From the Sector

The identification of profitable new niche markets has been central to the success and continuous expansion of Germany’s Dolinschek, a leading knitting, dyeing and finishing specialist, located in Burladingen in Baden-Württemberg.

“There is so much more to textiles than just clothing,” says Theo Dolinschek, who runs the company with his brother Erwin. “We handle many different technical materials such as automotive components, geotextiles and wallcoverings, but also those for more unusual applications such as inlays for extractor hoods, cut protection fabrics and even wool felts which are employed as insulation on wind turbines.

“We have also recently started to produce compression stockings in a variety of colours, because not everyone wants them black, beige or skin coloured. The most important product areas for us now are in sportswear, corsetry and lingerie, as well as orthopedic and medical products, workwear and protective clothing, but in addition, many other technical applications.”

The Dolinschek brothers moved their business to the historic site of the former Ambrosius Heim textile company in Burladingen in 2001 in order to expand. At the time, the company – founded by their father in 1980 as a textile wholesaler before moving into dyeing – employed just 13 people. Within a year, the company had bought additional space at the site.

Now, with Theo in charge of technology and sales, and Erwin responsible for production, the company employs almost 100 people and operates on an integrated site of 35,000 square metres.

In 2005, a laminating department was established by the company and since 2012 investment in knitting machines has been ongoing.

“The further we went into vertical integration, the more of our own products we were able to position on the market and so we were also able to make ourselves more independent,” says Theo. “We have continued to develop and today we can produce high-quality fabrics for many fields, with 42 knitting machines, 36 dyeing machines, three stenter frames and many other production and processing machines.”

Dolinschek has also developed its own proprietary TMG dyeing machines which have subsequently been successfully sold to many other companies all over the world. There are currently 11 of these machines  in operation at the Burladingen site and around 45 installed at other companies.

For finishing technology, however, the company relies on Monforts, and has installed a new seven chamber Montex TwinAir stenter range with a Montex®Coat coating unit in knife execution, enabling the coating of dimensionally stable knitted fabrics with polyurethane or acrylate. Another unique feature is the Teflon-coated (non-stick) transportation belt through the system.

The Montex line is also equipped with integrated heat recovery and exhaust gas purification to ensure the most resource-efficient processing available on the market. The exhaust air goes from the Monforts heat recovery system into an existing air/water heat recovery system and then into an electrostatic precipitator.

Highly-intuitive Monforts Qualitex visualisation software allows all machine functions and process parameters to be assessed and controlled easily.

At the recent CAMX 2022 Composites and Advanced Materials Expo in Anaheim, California, The Heat Sealing Module – HSM from Zünd was recognized with an Unsurpassed Innovation Award. The HSM significantly facilitates the processing and handling of dry fiber materials with thermoplastic content. This new tool is Zünd’s answer to a demand in the composites industry for wider-spread use and easier processing of these types of materials.

The American Composites Manufacturing Association, ACMA, proclaimed the Heat Sealing Module – HSM the winner of the ACE Award for Unsurpassed Innovation in the “Manufacturing: Equipment and Tooling” category. This award is presented annually to equipment, tooling, a production aid, or software designed to improve manufacturing production, environmental sustainability, or product quality and performance in composites manufacturing.

During processing, dry fiber materials are prone to fraying along the edges. Using hot air, the HSM seals the fabric along the cut path in advance of the Zünd Power Rotary Tool – PRT cutting it. Because of this sealing process, the cut can then be performed at full speed, in any direction, and produces both higher-quality parts and greater production efficiencies.

The HSM helps create clean, sealed edges when cutting fiber-reinforced thermoplastic composites. It benefits not only the cutting process itself, but other production processes downstream. Cutting this way leaves behind no loose or uncut fibers and maintains a clean cutting surface and uncontaminated production environment. At the same time, it ensures that cut parts maintain their shape, and this increased stability makes them much easier to handle, especially in fully automated production workflows.

Freudenberg Performance Materials (Freudenberg) has concluded a high-volume, multi-year contract with a global automotive tier one supplier to supply high-performance gas diffusion layers for the stacks forming the core of the fuel cell systems produced by the leading automotive supplier. Global target applications are mid-sized and heavy commercial vehicles as well as buses. Freudenberg is supporting the customer’s global fuel cell activities, thereby also accelerating the breakthrough of mass-produced fuel cell stacks.

Fuel cell technology is an important element of a successful energy transition. Gas diffusion layers play a key role in this context: they are indispensable for the functioning of a fuel cell and have a significant impact on the performance of a fuel cell stack.

A fuel cell converts the chemical energy of hydrogen and atmospheric oxygen into electricity. Functionally-optimized gas diffusion layers made of carbon-fiber based nonwoven are installed on both sides of a catalyst-coated membrane positioned in the middle of the fuel cell. The gas diffusion layers distribute hydrogen and oxygen evenly to the membrane and remove the electricity, heat and water generated by the CO₂-free chemical reaction. They also protect the sensitive membrane and are optimized to suit the bipolar plate. A fuel cell stack is made up of several individual fuel cells.

Freudenberg already has more than 20 years of unique expertise in the development and production of gas diffusion layers for fuel cell applications in the mobility sector and for porous transport layers used in electrolyzers. Freudenberg is currently expanding its production capacity at its Weinheim headquarters by installing additional lines. Further investments are on the verge of implementation.

Viscose speciality fibres manufacturer Kelheim Fibres partners with TextileGenesisTM, a traceability platform that creates radical transparency from fibre-to-retail and ensures authenticity d provenance of sustainable textiles against generics.

“Our wood-based fibres are an environmentally friendly basis for sustainable textiles - it's just that consumers often don't know what's behind their garments. But they need to know it’s in their hands to minimise the ecological footprint of the textile industry. Transparency and traceability are the foundation that enables consumers to make informed decisions.”, says Dr. Marina Crnoja-Cosic, Director New Business Development at Kelheim Fibres.

TextileGenesisTM uses blockchain technology to track and verify the use of sustainable fibres all the way from fibre to garment. A digital fibercoin ensures transparency and reliability throughout the entire production line and beyond.

Amit Gautam, Founder & CEO at TexileGenesisTM:"Fashion and textile value chain is undergoing major transformation driven by sustainable materials, shifting consumer demand for sustainable products, and increasingly stringent regulations on transparency. Great to see Kelheim moving the industry forward by actively participating in the traceability journey."

Perstorp has been acquired by PETRONAS Chemicals Group Berhad (PCG), Malaysia´s leading integrated chemicals provider and part of PETRONAS Group, on 11 October 2022.

In May this year, PCG signed a Securities Purchase Agreement with Financière Forêt S.à.r.l, a company under PAI Partners, a European private equity firm, to acquire the entire equity interest in Perstorp, a leading sustainability-driven global specialty chemicals company based in Sweden. With the completion of the acquisition, Perstorp is now PCG’s wholly-owned subsidiary.

PCG will strive to ensure the timely completion of Perstorp’s growth projects in a safe and cost-effective manner. Perstorp has several projects lined up in the near future, including the launch of Project Air which aims to reduce carbon emissions through the production of sustainable methanol. Recently, The European Union Innovation Fund selected Project Air, as one of the 17 large-scale green tech projects, which together will be granted more than EUR 1.8 billion. Project Air is a gamechanger for the chemical industry, moving from fossil raw materials to recycled and bio-based feedstock, thereby enabling sustainable chemical products to a large variety of industries and end products. At full capacity, it will reduce global CO2 emissions with close to 500,000 metric tons per year from today’s levels, corresponding to one percent of current emissions in Sweden.

RHEON LABS, a fast-growing materials technology company based in Battersea, London, has completed an extensive 6 month trial with FET, a world leader in laboratory and pilot meltspinning equipment. Backed by a £173,000 grant from Innovate UK for feasibility studies, RHEON LABS has further developed its RHEON™ technology, a reactive polymer that dynamically stiffens when subjected to force. The technology can control energy of any amplitude or frequency, from small vibrations to forces at ballistic-speeds and therefore has a wide range of applications.
 
This Innovate UK Smart Grant-backed project aims to develop a hyper viscoelastic fibre from RHEON™ which displays high strain-rate sensitive properties. Creating a fibre with unique strain-rate sensitive properties will be a world first. It will enable the creation of a 'breakthrough-generation' of stretch textiles that can actively absorb, dampen and control energy during movement, rather than simply acting as a spring.

For close-fitting activewear and sports bras, the ability to actively control muscle mass or soft tissue movement during exercise will be a game-changing advancement. It will allow brands to engineer garments that relax during everyday use but actively stiffen during exercise for improved support and performance.
The Innovate UK grant was awarded under the category of Hyper-Viscoelastic Fibre Extrusion for Textile Manufacture. Fibre Extrusion Technology Limited (FET) enabled the customer trials at its bespoke Fibre Development Centre in Leeds, England using its in-house FET-103 Monofilament meltspinning facilities, in harness with RHEON and FET technical operatives. The next phase will be to upscale the trials of preferred materials on RHEON’s own new FET-103 meltspinning line, with FET’s continued support and expertise on hand.
 
Creating a fibre with unique strain-rate sensitive characteristics could be as radical a change in the market as the initial introduction of stretch fibre with the launch of Lycra™. The textiles would have a multitude of beneficial properties and would provide significantly less compression in the garment than conventional materials, substantially improving user comfort, support and performance.

• Partnership with Spectro Coating Corp. Expands Horizons for the World’s First In-fiber Sustainable Infrared Viscose

CELLIANT® Viscose, which converts body heat into energy, is a combination of nature and performance. It was developed by materials science leader Hologenix®, creators of CELLIANT, a natural blend of IR-generating bioceramics used in textiles, and Kelheim Fibres, a leading manufacturer of viscose specialty fibers. It is the world’s first in-fiber sustainable infrared viscose.  Now Hologenix has partnered with Spectro Coating Corp., the largest vertically integrated flock coating and flock fabric manufacturer in the world, to create the first flocked infrared material with CELLIANT Viscose.

Flocking is an application method in which tiny fibers are piled on to the surface of a textile, creating textures for both decorative and functional purposes. CELLIANT Viscose in a flocked material has many potential applications in the medical field for tapes, bandages, braces and orthopedic products, home textiles and decor, dog beds, clothing, and more.  CELLIANT features natural, ethically sourced minerals, which convert body heat into infrared energy for increased local circulation and cellular oxygenation.  These CELLIANT minerals are then embedded into viscose plant-based fibers. The Viscose fibers are then flocked onto a base material. CELLIANT Viscose provides all the benefits of being a viscose fiber — lightweight, soft, highly breathable, excellent moisture management — as well as the fiber enhancements from CELLIANT infrared technology.

CELLIANT Viscose is the first IR flocked material that Spectro is producing. CELLIANT Viscose also represents a further expansion into sustainable products for Spectro. In addition, Spectro products are made in the USA, as is CELLIANT’s mineral blend.

This year’s JEC forum DACH, taking place from November 29 to 30, 2022, is strategically located in a composites « golden triangle », between Munich, Augsburg and Ingelstadt. This dynamic area, at the heart of the Bavarian region is known to be hosting major companies such as Airbus, Faurecia, Kuka, Siemens, Voith Composites, KraussMaffei Technologies, Cevotec, Munich Composites, or Premium Aerotec, thus promising a two-days opportunity to meet with key decision makers.

The digital platform available to all participants prior to the event enables to schedule one to one business meetings between buyers and suppliers from the whole value chain of composites, as well as informal networking during breaks, lunches and evening event.

In total, 500 attendees, suppliers and buyers, from Germany, Austria and Switzerland, are expected to participate to JEC Forum DACH 2022.

Business meetings event*
DAY 1 – November 29, 2022:

• 10.15 – 11.45 am – “Keynote and Plenary Conference Session : Market Developments
• Moderator: Dr. Michael Effing, AVK
• 4.0 – 5.30 pm – “Keynote and Plenary Conference Session: Recycling of Composites

DAY 2 – November 30, 2022:

• 9.00– 10.30 am – “Keynote and Plenary Conference Session: Sustainability of Composites
• 3.15 – 4.45 pm – “Keynote and Plenary Conference Session: Innovations: Raw Materials, Processes and Applications

Celebrating composites innovation through awards and startup competition

• The AVK Innovation Awards: Goal is to promote and give prominence to new products/components and applications made from fiber-reinforced plastics (FRP) and promote new processes and methods for manufacturing FRP products.
• Startup Booster competition: The contest is open to entrepreneurs, SMEs, startups and academic spinoffs building innovative composite and advanced materials projects that are based in Germany, Austria or Switzerland (the DACH region).

*You can view the full program here.

C.L.A.S.S. continues its path of "strategic sustainable synergies" with the aim of sharing its message of responsible innovation, and returns for the second time to Milan Fashion Week with WSM White Sustainable Milano. The objective is to represent a selected and smart path of the production chain related to materials, technologies, production, customization, finishing processes and dyes that are increasingly less impactful on the environment.
 
After debuting last February, “Unveiling the Fashion Backstage”, the educational and narrative journey of WSM | White Sustainable Milano developed in synergy with Giusy Bettoni, founder and CEO of C.L.A.S.S., returns to the VISCONTI HALL and grows in terms of attendance and thematic areas.

The exhibiting copmpanies are: Bemberg™ by Asahi Kasei, Maeba International, Linificio e Canapificio Nazionale SB, Edmos, Toyoshima, Iluna Group and YKK.

Freudenberg Performance Materials – the Freudenberg Group’s nonwovens specialist – was hosting a meeting of the German National Hydrogen Council at the Freudenberg headquarters in Weinheim, Germany, on September 16. As a leading global supplier of technical textiles, Freudenberg Performance Materials provides fuel cell components for mobility applications and for electrolyzers used to produce CO₂-free hydrogen.

The German National Hydrogen Council was appointed by the German government and acts as an independent, non-partisan advisory board. The council board currently consists of 25 high-ranking experts in the fields of economy, science and civil society. The objective is to assist and advise the State Secretaries’ Committee on Hydrogen in the further development and implementation of Germany’s National Hydrogen Strategy. Council meetings are hosted by one of the board members to enable the council to deepen its knowledge of the relevant technologies, value chain roles and challenges. Dr. Silke Wagener is a member of the council board, and represents the Freudenberg technology group, giving input on suppliers’ know-how as well as contributing her decades-long expertise in technological solutions for the hydrogen industry.

During a tour of the factory organized for the council board members, Freudenberg Performance Materials explained the development and production of performance-critical gas diffusion layers manufactured from carbon fiber-based nonwovens for fuel cells and porous transport layers for electrolyzers. The tour highlighted the potential for improvements from a supplier’s perspective, such as the need for very timely exchange and collaboration along the value chain. Functioning, unbroken and scalable value chains, in parallel with the development and scaling of hydrogen infrastructure, are key prerequisites for the hydrogen industry to fulfill its vital role in the transformation to climate neutrality.

Gas diffusion layers are one of the main components at the heart of the fuel cell. Their function is to transport gases and liquids in the cells. They have a significant impact on system performance and costs, and are indispensable for the functioning of fuel cells. The same applies for porous transport layers that are the key component of electrolyzers for the CO₂-free production of what is called green hydrogen.

Fuel cells in combination with green hydrogen are an important technology for CO₂-free mobility, in particular with reference to buses, heavy-duty trucks and trains. Other uses include stationary applications such as stationary power generation or heat generation in buildings or industry.
Apart from mobility, green hydrogen also plays a key role in climate-neutral energy supplies in the industrial sector, particularly in the chemical and steel industries.