From the Sector

Cost-efficient BCF yarn production for demanding processes with Sytec One from Oerlikon Neumag

Cost-efficient production of carpet yarns beyond commodity products can constitute a challenge. Highly standardized production systems must strike compromises with regard to throughput, quality or cost-efficiency. At the Domotex 2018, the world's largest trade fair for floor coverings, Oerlikon Neumag will present the Sytec One solution for demanding BCF processes.

The Sytec One is a BCF plant with only one end per position. Due to this single-end characteristic, it is particularly well suited for demanding production processes, such as recycled polyester or fine filaments. The reason: In the event of a yarn break, only one end breaks. All the other positions are not affected and continue to run. As a result, this plant has a higher efficiency compared with a multi-end technology plant. For example, with ten breaks a day, the efficiency of the Sytec One is still over 98%, while a threeend technology achieves only 92% efficiency.

Higher productivity due to the straight yarn path

The machine concept of the Sytec One with its absolutely straight yarn path in spinning and texturing also enables significantly higher process speeds compared to multi-end technologies. This results in a speed increase of up to 15%. In addition to standard processes, more demanding processes with higher break rates play an increasingly important role. "The product mix is critical to the choice of technology," said Martin Rademacher, vice president of sales Oerlikon Neumag. "We are in the comfortable position of being able to offer our customers both a single-end and a three-end technology."

• Nathalie Brunel’s role is to support Lectra’s global teams in the roll-out of its new strategy to customers

Paris – Lectra, the world leader in integrated technology solutions dedicated to industries using fabrics, leather, technical textiles and composite materials, is pleased to announce the appointment of Nathalie Brunel to the role of Vice-President Sales, Fashion & Apparel. Based at Lectra’s headquarter’s in Paris, Nathalie reports to Edouard Macquin, Chief Sales Officer, Lectra and a member of the executive committee.

Nathalie Brunel’s role is to support Lectra’s subsidiaries as they conduct the Group’s strategic roadmap through the deployment of an offer—integrating the PLM and the cutting room of the future—which is rooted in customer experience. Nathalie will notably work with six countries: United States, China, Germany, United Kingdom, France and Italy.

“The fashion and apparel industry, a historic market for Lectra, is the pillar of our international presence. Our customers expect a high level of expertise and advice to meet the challenges they face due to the digitalization of their professions. Nathalie Brunel’s experience in transforming organizations and developing business for complex solutions within large groups is a valuable asset for both Lectra and our customers,” states Edouard Macquin.

“The fashion and apparel ecosystem is clearly entering the digital era. I aim to bring Lectra’s value proposition to our customers, facilitating their adoption of Industry 4.0 principles. I am proud to contribute to the integration of new technologies in their processes, from design to the finished product. It is crucial to meet the needs of companies facing a complex and fragmented market that is generating both local, and global, pressures,” underlines Nathalie Brunel.

Nathalie Brunel has over 20 years of experience in managing large accounts and management responsibility. In 1996, she joined the Altran group where she successively held the roles of Development Director, Director of a business unit, Associate Director, and Executive Director of large accounts. In 2011, Orange Business Services recruited Nathalie Brunel as Vice-President, Business Operations and Support, then Vice-President Large Accounts, Manufacturing and IT. Prior to joining Lectra, Nathalie Brunel held the position of CEO and shareholder of Okavango Energy, a consulting and industrial energy performance company.

Nathalie has a diploma from the Institut supérieur de commerce de Paris.

• HPR is the highest status a plant can achieve for fire risk prevention and protection
• The site Ideal Fibres & Fabrics Comines is the second in the Beaulieu International Group to reach HPR status
• Underlines Group’s commitment to risk prevention at B.I.G. sites & to reinforcing our strong business contingency plan

Wielsbeke, Belgium – Beaulieu Yarns, the global supplier of high-quality polyamide and polypropylene yarns, is pleased to announce the achievement of Highly Protected Risk (HPR) status for its French production site, Ideal Fibres & Fabrics Comines. Awarded by FM Global, HPR designation means a facility meets the highest industry standards for property protection.

FM Global, Beaulieu International Group’s (B.I.G.) industrial property and business interruption insurer for the past two years, offers a unique concept that supports the Group in reducing its exposure to loss and increases its business resilience. A dedicated worldwide team of engineers focuses on providing assistance and protection of its assets, helping the Group to achieve a higher level of risk protection.

The Ideal Fibres & Fabrics Comines site produces high quality yarns for a large variety of application and market segments including the automotive industry. It scored exceptionally well in its FM Global assessment which focused on aspects including fire protection, protection against natural hazard, mechanical breakdown of machinery and also cyber risks.

Its overall risk mark of 76 ranks it within the top 25% of its industry for fire risk prevention and protection.

Commenting on the Award, Emmanuel Colchen, Global Sales Director Yarns within BU Beaulieu Engineered Products, said: “This HPR yarn production site reinforces strongly our supply chain security and demonstrates our engagement towards our customers and partners. Our contingency planning and risk management are essential, well-considered elements within our long-term business strategy to demanding sectors such as Automotive and Commercial & Residential floor covering contracts.”

Ideal Fibres & Fabrics Comines is the second facility in the Group to attain HPR status, and the very first in Europe. Pinnacle Polymers LLC in the USA also achieved the HPR as a chemical plant, which is a rare achievement within the chemical business. Fire risk prevention is part of the Group’s broader risk management activities. B.I.G. is investing in increasing the level of protection at all B.I.G. plants in order to protect its business continuity.

The divisions of B.I.G. are also implementing a number of safety programmes to raise awareness of workplace safety and to maintain strong safety records.

Karena Cancilleri, Vice President BU Beaulieu Engineered Products, commented: “I am proud of Beaulieu Yarns for achieving the highly-regarded FM Global HPR Award and setting an example for the whole Beaulieu International Group. This positive step reflects the strong commitment of the Engineered Products division and the rest of the Group to improving safety and protecting our workplaces and our production facilities.”

Beaulieu Yarns received the HPR Award at a ceremony on November 7, 2017 attended by all staff, and representatives of B.I.G. Management, Beaulieu Yarns Management and FM Global Management.

• Huntsman continues to inject its leading edge innovation in bangladesh to support textile industry with sustainable practices

Singapore - In a signing ceremony, Huntsman Textile Effects announced that it has extended the partnership and collaboration agreement with Viyellatex Group for another two years. The agreement will see the Viyellatex Group continuing to use Huntsman as its preferred and sole supplier for industry leading dyes, chemicals and dying auxiliaries. This partnership, now in its 17th year reinforces the recognition of Huntsman as a trusted and preferred supplier for the Viyellatex Group. Under this agreement, Huntsman will support Viyellatex’s Group of mills to streamline operations and optimize processes, train technical staff, and make recommendations to help improve yield and productivity. This strategic cooperation will enable Viyellatex Group to continue to achieve operational excellence.

“We are extremely pleased and proud of this continuing partnership with the Viyellatex Group. As a global leader in the transition to a more sustainable textiles sector, we are pleased to join hands with one of the country’s leading exporter of ready-made garments (RMG) and a supplier to leading international brands, commented Chuck Hirsch, Vice President, Sales and Technical Resources, Huntsman Textile Effects. “This cooperation agreement will also help Viyellatex Group to maintain its leading edge in the textile industry by leveraging on Huntsman’s R&D capabilities, innovation and focus on sustainability, while continuing to comply with the stringent requirements of its export customers around the world,” continued Mr Hirsh.

Speaking on the occasion Mr. David Hasanat, Chairman of Viyellatex Group said, “Viyellatex Group is the leading company in the area of sustainable apparel in Bangladesh. This continuing support and technical expertise from Huntsman will help us be more competitive in this increasingly challenging market. It will help us to comply with the stringent product demands from our global customers and better equip us to face challenges from the operational and environmental aspects.” He continues, “Viyellatex Group places strong emphasis on sustainability by minimizing energy usage, adopting waste and water recycling, and using only organic materials and environmentally compliant chemicals and dyes and Huntsman is the perfect partner in this regard as they share this vision.” “We are pleased to be conferred Preferred Supplier Status from Viyellatex Group, partnering with one of the leading apparel groups in Bangladesh” , said Mr. Dheeraj Talreja, Commercial Director - South Asia, Middle East & Africa of Huntsman Textile Effects. “This partnership is a great testament of our customers’ trust and confidence in Huntsman’s quality, proven expertise, products and service delivery,” he continued.

In conjunction with this signing ceremony and as an active supporter of Bangladesh’s textile industry, today Mr Hirsch also hosted a customer seminar for more than 500 customers and prospects in the country’s capital, to provide them with leading edge technologies to help them be more sustainable with competitive value-add to customers.

Huntsman Textile Effects holds regular seminars and workshops and also collaborates with textile mills and apparel manufacturers to adopt new technologies and processes that conserve resources, reduce waste and improve productivity.

Bangladesh’s textile industry is the nation’s largest export sector. The ready-made garment (RMG) sector is worth US$28.14* billion in 2016-2017, with more than 4,300 garment factories employing about 4 million people and accounting for 80.7% of the country’s total exports. To remain internationally competitive, local textile mills and RMG factories increasingly have to demonstrate that they operate in a socially and environmentally sustainable way.

• Revenue up 11 percent to EUR 1,149.1 mn
• EBITDA increase of 38.8 percent to EUR 270.7 mn
• Detailed planning for new production plant for TENCEL® fibers in Thailand in Progress
• New sales offices opened in Turkey and Korea
• New EcoVeroTM branded viscose fibers with very favorable ecological footprint launched

The Lenzing Group generated new record highs in the first half of the 2017 financial year for both revenue and earnings. The key underlying factors were good capacity utilization, higher selling prices and an attractive product mix. Lenzing will continue to focus on the disciplined implementation of the Group strategy sCore TEN, in order to be even closer to the customer and to further expand the offering of specialty fibers.

Consolidated revenue increased by 11 percent from the first half of the previous financial year to EUR 1,149.1 mn. Consolidated earnings before interest, tax, depreciation and amortization (EBITDA) were up 38.8 percent to EUR 270.7 mn, corresponding to an EBITDA margin of 23.6 percent in comparison to 18.9 percent in the prior-year period. Earnings before interest and tax (EBIT) increased by 57.4 percent to EUR 204.2 mn, resulting in a higher EBIT margin of 17.8 percent (H1 2016: 12.5 percent). The profit for the period improved by 58.9 percent to EUR 150.3 mn, and earnings per share climbed 59 percent to EUR 5.55 per share.

“The first half-year developed very well for the Lenzing Group, and we are pleased with the best half-year period in the company’s history. We will continue our disciplined implementation of the sCore TEN strategy. The expansion of new state-of-the-art production capacities for our specialty fibers is proceeding well and will support our customers in their own expansion efforts for products made of our botanic fibers. The decision to set up a subsidiary and acquire a respective landplot in Thailand is the next step in the implementation of this strategy. On the innovation side we are proud that after the introduction of RefibraTM branded lyocell fibers, we launched now EcoVeroTM. This is a particularly high-performance fiber featuring a very favorable ecological footprint and sets the new benchmark for the entire industry – from fiber to garment”, states Stefan Doboczky, Chief Executive Officer of the Lenzing Group. “Assuming that fiber market conditions remain at current levels, we expect a substantial earnings improvement in 2017 compared to 2016.”

Lectra has leveraged more than 10 years of experience in connected manufacturing to offer Versalis®, an innovative digital solution designed to cut leather without compromise on quality. Featuring a powerful automatic nesting system for overall improvements in efficiency, the fully automated solution enables automotive leather suppliers to cut costs, improve productivity and minimize waste while also establishing a pathway to value-added Industry 4.0 processes.

Currently, almost 90% of leather used for automotive applications is cut using manual die presses, which require designers to build a physical prototype and finalize the design through trial and error. Lectra offers a fully digitalized leather solution from prototyping to cut parts—when used in combination with Lectra’s 3D prototyping and pattern-making software, Versalis digital leather cutting solution enables a 12-16 week reduction in development and launch cycles for vehicle seating models.
During the leather-cutting phase, the latest release of Versalis LeatherSuite allows automotive leather suppliers to achieve up to 15% greater productivity. Lectra’s end-to-end automotive leather offering furthermore guarantees optimal uptime through an extensive worldwide support network of field engineers and technical experts.
"Lectra focuses on a consultative approach that allows it to fully understand the customer’s needs before building a solution comprising software, hardware, consulting, training, and after-sales support,” said Frost & Sullivan Industry Analyst Kamalesh Mohanarangam. "Lectra’s equipment is fitted with more than 200 sensors that predict failure and immediately report issues to its call centres. This product feature and service has resulted in 98% uptime and very fast mean time to repair."

Although digital leather cutting solutions are an investment, leather cutters and Tier-1 suppliers have begun to recognize the value of these products. On average, Lectra’s solutions help customers achieve up to 7% savings on leather compared to manual die-press methods by minimizing human error and variability in the cutting room. A benchmark test of leather trim cutting for door panels demonstrated a 3.5% gain in material made possible by Versalis’ superior nesting capabilities compared to the customer’s yield using manual nesting with die press machines, representing potential savings of €9 million per year.
Versalis is the fruit of significant R&D investment for the company, which has always made re-investment of capital a priority. As part of a transformational plan, Lectra spent more than €50 million in investments between 2011 and 2015. With Lectra’s new strategy focusing on supporting their customers’ transition to Industry 4.0 standards, Lectra will increase the share of revenues dedicated to R&D to 10% for the period from 2017 to 2019, representing a rise of about 50% between 2016 and 2019.

 Hall 4.1 Booth F13, 9-12 May, Frankfurt-am-Main, Germany Wielsbeke, Belgium – May 8, 2017 – Beaulieu Fibres International, the leading European polyolefin fibre producer, demonstrates its strengths as a “Technology Innovator” at Techtextil 2017, promising more fibre innovations to address market demand in segments such as automotive, flooring and geotextiles.
Beaulieu Fibres International’s recent Supplier Excellence for Technological Innovation Award from Yanfeng Automotive Interiors, is just one example of its commitment to developing innovative new products in close cooperation with customers to enable them to bring more environmentally-friendly, lighter and better performing products to market.
To support this, Techtextil visitors will hear first-hand of Beaulieu Fibres International’s investment in new fibre technology on an industrial scale in Belgium. The EUR 15 million investment will be commissioned in November 2017. It is part of an ongoing programme to extend fibre production to meet future challenges and customer needs.

At Hall 4.1 Booth F13, Techtextil visitors can get insights on upcoming products and explore Beaulieu Fibres International’s extensive and diversified portfolio of Mono, Round and Trilobal fibres, plus BICO-fibres. Donald De Deygere, Sales and Marketing Manager Fibres Industrial, Beaulieu Fibres International, comments: “Being the European leader for polyolefin staple fibres, it is also our commitment to stay ahead as Technology Innovator. Our innovation strategy is the cornerstone of our activities and various awards have proven this success. We are proud to announce new industrial investments in both Belgium and Italy amounting to more than EUR 80 million over 2016-2018.”