From the Sector

Following the successful commissioning of two new Monforts Montex wide-width stenter lines and additional environmental management equipment at its plant in Germany, GtA – Society for Textile Equipment GmbH – is aiming to be the first textile finishing company to become entirely CO2-neutral in the manufacture of all of its products by 2025.

GtA is a partner company to Germany’s large-format digital printing fabric leader, Georg and Otto Friedrich GmbH, which has has this year been able to considerably expand its portfolio due to the new Monforts lines.

Headquartered in Gross-Zimmern, close to Frankfurt, Georg and Otto Friedrich GmbH and its partners in Germany have an annual production of 37 million square metres of warp knits for a range of end-use applications, including garments, automotive interiors and technical textiles, but increasingly with a concentration on digital printing substrates.

Fault-free textiles

A new standard in pure white, 100% clean and fault-free textile substrates has been demanded by this market in recent years due to the rapid growth in digitally-printed banners and billboards – often referred to as ‘soft signage’.

The substrates of choice for digital printing are 100% polyester warp knits which are resilient and allow excellent take-up of inks, and vibrant colours and clear and precise images to be achieved with digital printing techniques. The knitted construction also has the advantage of elasticity, which is a plus in terms of flexibility for installers.

Critically, the warp knitted fabrics have extremely smooth surfaces which is becoming increasingly important due to the general move away from PVC coatings which were the standard in the past.

It was to finish these fabrics for Georg and Otto Friedrich GmbH as well as providing such services for many other customers, that the GtA plant in Neresheim, Baden-Württemberg, was established in 2015.

The purpose-built plant on a greenfield site was initially equipped with a fully-automated, 72 metre long Monforts installation comprising a washing machine integrated with a 3.6 metre wide, seven-chamber Montex stenter. The line quickly went from single to double shift production and then to 24/7 operation  to meet demand.

Expanded widths

Building on the success of this installation, GtA has now installed two more Montex stenter lines – both in expanded working widths of 5.6 metres and purpose-built at Montex GmbH in Austria.

A six-chamber Montex unit is combined with a washing machine to guarantee the purity of the substrates, while a five-chamber line is integrated with a wide-width coating machine. This new coating capability at GtA has led to a number of new additions to the Georg and Otto Friedrich DecoTex range for digital printing, including wide width fabrics with flame retardant, antimicrobial and non-slip finishes.

The new Montex stenter lines benefit from all of the latest innovations from Monforts, including the Smart Sensor system for the optimised maintenance planning of key mechanical wear components on the stenters. A comprehensive overview of the condition of all parts at any time is now available for operators within the highly intuitive Qualitex visualization software.

With Qualitex, all article-specific settings can be stored and the formulations for thousands of treatment processes called up again at any time. Individual operators can also personalise their dashboards with the most important machine functions and process parameters.

Environmental commitment

GtA is run by a seasoned team of textile professionals led by Managing Director Andreas Niess.

“We have received excellent service from Monforts from the outset and we were happy to place the order for these two new lines as part of our ongoing cooperation,” he says. “With all of the latest Monforts advances in technology we are fully in control of all production and quality parameters with these lines, as part of our significant commitment to innovative environmental technology.”

The GtA plant, which operates in near-cleanroom conditions, has also been equipped with proprietary technology to fully exploit the Monforts air-to-air heat recovery systems that are now standard with Montex stenters.

“Around 30 per cent of our investment volume at the site goes to energy-saving measures and we are sure that this commitment is worthwhile,” Mr Niess says. “As an example, our integrated heat recovery system fully exploits the waste heat from the process exhaust air and the burner exhaust gases of the Monforts stenters, allowing us to achieve an exhaust air temperature of  between 30 to 34°C, compared to what would conventionally be between 140 to 160°C. Another focus has been on exhaust air purification technology and here too, the latest technology has been installed with integrated heat recovery elements.”

This, he adds, saves 52% of the energy that would normally be used – equating to 5,800,000 KwH per year. The necessary audits for energy-efficient companies are also carried out annually.

In addition, GtA has purpose-designed the automatic chemical mixing and dosing systems that feed the padders for the key treatments that are carried out on the fabrics through the stenters.

The company is going further, however, in its pursuit of clean production and raw materials.

"We want to be an asset and not a burden on our immediate environment and therefore do not use any additives containing solvents," Mr Niess says. “We were the first to use fully halogen-free flame retardant chemistry, and we use bio-based, finely ground alumina products for the washing process instead of surfactants. PES polyester yarns made from recycled material are also increasingly used and the latest additions to our raw materials portfolio, the RC-Ocean products, are made from recycled sea plastic.

“We are now planning a combined heat and power plant for the production of electrical energy and heat and we will also build a photovoltaic system that converts solar radiation into electrical energy. GtA wants to be the first textile finishing company to be CO2-neutral in the manufacture of all of its products by 2025. The complete heat supply and heating for the 13,000 square metre production hall, as well as the office building and the hot water supply for the domestic water, is already energy-neutral. We are convinced that this commitment will pay off in the long term and our positive business development proves that sustainability and business profitability are perfectly compatible.”

In addition to the products for Georg and Otto Friedrich GmbH, GtA  offers its manufacturing capacities for other customers as a contract service.

All products are manufactured in accordance with Öko-Tex Standard 100, product class 1 and the company is also involved in the research and development of new sustainable manufacturing processes, in cooperation with many regional universities and funding project partners.

Focus on Sustainability and Climate Change

Passion for Cotton: The 35th International Cotton Conference Bremen starts on 25 March in the Hanseatic city’s historic Town Hall. But before subject-specific questions are discussed in depth in the individual sessions, the concise and inspiring keynotes by leading business experts from science and industry will draw attention to the current trends and challenges in the industry at the start of the conference. A large part of the presentations is shaped by the current discussion on environmental and sustainability issues and the resulting consequences for the global economy.

Climate Change and Sustainability

“Climate change - a storm in a teacup?” asks Kai Hughes, Executive Director of the International Cotton Advisory Committee, Washington D.C., USA, in a provocative speech. The aim of his presentation is to work out the challenges of climate change especially for agriculture and cotton production. This should form the basis for later discussion on concrete approaches and solutions within the cotton community.

With his lecture “The HUGO BOSS sustainability programme ... and what our customer has to do with it” Andreas Streubig, Director of Global Sustainability at Hugo Boss AG, Metzingen, Germany, rolls up the textile value chain from a different angle, starting at the consumer level. As a representative of a premium brand for women's and men's clothing, Streubig discusses sustainability as a strategic element of the corporate strategy and provides information on how elements of the strategy are being implemented at Hugo Boss.

Rüdiger Senft, Head of Sustainability at Commerzbank, Frankfurt am Main, Germany, looks at the changing role of banks in financing the cotton market. In addition to a general introduction to the topic of sustainability and banking regulation, Senft's presentation deals with the financing of the cotton trade from a social and ecological point of view.
The opening session on 25 March is hosted by Bill Ballenden, founder and owner of Dragontree, Swindon, UK, an online auction platform for the cotton trade. As a former cotton manager for Louis Dreyfus in Europe and Asia, Bill Ballenden has many years of experience in the industry.

Cross-Cutting Issues: Digitalisation, Gender, Value Chains

The subsequent session in the conference programme with the headline “A Wider View” is devoted to currently defining trends and important cross-cutting issues in the industry. This goes far beyond classic cotton themes.

A lecture by Mark Messura, Senior Vice President, Global Supply Chain Marketing for Cotton Incorporated, Cary, North Carolina, deals with the role of cotton in an increasingly digitally controlled supply chain. Significant keywords here are faster delivery times, vertical integration, transparency and traceability.

The presentation by Roger Gilmartin, Managing Director of Tri-Blend Consulting, Charlotte, USA, entitled “The secret recipe for timely, cost-optimised and high-quality cotton clothing” promises exciting and enlightening insights. Tri-Blend Consulting conducts studies on the performance of different cotton varieties during the entire consumption process to the finished yarn and evaluates them from an economic point of view.

Amy Jackson, from the Better Cotton Initiative, London, UK, presents ICA Liverpool's “Women in Cotton” initiative. With this commitment, the initiative aims to increase the influence of women in the cotton industry and give them a stronger voice, for example by building networks in cooperation.

Navdeep Singh Sodhi, International Strategic Management Consultant at the Gherzi Textile Organisation, Switzerland, gives an insight into the current development of the value chain for cotton, textiles and clothing in Africa. Looking ahead to the coming decades, also in view of population growth, Africa is seen as having a high potential for building economic structures to improve income and prosperity.

Thomas Schneider, Professor at the University of Applied Sciences in Berlin and active in the field of production planning and control, textile materials and materials testing will host the session. A leading light in his field, Thomas Schneider has more than 30 years of experience in scientific and application-oriented research in the textile and fibre sector, including at the Fibre Institute Bremen e.V.

After an intense dialogue and a series of meetings during the past year between the ZDHC Board of Directors and the GCIRT, an alignment was gained on ZDHC organisational commitments and a mutual understanding of the role of chemical suppliers within the ZDHC Programme. This opens the doors for broader, more active distribution of chemistry expertise and implementation support of textile dye and leather chemical manufacturing industry in the ZDHC Programme.

The Global Chemical Industry Round Table (GCIRT), sent an open letter to ZDHC in May 2018 and is a group of the leading chemical solution providers in the textile and leather industry with the collective aim of driving the industry further to become more sustainable. GCIRT’s signatory’s engagement into the ZDHC Programme will support a faster transformation of the industry by taking complexity out of the supply chain and to find appropriate solutions for the industries’ requirements.

The GCIRT members are: ARCHROMA (Switzerland); CHT Germany GmbH (Germany); Colourtex Industries Private Limited (India); DyStar Singapore Pte Ltd (Singapore); Huntsman Textile Effects (Singapore); KISCO (Korea); Pulcra Chemicals Group (Germany); RUDOLF GmbH (Germany); TANATEX Chemicals B.V. (Netherlands).

• GS1 Germany verleiht auf der Log 2019 Lean and Green Awards und Stars. Unter anderem wird erstmalig der Lean and Green 2nd Star überreicht.

Mindestens 20 Prozent weniger CO2-Austoß in fünf Jahren lautet das Ziel der Lean and Green Initiative. Sie zertifiziert ökologisches Verantwortungsbewusstsein mit konkretem Bezug zu Lager- und Logistikprozessen. Zahlreiche Unternehmen wurden innerhalb dieser Initiative bereits für ihr erfolgreiches Engagement mit den Lean and Green Auszeichnungen geehrt. Am 26. März 2019 vergab GS1 Germany an weitere Unternehmen aus Industrie, Handel und Logistik die Lean and Green Stars sowie Awards, die sich nach dem Grad der Umsetzung staffeln. Auf der Logistik-Nacht in Köln erhielt Chep als erstes Unternehmen in Deutschland den „Lean and Green 2nd Star“. Der „Lean and Green 1st Star“ ging an Mars sowie die Spedition Adam Serr, und den „Lean and Green Award“ gab es für das BTK Befrachtungs- und Transportkontor sowie den Anbieter von Premium-Feinfisch Gottfried Friedrichs. Die Logistik-Nacht fand in „Halle Tor 2“ im Rahmen des 25. Handelslogistik Kongress Log 2019 statt.

Pedex GmbH, the Wald Michelbach based Perlon Group company was named as a finalist of the ‘Großer Preis des Mittelstandes 2018’ (award for small and medium sized companies) at the gala dinner on 15th September 2018. Together with 21 other finalists from the four competing regions Baden Wurtemberg, Bavaria, Hesse and Thuringia came out on top against 2436 nominated businesses.

The motto for this year’s competition -‘Building for the future’ – is the foundation of the unity within our society.
On 24th May, the Oskar-Patzelt-Stiftung, the founder of this award for small and medium sized companies asked for nominations of excellent medium sized companies for the competition, (nominations cannot come from the company itself.) Only 1 in every 1000 German companies make it onto the list of nominations – this year Pedex GmbH made it! The prize winners meet 12 regional juries and a final jury. The focus of the jury (made up of representatives from business and education) is on the company as a whole and its multifaceted role within society. To aid evaluation, the jury asked about the establishment and safeguarding of jobs and apprenticeships, innovation and modernisation, involvement in the local area as well as service and proximity to customers.

Germany’s most sought after business accolade.
In 2018, more than 7400 institutions from the 16 counties (12 competing regions) throughout Germany nominated a total of 4,917 small and medium sized companies as well as banks and local authorities for the competition, from which a short list of 742 was selected. No other business award in Germany carries such weight (and has now for more than two decades) as the one that the Leipzig based Oskar-Patzelt-Stiftung has been awarding since 1994. The prize doesn’t offer any monetary reward. For the businesses involved, it’s simply about honour, public recognition and approval of their performance, without financial incentive.

• Successful acquisition of Austrian plastics recycling company Ecoplast Kunststoffrecycling GmbH

Borealis, a leading provider of innovative solutions in the fields of polyolefins, base chemicals and fertilizers, announces today that it has fully acquired the Austrian plastics recycler Ecoplast Kunststoffrecycling GmbH (“Ecoplast”). Based in Wildon, Austria, Ecoplast processes around 35,000 tonnes of post-consumer plastic waste from households and industrial consumers every year, turning them into high-quality LDPE and HDPE recyclates, primarily but not exclusively for the plastic film market.

The expectation of Borealis is that the recycled PO market will grow substantially by 2021, which is the strategic rationale behind the acquisition. The company has made PO recycling a key element of its overall PO strategy because of its potential to support both growth and sustainability. Borealis has been an industry frontrunner in making polyolefins more circular. In 2014, it began offering high-end compound solutions to the automotive industry, consisting of 25% and 50% post-consumer recycled content. Borealis was also the first virgin PO producer to explore the possibilities of mechanical recycling, by acquiring one of Europe's largest producers of post-consumer polyolefin recyclates - mtm plastics GmbH and mtm compact GmbH – in July 2016. Since then it has continued to invest into the development of technology and new products in the area of circular polyolefins.

“Borealis recognises the increasing need for plastic recycling and sees the Circular Economy as a business opportunity. Borealis already has a long-term collaboration with Ecoplast and this acquisition is the next logical step in building our mechanical recycling capabilities. As an important complement to mtm in Germany, Ecoplast will help us address critical sustainability challenges and become a polyolefin recycling leader. Eventually, we want to use our experience to develop an effective blueprint for the end-of-use phases for plastics that can be applied in other parts of the world,” says Borealis Chief Executive Alfred Stern.

“We are very happy that the transaction with a strong and reliable partner such as Borealis has been successfully concluded and are looking forward to our common future activities on the recycling market. We have located potential synergies in many operative and strategic areas, especially in product quality R&D and future applications of polyethylene-film-recyclates. The combination of Ecoplast and Borealis holds the potential to be groundbreaking for the market,” says Ecoplast’s Managing Director Lukas Intemann.

• GS1 Germany, PwC und rheingold institut entwickeln sieben Szenarien für die Konsumgüterbranche im Jahr 2025
• Erstes Szenario fokussiert zukünftiges Einkaufsverhalten: immer, alles, sofort, bequem, preiswert, State of the Art
• Lösungswege und Handlungsempfehlungen für Unternehmen

Das Jahr 2025: digitale Sprachassistenten, selbstfahrende Autos, das Ende traditioneller Einkaufszeiten. Omni-Channel ist Standard und künstliche Intelligenz im Alltag der Verbraucher angekommen. Shopping 4.0 passiert überall und zu jeder Zeit. „Unternehmen der Konsumgüterwirtschaft stehen vor der Herausforderung, sich in wenigen Jahren grundlegend zu transformieren“, sagt Studienleiter Klaus Vogel, Innovationsmanager bei GS1 Germany. „Der Kunde mit seinem steigenden Bedürfnis nach individuellem und gleichzeitig einfachen, schnellen Einkaufen steht so stark wie nie zuvor im Mittelpunkt der Entwicklungen. Wem es nicht gelingt, ihn mit seinen Produkten, Angeboten und Services zu überzeugen, verliert.“ Doch wie genau sieht das Einkaufsverhalten der Zukunft aus? Und wie können Unternehmen sich auf die Herausforderungen einstellen? Das beleuchten GS1 Germany, die Wirtschaftsprüfungs- und Beratungsgesellschaft PwC und das rheingold institut im ersten von insgesamt sieben Teilen der gemeinsamen Zukunftsstudie „2025: Smart Value Networks“.

Shoppertypen adé
„Der Shopper der Zukunft ist sich seiner Möglichkeiten bewusst und hat hohe Ansprüche an die Unternehmen seiner Wahl“, sagt Sebastian Buggert, Mitglied der Geschäftsführung und CIO am rheingold institut. „Treiber für diese Entwicklung sind vor allem komplexe Wechselwirkungen zwischen technologischen und gesellschaftlichen Entwicklungen sowie die daraus resultierenden Erwartungen der Menschen.“ So wünscht sich der Verbraucher der Zukunft auf der einen Seite Individualität, Orientierung und Sicherheit in einer hochkomplexen und digitalisierten Welt. Denn die Produkt- und Preisvielfalt sowie die Daten- und Informationsflut verstärken das Gefühl von Unübersichtlichkeit und Intransparenz. Auf der anderen Seite steht der Wunsch nach größtmöglicher Freiheit und einem preiswerten, einfachen Einkauf zu jeder Zeit und über jeden beliebigen Kanal. Um Einkäufe schnell und agil zu tätigen, werden zukünftig intuitiv bedienbare Anwendungen wie persönliche Assistenzsysteme zum Einsatz kommen. Digitale Plattformen sorgen gleichzeitig rund um die Uhr für einen komfortablen Zugang zu einer Vielzahl von Lieferanten und Marken mit einheitlichem Qualitätsversprechen und einfachen Zahlungsabläufen. Bestellungen per digitalem Sprachassistenten im selbstfahrenden Auto auf dem Weg zur Arbeit werden so schon bald keine Vision mehr sein, sondern Shoppingalltag.

Die neuen Möglichkeiten des Verbrauchers stellen Unternehmen vor große Herausforderungen: „Die klassischen Shoppertypen wird es zukünftig nicht mehr geben. Der Kunde agiert situativ. Die Kunst für Unternehmen wird also vor allem darin bestehen, sich flexibel auf die situativen Bedürfnisse der Shopper einzustellen“, erklärt Dr. Stephanie Rumpff, Head of Industry Development bei PwC Europe. Shopping 4.0 steht darum für einen Markt, der hochgradig durch Nachfrage getrieben ist. Kunden möchten kaufen, was sie wollen – nicht das, was angeboten wird.

Kein Vertrauen, kein Kunde
Ein weiterer Erfolgsfaktor für Unternehmen liegt in ihrer Vertrauenswürdigkeit – auch in Zukunft eine essentielle Grundlage für die Kundenbindung. Eine starke Vertrauensbasis schaffen Unternehmen unter anderem durch technischen Schutz der Kundendaten, die Sicherheit der eigenen Systeme und ein hohes Maß an Transparenz. Verliert ein Kunde sein Vertrauen, verliert das Unternehmen seinen Kunden. Und der Wettbewerber ist nur einen Klick entfernt. „Das Jahr 2025 beschreibt eine neue Ära der Kundenorientierung“, so Vogell. „Nur Unternehmen, die sich konsequent auf das veränderte Shopperverhalten einstellen und neue Lösungen integrieren, werden sich behaupten können.“ Diese Entwicklung betrifft sämtliche Unternehmensbereiche – von der Unternehmenskultur über die Organisation bis hin zu eingesetzten Technologien. Entscheidend ist ein gemeinsames Verständnis für die neue Einkaufswelt, in der Online und Offline miteinander verschmolzen sind. Zugleich gilt es für die Anbieter, tradierte Denkmuster aufzulösen und Innovations- und Digitalkompetenzen ihrer Mitarbeiter zu fördern. Auch wird die Einbindung von künstlicher Intelligenz im Zusammenspiel mit dem Personal wettbewerbsrelevant sein. Gelingt den Unternehmen diese anspruchsvolle Transformation, sind die Weichen in Richtung Zukunft gestellt.

•  Kölner Jungunternehmen startet Pilotprojekt mit Mittelstand 4.0-Kompetenzzentrum eStandards
•  Neues Geschäftsmodell soll Produkte nachhaltiger machen und Kundenbindung stärken

Köln, 9. April 2018. Der Kölner Rucksack-Hersteller Fond of, bekannt durch Marken wie Ergobag und Satch, will eine Lösung finden, um die Nutzung von Rucksäcken zu verlängern oder die verwendeten Rohstoffe nochmal neu zu nutzen. Dazu startete das Unternehmen eine Zusammenarbeit mit dem Mittelstand 4.0-Kompetenzzentrum eStandards.

„Bereits seit der Gründung in 2010 legt Fond of großen Wert auf eine verantwortungsvolle Produktion. So wird ein Großteil der für die Rucksäcke und Taschen verwendeten Stoffe aus recycelten PET-Flaschen hergestellt“, erklärt Hannes Weber, verantwortlich für Corporate Responsibility bei Fond of.
„Was geschieht aber mit Rucksäcken, die nicht mehr genutzt werden? Viele Rucksäcke landen irgendwann auf der Müllkippe oder in der Verbrennung, manche werden in passablem Zustand im Kleiderschrank oder auf dem Dachboden vergessen. Dadurch gehen wertvolle Ressourcen verloren“, so sein Kollege Julian Conrads weiter.
Eine Herausforderung, die Fond of in einem Pilotprojekt mit dem Mittelstand 4.0-Kompetenzzentrum eStandards angehen möchte.

Nachhaltiges Geschäftsmodell für bessere Kundenbeziehungen
In diesem Projekt hat Fond of sich zum Ziel gesetzt, die Lebenszeit von Rucksäcken oder den genutzten Rohstoffen zu verlängern. Dabei soll speziell auf digitale Lösungen und eStandards zurückgegriffen werden. Gemeinsam mit dem Kompetenzzentrum eStandards entwickelt Fond of ein Circular Economy Geschäftsmodell, welches dem Kunden einen zusätzlichen Mehrwert bietet und somit die Kundenbindung und -kommunikation stärkt. Mittels des Modells sollen außerdem Ressourcen effektiver eingesetzt werden.
„Unser Ziel ist es, durch das Projekt eine Weiterentwicklung unseres Geschäftsmodells zu bewirken, welche dazu führt, dass Materialien und Rohstoffe länger im Wirtschaftskreislauf gehalten werden und somit zu weiterer Wertschöpfung beitragen. Gleichzeitig entwickeln wir neue After-Sales Services und stärken die Kundenbindung“, sagt Nachhaltigkeits-Experte Hannes Weber.

Warum sollen Rucksäcke weiterleben?
„Ein Circular Economy Geschäftsmodell zu entwickeln hat viele Vorteile. Die Materialien und Rohstoffe werden im Wirtschaftskreislauf gehalten und tragen somit zu weiterer Wertschöpfung bei. Zusätzlich wird die Kommunikation über die gesamte Wertschöpfungskette hinweg optimiert und Innovationen ermöglicht“, sagt Thomas Wagner, der als Experte am Kompetenzzentrum eStandards Fond of bei dem Projekt begleitet. Fond of setzt auf die Unterstützung des Kompetenzzentrums, da die unterschiedlichen Ansätze Auswirkungen auf das Geschäftsmodell, auf die Logistik, auf die Interaktion mit dem Handel, als auch auf die Beziehung zum Kunden haben.