From the Sector

• 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.

Launched this September, the new Horizon Europe project CISUTAC will support the transition to a circular and sustainable textile sector. As part of a consortium of 27 partners working on the project, TEXAID will among others support the project with sorting, disassembly and repair trials.

The production and consumption of textile products continue to grow, together with their impact on the environment, due to a lack of reuse, repair and recycling of materials. Quality, durability, and recyclability are often not being set as priorities in the design and manufacturing of clothing (EU Strategy for Sustainable and Circular Textiles, March 2022).  

CISUTAC aims to remove current bottlenecks in order to increase textile circularity in Europe. The objective is to minimise the sector’s total environmental impact by developing sustainable, novel, and inclusive large-scale European value chains.  

The project will cover most parts of the textile sector by working on two material groups representing almost 90% of all textile fibre materials (polyester, and cotton/cellulosic fibres), and focusing on products from three sub-sectors experiencing varying circularity bottlenecks (fashion garments, sports and outdoor goods, and workwear).  

CISUTAC will follow a holistic approach covering the technical, sectoral and socio-economic aspects, and will perform three pilots to demonstrate the feasibility and value of:

• Repair and disassembly
• Sorting (for reuse and recycling)
• Circular garments through fibre-to-fibre recycling and design for circularity

To realise these pilots, the consortium partners will:

• Develop semi-automated workstations
• Analyse the infrastructure and material flows
• Digitally enhance sorting operations (for reuse and recycling)
• Raise awareness among the consumers and the textile industry

As part of the CISUTAC consortium, TEXAID, will conduct different trials of sorting, repair, and disassembly, and be active in the LCA and Standardisation work packages.

• Lenzing has been awarded the highest CSR rating from EcoVadis for the second consecutive time
• Global rating standard evaluates 90,000 companies: Lenzing among top 1 percent of its industry
• enzing joins the UN Global Compact sustainability initiative

Lenzing Group has been awarded platinum status in the CSR rating from EcoVadis. This comprehensive assessment covers the four key practices of corporate social responsibility: the environment, fair working conditions and human rights, ethics and sustainable procurement.

This is the second time that EcoVadis, a leading international provider of sustainability ratings for businesses, has awarded platinum status to Lenzing for its sustainability performance. As a result, Lenzing ranks among the world’s top 1 percent of companies in its sector that are rated by EcoVadis.

In line with its “Naturally positive” sustainability strategy, the Lenzing Group has set ambitious targets in each of its core strategic areas, aimed at bolstering its capacity to move from a linear to a circular model. Lenzing reports the corresponding implementation measures and the progress it has made in its annual sustainability report. This high level of accountability and transparency was particularly praised in the assessment by EcoVadis. The rating provider also highlighted Lenzing’s comprehensive measures to reduce air pollution, wastewater and greenhouse gases, in addition to its provision of skills development training and health care programs for staff members.

Partnerships for systemic change
Lenzing forges strategic partnerships with various stakeholders to meet its ambitious climate and sustainability targets and drive forward systemic change in the textile and nonwoven industries. This is why Lenzing, as one of 15,000 companies worldwide, joined the United Nations Global Compact. As a member, Lenzing is committed to upholding human rights, respecting the rights of employees and their representatives, protecting the environment, enabling fair competition and combating corruption.

SHIMA SEIKI announces a sales promotion package for the apparel industry together with KDDI, Linking 3D fashion design with cross-reality― realizing digital catalogs, VR showrooms and new customer experience allowing 360-degree viewing without actual samples

Leading fashion technologist SHIMA SEIKI MFG., LTD. of Wakayama, Japan together with telecommunications company KDDI Corporation of Tokyo, Japan launched "XR Mannequin for APEXFiz," a sales promotion package that links SHIMA SEIKI's APEXFiz design software for the apparel industry with KDDI's XR (cross-reality) technology.

XR Mannequin for APEXFiz will be offered to the apparel industry. Using an XR Mannequin that enables viewers to check product images from any angle in 360 degrees on various devices, XR Mannequin for APEXFiz enables digital catalogues with 3D virtual sample image data of garments designed on APEXFiz design software, 360-degree VR showrooms, as well as digitally extended stores. It also realizes virtual proposals at exhibitions, showroom-style stores with no inventory, and user-friendly purchase experience on e-commerce sites, and more. It also allows users to reduce excess stock at stores and create new sales opportunities.

Eventually, by adding movement to models wearing Virtual Samples and rendering them on a cloud server, customers will be able to view high-resolution virtual fashion shows on their smartphones and other devices.

 Until now, the apparel industry has been making actual product samples in each of the planning and design stages of production. This process not only takes an enormous amount of time and cost, but generates waste of raw materials including fabric that require disposal. At the retail stage, stores also needed to have various sizes and colors in stock to address a wide range of customer preferences, resulting in excess inventory.

With SHIMA SEIKI's APEXFiz, designs can be evaluated without making actual samples, minimizing resources spent on sample production as well as lead time, enabling environmentally-friendly manufacturing.

In May 2022, KDDI developed a high-resolution XR mannequin for apparel sales, with support from Google Cloud. It enables various devices such as store signages and smartphones to check products from any angle in 360 degrees, enabling stores to sell products without maintaining inventory.

SHIMA SEIKI and KDDI combines APEXFiz and XR Mannequin to start providing XR Mannequin for APEXFiz. This brings DX solutions to all stages in the supply chain for the apparel industry, from planning and design to sample making, production, distribution, and retail sales. SHIMA SEIKI and KDDI will continue to create services together that link each other's products, to bring about a sustainable society by reducing excess stock, and providing a customer experience that gives peace of mind when purchasing products.

• First product development centre in Germany

ISKO has opened its second product development centre, based in Stade, Lower Saxony, following the success of the Creative Room London in the UK which had its opening earlier this year.

Creative Room Germany is a innovative space and the first of its kind in Germany. It is the latest initiative of Creative Room Services (CRS), a division of ISKO devoted to offering streamlined and simplified solutions for all denim requirements – from fabric to finished garment.

With a focus on sustainable washing and finishing techniques, customers of Creative Room Germany will be able to work in parallel with ISKO’s experts to achieve their desired denim looks. Together with machine technology partner Jeanologia, they have been able to develop innovative washing and finishing techniques that meet the highest quality and sustainability standards with a significantly lower environmental impact. Creative Room Germany will also be the central point for its customers full product development, ensuring the whole process is agile and more efficient.

By utilising ISKO’s patented recycling technology, they are now able to develop brand new garments by using fibres from post-consumer denim, finally closing the loop and giving a new and cutting-edge circular supply solution for their customers. As well as a hub for its customers, Creative Room Germany will also act as a platform for the wider denim community to share knowledge, create new and innovative ideas and to bring them to life.

“Building on from the success of our London facility, our goal will be to offer tailor made garment supply solutions for customers in the DACH, Benelux and Nordic markets and this facility will be the focal point of that offering. With a collaborative approach, we will fulfil our vision of bringing a new circular supply solution to the market.”
Pau Bruguera, Executive Director @ ISKO

The substance graphene can become increasingly important as a component in textile catalysts when purifying water from textile dyeing as has been shown in a recently completed doctoral project at the University of Borås.

In his project, Milad Asadi, a new doctor in Textile Technology, has modified conventional yarn by encapsulating iron particles in graphene and developed a multifunctional smart e-textile. The focus was on developing a method for purifying wastewater from textile dyeing. The smart e-textile acts as a catalyst that causes the substance hydrogen peroxide to be formed, which is needed in order to break down pollutants in wastewater.

The project has generated a complete textile reactor for the treatment of wastewater through the so-called electro-Fenton technology, which is mainly used industrially to purify wastewater. The novelty of the technology is to use the properties of both graphene and iron, which is the main catalyst.

“Previous research has mainly been about the treatment of wastewater by using chemicals to break down the textile dyes. My project is the first where graphene, which is electrically conductive, is used to encapsulate iron. The e-textile can also be used several times, unlike when chemicals are used and which are then rinsed off. The challenge in the project was to scale up the technology so that the treated yarn can be fed into automatic knitting machines”, explained Milad Asadi.

The e-textile catalyst can be reused and hydrogen peroxide is formed internally inside the reactor, which reduces the use of biological catalysts, making the technology more sustainable compared to chemical methods.

• Monomaterial solution contains renewably-sourced polypropylene from the Bornewables™ portfolio of circular polyolefins
• Trexel employs its proprietary MuCell® technology to deliver a range of lightweighting benefits
• EverMinds™ in action: reuse and design for recycling are focus of value chain collaboration

Borealis and Trexel, an expert in foaming injection and blow moulded parts, announce that they have co-developed a new plastic bottle based on a grade from the Bornewables™ portfolio of polyolefins made using renewable feedstocks derived 100% from waste and residue streams. The lightweight bottle – which will be showcased at the Borealis stand at the K 2022 (from 19 to 26 October 2022 in Düsseldorf) – is reusable and fully recyclable. It boasts a significantly lower overall CO₂ footprint because it is composed of renewably-sourced feedstock and produced in the foaming process.

The Bornewables™ portfolio of circular polyolefins helps reduce the carbon footprint while offering material performance equal to virgin polymers. Using Bornewables grades allows for design freedom and colour flexibility, and helps retain a premium look and feel. The grades – which are commercially available in Europe – help conserve natural resources because they are derived solely from waste and residue streams, for example from used cooking oil. Reusing waste already in circulation instead of fossil fuel-based feedstocks enhances the sustainability of applications made using the Bornewables grades.

The reusable new bottle developed by Borealis and Trexel retains its value over many life cycles thanks to the use of Trexel’s proprietary technology in tandem with Bornewables grades; as a material solution, the new bottle minimises the use of valuable raw materials. Moreover, converters consume less energy in the production process when using the MuCell® technology. The bottle thus helps close the loop on plastics circularity by way of design for recycling, the use of renewable feedstocks, and excellent material performance across multiple life cycles.

• 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/.

• Aims to tackle the immense textile waste generated in urban environments, on the back of import bans of waste materials
• Addresses the shortcomings of current textile recycling technologies, which are unsuitable for urban settings due to the use of heavy chemicals
• Technologies developed by the newly-formed RGE-NTU Sustainable Textile Research Centre will be test-bedded in RGE’s pilot urban-fit textile recycling plant, projected for completion as early as 2024

Royal Golden Eagle (“RGE”), a global group of resource-based manufacturing companies, which includes a world-leading viscose fibre producers Sateri and Asia Pacific Rayon (APR), is developing urban-fit, closed-loop textile-to-textile recycling solutions, through the newly-formed RGE-NTU Sustainable Textile Research Centre (RGE-NTU SusTex). This is a five-year research collaboration between RGE and Nanyang Technological University, Singapore (“NTU”), to accelerate innovation in textile recycling that can be deployed in urban settings. The research centre will develop new technologies to recycle textile waste into fibre and create new, next-generation eco-friendly and sustainable textiles.

This move comes on the back of the tightening of waste import bans in countries such as China, India and Indonesia, which are among the world’s largest waste processors. The stricter import bans have left cities in need of viable local textile recycling solutions to tackle the immense textile waste generated.

RGE Executive Director, Mr Perry Lim, said, “Current textile recycling technologies, which rely primarily on a bleaching and separation process using heavy chemicals, cannot be implemented due to environmental laws. At the same time, there is an urgent need to keep textiles out of the brimming landfills.” He added, “As the world’s largest viscose producer, we aim to catalyse closed-loop, textile-to-textile recycling by developing optimal urban-fit solutions that can bring the world closer to a circular textile economy.”

Globally, an estimated 90 million tonnes of textile waste is generated and disposed of every year, with less than 1% being upcycled into new clothing or other textile materials. By 2030, the amount of global textile waste, which currently accounts for almost 10% of municipal solid waste, is expected to reach more than 134 million tonnes. The textile industry is also responsible for 10% of global greenhouse gas emissions – more than international flights and maritime shipping combined.

At present, most of the available textile recycling technologies are open-loop, where textile waste is typically downcycled to lower-quality products (insulating materials, cleaning cloths, etc.) or be used in waste-to-heat recycling.

“Closed-loop textile-to-textile recycling processes, particularly chemical recycling, are still under development. Scaling up the technologies to industrial scale remains a challenge. A key bottleneck is that refabricating textile waste into fibre needs purity standards for feedstock. However, most of the clothes that we wear are made of a mixture of different synthetic and natural fibres, which makes separating the complex blends of materials challenging for effective recycling.

“Our aim is to address this industry pain point by developing viable solutions that use less energy, fewer chemicals and produces harmless and less effluents, and then potentially scale up across our global operations,” Mr Lim said.

To tackle the key challenges in closed-loop textile recycling, RGE-NTU SusTex is looking into four key research areas, namely cleaner and more energy efficient methods of recycling into new raw materials, automated sorting of textile waste, eco-friendly dye removal, and development of a new class of sustainable textiles that is durable for wear and, at the same time, lends itself to easier recycling.

Technologies developed by RGE-NTU SusTex will be test bedded at RGE’s pilot urban-fit textile recycling plant in Singapore, which is projected for completion as early as 2024. If successful, RGE has plans to replicate the plant in other urban cities within its footprint.

• Innovations in Recycling and Sustainability: Sustainable Diaper Components, Natural Fibers, and Kitty Litter from Recycled Nappies

INDA, the Association of the Nonwoven Fabrics Industry, announced the three finalists that will present their innovative material science solutions as they compete for the prestigious RISE® Innovation Award during the 12th edition of the Research, Innovation & Science for Engineered Fabrics Conference (RISE®) to be held in person September 27-28, 2022 at North Carolina State University.  The award recognizes novel innovations within and on the periphery of the nonwovens industry that creatively use next-level science and engineering principles to solve material challenges and expand the usage of nonwovens and engineered fabrics.

Finalists for the 2022 RISE® Innovation Award:
Cat Litter Made from Recycled Nappies – DiaperRecycle
DiaperRecycle has developed technology to recycle used diapers into cat litter. The aim of the company is to make an environmental impact and decrease the climate changing emissions of diaper waste. They’re diverting used diapers (used in households and businesses such as elder care) from landfill, separating the plastic and fiber and making cat litter. The plastic is prepared for recycling by plastics recyclers. The cat litter product is made by DiaperRecycle from the super absorbent fiber of diapers; it’s highly absorbent and flushable.

Biodegradable Diaper Components – Gottlieb Binder GmbH & Co. KG
Together, Avgol and Binder take on the challenge of disposable absorbent articles for the good of future generations and came up with sustainable diaper components. The technologies used are based on biotransformation technology, which makes it possible to achieve more sustainable products by supporting recycling and providing an alternative route for non-recyclable/fugitive waste management.

sero® hemp fibers – Bast Fibre Technologies, Inc.
Bast Fibre Technologies’ sero® hemp fibers offer the nonwoven industry an all-natural substitute for plastic fibers. From dedicated European- and US-based production facilities, BFT transforms raw bast fibers into premium natural fibers for applications ranging from single-use and durable wipes to industrial applications. Suitable for minority or majority blends, sero® hemp combines easily with standard nonwoven fibers to produce fabrics that meet the industry requirements for strength, uniformity, and processing efficiency.

RISE® conference attendees, technology scouts and product developers in the nonwoven/engineered fabrics industry seeking new developments to advance their businesses, will electronically vote for the recipient of the 2022 RISE® Innovation Award. The winner will be announced Wed., Sept. 28^th.

Technical experts on INDA’s Technical Advisory Board selected three finalists from among 12 nominations.  The 22-member board of technical professionals is represented by companies such as Absorbent Hygiene Insights LLC, Attindas Hygiene Partners, Berry Global, Cotton Incorporated, Crown Abbey, LLC, The DAK Group, Fi-Tech, Inc. Freudenberg Performance Materials, Glatfelter Sontara Old Hickory, Inc., Lenzing Fibers, Inc., Natureworks LLC, Nice-Pak Products, Inc./PDI, Nonwovens by Design, Norafin (Americas) Inc., The Nonwovens Institute at North Carolina State University, Poccia Consulting, LLC, The Procter & Gamble Company, RKW North America, Inc., Rockline Industries, Smith, Johnson & Associates, Suominen Corporation, and Texas Tech University.

“The RISE Conference recognizes and promotes innovation across the nonwoven and engineered material industry. Technology leaders will share invaluable information on innovative new approaches and concepts to resolve material science challenges. For any technical leader, technology scout or new product innovator, RISE is an event not to be missed,” said Tony Fragnito, INDA’s President.

The conference program will cover relevant and timely topics including: Creating a Circular Industry, Advancements in Sustainable Inputs in PLA, Developments in Natural Fibers I and II, Sustainable Inputs in Fibers and Biofibers, Sustainable Inputs from Waste Products, and Economic Insights and Market Intelligence.