From the Sector

Der chinesische Vliesstoffhersteller Alear Silk Road New Materials Co., Ltd. hat ANDRITZ mit der Lieferung von drei neXline aXcess Spunlace-Linien mit Kreuzlegern für die Vliesstoffproduktion beauftragt. Diese Investition beurteilt das Unternehmen als wichtigen Expansionsschritt und die Entwicklung der Vliesstoffindustrie in der Region Alear der chinesischen Provinz Xinjiang.

Auf den neuen Linien werden Viskose- und Baumwollfasern zu Vliesstoffen für den Hygiene- und Medizinbereich verarbeitet. Die Spunlace-Linien von ANDRITZ gewährleisten eine gleichmäßige, zugfeste Vliesbahn bei hoher Produktionsleistung. Die modernen Profile®-Kreuzleger sorgen für eine gleichmäßige Faserverteilung und tragen damit zur Senkung der Produktionskosten bei. Die Inbetriebnahme der neuen Linien ist für das 4. Quartal 2025 geplant.

Feng Quanzhi, General Manager von Alear Silk Road New Materials, sagte: „Mit der modernen Technologie von ANDRITZ erreichen wir eine hohe Produktionseffizienz; so können wir die steigende Marktnachfrage nach hochwertigen Vliesstoffen bedienen und unsere Nachhaltigkeitsziele erreichen. Dieses Projekt ist ein wichtiger Meilenstein für unser Unternehmenswachstum und der Beginn einer langfristigen Zusammenarbeit mit ANDRITZ.“

Shi Wei, Vice President ANDRITZ Paper and Textile Asia Pacific, meinte dazu: „Wir schätzen das Vertrauen, das Alear Silk Road uns mit diesem großen Auftrag entgegenbringt, und freuen uns auf eine lange Partnerschaft. Gemeinsam wollen wir die nachhaltige Entwicklung der Vliesstoffindustrie in der Provinz Xinjiang fördern und zum Wirtschaftswachstum und industriellen Fortschritt in der Region beitragen.“

Der internationale Technologiekonzern ANDRITZ hat vor Kurzem eine neXline Airlay-Anlage an Revibat in Frankreich geliefert und in Betrieb genommen. Die Anfang Februar eröffnete innovative Linie ermöglicht die Produktion von Dämmstoffplatten aus Glaswolleabfall. Abfall, der andernfalls in Deponien entsorgt werden würde.

Mit der neuen ANDRITZ Linie wandelt Revibat die komplexen Reststoffe, die im Großraum Paris gesammelt werden, in wertvolle Produkte. Aus Glaswolleabfall werden neue Dämmstoffe, gleichzeitig wird der CO2-Fußabdruck in der gesamten Produktionskette verbessert. Die Linie verarbeitet bis zu 1.500 kg Fasern pro Stunde und ist speziell für die Herstellung dieses Vliesmaterials ausgelegt.

Revibat ist auf die Herstellung von Baustoffen aus recycelten Bauabfällen spezialisiert. Das französische Unternehmen hatte sich zum Ziel gesetzt, eine wirtschaftliche Lösung für das Recycling von Glaswolle zu finden. Mit einem hoch entwickelten Labor verarbeitet Revibat Glaswolleabfall im industriellen Maßstab und möchte sich als wichtiger Akteur positionieren, der Unternehmen und Organisationen dabei unterstützt, Bauabfall und Baustoffe zu sammeln, zusammenzuführen und zu verwerten.

Der internationale Technologiekonzern ANDRITZ hat zwei neue Refiner- und Kotonisierungslinien an Van Robaeys, Frankreich, geliefert und in Betrieb genommen. Die maßgeschneiderten teXline-Anlagen ermöglichen es dem Unternehmen, die Produktion von Textilfasern aus Flachs zu steigern. Das Familienunternehmen Van Robaeys stellt das Flachsfasern für die Spinnereiindustrie her. Sein Know-how in der Flachsverarbeitung reicht bis ins Jahr 1919 zurück.

Mit der Errichtung der neuen Linien reagiert Van Robaeys auf die zunehmende Nachfrage des französischen Marktes nach hochwertigen baumwollartigen Textilfasern aus natürlichen Rohstoffen. Europa ist der weltweit größte Produzent von Flachsfasern und verzeichnete zwischen 2010 und 2020 einen Anstieg der Flachsanbauflächen um 133%.

ANDRITZ-teXline-Bastfaser-Linien können bis zu 800 kg Fasern pro Stunde verarbeiten und sind mit modernsten Anlagen ausgestattet, die ein hohes Maß an Flexibilität in der gesamten Faserverarbeitung gewährleisten.

Bei den nun gelieferten Anlagen handelt es sich um die siebente und achte ANDRITZ-Kotonisierungslinie für Van Robaeys, wobei die erste schon seit 50 Jahren in Betrieb ist. Die jüngste Investition unterstützt die Bemühungen des Unternehmens um eine nachhaltige und abfallfreie Faserproduktion.

International technology group ANDRITZ has received an engineering order from US textile recycling innovator Circ in anticipation of its first large-scale textile recycling plant. The plant will be the first to recover cotton and polyester from blended textile waste.

Circ® is a pioneering company focused on sustainable solutions for the fashion industry. By converting fashion waste into reusable raw materials for fabrics, Circ reduces the need for petroleum and natural resources. The company’s mission is to build a truly circular economy to protect the planet from the cost of clothing.

ANDRITZ has been successfully conducting trials for Circ at the ANDRITZ Fiber R&D Center in Springfield, Ohio, USA, for several years. The successful partnership and recent developments have led to the decision to expand this cooperation.

The majority of fashion waste consists of polyester-cotton blends, which poses a significant challenge to achieving greater circularity. In particular, the separation of cellulosic and synthetic fibers from textile waste has been a major obstacle. Circ’s innovative recycling process can break down polycotton textile waste into its original components – polyester and cotton. The forthcoming plant will process 200 tons of textile waste per day, allowing cotton to be recycled for lyocell production and polyester to be reused for polyester production. This will reduce the need for virgin raw materials.

Conor Hartman, Chief Operating Officer at Circ, says: “We remain excited about this continued collaboration with ANDRITZ. Together, we will commercialize Circ’s innovative recycling process and take another step towards a truly circular fashion industry. With its expertise in engineering and building large-scale process equipment, ANDRITZ is the right partner to help us transform textile waste into recycled fibers on an industrial level.

Michael Waupotitsch, Vice President Textile Recycling at ANDRITZ, comments: “We are eager to support Circ in their vision of circularity because the technology they have developed is uniquely suited to solve one of the biggest challenges in fashion waste and recycling. With our holistic knowledge in resizing, mechanical separation, hydrothermal processing, recovery of cellulosic pulp as well as pulp cleaning and pulp drying, we have the right expertise to help them achieve their goals. Our experience in process development and machinery will help bring their innovative recycling technology to life.”

EDANA, the global association for the nonwovens and related industries, concluded its annual Sustainability Forum at the KBR Royal Library of Belgium in Brussels. This year's forum, themed “Building a Sustainable Future Together,” featured a series of keynote addresses, panel discussions, and collaborative sessions focused on environmental responsibility, corporate social responsibility, and circular economy innovations within the nonwovens sector. With an agenda that bridged policy and practice, the Forum highlighted the latest advancements and strategies aimed at tackling climate change, reducing waste, and enhancing sustainability practices.

Keynote Highlights
The forum featured two keynote speakers: Ana Rovzar, Founder of Polygon AR, opened the Forum with a keynote on the accelerating transition to clean energy. In her speech, she discussed the shift from conventional energy investments to renewables, noting a 50% growth in renewables in 2023 alone. “It is accelerating much faster than people think” she remarked, emphasizing that “real progress requires a united front from governments, businesses, and communities to remove regulatory and technological barriers”.

In another keynote, sustainability expert Mike Barry, formerly of Marks & Spencer, stressed the importance of aligning corporate strategy with sustainability. “Citizens see climate change as a top priority, and companies must act boldly to reduce emissions, especially Scope 3”, he said. “Sustainability is now a vital part of brand identity, and consumers expect more transparency and commitment than ever”.

Innovative Industry Perspectives and EU Policy Impacts
Brieuc Lits, Public Affairs Director at EDANA, examined the potential effects of the EU Green Deal on the nonwovens industry. “The EU’s shift towards balancing sustainability with competitiveness will shape not only policy but the very framework within which we operate”, he noted, emphasizing that the sector must adapt to stay competitive and aligned with regulatory expectations.

Lastly, Paolo Haeusermann, Senior Brand Director and Europe Sustainability Leader at Procter & Gamble, shared insights on advancing sustainability in absorbent hygiene products and emphasized the importance of these items. “We are talking about essential products in people’s lives”, he remarked.

Corporate and Product Sustainability: A Deep Dive
Several industry leaders shared insights on integrating sustainability at every level of business. Carsten Ruff from Nitto Advanced Film Solutions discussed the challenges and strategies of embedding sustainability in corporate culture, particularly in a multinational setting. “Sustainability is not a contradiction to industrial applications; it’s a powerful driver of innovation”, he observed.

Martijn Gipmans from Sphera Solutions highlighted the business value of transparency and life-cycle assessments (LCA). “LCA and transparent ESG reporting can catalyse both business growth and environmental progress”, he explained, stressing the importance of integrated sustainability assessments to reduce the carbon footprint of entire product portfolios.

Christophe Morel-Fourrier, Sustainability Leader for Hygiene, Packaging, and Converting Adhesives at Bostik, introduced the Archimedes tool as a strategic asset for Portfolio Sustainability Assessment. “Archimedes allows us to make transparent, informed decisions that align with our long-term sustainability goals”, he explained. He highlighted that this tool helps companies evaluate the sustainability of their product portfolios, empowering them to make impactful choices that support environmental goals.

The Path Forward: Advancing Circularity and Green Innovation
One of the most discussed topics was the industry's transition toward a circular economy. Albert Hammerschmied from Freudenberg Performance Materials highlighted the importance of post-industrial waste in achieving circularity, particularly in the automotive sector. “The potential for nonwovens in the automotive circular economy is vast, but requires industry-wide collaboration”, he commented.

In a session addressing the future of sustainable practices in building insulation, Alexandre Butté of ANDRITZ Laroche emphasized the importance of sustainable materials and collaboration among stakeholders. “The building industry faces unique sustainability challenges, but with innovation and eco-friendly materials, we can bridge the gap between goals and achievable practices”, he said.

Building a Sustainable Health Sector
Danielle van Horzen, Global Marketing Manager for Hygiene and Healthcare at SABIC, discussed advanced recycling solutions in the healthcare sector. Addressing the challenges of medical waste recycling, she stated, “A significant amount of medical waste is not contaminated, offering us opportunities to create circularity in healthcare.” She pointed to the potential for advanced chemical recycling to enable circular models, helping to tackle the pressing issue of sustainable medical waste management.

The day concluded with a session on the circular potential within healthcare. Kristien Depraetere, Sustainability Coordinator at UZ Leuven, outlined sustainable practices in hospitals, from waste reduction to advanced recycling in medical waste. “Healthcare can lead by example in the transition to circularity, yet we need practical and legislative support to address unique industry challenges”.

Visit to the European Commission
The third day of EDANA’s Sustainability Forum 2024 concluded with an insightful visit to the European Commission, offering attendees a unique opportunity to engage directly with policymakers and gain firsthand insights into the EU's sustainability agenda. Hosted at the Charlemagne Building, discussions centered on pivotal elements of the EU Green Deal, including the establishment of Extended Producer Responsibility (EPR), the scope and implementation of the Single-Use Plastics Directive (SUPD), and the Ecodesign for Sustainable Products Regulation.

Featuring presentations from prominent EU officials like Vicenzo Gente and Werner Bosmans, attendees delved into how these regulations are shaping sustainability strategies across industries. Bridging policy and practice emerged as essential, reinforcing the forum’s dedication to aligning industry actions with current EU regulatory frameworks. The session offered a strong conclusion to the event, reinforcing a shared commitment to a sustainable future in collaboration with EU leaders and regulatory bodies.

CARBIOS and Nouvelles Fibres Textiles, a French company specializing in the recovery of end-of-life textiles, announce the signing of a Memorandum of Understanding to establish a contract for the supply of polyester textiles to the world's first PET biorecycling plant currently under construction in Longlaville, France. The polyester textiles supplied will come from used or end-of-life textiles prepared in France by Nouvelles Fibres Textiles for recycling using CARBIOS' enzymatic depolymerization technology. This contract will enable 5,000 tons a year of these textiles to be redirected towards biorecycling from 2026 onwards, over an initial 5-year period, demonstrating the commitment of industrial players all along the value chain to achieving textile circularity for a more sustainable textile sector.

Nouvelles Fibres Textiles and its various partners opened a semi-industrial site with an annual capacity of 1,000 tons in November 2023, the first step towards building a 20,000-to-30,000-ton unit in 2026. This first site, a research center for textile recycling, combines the know-how of Andritz Laroche (a leader in textile recycling), Pellenc ST (French leader in intelligent sorting solutions), Synergie TLC (a French player in collection and first sorting for solidarity) and the Tissages de Charlieu group (a French player in weaving, garment manufacturing and textile recycling). This unit transforms used textiles into high-quality raw materials, supplying the various industries that use textile fibers (non-wovens, insulation, plastic, textiles, etc.) by automatically sorting them by composition, while eliminating hard points (buttons, zips, patches, etc.).

CARBIOS' biorecycling technology uses enzymes to break down polyester fibers into their basic components. These components are then used to produce high-quality recycled PET materials, such as fibers for the textile industry. This “fiber-to-fiber” solution will enable polyester to become a truly circular fiber on a large scale.

International technology group ANDRITZ has successfully started up a new nonwovens production line supplied to Teknomelt Teknik Mensucat San. ve Tic. A.S. in Kahramanmaras, Türkiye. The new neXline wetlace CCP (carded-carded-pulp) line produces nonwoven roll goods for biodegradable, plastic-free wet wipes

By combining the benefits of two technologies, spunlace and wetlaid, the line enables the use of bio-based fibers, like viscose and wood pulp, to produce a high-performance and sustainable wipe with the same technical product characteristics and performances as a conventional wipe made of synthetic fibers while protecting the environment.

Teknomelt is one of the leading manufacturers of nonwoven meltblown, spunbond, SMS and SMMS fabrics in Türkiye. The company serves a wide range of markets, exporting 45% of its production. With the new ANDRITZ Wetlace CCP line, the company is expanding its range of sustainable nonwovens production for wipes. 

ANDRITZ has received an order from Lotus Teknik Tekstil A.Ş., Türkiye, to install a Metris All-In-One digitalization platform for its new WetlaceTM CP nonwovens production line from ANDRITZ. The integration will be finalized in September 2023.

Lotus Teknik Tekstil A.Ş. is a leading nonwoven roll good producer and a member of the Sapro group, one of the top three producers of wet wipes globally.

The Metris All-in-One platform developed by ANDRITZ provides full support for industrial plants throughout their entire life cycle. It combines a complete range of functionalities for professional production management, simulation and optimization using the latest artificial intelligence methods, plus cyber security, and condition monitoring with smart sensors in an integrated approach.

It will support Lotus Teknik Tekstil in further optimizing the operating efficiency of its ANDRITZ Wetlace CP line by

• ensuring a stable production process via data collection and process monitoring,
• reducing operational costs through optimized production traceability and energy monitoring,
• improving final product quality thanks to a stable process, and
• reducing production waste by optimizing raw material management.

International technology group ANDRITZ has delivered, installed, and commissioned a mechanical textile recycling line and an airlay line at Novafiber’s nonwovens production mill in Palín, Guatemala. Both lines have been successfully operating since December 2022.

The recycling line – the second tearing line ANDRITZ supplied to Novafiber – processes post-industrial textile waste from Central America. The recycled fibers feed the latest ANDRITZ Flexiloft airlay line, which produces nonwoven end-products for the bedding and furniture industries – a true example of a circular textile-to-nonwoven approach. The production process ensures complete material use as a state-of-the-art edge trim recycling system returns any waste directly to the tearing and/or airlay line.

This combination of ANDRITZ tearing and airlay lines allows Novafiber to process large amounts of post-industrial garments, controlling the supply chain from raw material to final product. In addition, it enables energy savings and a reduced carbon footprint due to the reduction of shipments.

Based in Palín, Novafiber is a leading company in Guatemala for producing nonwovens from post-industrial textile waste for both the local market and export.

Zhoukou Xuwang Co., Ltd. has successfully started up two new ANDRITZ neXline spunlace lines at its facilities based in Henan province, China. Combining equipment from the aXcess and eXcelle ranges, both lines are dedicated to the production of spunlace fabrics of 30 to 120 gsm made out of viscose and polyester fibers. The ANDRITZ design will allow Zhoukou Xuwang to serve the premium product market, especially for premium hygiene and technical wipes, in China.

The ANDRITZ scope of supply for the two lines included:

• aXcess opening and blending systems
• high-performance eXcelle card and crosslapper
• robust aXcess CA25 carding machine
• efficient Jetlace Avantage hydroentanglement unit

This configuration will enable Zhoukou Xuwang to manufacture high-quality products while reducing raw materials consumption. These goals are further enabled by the installation of an ANDRITZ Asselin-Thibeau crosslapper PRO35-140, generating a uniform profile over the entire web width.

In spite of the difficult circumstances and supply chain disruptions related to the Covid crisis, both spunlace lines were installed smoothly and on time. They quickly went into commercial production, with a line speed of up to 100 m/min and high-performance MD/CD ratio.