bemberg™ yarns are entirely biodegradable and ecotoxicity-free – meaning that at the end of their life circle they break down into the environment leaving no trace in terms of toxic substances as attested by the Innovhub-SSI report.

On show at Première Vision some of the most recent collaborations with GRS-certified partners such as FIVEOL, SMI TESSUTI, TESSITURA UBOLDI, INFINITY, SIDONIOS, MATIAS & ARAUJO, TINTEX, IPEKER, EKOTEN, for fashion fabrics as well as PEZZETTI and BRUNELLO & G.CRESPI from lining partners.

The first Bemberg™ partner to present a commercial collection enriched by Velutine™ Evo is the Portuguese Matias & Araújo. With an innovative spirit, dynamism and a determined entrepreneurial spirit, the company is a leading knitwear producer for the textile industry.

In the Hall 6 Bemberg™ displays key commercial items developed by premium brands such as CAALO that is making its mark in the outerwear market with its Sustainably produced Functional-Luxury proposal. For SS20, CAALO utilized Bemberg™ lining because of the sustainability properties and it's unique colour.

CAALO looks to utilize as much eco-friendly and sustainable materials as possible without compromising on design or quality. This Bemberg™ lining was a perfect fit.

All the glamour of fur meets the technology of responsible ISKO™ denim, for a first-of-its-kind concept that provides fashionable and conscious alternatives to furs and other synthetic imitations.

Over the years, ISKO has set out on a journey of innovative firsts consistently providing what the market had been missing. ISKO Wild™, the latest achievement of this long-lasting enterprise and the first-in-the-world denim fur program, is set to impress the industry and revolutionize fashion.

Resulting from ISKO’s Responsible Innovation™ approach based on creativity, competence, and citizenship, ISKO Wild™ reflects the company’s commitment to making both the world and the industry better. This technology does not harm animals nor does it destroy their home. Unlike other imitation furs, it does not release micro plastics into the environment.

With the claim to inspire and delight the fashion world, stakes are high but the concept is a real hit for it represents the perfect combination of glamorous fashion and conscious responsibility.
Despite attempts of imitations ISKO Wild™ is a one-of-a-kind concept in the industry. Available in both Indigo and RFD, featuring cotton and cotton wool blends, this product stands out from a quality, look and performance standpoint.

• Construction of a new air purification and sulfur recovery plant
• Further improvement of the exhaust emission values at the Lenzing site
• Important step in achieving the CO2 targets of the Lenzing Group

Lenzing – The Lenzing Group is a global leader in the climate-friendly and sustainable production of wood-based textile fibers. Lenzing announced its climate targets in August of this year. By 2030, the company aims to reduce its specific CO2 emissions per ton of manufactured pulp and fibers by 50 percent. By the year 2050, the Lenzing Group will no longer generate any net CO2 emissions.

Lenzing‘s Management Board has now resolved to invest EUR 40 mn to expand the production of the raw material sulfuric acid at the Lenzing site. This comprises an important milestone on the path towards climate neutrality. In the future, a new air purification and sulfur recovery plant will not only optimize the company’s self-sufficiency for this raw material and enhance process reliability but improve environmental protection within the context of a clear forward-looking strategy.

Improved exhaust emission performance

The new plant represents an important contribution towards implementing the sustainability strategy of the Lenzing Group, and also helps to ensure an even higher level of environmental compatibility of all production operations at the Lenzing site. The application of state-of-the-art technologies will further improve exhaust emission values. Furthermore, the new facility will help further reduce the use of fossil fuels by generating steam which will, in turn, be converted into electricity. In this way, it will also support the energy self-sufficiency of the company’s operations in Lenzing.

Improved CO2 scorecard

As a result, the production plant in Lenzing will reduce its annual CO2 emissions by 15,000 tons. This is an important step towards further advancing the company’s ambitious plans in the coming years and also strengthen Lenzing’s leadership role as a driver of ecologically sustainable industry. “On the basis of these investments, Lenzing is taking the next step in achieving its climate targets. At the same time, it will also reach a significantly higher level of autonomy with respect to a vital raw material”, states Stefan Doboczky, Chief Executive Officer of Lenzing.

Market and technology analysis confirms big potential for tape inserts in the injection molding process. Following the finalization of a major consortial project led by the Aachen Center for Integrative Lightweight Production (AZL) and the Institute for Plastics Processing at RWTH Aachen University (IKV), the result is clear: tape inserts offer enormous potential for injection molding parts. For suitable components, product costs and component properties can be positively influenced.

In cooperation with 20 industrial partners, the two renowned Aachen research institutes AZL and IKV carried out a detailed analysis of tape inserts in injection molded components over a period of eight months. The tapes, which are a few tenths of a millimeter thick, are continuous fibers, typically made of glass or carbon, completely impregnated and embedded in a thermoplastic matrix. The tapes can be precisely aligned to the loads in a component and are used primarily in high-performance applications with the aim of weight reduction. The aim of the conducted analysis was the identification of potential applications and the estimation of a wider range of applications.

The project was divided into several phases: Phase I was used to identify the current status. In 20 interviews with representative companies of the injection molding industry, the researchers gathered why tape inserts have rarely been taken into account so far, when defining the material concepts to be analyzed. The lack of information about the material class, the procedure and tools for the development process and the necessary production technologies were cited as major challenges. This is where the consortium will take action and provide comprehensive information during the “Technology Information Day” on the extensively prepared state of the art and the high degree of maturity of the supply chain. Based on the status quo, they developed a methodology for analyzing the technological and economic potential of tape inserts in injection molding applications.

Both the previous results and the planned follow-up projects are the subject of the “Technology Information Day" at K 2019, to which the companies involved in the study, the AZL and IKV, invite all companies along the value chain, from raw material manufacturers to injection molders to OEMs. (Date: 18th October 2019, 10:00 am to 1:30 pm, Trade Fair Düsseldorf CCD South, Room 002).

The consortium, amongst others consisting of Asahi Kasei Europe GmbH, BASF SE, Borealis AG, BÜFA Thermoplastic Composites GmbH & Co. KG, ENGEL AUSTRIA GmbH, Huesker Synthetic GmbH, LG Hausys R&D Center, Mitsui Chemicals, Nippon Electric Glass, Polyscope Polymers BV, POLYTEC GROUP, Simcon kunststofftechnische Software GmbH, SABIC and Toray International Europe GmbH, is inviting to the “Technology Information Day” at K 2019. The goal is to inform about the technology and to identify topics for future collaboration.

On 5 August 2019, Trevira received the “Systematic Safety” seal of approval from the German Social Accident Insurance Institution for the Raw Materials and Chemical Industry (Berufsgenossenschaft Rohstoffe und chemische Industrie, BG RCI). The award confirms that Trevira GmbH meets the requirements for systematic and effective occupational health and safety management through the company’s occupational health and safety management system, which helps optimise production workflows and demonstrates the value that Trevira GmbH places on the health and safety of its employees. The “Systematic Safety” award, valid for three years, also certifies that Trevira fully meets the requirements of industry standard ISO 45001:2018. The award was handed over to Trevira CEO Klaus Holz together with management representative Stefan Rauterkus.