From the Sector

To expand its support for high-end and luxurious automotive interiors, B.I.G. Yarns has completed its first industrial production runs of virgin polyester BCF yarns for automotive carpet to complement its line of polyamide PA6 superior yarns.

There is a growing market in PET for automotive interior applications, with polyester allowing automotive OEMs and Tier 1 to develop products that, from the outset, consider eco-design by building MONO-polymer carpets and flooring that are 100% recyclable at End of Life (EOL ). These materials are helping to ensure improved and more sustainable EOL recycling of electric vehicles that are driving the future of the car industry.

The new PET BCF Yarns offer high-performance for automotive carpets, including abrasion and stain resistance, and durability, passing all stringent automotive tests including the Taber test for abrasion performance, compressibility and recovery ability test, light fastness in automotive (DIN EN ISO 105-B06) and VOC (fogging) according the VDA 278 test on VOC and FOG emission. The yarns can be color solution dyed, have a dTex between 1300 – 1500, 81 filaments and are ideally for mats with a composition of 400 to 800 gram per m², while the yarns for molded carpets have a dTex of 1200, 144 filaments for 380 gram per m².

With the addition of PET BCF yarns, B.I.G. Yarns is now a one-stop-shop for 3 types of Solution Dyed BCF carpet yarns for the automotive industry: nylon (PA6), polypropylene (PP) and polyester (PET), and the Eqo-range of PA6 yarns – the sustainability focused EqoBalance, EqoCycle and EqoYarn.

The automotive carpet market is expected to grow strongly in the coming decade with the increased demand for vehicle customization and personalization driven by owners looking to upgrade and enhance interiors, including the flooring area.
A growing awareness around car hygiene is also boosting the market as consumers become more conscious of maintaining cleanliness in their vehicles, including the floors. Automotive carpets provide an effective solution by trapping dirt and preventing it from spreading to other areas.

The GoodTextiles Foundation has implemented a school library in the local primary school in Tamil Nadu, India. As a result, the children now have unrestricted access to additional literature.

At the PUPS Naranikuppam primary school in Tamil Nadu, the GoodTextiles Foundation has already provided access to separate sanitary facilities and clean drinking water. Now, with the help of the foundation, a school library has also been set up. The GoodTextiles Foundation is supporting the project with a total of €3,900.00, of which €1,425.00 comes from a donation from Dibella, which was realised with the greenhouse gas premium. The remainder was financed with donations already received.

A large selection of books tailored to the age and interests of the pupils was purchased for the library, as well as a shelf and a seating area. With a new Smart TV, the children can now also be introduced to digital media and how to use it. An air conditioning system provides pleasant temperatures to improve learning conditions. The newly tiled floor, new glass windows and a new glass door also improve the building-specific conditions.

The school is located directly next to a sewing company where the single mothers of the pupils work.

In 2016, the textile company Dibella established the GoodTextiles Foundation with the aim of making textile value chains more sustainable. It raises donations and implements its own funding projects to benefit people at all stages of the textile industry.

On 10 January, Re:NewCell AB ("Renewcell") announced that they are planning to start negotiations with the relevant trade unions regarding restructuring of the organization to improve efficiency while maintaining focus on sales.

As part of the restructuring, the local authorities (Arbetsförmedlingen) will also be notified. The planned restructuring will lead to a decrease in workforce of approximately 25%, just over 30 persons, and will also result in annual savings – reduction of personnel cost and other operating costs – of approximately 35 SEKm in total per annum when finalized.

Magnus Håkansson, acting CEO, says: “This kind of decision is never easy to make and would not be planned for unless it was absolutely necessary for our long-term success. The planned restructuring of the organization means that Renewcell will maintain conditions for efficient production while continuing to focus on the development of sales to fiber producers as well as focusing on marketing activities to the major clothing brands that determine the final demand in the supply chain.”

Devan will showcase the newest additions to their R-Vital NTL Range and Thermic High Cooling technology.

R-Vital® NTL enables textile manufacturers to boost their textiles with a range of active, natural ingredients that have a positive effect on the body and mind. Elements such as Chamomile oil and Arnica Montana are absorbed by the skin and have relaxing, moisturizing or hydrating effects. The biobased content of the R-Vital well-being technology is +97%, readily biodegradable (OECD 301B).

R-Vital® NTL Regenight™: Devan and Lucas Meyer Cosmetics join forces to launch a ground-breaking technology, R-Vital NTL Regenight™, a technology which improves sleep quality and also improves nighttime skin recovery. Using an upcycled oil soluble fraction obtained from Australian Tea tree oil distillation process, Regenight™ acts through both inhalation to improve nighttime rest and through topical action to provide skin recovery.

Tested in real-life context using proven biometric technology, the dual action provided individually by Regenight™ proposes a breakthrough approach to reduce the impact of poor-quality sleep on the skin.

R-Vital® NTL Chamomile oil: Chamomile oil is known for its moisturizing and soothing properties. Additionally, this oil is believed to have antioxidant and inflammatory properties. Furthermore, chamomile oil is renowned for its calming effects and potential to reduce stress and anxiety, helping improve sleep quality.

R-Vital® NTL Warming: Engineered to deliver a gentle warmth, the R-Vital NTL Warming technology ensures a cozy and comfortable sleeping experience. This blend is a solution that infuses a sense of warmth, promoting physical and emotional well-being.

R-Vital NTL Arnica Montana: Harnessing the natural benefits of Arnica Montana, this ingredient, is celebrated for its potent healing and recovering properties.

At Heimtextil Devan will also present a new high cooling technology that provides an optimal and refreshing sleeping climate, ensuring a cool and restful night's sleep. Thermic High Cooling is based on reactive microencapsulated Phase Change Materials (PCMs). The smart heat exchange mechanism keeps the body within its comfort zone. This makes the body suffer less from night sweats, and results in a longer, healthier and more comfortable sleep with fewer awakenings. This new formulation with high cooling level and high solid content, presents around 30% more cooling than standard PCM formulations. One padding allows to achieve high cooling level (no need to run multiple applications). A Bio-based version is also available - Thermic® Bio, where the PCMs are derived from sustainable, natural sources.

• Dibella increases the use of Cotton made in Africa cotton according to the mass balance system from 300,000kg in 2023 to 750,000kg in 2024.

With Cotton made in Africa (CmiA), Dibella is making its business model even more sustainable. This enables the company to minimise its environmental impact and support the people in the growing regions. Dibella relies on the CmiA mass balance system in the chain to achieve its corporate goal of "increasing the use of sustainable fibres".

Cotton made in Africa initiative is an internationally recognised standard for sustainable cotton grown by African smallholder farmers. With up to 13% less greenhouse gas emissions, CmiA-verified cotton has a significantly lower impact on the environment than the global average and also supports village communities in Africa beyond sustainable cotton cultivation. CmiA supports smallholder farmers in sub-Saharan Africa in the sustainable cultivation of genetically unmodified cotton and is committed to improving working conditions in ginning factories. Through a licence fee, which is paid by customers like Dibella, the farmers receive training and access to operating resources in order to reduce the use of pesticides and increase the quality of their cotton and yields from their fields at the same time.

Cotton made in Africa takes a pragmatic approach to the processing of its cotton with two different models in order to best meet the demands for transparency and feasibility in the chain: The Hard Identity Preserved System and the Mass Balance System; Dibella has opted for the latter. While CmiA-verified cotton is always traded separately from other cotton right up to the spinning mill and can therefore be traced seamlessly from the growing region to the ginning plant to the spinning mill, the mass balance system allows CmiA cotton to be mixed with cotton of other origins at the spinning mill level as long as a balance between cotton purchases and CmiA-labelled yarns is ensured. This principle ensures the purchase of sustainably grown fibres and helps Dibella to bring a larger quantity of sustainable cotton into its textile cycle, which ultimately benefits smallholder farmers.

Monforts' new Montex 8500 stenter line was recently installed at Curt Bauer’s plant in Aue in Germany.

Curt Bauer has been in continuous operation for 150 years, beginning as a weaving mill in Aue in the Ore Mountains region of Saxony back in 1882. Today, with 120 employees, the company has an annual production of 2.2 million metres of fabric and specialises in three key fields – home textiles, special damask fabrics for West African garments and technical textiles.

A first Montex stenter was installed by Monforts at the Aue plant in 2003 and an older machine from a third party supplier was also still in operation prior to the latest upgrade.
“The replacement of our older existing stenter, which was installed in 1985, was long overdue,” explains Gert Bauer. “It had a maximum working width of 2.2 metres and we were looking to both increase productivity and reduce energy requirements.”

As a consequence, the company opted for a new Montex 8500 line with a working width of 3.2 metres equipped with the MonforClean heat recovery and exhaust air purification system. The Montex stenter remains unmatched in terms of its robustness and long service life and with MonforClean technology, the waste heat from the drying process is used to pre-heat the drying air. This results in a radical reduction in the conventional heat supply required, compared to full gas and thermal oil heating. Overall energy savings of up to 40% can now be achieved compared to conventional stenters.

The first challenge at the Aue plant was how to fit the significantly larger machine into the available space without restricting the area required for docking operations.

The special multi-level configuration that Monforts designers and Curt Bauer’s team devised in order to meet these requirements involved raising all of the line’s drying zones – with a combined length of over 28 metres – on scaffolding platforms, to enable the ground floor space below them to continue to be fully utilised.

The next challenge involved configuring the MonforClean system without having to make any costly changes to the roofing structure. This, Gert Bauer observes, demanded “millimetre precision”.

With the new line now fully operational, the savings it is providing have yet to be fully calculated.

SGL Carbon relies on climate-friendly manufacturing processes in the production of its own carbon fibers. By using renewable energy, the carbon footprint of SGL fiber can be reduced by up to 50% compared to a conventional fiber.  

SGL carbon fiber is produced at the Lavradio (Portugal) and Moses Lake (USA) sites. When the Moses Lake site was selected in the 1990s, the use of hydropower as an energy source played a particularly decisive role. As a result, around 75,000 tonnes of CO₂ can be saved in Moses Lake by purchasing electricity from hydropower plants compared to a fossil fuel-based electricity mix.

As part of the consistent implementation of its climate strategy, SGL Carbon will be using a CO₂-neutral biomass system to generate energy from the beginning of 2024, which will make the production system, which was previously based on natural gas, more flexible and climate-friendly. At full capacity, the biomass system in Lavradio can save more than 90,000 tons of CO₂.

The raw material used is wood pellets, which are sourced from a radius of 250 kilometres via short transport routes.

The climate-friendly energy supply at the site in Moses Lake (USA) combined with the new biomass plant in Lavradio (Portugal) lead to a reduction in CO₂ emissions of up to 50% in the production of SGL's own carbon fibers compared to conventional fibers. With the investment in the biomass system, SGL Carbon is pursuing its climate strategy. The target is to save 50% CO₂ emissions by the end of 2025 compared to the base year 2019 and to be climate-neutral by the end of 2038. In the period 2019 to 2022, SGL Carbon has reduced its CO₂ emissions by 17%.

The kick-off meeting for the "Trends and Design Factors for Hydrogen Pressure Vessels" project, recently held at AZL Aachen GmbH, was a successful event, bringing together more than 37 experts in the field of composite technologies. This event laid a solid foundation for the Joint Partner Project, which currently comprises a consortium of 20 renowned companies from across the composite pressure vessel value chain: Ascend Performance Materials, C evotec GmbH, Chongqing Polycomp International Corp. (CPIC), Conbility GmbH, Elkamet Kunststofftechnik GmbH, F.A. Kümpers GmbH & Co. KG, f loteks plastik sanayi ticaret a.s., Formosa Plastics Corporation, Heraeus Noblelight GmbH, Huntsman Advanced Materials, Kaneka Belgium NV, Laserline GmbH, Mitsui Chemicals Europe GmbH, Plastik Omnium, Rassini Europe GmbH, Robert Bosch GmbH, Swancor Holding Co. Ltd. Ltd., TECNALIA, Toyota Motor Europe NV/SA, Tünkers do Brasil Ltda.

The project follows AZL´s well proven approach of a Joint Partner Project, aiming to provide technology and market insights as well as benchmarking of different material and production setups in combination with connecting experts along the value chain.

The kick-off meeting not only served as a platform to foster new contacts and get informed about the expertise and interests of the consortium members in the field of hydrogen pressure vessels, but also laid the groundwork for steering the focus of the upc oming project's ambitious phases. As a basis for the interactive discussion session, AZL outlined the background, motivation and detailed work plan. The central issues of the dialogue were the primary objectives, the most pressing challenges, the contribut ion to competitiveness, and
the priorities that would best meet the expectations of the project partners.

Discussions covered regulatory issues, the evolving value chain and the supply and properties of key materials such as carbon and glass fibres and resins. The consortium defined investigations into different manufacturing technologies, assessing their matu rity and potential benefits. Design layouts, including liners, boss designs and winding patterns, were thoroughly considered, taking into account their implications for mobile and stationary storage. The group is also interested in cost effective testing m ethods and certification processes, as well as the prospects for recycling into continuous fibres and the use of sustainable materials. Insight was requested into future demand for hydrogen tanks, OEM needs and strategies, and technological developments to produce more economical tanks.

The meeting highlighted the importance of CAE designs for fibre patterns, software suitability and the application dependent use of thermoset and thermoplastic designs.

The first report meeting will also set the stage of the next project phase, which will be the creation of reference designs by AZL's engineering team. These designs will cover a range of pressure vessel configurations using a variety of materials and production concepts. The aim is to develop models that not only re flect current technological capabilities, but also provide deep insight into the cost analysis of different production technologies, their CO₂ footprint, recycling aspects and scalability.

AZL's project remains open to additional participants. Companies interested in joining this initiative are invited to contact Philipp Fröhlig.

With the growing demand among brands and consumers for plastic-free materials and ingredient transparency, VEOCEL™, the flagship specialty nonwovens brand of Lenzing Group, showcased LENZING™ Lyocell Dry fiber at Hygienix 2023. LENZING™ Lyocell Dry fiber which is not classified as “plastic” according to EU SUPD, meets the growing interest for plastic-free nonwoven products across the industry and among consumers. Additionally, along with being an environment-friendly solution, the fiber delivers high-performance dryness and comfort which makes it the optimum fiber choice for absorbent hygiene applications.

Comprised of mostly fossil-based materials, absorbent hygiene products are an essential part of many consumers’ daily lives. With heightened concerns towards environmental impact, the product segment has been undergoing a change caused by shifting consumer preferences, increased consciousness and concerns towards plastic waste, and technology advancement. LENZING™ Lyocell Dry fiber has embraced these changes without compromising on quality or performance.

LENZING™ Lyocell Dry is a cellulosic environment-friendly wood-based alternative to fossil-based fibers. Besides offering great performance features such as liquid management, dryness, gentle-on-the-skin comfort, softness, and quality, LENZING™ Lyocell Dry helps to meet the needs of customers who are aiming to produce plastic-free applications or end products that do not harm the planet without compromising on performance or comfort.

Featuring Lenzing’s unique Dry technology, LENZING™ Lyocell Dry’s hydrophobic characteristics and liquid-controlling properties make it the ideal fiber for absorbent hygiene products. Its high-performing hydrophobicity makes it the optimal choice for a wide range of applications, including baby diapers, feminine care and personal hygiene products as well as adult incontinence products.

The fiber has consistently been tested by Lenzing as the softest* fiber among cellulosic fibers in both dry and wet stages. LENZING™ Lyocell Dry will enable brands and manufacturers to deliver quality hygiene products that provide a high level of comfort, softness, and dryness.

*Lenzing AG softness panel test

Archroma is bringing its most impactful planet-conscious innovations, including SuperSystems+, to ChromaTexChem 2023 in Mumbai from December 19-20.

Super Systems+ is a new set of end-to-end systems that combine processing solutions and intelligent effects for the entire textile processing workflow, from sizing to finishing. Developed for different end-use segments – from blue and colored denim to performance athletic wear, bottom weights, towels and sheeting – Super Systems+ aims to empower fashion and textile brands and mills to add value to their products while they deliver measurable environmental impact and enhance production efficiency.

Super Systems+ leverages the industry’s broadest product portfolio and authentic evidence-based data to support informed decision making. It is supported by The SafeEdge by Archroma, an online portal that gives Archroma customers and brands real-time access to product-related regulatory and compliance certifications and information, as well as the Archroma ONE WAY Impact Calculator, a process simulation and calculation tool designed and used by our textile processing experts to provide our customers and partners with an accurate estimate of the process costs, resource utilization, effluent discharge quality, and CO₂ emissions of the existing production process and of the newly evaluated system. These help them to select solutions that meet their performance requirements and deliver against significant sustainability targets.