From the Sector

The Board of Renewcell has appointed Magnus Håkansson as the new acting CEO. Magnus has experience from leading roles in the retail and fashion sector and from leadership in a listed environment. On Monday, October 16, he started his position, replacing Patrik Lundström, who has been the company's CEO since 2019.

Magnus Håkansson has a degree in economics from the Stockholm School of Economics and an MBA from MIT Sloan School of Management. He started his career as a management consultant at McKinsey and has since held several leading roles in global growth companies in the retail sector, as well as the pulp industry, including many years with experience from a listed environment. He most recently came from a role as CEO of MediaMarkt Sweden.

Comment from Michael Berg, Chairman of the Board of Renewcell:
"With a slower adoption in the value chain, and thus lower sales growth, than expected, the Board has decided that a new leadership in the company is necessary. I would like to thank Patrik for his contribution to the development of Renewcell, he has been instrumental in taking the company from the development stage to listing, factory construction and production.

We are very pleased that Magnus Håkansson is now stepping in as acting CEO. His experience from consumer focused companies and his solid leadership skills will add value to the company in its current phase – focusing on sales to brand companies in the clothing retail sector, where we see continued strong interest."

The innovative company RUDOLF has been honoured for its outstanding achievements in the field of sustainability and environmental protection and has won the coveted Responsible Care Federal Competition 2023 in the category SME.

The award was presented as part of a competition organised by the German Chemical Industry Association (VCI). Responsible Care is a voluntary initiative of the chemical industry. Its aim is continuous improvement in the areas of environmental protection, health and safety. Chemical companies and associations in more than 50 countries support the initiative. The award-winning project of the innovative company RUDOLF impressed the jury with its pioneering technology, which reduces CO2 emissions by up to 99.9 % compared to conventional cooling systems. „The project uses near-surface geothermal energy for industrial cooling - according to the motto „Efficiency First“ the most efficient way has been chosen!“ - Jury statement
 
TerraCool‘s winning system uses near-surface geothermal energy as the most natural form of cooling. It utilises the constant temperature of around 10°C at a depth of around 10 metres below ground. A specially developed heat exchanger system takes advantage of this natural cooling effect. In the future, it will be used to cool chemical production processes at RUDOLF. The main advantage of this technology is that it is CO₂ neutral. The technology is highly efficient and consumes only 0.1 % of the electricity used by conventional cooling systems.  By using natural resources, the system reduces CO₂ emissions by up to 99.9 % compared to conventional cooling systems, resulting in a very presentable carbon footprint. Another impressive aspect is its high energy efficiency. With just 1 kW of electrical energy, the system generates up to 600 kW of cooling capacity, thanks to the use of a highly energyefficient circulating pump system. Energy is, and will continue to be, a valuable „raw material“ for our industry and one that we need to manage carefully. The system is self-contained and has no contact with groundwater. No environmentally harmful refrigerants or antifreeze are required. With this technology, RUDOLF has made a pioneering contribution to the climate-neutral transformation of the economy, proving that innovative solutions can go hand in hand with environmental protection and sustainability. The Responsible Care award recognises the company‘s commitment to a greener future.

After four decades in the packaging industry, the Manjushree Group is entering the Indian nonwovens market. The entrepreneurs rely on a flexible RF Smart Composite line from Reifenhäuser Reicofil to meet very different customer requirements.

The Manjushree Group operated a blown film line for packaging materials for the tea industry in the eastern part of India as early as 1983. In the years that followed, Manjushree Technopack Ltd. developed into one of the largest suppliers of solutions for rigid plastic products in South Asia - and the family business grew into a group with several business segments. In 2018, the entrepreneurial family repositioned itself: it sold its previous core business to a financial investor and established Manjushree Ventures with footholds in start-up financing, real estate business, and manufacturing - the largest of which is Manjushree Spntek as a producer of high-quality spunmelted fabrics.

Since February 2023, Manjushree Spntek has been producing high-performance spunmelts on an RF Smart Composite line from Reifenhäuser Reicofil - benefiting both from many years of experience in the packaging industry and from experience with Reifenhäuser's blown film lines. "We know a lot about plastic extrusion, for example when it comes to line operating parameters such as temperature and pressure. Processing is similar in both industries," explains Rajat Kedia. "The main difference is the distribution of the products: In plastic packaging, we had an established customer base and sold a lot of material to the big consumer goods manufacturers. The nonwovens market in India, on the other hand, is still forming, with thousands of small companies currently getting involved." These serve customers in their regions, such as hospitals.

The RF Smart Composite line is a standardized spunmelt line for smaller and emerging markets. The line produces nonwovens of the highest Reicofil quality with appropriately adapted throughput. This makes it ideally suited for applications in hygiene and medical technology and, with typically 8,200 annual production hours, it is extremely reliable. In addition, operators can start production quickly because in many cases the line can be integrated into existing buildings.

Before production could start, Manjushree built a new production building in Bidadi, a town an hour's drive from Bangalore International Airport. The building is designed to be sustainable: It uses natural light and fresh air, has comprehensive contamination control, and obtains almost all of its energy from renewable sources. Reifenhäuser Reicofil then installed, commissioned and tested the RF Smart Composite line.

Since February 2023, Manjushree Spntek has been producing high-quality spunmelted nonwovens, including ultra-soft fabrics and fabrics with special coatings for customers in the hygiene and medical industries. The material can be used, for example, for baby diapers and feminine hygiene products, but also for medical articles ranging from surgical gowns to surgical drapes.

International technology group ANDRITZ has successfully started up the new carding machine and opening/blending line it delivered to Albis in Roasio, Vercelli, Italy.

With its large working width of 5.10 meters, the machine allows for the production of nonwoven fabrics tailored to specific customer requirements while maintaining excellent properties and consistent quality. One example is Albis Curacell ®, a multilayer composite nonwoven fabric in a weight range between 35 and 70 gsm that is produced with a fully water-free patented process and is able to absorb liquid flows of over seven times its own weight. The production line also includes an advanced upstream opening and blending system from ANDRITZ.

Albis, a privately owned group founded in Italy in 1995 by Gianni Boscolo, has been a major player in the nonwoven market for over three decades. Through continuous research and development, the company offers innovative, high-quality nonwoven solutions across various sectors, including hygiene, medical, personal care, textiles, filtration, and agriculture.

•    First production supercar created with Hypetex coloured carbon fibre
•    Paint-replacement technology reduces weight to enhance performance

British car manufacturer Briggs Automotive Company (BAC) has created a unique Hypetex coloured carbon fibre version of its Mono R, reducing the weight by removing the need for paint.  

The original BAC Mono R was created to be lighter and more powerful than the standard model, with 343bhp and 555kg total weight, equating to a power-to-weight ratio of 618bhp-per-tonne. By removing the need for paint coatings in this version, the net weight of the exterior is reduced compared to a painted shell, resulting in a further improved overall performance.

The car’s body was created using Hypetex’s titanium carbon fibre twill, and finished with a crystalized lacquer, offering a unique aesthetic finish. The ultra-lightweight supercar can accelerate from zero to 60mph in less than 2.5 seconds.  

Hypetex’s paint-replacement technology retains the visible weave, allowing for a bold design and a choice of colours without technical compromises, perfectly aligning with BAC’s initiatives to maximise performance whilst creating bespoke supercars. Paint generally adds 138 grams per metre squared, whereas Hypetex adds just 17 grams for the same area, offering an 8x weight saving.
This bespoke version of BAC’s single-seater Mono R was subject to BAC’s renowned BAC Bespoke programme, which ensures that no two Monos are the same. The client, a US-based collector, worked with BAC’s design team to design the car to their personal taste.   

Born out of Formula 1 technology, Hypetex offers manufacturers sustainable aesthetic materials with technical and efficiency benefits. This collaboration is an all-British success story, with the Hypetex carbon fibre body built by Formaplex, a leading UK-based manufacturing company who manufacture lightweight engineered solutions for top tier customers in Automotive, Aerospace and Defence markets. BAC’s supply chain is 95% UK-based.  

Hypetex continues to expand its growing portfolio of the use of coloured carbon fibre to add personalisation to the automotive field, with its material recently featured on the 2024 Ford Mustang Dark Horse.  

The combination of high strength and rigidity with sustainability and a neutral carbon footprint makes flax the ideal raw material for natural fibre-reinforced plastics. vombaur offers composite textiles made of this natural fibre for the automotive, wind power, construction or sports industries and many other sectors.

Flax fibres are rigid and tear-proof. They have natural bactericidal properties, are virtually antistatic, stain resistant and easy to spin. Humans have taken advantage of these properties to manufacture robust, stain-resistant and lint-free textiles. Between the late 19^th and late 20^th centuries, cotton largely replaced natural fibres. Because flax can be grown in Europe and consumes less energy and water than cotton production, the material's importance is currently growing again, for both clothing and composites. Regional textile value added chains in Europe – flax makes them possible.

Ideal mechanical properties
vombaur makes the mechanical properties of flax usable for lightweight design. Because flax fibres are particularly rigid and tear-resistant, they ensure great stability in natural fibre-reinforced plastics (NFRPs). And thanks to their low density of 1.50 g/cm3, the fibres weigh virtually nothing. On top of this, fibre-reinforced plastics are less prone to splintering than glass fibre-reinforced plastics.

Excellent carbon footprint
The cultivation of flax binds CO₂ and the production of natural fibre-reinforced plastics (NFRPs) generates approximately one third less CO₂ emissions compared with conventional fibre-reinforced plastics. Energy consumption is substantially lower. This saves resources. The use of flax fibre tapes by vombaur in lightweight design applications also improves the product's carbon footprint and contributes to a secure, regional supply chain.

Recycling without impacting on quality
Flax offers another sustainability benefit: more recycling cycles than glass- or carbon fibre-reinforced plastics – without impacting on quality. Thermoplastic fibre-matrix prepregs are melted and reused in the recycling process. The natural fibres can be used in other products such as natural fibre-reinforced injection moulded parts.

Sustainable product developments for many industries
"Orthoses for high-performance sports, high-tech skis, wind turbines, components for the automotive industry or aerospace, but also modern window profiles – the application scope for our lightweight design flax tapes is amazingly diverse", as Carl Mrusek, Chief Sales Officer at vombaur explains. "After all, wherever flax tapes are used, three key properties come together: light weight, strength and sustainability".

The Südwolle collection of yarns for weaving and circular knitting continues its evolutionary path based on the key concept of Responsibility. This principle guides Südwolle Group's commitment and engagement regarding all areas of business and stakeholders - the environment, the textile industry production chain, consumers, employees and the social repercussions of its business.

The intersection between these 6 areas has resulted in a collection in which the concept of seasonality is blurred, and products have a flexible, versatile use. The use of cutting-edge technology means yarns offer a high level of quality, suitable for apparel with outstanding durability, a factor that helps to reduce the environmental impact of textile waste and disposable fashion.

Overview of the collection
The collection is divided into 4 themes.
Natural, biodegradable or recycled fibre blends intended for crepe and crinkled fabrics are characterized by substantial twist and a high level of performance. The selection of fibres is oriented towards sustainability, with wool and silk organze combined with LENZINGTM ECOVEROTM viscose and Q-NOVA® regenerated polyamide.

Fuji crepe X-compact Nm 40/1 Z 1050 (40% wool 21.2 μ, 60% FSC certified LENZINGTM viscose EV), new this season, features a smooth look and no pilling thanks to the use of X-compact spinning technology, which produces yarns with excellent performance and durability.

When it comes to light, natural blends, wool and linen or wool, linen and silk blends follow the trend for softly fluid structures, such as the new Peschici Nm 42/1 Z 600 (53% wool 18.4 μ, 23% linen, 24% silk), with a fresh, dry handle and very current dappled effect, which results from the skilful combination of different fibres.

Contributing to a more sustainable and traceable textile production also involves attention to all fibres used. Mohair used for luxury yarns in noble fibres is strictly RMS (Responsible Mohair Standard) certified, which traces its origin, guaranteeing animal welfare and production according to responsible standards, similar to the analogous RWS (Responsible Wool Standard) used for wool. Bosforo RWS RMS Nm 32/1 Z 950 (20% wool 20.8 μ RWS, 60% FSC certified LENZINGTM viscose EV, 20% RMS Kid Mohair) is a fresh, bright yarn that is soft on the skin, suitable for trans-seasonal products, an example of careful selection of raw materials.

Among the fancy yarns, delicately animated structures predominate for naturally elegant creations, represented by Niche Nm 34/2 S 460 (42% wool 21.2 μ, 58% bourette silk), a twisted yarn in wool and bourette silk, which adds dynamism with its characteristic rough, knotty surface.

OCSiAl, a leader in graphene nanotube technologies, has been granted a construction permit for a nanotube production facility near Belgrade, Serbia. The new nanotube synthesis plant will be launched in 2024 and will have an initial annual capacity of 60 tonnes of graphene nanotubes. Over the next two years, the capacity of this plant will be increased to 120 tonnes per year. “The project will facilitate logistics and lower supply chain costs. European-produced nanotubes and nanotube derivatives will be primarily supplied to our customers in central and western Europe, North America, and Asia,” said OCSiAl Group Senior Vice President Gregory Gurevich.
 
In addition to synthesizing nanotubes, the facility will manufacture nanotube suspensions for lithium-ion battery manufacturers in Europe, the US, and Asia – enough to enhance the performance of more than 1 mln electric cars with an average battery capacity of 75 kWh per car. OCSiAl nanotubes create long and robust electrical networks between active material particles, improving key battery characteristics, including cycle life, lower DCR, C-rate performance, and cohesion between active battery material particles, making the battery electrodes more durable. Graphene nanotubes unlock new battery technologies, including high-silicon content anodes, thick LFP cathodes, fast-charging graphite anodes, and more. They can be applied in both conventional and emerging battery tech, such as a dry battery electrode coating process, and solid-state batteries.
 
As well as synthesizing nanotubes and producing suspensions, OCSiAl project includes manufacturing of nanotube concentrates for high-performance polymers. The project has passed environmental impact assessment and it is 100% powered by green energy. It enjoys support from Serbian municipal and national governments. The plant is planned to be certified in accordance with ISO 9001, ISO 14001, and ISO 45001, and to be compliant with the IATF 16949 automotive industry standard. The project will create more than 200 job opportunities for engineers, scientists, managers, operators, and administrative staff.
 
Currently, OCSiAl has an extensive manufacturing system of nanotube-based products in the regions of highest market demand, such as China, Japan, Sri Lanka, Brazil, Malaysia, and other countries. The Serbia nanotube hub will operate in conjunction with the company’s operational R&D center and planned graphene nanotube synthesis facility in Luxembourg.

Die AZL Aachen GmbH, bekannter Innovationspartner für Industriekooperationen auf dem Gebiet der Leichtbautechnologieforschung, startet eines neuen Projekts mit dem Titel "Trends und Designfaktoren für Wasserstoffdruckbehälter". Das Projekt wird Fragestellungen der Industrie in Bezug auf die Wasserstoffspeicherung adressieren.

AZL Aachen GmbH, a recognized innovator in lightweight technologies research and industry collaboration, announces the initiation of a new project titled "Trends and Design Factors for Hydrogen Pressure Vessels". The project aims to address industry needs surrounding hydrogen storage.

Hydrogen has gained significant attention as a key technological solution for decarbonization, with high pressure storage and transportation emerging as vital components. Its applications extend from stationary storage solutions to mobile pressure vessels employed in sectors such as transportation and energy systems.

The AZL team, renowned for its high reputation in providing market and technology insights as well as developing component and production concepts in the format of Joint Partner Projects seeks for companies along the whole composite value chain interested in further developing their application know how in this economically highly relevant field.

The project will provide an in depth exploration of market insights, regulatory standards, and intellectual property landscapes. Beyond this, there is a dedicated focus on staying updated with state of the art and advancements in design, materials, and man ufacturing techniques.

An integral component of the project involves the creation of reference designs by AZL´s engineering team. The reference designs will encompass a variety of pressure vessel configurations and will consider a diverse range of materials and production concep ts.

With the scheduled project start in October 2023, and a project timeline of approximately nine months, AZL encourages companies active across the composite value chain to participate. Companies interested in participating or seeking further information should reach out directly to the AZL expert team.

Germany-based ZwissTex is a leading manufacturer of textiles with over 150 years of experience, creating innovative and sustainable textile solutions for the automotive and apparel industries. The company also operates in Mexico, to specifically serve the automotive sector across North American Free Trade Agreement (NAFTA) markets. Via OEMs, ZwissTex supplies German automakers including Volkswagen Auto Group, BMW, and Mercedes, as well as American manufacturers in select cases.

Unlike other Kornit customers, ZwissTex had no previous experience printing their own materials, and saw Kornit’s sustainable, single-step, Presto MAX S production system as an effective means of increasing their product capabilities.

“Our textiles were not classically printed in the past, and we did not produce any classical textiles in fashion, which is why we didn’t have any printing experience internally,” said Ralph Moldan, Technical Specialist at ZwissTex, as the system was being installed in their facility. “The only option was to find a system that would enable us to implement the areas in which we are active on the market easily and quickly, without requiring a lot of printing experience.”

One benefit of integrating Kornit technology into the ZwissTex production ecosystem: applying ink only where it is needed and seen, rather than to the full surface of each material. This translates to both reducing the company’s carbon footprint, and minimizing materials waste for a more cost-effective operation.

Prior to making the decision to invest in Kornit, ZwissTex conducted a series of tests and consultations, evaluating possible applications for different materials and engaging with their own key clients to ensure these finished products would meet their rigorous quality and durability standards. This included presenting Kornit-decorated samples at the Techtextil 2022 exhibition in Frankfurt.

Moldan found Kornit’s production capabilities opened new doors to customization of interior areas, a market that continues to grow. He anticipates this technology will create new opportunities with customers they could not reach previously, including new opportunities in sectors such as motor homes, airlines, and aircraft outfitters.