From the Sector

On June 1, EREMA hosted the EREMA Discovery Day focusing on the post consumer segment from a European perspective. Live demonstrations showcased the latest machine innovations for PET and polyolefin recycling.

The invitation was accepted by around 400 customers and partners, mainly from Europe, to find out about the wide range of recycling technologies for PO and PET plastic waste. The technology that was presented and explained by EREMA experts and guest speakers during lectures in the morning, could then be seen live in-action in the afternoon when the recycling machines were demonstrated in operation. A total of six innovative recycling technologies were on display: INTAREMA® TVEplus® DuaFil® Compact, INTAREMA® TVEplus® RegrindPro® + ReFresher, the COREMA® cascade extrusion system, a VACUREMA® Inline Sheet line equipped with new EcoGentle technology, the new INTAREMA® FibrePro:IV machine, and the PCU-
TwinScrew. These allowed visitors to witness their performance and the high quality of recycled pellets that they produce.

"This wide range of technologies is necessary because the recycling process each of our customers choose depends on the type of plastic, the level of contamination of the input material, and which product will be made using the recycled pellets. Following the expansion of our Ansfelden site and with the new site nearby in St. Marien, we can now demonstrate all these processes, carry out test runs with customers' material and focus on development work independently of our Customer Centre," says EREMA's Managing Director Markus Huber-Lindinger.

EREMA is driving forward research and development work in the company's new R&D Centre. Two halls with a total area of 1,550 square metres and a new office building offering space for 50 workplaces has been built. Here, the company bundles cross-departmental test machines and laboratory facilities for post consumer and inhouse recycling applications. R&D is decentralised at EREMA. Employees from different departments handle process engineering challenges, innovations in mechanical engineering and automation technology - all with the aim of meeting customer requirements and achieving the highest possible quality of recycled pellets.  

On the evening before Discovery Day, EREMA celebrated its 40th anniversary together with customers and partners. A review covered the company's history - from the first workshop in a garage in 1983, to its position today as a innovation pioneer and one of the market leaders.

DyStar, a specialty chemical company with a heritage of more than a century in product development and innovation, is announcing the sale of its auxiliary manufacturing site located at Pietermaritzburg, South Africa.

Oakland Polymers Pty Ltd, a local manufacturer, has acquired DyStar’s manufacturing facility and will take over the site to expand their polymer business. Under the sale and purchase agreement, DyStar divested the entire facility, which is approximately 12,000 sqm, to Oakland Polymers and Oakland Properties. DyStar Africa’s operations will continue to lease part of the premises from Oakland for office and warehousing use.

Mr. Xu Yalin, Managing Director, and President of DyStar Group said, “The sale of the manufacturing site at DyStar Africa is part of our ongoing efforts to reconsolidate our business resources in Turkey, Africa & Middle East (TAME) region, with a focus on improving productivity and utilization rates.”

As a result of the acquisition, all employees at the manufacturing site have already been informed. Compensation packages are offered to affected colleagues as well.

Customers have also been informed of undisrupted supply to their orders during the transition period and are further assured of a seamless customer journey going forward when the acquisition is completed.

HeiQ will display its biobased textile solutions for allergen reduction, odor control, and dynamic cooling at ITMA Milano 2023. The event will take place from the 8th to the 14th of June at Fiera Milano in Italy, where HeiQ will also showcase HeiQ AeoniQ™, its cellulosic fiber and flagship advancement in biobased textile technologies.

The focal point of the HeiQ exhibition at ITMA Milano 2023 will be the company’s biobased textile technologies. These innovations address one of the major challenges faced by the textile industry, making fabrics more functional while contributing to a sustainable future.

The ready-to-use HeiQ technologies on display are HeiQ Allergen* Tech, providing synbiotic protection in home textiles and unmatched defense against inanimate allergens, HeiQ Cool, the dual-action cooling that keeps one cool and comfortable, even in the most demanding conditions, HeiQ Mint, the botanical odor control that provides plant-based and effective odor management, and HeiQ Fresh, for sustainable odor control.

Additionally, HeiQ will present a glimpse into the future with HeiQ’s groundbreaking carbon-positive continuous filament yarn, HeiQ AeoniQ™, that turned from an idea into a breakthrough piece of garment in just 15 months.

This cellulosic fiber has the objective to render polyester and nylon obsolete until 2030 and has attracted the support and active engagement of global partners who saw HeiQ AeoniQ™ as the solution to change the future of the textile industry.

International technology group ANDRITZ has successfully delivered, installed, and commissioned a converting line for manufacturing baby diapers at Naturopera’s new plant in Bully Les Mines, France.

The eXcelle converting line from ANDRITZ Diatec features special technology to produce both traditional and bio-based baby diapers, supporting Naturopera in its efforts to become a leading producer of a new generation of sustainable diapers.

While most diapers available on the market consist of 70% fossil-based plastic, Naturopera is preparing to produce diapers made of 90% bio-based raw materials. This groundbreaking diaper concept was developed in a close collaboration between Naturopera and ANDRITZ. It replaces the traditional spunbond and meltblown nonwoven layers with spunlace nonwovens mostly made of natural fibers. A prototype of the 90% bio-based diaper was recently produced at Bully Les Mines.

The ANDRITZ converting machine operating at Naturopera is highly flexible, taking just a few settings to switch to the production of bio-based diapers. It is designed for a multiple-size process, features an operator-friendly interface, and guarantees a production speed of 800 ppm.

Naturopera is a French company producing baby care, femcare and household products with a strong focus on local production and sustainability.

Groz-Beckert will be represented at ITMA with its six product sectors and will showcase its various innovations. The presentations at the booth will be supported by augmented reality applications. This allows visitors to discover the products both live and virtually.

The Knitting product sector will be represented at the Groz-Beckert stand with its four product groups circular knitting, flat knitting, legwear and warp knitting. In the circular knitting segment, for example, two newly developed knitting systems will be on show which have been realized in collaboration with machine manufacturers. The developments focus on energy savings, extended cleaning intervals and increased process reliability.

In addition to the machines for weaving preparation, the Weaving product sector will present its recently expanded portfolio of technical weaving reeds. The new weaving reeds make it possible to supply customers who produce fabrics with high densities. The weaving reeds are used in the production of special fabrics, for example, in technical filtration, membrane technology, solar cells or touch screens.

Products and services for classic needling and hydroentanglement will be presented by the Felting (Nonwovens) product area. In the field of felting needles, visitors can look forward to two innovations: a new notch shape and the Groz-Beckert felting needle module. In the felting needle module, the needles are embedded as a module in a plastic mold for the first time. The needle modules are characterized by high deformation resistance and offer new dimensions in needle density.

For the production of tufted floor coverings such as carpets, bath mats or artificial turf, the Tufting product sector will be presenting its proven Gauge Part system.

Various new and further developments will also be shown by the Carding product area. For those interested in the nonwovens industry, for example, the world's finest Interlocking wire for reduced risk of crashis included. For customers of the spinning industry, the division will be presenting further developed stationary flats and revolving tops. The new revolving tops have been adapted to the processing of fine yarns, while the stationary flats have been provided with a new, resistant aluminum profile.

The Sewing product sector is focusing on the presentation of its special application needles, SANTM. The sewing machine needles of the SANTM series have been specially developed for demanding sewing operations – e.g. for sewing technical or finest textiles. The division will also be presenting its new Needle Finder. The Needle Finder is an interactive tool in the online customer portal that helps customers select the right needle.

Lectra’s Annual Shareholders’ Meeting held on April 28 appointed two new Directors, Karine Calvet and Pierre-Yves Roussel for a four-year term. They both will become members of the Strategic Committee, replacing Bernard Jourdan, Lead Director, and Anne Binder. Karine Calvet also becomes a member of the Corporate Social Responsibility (CSR) Committee.

With its new strategic roadmap for 2023-2025, the Group aims to use its expansion – mainly due to the acquisition of Gerber in June 2021 – to accelerate its growth, significantly increase the share of SaaS in its sales, and seize opportunities for external growth. Supported by the commitment of its staff and recognized by its customers, Lectra will also be at the forefront of a more sustainable future.

Karine Calvet is Vice-President EMEA responsible for Partners at AVEVA, a subsidiary of Schneider Electric. She began her career at CGI in 1993 and has spent most of it in IT: sixteen years in services companies, seven years in telecommunications, and six years in software. She has had leadership roles in telecommunications environments for leading global companies (CGI, Capgemini, Alcatel-Lucent, Verizon, Microsoft and currently Schneider-Aveva), focusing on digital transformation. Karine Calvet served as Head of Industry at Capgemini, then managed worldwide teams at Alcatel-Lucent as Vice-President, Eastern Europe then at Verizon as Managing Director. Her time at Microsoft strengthened her software expertise, her direct and indirect channels skills, and her experience in IT services. In the last two years, as Vice-President, Southern Europe then Vice-President, Partners and Alliances at Schneider-Aveva, Karine Calvet has worked closely with industrial companies to help them meet the challenges of operational efficiency, safety, cost management, sustainability and decarbonization by taking advantage of digitalization.

Pierre-Yves Roussel has been CEO of leading US fashion label Tory Burch since January 2019. He began his career in investment banking with HSBC in Brussels, then at Morgan Stanley in London. In 1990, he joined management consulting firm McKinsey & Company in France, where he led numerous consultancy assignments in the fashion, luxury, distribution and media sectors in Europe and Asia. In 1998, he was elected Partner then, in 2004, Global Senior Partner (Director). In 2004, he joined the LVMH Group Executive Committee as Executive Vice-President, Strategy and Operations, reporting directly to Bernard Arnault. In 2006, he was appointed Chairman and CEO of LVMH Fashion Group, one of the LVMH Group’s five branches of operational activity. From 2006 to 2018, he was Chairman of the Board of the brands Céline, Givenchy, Loewe, Kenzo, Pucci, Rossimoda, Marc Jacobs, Donna Karan, Berluti, JW Anderson and Nicolas Kirkwood. He has also been a member on several prestigious fashion juries including Andam, CFDA Fashion Incubator, and the LVMH Fashion Prize. He was a member of the management committee of the Chambre Syndicale de la Mode et de la Couture from 2010 to 2018. In 2018, he left the LVMH Group to take up the post of CEO – based in New York – of the company Tory Burch. Founded by his wife in 2004, the private family-run company has more than 350 stores worldwide, 13 retail websites, and nearly 5,000 employees.

Since 1 April 2023 sales and service of Mayer & Cie. circular knitting machines in Bangladesh have been under new management. A new dynamic team “Mayer Bangladesh” has been formed. Mayer & Cie.’s longstanding Indian representative Batliboi has joined business activities in Bangladesh since the beginning of the month, supported by the team of Brady Services and by Almani Biz.

In Batliboi, Mayer & Cie. has set up a business partner of many decades standing as its representative in Bangladesh. For around 40 years Mumbai-based Batliboi has overseen sales and service of Mayer & Cie. circular knitting machines in India. Abhay Sidham heads Batliboi’s Textile and Machinery Group. He and his team have many years of experience in strategic marketing, and a focus on sustainability and processing recycled raw materials is part of Batliboi’s expertise.

These competences are of relevance in the Bangladesh market because “we face strong competition from Asian manufacturers here,” as Wolfgang Müller, Mayer & Cie.’s sales director, explains. The premium market was growing smaller, and the trend was toward specialities – value-added fabrics, spacer fabrics and athleisure with a high proportion of elastic. Mayer & Cie. sees in these requirements significant potential for its machines – and in Batliboi a partner able in view of its experience to put them to optimal use.

One building block in the set-up of Mayer & Cie. representatives is unchanged. Brady Services will continue with Batliboi to contribute its close ties with the local market. A significant number of existing companies will continue to be looked after by Brady Services.

The new member in Mayer Bangladesh team is Dhaka-based Almani Biz. A lubricants specialist for circular knitting machines Almani Biz has a wide network with Bangladesh knitting industry.

Mayer & Cie. feels well positioned by this new set-up. “We,” Wolfgang Müller says, “are of the opinion that the market for textile machinery in Bangladesh will continue to grow and we are confident that by strengthening our sales, service and marketing team we will be able to make good use of this opportunity.”

Customers in Bangladesh have placed large orders in the past. The latest, placed in January, was for several dozen machines to be delivered this autumn. Further orders from Apex and BEXIMCO (Bangladesh Export Import Company) are also scheduled for delivery in the second half of 2023.

While reorganising the set-up of its representatives in Bangladesh Batliboi has also taken over as Mayer & Cie.’s representative in Nepal, where the company had previously had no local representative. There is a demand for machines for interlock, 8-lock and single jersey, but sales are still in single figures.

adidas has announced a new milestone in its journey towards replacing virgin polyester with recycled polyester . 96% of all polyester used in adidas products is now recycled polyester. The achievement of the ambition that adidas first set in 2017 – to replace all virgin polyester with recycled wherever possible by the end of 2024 – is on track to be achieved earlier than expected.

Since the first adidas high-performance shoe was made with recycled materials in 2015, the brand has been working towards reducing its dependency on virgin polyester. Last year it announced that in 2021, more than 90% of the polyester used in adidas products was recycled, which – if it had been virgin polyester - would have accounted for 390 thousand metric tons of CO₂e – the equivalent to the greenhouse gas emissions generated to provide power to 50 thousand homes in the US^[1].

According to Textile Exchange^[2], global recycled polyester fiber production volume increased in 2021, but still accounts for just 14.8% of all global polyester production.

Sport is about meeting challenges head-on and finding ways to overcome those – material innovation is no different. For the team at adidas, the road to 96% has been long and full of challenges. The confirmation of its polyester commitment in 2017 was a crucial step in helping to initiate a transformation across adidas and its entire supply chain. This transformation has been made possible through creating technical solutions and imagining new possibilities that previously didn’t exist.

To accompany the announcement, adidas has created a short film about its new ‘PB’, featuring star athlete Jazmin Sawyers. The film highlights the sports brand’s pride in making progress, and its determination to push further.

As the brand looks ahead to 2024 and beyond, it will continue to expand its focus beyond recycled polyester. It will be doing this through three main areas of focus: changing materials by testing and scaling new raw materials, rethinking entire processes to design products that have a circular end-of-life solution, and reducing its carbon footprint.

^[1] adidas Footprint Analytics team
^[2] Textile Exchange Preferred Fiber & Materials Market Report, October 2021, https://textileexchange.org/app/uploads/2022/10/Textile-Exchange_PFMR_2022.pdf

Yanfeng has reached another milestone in its sustainability journey by bringing the power of solar energy to its plants in South Africa. The global automotive supplier already uses renewable energy at all its locations in Europe – some of which are already operating with 100% green energy – and now will supplement its operations in South Africa with sustainable and emission-free solar energy generation.

Many sectors are facing major challenges with the transition to a low-carbon economy. The automotive sector in particular faces many operational and economic challenges when transforming production plants into net-zero emission operations. Thanks to its commitment to sustainability, 100% of the solar energy generated by the PV systems is used to power Yanfeng’s production plants in South Africa, helping them save around 2,559 tons of CO2 annually while reducing their monthly costs and increasing efficiencies.

The solar energy systems were funded by SolarAfrica, which will also operate, maintain and monitor the systems going forward. “From the outset of these projects, Yanfeng’s focus was on reducing their CO2 emissions and SolarAfrica is proud to partner with them to make their journey towards sustainability a success,” said David McDonald, CEO of SolarAfrica. “It’s inspiring to see a global company like Yanfeng invest in world-class facilities in South Africa, contributing to our country’s green economy and supporting job creation in the automotive industry.”
 
All Yanfeng European plants were converted to renewable energy by the beginning of 2022. With this new PV system, Yanfeng has implemented a milestone in the conversion to net-zero emission production at its two plants in South Africa.

Absorbent hygiene products such as diapers, sanitary pads, and incontinence products are an integral part of our daily lives. However, most of these products contain synthetic components and contribute to the global plastic waste problem. The search for alternatives is becoming increasingly urgent. The catch is that only innovations that offer the same performance and reliability as conventional products can be successful in the market. After all, no one wants to compromise in such a sensitive area as personal hygiene.

Kelheim Fibres is currently working on various development projects to design fully biobased AHP (absorbent hygiene product) concepts that do not compromise on performance. In this area, the company continues to focus on its wood-based specialty fibres, which the tampon industry has trusted for decades. However, the requirements for AHP products differ, as each layer must fulfil a specific function.

To meet these requirements, Kelheim Fibres has developed a range of functionalized specialty fibres, including hydrophobic Olea, trilobal Galaxy®, and the hollow fibre Bramante. These specialty fibres ensure optimal results in every layer of the AHP product.

All of Kelheim's fibres are manufactured from 100% wood pulp derived from certified and sustainably managed forests. They are fully biodegradable - microorganisms in soil and seawater ensure that no residues remain.

A current example of such a partner project is the development of a completely bio-based panty liner with the nonwovens manufacturer Sandler and the hygiene products manufacturer pelzGROUP, which is due to be launched on the market shortly.

In addition to new projects in the field of biobased disposable and reusable solutions, Kelheim will also present its tried and tested fibres at INDEX™23, for example for tampons or flushable wipes.