From the Sector

Perlon® – The Filament Company, a manufacturer of synthetic filaments headquartered in Munderkingen, Germany, celebrated the opening of its new plant in Goa, India. The event marked a significant milestone in Perlon®‘s global expansion strategy and underlines the company’s commitment to growth and innovation.

The plant in Goa was made possible by the recent acquisition of Shaun Filaments, a renowned Indian manufacturer of filaments. The integration of the Shaun Filaments production facility into the Perlon® Group not only offers the opportunity to strengthen market presence, but also to expand capacities and improve production processes.

The Perlon® plant in Goa will play a key role in the production of synthetic filaments for various industries, including paper, technical textiles, brushes, cosmetics and dental care. The acquisition of Shaun Filaments brings not only experienced professionals but also established production lines and technologies to the company.

Florian Kisling, CEO of Perlon®, expressed his enthusiasm about the successful purchase: “The opening of this plant in Goa is a crucial step in our global growth strategy. We are proud to strengthen our presence in Asia while delivering the quality and innovation that Perlon® is known for worldwide.”

Fibre Extrusion Technology Limited (FET) has been awarded £50,000 of grant funding to collaborate with the University of Manchester on complex spin pack and spinneret designs. This funding will provide FET with access to the expertise of four universities and the National Physical Laboratory to develop the next generation of machinery.

The grant is awarded by a consortium led by AMPI (The Advanced Machinery and Productivity Institute) and NPL (The National Physical Laboratory). AMPI’s Innovation for Machinery (I4M) programme supports businesses in West Yorkshire and Greater Manchester as part of an overall initiative to drive innovation for the UK’s advanced machinery manufacturers to meet the challenges of developing new technology and entering emerging markets.

In this project, FET will be working with the University of Manchester to conduct computational fluid dynamics (CFD) studies on a number of complex spin pack and spinneret designs. The aim of this work is to identify areas of improvement for FET’s spin packs and spinnerets and to use computer aided designs to develop significantly more efficient versions. The goal is that the research will improve the throughput of FET extrusion systems, thus reducing the amount of polymer lost through inefficient flow paths. This development, in turn, will reduce the environmental impact of synthetic polymer processing.

FET designs, develops, and manufactures extrusion equipment for a range of high value textile material applications worldwide. Established in 1998, FET’s major strength has always been to collaborate with customers in testing, evaluating and developing high value materials with diverse, functional properties. Efficiency and sustainability are key, so enhanced development of spinneret technology will contribute significantly to these objectives.

Carbon fiber-reinforced polymer lamellas are an innovative method of reinforcing buildings. There are still many unanswered questions regarding their recycling, however. A research project by Empa's Mechanical Systems Engineering lab is now set to provide answers. Thanks to the support from a foundation, the project could now be launched.

The construction sector is responsible for around 60 percent of Switzerland's annual waste. The industry's efforts to recycle demolition materials are steadily increasing. Nevertheless, there are still end-of-life materials that, for the time being, cannot be reused as recycling would be too time-consuming and expensive. One of these are carbon fiber-reinforced polymer (CFRP) lamellas.

Making buildings "live" longer
The reinforcing method developed by Urs Meier, former Empa Director at Dübendorf, has been used in infrastructure construction for 30 years. CFRP lamellas are attached with epoxy adhesive to bridges, parking garages, building walls and ceilings made of concrete or masonry. As a result, the structures can be used for 20 to 30 years longer. The method is increasingly being applied worldwide – mainly because it massively improves the earthquake resistance of masonry buildings.

"By significantly extending the lifespan of buildings and infrastructure, CFRP lamellas make an important contribution to increasing sustainability in the construction sector. However, we need to find a way how we can further use CFRP lamellas after the buildings are being demolished," explains Giovanni Terrasi, Head of the Mechanical Systems Engineering lab at Empa. To achieve this, he wants to develop a method for recycling CFRP lamellas. Convinced by this idea, a foundation supported it with a generous donation. The project officially launched in October.

Gentle separation
First, a mechanical process will be developed to detach the CFRP lamellas from the concrete without damaging them. Initial tests at Empa are encouraging: After the lamellas were separated from the concrete, they still had a strength of 95 percent – even if they had already been used for 30 years.

Then, the demolished CFRP lamellas shall be used to produce reinforcement for prefabricated components. Terrasi's goal: saving thousands of tons of CFRP lamellas from ending up in landfills after the demolition of old concrete structures and reuse them in low-CO₂ concrete elements. After completion of the project, Giovanni Terrasi and his team – consisting of Zafeirios Triantafyllidis, Valentin Ott, Mateusz Wyrzykowski and Daniel Völki – want to produce railroad sleepers from recycled concrete, which will be reinforced and prestressed with demolition CFRP lamellas. This would give the "waste-to-be" material a second life in Swiss infrastructure construction.

Autoneum’s sustainable, textile and lightweight Propylat technology reduces both interior and exterior noise of vehicles. Propylat was originally developed by Borgers Automotive, which was acquired by Autoneum in April 2023. The versatile technology is characterized by a flexible material composition of natural and synthetic fibers with a high recycled content and contributes to significant waste reduction thanks to its complete vertical integration. In addition, the fully recyclable technology variant Propylat PET is now part of the sustainability label Autoneum Pure.

The ongoing electrification of mobility as well as increasingly strict regulatory requirements for vehicle performance in terms of sustainability and acoustics are presenting new challenges to car manufacturers worldwide. With Propylat, Autoneum now offers another lightweight, fiber-based and versatile technology whose sound-insulating and -absorbing properties as well as high content of recycled materials help customers address these challenges. Propylat-based products not only contribute to reducing pass-by noise and improving driver comfort, but they are also up to 50 percent lighter than equivalent plastic alternatives; this results in a lower vehicle weight and, consequently, less fuel and energy consumption as well as lower CO2 emissions.

Autoneum's innovative Propylat technology consists of a mixture of recycled synthetic and natural fibers – the latter include cotton, jute, flax or hemp, for example – that are consolidated using thermoplastic binding fibers without adding any further chemical binders. Thanks to the flexible fiber composition and the variable density and thickness of the porous material, the properties of the respective Propylat variant, for example with regards to acoustic performance, can be tailored to individual customer requirements. This allows for a versatile application of the technology in a variety of interior and exterior components such as wheelhouse outer liners, trunk trim, underbody systems and carpets. For instance, Propylat-based wheelhouse outer liners significantly reduce rolling noise both inside and outside the vehicle while at the same time offering optimum protection against stone chipping and spray water.

In terms of sustainability, Propylat always contains a high proportion of recycled fibers – up to 100% in some variants – and can be manufactured with zero waste. Thanks to the full vertical integration of Propylat and Autoneum’s extensive expertise in recycling processes, the technology also contributes to a further significant reduction in production waste. Moreover, the Propylat PET technology variant, which consists of 100% PET, of which up to 70% are recycled fibers, is fully recyclable at the end of product life. For this reason, Propylat PET has been selected for Autoneum Pure – the Company’s sustainability label for technologies with excellent environmental performance throughout the product life cycle – where it will replace the current Mono-Liner technology going forward.

Propylat-based components are currently available in Europe, North America and China.

The adoption of composite parts based on flax fibres by the Marine Industry continues to grow, with major OEMs as well as smaller shipyards now aiming to take advantage of the reduced carbon impact and impressive mechanical properties they can provide.

“Over the last ten or fifteen years, several innovative flax fibre boats have been built and the fibre has started to gain significant traction,” says Julie Pariset, Innovation & CSR Director at the Alliance for European Flax-Linen and Hemp. “In addition to the environmental benefits, manufacturers are realising significant technical and processing gains with flax fibre composites.”

“Flax is a very low-density fibre, with a high specific stiffness,” she explains. “It can be used to manufacture composite laminates with mechanical properties not dissimilar to typical E-glass composites and the coefficient of thermal expansion of a flax fibre epoxy part is also quite close to that of a carbon fibre part.” This allows the materials to work well in combined assemblies with carbon fibre composites and the flax parts are also highly impact resistant.

Flax fibres also provide acoustic and vibration damping in composite applications, as well as providing a warm and aesthetically pleasing appearance below decks.

ecoRacer30
As a member of the Alliance for European Flax-Linen and Hemp, Bcomp, headquartered in Fribourg, Switzerland, has this year been working with Northern Light Composites (nlcomp), based in Monfalcone, northern Italy, on the creation of what is billed as the first fully recyclable nine-metre-long sailing boat – the ecoRacer30.

The boat is based on nlcomp’s proprietary rComposite technology – a combination of thermoplastic resins and BComp’s ampliTex high-performance natural fibre reinforcement fabrics and patented powerRibs technology.

It was built in a collaborative effort with the help of Barcelona-based Magnani Yachts, which took care of the composite manufacturing, and Sangiorgio Marine, which provided technical assistance as the boat was being assembled at its shipyard in Genova, Italy.

Magnani Yachts has subsequently become the first shipyard to hold an rComposite license and others are now being encouraged to adopt the technology.

The second ecoracer30 is currently under construction and has already been sold and nlcomp is planning to build a fleet of eight of these boats in time to enter a series of regattas in the summer of 2025.

Flax 27 Daysailer
Greenboats, based in Bremen, Germany, is another specialist in building boats from natural fibre composites and has this year launched the Flax 27 daysailer.

The lower hull of this vessel is also made from Bcomp’s ampliTex technical fabrics in combination with a sandwich core of recycled PET bottles. Using a vacuum infusion process, the fibres were integrated with a plant-based epoxy resin in order to further reduce the CO₂ footprint of the vessel.

The light structure and modern shapes of the lower hull of the boat result in very fast, sharp and agile handling on the water.

Greenboats has also recently announced significant new backing from alliance member Groupe Depestele, which manages 13,000 hectares of flax land in Normandy, France.

Blue Nomad
A project in Switzerland has meanwhile proposed the use of flax fibre composites in solar-powered habitats designed for comfortable living on the oceans – as the world grapples with the frightening implications of climate change and rising sea levels.

As envisaged by students from Institut auf dem Rosenberg in St Gallen, Switzerland working with Denmark-based SAGA Space Architects, Blue Nomad structures would form modular blocks to establish large communities and oceanic farms.
 

Making outdoor sports accessible to as many people as possible since 1976 through quality, innovative gear, powerhouse sporting goods brand Decathlon has launched the first product of its long-term partnership with CELLIANT® infrared technology from Hologenix® – Adult Ski Socks. They are introduced in its Wedze range of ski and snowboarding socks (“wed’ze” means ‘“a small turn on the snow” in the Savoyard dialect in the Alps where this brand is headquartered).  

Decathlon was attracted to CELLIANT’s ability to convert body heat into infrared energy, improving local circulation and cellular oxygenation to support stronger performance and faster recovery. Skiers who often suffer from muscle fatigue in the calf area will appreciate the infrared infusion and light compression attributes that were specifically chosen with this in mind. The sock was also thoughtfully designed for minimum thickness, allowing for a comfortable fit within the ski boot, without sacrificing warmth or durability. Anti-friction thread on the sole and toes helps limit irritation, and seams are intentionally positioned to eliminate discomfort. The socks are offered in a Asphalt Blue color in a variety of sizes, both online and in retail stores worldwide.

Trumpler has teamed up with Archroma to offer a leather production process that can be used to produce high-performance leather in a more eco-friendly and cost-efficient way.

The new process DyTan®combines offers an alternative to existing metal-free and chrome-tanned leather. It enables the reliable production of leather with great shavability, color depth and migration and abrasion resistance. Free from metal salts and reactive aldehydes, DyTan® is suitable for a wide range of leather applications, from garment and footwear to automotive and furniture upholstery, for today’s eco-conscious leather producers and consumers.

At the core of the DyTan® process is Archroma’s patented AVICUERO® System, which is based on novel molecules that enable more sustainable leather tanning and dyeing, developed by Archroma in cooperation with leather technology consultant Dr Leather. It enables collagen fibers in the leather to be covalently cross-linked through a simplified process at low temperatures. As a result, the system shows strong potential to save energy and water, while also reducing process time and CO₂ emissions by up to 23%.*

The DyTan® process combines the AVICUERO® System with Trumpler’s bio-based fatliquors and retanning agents based on functional biopolymers produced from hydrolyzed shavings – resource-saving technology that Trumpler has been refining for 15 years.

As a global partner of Archroma, the Trumpler Group is responsible for the distribution of the AVICUERO® System worldwide. Delivering technical support and first-class customer care, Trumpler will help leather manufacturers and brands to implement sustainable tanning and draw on its comprehensive product portfolio and process knowledge of tanning, retanning and fatliquoring processes.
 

* Estimations carried out with the Archroma ONE WAY Impact Calculator show energy savings of up to 25% and reduced process time leading to a reduction in CO₂ emissions of up to 23%, compared to traditional chrome tanning. They also show significant water savings compared to other metal-free tanning systems¹. With the ONE WAY Impact Calculator, customers will be offered personalized calculations for their specific processes.

¹ Trials made at Trumpler GmbH application lab.

The expansion of production capacities is a milestone for the Brembo SGL Carbon Ceramic Brakes (BSCCB) joint venture and is evidence of the company's successful development in recent years.

After completion, the two new production halls will have a total area of around 8,500 m². The construction is scheduled to be completed as early as October 2024. Immediately after completion, the installation of new production machinery will begin. The start of production in the new manufacturing facilities for high-quality carbon ceramic brakes is scheduled for January 2025. The expansion of production capacities will create around 80 new jobs in various production professions at the Meitingen site.

Production capacities at the Meitingen and Stezzano (Italy) sites will be expanded by more than 70%. The demand for carbon ceramic brake discs from BSCCB has increased worldwide. The high product quality and performance of carbon ceramic brake discs meet the specific requirements of automotive manufacturers, especially in the premium and luxury segments where high braking performance is required.

Fibre Extrusion Technology Ltd (FET) of Leeds, UK is celebrating a year of achievements since its new Fibre Development Centre was first opened. This period has shown a marked acceleration in the number of client technical trials conducted, involving the ever-increasing development of new polymers.

FET designs, develops and manufactures extrusion equipment for a range of high value textile material applications worldwide, offering melt spinning, wet spinning and spunbond/meltblown options. Since its inception in 1997, a major part of FET’s service portfolio has always been to collaborate with industrial and research establishments in testing, evaluating and developing high value materials with diverse, functional properties. FET’s previous Process Development Laboratory presided over the development of about 60 new polymer types in multifilament, monofilament and nonwoven formats.

Since the new Fibre Development Centre came on stream, this process has accelerated and the number of new polymers has now increased to over 70, with considerably enhanced facilities more than doubling capacity and increasing efficiency. Clients frequently spend several days on site participating in development trials and technical sales meetings, so the new Centre is designed to make their stay even more efficient and comfortable.

With more new trials booked for the rest of the year and well into 2024, it is expected that many more new polymers will be developed, with sustainable fibres leading the way.

Since 1967, ‘OETI - Institute for Ecology, Technology and Innovation’ has made a name for itself worldwide as an accredited and notified centre of excellence. With decades of experience as a service provider, the company specialises in the testing and certification of textiles, leather, personal protective equipment (PPE), floor coverings and interior furnishing materials. It also assesses indoor air quality. As a founding member of the international OEKO-TEX® association (1992) and official OEKO-TEX® testing institute, OETI also comprises the entire OEKO-TEX® product portfolio.

Between its own international branches and the branches of OETI’s Swiss parent company, TESTEX AG, OETI’s network of locations spans several continents. Recently, one more branch has been added in Pakistan (headquartered in Faisalabad).
OETI Pakistan is managed by Akhlaq Hussain, who has decades of experience in the textile and apparel industry for testing, inspection, certification, auditing, product safety, training and sustainability management.

Akhlaq Hussain’s main goal is to ‘create visibility for the OETI brand in Pakistan. We want to offer sustainable, reliable, and competitive services to Pakistan’s textile industry. My aim is to foster Pakistan’s exports by offering more sustainable certifications and training in environmental and social topics as well as due diligence in supply chains, which are in high demand in European countries.’

Markus Lang’s - OETI’s Global Head of Marketing & Sales – main goal is to ‘increase the awareness of sustainability within Pakistan’s textile and leather industry, which is also the main objective of our future development.’