From the Sector

For the second time in a row, the speciality viscose fibre manufacturer Kelheim Fibres was awarded a place on the podium at the Cellulose Fibre of the Year Awards. The concept for sustainable menstrual underwear made from Kelheim’s functionalised speciality fibres achieved third place. Kelheim Fibres thus emerges from the competition as the most innovative fibre manufacturer.

Project manager New Business Development Natalie Wunder presented the promising concept from Kelheim at the International Conference on Cellulose Fibres: "We have been able to use our experience as a long-established supplier for the tampon industry to develop further sustainable solutions in the feminine hygiene sector, in this case reusable menstrual underwear. As an innovation pioneer, we are thus helping to break the taboos that surround the topic of menstruation. We offer women the choice between different environmentally friendly products which also offer high levels of performance - depending on what fits their lifestyle."

For the next step, the commercialisation of the concept, Dr Marina Crnoja-Cosic, Director New Business Development at Kelheim Fibres, puts her trust in the proven open innovation approach: "We want to bring partners from the entire value chain together. By bringing in our joint expertise, we can significantly accelerate the path from idea to finished product in the market. At the same time, through open dialogue, we ensure that the concept works seamlessly from fibre through processing to the final product.

Hologenix® is pleased to announce that its newest innovation – pure white CELLIANT® – is a Top Ten winner in the Fibers & Insulation Category of ISPO Textrends Fall/Winter 2023/24. Twice a year, ISPO recognizes innovative fabrics and components that are used to manufacture sports apparel. It’s no surprise that this innovation, whereby CELLIANT infrared technology can be embedded in fibers and for those fibers to be pure white, has achieved this honor. Pure white expands the potential applications of CELLIANT to crisp white performance and athleisure apparel, athletic uniforms and jerseys, towels, bedding, baby clothes, medical apparel and more, while maintaining its well-known wellness benefits. Pure white is the foundation that makes delicate pastel fabrics, as well as any color, possible.

Pure white CELLIANT still captures and converts body heat into infrared energy, increasing local circulation, aiding in temperature regulation and promoting stronger performance, faster recovery and better sleep. Pure white CELLIANT is also still made from ethically sourced minerals from the earth and is available in nylon, polyester and recycled polyester fibers, while retaining the natural characteristics of the polymer.

This award follows on the heels of the 2022/23 ISPO Textrends Awards finalist selection of CELLIANT viscose in the Fibers and Insulations category, which features CELLIANT embedded into plant-based fibers.  “We are honored to achieve this recognition from ISPO for our pure white CELLIANT,” said Courtney OKeefe, Chief Supply Chain Officer for Hologenix. “This new formulation took years of work to achieve and is a testament to the dedication and talent of our global research team. We are also very proud to be able to state that we now have two ISPO-recognized fibers.”

• The 16th World Pultrusion Conference will be postponed to 5-6 May 2022

The EPTA – European Pultrusion Technology Association in cooperation with the American Composites Manufacturers Association (ACMA) will postpone the 16th World Pultrusion Conference to 5-6 May 2022 due to the corona situation and the postponement of the JEC World, with which there is a close partnership.

This conference takes place every two years and is the meeting point of the European and worldwide Pultrusion Industry. More than 25 international speakers from Belgium, Germany, France, Spain, The Netherlands, Turkey, UK and the USA will present practical presentations about innovative applications, technologies and processes. Equally current market trends and developments are on the agenda.
This World Pultrusion Conference takes now place on 5-6 May 2022 in Paris, France. The presentation language will be English. The program, further details and registration information is available at www.pultruders.com.

Strict protective measures will make the industry meeting possible at the International Conference on Cellulose Fibres in Cologne on February 2 and 3, 2022. The latest innovations will be shocased: from hygiene and textiles to non-wovens and carbon fibre alternatives to lightweight construction applications. Online participation is also possible.

Cellulose fibres show an increasingly expanding wide range of applications, while at the same time markets are driven by technological developments and political framework conditions, especially bans and restrictions on plastics and increasing sustainability requirements. The conference provides rich information on opportunities for cellulose fibres through policy assessment, a session on sustainability, recycling and alternative feedstocks as well as latest development in pulp, cellulose fibres and yarns. This includes application such as non-wovens, packaging and composites.

Live at the conference, host nova-Institute and sponsor GIG Karasek GmbH will grand the “Cellulose Fibre Innovation of the Year” award to one of six highly interesting products, ranging from cellulose made of orange and wood pulp to a novel technology for cellulose fibre production. The presentations, election of the winner by the conference audience and the award ceremony will take place on the first day of the conference.

The conference sessions reflect the current topics of industry and research. “Strategies and Market Trends” provides an overview of the rapid development of cellulose fibres and their technological progress across the fibre market. An analysis of the key cost components of these fibres to benchmark against current cost levels will highlight future opportunities and challenges for novel textile fibres. The session will conclude with an overview of the industry's recent strategies to defossilize the fibre market.

The session “New Opportunities for Cellulose Fibres in Replacing Plastics”, focusses on questions such as: “What impact does the ban on plastics in single-use products have on the industry?” and “What are the latest regulatory issues and policy opportunities for cellulose fibres?”. This part of the conference presents new opportunities for the replacement of fossil-based insulating materials with cellulose-based technologies suitable for use in a variety of applications, from aerospace to mobility and construction.
Institutefor Ecology and Innovation

“Sustainability and Circular Economy” highlights crucial issues with regard to the overall goal of keeping the environmental impact of cellulose fibres low. A core theme of the session is the responsible use of wood and forests. With this objective, the five speakers discuss the importance of circular concepts for cellulose feedstocks. Exciting insights into the important “Hot Button Report” are offered by Canopy. The “Hot Button” report enables the producers of cellulose fibres to better understand the impact their raw materials have on forests and the climate development worldwide.

The full conference programme is available at www.cellulose-fibres.eu/program.

• AMSilk Partners with Mercedes-Benz to Present a Sustainable Bio-Based Product
• The use of a biotechnology-based and certified-vegan silk-like fabric marks a first in the automotive sector

AMSilk GmbH (“AMSilk”), a leader in supplying innovative high-performance bio-based silk materials, announced a partnership with Mercedes-Benz, for the development of novel, sustainable car door pulls, as part of the car manufacturer’s latest technology programme, the VISION EQXX.

The new concept car, VISION EQXX, features innovative interior materials, revealing a way forward for luxury design that conserves resources and is in balance with nature. Among the organic interior design features are new door pulls made from AMSilk’s Biosteel® fiber. This high-strength, certified-vegan, silk-like fabric is made using AMSilk’s proprietary biotechnology expertise. AMSilk is the world’s first industrial supplier of vegan silk biopolymers which are 100% biodegradable, recyclable, renewable and zero-waste.

Marking a first in the automotive sector, AMSilk’s Biosteel® provides a solution to the car industry whose need to replace petroleum-based content by natural, bio-based materials is increasingly growing.
This new project is the most efficient electric vehicle Mercedes-Benz has ever built and marks a new expression of efficiency and sustainability in interior design. The all-electric VISION EQXX was unveiled in a digital world premiere on the “Mercedes me” media online platform.

Ulrich Scherbel, Chief Executive Officer of AMSilk said: “We are extremely proud to partner with Mercedes-Benz on the technology programme VISION EQXX, providing sustainable interior design solutions from our best-in-class bio-based fibers. Amid a fresh wave of ambitious climate pledges, we are proud to be playing a leading role in providing solutions for a zero-waste future.”

The AVK – Industrievereinigung Verstärkte Kunststoffe – has once again presented its Innovation Awards to companies, institutes and their partners. Three composites innovations were recognised in each of the three categories – “Innovative Products/Applications”, “Innovative Processes” and “Research and Science” – at the new event JEC Forum DACH on 23 November 2021, the first edition of which was held in Frankfurt.

“As usual, the submissions included a lot of very interesting and promising products and processes this year. The Innovation Awards highlight the outstanding efficiency, cost-effectiveness and sustainability of fibre-reinforced plastics as well as the companies and institutes operating in the sector,” explains Dr. Elmar Witten, Managing Director of the AVK. The jury of leading experts from the industry honoured the following innovations this year:

Category “Research and Science”
First place in the “Research and Science” category was awarded to the German Aerospace Center (DLR) for its Bondline Control Technology (BCT). This innovative process is used for quality control and assurance of bonded joints. The core element is a porous fabric which is applied to a joining surface using an epoxy adhesive or matrix resin. Peeling away the fabric creates a chemically reactive and undercut surface and can also be used as a test to check adhesion to the substrate. BCT has potential in a variety of possible applications. For example, peel ply can be replaced by BCT fabric to produce composite components with an optimised joining surface. The cost-effective BCT peel test is suitable for coupon testing and process control. In addition, the combined adhesion test and surface pre-treatment can be used for quality assurance of bonded repairs on fibre composite structures.

Second place was taken by the Institute of Textile Technology (ITA) at RWTH Aachen University and its partners AEROVIDE GmbH, Altropol Kunststoff GmbH, Basamentwerke Böcke GmbH, TechnoCarbon Technologies GbR with “StoneBlade – Lightweight construction with granite for the wind industry”. This innovation enables manufacturers to reduce the amount of non-recyclable materials used in rotor blade construction. At the same time, it reduces the weight of these components and improves the mechanical properties relating to the stability of wind turbines. The innovative approach replaces glass-fibre reinforced plastic in the blade components with hard rock – a natural, cost-effective and recyclable lightweight material. The slabs of rock are cut and ground to a thickness of just a few millimetres and embedded in a fibre composite laminate with carbon fibre, which stabilises them for alternating load cases. The pre-stressed material is pressure-stable in the composite and can absorb tensile forces in the event of continuously alternating loads without any loss of stiffness.

Third place went to the Dresden University of Technology – Institute for Lightweight Construction and Plastics Technology (ILK) with its partner Mercedes Benz AG for the interdisciplinary development of a highly integrated inductive charging module for electric vehicles. The ultra-thin charging module was designed to make optimum use of space in the vehicle underbody without reducing ground clearance. An interdisciplinary approach was adopted for the development process. This involved the electrical, mechanical and process characterisation of high-frequency Litz wires, ferromagnetic foil and metal wire cloth as well as the creation of a simulation model. The result is a demonstrator for a charging system with a structural height of 15 mm and a total weight of 8 kg. It achieves a transmission efficiency of up to 92 percent at 7.2 kW nominal power and active air cooling. The hardware demonstrator was fabricated in a 3-step process using RTM and VARI techniques.

Overview of all the winners in the three categories:
Category “Innovative Products/Applications”
1st Place: “Traffic signs from Nabasco (N-BMC)” – Nabasco Products BV and Lorenz Kunststofftechnik GmbH, partners: Pol Heteren BV and NPSP BV
2nd Place: “Novel, ultratough vinyl ester resin for the construction of large marine vessels” Evonik Operations GmbH
3rd Place: “Air intake housing with a multi-material design for gas turbines” – MAN Energy Solutions SE, Leichtbau-Zentrum Sachsen GmbH and Leichtbau-Systemtechnologien KORROPOL GmbH.
Category “Innovative Processes”
1st Place: “In-mould wrapping” off-tool, film-coated, fibre composite components for exterior applications – BMW Group, Partner: Renolit SE
2nd Place: “Adaptive automated repair of composite structural components in the aviation sector” – Lufthansa Technik AG, Partner: iSAM AG
3rd Place: “Automated surface pre-treatment using VUV excimer lamps” – CTC GmbH
Category “Research and Science”
1st Place: “Bondline Control Technology (BCT)” – German Aerospace Center (DLR)
2nd Place: “StoneBlade – Lightweight construction with granite for the wind industry” – Institute of Textile Technology at RWTH Aachen University, Partners: AEROVIDE GmbH, Altropol Kunststoff GmbH, Basamentwerke Böcke GmbH, TechnoCarbon Technologies GbR
3rd Place: “Interdisciplinary development of a highly integrated inductive charging module for electric vehicles” – Dresden University of Technology – Institute for Lightweight Construction and Plastics Technology (ILK), Partner: Mercedes Benz AG

Submissions for the next Innovation Award can be made from the end of January 2022.

International technology group ANDRITZ has received an order from Welspun Advanced Materials, India, to deliver a complete neXline spunlace line for the production of nonwoven roll goods and wipes for their new plant in Hyderabad, Telangana. The line has a capacity of up to three tons per hour. Start-up of the line is scheduled for the fourth quarter of 2021.

The ANDRITZ high-capacity spunlace line will process various types of synthetic or natural fibers, such as polyester, viscose and cotton. The final products will have fabric weights ranging from 25 to 120 gsm, thus covering many applications. This neXline spunlace line also offers the option to integrate a third component from a selection of smart layers, enabling Welspun to also manufacture products for the health care and hygiene sectors.

Welspun is the largest global exporter of home textiles. Innovation and quality lie at the heart of the company’s success, which already has nonwoven production lines in operation, including needlepunch and spunlace equipment. With its new plant in Telangana, Welspun will significantly increase its existing spunlace capacity and also maintain a broad range of applications as the final products are used in hygiene, home care and industrial cleaning. The new, advanced facility is a 100,000 sqm greenfield development that is part of a larger 1,500,000 sqm industrial complex also accommodating the Welspun floorings facility.

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.

• 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.