From the Sector

A much more sustainable, cost effective and very flexible process for manufacturing critical fibres based on ultra high molecular weight polyethylene (UHMWPE) is being launched by the UK’s Fibre Extrusion Technologies (FET).

UHMWPE is prized in many industries due to its extraordinary properties. The fibre is, for example, ten times stronger than steel by weight, while exhibiting outstanding abrasion resistance, low friction and high impact strength. UHMWPE fibres are also chemically inert, resistant to most chemicals and UV light and do not absorb water. They maintain performance in a wide range of temperatures and despite their toughness are extremely lightweight.

As a result, they are unbeatable in demanding applications such as high-performance ropes in maritime industrial and rescue applications. In addition, they are invaluable in ballistic protection, cut-resistant clothing and high-performance sports gear – and increasingly in medical implants.

Biomedical market
“FET has supplied many extrusion systems to the biomedical market, most notably for the production of both resorbable and non-absorbable sutures,” says FET Managing Director Richard Slack. “In exploring what else we could do in assisting these customers, it became clear that there was a need for smaller quantities of UHMWPE fibres in bespoke sizes.”

“The current systems for manufacturing UHMWPE filament yarns are on a huge scale, with very complex processing routes,” adds Research and Development Manager Jonny Hunter. “This means the supply chain is currently very inflexible with minimal opportunity for new product development. These disadvantages have been fully addressed in the development of our new FET-500 series lab and small scale gel spinning system.”

Solvent extraction
A major FET innovation is the introduction of a patented batch system for solvent extraction exploiting supercritical carbon dioxide (CO2).

UHMWPE production, until now, has involved the use of large volumes of hazardous solvents such as dichloromethane (DCM) or hexane. The UHMWPE powder is mixed with mineral oil to form a gel which is subsequently extruded, cooled and solidified. The oil is then extracted from the fibres using DCM or hexane and the solid fibres are then drawn at high temperature to further align the polymer chains, resulting in final strong and tough fibres. Typically, it takes 10 kg of Hexane to extract 1 kg of oil. 

“Solvent reclamation using extraction baths and hot air drying chambers is not practical for the scale of our system,” explains FET’s Senior Material and Process Scientist Kris Kortsen. “The current baths employed can be up to 200 metres long and the waste volumes are considerable. Expertise is needed in dealing with such dangerous chemicals and overall the process has an immense environmental impact.

“CO2, by contrast, is a cheap and abundant sustainable solvent that is non-toxic, non-flammable and leaves no residue.” 

Closed loop
FET’s closed-loop system can achieve more than 95% solvent recovery without loss of performance, resulting in residue-free UHMWPE filament yarns via a vastly improved route in terms of both safety and logistics.

A further innovation is the highly modular drawing system based on heated godet rollers, enabling flexible temperature and drawing control for new product development and the ability to be expanded at any time to meet customer needs.

A comprehensive LCA study detailing the full savings potential is currently being prepared and will be published shortly.

“Having processed over 130 separate polymers in the development of our extrusion systems, we believe the FET-500 is a game changer,” concludes Richard Slack. “We believe there is a big gap in the market for smaller quantities of UHMWPE, and our first line is now fully operational at the FET Fibre Development Centre in Leeds. We look forward to demonstrating it and discussing its full potential with interested companies from around the world.”

DyStar, a leading specialty chemicals company with more than a century of tradition in product development and innovation, announced that its main shareholder, Zhejiang Longsheng Group Co., Ltd, has entered into a share purchase agreement to acquire 37.57% of the issued shares of DyStar Global Holdings (Singapore) Pte. Ltd., previously held by Kiri Industries Limited. 

The acquisition follows a ruling by the Singapore International Commercial Court (SICC) requiring the sale of 100% of DyStar's equity. As the controlling shareholder with 62.43% of DyStar, the strategic acquisition of the outstanding shares by Zhejiang Longsheng Group will result in DyStar becoming a wholly owned subsidiary. This transaction ends the long-standing legal dispute with Kiri Industries and thus prevents a complete sale of DyStar. 

The total purchase price is $696.5478 million, subject to adjustments on or after the closing date. Closing is subject to regulatory approvals and other customary conditions, with the expected closing date being no later than 3 November 2025. 

Xu Yalin, Managing Director and President of the DyStar Group, said: ‘We are pleased with the final settlement of the legal dispute, which will enable the DyStar Group to move forward with certainty, confidence and a new strategic focus. This is a significant milestone in our 30-year history, as it strengthens our long-term stability and commitment to our global stakeholders.’ 

This development will enable DyStar to further expand its leadership position in the specialty chemicals sector and its value chain. The group remains firmly committed to driving innovation, promoting sustainable practices and pursuing strategic growth initiatives to strengthen its global competitiveness.

Borealis continues to invest in growth through sustainable solutions that are transforming the polymer industry. Its facility in Burghausen, Germany, is significantly expanding production capacity for an innovative polymer foam solution called Daploy™ High Melt Strength polypropylene (HMS PP). This investment—totaling over EUR 100 million—addresses growing global demand for recyclable, high-performance foam solutions. The new line, scheduled to start up in the second half of 2026, will triple Borealis’ supply capability for fully recyclable HMS PP. This expansion enables the transition to more circular and recyclable material solutions for customers in the consumer products, automotive, and building and construction industries.  
 
The development of Daploy HMS PP took place at Borealis’ Innovation Headquarters in Linz. The new product provides exceptional foamability, lightweight properties, and mechanical strength—characteristics that support material efficiency and help cut both costs and CO2 emissions. It is suitable for use in monomaterial solutions, which are easily recyclable at end of life.  
 
By supporting the sustainability principles of Reduce, Reuse, and Recycle, Daploy HMS PP addresses the growing demand for recyclable solutions across multiple industry segments:
 
In the automotive industry, Daploy is used for ultra-lightweight foamed interior and under-the-hood components. Typically 60-90% lighter than non-foamed alternatives, these components help improve fuel efficiency and reduce carbon emissions. It also enables zero-waste production as all production trim-offs can be easily recycled. In addition, Daploy makes it possible for these parts to be constructed from a single material, facilitating recycling at the end of the vehicle’s life.  
In the building and construction sector, Daploy HMS PP is used to replace heavier materials in insulation and paneling applications. Its durability, strength, and heat resistance ensure excellent performance, while its lightweight properties and recyclability improve the sustainability of these components.
 
“In line with our We4Customers strategy, this investment creates value for customers by enabling them to design recyclable, foam-based products for a wide range of high-performance applications,” explains Craig Arnold, Borealis Executive Vice President Polyolefins, Circular Economy Solutions and Base Chemicals. “By expanding production, we’re ensuring a reliable supply of this advanced material to help our customers achieve their sustainability goals and deliver high-performance solutions.”

The winners of the 2025 IDEA® Achievement Awards and FiltXPO™ Innovation Awards were announced during special ceremonies held April 29 and 30 at the Miami Beach Convention Center in Miami Beach, Florida. Presented at the co-located IDEA®25 and FiltXPO™ 2025 events, the awards celebrate outstanding innovations driving progress in nonwovens and filtration. INDA, the Association of the Nonwoven Fabrics Industry, collaborated with International Filtration News for the FiltXPO™ Awards and Nonwovens Industry magazine for the IDEA® Achievement Awards.

IDEA® Equipment Achievement Award
Dilo Systems GmbH – MicroPunch
The rising energy costs and water shortages have led to a re-evaluation of production methods, with a stronger focus on environmental impact. With MicroPunch, it is possible to reduce energy consumption by approximately 75 percent compared with other consolidation techniques that produce lightweight nonwovens. This technology enhances efficiency and reduces the manufacturing costs and the environmental footprint.

IDEA® Nonwoven Products Achievement Award
Innovatec Microfibre Technology GmbH & Co. KG – InnovaWipe® Water-Soluble Nonwoven
This water-soluble nonwoven is completely biodegradable under both aerobic and anaerobic conditions. It offers excellent resistance to oils, greases and chemicals. It does not leave any microplastics behind, breaking down into carbon dioxide, water and biomass. It also has no ecotoxic effects, is safe for the marine environment and does not cause fatbergs or blockages in wastewater systems – flushable and home compostable.

IDEA® Raw Materials Achievement Award
Woolchemy NZ Ltd. – neweFibre
Woolchemy’s neweFibre is the world’s first hygiene-grade wool, engineered for high-performance, sustainable hygiene products. This fully traceable, renewable fiber enhances moisture management, thermal comfort, and odor control. Seamlessly integrating into production, neweFibre powers innovations like neweFlex ADL for exceptional fluid distribution and skin dryness.

IDEA® Short-life Achievement Award
Egal Pads, Inc. – Egal™ Pads on a Roll
At Egal, we believe pads should be as common as toilet paper.  Our vision is that “pads on a roll” will be put in every toilet stall – where they are needed most – to ensure privacy and dignity to all who menstruate.  Egal pads are manufactured in roll form, 40 individually wrapped on each roll, so they can be mounted on existing toilet paper dispensers or in Egal’s custom-designed dispensers.

IDEA® Long-life Achievement Award
Magnera – Sontara® EcoRE Bag
EcoRE bags are produced entirely from cellulosic fibers, presenting a sustainable alternative to traditional synthetic materials. Made with Sontara fabric certified by OK compost HOME, these bags maintain their durability and strength without the need for added binders, addressing a common concern with compostable goods. With plastic bag bans now in place in many states, Sontara offers a timely and eco-friendly solution for the retail and shopping market.

IDEA® Sustainability Advancement Award
KINDCLOTH™ – PURA HEALTH Insect Repellent – Water Dissolvable Wipes
This wet wipe combines water-dissolvable Hydropol™ technology with a natural formula featuring lemongrass and citronella. Designed for eco-conscious consumers, this innovative wipe provides effective insect protection while leaving no waste behind. Certified biodegradable, flushable, and designed not to create harmful microplastics, it safeguards fragile ecosystems and supports sustainability goals.

IDEA® Entrepreneur Award
Dude Products, Inc.
In less than a decade, the Dude Wipes brand has grown from an entrepreneurial concept conceived in a bachelor’s post-college apartment to a more than $200 million global brand. These flushable wipes have flourished in flushable wipes industry, successfully going head to head against multinational consumer product companies Kimberly-Clark, S.C. Johnson, and Procter & Gamble.

FiltXPO Air/Gas Filtration Award
Greentech Environmental LLC – Greentech Filters with ODOGard®
ODOGard® technology deeply integrates odor-neutralizing polymers into nonwoven and nanofiber filters, offering an innovative, non-toxic approach to indoor air quality. ODOGard® significantly enhances filtration durability and performance.

FiltXPO Water/Liquid Filtration Award
Ahlstrom – BioProtect™
Ahlstrom’s sustainable BioProtect™ material offers superior dye-catching performance for laundry applications. Manufactured from 100 percent naturally derived fibers and OC-Biobinder®, BioProtect™ is both biobased and home compostable, combining premium performance with environmental responsibility.

FiltXPO Filtration Equipment Award
Filtration Advice Inc. – FA-TCO Software
This cutting-edge software provides comprehensive Total Cost of Ownership (TCO) analysis and predictive modeling for air filtration systems. FA-TCO enables data-driven decisions, extending filter lifespans, reducing operational costs, and enhancing overall sustainability in filtration management.

Archroma, a global leader in specialty chemicals towards sustainable solutions, will present its groundbreaking solutions for textile and fashion brands at this year's China Interdye. Archroma’s showcase will emphasize its High IQ® Lasting Color assurance program and the PHOBOTEX® range of durable water-repellent finishes, underscoring the company’s dedication to providing low impact, durable, and long-lasting garment solutions.

As the largest specialized exhibition for textile dyes and chemicals, China Interdye 2025 offers a key platform for Archroma to present its latest advancements. This year’s focus is on innovative solutions that help brands achieve not only their sustainability goals but also meet the increasing demand for high-performance, long-lasting products in the textile and fashion industries.

“China continues to play a pivotal role in global textile production, with increasing demand for lower impact and high performance solutions,” said Christine Cai, Vice President of North Asia, Archroma Textile Effects. “We are excited to bring our High IQ® Lasting Color and PHOBOTEX® solutions to China Interdye, enabling brands to deliver garments that combine outstanding functionality, durability, and sustainability.”

Brilliant colors and long-lasting garments
Archroma is evolving its well-established High IQ® performance assurance program to include its innovative and sustainable intelligent textile effects.

As the first High IQ® program to be reintroduced, High IQ® Lasting Color incorporates Archroma’s most innovative color-retention technologies to ensure that garments stay looking new for longer—with bright shades that retain their intensity and dark shades that stay dark. Powered by specially selected AVITERA® SE and NOVACRON® dyes, High IQ® Lasting Color also helps mills and brands reduce their environmental footprint by using up to 50% less water and energy in processing.

PHOBOTEX® Range: Durable Water Repellency
Another highlight of the showcase at China Interdye will be the PHOBOTEX® range of durable water-repellent (DWR) finishes. With over a decade of innovation in fluorine-free “C0” technologies, PHOBOTEX® is at the forefront of the shift toward non-PFC DWR solutions. These advanced technologies provide long-lasting protection and comfort, incorporating renewable raw materials for a more sustainable approach.

Designed to meet current and future industry standards, the PHOBOTEX® range includes fluorine-free hydro polymers and bio-based options. It is easy to apply to any substrate, offering solutions for a variety of end uses. From everyday stain protection without compromising fabric feel, to extreme environment defenses, PHOBOTEX® ensures versatility. Additionally, it enhances mill productivity with excellent runnability, enabling faster, trouble-free production and consistent results.

EIM (Environmental Impact Measuring), the leading global platform for measuring the environmental impact of garment finishing—trusted by the world's top brands and textile production centers—presents the "Innovations and Challenges in Denim Finishing: 2024 Report." This pioneering report provides an analysis based on accurate, objective data from over 115,000 denim finishing processes collected through the EIM platform, setting new benchmarks for sustainability in the industry.

The report reveals that 63% of the analyzed processes are already classified as low environmental impact, reflecting a positive shift toward more responsible practices. However, it also highlights critical challenges, such as the high use of hazardous chemicals (24% of processes), particularly pumice stones and potassium permanganate—practices that urgently require safer and more sustainable alternatives due to their negative effects on both the environment and worker health.

Progress in water consumption management is also considered, as this remains one of the key environmental challenges for the textile sector. The report shows that the current average water usage in denim finishing is 30 liters per garment—still above the recommended benchmark of 22.5 liters per garment. Effective strategies for reducing water consumption include optimizing rinsing processes, selecting fabrics that require less aggressive treatments, and implementing technologies such as ozone, e-flow, and smart foam systems.

Among the proposed improvements are also the adoption of advanced technologies to reduce chemical use and protect worker health, such as the strategic selection of ZDHC-certified chemicals and the automation and digitalization of manual processes.

Begoña García, creator of the EIM platform and co-author of the report, states: “For years, the textile industry has lacked reliable tools to measure its environmental impact, making data-driven decisions difficult. This report marks a crucial step toward transparency and continuous improvement, showing that technology is key to measuring and reducing environmental impact.”

The report aims to support informed decision-making based on verifiable data, positioning EIM as a global standard essential for transparency and ongoing sustainability improvements in the textile industry.
The full report is available for download and will be updated annually, serving as a vital tool for brands and suppliers to collaborate in reducing their environmental footprint and advancing toward a more responsible and sustainable production model.

The initiative will deploy 60 vehicles by 2030, aiming for a 90% reduction in Cavalinho’s fleet transport carbon emissions.

Solvay is advancing its sustainability efforts by partnering with Cavalinho, the leading road transport provider for its operations in Brazil. This collaboration aims to reduce the carbon footprint of Solvay's operations in Paulínia, the largest chemical complex in Brazil, which produces over 1.2 million tons of chemicals annually. Solvay will be one the first companies in Brazil to adopt biofuel-powered trucks for transportation, supporting its goal of cutting scope 3 emissions by 20% by 2030.

The project, launched on April 1, 2025, at Solvay's Paulínia site, will start operations in 2026 with an initial fleet of 20 vehicles, each with a range of 650 km. To achieve a 90% reduction in Cavalinho’s transport carbon emissions, the fleet will grow to 60 vehicles by 2030. This strategic move addresses Brazil's infrastructure challenges for long-haul electric truck travel, offering a sustainable alternative through biofuel.

This initiative is part of Paulínia's broader sustainability push. Solvay recently announced a climate project to replace two-thirds of the steam produced in its boilers, currently using fossil natural gas, with a biomass boiler initiative. Since 2005, the Paulínia site has achieved a 95% CO₂ reduction, which will reach 97% by 2027 with the biomass initiative.

At the SaigonTex 2025 textile machinery exhibition which is taking place from April 9-12 in Ho Chi Minh City, Vietnam, Monforts will highlight the benefits of its advanced finishing technologies for denim.

Over 900 Monforts THERMEX hotflue dyeing systems are now operational in the main textile producing countries, with many of them devoted to denim production, and a significant number already reaping the benefits of the Econtrol® and Econtrol®T-CA processes*.

Econtrol® is a continuous process for the dyeing of woven cotton and cellulosic fabrics in which reactive dyestuffs are fixed into the fabric in a one-step dyeing and drying operation with a controlled combination of steam and air. The entire pad-dry process takes just two-to-three minutes at a temperature of between 120-130°C and a relative humidity volume of 25-30%.

Monforts denim range concepts which are successfully running worldwide enable the processing of high-qualtiy and reproducible fabrics which are stretched and skewed far more gently than with conventional range combinations. The ‘double rubber’ version of a THERMEX range comprises two compressive shrinkage units and two felt calenders in line, for super elastic and bi-elastic materials. Additionally, the combined drying, stretching and skewing functions for denim fabric are possible with the ThermoStretch unit, which can also include an EcoApplicator system for the minimum application of necessary finishing chemicals.

In 2024, Vietnam surpassed Bangladesh to become the world’s second-largest textiles and apparel exporter, trailing only China, with total export revenues reaching $44 billion. This is in part due to tariffs that are currently 10-20% lower than China’s and significantly cheaper labour costs – less than half of China’s.

Vietnam’s textile and apparel industry is poised for further expansion in 2025, leveraging cost advantages and rapid production turnaround while proactively managing rising logistics costs and adapting to shifting trade dynamics.

* Econtrol® is a registered trademark of DyStar Colours Distribution GmbH, Germany.

Fueled by robust demand, the fair wrapped up successfully on 13 March at the National Exhibition and Convention Center (Shanghai). Over 370 exhibitors engaged with more than 25,000 visitors from 85 countries and regions, with total visitor numbers up by 8%, and the number of international visitors more than double that of the previous Spring Edition. As consumer preferences continue to evolve, buyers increasingly sought home products that harmoniously blend style, comfort and sustainability. This trend was evident throughout Hall 5.2, highlighted by the extensive mix of exhibitors and the accompanying fringe program focused on eco-innovation and smart sleep, reinforcing the fair as an important business platform for the advancing industry.

Speaking on the final day, Ms Wilmet Shea, General Manager of Messe Frankfurt (HK) Ltd, said: “The visitor flow throughout the hall clearly demonstrated the strong demand and recovery within the Chinese home textile market, with many exhibitors reporting high-quality leads. Notably, there was a significant increase in overseas visitors, highlighting the event's growing international appeal. We observed various trends, but prominent themes were sustainability and smart bedding solutions, as more exhibitors are increasingly incorporating technology and eco-friendly practices into their materials and production processes. Overall, the comprehensive selection of products catered to the varied interests of buyers across the industry.”

Eco-consciousness has evolved from being just a nice-to-have to becoming an essential aspect in the home textiles market. In the bedding sector, this has led to a growing emphasis on organic, reusable, and recyclable materials that are free from hazardous chemicals. Throughout the three-day fair, the fairground was abuzz with products that offered both comfort and environmental responsibility.

From smart bedding, featuring temperature regulation and antibacterial technologies, to sustainable home textiles using biodegradable and organic materials, exhibitors showcased a diverse collection of solutions designed to elevate the modern home. Particularly notable was CoolisT Life Technology Co Ltd, which displayed bio-based biodegradable sponges, including Zero Foam and Hydrophilic Foam. Renowned buying brands, including Sainsbury’s, Americana International, Li & Fung, and many more, proactively pursued technological innovations, sustainable solutions, and high-end products to better meet the demands of consumers.

The fringe programme also played a key role in driving industry dialogue around eco-consciousness and innovation. The Green and Low Carbon Forum explored sustainable textiles for bedrooms and homes, while the Sleeping Aid Summit 2025 discussed the integration of smart home technologies into bedding. Another event in the spotlight was Timeless and Transformative Colour: Celebrating the Rich Diversity of Modern Living for 2026, held by the Pantone Color Institute. At this event, participants discovered the vibrant colour palettes for home interiors that are expected to be popular trends in 2026.

Archroma, a global leader in specialty chemicals towards sustainable solutions, has taken sustainable and cost-effective cellulosic dyeing to the next level with the introduction of AVITERA® RASPBERRY SE.

Extending the AVITERA® SE GEN NEXT platform color of deep shades, the IP-protected brilliant trichromatic red empowers mills to achieve rich, dark and extra-dark shades while meeting the stringent fastness and sustainability requirements of leading brands and retailers. The newest element also offers significantly lower processing costs, with focus on reducing the recipe cost together with reliable right-first-time performance as well, “AVITERA® SE revolutionized the dyeing of cellulosic fibers and blends when it was introduced 15 years ago – setting a new benchmark with state-of-the-art application and fastness performance and advanced sustainability,” Dhirendra Gautam, VP Marketing, Archroma said.

“Our goal was always to offer a full range of attractive colors without limits. With AVITERA® SE RASPBERRY SE as our new trichromatic red, we are now enabling fashion and textile companies to produce differentiated end articles in consistent and long-lasting dark and extra-dark shades with the same cost-competitiveness as in pale and medium shades. This is another major step forward on our PLANET CONSCIOUS+ journey to economic and environmental sustainability for our industry,” he continued.

Substantial Savings on Challenging Dark Shades
Dyeing darker shades – such as black, navy and especially red – has traditionally been more challenging and costly than dyeing lighter colors. Achieving a deep, uniform color requires higher dye concentrations and more water and energy, and often also demands additional steps or re-dyeing. Dark shades, particularly red, also tend to fade more quickly than light colors, especially when exposed to sunlight and repeated home laundering.

With high-speed low-temperature wash-off, high process reliability and excellent reproducibility on dark and ultra-dark shades, the AVITERA® SE GENERATION NEXT dyestuffs allow mills to achieve water and energy savings of up to 50% compared to best available technology, and to slash CO2 emissions and effluent discharge by up to 50% as well. They can also increase mill output by up to 25% or more.