From the Sector

Staggered in terms of timing and with varying magnitude, the global spread of coronavirus is impacting the development of the regional economies in the core markets of the Manmade Fibers segment of the Swiss Oerlikon Group.
The sales markets for manmade fiber systems and equipment have been primarily located in China, India and Turkey for many years now. Together, these markets – above all China – make up the lion’s share of the project landscape at Oerlikon Manmade Fibers. And this is paying positive dividends at the moment. Because the production facilities of the major manmade fiber manufacturers in
China have been systematically fired up again over the past few weeks, with capacity utilization increasing consistently.

Going against the flow
The Segment CEO, Georg Stausberg explains the reason: “Long before the coronavirus situation developed, the major manmade fiber manufacturers in China had decided to reverse-integrate their production chains to include petrochemicals in order to expand their portfolios with targeted investments, to reduce their dependence on a ,single product’, to optimize their costs and ultimately to acquire greater control over margins in a global volume business”.
Similar processes and decisions – albeit not on the same scale as in China – have also
been detected at the large manmade fiber manufacturers in India and Turkey. Even though businesses in India and Turkey are presently still temporarily severely impacted by the coronavirus situation, their long-term commitment cannot however be questioned, as the company-internally-agreed plans will be systematically implemented moving forward.

Long-term investments of global market players
All this has recently resulted in increased demand for spinning and texturing systems – just like those supplied by total solutions provider Oerlikon Manmade Fibers with its
Oerlikon Barmag, Oerlikon Neumag and Oerlikon Nonwoven product brands.
“The investments in petrochemical systems are based on long-term strategic considerations and are resulting – even during the coronavirus pandemic – neither in short- and medium-term economic dips, nor in changed customer behavior. (...)”, states Segment-CEO Georg Stausberg.
As a result of Oerlikon Manmade Fibers delving into the digital age years ago, the segment has experienced the intensive and short-term benefit from all the measures, in part also in its processing of customer projects.

Technology transfer that is creating waves

For more than a decade now, the Manmade Fibers segment of the Swiss Oerlikon Group has been hosting a comprehensive technology symposium at the beginning of each year in the Indian region around Silvassa/Daman. Numerous Indian manmade fiber producers have settled in this area, around a four-hour drive north of Mumbai. Fed from Oerlikon polycondensation and extrusion systems, these companies manufacture polyester, nylon and polypropylene on large-scale installations with Oerlikon Barmag WINGS POY, WINGS FDY, IDY and DTY product lines and using Oerlikon Neumag’s staple fiber and BCF technologies. Reason enough for the Manmade Fibers segment’s experts to regularly provide their clientèle with detailed specialist presentations in India on the latest developments of the product and service portfolio.

And this was once again the case at the event held at the beginning of 2020, where around 450 managers and employees from local businesses took the opportunity to exchange ideas and information. For the third time in succession, Oerlikon also entered into dialog with the next generation of managers at major Indian polyester and nylon manufacturers in a separate event hosted in Mumbai beforehand. The technology symposium was again held – for the very first time – just a few days later and in a slightly modified form at a second venue: in Kolkata in West Bengal, a potential second future key location for manufacturing manmade fibers in India according to plans revealed by the Indian government. Here, the discussions held by the Oerlikon experts focused above all on the transfer of technologies for manufacturing polyester, nylon and polypropylene. Oerlikon is able to offer the entire process chain – from the melt to the textured yarn or the fibers and including the necessary semi- and fullyautomated logistics process – from a single source. This is of interest above all for potential new customers and investors in West Bengal and neighboring Bangladesh, as some do not have decades of expertise in manufacturing manmade fibers, as is the case for most companies in the region around Silvassa/Daman.

Monforts Textilmaschinen GmbH & Co. KG will be providing information on its extensive range of coating and finishing technologies for the production of nonwovens and technical textiles at the forthcoming Techtextil India exhibition.

“India is already a very important market for Monforts and there are exciting prospects ahead for Indian manufacturers of technical textiles, who are well positioned to capitalise on growth opportunities,” says Monforts Head of Denim Hans Wroblowski, who will be at the Monforts stand in Hall 4, booth C52 at the show. “India has one of the largest working-age populations in the world and a complete textile value chain for both natural and synthetic fibres.”

In addition, he adds, India’s government, through its Ministry of Textiles, has been actively promoting the growth of technical textiles through various programmes based on investment promotion, subsidies, the creation of infrastructure and the stimulation of consumption.

As a result, India’s Ministry of Textiles is forecasting that the growth of technical textiles in the country will be over 18% annually in the next few years, from a value of US$16.6 billion in 2018 to US$28.7 billion in 2021.

Value addition

High value-added technical products such as wide-width digital printing substrates, carbon fabrics for high-performance composites, filter media, flame retardant barrier fabrics and heavy-duty membranes are now being coated on Monforts texCoat ranges and finished with the company’s industry-leading Montex stenters.

“Since we acquired the technology that our coating units are based on in 2015, we have made a lot of refinements,” says Hans. “All of these developments are reflected in higher coating accuracy and the resulting quality of the treated fabrics. At the same time, our latest multi-functional coating heads offer an unprecedented range of options, with a wide range of modules available.”

The texCoat user interface is now equipped with the unique Monforts visualisation system and the magnetic doctor blade has greater power reserves. Options include a carbon fibre-reinforced composite coating drum with a more scratch-resistant surface and maximum rigidity and remote control which simplifies exact adjustment for the operator.

Montex stenters in special executions are meanwhile ideal for the drying and finishing of both technical woven fabrics and nonwovens and characterised by high stretching devices in both length and width.

“The European-built Montex range of stenters has earned its leading position in the technical textiles market due to the overall robustness, reliability and economy of these machines,” Hans concludes. “Whatever the intended end-product – and we continue to discover potentially new areas in which technical textiles can be utilised all the time – we have the machine specification and know-how to turn ideas into reality. In India we also benefit from the strong sales and service support of A.T.E. Enterprises.”

Texchtextil India takes place alongside World of Composites at the Bombay Exhibition Centre in Mumbai from November 20-22.

• Clean Technology. Smart Factory.

Remscheid – Oerlikon invites all visitors to this year's ITMA in Barcelona on a journey into the future of manmade fiber production. From 20 to 26 June 2019, the world market leader will show all its guests its vision of a sustainable and automated manmade fiber production in a virtual 4D showroom at its 1,000 m² stand in Hall 7, A101: "Clean Technology. Smart Factory." is the motto of the future. And this is only a stone's throw away from reality at the stand. Because today Oerlikon is presenting four world premieres for efficient machine and plant concepts in a new, innovative industrial design. Together with numerous other innovations, all this forms the new DNA of the Oerlikon Manmade Fibers segment.

The challenges for the manmade fiber industry are manifold and Oerlikon shows its customers solutions:

1. Choosing the right business model
Price pressure on fiber and yarn manufacturers is growing due to global market consolidation. Here it is important to position oneself correctly. Are you producing polyester, nylon or polypropylene for the niche market and skimming off good margins with innovative products and ingenious material properties, or are you looking for business success through economies of scale in the volume market such as the constantly growing apparel sector? Oerlikon has the right answers for both business models. And the most important thing: the market leader supplies all solutions from a single source. See for yourself at the world premieres of the machine and system concepts of WINGS FDY PA6, BCF S8 Tricolor and the revolutionary eAFK Evo texturing machine.

2. Finding alternatives for good personnel
Finding good operators in the manmade fiber industry is becoming increasingly difficult, even in emerging industrial nations such as China, India and Turkey. The solution is obvious. What, for example, the automotive industry achieved years ago with the 3rd Industrial Revolution is now also taking its course in the textile industry. And at the same time it is even shifting up a gear. In the next step, automation in combination with digitization will lead to new, sustainable production. Oerlikon will be showing how automation and digitization interact at ITMA. Self-learning machines and systems, artificial intelligence (AI), remote services and edge computing are just a few of the key words in the digital half of the new Oerlikon Manmade Fibers DNA.

3. Guarantee quality and traceability
The qualities of the fibers and yarns must meet the highest demands and their production must be traceable throughout the textile value chain. This no longer only plays an important role in the automotive industry, where safety is of paramount importance. Other branches of industry that use fibers, yarns and nonwovens also want to know where the raw materials they produce for consumer articles come from. Legal regulations are demanding this more and more frequently. Oerlikon offers optimal solutions with its DIN ISO certified manufacturing processes. More than half of the world's manmade fiber producers are convinced every day that the qualities produced on Oerlikon Barmag, Oerlikon Neumag and Oerlikon Nonwoven equipment are right – and all visitors to ITMA can do the same on site.

4. Efficient and sustainable production
In the future, the materials produced from manmade fibers must become part of a further improved global recycling economy. The recycling of polyester – with over 80% market share the most frequently used manmade fiber in the world – has not only been on the agenda since today. Oerlikon already has solutions at hand: from PET bottles to fibers and filaments, to textiles and carpets. ITMA is the next step. With the VacuFil® Oerlikon in cooperation with the subsidiary company BBEngineering presents the world premiere No. 4 – a recycling solution within a running polyester production with a waste-free approach.

Vision becomes reality
The Oerlikon Manmade Fibers segment thus demonstrates what the ITMA in Barcelona promises as the world's leading trade fair for textile machinery and plant construction: "Innovating the world of textiles – sourcing for a sustainable future". In Hall 7, A101, this is already reality.

Hexcel is exhibiting at the Aero India show for the sixth time, continuing to support customers in the Indian subcontinent and throughout Asia. This year’s show takes place in Bangalore from February 20-24 (Stand AB2.5D, Hall AB) to promote a range of carbon fibers and composites that are benefiting Indian aerospace manufacturers for commercial aircraft, helicopters and space programs.

To coincide with the show, Hexcel is announcing the opening of its new sales office, Hexcel Composites India LLP. The office is located in Bangalore and will be fully operational in March 2019. Mr Vijay Sharma, Sales Manager, and Mr Ram Kumar, Technical Representative, will manage the sales activities and support key customers in the region.

Hexcel has supplied carbon and glass fiber fabrics, prepregs, honeycombs and adhesives to Indian aerospace companies for more than 28 years, including Hindustan Aeronautics Ltd (HAL), National Aerospace Lab (NAL), Indian Space Research Organisation (ISRO), Vikram Sarabhai Space Centre (VSSC) and TATA Advanced Materials.

Hexcel’s high strength and intermediate modulus carbon fiber range has been augmented by the launch of HexTow® HM63, a high modulus carbon fiber that has the highest tensile strength of any existing HM fiber. HexTow® HM63 provides outstanding translation of fiber properties in a composite, including superior inter-laminar shear and compression shear strength. HexTow® HM63 is therefore ideal for any high stiffness and strength-critical applications including space, satellites, UAV, commercial aerospace and helicopters.

India is a very important market for the German textile machinery industry, with an export of more than €255 million (+ 8 %) in 2017. Many German machinery builders have longstanding relations with Indian customers and quite a number of them also provide production plants and training centres in India. Not surprisingly, about 370 decision-makers and experts from the textile and nonwoven related industry attended the VDMA conference and B2B event called “German Technology meets Indian Textiles and Nonwovens” in Mumbai on 15-16 May 2018 (www.germantech-indiantextile.de).

According to a survey, both the event and German textile machinery engineering received the highest marks among the visitors. About 57 % of the visitors stated very good and 38 % good experience with machines and components from German suppliers. The performance and service promise as well as the high-quality standards have made German machine suppliers as most reliable partners in India and other countries. This positive result has by far not been reached by any other manufacturing nation from Europe or Asia. Asked for future processes, investments in technical textiles and/or nonwoven production seem to be the most favorite sectors in India. Around 74 % of the visitors plan to expand their production capacities with new machines and components whereas 26 % intend to replace old machinery by new machines and components. High productivity, after-sales service, end-product quality, low operating and acquisition costs are the decisive machine procurement criteria in this order. The investments plans are based on a positive business and investment outlook in India. 45 % of the visitors surveyed plan to invest more than 10 % within the next 12 months and 30 % up to 10 %. 25 % of the visitors expect a sales increase by more than 10 % for the next 12 months and 60 % anticipate a sales growth of up to 10%.

Considering this positive business climate and the high interest from the Indian industry, the 32 well-known VDMA members participated in the conference have good chances to offer the right technologies and to place new orders. The presented technology topics along the entire textile value chain will help the Indian industry to fulfill their expansion plans and to meet the challenges such as rising salary costs and shortage of labor in industrial regions. The major cutting-edge topics of the conference program were as follows:

•    Higher profits throughout the entire textile value chain
•    Energy, material, water and dyestuff savings for an environmentally friendly production
•    New applications such as technical textiles, nonwovens (e. g. hygiene products) or home textiles (e. g. terry towels)
•    Automation, industry 4.0, digital communication and smart factory solutions
•    Quality improvements e. g. with measurement and control systems
•    Lower investment costs in spinning preparation with integrated draw frames
•    New technologies to combine spinning and knitting
•    Smart textiles and added value products e. g. with embroidery machines

Whereas the event on 15-16 May 2018 focused on customers, a training session at the prestigious Veermata Jijabai Technological Institute VJTI in Mumbai on 17 May 2018 was addressed to future engineers. More than 220 textile manufacturing and mechanical engineering students followed the technical presentations. The VDMA's contribution to improve the education of future customers and partners was very much appreciated.

Huntsman Textile Effects has been named winner in the 2016 Dyestuff Manufacturers Association of India (DMAI) Awards. Huntsman bagged two awards in recognition of its ‘Excellent performance in exports of Dyestuffs by a large scale unit and ‘Excellent performance in Pollution Control by a Large Scale Unit’. The accolade is presented for outstanding contribution in supporting environment, health and safety and sustainability for the textile industry.
The awards were presented at the 67th Annual General Meeting of DMAI in Mumbai. Huntsman Textile Effects received the awards based on criteria such as innovation, creativity, development and quality.
“We are honored to receive the prestigious awards and are grateful to be recognized again this year,” said Nipun Soni, Site Manager for Huntsman Textile Effects’ Baroda plant. “This acknowledgement reaffirms Huntsman Textile Effects’ focus on innovation and continuous improvement in safety and hazard controls to meet industry demands. We continue to draw on the expertise of our people and established processes in product stewardship.”

Winners of the DMAI awards 2016 were determined by judging panel from chemical, pharma, dyes and dye intermediates manufacturing industries, among others. The DMAI ceremony was held in Mumbai on July 7, 2017.
This is the second consecutive year Huntsman Textile Effects has been presented DMAI Awards. Last year Huntsman was presented with awards for ‘Excellent Performance in Exports of Dyestuffs by Large Scale unit. Huntsman Textile Effects also won the award in the category for ‘Excellent Performance in Safety & Hazard’s Control by a Large Scale unit’.