From the Sector

• Inspiring Interiors

Textiles are an inseparable part of the interior as they give a room atmosphere and good acoustics. But which fabric is best suited for which purpose?
This month's drapilux recommendation is drapilux 115 and is aimed at classic and modern hotels as well as offices.

• The epitome of piece dyeing: drapilux 115

Sustainable, flame retardant and a true eye-catcher – drapilux 115 combines all these features in one fabric. This decorative fabric, which resembles the material of a bedspread, has been created using an innovative yarn, part of which has been manufactured with sustainably produced fibres. The unusual look is achieved by means of a two-tone effect, as the woven material is dyed using a complex cationic/anionic process. The combination of sustainably produced fibres and flame retardancy makes drapilux 115 the quintessence of piece dyeing. Thanks to the modern colours, the fabric is very versatile.

Devan is launching a new range of bio-based fragrances, named SceNTL®. The range uses traceable raw materials and an external lab has confirmed that the bio-content of the fragrances is above 85%.

SceNTL® is a unique and wide range of encapsulated fragrances that can be integrated onto the fabric and are gradually released over time. Upon release, the fragrances appeal to the senses, promoting relaxation, wellbeing and feel-good sensations.

While synthetic fragrances are composed of synthetic, man-made ingredients, natural scents and oils are created by isolating natural aroma components from raw plant materials. This also explains why every SceNTL® batch can have a slight variation in smell. As natural conditions differ from time to time, every harvest is a little different from the previous one.

Although aromatherapy is still a young and understudied domain, recent studies have shown that essential oils can indeed have neurological effects. Linalool for example, a component found in Lavender and rosewood, is found to enhance sleep, while Limonene, a component found in the peel of citrus fruits, is clinically proven to have an uplifting effect.

At this moment, the SceNTL® range is intended for low-wash items such as mattress ticking, decorative pillows, upholstery, curtains, carpets, etc. It can also be used as a natural ‘masking scent’ for products that have a strong artificial smell caused by the production process. The company is already looking into further development of other scents and broader application use.

Archroma, a global leader in specialty chemicals towards sustainable solutions, and Jeanologia, a world leader in sustainable and efficient technology development, today announced the launch of ‘Pad-Ox G2 Cold’, a water-saving dyeing process at room temperature for casual looks.

Archroma initially introduced its eco-advanced Pad-Ox dyeing process for woven fabrics, and then used it as part of its ADVANCED DENIM concept. By combining the oxidation and fixation steps, it is possible to shorten the dyeing process and thus realize substantial resource savings in water, wastewater, cotton waste, and energy.

Over the years the company has worked with its textile manufacturers and partners to improve the Pad-Ox process, in particular woven applications such as chinos and casual wear. To achieve maximum positive impact, Archroma is using its Diresul® range of low sulfide sulfur dyes and, more recently, its innovative plant-based range of EarthColors®. A wide selection of dyes from these two ranges have received the Cradle-to-Cradle Product Innovation Institute’s Platinum Level Material Health Certification.

Meanwhile, Jeanologia has been working on the technology side, with laser and eco-finishing solutions for more than 25 years, accompanying the textile industry on their way to producing with zero discharge. In 2008, the company introduced its G2 Dynamic the first ozone treatment for continuous fabric that dramatically reduces the amount of water and chemicals used, while at the same time saving costs at the mill and eventually at the garment finishing facilities. This technology makes fabric more stable and consistent and prepares the fabric better for the use of other technologies like laser. This machinery can be used along with Pad-Ox technology to help cleaning fabric thus improve fastness results. While it allows process to work at room temperature.

Project focus on water saving
Archroma and Jeanologia therefore understandably decided to team up and combine their expertise in sustainable dyeing and finishing technologies. The objective of the project was to improve the Pad-Ox dyeing process even further, in particular in one area that still offered room for positive impact: temperature and fastnesses.

The new ‘Pad-Ox G2 Cold’ dyeing process works thanks to the insertion of very small machinery into the existing finishing range process, using cold processing and thus operating with much less water, carbon footprint and energy than traditional benchmark fabric finishing processes, whilst retaining the water and other resource savings offered by the Pad-Ox technology.

Maximum savings can be achieved by mills and garment manufacturers who wish to switch from a conventional dyeing process straight to ‘Pad -Ox G2 Cold’ to obtain high quality fabrics for comfortable and casual wear.

International technology Group ANDRITZ has received an order from Pureko Sp. z o.o. to supply a needlepunch line for their plant in Myszków, Poland. The line will process recycling fibers from garment waste for the production of technical felts dedicated to furniture and geotextile applications. The final products will have fabric weights ranging from 300 to 500 gsm, and the production capacity will be up to 750 kg/h. Installation and start-up are scheduled for the third quarter of 2021.

The ANDRITZ scope of supply includes a complete neXline needlepunch eXcelle line – from web forming to needling – as well as engineering and ANDRITZ’s recently launched scanning gauge.

This is the second ANDRITZ line to be supplied to Pureko, thus demonstrating the strong partnership between both companies. Three years ago, Pureko invested in a new, modern plant supplied by ANDRITZ Asselin-Thibeau to produce fluffy nonwovens used in the furniture, textile, and clothing industries. The new line will enable Pureko to continue its ongoing growth.

Founded in 2009, Pureko is one of the most important producers of nonwovens in Poland. The company’s nonwoven products are mainly used for wadding; they are free of chemicals, do not involve any health hazards, and are hypoallergenic. Pureko’s products carry top certificates such as INTERTEK, FIRA, OEKO-TEX, and the National Institute of Hygiene.

JEC Group, dedicated to promoting composite materials, introduces all-new digital event series for the composites community: JEC Composites CONNECT. On June 1-2, 2021, this first round-the-clock event will be one of the industry’s most significant events, hosting major industry players, enabling participants to discover the latest trends thanks to business conferences and get networking opportunities. This live-streamed event will also be the place to highlight innovation through competitions, awards ceremonies and keynote speeches.

JEC Composites CONNECT: a digital event to bring the composites community together
Participants can access the free non-stop digital floor from 8:30 am on June 1 to 6 pm CEST on June 2. This first JEC Composites CONNECT will work as an online trade show, with digital stands for companies showcasing their latest products, from raw materials to composites parts manufacturers with various networking rooms, a meeting requests platform, and with a conference area to access live streaming content.

Composites innovation at the core
JEC Composites CONNECT will host outstanding keynote speakers and all the major JEC Composites competitions and awards promoting innovation, research teamwork, and entrepreneurship in the composites industry.

• The JEC Composites Innovation Awards celebrate the most innovative composites projects and fruitful collaborations between different value chain players in 2021.
• The 2021 JEC Composites Startup Booster competition, with live pitches and winners ceremony.
• The JEC Composites Challenge, where Ph.Ds will present their research projects in front of the jury.

The Awards ceremony will take place on Wednesday, June 2, with an opening keynote speech from inventor and genius entrepreneur Franky Zapata, a.k.a. ‘the Flying Man.’ As the CEO and founder of the company that bears his name, he became well-known for his famed crossing of the English Channel in August 2019 on his Flyboard® Air.

• SGL Carbon receives €42.9 million funding under IPCEI for graphite anode materials (GAM) in lithium-ion batteries
• Funding in the amount of €42.9 million to 2028 for SGL Carbon GmbH from the German Federal Government and the Free State of Bavaria
• SGL Carbon project aims at European production of innovative anode materials as a key value-added step in electromobility

SGL Carbon, a leading supplier of graphite and carbon products, today received a funding notification for the development and industrialization of innovative anode materials made of synthetic graphite for use in lithium-ion batteries. The funding program is part of the second European IPCEI (Important Project of Common European Interest) / EUBatIn (European Battery Innovation) program, which aims at a competitive European value chain for lithium-ion batteries based on innovative and sustainable technologies.

SGL Carbon is one of a few manufacturers of synthetic graphite for anode materials in Europe. The company’s contribution to the IPCEI project ranges from the development of anode materials with increased performance, energy-efficient and sustainable manufacturing processes to novel recycling concepts. It also includes scaling them up to pilot scale and finally mass production. Over the project lifetime until 2028, the goal is to also establish a closed cycle for this cell component. SGL Carbon has already created a solid foundation for the project through previous investments such as the battery application laboratory at its Meitingen site. The German federal government and the Free State of Bavaria provide funding for the SGL Carbon project totaling €42.9 million, which can be drawn down over the duration of the project.

"With our development and industrialization project for new innovative anode materials and processes, we make an essential contribution to establishing a sustainable and competitive European value chain and circular economy for lithium-ion batteries. In turn, this enables us to support our customers with tailored materials and services in their innovation and industrialization process. We are very pleased about the support from the federal and state governments in this important task and would like to express our sincere thanks," explains Burkhard Straube, President Business Unit Graphite Solutions at SGL Carbon.

"In order to produce competitive, high-performance and particularly environmentally friendly batteries in the future, we need innovations. The companies participating in the IPCEIs base their battery materials, cells and systems pursued in the projects on their own research - in cooperation with their partners. This way, we ensure that the battery ecosystem being created in Germany and Europe will also place us among the world leaders in terms of technology," says Elisabeth Winkelmeier-Becker, Parliamentary State Secretary at the German Federal Ministry of Economics and Technology.

"The funding ensures value creation in a central high-tech segment with great future potential, which is ideally suited to Bavaria as a business location. In the course of the project, 25 jobs will be secured or newly created in Meitingen. SGL Carbon is an important company for the entire region and a major employer," says Hubert Aiwanger, Bavarian Minister of Economic Affairs and Bavarian Deputy Minister-President.
 
Synthetic graphite is utilized as anode material for lithium-ion batteries in many fast-growing applications such as electric vehicles, stationary energy storage systems and mobile consumer devices. Compared to natural graphite, synthetic graphite has a better performance, higher quality consistency and easier production scalability, as well as a better profile in terms of environmental footprint and safety in manufacturing. In the project described, SGL Carbon builds on its core competencies in the development and mass production of synthetic graphite.

• Several members of TMAS – the Swedish Textile Machinery Association – are actively advancing new coloration technologies as part of a wave of innovation that is currently sweeping out from Scandinavia.

New manufacturers of regenerated cellulosic fibers as alternatives to cotton and synthetics, for example, have been gaining a lot of attention recently, as they scale up to meet demands for a circular approach to the manufacturing of textiles and garments.

These companies have, in turn, been embraced by major Scandinavian brands such as the Danish clothing company Bestseller, Finnish fashion house Marimekko, Norwegian outdoor brand Bergans and Sweden’s own H&M Group.

Fiber journey
From the field or the forest to the retail shelves, however, the journey of every single textile fiber is currently a long one, in which it passes through many hands and moves around the world. The good news is that many of these individual stages are now being greatly simplified by digitalization.

“Digitalization will lead to a significant reduction in garments that for one reason or another are never sold and end up in landfill,” says Therese Premler-Andersson, Secretary General of TMAS. “There will of course, be a huge ecological benefit.”

At the very center of any fiber’s journey, once it has become part of a knitted or woven fabric, are the dyeing and finishing stages of textile production. Dyeing and finishing currently involves many washing and drying process steps which add a huge burden to the overall carbon footprint of finished garments and textile products.

Coloreel expansion
Here is where the latest fully digital technologies of TMAS member companies are making a dramatic difference, such as the instant thread coloration technology, of Coloreel, which has just raised SEK 100 in new financing to support its market expansion and growth.

Initially targeting the embroidery market, Coloreel technology enables the high-quality and instant coloring of a textile thread while it is actually being used in production and can be paired with any existing embroidery machine without modification, while also making it possible to produce gradients in an embroidery for the first time.

Based on a CMYK ink system, Coloreel’s advanced rapid color formulation software and high-speed drive technology allow a single needle to carry out what previously required many multiples of them to do – and with much more consistent stitch quality,

In addition, existing thread dyeing plants can add a single solid color to a thread, but by instantly coloring a white base thread during production, Coloreel enables complete freedom to create unique embroideries without any limitations in the use of colors. Color changes along the thread can either be made rapidly from one solid color to another, or gradually, to make smooth transitions or any coloring effect desired.

This provides big benefits when it comes to sustainability. There is a significant reduction in wasted inks, while water usage is minimized, and production speeds are increased. The technology allows set-up and lead times to be reduced as well as significant flexibility in production schedules, while eliminating the need for large thread inventories.

“Our system is allowing customers to achieve color effects that have never been seen before – and at a new level of efficiency,” says VP of Sales and Marketing at Coloreel, Mats Sjögren. “We are setting the new benchmark for the embroidery industry.”

Despite the Covid-19 pandemic, Coloreel, has recently successfully delivered units to companies in Europe, the United States and Asia, and has also partnered with the world’s largest distributor of embroidery machines, American Hirsch Solutions, which has already installed the technology at a number of customers in the USA.

imogo
Another TMAS member achieving rapid progress is imogo, which is currently installing its first industrial scale Dye-Max spray dyeing line at the plant close to Borås of Swedish commission dyeing company 7H Färgeri – the Nordic region’s most complete dyeing and processing plant.

The new line has a working width of 1.8 meters with an operating speed of up to 50 meters for the reactive dyeing of cellulosic fiber-based fabrics. In addition, it can carry out the application of a wide range of fabric pre-treatments and finishing processes, providing the company with unbeatable flexibility in production.

A proven Mini-Max laboratory unit for pre-determining application volumes and color matching has also been installed at the 7H plant.

With the potential to slash the use of fresh water, wastewater, energy, and chemicals by as much as 90% compared to conventional jet dyeing systems, the DyeMax has gained considerable attention since the concept was outlined and a prototype machine constructed in 2019.

The application unit of the Dye-Max consists of a closed chamber containing a series of spray cassettes with precision nozzles for accurate and consistent coverage, in combination with the patented imogo Pro Speed valve that controls the volume to be applied.

“We are achieving an extremely low liquor ratio of around 0.5-1 liters per kilo of fabric and we fully control the pickup, applying precisely what is required to the specific fabric,” says imogo founding partner Per Stenflo. “Compared to traditional padders there is no contamination of the dyebath or dilution of the dye liquor to worry about.”
Fast changeovers with virtually no waste, together with a high production speed, enable a high productivity and unmatched production flexibility.

“The Dye-Max will be implemented in 7H daily production and producers and brands are welcome to visit when the Covid-19 situation allows. They are also welcome to do test productions at 7H to verify the performance on their fabrics.”

Perfect bridge
“Such new digital technologies from TMAS members represent the perfect bridge for sustainable new fibers on their route to the finished garments of responsible brands on the retail shelves,” concludes Therese Premler-Andersson. “There is now a real momentum building industry-wide for new circular manufacturing, and TMAS companies intend to be very much a part of it.”

• Major Monforts denim customers continue to pioneer new initiatives that are pushing the boundaries of sustainable production.

Recycling their cotton waste has become one way these companies can do more with less, and at the recent Kingpins24 Flash online event, Sedef Uncu Aki, director of Orta, headquartered in Istanbul, Turkey, announced a new partnership with leading recycling operation Gama Recycle.

Traceable
“Through this local partnership we will supply the waste from our spinning mills and return around 3,000 tons of premium quality cotton back to them,” she said. “We have established a truly controlled and traceable system and partnering with a domestic recycling centre is important because a lot the carbon emissions associated with recycling usually come from transportation.”

Orta’s ZeroMax range meanwhile uses no cotton at all, being based on Lenzing’s Tencel cellulosic fibre, while the company’s involvement in denim production for a recent launch by Levi Strauss, of jeans made with organic cotton and Circulose – a breakthrough material developed by re:newcell of Sweden and partners – was hailed as a further step forward.

To make Circulose, re:newcell repurposes discarded cotton textiles, such as worn-out denim jeans, through a process akin to recycling paper. The incoming waste fabrics are broken down using water. The colour is then stripped from these materials using an eco-friendly bleach and after any synthetic fibres are removed from the mix, the slurry-like mixture is dried and the excess water is extracted, leaving behind a sheet of Circulose. This sheet is then made into viscose fibre which is combined with cotton and woven into new fabrics.

Circular Park
Omer Ahmed, CEO of Artistic Milliners also announced plans for his company’s new 70,000 square-foot Circular Park in Karachi, Pakistan, at Kingpins24 Flash.

Once complete, this will add three million square metres of additional denim capacity a month to the company’s production and take its total recycled output to a monthly five million metres.
Ahmed observed that there is currently a lack of sustainable fibres that are readily available to use for denim production at scale.

“Organic cotton is too expensive, and in my opinion always will be,” he said. “Cottonised hemp is also not cheap and it’s hard to mix with cotton, while the new regenerated cellulose fibres that are now emerging are promising, but currently in short supply. Recycled polyester is meanwhile still based on petroleum resources which we want to move away from. As a consequence, there are only a few other options for us as a manufacturer and this new project will help us minimise our own waste while significantly lowering our carbon footprint.”

Other Monforts denim customers to introduce cotton fibre recycling operations at their plants recently include AGI Denim, Bossa and Soorty.

Vertical savings
Refresh is the name of the latest collection from AGI Denim – reflecting the company’s significant reduction in water consumption.

The company has just opened new fibre spinning and denim mills at its complex in Karachi, Pakistan.

“Over the years we’ve gone through a series of backward integration steps to become fully vertical,” said AGI Denim executive director Ahmed Javed, at Kingpins24 Flash. “In our latest expansion, we revisited every step of the production processes in order to make resource savings.”

Innovations have included the installation of proprietary robotics for garment finishing, but the most attention has been paid to water savings.

“Pakistan is one of the largest cotton-producing companies in the world and we’re fortunate that the type of cotton that is grown here is well suited to denim production and also helps us lower our carbon footprint, with everything done in close proximity,” Javed said. “In the lifecycle of a pair of denim jeans, however, cotton fibre production contributes 68% of water consumption. While we cannot control how much water cotton needs for it to grow, we can rethink the way we use it in our factory.”

Refresh-branded denims are washed from 100% recycled water as a result of the company’s new wastewater treatment plant, which puts production wastewater through a series of steps beginning with equalisation, followed by aeration and concluding with sedimentation. The water travels through filtration and ultrafiltration systems before being subjected to an activated carbon system and finally a reverse osmosis system to reduce any dissolved salts.

AGI now recycles 4.4 million gallons of water each month – enough to wash a million pairs of jeans.

Sustainable
Monforts has a leading position in the field of denim finishing with its well proven Thermex continuous dyeing systems, Montex stenter dryers and other lines for resource-efficient and economical processing.

“Our denim partners are constantly setting themselves new goals in respect of sustainable production – and more importantly, achieving them,” says Hans Wroblowski, Monforts Head of Denim. “We work closely with them with the aim of constantly optimising processing parameters and achieving further savings in energy, water and raw materials throughout the dyeing and finishing stages of production.”

The latest Monforts innovation for denim is the CYD yarn dyeing system. This technology is based on the effective and established dyeing process for denim fabrics that is now being applied for yarn dyeing. The CYD system integrates new functions and processes into the weaving preparation processes to increase quality, flexibility, economic viability and productivity. A full CYD line is now available for trials at the company’s Advanced Technology Centre in Mönchengladbach, Germany.”

Archroma, a global leader in specialty chemicals towards sustainable solutions, announced that it has become a The BHive® partner to help foster chemical compliance and management across the textile supply chain.

The BHive® is an innovative digital chemical management platform that provides at-a-glance information about chemical products to its users. It was developed by GoBlu International Ltd. to allow manufacturing facilities to easily create digital inventories of the chemical products used onsite using a smartphone. They can identify in a matter of seconds which products meet sustainability requirements of their brand and retail customers, who they can share this information with as well. This enables brands and retailers to achieve full transparency about the chemical use in their global supply chain. Now, over 30 international fashion brands and 500 factories are partnered with The BHive® to drive sustainable chemistry in the textile and fashion industry.

More than 2000 Archroma chemical products and dyes are now included in The BHive® database.
The company has been very active in the past few years in developing solution systems and innovations in line with the 3 pillars of 'The Archroma Way to a Sustainable World: Safe, efficient, enhanced. It’s our nature'.

Paul Cowell, Head of Archroma’s Competence Centers for Brand & Performance Textile Specialties, explains: "With the pandemic crisis, textile manufacturers are experiencing numerous logistic bottlenecks and challenges. With The BHive®, our partners have now an additional access path to the information about chemical usage and compliance for the Archroma products they keep at their facilities."

• 75% recycled content yarn with no performance compromise
• A circular, endlessly recyclable solution for contract, automotive and residential carpets
• Significant resource efficiency in EqoCycle production compared to virgin-based PA6 yarn: 58% reduction in fossil fuel use; 27% less energy consumption; 37% CO₂ emission reduction

B.I.G. Yarns announces its latest development, EqoCycle, a fully recyclable PA6 yarn with 75% recycled content, offering the same high-quality performance of virgin PA6 yarn. The new recycled yarn mainly based on post-industrial waste supports contract, automotive and residential carpet manufacturers with a drop-in circular solution to reduce the ecological footprint of their end products.

EqoCycle is made with recycled granulates derived from pre-consumer recycled and regenerated PA6, certified by Control Union for Global Recycled Standard (GRS) Certification. The use of less virgin materials implicates a decrease of fossil fuels by 58% and a 27% decrease in energy consumption. On top, EqoCycle yarns allow a reduction of 37% of CO₂ eq./kg compared to the fossil based yarns. The environmental impacts of EqoCycle with 75% recycled content were calculated through an LCA analysis, verified according to ISO 14025 and EN 15804+A1 and published in an Environmental Product Declaration (EPD registration number S-P-02415).

Customers have the assurance that for every 1.000 tons of EqoCycle yarn, 13,562 barrels of oil are saved and 2.700 tons of CO₂ emission are reduced, compared to PA6 traditionally made from virgin materials.

Emmanuel Colchen, General Manager Yarns Division, comments: “EqoCycle is a perfect example of how higher resource efficiency in our industry can promote greater circularity in our customers’ industries. Minimizing waste, re-using materials, and saving energy and carbon emissions in production, it provides our customers and carpet brands with a new sustainable alternative that won’t compromise their end-product performance but will support their increasing focus on CO₂ reduction and global warming potential. All part of our wider commitment to encourage decoupling from the need for only virgin feedstocks and moving towards a circular economy for yarns and soft flooring industries.”

EqoCycle is the latest circular solution in B.I.G. Yarns’ PA6 portfolio, joining EqoBalance PA6, based on biomass balance renewable resources, which offers up to 75% CO₂ reduction. Both exemplify the company’s on-going investment in developing new products that better serve customers’ needs in a sustainable way. B.I.G. Yarns fully pursues opportunities to support and solve the global environmental challenges through innovation, investment and collaboration, as part of its sincere belief in, and broader commitment to, Social Responsibility.

The innovation of EqoCycle and EqoBalance PA6 aligns with the company’s active integration of the UN Sustainable Development Goals (SDGs) into its business activities, creating value for customers and engaging employees and value chain partners.