From the Sector

Once again Tonello will be present their technologies and partnerships at Kingpins from October 18-19.

DyeMate, the ozone, THE Laser
DyeMate is Tonello's new "patent-pending" technology that reinterprets the traditional indigo garment dyeing process, by making it automatic and repeatable, efficient and sustainable: carried out in a nitrogen atmosphere, without oxygen, with controlled reduction and oxidation, to achieve results that are perfectly comparable, in terms of authenticity and "aesthetic flavor," to those of denim that fades and becomes vintage with the passage of time.

Tonello will present a collection of garments with super bleach effects. With OBleach, EGO and O-Zone triad redefined the garment bleaching process, including no harmful chemicals such as chlorine and permanganate, in favor of sustainable and healthy production.

The entire collection will be embellished and finished with aesthetic solutions and details: the natural overdyeing of Wake, the ultra-thin graphics made with THE Laser Lab, the reproducible breakages of THE Laser T and TM.

Collections, design, collaborations
The MSP - Most Sustainable Product - collection, developed together with Kingpins and Denim House, designed by Piero Turk and Serena Conti, and processed in Tonello's Research and Development Center with the latest responsible finishing technologies, returns this year.

Tonello will also present another project: ONE Denim. A collection that aims to combat resource waste in the denim industry by demonstrating concretely how many new denim garments could be made from a single fabric by optimizing processes and choosing appropriate technologies and production methods. The fabrics chosen are from Sharabati Denim, the design is by Piero Turk, and the collection is processed by Tonello.

SA-KE
This project was born out of a dialogue between Tonello's technology and the creativity of British designers Sadia Rafique and Kelly Harrington, who produced as many as 70 artworks that are partly physically present at Kingpins and partly published in a book-zine that tells the philosophy and logic of this unique and original work. A work that combines technology, expressive research and all new forms of image generation, across the boundary between natural and artificial, but still totally human.

Digital fashion outlet Otrium announces the launch of a dedicated garment refurbishment and repair programme for damaged returns following a successful pilot scheme. The initiative is being run in partnership with Bleckmann, experts in supply chain management for fashion and lifestyle brands. Working with Bleckmann’s team of circular fashion experts from The Renewal Workshop, Otrium is taking the next step in its strategic journey to help reduce the number of that might ultimately end up in landfills or destroyed.
 
Most of the returns that Otrium currently receives can be easily restored and put back on sale. However, in rare cases, returned items are damaged. “Preventing waste is an important part of Otrium’s DNA, and thanks to our partnership with Bleckmann and their Renewal Workshop team, we can now repair the majority of damaged returns and put them back into circulation,” said Kevin Carolan, Director of Logistics at Otrium. “We are happy that we can use our position in the fashion supply chain to create lasting change and accelerate towards our mission of reducing the volume of garments that go to landfill.”

Since 2020, Otrium is exploring refurbishment and repairs with their third-party logistics provider Bleckmann. In April 2023, both partners started a three-month pilot at Bleckmann’s facility in Almelo, the Netherlands, to expand the programme with a broader range of repairs and optimised processes through data use. During the pilot, the Renewal Workshop team at Bleckmann refurbished more than 1,000 returned garments, shoes and accessories for Otrium each month.

“With hundreds of high-end labels on the platform, we needed an efficient solution tailored to the needs of a wide range of products – from shoes and coats to bags,” explained Marlot Kiveron, Head of Sustainability at Otrium. “The Renewal Workshop team worked closely with us to develop a streamlined and scalable process that could grow in line with our ambitions, delivering like-new repairs at the speed of e-commerce. Their combination of purpose, professionalism, agility and expertise makes them the ideal partner for this kind of project.”
 
Bleckmann’s integrated data capabilities were also crucial to the success of the partnership. “Data collection and analysis can be vital in demonstrating the commercial viability of sustainability initiatives,” said Tamara Zwart, Director of Renewal at Bleckmann. “Using our advanced stock tracking systems, we determined that 70% of the renewed Otrium stock had been sold within seven weeks. We’re all delighted with the results!”
Furthermore, carbon-tracking software Vaayu calculated that on average, a refurbished return sold on Otrium avoids 2.760kg of carbon emissions and 69g of waste proofing that this programme can have a positive impact on both: the planet and the business.

Having established the business case, the team decided to expand the initiative beyond the pilot phase. “This project is a milestone in our sustainability journey,” concluded Marlot. “It’s a key part of our ongoing commitment to finding more ways to reduce our environmental impact while helping to ensure that more clothes get worn. By the end of 2023, we aim to repair at least 25,000 damaged garments. Together with Bleckmann and their renewal experts, we’re well on our way to proving that this circular business model can be a valuable part of our future growth.”

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.

Beaulieu International Group will turn the spotlight on geotextile products with sustainability benefits to support progress in resilient civil engineering projects at the 12^th ICG Rome from 18^th -21^st September 2023, presenting options to target fossil carbon reduction by choosing PP-based staple fibres or woven geotextiles that are among the lowest in carbon footprint for geosynthetics.

For manufacturers of nonwoven geotextiles, Beaulieu Fibres International (BFI) offers PP fibres with > 25% carbon footprint reduction compared to the European standard PP fibres, generating 1.48 kg CO₂/kg PP fibres. A step further is to accelerate the replacement of fossil carbon in engineered fibre applications by choosing its ISCC Plus certified bio-attributed MONO-PP with a negative carbon footprint.

For construction projects, nonwoven geotextiles made with high-tenacity HT8 fibres are proven to secure a longer service lifetime and reduce the environmental impact, as they offer high mechanical performance at a reduced weight.

Beaulieu Technical Textiles' (BTT) woven geotextiles provide a wide range of functions, including separation, filtration, reinforcement and erosion control, and are among the most sustainable in the industry. Depending on weight, the carbon footprint of its woven geotextiles (m²) ranges between 0.37 and 1.40 kg CO₂ eq./m². They also minimize the use of natural resources for more sustainable infrastructure development. Case studies such as at the Ostend-Bruges airport highlight significant CO2 reduction on the jobsite by replacing the transport of 960 trucks of gravel with 3 trucks of woven geotextiles, and by extending the runway’s life span.

The ICG launch of its new line Terralys MF woven filtration geotextiles with monofilament boosts the performance of a common solution in building layers that require high water flow rates. High-tenacity extruded polypropylene tapes and monofilaments are interwoven to form dimensionally stable and highly permeable geotextiles. These new filtration geotextiles provide greater resistance to dirt and biological clogging. They allow water to travel freely while reducing soil erosion when employed as a separation and stabilizing layer.

As of September 2023, all PP staple fibres and woven geotextiles will have Environmental Product Declarations (EPD) based on LCAs. Each EPD is an essential tool for communicating and reporting on the sustainability performance and helps carbon-conscious customers in their purchasing and decision making. Registered EPDs are globally recognized, publicly available and free to download through EPD Libraries.

The FoxCore founding team and the ITM at TU Dresden aim to usher in a new era for fastening solutions in lightweight construction with the start of the Exist research transfer project FoxCore. The project started on June 1, 2023, and will run until November 30, 2024, with support from the German Federal Ministry of Economics and Climate Protection (BMWK) and the European Social Fund (ESF).

The innovative company is to develop and offer new and customer-oriented fastening solutions for lightweight construction applications. Safety and performance of lightweight solutions in various industries are to be increased. FoxCore's objective is to take a leading role in fastening technology.

Daniel Weise, Philipp Schegner, Michael Vorhof and Cornelia Sennewald form the FoxCore team; they will work closely with the Institute of Textile Machinery and Textile High Performance Materials (ITM) at TU Dresden. Together, they will develop optimal manufacturing technologies and establish a widespread network of customers and suppliers.

• Revenue of US$4B, a decline of 1% QoQ and 27% YoY
• Reported EBITDA of US$321M, an increase of 7% QoQ and decrease of 68% YOY
• Operating cash flows of US$491M
• Net Operating Debt to Equity of 0.95x
• Reported EPS of THB 0.04

Indorama Ventures Public Company Limited (IVL) reported marginally improved quarterly earnings as the company’s inherent advantages and continued focus on improving competitiveness helped bolster its business amid a continued weak operating environment.

Indorama Ventures achieved Reported EBITDA of $321 million in 2Q23, an increase of 7% QoQ and a decline of 68% YoY. Sales volumes remained resilient, rising 4% QoQ, amid continued destocking in the global chemicals industry from its peak in 4Q last year. Management is taking steps to conserve cash and safeguard the company’s competitive advantages as the global industry is impacted by increased capacity and lower margins with China boosting exports to offset muted domestic demand. Measures include redoubling efforts to reduce working capital and capex targeting $500 million of cash savings this year, optimizing the company’s European manufacturing footprint, and continued focus on Project Olympus, digitalization, and organizational enhancement.

Volumes are expected to improve in the second half of the year, with all three of Indorama Ventures’ business segments benefiting from the management measures and a gradual improvement in the outlook for the industry. Combined PET, the company’s largest segment, posted Reported EBITDA of $194 million, a 37% increase QoQ as destocking eased in most markets and supported stable volumes. Sales volumes are expected to grow in the second half of the year as manufacturing is optimized in Europe and expansion projects ramp up in India.

Fibers segment achieved Reported EBITDA of $20 million, a decrease of 37% QoQ, impacted by lower margins in the Lifestyle vertical and weak demand for Hygiene products in Europe. Volumes are expected to improve as manufacturing in Europe is optimized and expansion projects come online in the U.S and India. Mobility fibers volumes will see improvement in line with increasing automotive demand. Integrated Oxides and Derivatives (IOD) segment posted a 27% decline in QoQ Reported EBITDA to $94 million amid destocking in Crop Solutions market. Volumes will continue to be supported by reducing levels of destocking in the downstream portfolio.

UK’s Optima 3D is delivering its weaving technology to the USA, for installation at the University of Maine’s Advanced Structures and Composites Center (ASCC).

The 3D weaving system consists of an Optima 3D Series 600 shuttle weaving machine with an integrated 2,688-hook Stäubli SX jacquard and harness. It is also complemented by Optima’s compact warp delivery creel and an associated pirn winder for shuttle bobbins and a spool winder for creel spools.

Optima’s looms offer many advanced features over conventional weaving machines, particularly in terms of versatility, as a result of the comprehensive use of digital control systems allowing rapid parameter and sequence changes, coupled with an innovative shuttle system.

The ASCC is certainly no stranger to advanced technology, or indeed ambitious composite projects – in 2019 it received no less than three Guinness World Records, for the world’s largest prototype polymer 3D printer, the largest solid 3D-printed object, and the largest 3D-printed boat. In its latest project it has further introduced BioHome3D – the first 3D-printed house made entirely with bio-based materials developed in a partnership with Oak Ridge National Laboratory. The 182-square-metre prototype features 3D-printed floors, walls and roof which are fully recyclable and highly insulated with 100% wood insulation and customisable R-values. Construction waste was nearly eliminated due to the precision of the printing process.

• Revenue of EUR 1.25 bn and EBITDA of EUR 136.5 mn in the first half of 2023
• EBITDA and net result for the period significantly improved compared with the first quarter of 2023
• Cost-cutting program and measures to strengthen sales activities being implemented as planned
• Liquidity position strengthened by successful capital increase and extension of credit terms
• Production of TENCEL™ brand modal fibers successfully launched in China

The business performance of the Lenzing Group, a leading global supplier of specialty fibers for the textile and nonwoven industries, largely reflected the subdued market trends in the first half of 2023. After the market environment deteriorated significantly in the second half of 2022, signs of recovery were evident during the first and second quarters of 2023 in terms of both raw material and energy costs as well as demand. Textile fibers recorded improving demand, and business with nonwoven fibers and with dissolving wood pulp proved to be very stable.

Outlook
The war in Ukraine and the more restrictive monetary policy pursued by many central banks in order to combat inflation are expected to continue to influence global economic activity. The IMF warns that risks remain elevated overall and forecasts growth of 3 percent for both 2023 and 2024. The currency environment is expected to remain volatile in the regions of relevance to Lenzing.

This market environment continues to weigh on the consumer climate and on sentiment in the industries relevant to Lenzing. Recently, however, the outlook brightened somewhat according to a global survey by the ITMF.*

In the trend-setting market for cotton, signs are emerging of a further buildup of stocks in the current 2022/23 crop season. Initial forecasts also see a further buildup of stocks in 2023/24, albeit to a lesser extent.

However, despite signs of recovery in both demand and raw material and energy costs, earnings visibility remains limited overall.

Lenzing is fully on track with the implementation of its reorganization and cost-cutting program. These and further measures are aimed at positioning Lenzing in the best possible way for the expected market recovery.

In structural terms, Lenzing continues to anticipate growth in demand for environmentally responsible fibers for the textile and clothing industry as well as the hygiene and medical sectors. As a consequence, Lenzing is very well positioned with its “Better Growth” strategy and plans to continue driving growth with specialty fibers as well as its sustainability goals, including the transformation from a linear to a circular economy model.

The successful implementation of the key projects in Thailand and Brazil as well as the investment projects in China and Indonesia will further strengthen Lenzing’s positioning in this respect.

Taking into consideration the aforementioned factors and assuming a further market recovery in the current financial year, the Lenzing Group continues to expect EBITDA in a range between EUR 320 mn and EUR 420 mn for 2023.

*Source: ITMF, 21st Global Textile Industry Survey, July 2023

The KARL MAYER GROUP and the Südwolle Group have joined forces in a project to explore the possibilities of merino wool for warp knitting technology. The project was triggered by the increasing demand for textiles made from sustainable and environmentally friendly materials. The cooperation was to develop innovative fabrics from renewable raw materials for use in underwear and functional sportswear. The focus of the work was on the use of wool as a material with excellent comfort properties and the look and feel of lightweight single jersey goods. The natural fiber fabric qualities are not typical for warp knitting processing, so the challenges during the project work were diverse.

Merino wool yarns with good running properties
Regarding the choice of material, the product development team of Südwolle Group recommended the Hidalgo yarn from their product portfolio. The yarn was created using the in-house developed Betaspun technology, in which a filament was twisted around a merino core. When natural fibres such as wool, cotton or silk are combined with sustainable fibres such as biodegradable polyamide as the filament, the spinning process can create durable, lightweight yarns that disintegrate completely without residue after use. The yarns made from the two components also have good running properties for use in warp knitting. "The polyamide content of the yarn increases its tenacity, reduces hairiness and makes it an excellent choice for warp knitting technology," confirmed Gabriela Schellner from KARL MAYER's Textile Product Development Department.

Shape stability paired with single jersey "look and feel"
The Hidalgo yarn, which is made from merino wool, was processed on a warp knitting machine using a carefully thought-out lapping selection to produce a light, soft fabric which, above all, retains its shape. The textile specialists at KARL MAYER had experimented with two different single bar fabric qualities beforehand and had thus adopted a new approach for jersey machines.

The first results are promising. Now more trials are needed to perfect the technique. Development partners are needed, including fabric producers, brands, and garment manufacturers, with whom the fabric qualities, machine equipment and orientation to the end applications can be refined. The KARL MAYER GROUP and the Südwolle Group are also unanimous in their desire to push the boundaries of what is possible with merino wool and knitting technology and to develop new solutions for the textile industry through further project work.