From the Sector

Carbitex – a leader in flexible carbon fiber composites focused on footwear, travel, and accessories – announces the appointment of Filippo Sartor to Vice President of Global Sales and Sam Gardner to the role of Vice President of Engineering and Operations. After a restructuring of manufacturing operations and the return of Carbitex founder, Junus Khan, as company president in 2023, the brand welcomes two strategic hires to catalyze the next phase of the leading materials brand.

With over 20 years in the footwear industry, including nearly 11 years as the Global Senior Sales Manager at JV International, official worldwide licensee for Michelin Soles, Sartor brings high level sales expertise within performance footwear and material innovation. With extensive focus on building new business in the US and Far East, and based in Milan, Italy, Sartor is uniquely positioned to help propel Carbitex globally into the next chapter.

Gardner, based in Renton, Washington, will manage product development and manufacturing at Carbitex. With time at Square One Distribution - a long-time Carbitex brand partner in the wake and waterski segment - and most recently as VP for Union Aquaparks, Gardner has considerable experience designing new products and managing sourcing, logistics, and supply chain. His background will help Carbitex strengthen both factory and brand partner relations and push product innovation.

These recent hires position Carbitex to better serve strategic brand partners, achieve forecasted growth in the short and long term, and expand global market presence.

In accordance with California’s Proper Labeling of Wet Wipes law (AB 818), state wastewater agencies and industry experts went deep to find out exactly what is passing through—and clogging up—municipal wastewater systems. The Responsible Flushing Alliance (RFA) alongside the California Association of Sanitation Agencies (CASA) and the Association of the Nonwoven Fabrics Industry (INDA) released the results from the largest known domestic sewage collection study conducted to reveal what’s really being flushed down the drain – and shouldn’t be.

“We took a forensic approach to this collection study, engaging industry and wastewater experts to examine our findings and determine what exactly is being flushed and how much of it,” said Adam Link, Executive Director at CASA, a co-sponsor of the Proper Labeling of Wet Wipes Law. “Now that we have the data to see what Californians are flushing and the types of non-flushable items that are causing issues within wastewater systems, local agencies can refine their public outreach and messaging to target specific problems and educate more efficiently.”

Collection and material investigation took place in October 2023 at two locations: Inland Empire Utilities Agency (IEUA) in Southern California and Central Contra Costa Sanitary District (Central San) in the greater San Francisco Bay Area in Northern California. Wastewater and wipes experts collected, sorted and identified more than 1,700 items pulled from the two locations during peak flow times. Kennedy Jenks, an independent engineering firm, designed the study and compiled the findings into the report.

Why Study What’s Being Flushed?
When products that aren’t meant to be flushed down the toilet wind up in the sewer system, it can cause serious threats to public and environmental health. In fact, estimates show that local public agencies throughout California (and the ratepayers they represent) are spending more than $47 million annually to repair wastewater treatment equipment and respond to sewer overflows caused by improper flushing.

“Part of keeping communities healthy requires not flushing things we shouldn’t,” said Lara Wyss, President of the RFA. “However, the data to support which non-flushable items to target as part of education campaigns has been lacking. That’s likely why when we surveyed Californians about what they are flushing, the results revealed that approximately 25% think baby wipes are flushable (which is never true) and 60% self-reported that they flushed something they knew they shouldn’t have.2 Our study results reinforce that finding, as more than 99% of materials collected were items that shouldn’t have been flushed.”

The breakdown of items collected from pipes at the two study locations included:
•    34.1% wipes labeled with the “Do Not Flush” symbol (baby wipes, cleaning wipes, makeup wipes, etc.)
•    64.9% other non-flushable items (paper towels, period products, trash, etc.)
•    0.9% wipes labeled as flushable

“We pulled material larger than 1-inch square directly from the bar screens, and it wasn’t until everything was sorted and identified that we could see what we actually had,” said Matt O’Sickey, Director of Education and Technical Affairs, INDA. “There were a lot of paper towels and baby wipes and all of the ‘Do Not Flush’ labeled wipes we collected were fully intact, showcasing why they should never be flushed.”

What Not to Flush—and How We Tell Consumers
According to the Proper Wet Wipes Labeling law, manufacturers of non-flushable wipes, including products such as baby wipes, cleaning wipes, makeup removal wipes and many others that are primarily used in a bathroom setting must include the “Do Not Flush” symbol on the front of the packaging.
The #FlushSmart consumer education campaign promotes the “Do Not Flush” symbol and provides information on what should and should not be flushed. The message shared with consumers is simple: Look for the “Do Not Flush” symbol on wipes packaging, and if you see it – throw the wipe out. Extrapolating from the results of this study, refraining from flushing “Do Not Flush” labeled wipes, paper products and feminine hygiene products would capture over 90% of items clogging sewers.

INDA, the Association of the Nonwoven Fabrics Industry, announced a call for presentations and award nominations for the RISE® (Research, Innovation & Science for Engineered Fabrics) Conference. RISE will be held October 1-2, 2024, at the James B. Hunt, Jr. Library, North Carolina State University, Raleigh, North Carolina. RISE is a two-day conference presenting new research and science that drives innovation and product development. The theme for this year’s event is “The Other Sustainability Story: Extended Use and Reduced Consumption.”

Nonwoven professionals are encouraged to submit their technical abstracts by Friday, April 12, 2024. Topics being considered are raw materials, equipment and processing, product-related technologies, and applications.  Abstracts may be submitted via the RISE website. For questions about abstract submissions, contact Deanna Lovell.

RISE® Innovation Award
In addition, INDA is requesting nominations for innovative nonwoven products and technologies for the RISE® Innovation Award. INDA will consider categories such as raw materials, roll goods, converting, packaging, active ingredients, binders, additives and end products for nominations. This Award recognizes innovation in areas within and on the periphery of the nonwovens industry, utilizing advanced science and engineering principles to develop solutions to problems and advance the usage of nonwovens.

Three finalists will be chosen to present their innovations to technology scouts, scientists, researchers, and industry professionals on Tuesday, October 1st. Nominations may be submitted via the INDA website. The Award submission deadline is July 29, 2024. For questions about the Award, contact Vickie Smead.

Last year, the RISE® Innovation Award was presented to TiHive for their SAPMonit technology.

Carbon fiber-reinforced polymer lamellas are an innovative method of reinforcing buildings. There are still many unanswered questions regarding their recycling, however. A research project by Empa's Mechanical Systems Engineering lab is now set to provide answers. Thanks to the support from a foundation, the project could now be launched.

The construction sector is responsible for around 60 percent of Switzerland's annual waste. The industry's efforts to recycle demolition materials are steadily increasing. Nevertheless, there are still end-of-life materials that, for the time being, cannot be reused as recycling would be too time-consuming and expensive. One of these are carbon fiber-reinforced polymer (CFRP) lamellas.

Making buildings "live" longer
The reinforcing method developed by Urs Meier, former Empa Director at Dübendorf, has been used in infrastructure construction for 30 years. CFRP lamellas are attached with epoxy adhesive to bridges, parking garages, building walls and ceilings made of concrete or masonry. As a result, the structures can be used for 20 to 30 years longer. The method is increasingly being applied worldwide – mainly because it massively improves the earthquake resistance of masonry buildings.

"By significantly extending the lifespan of buildings and infrastructure, CFRP lamellas make an important contribution to increasing sustainability in the construction sector. However, we need to find a way how we can further use CFRP lamellas after the buildings are being demolished," explains Giovanni Terrasi, Head of the Mechanical Systems Engineering lab at Empa. To achieve this, he wants to develop a method for recycling CFRP lamellas. Convinced by this idea, a foundation supported it with a generous donation. The project officially launched in October.

Gentle separation
First, a mechanical process will be developed to detach the CFRP lamellas from the concrete without damaging them. Initial tests at Empa are encouraging: After the lamellas were separated from the concrete, they still had a strength of 95 percent – even if they had already been used for 30 years.

Then, the demolished CFRP lamellas shall be used to produce reinforcement for prefabricated components. Terrasi's goal: saving thousands of tons of CFRP lamellas from ending up in landfills after the demolition of old concrete structures and reuse them in low-CO₂ concrete elements. After completion of the project, Giovanni Terrasi and his team – consisting of Zafeirios Triantafyllidis, Valentin Ott, Mateusz Wyrzykowski and Daniel Völki – want to produce railroad sleepers from recycled concrete, which will be reinforced and prestressed with demolition CFRP lamellas. This would give the "waste-to-be" material a second life in Swiss infrastructure construction.

The kick-off meeting for the "Trends and Design Factors for Hydrogen Pressure Vessels" project, recently held at AZL Aachen GmbH, was a successful event, bringing together more than 37 experts in the field of composite technologies. This event laid a solid foundation for the Joint Partner Project, which currently comprises a consortium of 20 renowned companies from across the composite pressure vessel value chain: Ascend Performance Materials, C evotec GmbH, Chongqing Polycomp International Corp. (CPIC), Conbility GmbH, Elkamet Kunststofftechnik GmbH, F.A. Kümpers GmbH & Co. KG, f loteks plastik sanayi ticaret a.s., Formosa Plastics Corporation, Heraeus Noblelight GmbH, Huntsman Advanced Materials, Kaneka Belgium NV, Laserline GmbH, Mitsui Chemicals Europe GmbH, Plastik Omnium, Rassini Europe GmbH, Robert Bosch GmbH, Swancor Holding Co. Ltd. Ltd., TECNALIA, Toyota Motor Europe NV/SA, Tünkers do Brasil Ltda.

The project follows AZL´s well proven approach of a Joint Partner Project, aiming to provide technology and market insights as well as benchmarking of different material and production setups in combination with connecting experts along the value chain.

The kick-off meeting not only served as a platform to foster new contacts and get informed about the expertise and interests of the consortium members in the field of hydrogen pressure vessels, but also laid the groundwork for steering the focus of the upc oming project's ambitious phases. As a basis for the interactive discussion session, AZL outlined the background, motivation and detailed work plan. The central issues of the dialogue were the primary objectives, the most pressing challenges, the contribut ion to competitiveness, and
the priorities that would best meet the expectations of the project partners.

Discussions covered regulatory issues, the evolving value chain and the supply and properties of key materials such as carbon and glass fibres and resins. The consortium defined investigations into different manufacturing technologies, assessing their matu rity and potential benefits. Design layouts, including liners, boss designs and winding patterns, were thoroughly considered, taking into account their implications for mobile and stationary storage. The group is also interested in cost effective testing m ethods and certification processes, as well as the prospects for recycling into continuous fibres and the use of sustainable materials. Insight was requested into future demand for hydrogen tanks, OEM needs and strategies, and technological developments to produce more economical tanks.

The meeting highlighted the importance of CAE designs for fibre patterns, software suitability and the application dependent use of thermoset and thermoplastic designs.

The first report meeting will also set the stage of the next project phase, which will be the creation of reference designs by AZL's engineering team. These designs will cover a range of pressure vessel configurations using a variety of materials and production concepts. The aim is to develop models that not only re flect current technological capabilities, but also provide deep insight into the cost analysis of different production technologies, their CO₂ footprint, recycling aspects and scalability.

AZL's project remains open to additional participants. Companies interested in joining this initiative are invited to contact Philipp Fröhlig.

Dyneema^® announced the launch of a next-generation unidirectional (UD) material innovation based on its third-generation fiber at the polymer level: a development poised to enhance the safety and mobility of law enforcement officers and military forces through molecular engineering.

This evolution enables a higher-tenacity fiber – resulting in increased ballistic stopping power when used in the new UD material, Dyneema^® SB301, for protective armor applications. The seismic shift in performance enables body armor manufacturers to design soft armor vests 10–20% lighter than previous protective solutions.

Beyond strength, Dyneema^® SB301 has the advantage of being made from bio-based Dyneema^® fiber, which enables a carbon footprint up to 90% lower than generic high modulus polyethylene (HMPE) fiber.

Now available for use in law enforcement vests for the US market, Dyneema^® SB301 material is manufactured in Greenville, North Carolina, in compliance with the Berry Amendment, with additional markets to follow.

“In every situation, weight is now considered to be the top priority after ballistic stopping power,” said Marcelo van de Kamp, global business director for personal protection at Avient. “That’s because survivability is directly tied to weight savings when speed and agility determine outcomes. We’ve long been known as the ‘world’s strongest fiber™,’ but that won’t stop us from finding new opportunities to get stronger. This new product is the latest demonstration of our commitment to both innovation and protection.”

Technological progress often results from close collaboration, and industries that rely on continual improvement stand to benefit from the return to in-person business. Cinte Techtextil China’s first edition since eased pandemic measures is set to reflect a 27.9% increase in exhibitor numbers, with a rejuvenated international contingent further supplemented by the return of the European Zone. Taking place from 19 – 21 September across 40,000 sqm at the Shanghai New International Expo Centre, the platform is expected to welcome buyers from across Asia, Europe, and beyond. Pre-registrations have doubled compared to the previous edition, and international buyers account for over 20% of the total.

The new zone, Marine Textile Zone, will be comprised of multiple Chinese green marine and nautical rope netting exhibitors, while also hosting the Technology Exchange Forum, and the awards ceremony of the Top 10 Suppliers in the China Rope Net Industry. Prominent exhibitors in this zone include Ropenet Group, Hunan Xinhai, and Zhejiang Four Brothers Rope.

Other domestic exhibitors, such as Shanghai Shenda Kebao New Materials, SIJIA New Material (Shanghai), Zhejiang Hailide New Material, and Zhejiang Jinda New Materials, will showcase products for applications in outdoor advertising, tents, boats, vehicles, environmental engineering, and much more.

Supplementing the fairground’s wide variety of domestic suppliers will be a much-increased showing of international exhibitors, with many to be found within hall E1’s European Zone. Several global industry leaders are featured in their categories below:

Nonwovens equipment

• Autefa Solutions, Germany: solutions provider for nonwovens lines and machines for carded-crosslapped needlepunching lines, spunlace lines and thermobonding lines.
• Dilo, Germany: in addition to offering general services, Dilo supplies opening and blending equipment, carding and airlay machines, and crosslapping and needling machines.
• Groz-Beckert, Germany: provider of industrial machine needles, precision parts and fine tools, as well as systems and services for the production and joining of textile fabrics.
• Reifenhäuser Reicofil, Germany: provider of innovative technologies and components for plastics extrusion, producing blown films, cast films, sheets as well as nonwovens.

Weaving equipment

• Itema, Italy: provider of advanced weaving machines, spare parts, and integrated services, specifically for rapier, air jet and projectile weft insertion technologies.
• Lindauer DORNIER, Germany: the company manufactures weaving machines, film stretching lines, and composite systems, also offering technical support and spare parts supply.
• Picanol, Belgium: producer and servicer of high-tech air jet and rapier weaving machines, with around 2,600 weaving mills utilising their systems worldwide.

Coating and lamination

• BRÜCKNER Textile Technologies, Germany: manufacturer of machines and lines for the coating and finishing of apparel fabric, technical textiles, nonwovens, glass fabrics and floor coverings.
• ROWA Lack, Germany: developer of high-quality materials and product solutions for the polymer industry, with applications including automotive, electrical engineering, construction, technical textiles, and medical technology.
• Stahl, the Netherlands: the Dutch company provides high quality coatings, dyes and process chemicals for leather, flexible coated substrates, textiles, films and foils, paper, and related products.

Fibre

• Monosuisse, Switzerland: with production sites in Switzerland, Poland, Romania, Mexico, and Germany, Monosuisse manufactures various precise, high-quality polymer monofilaments from 19µm to 3.00 mm in diameter.
• Perlon, Germany: specialised in the manufacture of synthetic filaments in diverse application areas, including paper machine clothing, dental care, and advanced technical textiles for agriculture, 3D printing, sports and leisure, home, and more.

Meanwhile, first-time exhibitors include Rökona (Germany), showcasing RE:SPACE, their range of recycled technical textiles; Testex AG (Switzerland), the official OEKO-TEX® representative in multiple countries including China; Hohenstein (Germany), the renowned testing laboratory and research institute; and zwissTEX (Germany), the knitted fabrics and lamination specialists. In addition, the returning Taiwan Pavilion is set to feature the debut of Shinih Enterprise Co Ltd (Taiwan China).

Beyond the innovation displayed at the booths, the fair’s programme is set to welcome global experts from various technical textile and nonwoven sub-sectors to offer specific insights and unveil innovations. Highlighted events include:

The 11th China International Nonwovens Conference
14 sessions cover topics such as the quality control of medical supplies; green development in technology and applications in the nonwovens industry; and the development and application of flashspun nonwovens in China.

Marine textiles and rope netting events
Events specific to this zone include the Top 10 Suppliers in the China Rope Net Industry; Conference on Textile Applications for Marine Engineering and Fisheries; and the China Nonwovens & Industrial Textiles Association (CNITA) Rope Net Branch Council Meeting

"Nonwovens, Creating a Better Life” Innovation Showcase
Product display area showcasing around 100 nonwovens products with applications in five areas: medical and health, quality of life, human habitat, sustainable development, and innovative design.

Advanced Technical Textiles Industry Chain Synergistic Innovation Development Forum
Includes presentations from multiple key players in the technical textile industry, including Mr Steven Liu, Commercial Manager of Polymer Additives Business of Sanitized (China) Ltd.

Beaulieu International Group will turn the spotlight on geotextile products with sustainability benefits to support progress in resilient civil engineering projects at the 12^th ICG Rome from 18^th -21^st September 2023, presenting options to target fossil carbon reduction by choosing PP-based staple fibres or woven geotextiles that are among the lowest in carbon footprint for geosynthetics.

For manufacturers of nonwoven geotextiles, Beaulieu Fibres International (BFI) offers PP fibres with > 25% carbon footprint reduction compared to the European standard PP fibres, generating 1.48 kg CO₂/kg PP fibres. A step further is to accelerate the replacement of fossil carbon in engineered fibre applications by choosing its ISCC Plus certified bio-attributed MONO-PP with a negative carbon footprint.

For construction projects, nonwoven geotextiles made with high-tenacity HT8 fibres are proven to secure a longer service lifetime and reduce the environmental impact, as they offer high mechanical performance at a reduced weight.

Beaulieu Technical Textiles' (BTT) woven geotextiles provide a wide range of functions, including separation, filtration, reinforcement and erosion control, and are among the most sustainable in the industry. Depending on weight, the carbon footprint of its woven geotextiles (m²) ranges between 0.37 and 1.40 kg CO₂ eq./m². They also minimize the use of natural resources for more sustainable infrastructure development. Case studies such as at the Ostend-Bruges airport highlight significant CO2 reduction on the jobsite by replacing the transport of 960 trucks of gravel with 3 trucks of woven geotextiles, and by extending the runway’s life span.

The ICG launch of its new line Terralys MF woven filtration geotextiles with monofilament boosts the performance of a common solution in building layers that require high water flow rates. High-tenacity extruded polypropylene tapes and monofilaments are interwoven to form dimensionally stable and highly permeable geotextiles. These new filtration geotextiles provide greater resistance to dirt and biological clogging. They allow water to travel freely while reducing soil erosion when employed as a separation and stabilizing layer.

As of September 2023, all PP staple fibres and woven geotextiles will have Environmental Product Declarations (EPD) based on LCAs. Each EPD is an essential tool for communicating and reporting on the sustainability performance and helps carbon-conscious customers in their purchasing and decision making. Registered EPDs are globally recognized, publicly available and free to download through EPD Libraries.

• TreeToTextile sustainable textile fibre demo plant in Sweden

TreeToTextile, owned by H&M Group, Inter IKEA Group, Stora Enso, and LSCS Invest, invested €35 million in constructing a textile fiber process technology demonstration plant in Sweden. AFRY supported TreeToTextile throughout the project in the development and implementation phases from 2016-2022. The demonstration plant is now in the start-up phase.

TreeToTextile is offering a new technology to produce bio-based textile fibers with a low environmental footprint and aims to make sustainable textile fibers available to all. The new fiber is a regenerated cellulosic fiber, produced from renewable and sustainably sourced raw materials from forests. TreeToTextile has invested €35 million in developing and constructing a new demonstration plant in Nymölla, Sweden. This investment is a crucial step prior to the scale-up and commercialization of this technology.

AFRY has been the leading consultant and engineering partner of TreeToTextile from its early stages of project development in 2016, continuing onto demo plant implementation engineering from 2020-2022 In the project development phase, AFRY’s assignment included several pre-feasibility and feasibility studies, process design, up-scaling evaluations, and supplier pilot runs planning. In the demo plant implementation phase, AFRY was responsible for the engineering, project management and site services, also providing many additional services like permit and procurement support as well as machine and IT solutions.

“AFRY and TreeToTextile have a long-lasting, mutually developing relationship that we hope to continue. Together with AFRY, we have overcome the challenges through close collaboration, flexibility, broad competence and most important of all, mutual commitment”, says Olli Ylä-Jarkko, CTO at TreeToTextile.

The commissioning of the demonstration plant started in the summer of 2022, and the project was handed over to TreeToTextile for start-up and further optimization of the process.

“I’m proud of the deep and long-lasting cooperation with TreeToTextile. This project shows AFRY’s ability and wide competence to meet various demands of customer investment projects – from early phase development to implementation. AFRY’s long experience with bio-based materials, combined with our extensive process industry and project execution experience, makes us a unique partner for industrial clients in accelerating their bio-based fibers to scalable commercial production”, says Lisa Vedin, Head of Process Industries Sweden at AFRY.

• Formula 1 cars will be cheaper in future

Carbon is the stuff Formula 1 cars are made of, at least the bodywork. But until now, carbon has been expensive. It can be produced more cheaply and efficiently if artificial intelligence monitors the production processes. A camera system combined with artificial intelligence automatically detects defects in the production of carbon fibres. This makes expensive manual inspection of the carbon fibres obsolete and the production price of the carbon fibre can be reduced in the long term.

For this idea, the young engineer Deniz Sinan Yesilyurt received the second prize of the "Digitalisation in Mechanical Engineering" Young Talent Award on 6 December.

Carbon fibres are sought after because of their good properties. They are very light - they weigh up to 50 percent less than aluminium. The combination of low weight and good mechanical properties offers many advantages. Especially in times of the energy transition, lightweight materials like carbon are more relevant than ever before. At the same time, carbon fibres are as resistant to external stresses as metals. However, achieving these good properties of carbon fibres is very complex.

Up to 300 individual fibre strands - bundles of individual fibres - have to be monitored simultaneously during production. If carbon fibres tear, it costs time and money to sort out the damaged fibres. This is just one example of various defects that can occur in the fibres during production.

Therefore, Deniz Sinan Yesilyurt attached a camera to the carbon fibre line that takes pictures of various fibre defects during production and collects them in a database. The artificial intelligence in the camera's information technology system evaluates the fibre defects by assigning the images to predefined reference defects. In doing so, it recognises various fibre defects with a classification accuracy of 99 per cent. The process can also be used in other areas that produce chemical fibres.

Deniz Sinan Yesilyurt received the prize from the German Engineering Federation (VDMA) in Frankfurt am Main, Germany. He is a Bachelor's graduate at the Institut für Textiltechnik (ITA) of RWTH Aachen University. The full title of his bachelor's thesis is: "Development of a Kl-supported process monitoring using machine learning to detect fibre damage in the stabilisation process". The VDMA awarded the prize to a total of four theses from different universities. The prize is awarded for outstanding theses and was offered in Germany, Austria and Switzerland.