From the Sector

• Innovations in Protection, Efficiency and Engineered Fabrics

INDA, the Association of the Nonwoven Fabrics Industry, announced the three finalists for the prestigious RISE® Innovation Award during the 11th edition of the Research, Innovation & Science for Engineered Fabrics Conference, (RISE®) to be held virtually September 28-30, 2021.  The award recognizes novel innovations in the nonwovens industry that creatively use next-level science and engineering principles to solve material challenges and expand the usage of nonwovens and engineered fabrics. These three finalists will present their innovative material science solutions as they compete for the RISE® Innovation Award.

Canopy Respirator
Canopy is an innovative respirator that is fully mechanical, non-electrostatic, with a filter designed for superior breathability while offering the wearer facial transparency. The breakthrough respirator features 5.5mm water column resistance at 85 liters (3 cubic feet) per minute, 2-way filtration, and a pleated filter that contains over 500 square centimeters of surface area. The patented Canopy respirator resists fluids, and eliminates fogging of eyeglasses.  

Evalith® 1000 Series
Johns Manville’s innovative Alpha Binder is a formaldehyde-free, high bio-carbon content, toxic-free binder formulation ideal for carpet mat applications. Alpha Binder eliminates monomer and polymer synthesis, uses a bio-degradable catalyst, and requires 70% less water in manufacturing. The resulting glass mats made of Alpha Binder are named “Evalith 1000” and reduces energy consumption during manufacturing by over 70% compared to alternative petroleum-based binders. Evalith 1000 was commercialized in North America in 2020.

Fiber Coated, Heat Sealable, Breathable, Hybrid Membrane, Fabric Protection
TiGUARD protective fabric is a construction of monolithic or hybrid imperious/moisture eliminating membranes with a surface covered with micro-fiber. This nonwoven product is a multi-layer all polyester fabric specifically for chemical and microbial protective fabrics, products, and garments. It is constructed of compatible heat seal-able materials which lend themselves to high-speed heat seal-able production and ultimately automated manufacture of garments without sewing. It is a combination of a densely flocked polyester fiber surface on polyester membrane supported by polyester scrim.
Virtual RISE™ conference attendees include technology scouts and product developers in the nonwoven/engineered fabrics industry seeking new developments to advance their businesses. These attendees will electronically vote for the recipient of the 2021 RISE® Innovation Award, on Wed. Sept. 29th. The winner will be announced Thurs., Sept. 30th.

The conference program will cover timely and relevant industry topics including: Material Science Developments for Sustainable Nonwovens; Increasing Circularity in Nonwovens; Market Intelligence & Economic Insights; Promising Innovations in Nonwovens; Process Innovations in Nonwovens; Material Innovations in Nonwovens;  the full program can be viewed on the link: https://www.riseconf.net/conference.php

• Combined HCl acid and steam generation enables significant energy savings and increased cost efficiency

SGL Carbon delivered a Hydrochloric Acid (HCl) synthesis unit with integrated steam generation to Travancore-Cochin Chemicals Ltd. (TCCL), a major producer in the chlor alkali business in South India. End of January, TCCL officially inaugurated its plant in Kochi in India’s Kerala state. Since then, the unit has already been ramped up at the customer’s site to full capacity.

The synthesis unit uses the efficient membrane wall technology and has a capacity of 60 tons of HCl per day. As an additional benefit, this innovative design enables the recovery of waste heat generated in the synthesis unit from the reaction of Hydrogen & Chlorine to produce up to 33 tons of steam at the high pressure of 10 bar every day. This steam can be used elsewhere in the chlor alkali plant, for example when concentrating caustic to flakes. As a result, the energy efficiency of TCCL’s plant goes up substantially since a huge portion of their steam demand can be covered by SGL’s unit. Thereby this helps to save costs as well as reduces CO2 emissions by more than 1.500 tons per year potentially.

The HCl synthesis has been completely engineered and produced at SGL’s production site in Pune, India. Scope of supply also included civil modification services at the customer site on a turnkey basis.

 “Our innovative combined HCl synthesis and steam production units offer a great business value to our customers in the growing Indian chemical market. Together with our proven technical and engineering competence on a global scale we can help our customers to enhance their energy efficiency as the example of TCCL shows”, comments Suneet Sangam, Sales Manager at SGL Carbon India.

“By engineering and producing our units also at SGL’s production site in India, we further strengthen our position as a global process solution provider for corrosive applications leveraging our extensive expertise from our worldwide network. Realizing such ambitious projects in these challenging times of Covid restrictions shows how capable our global team is.“ says Christoph Koch, Director Sales EMEIA at SGL Carbon.

With zwissCLEAN® masks, zwissTEX is a pioneer among manufacturers of antiviral and antibacterial oronasal masks. Unlike conventional models they actively and highly effectively eliminate viruses and bacteria thanks to the latest textile technologies. This is made possible by an environmentally friendly finishing that foregoes the use of silver and zinc. "The formula physically interrupts the cell membrane of the viruses and bacteria - so no development of resistance is possible. In this way 99.9 percent of viruses and bacteria are eliminated within a very short time," says Maximilian Schönfließ - Business Development Manager of zwissTEX.

The zwissCLEAN MASK BASIC is particularly suitable when a mask is to be worn over a longer period of time - whether for school, concerts, trade fair visits or air travel. "The special feature of our zwissCLEAN MASK BASIC is that it can be worn for up to 12 hours without any problems due to the breathable material", says Schönfließ. "With it even sleeping is possible. And unlike disposable masks it can be washed up to 10 times at 30 degrees. Disposal by type is also possible".

The zwissCLEAN MASK COMFORT is recommended for daily protection at shopping, on public transport, at business appointments or similar events. It consists of a three-layer structure and combines efficient antiviral protection with long-term wearing comfort. The outer material and the integrated fleece promote protection against viruses and bacteria. The lower material made of organic cotton guarantees a lasting pleasant feeling on the skin. The mask can be washed up to 30 times, thus replacing up to 210 disposable masks and saving resources sustainably.

• Gorilla Protect is a new company formed in May this year to promote the Catus face mask – a major leap forward in the effectiveness of personal protection products that are available to consumers in the fight against Covid-19.
• Behind Catus and the new company is Nova Textil, the established fabric finishing company based in Grefrath, Germany, and now run by father and son team Rainer and Oliver Hurtz.

Single stenter

Rainer Hurtz founded Nova Textil with a single Monforts Montex stenter and just five employees in 1999 and has steered its constant development and growth over the past twenty years.

“Our initial focus was on the coating of mainly glass fibre fabrics, awnings and sun protection products for outdoor furnishings,” he said. “We had a great customer who was providing us with so many orders that by 2005 we took the decision to order a second Montex stenter, in a special configuration. This also allowed us to enter the market for blackout and digital printing fabrics. We’ve had a great ongoing relationship with Monforts from the beginning.”

A third Montex stenter line was installed at the company’s Grefrath plant in 2015, by which time the company had grown to 40 people and a major new market had opened up in the supply of fabrics for promotional materials at exhibitions and trade shows.

“We had a fantastic two years in 2018 and 2019 and everything was going great for the first three months of this year, but in April it all came crashing down,” said Oliver Hurtz. “Coronavirus put an end to trade shows in 2020, which had a very serious impact on our business.”

At the same time, however, the company was exploring the potential of a new biocidal product from one of its chemicals suppliers which has both antiviral and antimicrobial properties.

Filtration

“We had already been producing coated fabrics for hot gas filtration and realised that in combination with this new microporous coating we had the basis for a very effective single-layer face mask,” Rainer said. “Achieving this with a single layer product rather than the usual three has resulted in a significant advance in comfort for the wearer and because the mask is able to disinfect itself and helps regulate humidity, it can be worn a number of times without needing to be washed, for greater convenience. It only needs to be washed when it gets dirty and can also be washed up to twenty times without losing its properties, which has to be preferable to single-use disposables.”

Catus face masks are based on 100% woven cotton and the active ingredients in the finish are a reaction mass of titanium dioxide and silver chloride certified to ISO 20743 for their antibacterial effect, and to ISO 18184 for their antiviral effect.

They are proven to  eliminate over  99.99% of the human coronavirus 229 E, with the multiplication of microorganisms such as germs and bacteria prevented by the biostatic action of silver salts and viruses destroyed by oxygen-releasing substances and a mechanism that attacks their fatty envelope. The virus membrane loses its cholesterol content and the virus is inactivated.

Colours

Gorilla Protect next plans to make the masks available in four colours – black, Bordeaux, olive and grey – and is also working on colour branding and printing labels.

“It’s not possible to print on the surface of the mask after it has been coated, but its is possible for volume orders to be printed before the treatment,” Oliver Hurtz said.

“Face masks are going to become an established part of life in the West like they are in Asia and need to be as comfortable and convenient as possible for the wearer,” his father concluded. “With these things in mind, we believe Catus is a significant step forward.”

Mexico and Switzerland - SANITIZED customers in the polymer industry in Mexico will profit from CHEMLOGIS’s expertise and established sales network. The Sanitized® antimicrobial additives for hygiene function and material protection for polymers will be marketed in Mexico by our new sales partner.

SANITIZED and CHEMLOGIS, two experts in their fields with similar understanding of values, have joined forces; both deal in high-performance products for the Polymer industry combined with the best possible service, which begins with the conception of value-added products and their optimum use. This collaboration with SANITIZED is a good fit for the portfolio as both companies focus on innovative, customer-specific solutions.

With the addition of the antimicrobial Sanitized® additives at CHEMLOGIS, the Polymer industry gets a new overall package, offering more than just products for hygiene function and material protection. As an addition to the core product services, SANITIZED supports development and production, regulatory queries and marketing through the use of the Sanitized® Ingredient Brand, which characterizes the end products within their differentiation and emphasis on quality.

The antimicrobial additives for Polymers from SANITIZED protect end products from bacterial infestation, growth of algae and mildew, material degradation, biofilms, pink stain, and odors caused by microbes. The Polymer industry uses the antimicrobial additive in flooring, industrial coatings, artificial leather, roof membranes, pool liners, tarpaulins, and all extruded products.

“Everyone at CHEMLOGIS is very excited to partner with SANITIZED for the sale of their antimicrobial products to the Polymer processors in Mexico. Together we bring a highly focused approach to customer´s needs in terms of technology service and products” says CHEMLOGIS’s CEO Ing. León Freiman K.” “The technical competence and the strong customer focus impress me about CHEMLOGIS”, says Michael Lüthi, Head of BU Polymer at SANITIZED AG.

• RUDOLF GROUP is thrilled to unveil the perfected antiviral features embedded in RUCO®-BAC AGP, the Company’s flagship antimicrobial product for textile applications.

As a consequence of COVID-19 global pandemic the demand for chemical auxiliaries with antimicrobial effect has boomed. RUDOLF GROUP invested important resources in the meticulous assessment of a new antiviral feature which is now added to one of their leading technologies .

Such an effort returned the surprisingly fast and most comprehensive antibacterial and antiviral textile finishing on the market: RUCO®-BAC AGP.

History has led to great vision and innovation

The powerful antimicrobial effectiveness of RUCO®-BAC AGP is rooted in the extraordinary properties of silver, whose antimicrobial magic is lost in the mists of time. Already known by the ancient Romans, Greeks and Egyptians, water and milk were preserved by using silver coins through the early modern age.

R&D at RUDOLF GROUP has mounted silver on highly sophisticated, functional and registered microstructures that strengthen and amplify the qualities of this noble metal.

RUDOLF’s proprietary microstructures are the responsible hidden secret and key technical breakthrough behind both efficacy and durability of RUCO®-BAC AGP. This innovation is now the preferred solution to help reducing proliferation and cross-contamination of bacteria and enveloped-virus on textiles.

One gram of microstructures has the astonishing superficial area of about 60 m². The advantage of a much higher surface is that the consumption of resources and dosages can be minimized by the factor 100 and that makes RUCO®-BAC AGP a highly conscious choice.

“Due to the microstructures, a virtually infinite protective shield is created in the textile from which highly effective positive silver ions are set free in small, exactly dosed quantities” says Dr. Dirk Sielemann, R&D Director at Rudolf Group.

Taking performance to the next level

RUCO-BAC AGP effectively protects any textile against bacteria (harmful and odour-causing) and its superior antiviral performance on textiles has been independently demonstrated by applying the most modern testing methods. Assessments were carried out on enveloped Coronaviridae families known to cause a broad spectrum of animal and human diseases.

The microstructures in RUCO®-BAC AGP trigger their powerful antibacterial and antiviral effects based on 3 distinctive inhibiting mechanisms:
1.    Blocking of oxygen-transporting enzymes therefore leading to impaired growth;
2.    Crushing of disulfide bonds and therefore structure of sulphur-containing proteins.
3.    Possible interference with Bacteria and virus surface protein in the membrane.

RUCO®-BAC AGP is intended for the protection of the treated textiles and the microstructures of RUCO®-BAC AGP were studied thinking of performance and safety. It is suitable for next-to-skin applications and cytotoxicity tests show that RUCO®-BAC AGP has no influence on the natural microflora of the skin. Furthermore, because of the adhesion mechanism of its microstructures, RUCO®-BAC AGP is only active in/on the textile and it is non-migrating. 

“This year 202o is being highly emotional and it’s leading to the widespread introduction of antimicrobials on textile and to a myriad of vague, misleading or unsubstantiated marketing claims”, states Dr. Gunther Duschek, Managing Director at RUDOLF GROUP. He concludes “As a highly responsible company, we move cautiously and stand for technologies and practices that are effective, truthful and limit the exposure of apparel manufacturers, retailers and buyers to any risk”.

Myant Inc. and Osmotex AG have agreed to enter into a joint venture for the commercialization of Osmotex’s HYDRO_BOT active membrane technology across various textile-based applications. The integration of HYDRO_BOT with Myant’s existing portfolio of textile-based sensing and actuating capabilities opens up new possibilities across a wide range of domains including sweat/moisture management and thermal regulation.

HYDRO_BOT technology is capable of moving 200 liters of fluid across a square meter of textile every hour via an electroosmotic process, providing a practically limitless ability to manage moisture in textile applications. Applied in conjunction with Myant’s existing capability to deliver heat via textile and to achieve effective passive moisture wicking via novel knitted structures, the combination of technologies is poised to dramatically improve the ability to regulate body temperature in applications such as personal protective equipment for workers in heavy industry, protective gear for workers in hot desert-like climates, performance wear like snow suits or skiing apparel in cold climates, footwear, motorcycling apparel, and more. In addition to apparel, significant market opportunities exist in the moisture management as applied to the automotive industry and in the healthcare industry.

“The creation of this joint venture between Myant and Osmotex reinforces our mission to develop textiles as bidirectional interfaces to the human body capable of optimizing health and performance across all spheres of life,” said Tony Chahine, founder and CEO of Myant. “Our team is excited to begin integrating HYDRO_BOT into our textiles and bringing this transformative technology to market.”

“We are excited to be working together with Myant to realize the full potential of the HYDRO_BOT technology,” said Joacim Holter, Managing Director and Chairman of the Board for Osmotex AG. “Myant’s ability to integrate our technology and to produce at scale all under one roof made them an ideal partner to help make our vision a reality.”

wear2wear is an innovative industrial partnership dedicated to high-quality and sustainable clothing. Five expert partners in Europe have come together to cover the entire recycling loop. On cutting-edge production systems, textile fibres from used clothing will be turned into functional fabrics. Schoeller Textil AG is supplying a wholistic textile portfolio for the workwear area. At Schoeller Textil, the recyclable, functional fabrics from the wear2wear concept belong to the Inspire fabric group. These are high-quality protective workwear fabrics made of 100 percent polyester, which offer the greatest clothing comfort and often feel just like cotton. They are also compliant with the stringent requirements of the bluesign® system.

The sustainable wear2wear concept is synonymous with high-quality, responsible clothing. In European operations, textile fibres from used garments are used to produce new functional fabrics. Depending upon the area of intended use, they also meet strict waterproofing, breathability, protection and comfort requirements. To ensure that the raw material cycle comes full circle, these textiles can be recycled again when they reach the end of their service life. As a result, there is no waste, and they go on to produce new garments. As the wear-2-wear partner companies guarantee that – from the quality of the raw materials to the guaranteed recycling end process – these are 100 percent recyclable, functional fabrics made of recycled textile fibres. Water- and dirt-repelling technologies based on renewable raw materials, along with the most advanced membrane technology, will ensure that the textiles are manufactured and impregnated entirely without the use of PFC in the future too.

Five partner companies  
The five European partner companies in the wear2wear cooperation cover the entire recycling loop. Heinrich Glaeser Nachfolger GmbH is a German fibre and yarn producer and the “recycler” in the loop. Märkischen Faser GmbH (D) is the “upcycler” and fibre manufacturer. Carl Weiske GmbH & Co. KG (D) develops the polymers, fibres, yarns, chemical additives and textile systems, and TWD Fibres GmbH (D), a fully-integrated filament yarn producer, covers the entire range of polyester and polyamide 6.6 continuous filament yarns. Schoeller Textil AG, the innovative Swiss company, is responsible for textile production and manufactures sustainable high-tech fabrics with maximum clothing comfort. The matching climate-neutral and similarly 100 percent recyclable PTFE and PFC-free membrane, as well as recycled outer materials and linings, are supplied by Sympatex Technologies (D), the ecological alternative among the textile function specialists. DutchSpirit is a Dutch company which has been dedicated to environment-friendly clothing since 2010. Its mission is to significantly increase the awareness for sustainable clothing and offer recyclable clothing in the workwear segment. DutchSpirit is the initiator for the development of the Inspire products from Schoeller Textil and provided the inspiration for the wear2wear concept. Further garment-making partners who now also belong to the cooperative group include: Anchor Workwear BV (NL), Hüsler Berufskleider AG (CH), Groenendijk Bedrijfskleding BV (NL), Bedrijfskledingdiscounter BV (NL) and Rifka'S (NL).

Koch Membrane Systems (KMS), a global leader in the development and manufacture of membrane-based filtration technologies, announces the commissioning of a PURON® PLUS packaged MBR system in Saskatoon, a city within the province of Saskatchewan, Canada.

The PURON® PLUS system provides a compact and turnkey wastewater treatment solution that is fully automated and provides consistent high-quality effluent for safe discharge or reuse.
 
Due to Canada’s challenging climate and dispersed populations outside of city areas, simple and reliable decentralized treatment systems are often preferred to treat municipal wastewater streams. As a differentiated membrane and system provider, KMS has been selected for this project due to their ability to provide a comprehensive solution with market leading technology.
 
For this project, KMS partnered with Proteus Water Inc., a Canadian company focused on providing integrated wastewater treatment solutions for small communities.
 
“We decided to go with KMS modules due to their reliable, compact and efficient MBR solutions,” said Jason Tratch, president and CEO of Proteus Water. “Compact MBR systems are the only answer for the small municipalities in Canada, meeting the financial expectations as well as the technical challenges. The PURON® PLUS system featuring PULSION MBR membranes is here with a very promising solution due to its increased efficiency and its decreased footprint.”
 
Capable of treating an average design flow of approximately 100,000 gpd (375 m3/d) of municipal wastewater, the PURON® PLUS P-100 system selected for this project features KMS’ latest innovative and patented PULSION® MBR technology. The benefits of PULSION® MBR offer best in class reliability and productivity with the lowest energy consumption.
 
“The efficiency and the reliability of MBR systems has been proven in thousands of places all over the world and it will be the best applicable solution for the Canadian market,” said Jack Noble, general manager Water and Wastewater (EMEA) of Koch Membrane Systems.

As the countdown to the 2018 edition of Cinte Techtextil China enters its last two months, the final exhibitor line-up is starting to take shape. A number of leading international and Chinese brands across the fair’s 12 product application areas will feature at the Shanghai New International Expo Centre from 4 – 6 September, with an expected 500-plus total exhibitors from around 20 countries & regions set to feature.

Nonwovens exhibitor highlights

As the fair’s largest product category, buyers have a wide range of domestic and overseas brands to source from, including:

• Johns Manville (US): who will showcase their polyester spunbond, PP & PBT meltblown, glass fibre nonwoven, micro glass fibre nonwoven, hybrid nonwoven, glass fibre needle mat and glass microfibre product lines among others at the fair.
•  J.H. Ziegler (Germany): with over 150 years’ expertise and their own production plant in China, they offer products for acoustic absorption in automotive interiors and exteriors, nonwoven foam composites for leather lamination, needle-punched nonwovens, foam nonwoven composites, laminated nonwovens and natural-fibre nonwovens.
• KOBE-cz (Czech Republic): a new exhibitor to the fair, their nonwoven fabrics, mainly made from glass fibre with temperature resistance up to 800°C, are used for high-temperature isolation in the automotive, marine, energy and building industries. They also have isolation materials made from natural fibres including hemp, wool, cotton and flax.
• TDF Nonwovens (China): one of the leading domestic brands, their specialties are polyester spunbond geotextiles, polyester filament roofing carriers, filter nonwovens, high-strength coarse denier polypropylene spunbond geotextiles and medical & health nonwovens.
• Kingsafe (China): they specialise in the production of fusible interlining and nonwoven fabrics for high-end garments.

Yarn & fibre exhibitor highlights

• Perlon (Germany): has developed a PET based monofilament, HighGrip, which guarantees long-lasting efficiency of conveyor belts, and is available in various types with different tribological characteristics, which they will feature at the fair.
• Sateri (China): is a global leader in viscose rayon made from 100% dissolving wood pulp, and the largest maker of viscose fibre in China. Their natural and high-quality fibre, made from trees grown on renewable plantations, can be found in textiles and skin-friendly hygiene products.
• Cordenka (Germany): producers of industrial rayon, their product range covers rayon tire cord, yarn, single-end dipped cord, short-cut fibre and more.
• EMS-Griltech (Switzerland): will showcase a range of technical fibres & yarns and thermoplastic adhesives at the fair.
• Barnet (Germany): several finished products (nonwovens, spun yarns and fabrics) made with their specialty fibre will be on display at the fair, including OPAN, para-aramid and carbon filament fibres. The application of their specialty fibre in flame retardant and anti-cut gloves and felts will be shown at their booth for the first time.

Coated textiles & solutions exhibitor highlights

• Stahl (the Netherlands): the Dutch company will present new products from their water repellent and flame retardant ranges at this year’s fair. According to the company, as the Chinese government continues its efforts to clean up the environment, eco-friendly chemicals remain in strong demand in the country.
• Sioen (Belgium): will showcase sign materials, truck tarpaulins, tents, membrane fabrics, apparel products, chemicals and specialty products such as inflatable boat fabrics, pool liners and more at Cinte 2018.
• ROWA Lack (Germany): a new exhibitor at this year’s fair, they will present their special lacquer systems and top coatings.
• Trelleborg (Sweden): also a new exhibitor, they will display engineered textiles, especially in the fields of outdoor, medical, protective and automotive.
• FPC Technical Textile (Saudi Arabia): another first-time participant at the fair, they will showcase a range of high-end specialty fabrics including PVC coated fabrics and fibre glass PTFE fabrics.
• Zhejiang Jinda New Materials (China): this supplier is known for its coated textiles for industrial, transportation and building uses, as well as warp knitted geo-synthetic materials and printable coated materials for advertisements.

Lenzing to showcase its new VEOCEL nonwovens specialty brand at the fair

First announced in June this year, and featuring at Cinte Techtextil, Lenzing’s new VEOCEL brand is billed as a premium range of nonwovens fibres for daily care, which “provides the nonwovens industry with fibres that are certified clean and safe, biodegradable, from botanic origin and produced in an environmentally responsible production process.” Products in this range can be applied to a multitude of uses including baby care, beauty and body care, intimate care and surface cleaning, under the VEOCEL Beauty, VEOCEL Body, VEOCEL Intimate and VEOCEL Surface brands.