From the Sector

With the PFAFF 4520, engineers and technicians from PFAFF have designed a full-automatic production line (CE compliant) for processing multi-layer disposable masks, which meets the requirements of "German engineering" in a unique way. The product combines 150 years of expertise in joining textile materials and a concentrated know-how of the PFAFF INDUSTRIAL and KSL brands in the areas of process control, automation and robotics.

The PFAFF 4520 is an investment in a robust and sophisticated production line (MADE IN GERMANY) with an exceptionally reliable working process. In times of Covid-19 it is so important to rely on the right equipment for the mask production and avoid costly readjustments or an unnecessary second investment!

Key facts of the unit:

-    Size of the mask: 175 x 95 mm
-    Output:  3,500 – 4,000 masks per hour
-    1-, 2- or 3 ply processing  (Non-woven/filtration fabric)
-    SPS (PLC) control of the entire mask system
-    Exceedingly quiet working process of the whole unit
-    Ultrasonic welding components from German manufacturers
-    Protective housing for occupational safety of the operator
-    Packing station + printing station for personalized masks (on request)

The machine package also includes important features in the pre- and after sales:

PFAFF technicians ensure the adjustment of the desired customer material (non-woven or similar filter material) and the number of layers (1-, 2-, 3-ply) to the machine and make a "Ready to production" installation of the whole unit at the customer.  A fast service response time in after-sales (by involvement of the PFAFF sales- and service partner on site) ensures a maximum production output.

• Fabric finishing and sanforization systems installed in the US and Turkey to enhance productivity

ST. LOUIS - Baldwin Technology Company Inc. has successfully installed six new fabric finishing and sanforizing precision spray systems in the US and Turkey. Despite the COVID-19 pandemic, the installations were completed in just 60 days, thanks to close collaboration between onsite Baldwin textile team members, local agents and remote support from the company’s product and technology center in Sweden.
For textiles, non-wovens and technical textiles, Baldwin’s precision spray technology processes a wide range of low-viscosity water-based chemicals, such as softeners, anti-microbial agents, water repellents, oil  repellents, flame retardants and more.

These systems enable fabric producers to significantly reduce chemical and water consumption, while speeding up production times and eliminating production steps, including drying and bath changeovers when switching fabric colors. “Our customers are major manufacturers in fabric dying, finishing and remoistening, and we want to provide outstanding service and support—even in times like this,” said Rick Stanford, Business Development Leader at Baldwin and the commercial leader of the US installations. “Not only does our precision spray technology enhance productivity in their process, but there is also zero waste, which goes hand-in-hand with the increased sustainability focus in the textile industry.”

In North Carolina, two new TexCoat G4 precision spray systems are now in production with major international vertical manufacturers of outdoor living, performance fabrics and automotive fabrics. In Georgia, a major vertical manufacturer of workwear and protective fabrics installed a sanfor precision spray system, which has helped the customer obtain deeper penetration of moisture into fabrics treated with durable water repellents. In Turkey, three new TexCoat G4 systems were installed in Çorlu, northwest of Istanbul, for a large producer of knit fabrics, such as T-shirts. “In Turkey, the manufacturer purchased and installed one TexCoat G4 system before COVID-19, and the customer was so pleased with the results that, during the pandemic, three more were purchased,” said Simone Morellini, Sales Manager- EMEAR at Baldwin and the commercial leader of the Turkish installations. “The systems were manufactured and installed during the lockdown, and now, all four systems are up and running, and being used heavily on a daily basis.” “With the success we have seen, we plan to apply the same strategies for upcoming installations, including the next one in Honduras: strong local management and customer coordination, combined with  effective remote support during the installation,” said Stanford.

• Fiber prices and demand under pressure
• Measures to protect employees, customers and suppliers and to keep plants operational implemented successfully
• Joint venture Hygiene Austria established for industrial production of protective masks in the fight against the COVID-19 pandemic – new distribution channel via shop.hygiene-austria.at
• Strategic investment projects progress according to plan – financing agreements for construction of pulp plant in Brazil concluded as planned
• Revenue and operating result in the remaining quarters of 2020 expected to exceed that of the second quarter

Lenzing – In the first half of 2020, the Lenzing Group faced a historically difficult market environment with increased pressure on prices and volumes resulting from the COVID-19 crisis. To counteract that, Lenzing intensified its cooperation with partners along the value chains and adjusted its production volumes and sales prices to market reality. The disciplined implementation of the sCore TEN corporate strategy and the focus on specialty fibers continued to have a positive impact.*

*Please read the attached document for more information

• With shop.hygiene-austria.at, quick access to MNS, FFP2 and child masks “made in Austria” is guaranteed.

Wiener Neudorf – Hygiene Austria LP GmbH has become known for its locally produced mouth-nose protective masks, FFP2 and children's masks during the COVID-19 crisis. The company is now well prepared for the reintroduction of the mask requirement. “Especially in times of a pandemic, it is important to us at Hygiene Austria to make a contribution to the security of Austrian supply”, said Stephan Trubrich, Managing Director of Hygiene Austria LP GmbH, confidently.

All interested parties who want to prepare for their purchases in the supermarkets or their visit to public facilities but also for their holiday trips can now purchase masks of different types at the following website: https://shop.hygiene-austria.at.

• Members of TMAS – the Swedish textile machinery association – have adopted a range of new strategies in response to the Covid-19 pandemic, aimed at assisting manufacturers of textiles and apparel to adjust to a new normal, as Europe and other regions emerge cautiously from lockdown.

“Many European companies have been forced into testing new working methods and looking at what it’s possible to do remotely, and how to exploit automation to the full, in order to become more flexible,” says TMAS Secretary General Therese Premler-Andersson. “Others have been taking risks where they see opportunies and there’s a new sense of solidarity among companies.

“It’s extremely encouraging, for example, that over five hundred European companies from across our supply chain are reported to have responded to the shortages of facemasks and PPE – protective personal equipment – by converting parts of their sites or investing in new equipment.”

New supply chains

Amongst them are TMAS members of the ACG Group, who quickly established a dedicated new nonwovens fabric converting and single-use garment making-up plant to supply to the Swedish health authorities. From a standing start in March, this is now producing 1.8 million square metres of converted fabric and turning it into 692,000 finished medical garments each month.

“In 2020 so far, we have seen new value chains being created and a certain amount of permanent reshoring is now inevitable,” says Premler-Andersson. “This is being backed by the new funding announced in the European Union’s Next Generation EU plan, with €750 billion marked for helping industry recover. As the European Commission President Ursula von der Leyen has stressed, “green and digital” transitions hold the key to Europe’s future prosperity and resilience, and TMAS members have new solutions to assist in both areas.”

Remote working

Automated solutions have opened up many possibilities for remote working during the pandemic. Texo AB, for example, the specialist in wide-width weaving looms for the paper industry, was able to successfully complete the build and delivery of a major multi-container order between April and May.

“Our new Remote Guidance software now makes it possible for us to carry out some of the commissioning and troubleshooting of such new lines remotely, which has been helpful” says Texo AB President Anders Svensson.

Svegea of Sweden, which has spent the past few months developing its new CR-210 fabric relaxation machine for knitted fabrics, has also successfully set up and installed a number of machines remotely, which the company has never attempted before.

“The pandemic has definitely led to some inventive solutions for us and with international travel currently not possible, we are finding better methods of digital communication and collaboration all the time,” says Svegea managing director Hakan Steene.

Eric Norling, Vice President of the Precision Application business of Baldwin Technology, believes the pandemic may have a more permanent impact on global travel.

“We have now proven that e-meetings and virtual collaboration tools are effective,” he says. “Baldwin implemented a home office work regime from April with only production personnel and R&D researchers at the workplace. These past few months have shown that we can be just as effective and do not need to travel for physical meetings to the same extent that was previously thought to be necessary.”

Pär Hedman, Sales and Marketing Manager for IRO AB, however, believes such advances can only go so far at the moment.

“Video conferences have taken a big leap forward, especially in development projects, and this method of communication is here to stay, but it will never completely replace personal meetings,” he says. “And textile fabrics need to be touched, examined and accepted by the senses, which is impossible to do via digital media today. The coming haptic internet, however, may well even change that too.”

Social distancing

The many garment factories now equipped with Eton Systems UPS work stations – designed to save considerable costs through automation – have meanwhile benefited from the unintentional social distancing they automatically provide compared to factories with conventional banks of sewing machines.

“These companies have been able to continue operating throughout the pandemic due to the spaced nature of our automated plant configurations,” says Eton Systems Business Development Manager Roger Ryrlén. “The UPS system has been established for some time, but planned spacing has proved an accidental plus for our customers – with improved productivity.”

“Innovations from TMAS member companies have been coming thick and fast recently due to their advanced know-how in automation concepts,” Premler-Andersson concludes.  “If anything, the restrictions imposed by the Covid-19 pandemic have only accelerated these initiatives by obliging our members to take new approaches.”

Masks yes, but with comfort, safety and also style: Cifra, Iluna Group, Rosti and Sitip launch masks with a fashion touch with the premium stretch fiber ROICA™
 
Big companies are updating their productions with high-performance and high technical characteristics masks, result of their historical experience and thanks to an exceptional partner in common: the premium stretch fiber ROICA™ by Asahi Kasei. And the solidarity race continues to donate them to hospitals and to the Red Cross
 
Forced to keep most of the face covered and often for a long time during the day, solutions that are above all performing and comfortable become increasingly necessary.

And solutions that are also a manifestation of our personality, which remains hidden and entrusted to the mere expression of the eyes. Walking on the streets we sometimes even don’t even recognize each other, since we are so hidden; and the desire to minimize the situation often takes over, together with that desire to make us recognizable, to possess and express an identity anyway. For fans of escaping homologation (now more than ever mandatory and for this reason even more difficult) “rescue comes” - and this is the case to say it - from illuminated companies who have thought about creative solutions for those with masks has to do all day, at home, at work, during sports and in leisure time. To feel more comfortable, there are many proposals: more “street style” for sports addicted and young people - inside and outside -, more elegant and sophisticated for women.

Textiles companies have joined the fight against Covid-19 engaging a strong and decisive personal and productive battle, which has seen many of them transform and convert their production units for the production of masks and gowns intended for medical personnel and the community.

Some of the most established excellences of the textile sector as Cifra, Iluna Group, Rosti and Sitip have made use of the precious collaboration of ROICA™, the premium stretch fiber by Asahi Kasei. ROICA™ is the innovative and smart premium ingredient chosen by these companies to guarantee even more comfort, thanks to an exceptional top-level component that gives elasticity for perfect adherence to the skin. Each of the companies then declined its production according to its specificity. And this is their important contribution.

Cifra presents the eco-sustainable version of the mask, the ECO-MASK™, which combines the high performance of Cifra knitting technology with the sustainability of the materials used. The 100% regenerated yarns create a 100% sustainable mask with 83% ECONYL and 17% ROICA™ V550 elastomer, the stretch fiber certified Cradle to Cradle Gold Health Level which allows excellent and lasting printability, as well as advantages regarding the circular economy as it does not release harmful substances into the test environment according to the Hohenstein Environmental Compatibility certification.

Iluna Group, European leader in the production of lace, has recently donated 400 protective “smart”  made with ROICA™ EF, the world first GRS - Global Recycled Standard – certified elastomer and which uses 58% of pre-consumer recycled content, mixed with Q-NOVA® by Fulgar. Multi-use, washable, bacteriostatic, breathable and water-repellent prevention masks gave to San Gerardo Hospital in Monza to answer to the Call to action launched on March 19th by the green journalist Diana De Marsanich, with the responsible and innovative materials expert Giusy Bettoni of C.L.A.S.S. Eco Hub, the fashion designer Marina Spadafora of Fashion Revolution Italia and the entrepreneur Simona Roveda of LifeGate. Iluna Group also announces the launch of the website dedicated to the direct sale of the different kind of masks all made with three layers, antibacterial and anti-drip treatment and washable up to 10 times. Iluna Group has also created the “smart” masks made with ROICA™ EF, the world first GRS - Global Recycled Standard – certified elastomer and which uses 58% of pre-consumer recycled content, mixed with Q-NOVA® by Fulgar.

In addition to the “smart” masks, available for women, men and children, Iluna Group has created two special versions of Lace Masks, covered with refined lace. One embroidered on a cotton base and one with soft microfiber.

Rosti, historic knitwear factory based in Brembate specialized in the design and production of cycling clothing with the best technical fabrics and the most advanced technologies, has put its experience at the service of the production of protective masks washable up to 20 times, made with Sitip fabric and with the anti-drop treatment Ecoacquazero®. Fascinating and protective like a second skin, the masks are sold in a pack of 10 pieces with captivating, colorful, geometric and original graphics, designed for every personality.

Rosti masks contain the premium stretch fiber ROICA™ Resistance, a family of premium stretch yarn with particular performances of resistance and durability.

FFP2 and mouth-nose protective masks for children are also being manufactured in Wiener Neudorf

The company “Hygiene Austria LP GmbH”, recently founded by Lenzing AG and Palmers Textil AG, has once again called attention to itself. Following the successful launch of the production of mouth-nose protective masks in Austria, Hygiene Austria commenced manufacturing FFP2 masks and mouth-nose protective masks for children.
For the first time, Federal Chancellor Sebastian Kurz personally took a closer look at production operations within the context of a visit to the facility this Tuesday morning. The Austrian Chancellor visited the  Austrian company Hygiene Austria together with Federal Minister of Labor, Family and Youth Christine Aschbacher.

The corona pandemic continues to put a strain on health systems around the globe. Many places lack effective textile protective kit among others for their medical personnel. HeiQ, a Swiss specialty chemicals company, has developed antiviral and antibacterial protective kit that is quickly effective against Coronaviruses (229E), as confirmed in wide-ranging studies. In cooperation with HeiQ, the CHT Group is supplying this technology to the market to help decrease the global shortage in protective wear.

A wide number of studies have proven that viruses and bacteria can remain active on textile surfaces for a longer period. The SARS-COV-2 virus, which causes the COVID-19 disease, can stay active on a textile for up to two days and therefore be infectious. Shortages in textile protective kit create a high risk for medical personnel who are in contact with COVID-19 patients: often, doctors and nurses cannot change their protective masks and clothing as frequently as would be necessary in order to adhere to hygiene rules and to prevent the spreading of the virus.

The HeiQ Viroblock NPJ03 that has been developed by HeiQ is a new technology that is also effective against Coronaviruses (229E) thanks to its antibacterial and antiviral properties. Comprehensive studies have demonstrated the kit‘s effectiveness. A combination of silver salts with a vesicle technology deactivates bacteria and viruses on textile surfaces within a few minutes and renders the bacteria and viruses harmless. Textiles equipped in this way reduce the rate of infection by 99.99%, which stops the transmission and the spread of bacteria and viruses through textiles.

Viroblock can be used on all types of fibers – not only for protective kit and masks, but also for work clothing, bed linen, towels and home textiles. The kit is wash-resistant and still highly effective after 30 standard wash processes.

• The “Newcomer Award” will still be presented at the 8th Convention & Fair for Hightech Textiles
• Chemnitz organisers considering forward-looking forums using the “mtex+” brand

The 8th mtex+ Convention & Fair for Hightech Textiles, which was scheduled to be held on 9-10 June 2020, will not take place because of the corona crisis. “We’ve made this decision following in-depth consultations with the members of the advisory board who are working in the textile sector; they were also opposed to moving the date to the autumn because of the unforeseeable consequences arising from the crisis,” says  André Rehn, Head of Sales for Trade Fairs & Congresses at the organiser, C³ GmbH, Chemnitz.

“Cancelling the event is a particularly severe blow for us, as the “mtex+” was supposed to be held with a modernised concept and a very attractive programme at our new Carlowitz Congresscenter at the heart of Chemnitz for the first time. The considerable economic loss associated with this is naturally painful for us too. However, we will be presenting our “mtex+” “Newcomer Award” to the prize-winners at the next possible, suitable opportunity. 15 students and graduates from all over Germany have taken part in the young people’s competition with creative ideas for recycling, upcycling and downcycling textiles. We’re also now considering special events, which could operate using our well-known “mtex+” brand in future. Sustainability in the textile value-added chain as well as health and protective textiles made by the domestic market are obvious, forward-looking topics in this field.”

Energiapura – Production of reusable, customised protective masks that are also fashion accessories

• The Italian company, a specialist manufacturer of functional sportswear, conducted research and began producing masks in response to the COVID-19 crisis
• Using Mimaki sublimation printers, the masks can be customised, getting away from their connotation with hospitals and transforming them into a fashion accessory

From functional sportswear to combatting the spread of the Coronavirus: Energiapura, an Italian company has developed a mask that meets the Class I medical device requirements. The EP PA 2020 (Energiapura Pure Air) facial device, optimised for air filtering and breathability, provides protection while working, and can be reused. But Energiapura has gone even further, branding and customising the masks with sublimation printing.
The EP PA 2020 mask, compliant with 93/42 EEC Medical Devices – Class I washable, meets the essential requirements of UNI EN 14683:2019. Having redirected the manufacturing process, Energiapura is now stepping up production levels to meet the rising demand from hospitals, pharmacies, chemists, companies and consumers.

Pure Air, Energiapura’s mask
The EP PA 2020 is based on a functional concept: protection, breathability and reusability are the main principles. EP PA 2020 is made up of three layers of fabric: the first, the outer layer, is DWR-treated polyester, the second is TNT polyester, providing a filtering function, and the third, which comes into contact with the face, is polyester containing special fibres, such as coolmax and carbon.  Therefore it can be reused via normal washing and steam ironing, which also sterilises it.
The CEO of Enegiapura, Alberto Olivietto explains the idea of the customisation of the mask: “We wanted to disassociate our masks from the hospital image. By decorating them with company branding and designs provided by customers.” This is where the Mimaki JV300 wide-format printer comes in.