From the Sector

• ESD protection in harsh environments:
• Polymer-coated chemical-resistant fabrics and fireproof special textiles with expanded electrostatic discharge (ESD) safety function have been developed.
• Graphene nanotubes used as an electrostatic dissipative material make it possible to add ESD protection without compromising resistance to aggressive environments.
• Efficient working loadings starting from 0.06% are sufficient for stable anti-static properties fully compliant with safety standards and position graphene nanotubes far ahead of other conductive materials.

Protective clothing, upholstery, and industrial fabrics that experience harsh conditions require advanced performance. Depending on the final application, specialty textiles can be augmented with flame retardancy, durability, chemical protection, and other properties. Additionally, ESD protection is obligatory in the chemical, rescue, mining, oil & gas, automotive manufacturing, and many other industries that are subject to safety regulations.
 
In applications where multifunctionality of textile is required, graphene nanotubes overcome the limitations of other conductive materials such as unstable anti-static properties; degradation of strength, or chemical or fire resistance; complicated manufacturing processes; dusty production; carbon contamination on the material’s surface; or limited color options. Recent developments show that graphene nanotubes provide ESD protection to textiles in full compliance with safety standards and without degrading the textile’s resistance to harsh environments, greatly enhancing the value of textiles.
 
One such example is textiles coated with fluoroelastomer (a polymer that is highly resistant to chemicals) augmented with graphene nanotubes from OCSiAl. Nanotubes provide the material with surface resistivity of 10^6–10^8 Ω/sq compliant with EN, ISO, and ATEX standards for personal protective equipment. This new technology opens the door for the fabric to be used in high-level protective suits, combining exceptional protection from chemicals with electrostatic discharge protection.
 
Another example is how graphene nanotube technology is being acknowledged as a replacement for metal yarns in fireproof and anti-static textiles, protecting against sparks, splashes of molten metal, high temperatures, and the risk of sudden electrostatic discharge. While metal yarns require a specific knitting process and storage conditions, incorporating nanotubes in a fabric does not require any changes in the manufacturing process as the water-based dispersion is introduced into the fabric at the fluoro-organic treatment stage. The fabric with OCSiAl’s graphene nanotubes has been proven to maintain the pre-set level of ESD protection (surface resistance of 10^7 Ω) after numerous washes.
 
Permanent and stable electrical conductivity, facilitated by graphene nanotubes, is not only a matter of safety but brings additional value in augmenting dust-repellent properties and touchscreen compatibility for comfort and time savings. At the same time, the ultralow nanotube concentrations result in maintained manufacturing processes and mechanical properties, and improve product aesthetics by making it possible to use a wide range of colors. Altogether, these benefits allow textile manufacturers to create next-generation special textiles with expanded functionality.

The Enforcement Forum of ECHA agreed that the next REACH enforcement project will investigate how companies fulfil the registration, authorisation and restriction obligations for products and chemicals they import from outside the EU. The project will be done in 2023-2025 and will require close cooperation between REACH enforcement and national customs authorities in the Member States.
In its November meeting, the Enforcement Forum, responsible for harmonising the enforcement of EU chemicals legislation, agreed to focus its next project on the control of imports of substances, mixtures and articles.

This subject was triggered by high levels of non-compliance in imported goods detected in previous Forum projects, including a recent pilot project. The pilot found that 23 % of inspected products were non-compliant with requirements set by EU law and further controls are necessary.

Control of imports at the point of entry is the most effective means of checking that non-compliant substances, mixtures and articles do not enter the European market. The project will also work on further developing and strengthening existing cooperation between REACH inspectors and customs. By strengthening the control of imports, the project will also contribute to the goals of the EU’s Chemicals Strategy for Sustainability.

The Forum also agreed to publish its future advice on enforceability of new restriction proposals under REACH.

Opportunities for expanding the future role of the Forum, strengthening the control of imports and other areas were on the agenda in an open session where 41 representatives from stakeholder organisations and four candidate countries joined. Among other topics, the open session also addressed the enforceability of REACH restrictions, for example, in textiles or on the use of lead gunshot in wetlands as well as analytical methods relevant for the control of REACH duties.

The Forum’s Biocidal Products Regulation Subgroup (BPRS) re-elected Helmut de Vos (BE) for a second term as a Vice-Chair.

Rieter is presenting the latest innovations in its systems, components and services at the upcoming India ITME 2022 in Uttar Pradesh (India), taking place from December 8 – 13, 2022.

Autoconer X6
The automatic winding machine Autoconer X6 completes the Rieter ring and compact-spinning systems. The machine serves as the final quality assurance in the ring and compact-spinning process and is key to the performance of the subsequent process stages. The Multilink system with Multilot offers maximum flexibility to handle a different type of yarn.

The latest splicer generation OZ1 and OZ2 provides an optimum splice quality based on an open prism. With only two prisms spinning mills can splice the entire spectrum of cotton yarns as well as blends. They are also used for the splicing of cotton-based elastic core yarns in combination with the Elastosplicer. The splice zone exhibits an impressive elasticity in the fabric.

Compacting Solutions
The Rieter compacting devices include the COMPACTapron, COMPACTeasy and COMPACTdrum. Spinning mills can change quickly between ring and compact yarn and offer customers a broader product range.

Recycling Expertise from Rotor to Ring
Rieter offers solutions for the integration of recycled raw material into yarn production to help close the textile loop and make fashion more circular. Both rotor and ring yarns can be produced with a considerable amount of mechanically recycled fibers.

ESSENTIALorder
Based on existing customer information, the webshop ESSENTIALorder visualizes which Rieter machines andn systems are available inside each spinning mill. It therefore offers a personalized shopping experience and facilitates order management, enabling spinning mills to optimize their internal stock levels.

ROBOspin
The piecing robot ROBOspin reduces personnel requirements in the ring spinning section by 50%. The robot also attains productivity increases thanks to higher spindle speeds at equal or higher efficiency.

SSM NEO-FD
SSM is presenting NEO-FD, the assembly-winding machine for precision wound packages for twisting. It meets all requirements for efficient production. The machine features the auto-doffing option and the online back-pressure system for low and high package densities.

Temco CoolFlow Disc
Temco’s CoolFlow texturing discs offer longer lifetime thanks to a brand-new geometry and the latest polyurethane technology. The texturing discs now generate a disc surface that operates at a lower temperature, resulting in slower ageing and abrasion. Further benefits are more stable yarn quality, higher productivity, and an overall process cost reduction.

• Carbios’ biorecycling and biodegradation technologies internationally recognized by consumers as promising answers to their top environmental concerns
• Carbios’ innovations considered one of the best for solving recycling effectively and achieving a real plastic circularity
• Consumer research including qualitative and quantitative fields was conducted between March and August 2022. The research institute, Strategic Research, conducted 6000 interviews in Europe and USA

Carbios’ biorecycling and biodegradation technologies acclaimed by consumers
During the first research field study, respondents were exposed to Carbios’ biorecycling process; a new enzyme-based biotechnology that enables biological recycling of all types of PET plastic waste (including bottles, packaging and textiles), and pushes the boundaries of recycling in terms of the number of cycles.

The research results demonstrated that European and US respondents find Carbios’ biorecycling technology more unique and innovative than traditional PET recycling (i.e. thermo-mechanical recycling), as well as more relevant in its ability to address their concerns and challenges regarding recycling.

In the second research study, conducted in the US, respondents were also exposed to Carbios’ biodegradation technology: an innovative enzymatic solution by which an enzyme is incorporated into plastics during the production process of bio-sourced PLA plastics (corn, sugar cane). This approach makes the material made from plants 100% compostable at ambient temperatures and degradable like plants with the built-in enzyme biologically breaking the bioplastic down in less than eight weeks without microplastics or toxic residues; creating a fully organic circularity.

Similarly to Carbios’ biorecycling technology, Carbios’ PLA biodegradation innovation caught US respondents’ attention with 64% overall liking it. Additionally, 93% of the respondents sampled described the concept as innovative, unique, easy to understand (49%), and believable (43%). Up to 82% of the most environmentally engaged respondents declared they would definitely buy more products made with Carbios’ fully circular biodegradable bioplastic.

Consumers: No other choice but to make plastic fully circular
The research says 99% of the respondents consider it important to protect the environment, while plastic pollution is now ranked the third most-concerning environmental issues after climate change and ocean pollution.

This awareness brings most of these consumers to be environmentally active when it comes to purchasing goods and sorting. For the US respondents, eco-friendly packaging comes in the fourth place in terms of purchase drivers for packaged goods and 65% of them declare sorting plastic from general waste on a regular basis, which makes plastic the most sorted type of waste.

Nevertheless, for a vast majority of the respondents across geographies, even if they would like to reduce their plastic consumption most of the time there is no suitable alternative that is as convenient, light, and cost-efficient as plastics. Hence in an ideal world, consumers would like all plastic waste in landfills and oceans to be collected, cleaned, reused and recycled.

Together with the Johann Jacob Rieter Foundation, the Rieter Group is supporting a new Endowed Professorship for Industrial Artificial Intelligence (AI) at the ZHAW School of Engineering. The Professorship is dedicated to teaching and research in the field of industrial applications of Artificial Intelligence and will be announced later this year.

The new Endowed Professorship will be established at the Center for Artificial Intelligence (CAI) of the ZHAW in Winterthur. It will focus, in particular, on the application of machine learning methods and knowledge-based systems in connection with processes in production and service.

For Rieter, the commitment is related to the implementation of its technology leadership strategy. The contribution of the Johann Jacob Rieter Foundation to sponsoring the Professorship is in line with the Winterthur Cluster Initiative. The increasing digitalization of production processes opens up new perspectives for Winterthur as a business location.

Building Expertise in the Field of Industrial AI
The Endowed Professorship will serve to build expertise in the field of Industrial AI and will oversee a group that will focus on teaching and research pertaining to trustworthy machine learning. This involves, for example, the deployment of artificial intelligence with the aim of optimizing production processes in relation to the use of raw materials and energy, and making expert knowledge more readily available.

In addition to research, for the purpose of knowledge transfer, the new professorship will also be active in teaching, in the bachelor's degree programs in Computer Science and in Data Science, in the Master of Science in Engineering, and in continuing education.

The annual commitment of CHF 300 000 over a period of six years will be financed equally by the Rieter Group and the Johann Jacob Rieter Foundation.
“The use of artificial intelligence in industry is becoming increasingly important, especially with regard to the potential of data for evaluation and control of complex processes. The support of the Johann Jacob Rieter Foundation and the Rieter Group will allow us to further expand AI research in the field of industrial applications,” explains Prof. Dr. Dirk Wilhelm, Director of the ZHAW School of Engineering.

“The use of Artificial Intelligence will make a significant contribution to automation and process optimization, and thereby advance sustainability in the textile industry. This makes it an important element of the leading technology that Rieter offers,” emphasizes Rieter CEO Dr. Norbert Klapper.

“The Smart Machines cluster is growing in importance,” says Thomas Anwander, member of the Foundation Board, and adds: “The Endowed Professorship for Industrial AI at the ZHAW aims to promote Winterthur as a technology location by pooling locally available strengths in mechanical engineering and Industry 4.0.”

Hexcel Corporation has received Type Approval for its HexPly® M9.6GF prepreg products from Bureau Veritas (BV), a leader in testing, inspection, and certification services.

This certification enables carbon fiber-reinforced epoxy prepregs to be used in the production of parts for all BV-approved marine vessels. It also guarantees the quality, performance and consistency of the prepregs for ship and boat builders.

BV-approved HexPly M9.6GF prepregs can be reinforced with unidirectional, non-crimp and twill-weave fabrics. They are particularly suitable for use in the manufacture of masts and other large structural components for wind-assisted ship propulsion (WASP). To reduce reliance on engines and cut fuel usage, WASP vessels harness the power of ocean winds often using large carbon fiber-reinforced masts flying durable composite solid sails.

HexPly M9.6 prepregs were recently used to manufacture the mast for the Chantiers de l’Atlantique Silenseas project. The HexPly M9.6 prepregs satisfied all the requirements of the Silenseas consortium’s mast-section manufacturers for quality, mechanical performance, and processing characteristics, while also proving to be cost effective.

Rieter is moving its Kahramanmaraş service station to a larger location covering 2 000 m² in a bid to broaden its offering and strengthen its market position in Turkey. The station will house one of the region’s largest test-spinning facilities and provide know-how in sustainable yarn manufacturing.

The comprehensive portfolio covers both mechanical and electronic services, including the revision of gear units, servomotor adjustments, and suction drums. The station will also offer preventive maintenance and mill optimization. The service offering spans the entire Rieter product portfolio.

Highlights of the Kahramanmaraş Service Station include the setup of a fully automatic rotor spinning machine R 70 and the winding machine Autoconer X6. Three-quarters of the 2 000 m² service space is reserved for functional activities, which will feature one of the region’s largest test-spinning facilities. Customers can run yarn comparison tests and analyze the impact of different technology parts so they can optimize machine setups. In-depth yarn trials and access to Rieter textile technology expertise will allow customers to cater more effectively to the dynamic demands of textile brands regarding performance, quality and sustainability, such as recycling applications.

The Kahramanmaraş service station is strategically located at the heart of the region’s textile industry, with a large proportion of Rieter’s installed base located within a radius of around 200 kilometers. Turkey is a textile powerhouse, currently ranking fifth in global exports and poised for additional growth. The country’s industry is also implementing a green action plan to help it meet the growing demand for sustainable textiles, especially from Europe.

The new service station starts operations in September 2022 and will accelerate the growth of the company’s three stations in Turkey. Rieter has been operating service stations in Turkey since 2005 with a presence in the country dating back to the 1990s.

Ulrich Reifenhäuser, CSO of the Reifenhäuser Group, was awarded the prestigious Georg Menges Prize 2022 at the 31st International Colloquium on Plastics Technology in Aachen from September 7-8, 2022. The prize recognizes individuals or groups who have rendered outstanding services to the transfer of research results into industrial practice. The sponsors of the award are the Plastics and Rubber section of Germany's Mechanical Engineering Industry Association (VDMA), together with PlasticsEurope Deutschland and the Association of Sponsors of the Institute for Plastics Processing (IKV) in Industry and Craft at RWTH University. The award is traditionally presented every two years during the colloquium organized by the IKV. Ulrich Reifenhäuser is the first businessman to receive the Georg Menges Award.

The award was presented by Professor Dr.-Ing. Christian Hopmann, Director of the IKV and Dr.-Ing. Herbert Müller, Chairman of the Board of the IKV Sponsors' Association. In his laudatory speech, Professor Hopmann highlighted Ulrich Reifenhäuser's great and successful commitment to the industry and his tireless search for optimal solutions that are sustainable in the best sense of the word, and praised him as a personality of integrity and integration. "The Georg Menges Prize is awarded for the consistent implementation of research and innovation in industry. The previously described achievements of our prizewinner would certainly have been enough to receive the award but, for the sponsors of the Prize, what was especially important and the key argument for their decision was Ulrich Reifenhäuser’s honorary dedication to the K tradefair," explained Professor Hopmann.

Ulrich Reifenhäuser has been a member of the Reifenhäuser Group management since 1992 and is responsible for international line sales. Together with his brother Bernd Reifenhäuser, he manages the company in the third generation. Ulrich Reifenhäuser has been a board member of the VDMA Plastics and Rubber Machinery Association for more than 25 years and has been its chairman since 2010. In 2020, he was inducted into the Plastics Hall of Fame, as was the award's namesake, and in 2022 he will be co-chairing the world's leading plastics trade fair in Düsseldorf for the seventh time in a row as "President of K show."

The future of e-mobility will be determined in particular by safe battery enclosures. As batteries for electric vehicles become more performant, higher volumetric energy density plays a crucial role. If more energy is to be stored in less installation space, new material and design solutions are required. The development of suitable enclosures made of safe and highly robust lightweight materials is also required. This is a case for the Aachen Centre for Integrative Lightweight Production (AZL). A project on cell-to-pack battery enclosures for battery-electric vehicles, which has been eagerly awaited in the industry, will start in October this year there.

The design of battery housings is crucial for safety, capacity, performance, and economics. The Cell-to-Pack project, which is starting now, will focus on developing concepts for structural components and for producing them based on a variety of materials and design approaches. The concepts will be compared in terms of performance, weight and production costs, creating new know-how for OEMs, producers and their suppliers throughout the battery vehicle value chain. Companies are now invited to participate in this new cross-industry project to develop battery enclosure concepts for the promising and trend-setting cell-to-pack technology.

The basis for the project is the lightweight engineering expertise of the AZL experts, which they have already demonstrated in previous projects for multi-material solutions for module-based battery housings. Together with 46 industry partners, including Audi, Asahi Kasei, Covestro, DSM, EconCore, Faurecia, Hutchinson, Johns Manville, Magna, Marelli and Teijin, 20 different multi-material concepts were optimized in terms of weight and cost and compared with a reference component made from aluminum. All production steps were modelled in detail to obtain reliable cost estimates for each variant. Result: depending on the concept, 20% weight or 36% cost savings potential could be identified by using multi-material composites compared to the established aluminum reference.

It is expected that the design concept of battery enclosures will develop in the direction of a more efficient layout. In this case, the cells are no longer combined in modules in additional production steps, but are integrated directly into the battery housing. The elimination of battery modules and the improved, weight-saving use of space will allow for higher packing density, reduced overall height and cost saving. In addition, various levels of structural integration of the battery housing into the body structure are expected. These new designs bring specific challenges, including ensuring protection of the battery cells from external damage and fire protection. In addition, different recyclability and repair requirements may significantly impact future designs. How the different material and structural options for future generations of battery enclosures for the cell-to-pack technology might look like and how they compare in terms of cost and environmental impact will be investigated in the new AZL project. In addition to the material and production concepts from the concept study for module-based battery enclosures, results from a currently ongoing benchmarking of different materials for the impact protection plate and a new method for determining mechanical properties during a fire test will also be incorporated.

The project will start on October 27, 2022 with a kick-off meeting of the consortium, interested companies can still apply for participation until then.

• European Textile Industry calls for immediate action to tackle the energy crisis;

The European textile & fashion in Europe, represented by EURATEX, calls for a single European strategy to tackle this energy crisis. To safeguard the future of the industry, a revision of the electricity price mechanism is necessary and an EU wide cap on gas prices at 80€/MWh. Special company support needs to be granted to avoid bankruptcy and relocation of textile production outside Europe.

Gas and electricity prices have reached unprecedented levels in Europe. Due to severe global competition in the market that characterizes the European textile & clothing industry, these cost increases are impossible to pass on to customers. This has already led to capacity reductions and production stops. Closures and the shift of production outside Europe are being forecasted should the current situation persist, leading to further de-industrialization of our continent and increased dependency on external suppliers.

Specific segments of the textile industry are particularly vulnerable. The man-made fibres (MMF), synthetic and cellulose-based fibres, industry for instance is an energy intensive sector and a major consumer of natural gas in the manufacturing of its fibres. The disappearance of European fibre products would have immediate consequences for the textile industry and for society at large. The activities of textile dyeing and finishing are also relatively intensive in energy. These activities are essential in the textile value chain in order to give the textile products and garments added value through colour and special functionalities (e.g. for medical applications).

The European textile industry calls for an EU-wide cap on gas prices at €80/Mwh, and a revision of the price mechanism for the electricity market, to reduce the huge price gaps with our foreign competitors.

Governments should ensure that critical industries, such textiles and all its segments, are able to ensure gas and electricity contracts towards the end of the year at an affordable price. Stable and predictable energy supply is of the utmost importance. Gas restrictions and rationing must only be used as a last resort. No mandatory consumption cuts should be foreseen.

In addition to these measures under discussion, currently a proliferation of contradictory, uncoordinated national initiatives to tackle the energy crisis is observed. This has led to a de facto fragmentation of the Single Market, resulting in a chaotic policy and regulatory environment that adds a further strain on our supply chain, which is fully integrated at European level. Measures that guarantee a level playing field in the EU are utmost important.

EURATEX President Alberto Paccanelli explained: “Given the current situation, a scenario where entire segments of the textiles industry will disappear can no longer be excluded. This would lead to the loss of thousands of companies and tens of thousands of European jobs and would further aggravate the dependency of Europe to foreign sources of essential goods. This applies specifically to SMEs who need temporary support measures (e.g. state aids, tax relieves, energy price cap) to survive the current crisis and to prepare for the green transition in the longer run.”