From the Sector

Borealis continues to invest in growth through sustainable solutions that are transforming the polymer industry. Its facility in Burghausen, Germany, is significantly expanding production capacity for an innovative polymer foam solution called Daploy™ High Melt Strength polypropylene (HMS PP). This investment—totaling over EUR 100 million—addresses growing global demand for recyclable, high-performance foam solutions. The new line, scheduled to start up in the second half of 2026, will triple Borealis’ supply capability for fully recyclable HMS PP. This expansion enables the transition to more circular and recyclable material solutions for customers in the consumer products, automotive, and building and construction industries.  
 
The development of Daploy HMS PP took place at Borealis’ Innovation Headquarters in Linz. The new product provides exceptional foamability, lightweight properties, and mechanical strength—characteristics that support material efficiency and help cut both costs and CO2 emissions. It is suitable for use in monomaterial solutions, which are easily recyclable at end of life.  
 
By supporting the sustainability principles of Reduce, Reuse, and Recycle, Daploy HMS PP addresses the growing demand for recyclable solutions across multiple industry segments:
 
In the automotive industry, Daploy is used for ultra-lightweight foamed interior and under-the-hood components. Typically 60-90% lighter than non-foamed alternatives, these components help improve fuel efficiency and reduce carbon emissions. It also enables zero-waste production as all production trim-offs can be easily recycled. In addition, Daploy makes it possible for these parts to be constructed from a single material, facilitating recycling at the end of the vehicle’s life.  
In the building and construction sector, Daploy HMS PP is used to replace heavier materials in insulation and paneling applications. Its durability, strength, and heat resistance ensure excellent performance, while its lightweight properties and recyclability improve the sustainability of these components.
 
“In line with our We4Customers strategy, this investment creates value for customers by enabling them to design recyclable, foam-based products for a wide range of high-performance applications,” explains Craig Arnold, Borealis Executive Vice President Polyolefins, Circular Economy Solutions and Base Chemicals. “By expanding production, we’re ensuring a reliable supply of this advanced material to help our customers achieve their sustainability goals and deliver high-performance solutions.”

The fine filament nonwoven technology from Freudenberg Performance Materials is made from a wide variety of polymers and blends using mono or bico fibers. The high flexibility and broad customization options provide benefits in a wide range of markets and applications – from roofing membranes to liquid filtration, as well as specific applications such as dehumidification products and artificial turf.

Freudenberg’s innovative fine denier spunbond materials rely on flexible manufacturing capabilities, which enable a high level of customization. They can be made of PET, PE or PP, not only as 100% composition but also in many different combinations, e.g. PET/PE, PET/coPET or PET/mPP, using mono or bico fibers with titer ranging from 2.5 to 3 dtex. The material weight spans 17 to 140gsm. The nonwovens are strongly bonded thanks to thermal bonding provided either by flat calendering or point sealing. The technology enables lightweight solutions with high tensile and tear strength, as well as a smooth and uniform surface.

Advantages for the construction industry
Suited for construction applications such as roofing & facade membranes, vapor barriers and house wrappings, Freudenberg lightweight fine denier nonwovens complement the well-known Terbond®, Texbond® and Colback® solutions for the construction market. They deliver mechanical strength and, in particular, a high nail tear strength as required by the market. Moreover, they have high UV and temperature resistance and stability thanks to the PET composition.

Filtration applications
The fine denier technology is also marketed under the Filtura® brand, specifically suited for liquid filtration, e.g. coolants & lubricants. The technology provides high efficiency and a regular surface, as well as new capabilities with PET-PA and PET-PE nonwovens. Support media applications for glass fiber, nano and activated carbon also benefit from the lightweight fine denier nonwovens as protective layers.

Packaging and coating: Efficient converting and high durability
The fully synthetic PET/PE fine denier materials are ideal for packaging applications such as desiccant bags and other dehumidifier products. They enable the efficient and fast production of such pouches due to their exceptional hot sealing capabilities, with no need for chemical binders or additional treatments. Freudenberg’s technology provides high strength, high abrasion resistance and high durability, allowing for long-lasting desiccant bags.

In the coating industry, too, Freudenberg’s fine denier spunbonds contribute to enhanced process efficiency. The materials are chemically resistant and have good thermal stability. High-quality coating results can be achieved by using these materials as coating substrates, thanks to their smooth and even surface. The material properties can be customized for coating, laminating and concealing applications thanks to different combinations of polymers, fiber types and bonding technologies. For example, a specific very lightweight flat bonded variant of the material is an ideal coating substrate for cold wax depilatory strips, providing the necessary high mechanical strength and material flexibility.

Other applications for Freudenberg’s fine filament technology are crop covers in agriculture, decoration applications and other industrial or consumer applications.

When textiles are equipped with electronic components, conductive yarns and textile sensors, the application possibilities are almost unlimited. These high-tech textiles are a global growth market. In Stuttgart, manufacturers, users and researchers presented amazing examples of applications in construction, architecture and mobility. The appropriate standards ensure quality and safety.

In keeping with the themes of the event, participants were able to take a look behind the construction fence of the Stuttgart 21 rail project on the first day. After the tour, DITF board member Götz T. Gresser drew parallels with the market for smart textiles. Just like the completion of the underground station, the market potential for smart textiles is developing more slowly than predicted.

One important reason for this is that there is still a lot to be regulated. Standardization was therefore a key topic in the presentations on the second day of the event. Norms and standards create trust among users. They reduce the error rate in design and therefore development costs, helping to bring innovations and new technological developments into use. Kristina Müller from the German Institute for Standardization explained that consistent compliance with standards can reduce error costs in construction, for example, from the current estimated eleven percent to five percent per year. Jan Beringer from the Hohenstein Group used the example of actively illuminated high-visibility clothing to show the hurdles that need to be overcome on the way to standardization.

In addition to high-visibility equipment, workwear offers many opportunities for smart functions. Despite all safety precautions, accidents at work cannot always be avoided, explained Silke Rehm from Adresys. Smart clothing can then automatically make an emergency call and trigger an emergency shutdown of the machine.

There are suitable testing devices for monitoring and quality assurance of materials and textile surfaces. Stefan Fliescher from Textechno presented a device that has so far been exclusively used at the DITF.

The second block of presentations focused on mobility: examples included textile ideas for flight cabins of the future from Diehl Aviation, precise and therefore energy-saving heating systems for vehicles from Köstler and contactless sensor technology from Rotec, which detects when fiber ropes need to be replaced. Erhardt manufactures flexible, customized bodies for commercial vehicles They are particularly suitable for logistics in city centers and are equipped with textile sensors, for example for measuring temperature or determining the optimum load. The textile superstructures not only offer a textile surface for design, they can also communicate with their surroundings. Digital lettering shows when the vehicle is giving way or warns cyclists of blind spots when turning. Modules that are not required can be folded or rolled up to save space.

In the construction and architecture application area, solutions for climate change are in demand. TEC KNIT has developed smart shading systems made from “shape memory” polymer fibers that close or reopen depending on the temperature. Optigrün relies on smart rainwater management for greening buildings. Textile sensor technology ensures that the water is optimally distributed over the surface - digitally controlled according to the weather forecast. Michael Schneider from the Smart Textiles Hub showed how intelligent knitted fabrics installed on flat roofs detect moisture and temperature by contracting or expanding accordingly. This can also prevent damage caused by icing, for example. Christoph Riethmüller from the DITF explained that the actual state of buildings is constantly changing due to events. The charm of smart textiles is that they can adapt to these changes. In this way, it is possible to intervene before negative consequences become noticeable. This saves a lot of energy. For example, the targeted heating of walls depending on the relative humidity prevents the occurrence of mold with low energy consumption. Intelligent shading systems also ensure that rooms remain at a pleasant temperature in summer without air conditioning and that the heat remains in the room in winter.

The event was accompanied by an exhibition where participants were able to try out numerous smart products.

The annual User Forum is organized by the German Institutes of Textile and Fiber Research Denkendorf (DITF), the Textile Research Institute Thuringia-Vogtland e.V. (TITV Greiz) and the Forschungskuratorium Textil e. V. (FKT).

The next SMART TEXTILES User Forum will take place on March 4-5, 2026 in Zeulenroda.

INDA, the Association of the Nonwoven Fabrics Industry, in partnership with International Filtration News magazine, announces the finalists for the inaugural FiltXPO™ Awards. Recognizing outstanding achievements across the entire filtration value chain, the awards celebrate groundbreaking advancements that utilize nonwoven fabrics and technology.

Presented at FiltXPO™, April 29-May 1, 2025, at the Miami Beach Convention Center, Florida, these awards highlight exceptional innovations in three categories:

• Air/Gas Filtration Media
• Water/Liquid Filtration Media
• Filtration Equipment

Each nominated product has demonstrated creativity, uniqueness, technical sophistication, and the potential to significantly advance filtration performance and sustainability. Voting takes place on the International Filtration News website and the deadline to submit votes is April 18, 2025:

FiltXPO Air/Gas Filtration Award

• Hollingsworth & Vose – NanoWave® ESA
  Introducing NanoWave®ESA, an all-synthetic, 3D filter media free from PFAS. This revolutionary product enables production of highly efficient, comfortable, stretchable respiratory protection, suitable for various protective applications.
• Lanaco – EcoStatic® ML Series Filter Media
  Lanaco’s wool-based air filtration solution utilizes advanced electrostatic technology, providing exceptional efficiency and ultra-low pressure drop, even under challenging environmental conditions. USDA-certified as 100% Biobased, EcoStatic® ensures sustainability without sacrificing performance.
• Greentech Environmental LLC – Greentech Filters with ODOGard®
  ODOGard® technology deeply integrates odor-neutralizing polymers into nonwoven and nanofiber filters, offering an innovative, non-toxic approach to indoor air quality. ODOGard® significantly enhances filtration durability and performance.

FiltXPO Water/Liquid Filtration Award

• Ahlstrom – BioProtect™
  Ahlstrom’s sustainable BioProtect™ material offers superior dye-catching performance for laundry applications. Manufactured from 100% naturally derived fibers and OC-Biobinder®, BioProtect™ is both biobased and home compostable, combining premium performance with environmental responsibility.
• Periodic Products, Inc. – MetalXtract® Filter Media
  Using patented Chelok® Polymer Technology, MetalXtract® provides remarkable metal adsorption capabilities—100 to 500 times greater than traditional resins—across a wide pH range. Ideal for wastewater treatment and environmental remediation, this biodegradable solution effectively controls contamination at high flow rates.

FiltXPO Filtration Equipment Award

• Luwa America Inc. – Multi Cell Filter (MCV)
  The space-saving MCV significantly reduces required floor space by approximately 70% compared to traditional drum filters. Its intelligent PLC-controlled design optimizes filter cleaning cycles, reduces energy usage, and substantially cuts operational costs and carbon footprint.
• Oerlikon Neumag – hycuTEC
  Oerlikon Neumag’s innovative hycuTEC technology hydrocharges nonwoven filter media, achieving over 99.9% filtration efficiency with dramatically lower pressure loss and minimal resource consumption. Easy to integrate and retrofit, hycuTEC represents a breakthrough in high-efficiency filtration media production.
• Filtration Advice Inc. – FA-TCO Software
  This cutting-edge software provides comprehensive Total Cost of Ownership (TCO) analysis and predictive modeling for air filtration systems. FA-TCO enables data-driven decisions, extending filter lifespans, reducing operational costs, and enhancing overall sustainability in filtration management.

Finalists will present their innovative solutions at FiltXPO, showcasing breakthroughs that elevate quality, efficiency, and sustainability across the filtration industry.

“We’re delighted to highlight these groundbreaking innovations that promise to reshape the filtration landscape,” said Matt O’Sickey, Ph.D., INDA’s Director of Education & Technical Affairs. “FiltXPO provides the perfect stage to recognize the industry’s most significant advances and inspire future developments.”

A new generation of space materials left Earth November. 5 as they head to the International Space Station (ISS) to undergo testing in the brutal conditions of low Earth orbit.

Developed at the University of Bristol, these high-performance materials could be used to build future space stations, spacecraft for interplanetary travel or a new ISS.

They will be placed on the Bartolomeo platform, located on the front of the ISS, where they will orbit Earth up to 9,000 times over the next 12 to 18 months at speeds of 17,000 mph.

The carbon fibre reinforced composites will need to survive temperatures between -150ºC and +120ºC, space debris travelling seven times faster than a bullet, severe electromagnetic radiation, high vacuum and atomic oxygen, which erodes even the toughest materials.

Prof Ian Hamerton, Professor of Polymers and Sustainable Composites in the University of Bristol’s world-leading Bristol Composites Institute, said:  

“Space is the most challenging environment for which to design new materials. You’re pitting your materials expertise, skills and ingenuity against extremes of temperature, mechanical stress, radiation, high speed impacts and more.

“Any one of those might be difficult, and, unfortunately, gaining access to repair them is not an easy option, so the materials we build must survive without maintenance.  

“The opportunity to test our materials in the proving ground of space is priceless and will help our University of Bristol scientists on the ground improve fibre-reinforced materials for next-generation space missions.”

There are four laboratory-made polymers heading to the ISS, each of which has been reinforced with carbon fibres and two contain nanoparticles. All four are the result of University of Bristol research and one is patented.

 If the materials cope in the harsh environment, they could be used to create longer-lasting space components, allowing spacecraft to travel further, and spend more time in space.

Future communities on new planets will need protection against galactic cosmic radiation. Dr Ali Kandemir, Senior Research Associate at the University of Bristol, is one of several Bristol researchers, supported by the UK Space Agency (UKSA), examining the effects of simulated galactic cosmic radiation on the materials, in a European Space Agency (ESA) project.

Dr Kandemir said: “We want materials that are resilient in the space environment and, importantly, materials that can shield humans from that radiation.

“We also want to make these materials sustainable, so that when they reach the end of their life they can be recycled and used again for the same purpose.”

The launch of the Space X Dragon CRS-2 spacecraft this morning is the culmination of five years of work for Prof Hamerton and his team.

It has included the efforts of early career researchers, postgraduates and several Aerospace Engineering undergraduates at the University of Bristol, whose final year research projects have been linked to the space materials project.

The practical support of the University of Bristol-hosted National Composites Centre (NCC) was crucial to the scale up of the composite materials.

Prof Kate Robson Brown, Vice-President for Research, Innovation and Impact at University College Dublin, and a collaborator on the project, said:

“After nearly five years of research to develop novel composite materials for space applications it is very exciting to see our experiment launch to the International Space Station.

“I am proud to be part of this mission, and to be working with the multidisciplinary and multisector research team to deliver integrated real world and digital testing for innovative materials which will help to drive growth in the new space economy.

“This mission also demonstrates how space research funding creates career changing opportunities for early career researchers and PhD students in a sector of huge value to both Ireland and the UK.”

Funding to support the project was supplied by the ESA, the UKSA, Oxford Space Systems and others.

INDA, the Association of the Nonwoven Fabrics Industry, announces the release of the International Fiber Journal’s (IFJ) special sustainability issue dedicated to nonwovens. This special edition, which was sponsored by INDA, is a key piece of the association’s 2024 strategic sustainability initiative, launched at the beginning of 2024 in response to feedback that sustainability remains one of the nonwovens industry’s highest priorities.

The IFJ special issue features exclusive content from industry leaders, including Kimberly-Clark Corporation, Glatfelter, Lenzing Fibers, NatureWorks LLC, Hollingsworth & Vose, MANN+HUMMEL, Nexus Circular, Henkel Corporation, and INDA. This edition explores key sustainability topics, structured around three core pillars vital to the industry’s future: Responsible Sourcing, Innovations in Sustainability, and End-of-Life Solutions. Featured topics include:

• Environmentally sustainable nonwoven materials
• Circularity in single-use plastics
• Potential of post-consumer recycled (PCR) materials in nonwovens
• Navigating regulatory challenges
• Advances in bio-based nonwovens
• The role of plastics and polymers in sustainability

“This special issue of the International Fiber Journal is a vital part of our multi-faceted sustainability initiative aimed at providing new and enhanced offerings to INDA members and the nonwovens industry. We are excited to see the industry come together to share insights on the sustainability challenges we face,” said Tony Fragnito, President of INDA.

Protective gloves, such as those used for work, sport or household gardening, retrieve their protective function from a special coating. This coating provides abrasion resistance, makes the material waterproof and resistant to chemicals or oil, and even protects against cuts and punctures. Until now, coatings made of oil-based polymers, nitrile rubber or latex have been the main materials used. Scientists at the German Institutes of Textile and Fiber Research Denkendorf (DITF) have succeeded in developing a robust yet flexible glove coating using environmentally friendly lignin in a 3D printing process.

Coatings that are subject to mechanical stress always suffer from a certain degree of abrasion that is dispersed in the surrounding area. This is also the case with coated protective gloves. In order to avoid long-term pollution of the environment, materials should be used whose abrasion particles are biodegradable. The aim of the research project was to improve conventional protective equipment and integrate more sustainable materials.

The biopolymer lignin is a natural component of plant cells that is produced in large quantities as a by-product of paper manufacturing. Due to its properties, it represents an environmentally friendly alternative to oil-based coating polymers.

The scientists developed biopolymer compounds containing lignin, which were used to produce thermoplastic materials that can be processed using 3D printing.

Lignin has few polar groups, which makes lignins hydrophobic and therefore insoluble in water. For this reason, they biodegrade slowly. This makes them particularly suitable for durable coating materials.

Despite this durability, lignin particles that are released into the environment through abrasion biodegrade faster than the abrasion of conventional coatings. This is due to the much higher surface/volume ratio.

The use of 3D printing makes it possible to produce the coating precisely and efficiently. The 3D printing process also makes it possible to adapt the glove to the individual needs of the wearer. This increases wearer comfort and promotes freedom of movement.

The research project shows that the use of lignin not only offers ecological benefits, but that protective gloves coated with it are also particularly durable and resistant. They meet safety standards and at the same time contribute to sustainability in the world of work.

Stahl, a provider of speciality coatings and treatments for flexible substrates, has launched the protective coating Stahl Integra® Dry 725, meeting the increasing demand for water-repellant technical fabrics.  
 
Part of the Stahl Integra® toolbox, Stahl Integra® Dry 725 is a fluorine-free coating for water-repellent technical textiles that harnesses Stahl’s proven polymer technology. Stahl has introduced Stahl Integra® Dry 725 in response to the growing market demand for fluorine-free, water-repellent technical textiles, which is projected to reach USD 605.1 million by 2029.  

Stahl Integra® Dry 725 offers a balanced performance between repellency, durability and adhesion. Stahl's durable water-repellent (DWR) technology, StayDry, repels water from fabric by modifying the surface tension of fibres. The solution can be combined with other top or back coatings and is specifically designed for technical textile applications such as camping equipment or luggage. As a fluorine-free, waterborne coating that is cured at low temperatures, Stahl Integra® Dry 725 can help reduce environmental impact without compromising on quality.

Stahl Integra® is a modular 'toolbox' of tailor-made, customer-orientated protective coating solutions that simultaneously ensure product quality and superior fabric integrity. This means that specific mechanical functionalities – from flame-retardant and breathable coatings to stay-clean technologies – can be introduced at different stages of the production process to meet specific end-market requirements as needed.

Textiles for technical applications often derive their special function via the application of coatings. This way, textiles become, for example wind and water proof or more resistant to abrasion. Usually, petroleum-based substances such as polyacrylates or polyurethanes are used. However, these consume exhaustible resources and the materials can end up in the environment if handled improperly. Therefore, the German Institutes of Textile and Fiber Research Denkendorf (DITF) are researching materials from renewable sources that are recyclable and do not pollute the environment after use. Polymers that can be produced from bacteria are here of particular interest.

These biopolymers have the advantage that they can be produced in anything from small laboratory reactors to large production plants. The most promising biopolymers include polysaccharides, polyamides from amino acids and polyesters such as polylactic acid or polyhydroxyalkanoates (PHAs), all of which are derived from renewable raw materials. PHAs is an umbrella term for a group of biotechnologically produced polyesters. The main difference between these polyesters is the number of carbon atoms in the repeat unit. To date, they have mainly been investigated for medical applications. As PHAs products are increasingly available on the market, coatings made from PHAs may also be increasingly used in technical applications in the future.

The bacteria from which the PHAs are obtained grow with the help of carbohydrates, fats and an increased CO₂ concentration and light with suitable wavelength.

The properties of PHA can be adapted by varying the structure of the repeat unit. This makes polyhydroxyalkanoates a particularly interesting class of compounds for technical textile coatings, which has hardly been investigated to date. Due to their water-repellent properties, which stem from their molecular structure, and their stable structure, polyhydroxyalkanoates have great potential for the production of water-repellent, mechanically resilient textiles, such as those in demand in the automotive sector and for outdoor clothing.

The DITF have already carried out successful research work in this area. Coatings on cotton yarns and fabrics made of cotton, polyamide and polyester showed smooth and quite good adhesion. The PHA types for the coating were both procured on the open market and produced by the research partner Fraunhofer IGB. It was shown that the molten polymer can be applied to cotton yarns by extrusion through a coating nozzle. The molten polymer was successfully coated onto fabric using a doctor blade. The length of the molecular side chain of the PHA plays an important role in the properties of the coated textile. Although PHAs with medium-length side chains are better suited to achieving low stiffness and a good textile handle, their wash resistance is low. PHAs with short side chains are suitable for achieving high wash and abrasion resistance, but the textile handle is somewhat stiffer.

The team is currently investigating how the properties of PHAs can be changed in order to achieve the desired resistance and textile properties in equal measure. There are also plans to formulate aqueous formulations for yarn and textile finishing. This will allow much thinner coatings to be applied to textiles than is possible with molten PHAs.

Other DITF research teams are investigating whether PHAs are also suitable for the production of fibers and nonwovens.

Textiles are a given in civil engineering: they stabilize water protection dams, prevent runoff containing pollutants from landfills, facilitate the revegetation of slopes at risk of erosion, and even make asphalt layers of roads thinner. Until now, textiles made of highly resistant synthetic fibers have been used for this purpose, which have a very long lifetime. For some applications, however, it would not only be sufficient but even desirable for the auxiliary textile to degrade in the soil when it has done its job. Environmentally friendly natural fibers, on the other hand, often decompose too quickly. The German Institutes of Textile and Fiber Research Denkendorf (DITF) are developing a bio-based protective coating that extends their service life.

Depending on humidity and temperature, natural fiber materials can degrade in the soil in a matter of months or even a few days. In order to significantly extend the degradation time and make them suitable for geotextiles, the Denkendorf team researches a protective coating. This coating, based on lignin, is itself biodegradable and does not generate microplastics in the soil. Lignin is indeed biodegradable, but this degradation takes a very long time in nature.

Together with cellulose, Lignin forms the building materials for wood and is the "glue" in wood that holds this composite material together. In paper production, usually only the cellulose is used, so lignin is produced in large quantities as a waste material. So-called kraft lignin remains as a fusible material. Textile production can deal well with thermoplastic materials. All in all, this is a good prerequisite for taking a closer look at lignin as a protective coating for geotextiles.

Lignin is brittle by nature. Therefore, it is necessary to blend the kraft lignin with softer biomaterials. These new biopolymer compounds of brittle kraft lignin and softer biopolymers were applied to yarns and textile surfaces in the research project via adapted coating systems. For this purpose, for example, cotton yarns were coated with lignin at different application rates and evaluated. Biodegradation testing was carried out using soil burial tests both in a climatic chamber with temperature and humidity defined precisely according to the standard and outdoors under real environmental conditions. With positive results: the service life of textiles made of natural fibers can be extended by many factors with a lignin coating: The thicker the protective coating, the longer the protection lasts. In the outdoor tests, the lignin coating was still completely intact even after about 160 days of burial.

Textile materials coated with lignin enable sustainable applications. For example, they have an adjustable and sufficiently long service life for certain geotextile applications. In addition, they are still biodegradable and can replace previously used synthetic materials in some applications, such as revegetation of trench and stream banks.

Thus, lignin-coated textiles have the potential to significantly reduce the carbon footprint: They reduce dependence on petroleum-based products and avoid the formation of microplastics in the soil.

Further research is needed to establish lignin, which was previously a waste material, as a new valuable material in industrial manufacturing processes in the textile industry.

The research work was supported by the Baden-Württemberg Ministry of Food, Rural Areas and Consumer Protection as part of the Baden-Württemberg State Strategy for a Sustainable Bioeconomy.