From the Sector

A new fabric inspection technique for accurately detecting the most subtle of defects on patterned fabrics during high speed production has been developed by BTMA member Shelton Vision, of Leicester, UK.

The patent-pending system has been integrated into the company’s WebSpector platform and validated through factory trials on a purpose-built full scale in-house demonstration system with sophisticated fabric transport capabilities. As a result, a first system has already been ordered by a manufacturer of both plain and patterned fabrics, including camouflage, in Colombia. This follows the successful conclusion of a 21-month Innovate UK project in which techniques for the resolution of complex pattern deformations were developed by machine vision and computer scientists in the company, backed up by the machine vision and robotics department at Loughborough University.

Restrictions
Traditional methods for defect detection rely on human inspection which is ineffective, with detection rates under 65%, while the Shelton WebSpector machine vision system offers a sophisticated platform for automated defect detection of over 97%, but until now has been restricted to plain textiles.

While pattern matching and neural network approaches have previously been tried for patterned textiles, they have failed to provide a practical solution due to the extreme complexity associated with pattern matching on deformable substrates like textiles, as well as the time required to train a neural network for each pattern type.

Challenges
The challenge is that fabrics are not rigid and can be creased or stretched and are also subject to local distortion,” says Shelton Vision Managing Director and CEO Mark Shelton. “As a result, inspection without the technique we have developed, would lead to thousands of false positives. Our sophisticated pattern inspection software techniques ensure a clean image, allowing the detection of faults on fabrics running at speeds of up to a hundred metres a minute.”

The full system consists of:

• A camera and lighting system for optimum image capture at high speed and associated image processing hardware.
• Self-training software utilising statistical analysis to automate the system configuration for new textile products.
• An advanced suite of defect detection algorithms for the detection of all textile defect types.
• An AI-driven defect classification system which learns and automates defect naming in real time, as well as a real time defect grading capability based on client decision rules.
• A system for recording and retrieving complete roll map images for subsequent review and quality control.

The generation of textile roll maps with complete defect data allows for an optimised textile cut plan, improved downstream processing and quality assurance.

Geosynthetics have become an indispensable part of the construction industry. PP nonwovens, for example - mechanically bonded continuous fibres made from specially UV-stabilised polypropylenes - are often used in blanket form as barriers, screens and filters, and their strength extends the service life of construction projects. Whether for road construction, or as barrier on glaciers or against weeds - there are myriad applications.

TenCate Geosynthetics uses the PURE LOOP ISEC evo technology to recycle this type of PP nonwoven. The European company, with locations in Austria, France and the Netherlands, is specialised in the development and production of geotextiles for modern civil engineering applications. The edge trimmings and production rejects generated during manufacturing used to be recycled at the Linz site, but not fed back into the company's own production process.

"The demands on us were high," recalls Patrick Wiesinger, project manager at PURE LOOP. "The PP nonwoven is highly tear resistant, which means its a very challenging recycling process. Our ISEC evo machine conserves the quality of the production waste really well during recycling, so we were able to achieve the specified increase in quality for the recyclates."

Another advantage of PURE LOOP technology is the wide range of shapes in which the production scrap can be delivered for processing. "Our ifeed technology with double feed ram system and singleshaft shredder offers the ideal conditions for direct processing of these large rolls - and without the need for prior preparation of the input material by employees before the material is fed into the recycling process", emphasizes Patrick Wiesinger. With the ISEC evo recycling machine TenCate can now manufacture its high-strength PP nonwoven product with a recyclate content of up to 10 percent.

• Aus Abfall wird Rohstoff

Alternativen zu Primärrohstoffen einzusetzen, ist eine Möglichkeit, die Nachfrage nach Rohstoffen zu decken und sich vom globalen Geschehen unabhängiger zu machen. Benötigte Materialien können durch Sekundärrohstoffe ersetzt bzw. die in der Produktion und am Ende des Lebenszyklus anfallenden Wertstoffe dem Kreislauf wieder zugeführt werden. Das VDI Zentrum Ressourceneffizienz (VDI ZRE) hat hierzu eine kostenlose Materialdatenbank zu Nebenprodukten und Sekundärrohstoffen entwickelt.

Bisher sind die Bereiche Metall und Kunststoff vorhanden, die Datenbank soll erweitert und ausgebaut werden.

Materialdatenbank des VDI ZRE zeigt Verwendungsmöglichkeiten von Wertstoffen
Für Unternehmen kann die Verwendung von Sekundärrohstoffen bzw. der Verkauf von nicht mehr benötigten Wertstoffen zu einer verbesserten Wettbewerbssituation beitragen, indem Kosten reduziert und zusätzliche Einnahmen generiert werden. Zudem beweisen die Betriebe mit diesem Handeln ökologische Verantwortung. Für dieses Vorgehen braucht es Wissen um die Verwendungs- und Vertriebsmöglichkeiten der Sekundärrohstoffe.

Rohstoffe verwerten, statt entsorgen
Die Materialdatenbank zu Nebenprodukten und Sekundärrohstoffen unterstützt insbesondere Unternehmen, die bisher wenig Erfahrung mit der Verwertung bzw. Veräußerung von in der Produktion anfallenden Wertstoffen haben. Die Datenbank führt Materialien in verschiedenen Kategorien auf. Zu jedem Eintrag gibt es eine kurze Beschreibung, sowie Angaben zu der Geometrie und den Einsatzmöglichkeiten des Wertstoffs. Zudem sind jeweils passende Händler zu den Wertstoffen verlinkt. Im Bereich „Beispiele aus der Praxis“ wird aufgezeigt, wie andere Unternehmen bereits erfolgreich Nebenprodukte und Sekundärrohstoffe einsetzen.

„Der Einsatz von Sekundärrohstoffen kann Unternehmen in der gegenwärtigen Krise helfen, sich von globalen Lieferketten unabhängiger zu machen und den CO₂-Fußabdruck ihrer Produkte zu senken. Mit der neuen Materialdatenbank leistet das VDI ZRE somit einen Beitrag zur Stärkung der Resilienz des verarbeitenden Gewerbes und mehr Klimaschutz“, unterstreicht Dr. Martin Vogt, Geschäftsführer des VDI ZRE, die Bedeutung von Ressourceneffizienz.

Erfolge in der Praxis
Beispiele aus der Praxis zeigen, dass die Einsparpotenziale für Unternehmen hoch sein können, wenn diese sich intensiver mit den eigenen Rohstoffen auseinandersetzen. Zudem wird ersichtlich, dass Sekundärrohstoffe zunehmend und nachhaltig zur Deckung des Rohstoffbedarfs beitragen. Die vom Bundesumweltministerium beauftragte Datenbank wird in regelmäßigen Abständen aktualisiert und erweitert.

Sie ist erreichbar unter: www.ressource-deutschland.de/werkzeuge/ressourceneffizienz-in-der-praxis/materialdatenbank/.

Due to the continued good business development, especially in the Carbon Fibers Business Unit, SGL Carbon SE is increasing its Group sales and earnings guidance for the current fiscal year and now expects Group sales of approximately €1.2 billion (previously: approximately €1.1 billion). The company expects to achieve adjusted EBITDA (EBITDA pre = earnings before interest, taxes, depreciation and amortization before one-off effects and non-recurring items) of €170 - €190 million (previously: €130 - €150 million) in 2022.

Based on lower prices for acrylonitrile as main raw material of the Business Unit Carbon Fibers as well as higher than expected customer demand for acrylic and carbon fibers combined with consistently good production capacity utilization and capability, the management of SGL Carbon SE assumes an improved earnings development of this Business Unit.

SGL Carbon assumes that the factors mentioned will continue at least until the end of the year and that the earnings situation of the Business Unit Carbon Fibers will exceed previous expectations. Combined with the continued good business development of the other three Business Units (Graphite Solutions, Process Technology and Composite Solutions), an improvement in the sales and earnings situation at Group level is expected.

In line with the forecast increase for adjusted EBITDA (EBITDA pre) to between €170 and €190 million (previously: €130 - €150 million), the company is forecasting adjusted EBIT (earnings before interest and taxes and before one-off effects and non-recurring items) of between €110 and €130 million (previously: €70 - €90 million). The forecast for return on capital employed (ROCE) of originally 7% - 9% has been raised to 10% to 12% corresponding to the development of earnings. The expectations for free cash flow (significantly below previous year's level of €111.5 million) remain unaffected by the expected improvement in sales and earnings.

The updated forecast for fiscal 2022 has been prepared on the basis of the currently prevailing market environment and assumes no deterioration in the general conditions, in particular due to the war in Ukraine and its consequences for the global economy.
 
The definition of key figures used in this release is aligned to the Annual Report 2021. There were no changes in the scope of consolidation or accounting methods compared with the previous guidance.

The future of e-mobility will be determined in particular by safe battery enclosures. As batteries for electric vehicles become more performant, higher volumetric energy density plays a crucial role. If more energy is to be stored in less installation space, new material and design solutions are required. The development of suitable enclosures made of safe and highly robust lightweight materials is also required. This is a case for the Aachen Centre for Integrative Lightweight Production (AZL). A project on cell-to-pack battery enclosures for battery-electric vehicles, which has been eagerly awaited in the industry, will start in October this year there.

The design of battery housings is crucial for safety, capacity, performance, and economics. The Cell-to-Pack project, which is starting now, will focus on developing concepts for structural components and for producing them based on a variety of materials and design approaches. The concepts will be compared in terms of performance, weight and production costs, creating new know-how for OEMs, producers and their suppliers throughout the battery vehicle value chain. Companies are now invited to participate in this new cross-industry project to develop battery enclosure concepts for the promising and trend-setting cell-to-pack technology.

The basis for the project is the lightweight engineering expertise of the AZL experts, which they have already demonstrated in previous projects for multi-material solutions for module-based battery housings. Together with 46 industry partners, including Audi, Asahi Kasei, Covestro, DSM, EconCore, Faurecia, Hutchinson, Johns Manville, Magna, Marelli and Teijin, 20 different multi-material concepts were optimized in terms of weight and cost and compared with a reference component made from aluminum. All production steps were modelled in detail to obtain reliable cost estimates for each variant. Result: depending on the concept, 20% weight or 36% cost savings potential could be identified by using multi-material composites compared to the established aluminum reference.

It is expected that the design concept of battery enclosures will develop in the direction of a more efficient layout. In this case, the cells are no longer combined in modules in additional production steps, but are integrated directly into the battery housing. The elimination of battery modules and the improved, weight-saving use of space will allow for higher packing density, reduced overall height and cost saving. In addition, various levels of structural integration of the battery housing into the body structure are expected. These new designs bring specific challenges, including ensuring protection of the battery cells from external damage and fire protection. In addition, different recyclability and repair requirements may significantly impact future designs. How the different material and structural options for future generations of battery enclosures for the cell-to-pack technology might look like and how they compare in terms of cost and environmental impact will be investigated in the new AZL project. In addition to the material and production concepts from the concept study for module-based battery enclosures, results from a currently ongoing benchmarking of different materials for the impact protection plate and a new method for determining mechanical properties during a fire test will also be incorporated.

The project will start on October 27, 2022 with a kick-off meeting of the consortium, interested companies can still apply for participation until then.

• Recypur successfully starts up a complete airlay line delivered by ANDRITZ for its mill in L’Alcúdia, Spain

The airlay line is designed for recycling of post-industrial and post-consumer foam and was developed specifically for the bedding and furniture industry, with material heights reaching 20 cm and densities of up to 120 kg/m3. Experimental tests carried out together with experts from ANDRITZ Laroche led to the conclusion that the mechanical method for recycling polyurethane is the most versatile and reliable.

With a capacity of 1.2 t/h, this airlay line enables Recypur to supply new mattresses made of industrial & post-consumer foam waste from old mattresses. This well proven process allows to reduce the environmental impact, increase self-sufficiency and eventually reduce the use of polyurethane. Such a set-up also allows multiple functional materials to be incorporated into the blend, such as flame-retardant, conductive and insulating fibers, among others. Thanks to this tailored approach, Recypur is now able to expand its diversification, innovation and reputation on the Spanish market.

The scope of supply includes a blending line with five feeders, an Exel 1500 for fine opening, an Airlay Flexiloft+ with 2.20 m working width, a recycling machine and an oven.

Airlay lines strongly support the circular economy and are part of ANDRITZ’s comprehensive product portfolio of sustainable solutions that help customers achieve their own sustainability goals in terms of climate and environmental protection.

Recypur, based in the Spanish province of Valencia, is part of DELAX, a Spanish group specialized in manufacturing and commercialization of innovative beds and mattresses. This company is the first Spanish manufacturer of recycled flexible polyurethane foam cores from post-consumer foam waste.

Adient, a supplier of seating systems for the automotive industry, has entered into a cooperation with Swedish steelmaker H2 Green Steel (H2GS) to reduce the carbon footprint in its value chain.
 
On 1st September Michel Berthelin, Executive Vice President Adient EMEA, and Henrik Henriksson, CEO of H2 Green Steel, have mutually signed an agreement to supply fossil-free steel with low carbon footprint from 2026 on and subsequently use it in Adient's metal products.

Michel Berthelin explains the background to the cooperation: “As a company, we are committed to the Science Based Targets Initiative, a collaboration between leading global institutions to set a science-based climate target. We also support the Carbon Disclosure Project, which helps companies and cities to understand and disclose their environmental impacts. The decision to shift parts of the steel volume sourced for our production to a steel with low carbon footprint is part of our sustainability strategy. It is our goal to reduce emissions at our production sites that are caused directly by our own sources or indirectly by our energy suppliers by 75% by 2030. In parallel, we aim to reduce emissions along our supply chains by 35% over the same period. In doing so, Adient actively fosters the industry's transformation towards a more responsible use of natural resources.”

Steel from H2 Green Steel is produced with up to 95% less CO₂ emissions compared to conventional steel production. The company achieves this by replacing coal with green hydrogen in production and by the use of electricity from non-fossil sources. In this way, mainly water and heat are produced as waste products.

Im Wettbewerb um die beste Social-Media-Kommunikation für Architektur konnte das Hamburger Projekt Alter Wall die Experten-Jury mit seiner Kompetenz überzeugen. Initiiert vom Rat für Formgebung gilt der Iconic Award als einzigartige Würdigung von Architektur- und Designlösungen. Im Mittelpunkt des Projektes stand die Gewinnung der Fashion-Influencerin Aylin Koenig als Mieterin für den Alten Wall, die mit ihrer eigenen Kommunikation aktiv dazu beiträgt, das Image des Gebäude-Ensembles als neues Wahrzeichen von Hamburg zu stärken.

Mit einem Angebot aus gehobenem Shopping, inspirierender Kunst sowie Gastronomie hat sich der Alte Wall seit Fertigstellung schnell einen guten Namen gemacht. Zur Erschließung neuer Zielgruppen, die den Flanier-Boulevard im Herzen der City besuchen sollen, entschied sich das Kommunikations- und Projektteam mit Aylin Koenig eine der führenden Mode-Influencerinnen anzusprechen. Das Mode-Label by Aylin Koenig wurde 2018 gegründet und hat seitdem über 700.000 Followern auf Social Media. Im Gegensatz zu anderen Influencer-Kooperationen ist Aylin Koenig eine dauerhafte Markenbotschafterin für den Alten Wall und transportiert ihrer Community authentisch, was vor Ort passiert. So zeigt sie ihre Mode in ihrem Store, besucht das Bucerius Kunst Forum und ist häufig im Wallter’s anzutreffen

India’s world famous Blue City, Jodhpur, has been repainted and refreshed by AkzoNobel as part of a major “Let’s Colour” project involving 250 homes.

More than 5,600 liters of Dulux paint has been used to revitalize the iconic area of Rajasthan, which is known the world over as a leading tourist destination. As well as painting exterior walls in a distinctive shade of vibrant blue, the roofs of more than 100 houses have been coated with Dulux Weathershield Protect, which can help to reduce temperatures by up to 5˚C.

In addition, 20 colorful murals have been created along the ancient streets leading up to Mehrangarh Fort, which towers over the city. All the work, which took around four months to complete, was carried out by AkzoNobel Paint Academy painters, local artists and residents, and AkzoNobel volunteers, who combined their creative talents.

The color blue has been an integral part of Jodhpur’s identity for centuries. And reigniting the city’s timeless appeal – making it more liveable and enjoyable – was key to the whole project. So in addition to painting more than 250,000 square feet of walls, community walkways and staircases have also been given a rainbow makeover using Dulux FloorPlus paint.   

AkzoNobel’s global “Let's Colour” initiative was launched in 2009. To date, more than 2,300 projects have taken place, with over 1.3 million liters of paint being donated all over the world.

In comparison to HY 21 revenue went up by 26% to 1,707.3 million EUR, the profit reached 123.9 million EUR (+6%).

Machines & Technologies revenue increased by +10%. The revenue of Agro increased by +46%, Bio-valorization revenue increased by +27%, the revenue of Industrial Solutions increased by +21%, and the revenue of T-Power increased by 4%. This revenue increase could be mainly realized thanks to higher sales prices, implemented to compensate the increase of raw material, energy and transportation costs in most segments.

In the first half of 2022, revenue increased by +10% for the segment Machines & Technologies. This increase in revenue took place both in weaving machines (Picanol) and other industrial activities (Proferro, PsiControl). Picanol launched the OmniPlus-i TC Connect weaving machine into the Machines & Technologies segment in early 2022. This model, which was specifically made for weaving tire cord, has been upgraded with the latest airjet technology and equipped with the features of the new generation Connect weaving machines. However, HY22 Adjusted EBITDA decreased by 64% compared to last year due to the negative impact of rising raw material prices, transportation costs and costs of late deliveries, which could not be translated into higher selling prices, partly due to the large order book.

The group anticipates a continued high level of uncertainty in the second half of 2022, as well as in 2023, due to the current conflict in Eastern Europe, the difficult supply chain circumstances, and other challenges following the coronavirus pandemic. The development of customer demand and sales margin could therefore come under pressure. However, based on currently available information, Picanol Group expects that the 2022 Adjusted EBITDA will be higher than the 2021 Adjusted EBITDA (430.3 million EUR). This revised outlook for the 2022 financial year reflects the strong first half of the year, while the result for the second half is expected to be in line with the same period in the previous year.