From the Sector

„Your reliable partner in the nonwoven industry“ – the slogan speaks for itself: Oerlikon Nonwoven is exhibiting at the world’s leading nonwovens trade fair – the INDEX in Geneva, Switzerland (October 19-22, 2021) – with one of the market’s broadest portfolios. The Neumünster-based systems constructor will be focusing on market- and customer-oriented system solutions for filtration, hygiene, medical, geotextile and other industrial applications. Trade fair visitors can delve deep into the company’s comprehensive product and process know-how both live at trade fair stand no. 2314 and via the INDEX online platform.

• Nonwovens for filtration, insulation and sorption applications
• Comprehensive spunbond portfolio
• Quality Sized Right-Technology: spunmelt systems for the hygiene and medical market
• Wipes using Oerlikon's Phantom technology
• Airlaid technology for sustainable nonwovens

International technology Group ANDRITZ will be presenting its innovative nonwovens production and textile solutions at INDEX20 in Geneva, Switzerland, from October 19 to 22. The broad ANDRITZ product portfolio covers state-of-the-art nonwovens and textile production technologies such as air-through bonding, needlepunch, spunlace, spunbond, wetlaid/WetlaceTM, converting, textile finishing, airlay, recycling, and natural fiber processing.

One highlight at INDEX will be the new member of the ANDRITZ Nonwoven division: ANDRITZ Laroche – a company that has been an important partner for ANDRITZ in the field of fiber preparation for drylaid nonwovens for over 10 years. ANDRITZ Laroche is a leading supplier of fiber processing technologies such as opening, blending and dosing, airlay web forming, textile waste recycling, and decortication of bast fibers.

One focus of this product range is complete recycling lines for post-consumer and industrial textile waste to produce fibers for re-spinning and/or nonwoven end-uses. Customer awareness and regulations are pushing clothing brands to recycle their textile waste in their own products. Recycled fibers can also be used in the nonwovens industry for various applications, such as automotive, insulation, mattresses, and furniture felts.

After a long break, the international nonwovens industry will meet again in Geneva, Switzerland, from October 19 to 22, 2021 on the occasion of INDEX. DiloGroup offers tailormade production systems from one supplier and will inform about its portfolio and the latest equipment developments from fibre opening to the finished felt.

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 by using the new needle pattern 8000X which is a milestone in the needle pattern development process and results in endproduct surfaces with low markings over a wide range of advances/stroke.

The “3D-Lofter” which was first presented during ITMA 2019 in Barcelona 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 are two examples for this technology which explores new application areas for needlefelts The 3D-Lofter technology may also be used “inverted” for filling up bad spots in web mats and thus achieves a better homogeneity of e. g. spunlace, thermobond 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”.

Apart from machines for needling technology we offer in cooperation with partner companies also production lines including thermobonding and hydroentangling components.

Archroma, a global leader in specialty chemicals towards sustainable solutions, announced that it has appointed Thomas Bucher as its new Chief Financial Officer (CFO) effective 1 October 2021, replacing Roland Waibel who will retire.

Thomas Bucher has a long career in Finance, having held CFO roles with leading industrial and services companies as well as senior Finance roles in the chemical sector. He joins Archroma from Alpiq Holding AG, where he has been Group CFO and a Member of the Executive Management Board since 2015. Prior to Alpiq, Thomas Bucher was Group CFO at Gategroup for 6 years, where he supported the company’s listing and subsequent strategic repositioning, and before that he held a number of senior Finance roles at Ciba Specialty Chemicals over more than 12 years.

Chief Executive Officer Heike van de Kerkhof comments: “We are very happy to have Thomas Bucher join us, and add his financial expertise to support our agenda towards confirming Archroma as an undisputed leader in innovative and sustainable specialty chemicals, supported by solid and profitable growth.”

She adds: “I want to thank Roland Waibel for his many contributions since the beginning of Archroma in 2013. He has played an important role helping the company deliver on our growth whilst building a strong finance expert team and expertise at Archroma.”

FibreCoat GmbH from Aachen, Germany, together with DBF Deutsche Basalt GmbH, developed a completely new type of fibre material to shield electromagnetic radiation from digital end devices, medical technology or e-car batteries cheaply and effectively. The joint project was awarded the overall prize of the“ IQ Innovationspreises Mitteldeutschland“ on 24 June in an online event broadcast live from Leipzig.

The prize is endowed with €15,000 and was sponsored by the Halle-Dessau, Leipzig and East Thuringia Chambers of Industry and Commerce.

Electromagnetic radiation from smartphones, hospital diagnostics and electric car batteries must be shielded so that they do not inter-fere with each other. To prevent mutual interference, they have so far been covered with metal fibre fabrics, a very time- and energy-consuming and thus expensive procedure. The new material from Basalt Faser GmbH and FibreCoat GmbH prevents this with a fibre core made of melted, thinly drawn basalt, which is coated with aluminium and bundled into the so-called AluCoat yarn. This yarn remains just as conductive and shielding, but is lighter, stronger, cheaper and more sustainable than previous alternatives. In addition, there are further advantages:

• The number of process steps required is reduced from ten to one.
• 1,500 metres of yarn are produced per minute instead of the previous five metres.
• The energy required is only 10 per cent of the previous amount.

The result is a price that is twenty times lower.

The textile made of AluCoat fibres is versatile and flexible: as wallpaper it can shield 5G radiation in offices or medical rooms or encase batteries and thus ensure the smooth functioning of electric cars. AluCoat is already being used in some companies. A European fibre centre in Sangerhausen is being planned for mass production.

The two innovative companies DBF Deutsche Basalt GmbH and FibreCoat GmbH from East and West combine the two materials basalt and aluminium to protect against electromagnetic radiation. In doing so, they coat basalt with aluminium and, through this novel combination, create an inexpensive, sustainable and quickly produced alter-native for a market worth billions.

FibreCoat GmbH from Aachen is a spin-off of the Institut für Textiltechnik (ITA) of RWTH Aachen University; the managing directors Dr Robert Brüll and Alexander Lüking and Richard Haas have completed their doctorates at the ITA or are in the process of preparing their doctorates. Georgi Gogoladze, Managing Director of Deutsche Basaltfaser GmbH, also studied at RWTH Aachen University. The two managing directors Brüll and Gogoladze know each other from their student days.

• Guidelines of the EU Commission to implement the Single-Use Plastics Directive have been published
• Uniform labelling obligation for wipes and feminine hygiene products containing plastics as of July 03, 2021
• Lenzing’s wood-based, biodegradable VEOCEL™ branded fibers as a sustainable alternative to plastic

The Lenzing Group welcomes the issuance of the guidelines for the implementation of the Single-Use Plastics Directive (EU) 2019/904, which took effect on June 05, 2019¹. In these guidelines, the EU Commission specifies which products fall within the scope of the directive, thus providing clarity in the joint fight of the EU member states against environmental pollution from plastic waste. Lenzing’s wood-based, biodegradable cellulosic fibers such as those of the VEOCEL™ brand comprise a sustainable and innovative solution to this man-made problem.

Uniform labelling rules for some single-use plastic products
The Commission implementing regulation (EU) 2020/2151 applying to the Single-Use Plastics Directive stipulate uniform labelling requirements for some of the single-use plastic products on the packaging or the product itself starting on July 03, 2021. They encompass feminine hygiene products and wet wipes for personal and household care containing plastic.

Consumers want sustainable hygiene products
Even before the implementation of the Single-Use Plastics Directive, Lenzing already gives consumers clear guidance in their purchasing decisions. Products bearing the VEOCEL™ brand logo on their packaging are produced in line with stringent certification criteria. As a consequence, consumers can be assured that the products contain biodegradable, cellulosic materials.

A Marketagent survey carried out in German-speaking Europe in October 2019² concluded that nine out of ten consumers would immediately change their purchasing behavior for wipes if they found out that their current product contains plastic. This would seem to imply that new market dynamics will emerge once the labelling rules for single-use plastic products takes effect. According to a Smithers Report³, about 500,000 tons of petroleum-based fibers are used each year for the production of wipes.

¹ Directive (EU) 2019/904 of the European Parliament and of the Council of 5 June 2019 on the reduction of the impact of certain plastic products on the environment
² Representative Marketagent Online survey, n = 1,005 (14 - 69 years old, from Austria and Germany). https://itsinourhands.com/
³ Smithers Report “The Future of Global Nonwoven Wipes to 2023”, published in 2018, page 23, reference year 2018

From leaders to entrepreneurs, JEC COMPOSITES CONNECT is welcoming a lineup of special guests. As part of conferences, they will share their expertise, vision, and perspective in front of all the players in the composites industry.

AEROSPACE – Towards a More Sustainable Strategy, Tuesday, June 1st –  9am to 10:15am (CEST)
The aerospace industry is a major source of innovation and technological advancements that often originates inspiration across a wide variety of other industries. Nowadays, in a context where environmental constraints are becoming increasingly stringent especially when it comes to air mobility, OEMs are constantly in search of innovative answers and solutions that will allow them to create a ‘greener’ future. The need for light-weighting, reduced maintenance and waste, and repurposing aerospace-grade CFRP towards other applications are expected to drive demand and adoption of composites in aerospace applications.

Yannick Willemin, Head of Marketing & Business Development, 9TLabs, will chair this conference with Clémentine Gallet, CEO, Coriolis, Hervé Gilibert,CTO, ArianeGroup, Jean Botti, CEO, Voltaero and Scott Finn, Chief Consulting Engineer for Composites, GE Aviation.

AUTOMOTIVE – The Right Material at the Right Place, Tuesday, June 1st –  3 pm to 5:05 pm (CEST)
Among the many challenges facing the automotive industry, reducing vehicle mass and therefore emissions all while maintaining safety and cost-efficiency remain key. Lighter materials implying higher costs, they limit mass production. Therefore, a combination of materials, albeit hybrid solutions, would help solve this issue and are becoming increasingly attractive for manufacturers. This conference consists of industry presentations and a panel discussion involving major OEMs & Tier1s from all over the world. It covers the challenges & opportunities of using composites materials in the Automotive field.

Dale Brosius CFO, IACMI, will chair this conference with Alice Swallow, Senior Innovation Engineer, FORD MOTOR GROUP, Christophe Kühn, Senior Project Manager – Composites & Hybrid Components, VOLKSWAGEN, Dominik Klaiber, Doctoral Candidate Body Advanced Engineering, PORSCHE and Gerard LIRAUT, Expert Leader Polymers, GROUPE RENAULT – ALLIANCE RENAULT NISSAN MITSUBISHI.

In a roundtable discussion during the recent Innovate Textiles & Apparel (ITA) textile machinery exhibition, imogo Founding Partner Per Stenflo and representatives from a number of like-minded European companies discussed the opportunities for new spray application technologies for the dyeing and finishing sector.

These technologies can achieve tremendous savings for manufacturers compared to traditional water-intensive processes it was explained at the event, held online from October 15-30th.

Pioneer
imogo – one of the latest companies to join TMAS, the Swedish Textile Machinery Association – is one of the key pioneers in this area with its Dye-Max system. Dye-Max spray dyeing technology can slash the use of fresh water, wastewater, energy and chemicals by as much as 90% compared to conventional jet dyeing systems. This is due to the extremely low liquor ratio of 0.3-0.8 litres per kilo of fabric and at the same time, considerably fewer auxiliary chemicals are required to start with.

Obstacles
Such technologies, however, face a number of obstacles to adoption and during the ITA discussion it was agreed that 2020 has not provided the ideal climate for adventurous investors. “The textile industry is quite conservative and is definitely in survival mode at the moment and it is not the time to be a visionary,” said Stenflo. “Day to day business is about staying alive – that’s the reality for many of our customers.” Nevertheless, all of the panellists agreed that sustainable production will remain top of the agenda for the textile industry in the longer term and spray technologies for dyeing and finishing processes will be a part of it.

“Any investment in something new is a risk of course, and we have to be able to explain and convince manufacturers that there’s a good return on investment, not only in respect of sustainability, but in terms of making good business sense,” said Stenflo. “Here we could use the help of the brands of course, in putting pressure on their suppliers to be more sustainable. Governments also have a role to play, in providing incentives for producers to move in the sustainable direction. Sustainability alone will never cut it, there has to be a business case, or it won’t happen.”

Marketing
The marketing of sustainable new fibers is comparatively easy for the brands compared to explaining the difficult textile processes and the chemistries involved in fabric and garment production, he added.

“These fibers, however, currently go through all the same dirty processes that we need to get away from, so it must happen,” he said. “In developing our technologies, it has been important for us to avoid disrupting existing supply chains, stick with using off-the-shelf chemistries and dyes, and involve the dye manufacturers who are an essential part in how operations are driven today. “In fact, collaboration across the entire textile supply chain – from the brands right back to the new technology developers – is essential in moving the sustainability agenda forward.

Business models
“We are also looking into new business models in terms of how to reduce or lower the thresholds for investment and minimise the risk for the manufacturers who are looking to be the innovators,” he concluded. Also taking part in the ITA roundtable discussion were Simon Kew (Alchemie Technology, UK), Christian Schumacher (StepChange Innovations, Germany) Tobias Schurr (Weko, Germany), Rainer Tüxen (RotaSpray, Germany) and Felmke Zijilstra (DyeCoo, Netherlands).

European innovations
“It’s fantastic that all of this innovation is taking place in Europe based on established know-how and forward thinking,” said TMAS Secretary General Therese Premler-Andersson.

“Spray application technologies are a perfect illustration of how new digital technologies can lead to more sustainable production, in this case by replacing water-intensive processes with the highly precise and controlled application of dyes and chemistries as vapour.
“There was a major project by the Swedish research organisation Mistra Future Fashion recently, involving many brand and academic institute partners. The project’s Fiber Bible 1 and 2 reports conclude that it’s very difficult to make assumptions that one fiber is better than another, because it’s so much about how fabrics and garments are being produced from them. The study also found that 55% of the chemicals used in a garment comes from the dyeing. This is where a number of TMAS companies can make a difference.
“An organic or recycled cotton t-shirt is not automatically more sustainable than a conventional cotton t-shirt, or even one made from synthetics – the alternative fibers are a good start but you have to consider the entire life cycle of a garment, and that includes the smart technologies in textiles production.
“TMAS members – backed by Swedish brands and advanced research institutes – are playing an active part in pushing forward new concepts that will work, and I have no doubt that digitalisation now goes hand in hand with sustainability for the textile industry’s future.”          

The collaboration between Tonello and denim designer Piero Turk gave birth to a sustainable denim collection, result of a combination of the latest responsible technologies, and created with the most eco-friendly fabrics selected by The Kingpins Show.

“When it comes to working on new developments, we always start from new ideas and the constant research that starts from a concept that becomes reality, by increasingly raising the bar of sustainability,” said Alice Tonello, R&D and Marketing Director of Tonello.

18 exclusive and contemporary denim pieces, result of the premium experience of Piero Turk, and Tonello with its new brand-new finishing process: The Laundry (R )Evolution.

This is a radically new conception thought to simplify and optimize the entire garment finishing process.

It involves only 2 technologies in the entire finishing cycle, reducing waste and optimizing resources: LaserBlaze, and The All-in-One-System. Finally we use Metro, our software that processes real data, in real time to check all laundry consumption, optimizing processing times and improving performance.

The All-in-One System performs all washing operations by integrating 4 sustainable technologies into a single machine: ECOfree 2, which uses ozone in both the water and air; NoStone® for authentic and pumice-free stone-wash effects; UP, for washing processes with at least 50% less water; Core, a nebulizing system improving performance and reducing water consumption.

As a result of The Laundry (R )Evolution, Tonello developed two innovative and patent-pending processes: OBleach and Wake.

OBleach is the new Tonello process, which, by using only ozone, “returns to the future” with an authentic, sustainable and cool Bleach. Without chemicals.
This is possible thanks to a combination of the technologies part of our All-In-One System.
In short, the real Bleach without Bleach has finally arrived. And this in the year of the total ban of permanganate too.

Wake is the first totally natural dyeing system that uses only plants and biodegradable vegetable waste like flowers, berries and roots, without harmful chemicals additives.

The capsule collection will be displayed at KINGPINS24 on October 27th during the seminar held by Alice Tonello and Piero Turk.

The Cetex Institut gGmbH, the thermoPre ENGINEERING GmbH and The FilamentFactory GmbH cooperate in the development, production and marketing of novel hybrid materials. The cooperation agreement signed on October 2, 2020 in Chemnitz takes the collaboration to a new level. "We are pleased to be able to supply the hybrid rovings to the end user not only in an application-specific manner, but also to offer the engineering for subsequent component applications, including the prototyping of the FRP components," says Sebastian Nendel, Managing Director of Cetex.

Patented process for the production of hybrid rovings
In the last 3 years the Cetex Institute has developed a plant technology for the production of hybrid rovings. By means of the patented process, different material combinations can be produced according to customer specifications. Material combinations of reinforcing fibers (glass, basalt, carbon, aramid or high-strength polymer fibers) can be combined with matrix fibers (PP, PET, PA, PPS, PEEK), but also special combinations of different reinforcing fibers or the combination of reinforcing fibers with metal fibers. Advantages of the new hybrid roving are the torsion-free and completely stretched fiber layer and the associated optimal utilization of the properties of the reinforcing fibers, as well as a very good homogeneity, whereby excellent processing can be achieved in later process steps.

Series production as next step
The next goal is clearly defined: Under the agreement, the process is to be jointly developed further by the project partners and transferred to series production. These joint activities form the basis for many years of intensive cooperation in this new field.