From the Sector

Flat knitting solutions provider SHIMA SEIKI MFG., LTD., Japan, together with its Korean subsidiary SHIMA SEIKI KOREA INC., will participate in the Preview in SEOUL exhibition in Seoul, Korea this month.

Taking advantage of new regulations at the show which allow for the display of textile equipment at the venue this year, SHIMA SEIKI will be showing its latest combination of WHOLEGARMENT® knitting technology that allows a garment to be produced in its entirety without the need for linking or sewing afterward, and SDS®-ONE APEX series design software yields revolutionary game-changing flexibility and efficiency, not to mention sustainability.

Shown for the first time in Korea, whose flat knitting market has a strong following for WHOLEGARMENT® knitwear, is the SWG-XR next-generation WHOLEGARMENT® knitting machine. The SWG- name pays homage to the original SWG-X model of 1997, sharing with it the same 4-needlebed configuration featuring the company's own SlideNeedle™. Add to this a renewed spring-type moveable sinker system, a compact and lightweight carriage featuring 4 systems as well as auto yarn carriers. All contribute up to 25% higher efficiency, higher quality and increased product variety for supporting knits for all seasons. SWG-XR sets new standards for the next generation of waste-free, sustainable WHOLEGARMENT® knitting.

APEXFiz™ is subscription-based design software that maintains the proven functions that have made SHIMA SEIKI’s SDS®-ONE APEX series design systems so popular with fashion designers. Installed on personal computers, those strengths are now enhanced with the added versatility to adapt to different work styles and business environments including teleworking and telecommuting. APEXFiz™ software supports the creative side of fashion from planning and design to colorway evaluation, realistic fabric simulation and 3D virtual sampling. Virtual samples are a digitized version of sample making that are accurate enough to be used effectively as prototypes, replacing physical sampling and consequently reducing time, cost and material that otherwise go to waste. APEXFiz™ thereby helps to realize sustainability and digitally transform the fashion supply chain.

As a sub-exhibitor of Oerlikon, BB Engineering will present its product range in the fields of extrusion, mixing and filtration as well as PET recycling with the VacuFil and VarioFil R+ systems at the K show 2022.

BB Engineering has been focusing its development work increasingly on recycling technologies for several years. In addition to extruders, filters and mixers that are suitable for both recycling processes and the processing of recyclate, BB Engineering offers a complete PET recycling plant called VacuFil.

With VacuFil, BB Engineering has developed an innovative PET LSP recycling process. The process combines gentle large-scale filtration and targeted IV regulation for consistently outstanding rPET melt quality. Thus, much more than simple "downcycling" is possible with VacuFil. VacuFil processes a wide range of input materials - post-production and post-consumer. The patented key component Visco+ vacuum filter removes volatile impurities quickly and reliably. VacuFil is a modular system that can be designed for different recycling applications. Simple granulation is possible, but also direct feeding into further processing, e.g. in the synthetic fiber spinning mill. BBE offers VacuFil in combination with its own VarioFil compact spinning plant to produce polyester yarn.

At the K show 2022, visitors can experience the VacuFil Visco+ recycling technology in operation with a connected VarioFil spinning plant and see live how recycling yarn is produced from PET waste.

• INDA Announces Full Program and Opens Registration for Premier Event in New Orleans

With reusable and recyclable products and new inputs offering growth opportunities in absorbent hygiene and personal care products, Hygienix™ will provide an insightful view into the market’s future this November in New Orleans.

Industry participants from around the world and throughout the supply chain will convene and connect for the eighth edition of the premier event for the fast-growing segment on November 14-17, at The Roosevelt New Orleans Hotel.

The in-person conference will highlight the segment’s continued growth and new opportunities with presentations by more than 20 industry experts on sustainable inputs, natural fibers, product transparency, reusable menstrual products, recyclable diapers and more as well as the latest market forecasts and insights into consumer buying trends.

Hygienix also will offer two specialized workshops, and a myriad of business connection opportunities including a welcome reception on Nov. 14 and a first-time attendee mentorship program.
Participants will discover innovative products in absorbent hygiene and personal care at tabletop exhibits with evening receptions on Nov. 15-16, providing opportunities for 60 companies to showcase their unique offerings.

Three finalists will each present their innovative and technically sophisticated disposable absorbent hygiene products as they vie for the prestigious Hygienix Innovation Award™. Nominations are open until August 29. Demonstrating the interest in sustainability, last year’s award recipient was Kudos Diaper Subscription featuring its 100% cotton disposable diaper.

Hygienix Highlights
Absorbent hygiene – the single largest nonwoven end‐use category (by square meters) – is expected to continue its strong growth over the next four years, creating market opportunities in this thriving area driven by growing consumer interest for environmentally-friendly options in material inputs and end-of-life options.

Participants will hear the latest data and forecasts from analysts during presentations by Robert Fry, Jr., Ph.D., Principal of Robert Fry Economics LLC on the Global Economy – What we Can Expect in 2023; Pricie Hanna, Managing Partner, and Colin Hanna, Director of Market Research, Price Hanna Consultants on Disposables versus Reusables; and Simon Preisler, Vice President of Logistics, Central National Gottesman delivering a Logistic Market Update.

A panel of entrepreneurs will discuss the challenges, biases and taboos to bringing innovations into the marketplace. Experts sharing their insights will be Mia Abbruzzese and Alexandra Fennell, co-founders of Grace; Amrita Saigal, founder and CEO, Kudos; and Cindy Santa Cruz, President of ParaPatch.

A session on Next-Generation Menstrual Products and their Users will feature Liying Qian, Research Analyst, Euromonitor International providing market data on disposable and reusable period products; Frantisek Riha-Scott, Founder, Confitex discussing reusable products; and Greta Meyer, Co-Founder and CEO, Sequel on Reengineering the Tampon.
Also focusing on period products will be a presentation by Danielle Keiser, Managing Director, Impact, Madami on Changing the Conversation with Consumersmoderated by Heidi Beatty, Chief Executive Officer, Crown Abbey, LLC.

Other intriguing not-to-be-missed presentations centered on sustainability trends include:

• Assessing Sustainable Fiber Options in the Context of Disposable Hygienic Products – Richard Knowlson, Principal, RPK Consulting LLC
• Five Generations of Hygiene + Sustainability – Matt Schiering, Professor of Marketing, Dominican University
• Recycling Approaches for Disposable Diaper Waste – Jeannine Cardin, Quality and R&D, RecycPHP Inc.

Hygienix will provide additional focused learning opportunities with two essential short courses (with separation registration fees) on Nov. 14 focused on Absorption Systems for Absorbent Hygiene Products, from 1 to 3:30 p.m. and Global Diaper Trends from 3:45 to 6 p.m.

The FACHPACK in Nuremberg ranks among the most important packaging industry gatherings. From 27 to 29 September 2022, Sappi will be presenting its latest products and solutions for functional paper packaging, flexible packaging papers, label papers, containerboard and paperboard. The company is focusing its efforts on sustainable, recyclable and innovative solutions.

• Wide range of barrier papers in the market for sustainable and recyclable packaging solutions
• High-impact brand presence in corrugated board packaging thanks to Fusion Nature Plus in combination with Fusion Topliner
• Parade Label Pro wet-glue label paper for an efficient operation and an excellent visual impression

Wide range of barrier papers
Sappi’s ultimate goal as a specialist in barrier papers is to replace non-recyclable aluminium and plastic multi-layer laminates through the introduction of truly sustainable alternatives that meet all market requirements in terms of performance and recycling. Sappi is continuously expanding its portfolio of barrier papers. At the show, Sappi will be showcasing several examples of food and non-food applications using these barrier papers.

A smooth surface and a high degree of whiteness: Parade Label Pro
Sappi will also be presenting its new, non-wet-strength wet-glue label paper Parade Label Pro – featuring samples from all over the world. This glossy, double-coated quality paper offers a smooth surface plus a high degree of whiteness. It’s suitable for numerous label and flexible packaging applications, such as labels for disposable bottles, food and non-food containers as well as wrappers for a variety of products. It can be printed in offset, flexo and gravure, and finished with hot foil and blind embossing, for example.

Brand presentation that appeals to the senses
“For manufacturers of branded goods, it is becoming increasingly important to convey brand values and product characteristics in a way that is emotionally appealing and that really sets the stage,” explains Luis Mata, Sales Director Packaging of Sappi Europe. At the FACHPACK, Sappi will also be presenting its containerboard products for corrugated board applications, which, with their brilliant colour reproduction, enhance on-shelf product impact and ensure real brand differentiation.

Sappi’s popular Algro Design paperboard portfolio also allows the design scope and leeway to communicate brand values in an emotionally appealing way.

International technology group ANDRITZ will be presenting its nonwovens production solutions at CINTE 2022 in Shanghai, China – one of the main trade fairs for technical textile and nonwoven products in Asia. ANDRITZ will show its product portfolio covering state-of-the-art nonwovens and textile production technologies such as air-through bonding, airlay, needlepunch, spunlace, spunbond, wetlaid/WetlaceTM, converting, textile finishing, recycling, and natural fiber processing.

ANDRITZ supports nonwovens producers in the move to sustainability with the aim of reducing or eliminating plastic components while maintaining the high quality of the desired product properties. This applies to all types of sustainable wipes, such as flushable, biodegradable, bio-sourced, carded pulp or standard carded wipes. The latest development in this field is the ANDRITZ neXline wetlace CP line, which integrates the carded-pulp (CP) process. This is a fully engineered production line combining the benefits of drylaid and wetlaid technologies to produce a new generation of biodegradable wipes.

The neXline wetlaid aXcess targets smaller and medium production volumes and has been devised for new and existing lines. The line is easy and fast to ship due to the compact design, which also fits perfectly into containers. An operator-friendly configuration and versatile design ensure efficient production at affordable investment costs.

The aXcess range was specially developed at ANDRITZ (China) Ltd. Wuxi Branch to handle medium capacities. The facility in Wuxi has an experienced platform for production and service specially geared to serve the Asian nonwovens industry. With the aXcess range, ANDRITZ has developed a hybrid line combining European and Chinese machines, which is the ideal combination to obtain the best added value from each component in the line and be very flexible to accommodate different business cases.

• Commitment for a sustainable fashion industry

RadiciGroup participated in the third edition of PHYGITAL SUSTAINABILITY EXPO, which took place on 11 and 12 July in Rome. The event was focused on the ecological transition of fashion and design brands through technological innovation.

During the “narrated fashion show”, at the archaeological site of the Museo Dei Fori Imperiali, two sustainable garments by RadiciGroup were shown: the first completely recyclable ski suit made with recycled nylon and the Yamamay swimsuit made with polyester yarn obtained from recycling of plastic bottles.

Yamamay chose the sustainable polyester yarn Repetable® by RadiciGroup, for its new green beachwear proposal, with the aim of combining beauty and sustainability. Repetable is an innovative polyester yarn obtained through a process of recycling plastic bottles. Compared to virgin polyester, Repetable allows lower CO₂ emissions (-45%), lower water consumption (-90%) and lower energy consumption (-60%), while guaranteeing high performance. The new line “Edit” by Yamamay, which includes the swimsuit made with Repetable, has already been on the market since the end of last May.

The participation of RadiciGroup in the PHYGITAL SUSTAINABILITY EXPO represents further confirmation of the Group commitment to creating a fashion industry that is increasingly respectful of the environment, thanks to the involvement of all the players in the supply chain, which are most sensitive to sustainability.

New ideas were exchanged, brainstormed, and discussed freely at members’ booths at the Swiss Textile Machinery Pavilion during the recent Techtextil in Frankfurt. “Customers and researchers met Swiss textile machinery companies to explore the possibility of the not-yet-invented. “We regard our Pavilion as the place where future innovations catch a spark,” says Cornelia Buchwalder, Secretary General of the Swiss Textile Machinery Association. Further developments in the field of hybrid yarns were a hot topic. One example of this involves producing a yarn which has all the typical characteristics and advantages of carbon – but which also prioritizes careful use of resources, combining carbon fibres with thermoplastics.

Technical textiles cover a vast range of applications, and it’s still growing thanks to intensive research by specialist institutes and universities. Many members of the Swiss Textile Machinery Association maintain long-standing partnership with such bodies. Innovations are often joint efforts.

Feel-good technical fabrics
Some technical textiles feel like a second skin. A well-known example is activewear from the ‘sport tech’ field. Activewear includes breathable clothing, usually consisting of a three-layer-laminate: an inner lining, a breathable membrane in the center, and an outer fabric. The challenge is to bond the individual layers without losing breathability or softness, while meeting technical requirements such as resistance to a number of wash cycles.

Bonding solutions meeting top quality requirements, as well as ambitious standards for environmental protection and sustainability, were reinvented by the Cavitec brand from the Santex Rimar Group. This company’s hotmelt technology uses one-component polymers applied to textiles in a hot, molten state. Bonding based on hotmelts is both water- and solvent-free. Drying and exhaust air cleaning are not necessary, which is an ecological advantage. Energy consumption is also significantly lower. Cavitec hotmelt technology is also developed for laminated medical protection fabrics which are safe, high-quality and sustainable. These fabrics can be washed, sterilized, and used again.   

A second skin with added value is the result of Jakob Müller Group’s cooperation with an institute for an established outdoor fashion brand. They have devised a heating mat applied as an inner jacket. Outdoor gear with a heated inlay offers the wearer a comfortable feeling even in a cold climate. The heating mat is particularly light, breathable, flexible and adjustable to three temperature levels.

Fabrics with these advantages are now possible thanks to multi direct weaving (MDW) technology from the Jakob Müller Group. A lacquer-insulated heating strand is inserted into the base textile as a ‘meander’ using MDW technology. The technology is offered with both label weaving machines and the latest generation of ribbon weaving machines. The textile pocket calculator is another MDW based future-oriented application developed in cooperation with a textile research institute.

Safety and health
Life-saving reliability is a must for vehicle airbags. They have to fulfil high security aspects, and must remain inflated for several seconds when an accident occurs. Airbags made of flat-woven fabric – cut and seamed – can show weakness at seams during the inflation phase. Latest Jacquard technology by Stäubli enables one-piece-woven (OPW) airbags to be produced, creating shape and structure in a single process. The final product is an airbag consisting of a sealed cushion with woven seams. OPW airbag weaving reduces the number of production steps, and increases the security aspects.
Another big advantage of Stäubli’s new weaving technology is the flexibility in formats required in today’s mid- and upper-range cars, where lateral protection (in the seat or in the roof over the door) has become standard and is designed in line with the car shape. Safe airbags are woven on modern high-speed weaving machines. The warp material, the variety of fabric patterns, and the importance of precisely shaped airbags require the use of a robust and reliable Jacquard machine.

A revolution for orthopaedic patients is a knitting machine from Steiger Participations, which uses compressive yarns developed to meet the needs of the specific health market. This machine model was exclusively designed for production with inlaid elastic yarns and offers optimum performance with guaranteed final product quality.

In the orthopaedic field, many Steiger flat knitting machines have already been operating as automatic, custom-made production systems. For example, the dimensions of an injured limb are taken by the doctor and fed into a web-based application. The doctor selects the compression class in the various sections of the item and a data file created by the software automatically applies a preconfigured program. With no human intervention required, the program is generated and produced on the machine, precisely matching the patient’s dimensions. Each product is different, and generally available within 48 hours.

The recent Techtextil show in Frankfurt emphasised the diversity of applications for nonwovens and technical textiles, according to finishing technology specialist Monforts.

“We fielded enquiries at top management level from an extremely wide range of companies, all with very different ideas for new product applications during the show,” said Alexander Fitz, who joined the company a year ago as engineer for textile technologies and co-ordinator of the Monforts Advanced Technology Centre (ATC). Fitz brings a background in both technical textile technology and processes to the role, having previously worked for a nonwovens machinery builder and a roll-goods manufacturer.

Trials
“We are now looking forward to interesting new trials and pilot production runs, as well as the commissioning of new orders for machines resulting from the extremely busy exhibition,” he says. “Obviously, everyone at the moment is looking to make energy savings, and we have developed a range of options for helping companies increase their resource efficiency, both on new lines and as retrofitted systems, but this is not stifling innovation at the new material level.

“There was a lot of interest in what is possible with the Montex®Coat coating system and the range of different techniques it enables, and at our ATC in Mönchengladbach, a Montex®Coat unit is integrated into the full technical textiles pilot line, on which it is possible to run new fabrics in widths of up to 1.8 metres.”

Explosion proof
The technical textiles line at the ATC incorporates a Montex four-chamber stenter and is fitted with an explosion-proof coating application chamber in order to allow treatment to be carried out with organic solvents and other volatile materials.

Every single component within the chamber has to meet the standards of the European Union’s ATEX directives for working in a potentially explosive atmosphere. A range of sensors linked to alarms operate at various levels within the chamber to ensure the specified lower explosion limit (LOL) is never exceeded and the ventilation adapts accordingly.

Advanced functions
Special features on the finishing line relate to further advanced functions such as the ability to treat materials not only at temperatures of up to 320°C, but also to be able to treat the top and bottom faces of certain materials at different temperatures within a single pass through the machine.

To achieve this, the first two chambers of the stenter are fitted with special, heavy duty TwinAir ventilation motors and separate burners for individual top/bottom temperature. A temperature differential of up to 60°C can be achieved between the upper and lower nozzles within the chamber, depending on the treatment paramenters.

Another key feature of the technical textiles line at the ATC is the special stretching device which is capable of pulling ten tons in length and ten tons in width – a huge amount per square metre of fabric and necessary in the production of materials such as woven or 3D knits for high temperature filter media.

The 2002 prize of the Walter Reiners Foundation of the VDMA Textile Machinery Association for the best Master's thesis in German textile mechanical engineering was awarded to a young engineer from the ITA Institut für Textiltechnik of RWTH Aachen University. The prize ceremony took place at Techtextil 2022 in Frankfurt am Main, Germany. Peter D. Dornier, Chairman of the Board of the Walter Reiners Foundation, presented the award at the VDMA Textile Machinery Association’s booth.

Felix Xaver Zerbes, M.Sc., was awarded the "Promotional Prize for the Best Master's Thesis of the German Textile Machinery Industry 2022", endowed with 3,500 EUR, for his master's thesis "Development and Construction of a Separation Unit for Weft Yarns in Air Jet Weaving".

The subject of the master's thesis was the development of a mechanism with which faulty sections in the weft yarn can be sorted out before they are woven into the textile. This way, both yarn-related weft defects and material defects can be drastically reduced. The prototype developed by Mr Zerbes shows how this can be done even during the ongoing weaving process without having to stop production. Due to its modular design, the yarn rejection unit can be retrofitted to many different types of air-jet weaving machines, which represents an enormous savings potential not only in Germany but in weaving mills all over the world.

On June 13, EREMA Group and Borealis invited representatives of the international plastics and recycling trade press to Upper Austria for a sneak preview of the technological developments and lighthouse projects that the companies will present at K 2022, the plastics industry's international meeting place. The venue for the pre-K event was EREMA Group headquarters in Ansfelden.

EREMA Group K 2022 preview
In Düsseldorf, the subsidiaries of the EREMA Group - which are EREMA, PURE LOOP, UMAC, 3S, KEYCYCLE and PLASMAC - will present their technological innovations, services and support together at a Group trade fair stand for the first time. Seven new recycling systems and components will be presented that enable large-scale plants with a production capacity of up to 6 t/h while setting a milestone in recyclate quality and process stability. This is made possible by technological innovations in the plasticizing unit that have been specially developed for high throughputs with low specific energy consumption, the new EREMA 406 laser filter with a 50 percent larger screening area, and new digital assistance systems that will be launched at K 2022 and made available on the BluPort® customer platform. These include, for example, the PredictOn app, which helps to anticipate and eliminate imminent malfunctions based on continuous measurement and evaluation of machine data.

New series of machines for new target groups
For customers looking for rapidly available recycling systems for simple applications, EREMA Group subsidiary UMAC has an innovation in store for K 2022. The company, which has so far specialised in refurbishing and trading in previously owned equipment, is expanding its business area and in Düsseldorf will launch READYMAC, a standardised, prefabricated recycling solution that can be produced from stock, based on proven EREMA TVE technology.

Finally, in the inhouse recycling segment, PURE LOOP and PLASMAC will round off the wide range of machines offered by the group of companies with their product portfolio.

Live recycling and lighthouse projects at the Circonomic Center
In the outdoor area of the K show, EREMA will bring plastics recycling to life with live demonstrations in conjunction with cooperation partners. Different waste streams are processed for this purpose. The wide variety of high-quality applications for recyclate will be showcased in the "products made of recyclate" exhibition, ranging from technical components to consumer goods and food packaging.

Borealis – accelerating the transition towards a more circular future
Borealis is committed to using their expertise and global reach to advance the circular economy of plastics. At the joint Pre-K 2022 kick-off on June 13, Borealis provided a preview of their integrated way of circular thinking and featured topics and activities at the K Fair 2022 in October. The preview covered new technologies and innovations including new packaging and infrastructure applications of the Bornewables™ portfolio of circular polyolefin products, manufactured with renewable feedstocks. New applications for Design for Recyclability, Re-Use, chemical recycling and advanced mechanical recycling were also on display.