From the Sector

During the conference it was very interesting to see how the Chinese recycling industry in general and the Chinese polyester recycling industry in detail is on its way to digest the drastic measures of the Chinese government to ban the import of any plastic waste from January first, 2018 onward.

While Europe is struggling with individual measures such as the ban on drinking tubes, cotton swabs, balloons, plastic bags or disposable tableware, the Chinese leadership has created eight ministerial administrative units covering the entire complex of environmental protection, renewable energies, circular economy including recycling and climate protection. There is still a substantial gap to European environmental standards but Chinese velocity of progress is impressive in this field.

More than 360 delegates form China and oversees listened to the latest results in polyester recycling technology, production and market and exchanged their recent experiences. Especially the exhibition was core of social and technical networking.

Two contributions from governmental organizations and three from industry associations are underlining the high administrative attention of the recycling issue and loop economy in general.

• Interfilière Paris, 6th-8th July 2019, booth D60

Able to offer an alchemy of design and sustainable innovation, Iluna Group with ROICA™ by Asahi Kasei join the latest edition of the Parisian tradeshow for lingerie with a range of innovations capable of combining innovation, aesthetics and quality. "Ethical" lace and stockings, where quality standards go hand in hand with fashion content, respecting both the environment and humans, an offer already selected among the protagonists of the Sustainable Thinking Exhibition of the Salvatore Ferragamo Museum, for its value in the field of responsible innovation.

Experts in the production of stretch lace since 1985, ILUNA today represents the largest European laces’producer. Thanks to the effectiveness of their responsible innovation strategy, Iluna Group has been the very first lace producer to have gained the GRS (Global Recycled Standard) for their transformed products, together with the company certification STeP (Sustainable Textile Production by Oeko –Tex®).
A relevant achievement for the firm that, thanks to the Green Label collection, now even richer, make responsible innovation an asset for production that focuses on smart ingredients as ROICA Eco-Smart™ family and Q-Nova® by Fulgar.

A range that culminates today in the launch of an athleisure and sporty-chic capsule collection that perfectly fit the contemporary modern wardrobe, result of a qualified and totally traceable supply chain, from yarn up to garment, based on design, sustainability and performance.

Of major interest is the fact that the Iluna fashion R&D based its strategic choice for the AI2020/2021 on the extension of the offer with new Black label’s developments between lace and embroidery, the premium R&D line.

The range of new Ultralight multicolor laces offers jacquardtronic and textronic 4 or 5 colours galloons with a 3D effect. The change of the color of thread in the background as well as in the design gives life to unique coordinated solutions for creatives. The match between expectations of brands and retailers are met always keeping as a priority the contemporary design, that is integrated to unique strategy committed to responsibility both at corporate and product level.

To ILUNA smart innovation is not just a project, its space at Interfilière where visitors will have the chance to discover the new collection and above all to experience and touch latest boundaries of lace smart innovations pursued staying true to the values the brand. Iluna team is pleased to welcome you with a special cadeaux created in collaboration with ROICA™ by Asahi Kasei.

Filo d’Oro has been selected by Première Vision to exhibit within the SMART CREATION area, the key research and sourcing space for those looking for new generation of sustainable solutions. An informative, educational, visionary and multimedia space where exhibitors, designers, buyers and fashion brands can experience and truly visualize the progress the industry is making in terms of responsibility. At the show in Paris above all they will present a consolidated system of collaborations and a virtuous network that works side by side to make the difference with certified superior quality products for the international market.

Within Filo D’oro, on the occasion of the inclusion in the Smart Creation, they present innovations that reflect "a real commitment to cultural sustainability as well as industrial and production". The organic silks are made with natural fibers from organic farming, the Global Organic Textile Standard (GOTS) certification guarantees both the quality of the raw materials and the sustainability of all production processes. The FSC® certified viscose comes from forests with sustainable management that respects the environment and the population, other viscose developments are made with Ecovero™ yarn from certified and controlled sources. The polyesters are GRS certified, they are made with Newlife™, a yarn born from the transformation through mechanical process of post-consumer plastic bottles collected in northern Italy, whose production process is entirely 100% Made in Italy. Some proposals combine Newlife™ with ECOANTEX, a yarn resulting from the transformation of post-industrial waste and the selective collection of Pet packaging.

Sappi to present its innovative papers and packaging solutions at FachPack 2019

Environmentally friendly packaging is a hot topic worldwide. Sappi has been a pioneer in the field of innovative and sustainable packaging solutions for years. The company will present its latest innovations at Stand 9-260 at FachPack in Nuremberg. Alongside barrier papers, these include the heat-sealable Sappi Seal paper. This is notable for being completely recyclable and can replace existing PE-coated packaging. The recently launched Atelier paperboard will be another focus of the trade fair presentation. This offers brilliant colour reproduction and a silky touch and feel.

Huntsman Textile Effects will be highlighting its HIGH IQ® intelligent effects and Durable Water Repellency technology at the upcoming OutDoor Retailer Summer 2019 show in Denver, Colorado.

As the industry leader in innovative and environmentally sustainable textile solutions, Huntsman Textile Effects offers mills and brands a comprehensive suite of intelligent effects through its HIGH IQ® performance assurance program. With a wealth of textile industry knowledge and experience, Huntsman Textile Effects helps mills around the world achieve greater productivity and efficiency.

imogo is a new Swedish company formed by a team with long experience in textile processing technology. It is now boldly aiming to change the face of the textile manufacturing industry with its new Dye-Max spray dyeing technology, to be introduced to the market at ITMA 2019 in Barcelona.

While still at the prototype stage, and with a first full-scale line currently under construction and due to be demonstrated this Autumn before delivery, the DyeMax nevertheless promises to slash the use of fresh water, waste water, energy and chemicals by as much as 90% compared to conventional jet dyeing systems.

Spray cassettes
Its application unit consists of a closed chamber containing a series of spray cassettes with precision nozzles for accurate and consistent coverage, in combination with the patented imogo pro speed valve that controls the volume to be applied. The chamber is equipped with an exhaust system and droplet separator to ensure that the environment around the unit is free from particles.

“The spray cassettes are a key part in the Dye-Max line,” explains Imogo’s founding partner Per Stenflo. “There is one set of spray cassettes for each of the three separate dye dispersion feed lines and they can be easily exchanged without the need for tools in less than a minute. This allows for extremely fast changeovers between different colours without the need for cleaning. And because the spray cassettes are removable, all maintenance can be performed off line. 
After applying the dye dispersion the fabric is rolled onto a shaft and moved to the autoclave for deep dye fixation via heat and pressure.”

The savings in treatment water the Dye-Max achieves are due to the extremely low liquor ratio of 0.5 litres per kilo of fabric Stenflo adds. 

“At the same time, the low liquor ratio and the spray process require considerably less auxiliary chemistry to start with, and all of it is used in the process, which also greatly reduces the production of waste water, with only 20 litres being required for wash at changeovers. The low liquid content in the fabric meanwhile minimises the energy needed for fixation.”

The Dye-Max has a working speed of up to 50m/min with the practical speed determined by the fabric weight and application volume. 
 

At home, at work, on the street, in the sky, on the water, even in space, technical textiles and nonwovens are swinging towards ever higher performances in amazing applications. Versatile and light, but sometimes stronger than metal, these materials of the future gain their superpowers from the interaction of precisely coordinated textile systems. At Techtextil in Frankfurt am Main from May 14 to 17, 2019 in Hall 3, B06, Oerlikon will be showing chemical fiber applications made of polyester, polypropylene and Co. and what they can do in these fields. However, these exhibits are only a communicative means to an end, as Oerlikon is primarily interested in placing the associated machinery and plant solutions at the centre of discussions with trade fair visitors.

More than two thirds of all technical innovations are directly or indirectly based on new materials, says the German Research Ministry. One could add: The key to a more advanced world, for technological products with amazing functions, breathtaking performance and greater environmental benefits, is also to improve the properties and processing of materials. This applies first and foremost to textiles. Probably no other fabric is so strong as a "team player" who draws its strength from its cohesion. A single polyester thread, for example, looks inconspicuous. Processed into a thigh-thick special weave, however, high-strength High Modulus/High Tenacity fibers anchor floating oil platforms in the deepest waters. These kilometer-long "Mooring Ropes" withstand a breaking load of well over 1,000 tons and perform their task better than steel. For decades, Oerlikon Barmag has been offering special solutions for the production of so-called industrial yarns (IDY) that are tailored to customers worldwide. "We will once again be presenting numerous innovations at this trade fair to inspire our customers," explains Dr.-Ing. Dipl.-Chem. Roy Dolmans, Technology Manager IDY and R&D Filament Processing.

JEC WORLD 2019 is turning Paris into the composites capital of the world.

As well as dozens of conferences, composites circles and live demos, plus hundreds of other events, the first day of the show was marked by the announcement of the three winners of the largest international startup competition in the composites field!

In the last three years, 270 projects have been picked out from over 30 countries, with 30 finalists and a total of nine winners.

THREE WINNERS
Ten finalists selected from 120 entries pitched to an international jury. The pitch session opened with an inspiring speech by Enrico Palermo, President of The Spaceship Company. He introduced the next generation of reusable space vehicles and their impact on costs, safety and the environment during the launch into space.
The programme incited enthusiasm from Peter Hopwood, founder of Hopwood Communications, who encouraged the finalists to develop their stage presence and galvanise their pitches.

At the afternoon’s award ceremony, three competitors were selected for the following prizes:

AIRGO DESIGN (Singapore)
World's first full composite economy class passenger seat developer.
www.airgodesign.com

AREVO (USA)
Delivering the future of composite manufacturing today through breakthrough advancements in software, materials, and robotics. Through enabling the 3D printing of large, mass-produced parts and structures, AREVO is revolutionizing mainstream manufacturing and the global supply chain.
www.arevo.com

WOODOO (France)
Augmented wood.
https://woodoo.fr

The public vote: LAVOISIER COMPOSITES (France)
New generation of material entirely sourced from the French aerospace transformation sector.
www.lavoisier-composites.com

• Hexcel’s Composite Innovations For Aerospace, Automotive, Energy And Marine Applications At JEC World 2019 Hall 5 - Stand J41

STAMFORD, Conn. – At this year’s JEC World taking place in Paris on March 12-14, Hexcel will promote a wide range of composite innovations for customer applications in aerospace, automotive, energy and marine markets.

Aerospace Innovations

Hexcel’s HiTape® and HiMax™ dry carbon reinforcements were developed to complement a new generation of HiFlow™ resin systems, producing high quality aerospace structures using the resin infusion process. HiTape® was developed for the automated lay-up of preforms and HiMax™ is a range of optimized non-crimp fabrics (NCF). Both products incorporate a toughening veil to enhance mechanical properties, meeting the structural requirements for aerospace parts.

Visitors to JEC will see an Integrated Wing Panel demonstrator and an I-beam, both made with HiTape® reinforcements, and an Opticoms rib made with HiMax™ NCF. The Opticoms rib and I Beam were both manufactured using C-RTM (Compression Resin Transfer Molding). They were injected with Hexcel’s RTM6 resin in a process taking less than 5 minutes. The total manufacturing cycle for both parts was just 4.5 hours.

Also among the Aerospace exhibits, Hexcel will display a composite petal for a satellite antenna, manufactured by Thales Alenia Space Italia. The petal is part of a set of 24 deployable structural elements that form the large area reflector assembly used on board Low Earth Orbit (LEO) observation satellites. Thales Alenia Space Italia selected Hexcel’s HexPly® M18 prepreg for this application, acknowledging the superior mechanical and outgassing properties provided.

Another Hexcel prepreg application on show is a “zero” frame, manufactured by Aerofonctions for the engine area of Daher’s TBM 910/930 single-engine turboprop aircraft. Hexcel’s HexPly® M56 prepreg was selected by Daher for the “zero” frame – a product developed for Out of Autoclave applications that provides the same high quality and performance as autoclave-cured prepregs, from a simple vacuum bag cure in an oven.

With 50 years of experience behind its comprehensive range of high-strength, high-strain PAN-based carbon fibers, Hexcel continues to innovate, and is introducing two new fibers to its portfolio. HexTow® HM50 combines high modulus and high tensile strength, making it ideal for commercial and defense aircraft and engines. HexTow® 85 was developed specifically to replace rayon-based carbon fiber for ablative applications.

HexTow® carbon fiber holds the most qualified carbon fiber positions on aerospace programs in the industry and is the best unsized fiber available on the market. It provides excellent bonding interfacial properties with thermoplastic matrices and is the best-performing fiber for 3D printing applications.

Additive manufacturing is another area of expertise for Hexcel, using PEKK ultra-high performance polymers and HexAM™ technology to manufacture carbon-reinforced 3D printed parts. This
innovative process provides a weight-saving solution for intricate parts in highly demanding aerospace, satellite and defense applications. HexPEKK™ structures offer significant weight, cost and time-to-market reductions, replacing traditional cast or machined metallic parts with a new technology.

Hexcel is well known for its range of weight-saving, stiffness-enhancing honeycombs and the company adds value by providing a range of engineered core solutions to customers from facilities in the USA, Belgium and the newly opened Casablanca plant in Morocco. Hexcel’s engineered core capabilities enable highly contoured parts with precision profiling to be produced to exacting customer specifications. An example of such a part will be on display at JEC. Made from Aluminum FlexCore®, the part is CNC machined on both sides, and formed and stabilized with both peel ply and flyaway layers of stabilization. Aircraft engines benefit from a number of Hexcel core technologies including HexShield™ honeycomb that provides high temperature resistance in aircraft engine nacelles. By inserting a thermally resistant material into honeycomb cells, Hexcel provides a core product with unique heat-shielding capabilities that allows for the potential re-use of material after a fire event.

Hexcel’s Acousti-Cap® broadband noise-reducing honeycomb significantly improves acoustic absorption in aircraft engine nacelles. The acoustic treatment may be positioned at a consistent depth and resistance within the core, or can be placed in a pattern of varying depths and/or resistances (Multi-Degrees of Freedom and 3 Degrees Of Freedom), offering an acoustic liner that is precisely tuned to the engine operating conditions. These technologies have been tested at NASA on a full engine test rig and meet all 16 design conditions without trade-offs.

HexBond™ – the new name in Adhesives

Hexcel’s range of high performance adhesives has expanded considerably following the company’s acquisition of Structil. The company has now decided to unite the range by marketing all of its adhesive products using HexBond™ branding. The comprehensive range of HexBond™ structural film adhesives, foaming adhesive films, paste adhesives, liquid shims, epoxy fillets and Chromium free liquid primers is suitable for a wide range of applications in combination with Hexcel’s prepreg and honeycomb products.

Automotive Innovations

Hexcel’s carbon prepreg patch technology provides an innovative way of locally stiffening and reinforcing metal parts, providing noise and vibration management functionality. HexPly® prepreg patches consist of unidirectional carbon fiber impregnated with a fast curing epoxy matrix that has self-adhesive properties, enabling it to bond to metal in a highly efficient one-step process. These key technology properties are demonstrated in an 18.5kg aluminum subframe (that is 50% lighter than steel equivalents), which was reinforced with 500 grams of HexPly® prepreg and tested by Saint Jean Industries. The part demonstrates a significant reduction in noise, vibration and harshness (NVH). Other benefits include lower production costs, energy savings, increased driver comfort, production flexibility and part count reduction. With this technology Hexcel is a finalist in the JEC Innovation Awards 2019 in the Automotive Applications category.

HexPly® prepreg patch technology was also applied to a hybrid side sill demonstrator developed with Volkswagen and Dresden University to address future crash test requirements, specifically for electric cars. Combining fiber-reinforced plastic (FRP) with metal, the hybrid construction allows for optimum performance including weight savings, enhanced safety, increased energy absorption, battery protection in a crash situation and production flexibility.

Hexcel will also display a lightweight CFRP transmission crossmember produced from Hexcel’s high performance HexMC®-i 2000 molding compound. The transmission crossmember was developed in partnership with the Institute of Polymer Product Engineering (at Linz University), Engel and Alpex. As the part connects the chassis together and supports transmission it has to be stiff and strong, resisting fatigue and corrosion. Hexcel’s HexMC®-i 2000 was selected as the best-performing molding compound on the market, curing in as little as two minutes to produce lightweight, strong and stiff parts.
To produce the transmission crossmember HexMC®-i 2000 preforms are laid up in Alpex molds and compression-molded in a v-duo press that was tailored for the application by Engel. Ribs, aluminum inserts and other functions can be molded into the part using the single-stage process, reducing component-count. Any offcuts from the preforms can be interleaved between the plies of material to provide additional reinforcement in key areas - meaning that the process generates no waste.

Other Automotive promotions on Hexcel’s stand at JEC World include a composite leaf spring manufactured by ZF using HexPly® M901 prepreg. In contrast to steel leaf springs, composite versions offer many advantages including weight savings of up to 70%, high corrosion resistance, optimized system integration and superior performance. HexPly® M901 prepreg reduces the cure cycle to below 15 minutes and provides 15% higher mechanical performance, with enhanced fatigue properties. It also operates at high temperatures, providing a Tg of up to 200°C following a post cure.

Marine Innovations

Hexcel has a comprehensive range of products aimed at racing yacht and luxury boat builders that include America’s Cup, IMOCA class and DNV GL-approved prepregs, woven reinforcements and multiaxial fabrics for hull and deck structures, masts and appendages.

At JEC World Hexcel will display an IMOCA yacht mast manufactured by Lorima using HexPly® high modulus and high strength carbon fiber prepreg from Hexcel Vert-Le-Petit. Lorima is the exclusive official supplier of masts for IMOCA 60 class racing boats.

Hexcel’s HexTow® IM8 carbon fiber has been selected as the highest performing industrial carbon fiber on the market and will be used by spar and rigging manufacturer Future Fibres to manufacture their AEROrazr solid carbon rigging for all the teams in the 36th America’s Cup.

Hexcel’s HiMax™ DPA (Dot Pattern Adhesive) reinforcements are non-crimp fabrics supplied pre-tacked, allowing multiple fabrics to be laid-up more easily in preparation for resin infusion. Providing an optimal, consistent level of adhesion, they allow a faster and more consistent resin flow, as well as eliminating the use of spray adhesive for a healthier working environment and lower risk of contamination. Simply unrolled and applied to the mold or core layer before the introduction of resin, HiMax™ DPA fabrics are widely used in boat building, where lay-up times can be reduced by up to 50%.

Wind Energy Innovations

Hexcel has developed a range of HexPly® surface finishing prepregs and semi-pregs for wind turbine blades and marine applications. Providing a tough, durable and ready-to-paint surface without using in-mold coats, these products shorten the manufacturing cycle and reduce material costs. HexPly® XF2(P) prepreg is optimized for wind blades and has a ready-to-paint surface, straight from the mold, saving at least 2 hours of takt time.

Polyspeed® pultruded carbon laminates were developed for load-carrying elements in a blade structure and are manufactured with a polyurethane matrix that provides outstanding mechanical performance in terms of stiffness and durability. The blade manufacturing process is optimized, with increased throughput. The pultruded laminates are supplied in coils as continuous cross section profiles.
HiMax™ non-crimp fabrics using E-glass, high modulus glass and carbon fibers are also available in a wide range of unidirectional, biaxial and triaxial constructions. HiMax™ fabrics have applications throughout the turbine, from the stitched carbon fiber UDs used in the main structural elements, to glass fabrics and hybrids for blade shells and nacelles. There are also specialist applications such as lightweight fabrics for heated leading edge de-icing zones.

China is the world's largest producer and exporter of nonwoven fabrics, as well as having the largest consumer market for products made from nonwovens, making the upcoming biennial China International Nonwovens Expo & Forum (CINE – supported by Techtextil) the place to be for industry players from 3 – 5 June. This year’s event will relocate to a different venue, the Shanghai Convention & Exhibition Center of International Sourcing, located conveniently between Hongqiao airport and downtown Shanghai.

“The nonwovens market has been one of the fastest growing sectors of the Chinese textile industry over the last decade, and we expect this to continue in the coming years,” Wendy Wen, Senior General Manager of the fair’s co-organiser, Messe Frankfurt (HK) Ltd, commented. “The demographic changes, evolution of the manufacturing sector and greater awareness of environmental protection that have driven growth in China, among other factors, are also evident in a number of markets in the region, particularly Southeast Asia, so we anticipate production growth will remain strong to meet export demand, even if the Chinese economy slows further.”

Reports by the China Nonwovens & Industrial Textiles Association (CNITA), the Freedonia Group and Smithers Pira support this. Nonwovens output in China grew year-on-year by 9.67% for the first 11 months of 2018, exceeding the corresponding figure for 2017 of 8.71%, while demand for nonwovens is predicted to reach 4.9 million metric tons in 2022, a 6.9% per year increase over this period.

Turning to the region, in 2015 Asia occupied 43.1% of the global nonwovens market – with China alone accounting for more than half of the share – with this figure expected to increase to 47.1% in 2020. The Freedonia report also notes that healthy growth in markets nearby to China such as India, Indonesia, Malaysia, the Philippines and Vietnam will also fuel nonwovens output in the country to meet export demand.

Globally, nonwovens demand is expected to increase 4.4% per year to 12.2 million metric tons in 2022, with developing regions being the main driver of this, in particular within Asia-Pacific. In the PP nonwovens sector, output is predicted to nearly double between 2013 and 2020, with the major drivers of this growth being baby diaper, adult incontinence and feminine hygiene products. In the durable nonwovens sector, annual growth of 6 to 7% for the period 2017 – 2023 is also anticipated for filtration, engineering construction and packaging uses.