From the Sector

Increasing energy and resource efficiency in the construction sector will be key to the EU’s ambition of achieving climate neutrality by 2050. By enabling the manufacture of strong, durable and lightweight products, composite materials can help the construction sector improve its environmental sustainability, as well as reduce total lifecycle costs. The latest EPTA industry briefing, Pultruded composites contribute to a more sustainable future for construction, discusses how pultruded composites answer the need for materials offering high performance, faster installation, corrosion resistance and low maintenance.

The report is available to download from the EPTA website.

The future of construction
As one of the largest global users of energy and raw materials, the construction industry is under immense pressure to improve its sustainability. At the same time, it must respond to demands for improved performance and reduced total cost of ownership. New materials will be needed to minimise the use of natural resources, enable a reduction of carbon footprint and facilitate circular economy practices. Choosing the optimum materials required for durability throughout the lifecycle will be increasingly important. A shift to off-site production is also forecast, where factory-controlled environments and automated processes can improve quality control, lower waste, and reduce work on site.

Lightweight pultruded parts can be pre-assembled into modules or complete structures in the factory for faster installation on site. Lightweight profiles lower energy use during transportation and installation, and a longer service life combined with minimal maintenance can deliver a reduced through-life carbon footprint. Pultruded parts such as profiles, gratings, beams, tubes and planks are increasingly found in a range of building, construction and infrastructure applications. Examples include bridge decks, fencing, stairs and handrails, train platforms, cladding, utility poles, modular building concepts, and window frames.

One application offering large growth potential for composites is bridges. Composite bridges are being designed to provide a service life of 100 years and unlike steel bridges do not require regular repainting to protect them from corrosion. Over recent years, pultruded glass fibre composite has become a highly popular choice for pedestrian and cycle bridges. Pre-fabricated ‘easy fit’ bridge decking planks, pre-assembled bridge modules and complete bridge ‘kits’ are now available. Corrosion-resistant composite bridges are ideal for use near water or on the coast, and in remote locations where regular maintenance operations would be difficult. A composite bridge can deliver the same performance as a steel structure with a weight saving of up to 50% or more. This enables more streamlined bridge designs which require less substantial supporting structures and foundations, greatly reducing consumption of materials and energy. Lightweight also results in easier logistics and simplified installation. Pultruded are more easily transported to the construction site, with lower fuel consumption, and easier to move on site, often reducing labour requirements and the capacity of lifting equipment.

A lifecycle approach
As the construction industry looks to the future, the environmental and economic benefits of composite materials linked to easier logistics and installation, durability and low maintenance are becoming increasingly valued. More projects are demonstrating the benefits of composite materials and standards covering the design, fabrication and installation of pultruded profiles are making it easier for the construction industry to use them. With ongoing development and collaboration, pultrusion has the potential to contribute to a more sustainable future for construction and many other industries. EPTA will continue to promote the advancement of pultrusion technology and its applications and foster sustainable practices within the industry.

June 1, the European Parliament has adopted its Report on an EU Strategy for Sustainable and Circular Textiles. The Report wants to step up the EU’s ambition towards sustainability and circularity even further, but it has failed to recognise the strategic role of the European textile industry to scale up sustainability, nor to appreciate the global competitive threat which our companies are facing.

Director General Dirk Vantyghem commented on the MEP Report: “We welcome the strong interest of the European Parliament in the textile and fashion industry, but encourage MEPs to develop a balanced vision which reconciles sustainability and competitiveness. Developing a new business model for our industry requires carefully crafted legislation at global level, and an open dialogue between the industry, the brands and the consumer.”

EURATEX supports the EU Textile Strategy, as it was presented over a year ago by the European Commission. The 160.000 European textile companies are committed to invest in sustainability, develop new circular business models and produce high quality textile products – not just in fashion, but also in home and medical textiles, construction, agriculture or cars. To do so, indeed a new regulatory framework is needed, with clear definitions, coherent rules and effective controls. But also, the companies should be able to comply with these rules and remain globally competitive.

The EP Report has failed to respect that balance between sustainability and competitiveness. Instead, it suggests even more rules and restrictions, totally disregarding the current economic challenges caused by high energy prices, loss in consumer confidence and assertive trade partners. Putting the bar even higher will simply mean that the European textile industry will be pushed out of the market, resulting in a bigger environmental footprint and increased dependency on foreign supplies. Quite the opposite of what the EU wants to achieve with its open strategic autonomy plans.

The Report also fails to differentiate between textile products. There is a mix up between fashion and technical textiles, between products made in Europe and outside, between high quality and durable products and low-quality items. It is regretful that the European Parliament did not make that distinction and simply refers to “textiles” as a general cause of concern, without acknowledging e.g. the high quality products, made by European textile and fashion companies.

The Report puts a strong responsibility on the supply side – the industry and the brands – and does not sufficiently address the role of the consumer. Initiatives therefore are essential to create a stronger demand for sustainable textiles, which includes better communication and transparency (avoid greenwashing), fiscal measures, green public procurement and better control of online marketplaces.

On a positive note, the EP Report does recognise the importance to invest in research and innovation, to support reskilling and upskilling, the need of scaling up circular economy and pay attention to the needs of SMEs. EURATEX has always insisted that such massive transition can only be successful if accompanied by significant and dedicated support programmes. The EU Textiles Transition Pathway should offer a clear perspective in this regard.

• Revenue grows to EUR 623.1 mn – fiber sales recovered over the course of the quarter
• EBITDA and net result for the period down compared with the first quarter of 2022
• Cost reduction program of more than EUR 70 mn being implemented according to plan
• Production of TENCEL™ brand modal fibers successfully launched in China
• Lenzing confirms guidance for 2023

The business performance of the Lenzing Group during the first quarter of 2023 largely reflected market trends. However, after the market environment had deteriorated significantly in the third and fourth quarters of the previous year, signs of recovery emerged during the first quarter in terms of demand as well as raw material and energy costs. Textile fibers recorded moderate but steadily improving demand. Business with fibers for nonwovens and with dissolving wood pulp performed better than expected. Raw material and energy costs were still at an elevated albeit decreasing level.

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 2.8 and 3 percent for 2023 and 2024 respectively. The currency environment is expected to remain volatile in the regions relevant to Lenzing.

This market environment continues to weigh on the consumer climate and on sentiment in the industries relevant to Lenzing. However, the outlook has brightened somewhat recently.

Demand picked up tangibly after the Chinese New Year. As a consequence, capacity utilization improved and stocks were further reduced both at viscose producers and at downstream stages of the value chain.

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 for 2023/24 anticipate a more balanced relationship between supply and demand.

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 the reorganization and cost reduction program. These and other measures are aimed at positioning Lenzing in the best possible way for the expected market recovery.

Structurally, Lenzing continues to anticipate growth in demand for environmentally responsible fibers for the textile and clothing industry as well as for 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 account 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.

Carbios, a compnay in the development and industrialization of biological technologies for reinventing the life cycle of plastics and textiles, announces its operating and financial results for the year 2022. The financial statements as of December 31, 2022, were approved by the Company’s Board of Directors at their meeting on April 5, 2023.

• Project to build, in France, the world’s first PET biorecycling plant: Progress in line with 2025 unit commissioning target6
• Excellent results from the demonstration plant validating the industrial scale-up of Carbios technology
• Carbios licensing documentation ready for worldwide industrial and commercial deployment
• Long-term exclusive strategic partnership with Novozymes to ensure supply of enzymes at industrial scale for the Reference Unit and all future licensee plants
• Creation of fiber-to-fiber consortium with On, Patagonia, Puma, PVH Corp., and Salomon
• CE-PET research project successfully completed
• Participation in WhiteCycle project co-funded by Horizon Europe and coordinated by Michelin
• Publication of scientific articles in the prestigious Biophysical Journal and in Chemical Reviews
• Carbios hosts world’s first PET Biorecycling Summit
• Carbios publishes first Sustainability Report and outlines objectives for environmental, social and governance (ESG) initiatives
• Carbios joins Ellen MacArthur Foundation’s circular economy network
• €30 million European Investment Bank loan drawn down in 2022
• Group’s cash position of €101 million as of December 31, 2022

January 2024 marks the official birth of ERCA TCS (Textile Chemical Solutions), a business unit of ERCA S.p.A. with a focus on the textile market. Founded in the 1960s, ERCA S.p.A. is an Italian company, present with six plants in three macro-regions: Europe, Latin America and Asia. The ERCA group produces specialty and auxiliary chemicals with a responsible innovation approach and its production covers several markets: textiles, cosmetics, polyurethanes, concrete.

Why a business unit that caters solely to the textile industry? The decision to give birth to ERCA TCS comes from the desire to be a unique and innovative reference point for ERCA's customers, with products and
services designed specifically for the needs of today's textile industry, grappling with the challenges and
opportunities of sustainability and responsible production.

ERCA TCS bases its activities on the principles of "Green Chemistry" with the aim of offering the textile industry chemical solutions that make the concepts of safety, performance and circularity a reality. The chemical auxiliaries of ERCA TCS are the result of a vision that incorporates responsible innovation, continuous research, and a desire to offer to the market effective yet ethically, environmentally, and economically sustainable solutions.

The green, high tech and circular commitment of ERCA TCS is demonstrated by a product and brand range that is totally based on the circular economy, which started from a problem - the disposal of used vegetable oil - and turned it into a resource, into a raw material for the production of chemical auxiliaries for the textile industry: REVECOL®, the circular range of high-performance, made-in-Italy, GRS-certified chemical auxiliaries. The REVECOL® range can be used on any type of fiber, recycled or not.

Textile waste is a problem in Europe. Out of 7-7.5 million tonnes of textiles discarded every year, 30-35 % are collected separately – and of that quantity, 15-20 % are sorted by medium and larger sorting facilities within the EU. After sorting, 60 % still qualify as wearable clothes, however after a second or third collection-loop, all of the textiles become non-wearable sooner or later. Therefore, fibre-to-fibre recycling is becoming increasingly important to preserve the valuable resources.
 
The textile recycling value chain is not yet mature, but we are on the verge of a turning point, as different fibre-recycling technologies are deployed on a large scale. If successful, the textile recycling industry could reach a recycling rate of 18 to 26 percent of gross textile waste in 2030. This would create economic, social and environmental value that could total 3.5 to 4.5 billion euros in 2030.

Today, there is a sorting gap to achieve a circular economy for textiles in Europe. To feed this new circular value chain, a significant sorting-capacity increase is needed with 150 to 250 sorting and recycling facilities nearby, as the McKinsey-study “turning waste into value” assessed.

There is also a technology and capacity gap in sorting for reuse and recycling to ensure that high quality raw materials from non-wearable textile waste can be made available on a large scale. This is why the “Transform Textile Waste into Feedstock” project was initiated by TEXAID, within the ReHubs initiative together with well-known stakeholders of the textile value chain.

The major outcome of this project will be a sorting-factory blueprint fulfilling the requirements to the future needs of fibre-to-fibre recycling, enabling the future of more sustainable textiles by using recycled fibres. TEXAID, who is leading the project, is committed to build and operate scalable sorting facilities across Europe, the first with a capacity of 50,000 tonnes by the end of 2024.

Companies like Concordia, CuRe Technology, Decathlon, Inditex, Indorama Ventures, L’Atelier des Matières, Lenzing, Marchi & Fildi, PurFi, Södra, Worn Again and others are taking part in the project to jointly evaluate technologies and the business case for scaled sorting for reuse and recycling. ITA Academy GmbH (in cooperation with RWTH Aachen) together with CETIA has been commissioned for the assessment of technologies. The outcome will be an innovative sorting system 4.0, building on cross-functional technologies with digitalization and automation are at the heart.

International experts will discuss topics along the entire cellulose fibre value chain at the upcoming Cellulose Fibres Conference, 8–9 March 2023 in Cologne and online.

How can the cellulose fibre industry contribute to the sustainability and circularity of the textile sector? How can fibre markets achieve a circular economy for their materials? What are the most sustainable technologies on the market? And, are there innovative, interesting raw materials and technologies worth exploring to meet the challenges of the coming years?

These and other questions in the field of cellulose fibres will be discussed within the program of the Cellulose Fibres Conference 2023. The two-day event will provide insights into the latest developments of the cellulose fibre sector and introduce innovative start-ups, technologies as well as novel fibre applications. A special focus will be set on the textile sector and its awaited paradigm shift towards circular economy in the following years.

Seven sessions will provide in depth views from fibre production to recycling, policy and market trends:

• Strategies, Policy Framework of Textiles and Market Trends,
• Circular Economy and Recyclability of Fibres,
• Alternative Feedstocks and Supply Chains,
• Innovation Award “Cellulose Fibre Innovation of the Year 2023″,
• Sustainability and Environmental Impacts,
• Ionic Liquids and New Technologies for Pulps, Fibres and Yarns,
• New Technologies and Applications beyond Textiles.

The full conference program is available here.

• Auraloop is a brand-new range of cushioning solutions made from an innovative structure of Polyester-based fibers, 100% recyclable, aimed at the mobility markets
• One of the objectives of Auraloop is a twofold reduction in the carbon footprint of car seat pads, currently made from polyurethane foam
• Auraloop offers an increased level of performance in terms of thermal comfort and durability

R&D teams within the Faurecia seating activity have recently penned an exclusive development agreement with Indorama Ventures. This partnership between Indorama Ventures and Faurecia, a company of FORVIA Group which is one of the largest automotive industry suppliers, has the aim of developing Auraloop, a new range of cushioning solutions for the mobility markets and intended to replace polyurethane foam currently used in car seats.

“By setting out these initial milestones in our close-knit collaboration with Faurecia, this partnership is an integral part of Indorama Ventures’ commitment to expand its existing Polyester (PET)-based portfolio and related activities into wider areas. By bringing together two leading players in the automotive industry, we aim to open up further growth opportunities for both partners”, stated Arnaud Closson, Chief Executive Officer at Indorama Ventures’ Mobility Group / Fibers Segment.

“Auraloop will replace those materials currently used in car seating with innovative and sustainable materials, based on polyester fibers that offer a total recyclability of 100%. This new material will allow for a twofold reduction in the carbon footprint of car seat pad solutions compared to current materials”, explains Nicolas Michot, Director of Technology at Faurecia Seating. Development of this product, which paves the way towards wider commercial release in two or three years, falls within the FORVIA Group strategy of going carbon neutral by 2045. For this, the group is seeking to root its commercial offer fully in the circular economy, with the development and production of sustainable cutting-edge materials under the banner of MATERI’ACT.

Auraloop offers a range of new perspectives in terms of seating comfort thanks to a more open fiber structure and permeability for air than current seating pad solutions, the breathability of seating is improved, enabling a better passive thermal regulation of occupants. The durability of seating is also increased by limited subsidence of the seat over its lifetime. The market for comfort aboard vehicles is constantly growing. The development of Auraloop falls within this dynamic, with a product offering significantly improved performances in terms of static, dynamic and welcoming comfort.

The plan of the European Commission to propose a price cap on wholesale gas price at 275€/MWh would be a bitter disappointment for the European textiles and clothing manufacturers, said EURATEX.

November 22nd, EURATEX stated in a letter to EC President, Ursula von der Leyen, that any price cap above the level of 80€euro/MWh would not help the EU industry – the textile sector in particular – to survive the current crisis. Indeed as early as July 2021, the wholesale gas price in the EU was below 30€/MWh. Now, the EU industry is facing gas and energy prices that have exceeded any coping capacity: from the record-high 320€/MWh last August, the price has reached to 127€/MWh today. Still, it is more than 300% than the business as usual prices.

The very existence of the European industry is at stake and with it the European sustainability agenda – and Europe’s capacity to implement it. Furthermore, Europe will lose its strategic autonomy, which guarantees essential goods and services are made available on the European Internal Market. If we continue on this path, the EU will soon become totally dependent on foreign imports with no leverage to implement its sustainability agenda, let alone lead the transition to a circular economy on the international stage.

At present, the EU industry is facing a dire international competition with the industry in China, India and the US working at energy prices of around 10$/MWh. In addition, these competitors are benefitting of sky-high subsidies from their own governments: the rollout of the US $369bln industrial subsidy scheme is just the latest example.

EURATEX Director General, Dirk Vantyghem, believes that “while the EU Industry is under immense, unprecedented pressure, a price cap at 275€/MWh would be meaningless: the European industry will be permanently pushed out on the market. The industry is at the heart of the European way of life and the fundament of our social market economy. The EU must save its industry to save Europe. The moment to act is now.”

The textile industry is the third largest consumer of plastics. While growth rates in the production of fibres and textiles are high, the circular economy has hardly become established in this segment. The EREMA Group is now intensifying development of recycling solutions for this application with their new fibres and textiles business unit. Currently, the focus is on PET fibre materials from fibre production and subsequent processing steps. Technologies for recycling mixed fibre textiles from textile collection sources are to follow in a follow-up project phase.

"With EREMA's VACUREMA® and INTAREMA® technology and PURE LOOP's ISEC evo technology, our company group already has an extensive range of machines for fibre and PET recycling applications. For ecologically and economically sound recycling, however, new technological solutions are needed to use the recycled fibres in higher-value end applications and to achieve a functioning circular economy," explains Wolfgang Hermann, Business Development Manager Application Fibres & Textiles, EREMA Group GmbH. The initial focus will be on PET, regarded as a key material for the production of synthetic fibres. The aim is to find recycling solutions that allow PET fibre materials to be prepared for reuse in PET fibre production processes. This is a significant step for the circular economy because PET fibres in textiles account for about two-thirds of the total volume of PET.

In this development work, the EREMA Group can build on existing know-how. Proven recycling technologies have been combined with a new IV optimiser. "This extends the residence time of the PET melt, which is particularly necessary in fibre recycling to efficiently remove spinning oils. Our recycling process also increases the IV value of the PET melt after extrusion back to the specific level that is essential for production of the fibre," explains Hermann. Waste PET fibre from production processes can therefore be further processed into rPET filament fibre, carpet yarn and staple fibre.

Fibre test centre with plant to test customers' materials
In order to accelerate development work, EREMA opened its own fibre test centre a few months ago, where a cross-company team is working on recycling solutions for fibre-to-fibre applications.