From the Sector

• CELLIANT®, Hologenix’s flagship product, makes impact in pure white color

 
Aeon, the largest retailer in Asia, is introducing “Recovery Wear,” called TOPVALU SELECT CELLIANT – undershirts – using the first-ever CELLIANT® fibers from Hologenix that are pure white in color.  It will be available in about 350 stores throughout Japan and at Aeon’s official online store, Aeon Style Online.  Aeon is expecting sales of TOPVALU SELECT CELLIANT to increase substantially by 2025.
 
TOPVALU SELECT CELLIANT offers the benefits of CELLIANT, a responsive textile that captures and converts body heat into infrared, with the pure white color Aeon customers have requested.
 
Many men prefer to wear white undershirts under their business shirts in Japan. In response to such demands, AEON planned and developed the pure white CELLIANT undershirt for the first time.  TOPVALU SELECT CELLIANT is registered as a general medical device in Japan.
CELLIANT mineral-infused fabrics have been shown to help regulate body temperature and improve local circulation in healthy individuals for faster recovery, better sleep and stronger performance during the day.
 
“We are very excited by the introduction of the first-ever CELLIANT product in pure white,” said Seth Casden, Hologenix Co-Founder and CEO. “Achieving this pure white color took a lot of dedicated effort from our global research team and we commend Aeon for being the first to introduce it to the consumer market.”

• Marchi & Fildi Group presents the selection of metalloplastic yarns with GRS certification of its Gleaming line, coming from 100% post-consumer recycled polyester

With the goal to expand the offer of yarns coming from recycled raw materials for a textile more attentive to the consumption of resources, the MFT division of the Marchi & Fildi Group completes the range of metalloplastic yarns of its Gleaming collection with the insertion of 100% recycled polyester yarns coming from post-consumer material and with the GRS (Global Recycle Standard) certification.
Starting from recycled polyester with traceable origin, in compliance with environmental and social criteria extended to all the phases of the supply chain, metalloplastic yarns are obtained with the same esthetic features and performance, compared to similar products based on virgin raw materials.

“Thanks to our commitment in the research of materials, we are able to propose metalloplastic yarns produced with 100% recycled material; the film used for the production of flat yarns, too, is in recycled polyester, with a quality level that is suitable for cutting – the Company explains -. Till now it was possible to find in the market only metalloplastic yarns with not recycled polyester flat yarn, twisted with certified fibers. This represents an important step forward to implement a circular economy possibility for this kind of products too”.

The Gleaming yarns GRS certified can be supplied in gold and silver, colors and transparent, in various counts, widths and types; they are suitable for use in flat and circular knitting, weaving, hosiery and as a component in fancy yarns.

The Gleaming line, with a wide selection of yarns in stock service, represents a completion of the offer of the Marchi & Fildi Group. The Gleaming yarns are offered in different thicknesses, widths and types with both metallized and transparent, iridescent, refracting and phosphorescent effects. The collection also includes items with special features of resistance to chemical and dyeing treatments. The Gleaming metalloplastic yarns find application in the world of fashion and furniture, for creative and fancy yarns and fabrics, accessories and decorations. Products with refractive features are also used in technical items like uniforms and workwear, sport garments and accessories, external ribbons and labels.

Kai-Chieh Kuo, PhD student at the Institut für Textiltechnik (ITA) of RWTH Aachen University, was awarded the German Textile Mechanical Engineering 2021 Best Master's Thesis Award for his master's thesis entitled "Modification of the tube weaving process of fine yarns for the production of woven ultra-low profile stent grafts". The prize is endowed with 3,500€. Peter D. Dornier, Chairman of the Board of the Walter Reiners-Stiftung (Foundation), virtually presented the award on the occasion of the ADD International Textile Conference on 9 November 2021.

Minimally invasive endovascular aortic repair (EVAR) with textile stent-graft systems is nowadays a clinically established therapy procedure for the treatment of abdominal aortic aneurysms (AAA) – pathological bulges of the aorta. Due to the thick profile of the folded stent graft systems, there is currently a high risk of injuring narrowed or highly angulated access vessels from the inside during implantation. Stent graft systems with smaller profiles could provide an improvement, which could overcome complicated access routes through a lower bending stiffness. One possible approach for reducing the system profiles is the use of thin-walled tubular woven fabrics made of ultrafine multifilament yarns (≤20 dtex) as graft material.

Up to now, it has not been possible to process the fine yarns with the required high thread density (>200 threads/cm) and the available weaving technology in order to guarantee sufficient tightness against blood.

In his master's thesis, Kai-Chieh Kuo made high-density tubular weaving of ultra-fine filament yarns possible for the first time by means of suitable modifications to a shuttle loom as well as adaptations in the weaving preparation. In particular, he developed a new innovative reed technology that reduces warp thread friction during the shedding process and thus improves the process stability of the dense tube weaving process of fine yarns.

With the help of the process modification, it was then possible to produce high-density, thin-walled tubular woven fabrics, which were positively evaluated with regard to their suitability for a stent graft. Above all the potential of these tubular fabrics lies in their extremely thin-walled fabric profile, which seals well against blood. By using these new types of tubular fabrics as graft material for stent grafts, the system profile of the folded stent graft system can be reduced without having to compromise the blood tightness of the implant. The technology developed by Mr Kuo is not only applicable to stent graft systems, but also offers great possibilities for use in all other endovascular implants such as trans catheter heart valves, covered stents and small-lumen vascular prostheses.

The Lenzing Group reported a significant year-on-year improvement in revenue and earnings in the first nine months of 2021 thanks to the largely positive market environment. Growing optimism in the textile and apparel industry and the recovery in retail led to a substantial increase in demand and prices on the global fiber market, particularly at the start of the current financial year.

Revenue rose by 32.9 percent to EUR 1.59 bn in the first nine months of 2021. This increase is attributable to a higher sales volume as well as higher viscose prices, which stood at more than RMB 15,000 in May thanks to significantly higher demand for fibers, especially in Asia. The focus on wood-based specialty fibers such as the TENCEL™, LENZING™ ECOVERO™ and VEOCEL™ branded fibers also had a positive impact on the revenue trend; the share of specialty fibers in fiber revenue amounted to 72.4 percent in the reporting period. This more than offset the negative impact of less favorable currency effects.

The earnings performance essentially reflects the positive market trend and was additionally reinforced by efficiency-enhancement measures. Energy, raw material and logistics costs increased significantly during the entire reporting period. EBITDA (earnings before interest, tax, depreciation and amortization) more than doubled to EUR 297.6 mn in the first nine months of 2021 (compared to EUR 138.5 mn in the first nine months of 2020). The EBITDA margin rose from 11.6 percent to 18.7 percent. Net profit for the period amounted to EUR 113.4 mn (compared to a net loss of EUR minus 23.3 mn in the first nine months of 2020) and earnings per share to EUR 3.77 (compared to EUR minus 0.1 in the first three months of 2020).

The Crypton Companies (Crypton LLC and Nanotex LLC), leaders in high-performance fabrics for contract and residential interiors, has partnered with Hologenix®, LLC, whose CELLIANT® infrared technology is an ingredient in world-class brands across many categories. The two have collaborated to create a new textile innovation, Crypton® CELLIANT®, the first woven upholstery fabric with CELLIANT.

CELLIANT, ethically sourced minerals embedded into fibers, reflects natural body heat back to us as infrared energy. It has been clinically tested and proven to increase cellular oxygenation for improved energy, stronger performance, faster recovery, better sleep and overall enhanced wellbeing. With the tagline “easy care meets self-care,” the new Crypton CELLIANT fabric additionally offers Crypton’s performance characteristics. These include moisture-resistance, stain-resistance, spill-repellence, odor-resistance and cleanability. Both Crypton’s contract fabrics and its Crypton Home lines will offer collections of this innovative blend of Crypton performance along with CELLIANT’s energy-enhancing properties.

Crypton CELLIANT is exclusively woven at The Crypton Mills at Broad River, the firm’s own mill in Cliffside, North Carolina, and enhanced with performance technology in its research and manufacturing facility in Kings Mountain, North Carolina, to the highest environmental standards. Like all Crypton products, Crypton CELLIANT is GREENGUARD® Gold Certified. Crypton CELLIANT will be introduced to market through distributors in early 2022.

International technology group ANDRITZ has received an order from Albaad Massuot Yitzhak Ltd. to supply a neXline wetlace hybrid line for their Dimona facilities, Israel. The line will produce a wide variety of pulp-based wet wipes and is scheduled for start-up during the third quarter 2023.

The state-of-the-art neXline wetlace hybrid is the perfect combination of inline drylaid and wetlaid web forming with hydroentanglement and drying, including quality control equipment and a Metris Industry 4.0 package. All components will be delivered by ANDRITZ and are designed to produce first-class fabrics, including biodegradable, carded-pulp and flushable/dispersible nonwovens for end uses as wipes.

Tobias Schäfer, Vice President Sales at ANDRITZ Nonwoven, comments: “Our innovative production line gives Albaad enormous flexibility in the production of wipes. In addition, the Metris digitalization package by ANDRITZ will provide Albaad with highly efficient and smart operation.”

Dan Mesika, CEO and President of Albaad, says: “We are dedicated to developing new products – such as eco-friendly, biodegradable wipes. As pioneering manufacturers of our Hydrofine® flushable wipes, we are committed to environmental sustainability. Thanks to the new ANDRITZ line, we will enlarge the product portfolio at our Dimona production site with innovative fabrics and high efficiency.

Gadi Choresh, President of the Nonwovens Division at Albaad, says: “Our knowledge and experience in drylaid and wetlaid technology, together with the state-of-the-art equipment supplied by ANDRITZ, will enable us to provide the market with natural-source nonwovens and the best answer to the market demand.”
 
Albaad is one of the world’s three largest wet wipe manufacturers and is committed to delivering excellent wipes for every need. The company runs world-leading production facilities on three continents, each equipped with the latest technologies. Albaad produces spunlace and flushable fabrics in its facilities as well as purchasing from other roll goods suppliers in order to support production of a wide variety of wipes.

The Hygiene Fibers Group of Indorama Ventures (IVL) came together at the Index Show to present an all-inclusive range of recycled and biodegradable solutions for Hygiene Fiber and Nonwoven applications.

The combination of polymers, technologies, processes and global reach supported by the Hygiene Fibers Group – one of three business segments that make up Indorama Ventures – positions it within the Hygiene industry to meet increasingly challenging market demand for innovative sustainable solutions within the hygiene sector. Across the six brands and companies that make up Hygiene Fibers Group – Auriga, Avgol, FiberVisions, Indorama Asia, Trevira and Wellman International – sustainability and supporting customers to achieve circular objectives is integral to all efforts and fundamental to the ethos of the Hygiene business segment.

At the Index Show, the Hygiene Fibers Group launched CiCLO®, a textile technology which allows polyester and other synthetic materials to biodegrade like natural materials do in wastewater treatment plant sludge, sea water and landfill conditions, reducing synthetic microfiber pollution generated during washing, and minimizing plastic accumulation in landfills caused by discarded textiles.

In line with the company’s commitment to support customers with high performance products, while also reducing the impact on the environment, several of the  Hygiene Fibers brands, including Wellman International, Trevira GMBH and Auriga, have been working closely over the last 12 months with the IAM team and the CiCLO® technology. Developments have focused on PET and rPET staple fiber and filament sustainable solutions for applications where recycling is particularly challenging, such as Hygiene, Home Textiles and Automotive applications.

Strengthening the profile of biodegradable offerings within the Hygiene Fibers Group’s sustainability portfolio, Trevira introduced a new range of bicomponent fibres based on PLA and PBS (polybutylene succinate) at the Index show. Both biopolymers offer an exceptional technological opportunity in terms of environmental care and sustainability, while delivering optimum performance. Equally to PLA, PBS is recyclable and up to 100% biodegradable under industrial conditions.

Efforts towards supporting customers to achieve circular objectives are a priority within the Hygiene Fibers Group. This is reflected in the recycled fibers expertise deployed across the segment. Four Hygiene Fibers Group brands, IVL Asia, Auriga, Trevira and Wellman International offer an extensive range of 100% recycled, accredited PET fibers, across a multitude of fiber and nonwovens applications.

The development and evolution of sustainable technologies is central to activity across IVL’s Hygiene Fibers Group, with particular focus on sustainable polyolefin solutions. FiberVisions and ES-FIBERVISIONS, leading Polyolefin mono and bico fiber brands and sister company Avgol, have partnered with UK-based Polymateria to commercially harness the innovative ‘biotransformation’ technology pioneered by Polymateria. The patented technology alters the properties of polyolefins to make them biodegradable in a natural process.  Other polyolefin sustainable innovations within the Hygiene Fibers Group were featured at Index include biosurfactant and biocolourant developments being undertaken by the Avgol team with FiberVisons progressing sustainable design solutions, including lightweight, high performance, reduced carbon solutions.

• Polynova to gain market share for the GRAFE Group in the Swiss region from November The GRAFE Group, Blankenhain, has found a new sales representative for Switzerland in Polynova Group AG, Risch-Rotkreuz (Switzerland).

The partnership will be officially launched at Fakuma 2021. "Our new Swiss agency specialises in the distribution and production of high-quality technical plastic granulates and has been active on the market for more than 20 years. The company has a large customer base and the necessary technical expertise to advance our goals in this important market. This includes raising our profile, educating people about our product range and ultimately gaining market share," says Stefanie Theuerkauf, Sales Manager for the D-A-CH region. Polynova employs five sales staff and three in logistics, all of whom have a technical background. The company's own warehouse in Rothenburg also ensures the availability of the plastics.

"GRAFE fits perfectly into our product portfolio," says Thomas Weigl, co-owner and responsible for business development at the Swiss distribution company, whose employees recently underwent intensive training in Blankenhain. "Our customers come from the sports goods, housing technology, automotive supplier and medical technology sectors - there are many synergies with GRAFE." Weigl himself has extensive experience in the masterbatch sector and has worked for two companies in the industry - Sukano and Americhem - as managing director. "Swiss companies want Swiss contact persons. We speak the languages German, Italian and French, are on site in the shortest possible time, offer direct contact and understand the needs of the customers and the requirements of the market," he explains. "Polynova is thus faster, closer and more direct." "The Swiss market is large and important for us," reports Theuerkauf and Weigl explains the background: "There are over 300 plastics processors, many are family-run and very technically oriented. The origins of the companies are often in the watch industry and in the production of the smallest precision parts such as gear wheels. In addition, coffee machine manufacturers, medical technology providers and automotive suppliers are important market players. A large number of well-known OEMs are located here."

Even though there are already masterbatch manufacturers in the Alpine country, says the sales expert, no one has the know-how to adjust compounds and masterbatches as perfectly and precisely as the company from Thuringia. In addition to a complete range of colours on practically all plastic substrates, flame retardants, UV additives, thermal stabilisers or lubricants are further examples of the extensive product portfolio. GRAFE is one of the specialists in the modification of thermoplastics and is an innovation driver in the production of colour masterbatches. "The technical possibilities in terms of a state-of-the-art technical centre and production machinery, as well as one of the largest research and development departments in the industry, are also not to be found elsewhere on the Swiss market. Our task now is to bring these to the attention of domestic customers," says Thomas Weigl, co-owner of Polynova AG together with founder Renato R. Huebscher.

• Next-Gen Technologies for Nonwovens/Engineered Materials
• Canopy Respirator from Canopy Wins Innovation Award

145 professionals in product development, material science, and new technologies convened for the 11th conference edition of RISE®—Research, Innovation & Science for Engineered Fabrics, held virtually, Sept. 28-30. The event was co-organized by INDA, the Association of the Nonwoven Fabrics Industry, The Nonwovens Institute, and North Carolina State University.

The program focused on Nonwoven Material Science Developments, Sustainability, Increasing Circularity, Promising Innovations, Process Innovations, Material Innovations, Government/NGO Challenges to Single-Use Plastics, Machine-Assisted-Learning Development of Biopolymers, and Market Intelligence and Economic Insights.

Participants praised the high-quality program content, in-depth round table discussions, networking and Q&A’s where participants ask expert speakers questions pertaining to their focused presentations.

Highlights among the 26 presentations included

• Sustainable Solutions for our Plastic Planet Predicament, by Marc A. Hillmyer, Ph.D., McKnight Presidential Endowed Chair, University of Minnesota;
• Closed-Loop Recycling Pilot of Single-Use Face Masks by Peter Dziezok, Ph.D., Director of Open Innovation, Proctor & Gamble;
• Innovating a Sustainable Future for Nonwovens: A European Perspective, by Matt Tipper, Ph.D., CEO, Nonwovens Innovation & Research Institute (NIRI);
• Phantom Platform: The Polyolefin-cellulose Coformed Substrates Technology, by Fabio Zampollo, CEO and Founder of Teknoweb Materials; 
• Guiding Environmentally Sustainable Innovations – From Reactive to Proactive Life Cycle Management, by Valentina Prado, Ph.D., Senior Sustainability Analyst, EarthShift Global LLC;  
• High-Loft, Ultra-Soft Hygiene Solutions, Paul E. Rollin, Ph.D., Senior Principal Scientist – Global Hygiene, Propylene-Vistamaxx-Adhesion (PVA) Global Technology, ExxonMobil Chemical Company;
• Canadian Plastic Policy Update, by Karyn M. Schmidt, Senior Director, Regulatory & Technical Affairs, American Chemistry Council (ACC).

Other highlights included the announcement of Canopy Respirator as the winner of this year’s RISE® Innovation Award winner. The annual award recognizes innovation in areas within and on the periphery of the nonwovens industry which use advanced science and engineering principles to develop unique or intricate solutions to problems and advance the usage of nonwovens.

RISE® Innovation Award Winner
The RISE® Innovation Award was presented to Canopy for their Canopy Respirator. The productis an innovative respirator that is fully mechanical, non-electrostatic, with a filter designed for superior breathability while offering the wearer facial transparency. The breakthrough respirator features 5.5mm water column resistance at 85 liters (3 cubic feet) per minute, 2-way filtration, and a pleated filter that contains over 500 square centimeters of surface area. The patented Canopy respirator resists fluids, and eliminates fogging of eyeglasses.

• JUMBO-Textil offers elastic high-tech braids – produced on high-tech systems

Developing narrow textile solutions for our customers – quickly, flexibly and precisely – that is our claim. For us and for our technology. Because first-class industrial solutions require first-class technology. Highly automated and digitally controlled. Technology like that found in our variation braider from Herzog – the high-performer among modern braiding machines. JUMBO-Textil is the first narrow textile manufacturer ever to produce elastic hole cords on the special system.

High-performance system for extremely stable textile components
The special system combines sophisticated bobbin lace technology with digital control and thus enables the production of highly complex, individually specifiable braided structures. The variation braider's technology ensures an uninterrupted fibre course across all branches. This not only allows individual, idiosyncratic geometries, it also and above all helps with the stability of the components. This is because where other methods create branching points that are susceptible to breakage due to laser cutting, seams or knots, the variation braider simply braids through the branched strands. As the fibre course is not interrupted in braided branches, the resilience of the textiles is significantly increased. And individual braids are created for very different applications.

Bobbin lace technology for highly complex structures
Unlike in classical braiding systems, the impellers of the variation braider are arranged in a square. Up to eight different strands can be braided and interlaced with the textile all-rounder. All bobbins can be programmed separately and thus the bobbin lanes can be combined variably and individually. JUMBO-Textil also produces tubular braids with precisely defined braided openings, triaxial braids and highly complex preforms with the variation braider. The geometries of the narrow textiles range all the way to net structures. For braided cables, we create stable connections in the core-sheath braiding by weaving the core and the protective sheathing, which provides protection especially at the turns: there is no longer any undesired core and sheath slippage.

Individual braid architectures – for automotive, outdoor and more
Complex non-elastic cords from the variation braider have been in operation at JUMBO-Textil for a long time. For hole cords – or bifurcation cords (from the Latin: furca, the fork) – the bobbin points are individually programmed so that the arrangement and length of the branching precisely meet the requirements. It is used, among others, in the automotive sector, in the construction industry and in the outdoor sector to hang or unhang elements without using metal.

Elastic hole cord from the elastics specialist
The elastic hole braids by JUMBO-Textil are new on the market. "The variation braider offers us fantastic possibilities: we can pre-configure what we want to braid and are completely free to do so. The repeat is computer-controlled," explains Holger Vehring, Project Engineer at JUMBO-Textil. "A seamless braided cable harness tubular that organises the cable mess (for automotive), braided hoses with defined openings for conductive elements in smart textiles or rehab applications, as tensioning elements in backpacks or functional clothing – the possible applications are vast. Thanks to this technology, textile – i.e. lighter, quieter and more flexible – components can be used for numerous applications in which metallic materials were previously used due to the fragile branching points."