From the Sector

The 17th World-Pultrusion-Conference (WPC) took place in Hamburg from 29 February to 1 March. Pultrusion, also known as the extrusion process, is a highly efficient method for producing fibre-reinforced plastic profiles for various applications in the construction/infrastructure and transport sectors.

A record number of almost 150 participants from all over the world attended the event. An international audience of experts from Europe and the USA, as well as China, India and Japan was represented.

The lecture programme with a total of 25 specialist lectures was strongly characterised by the topic of sustainability. The process development of thermoplastic pultrusion and applications in wind energy, solar panels, bridge construction and the automotive industry were also discussed at length. Despite the difficult market environment, many opportunities and possibilities for the pultrusion industry were presented.

The conference takes place every two years in a European country of importance to the pultrusion industry and is organised by AVK for the European Pultrusion Technology Association (EPTA), in cooperation with the American Composites Manufacturers Association (ACMA).

The German Institutes of Textile and Fiber Research Denkendorf (DITF) have modernized and expanded their melt spinning pilot plant with support from the State of Baden-Württemberg. The new facility enables research into new spinning processes, fiber functionalization and sustainable fibers made from biodegradable and bio-based polymers.

In the field of melt spinning, the DITF are working on several pioneering research areas, for example the development of various fibers for medical implants or fibers made from polylactide, a sustainable bio-based polyester. Other focal points include the development of flame-retardant polyamides and their processing into fibers for carpet and automotive applications as well as the development of carbon fibers from melt-spun precursors. The development of a bio-based alternative to petroleum-based polyethylene terephthalate (PET) fibers into polyethylene furanoate (PEF) fibers is also new. Bicomponent spinning technology, in which the fibers can be produced from two different components, plays a particularly important role, too.

Since polyamide (PA) and many other polymers were developed more than 85 years ago, various melt-spun fibers have revolutionized the textile world. In the field of technical textiles, they can have on a variety of functions: depending on their exact composition, they can for example be electrically conductive or luminescent. They can also show antimicrobial properties and be flame-retardant. They are suitable for lightweight construction, for medical applications or for insulating buildings.

In order to protect the environment and resources, the use of bio-based fibers will be increased in the future with a special focus on easy-to-recycle fibers. To this end, the DITF are conducting research into sustainable polyamides, polyesters and polyolefins as well as many other polymers. Many 'classic', that is, petroleum-based polymers cannot or only insufficiently be broken down into their components or recycled directly after use. An important goal of new research work is therefore to further establish systematic recycling methods to produce fibers of the highest possible quality.

For these forward-looking tasks, a bicomponent spinning plant from Oerlikon Neumag was set up and commissioned on an industrial scale at the DITF in January. The BCF process (bulk continuous filaments) allows special bundling, bulking and processing of the (multifilament) fibers. This process enables the large-scale synthesis of carpet yarns as well as staple fiber production, a unique feature in a public research institute. The system is supplemented by a so-called spinline rheometer. This allows a range of measurement-specific chemical and physical data to be recorded online and inline, which will contribute to a better understanding of fiber formation. In addition, a new compounder will be used for the development of functionalized polymers and for the energy-saving thermomechanical recycling of textile waste.

Kelheim Fibres is showcasing recent research findings at this year's Cellulose Fibres Conference (13rd-14th of March). The development, led by Dr. Ingo Bernt, Project Leader of Fibre & Application Development at Kelheim Fibres, and Dr. Thomas Harter from Graz University of Technology, provides insights into the correlation between the geometry of viscose fibres and the liquid absorption of tampons.

Kelheim Fibres has long been engaged in the functionalization of viscose fibres, including the specific adaptation of fibre cross-sections. The trilobal Galaxy® serves as an example. The current study underscores the properties of the fibre, primarily rooted in its geometry. This involves taking a closer look at the underlying mechanisms. It has been confirmed that, in contrast to the traditionally round viscose fibres and despite similar chemical compositions and mechanical properties, Galaxy® enables significantly better liquid absorption.

While the higher specific surface area of trilobal fibres already promotes improved liquid absorption, this is not the main factor accounting for the difference in absorption. Instead, the geometric shape of the fibres proves to be crucial. Trilobal fibres create and maintain a more voluminous, extensive network within the absorbent body, providing a larger volume for liquid absorption.

Dr. Ingo Bernt emphasizes, "The results of our study are not limited to tampons—any application requiring increased absorbency can benefit from the properties of our Galaxy® fibres."

The lecture "Geometry Matters: Unveiling Tampon Absorption Mechanisms" by Dr. Ingo Bernt und Dr. Thomas Harter takes place on the 14th of March at 2:50pm.

Fibre Extrusion Technology Ltd (FET) of Leeds, UK has appointed Dr Kristoffer Kortsen as Senior Materials and Process Scientist. He will report directly to R&D Manager, Dr Jonny Hunter, who joined FET in early 2023 in a growing Research and Development team.

Kortsen’s main area of work is in Gel Spinning of UHMWPE (Ultra-High Molecular Weight Polyethylene). His contribution will help provide gel spinning expertise and equipment in the near future to a range of industries including medical, aerospace, defence aerospace and marine.

He completed a Master’s in chemistry at KU Leuven, graduating magna cum laude in 2018. For his Master’s placement, he worked on the production of impact modifier additives for PVC at Kaneka Belgium. Continuing a partnership with this international chemical manufacturing company, he joined the Howdle group at the University of Nottingham for a PhD project looking into the industrial potential of scCO₂ dispersion polymerisations for additive production. After graduating, he worked in the Shaver group at the University of Manchester, developing a holistic approach to plastics recycling and sustainability across the many stakeholders in the field.

SGL Carbon SE is currently evaluating various strategic options for the Business Unit Carbon Fibers (CF). These include a possible partial or complete divestment of the Business Unit. In a first step, potential interested parties shall be approached with the general data of the Business Unit to determine their interest in an acquisition. If there is sufficient interest, a structured transaction process will be carried out in a second step. Overall, a share of sales amounting to around € 179.6 million after nine months in 2023 (9M 2022: € 269.0 million) is therefore under review. The CF sales share corresponded to 21.9% of SGL Carbon's consolidated sales after nine months in 2023 (9M 2022: 31.5%). Adjusted EBITDA of the Business Unit excluding the result from joint ventures amounted to minus € 10,9 million after nine months in 2023 (9M 2022: € 27,9 million). Despite the operating loss of CF after nine months in 2023, SGL Carbon maintains its guidance for fiscal year 2023. This shows the positive development of the three other business units and the resilience of SGL Carbon's business model.

Carbon Fibers manufactures textile, acrylic and carbon fibers as well as composite materials at seven locations in Europe and North America. Following the temporary drop in demand for carbon fibers from the important wind industry market, the Business Unit's sales and earnings fell significantly in the course of fiscal year 2023. Due to the importance of the wind industry for the European Green Deal, SGL Carbon and many experts assumed that the wind industry recovers quickly. Unfortunately, this is currently not the case. Even if demand picks up, the company assumes that Carbon Fibers will need additional resources to remain competitive in the international market environment and to exploit market opportunities in the best possible way. Against this background, SGL Carbon is reviewing all possibilities to support a positive further development of the Carbon Fibers Business Unit.

At this year's JEC World, STFI will be presenting highlights from carbon fibre recycling as well as a new approach to hemp-based bast fibres, which have promising properties as reinforcement in lightweight construction.

Green Snowboard
At JEC World in Paris from 5 to 7 March 2024, STFI will be showcasing a snowboard from silbaerg GmbH with a patented anisotropic coupling effect made from hemp and recycled carbon fibres with bio-based epoxy resin. In addition to silbaerg and STFI, the partners Circular Saxony - the innovation cluster for the circular economy, FUSE Composite and bto-epoxy GmbH were also involved in the development of the board. The green snowboard was honoured with the JEC Innovation Award 2024 in the “Sport, Leisure and Recreation” category.

VliesComp
The aim of the industrial partners Tenowo GmbH (Hof), Siemens AG (Erlangen), Invent GmbH (Braunschweig) and STFI united in the VliesComp project is to bring recycled materials back onto the market in various lightweight construction solutions. The application fields "Innovative e-machine concepts for the energy transition" and "Innovative e-machine concepts for e-mobility" were considered as examples. On display at JEC World in Paris will be a lightweight end shield for electric motors made from hybrid nonwovens - a mixture of thermoplastic fibre components and recycled reinforcing fibres - as well as nonwovens with 100% recycled reinforcing fibres. The end shield was ultimately manufactured with a 100% recycled fibre content. The tests showed that, compared to the variant made from primary carbon fibres using the RTM process, a 14% reduction in CO₂ equivalent is possible with the same performance. The calculation for the use of the prepreg process using a bio-resin system shows a potential for reducing the CO₂ equivalent by almost 70 %.

Bast fibre reinforcement
To increase stability in the plant stem, bast fibres form in the bark area, which support the stem but, in contrast to the rigid wood, are very flexible and allow slender, tall plants to move in the wind without breaking.A new process extracts the bast bark from hemp by peeling.The resulting characteristic values, such as tensile modulus of elasticity, breaking strength and elongation, are very promising in comparison with the continuous rovings made of flax available on the market.The material could be used as reinforcement in lightweight construction.At JEC World, STFI will be exhibiting reinforcing bars that have been processed into a knitted fabric using a pultrusion process based on bio-based reinforcing fibres made from hemp bast for mineral matrices.

INDA, the Association of the Nonwoven Fabrics Industry, will join the ISSA – The Worldwide Cleaning Industry Association to host the 2024 Clean Advocacy Summit, April 10-11, in Washington, D.C. This advocacy and fly-in summit will offer participants the “inside scoop” on the key public policy issues facing their industry, including labor and supply chain challenges, cleaning product regulations, promoting healthy workplaces, ending period poverty, and more.

The summit will include networking opportunities and scheduled meetings with members of Congress and their staff to discuss key policies and legislation pertaining to the nonwovens industry. Attendees will have the chance to advocate for their businesses to support innovation, growth, and sustainability within the industry, while also highlighting their contributions to economic development and job creation.

HeiQ AeoniQ Holding, a subsidiary of HeiQ Group, is appointing Julien Born as its CEO, leveraging his extensive executive leadership and profound textile industry expertise cultivated in prestigious organizations such as DuPont, KOCH Industries, and The LYCRA Company, where he served as CEO since 2021. Julien Born will champion the growth of the cellulosic filament fiber HeiQ AeoniQ™.

The HeiQ AeoniQ™ technology is poised for commercial production at the inaugural manufacturing facility in Portugal by the close of 2025. The just concluded €5M acquisition of land and buildings, within a 2-year project total investment of €80M, marks a pivotal milestone for the 15,000m2 facility in Maia, Porto. Situated strategically in Portugal's textile hub and a mere 20 minutes from a major commercial port, this facility is poised to catalyze the scale-up phase of the business, going from pilot manufacture to mass production when it wants to compete at full-scale on cost and performance with fossil fuel-based fibers.

HeiQ intends to consolidate the Group’s current and future activities in Portugal at the newly acquired site. This includes Shared Service Center functions as well as the Innovation Hub for the HeiQ Textile & Flooring business unit.

The recent addition of Julien Born to lead the charge follows the nomination of Robert van de Kerkhof to the HeiQ Board, a seasoned executive with extensive textile experience holding positions as CCO, CSO, Board member of Lenzing Plc, and Chairman of CIRFS, the European Man-Made Fibres Association. Robert will also serve as the Chairman of the HeiQ AeoniQ Holding Board.

HeiQ AeoniQ Holding, established as an independent subsidiary to attract new investors, value-chain partners, and brands, embarks on an ambitious multi-year scale-up strategy. This strategy involves integrating diverse sources of bio-derived feedstock and hyper-scaling cellulosic filament fiber production capacity over the next decade, targeting industries such as apparel, footwear, automotive, home textiles, and aeronautics.

Haelixa, the trailblazer of physical traceability solutions, has partnered with Trudel Silk, a market leader for sustainable organic and recycled silk products. This collaboration brings traceability and transparency to silk production.

Silk is one of the finest and smoothest fabrics; the better the quality of the silk, the more luxurious it feels to the touch. To create the best quality silk, the conditions for mulberry cultivation must be up to the highest standards. A healthy micro-ecosystem in the fields translates to top-grade silk cocoon quality. At Trudel, this is the environment they have created for the vertical integration of their business. Trudel aims to succeed at every stage of the process, which can only be accomplished through the active involvement and visible cooperation of all market players. These players include farmers, reeling mills, twisting/spinning mills, weaving mills, dyeing and printing mills, and brands. They are involved in every step, from the cultivation of mulberry trees to the production of silk fabrics.

Haelixa and Trudel have collaborated to improve silk’s robust and consistent traceability. As the demand for validation of the silk value chain increases, they have partnered with groups from Italy and Asia to develop a unique solution that uses DNA markers to trace the entire supply chain of silk production. This innovative approach ensures each silk product’s ethical sourcing.

The silk fibers used in their spun silk yarns are marked with a specific DNA per farm set selected by Trudel. Throughout the supply chain, samples of yarn, fabrics, and finished products undergo testing to verify the presence of original silk fibers. Based on the reporting, the brand can trace the finished accessories or garments to Trudel.

“From Earth to Earth”: The new plan defines goals and concrete actions in Environmental, Social and Governance (ESG) areas to foster value creation for all stakeholders and put new sustainability regulatory requirements at the centre of attention.

A project, designed to enhance RadiciGroup's transparency and commitment to develop a responsible business along its entire value chain from an economic, social and environmental perspective and focus on the ever more widespread and stringent sustainability regulatory requirements. These are the features and goals of the Sustainability Plan presented by the Group and called "From Earth to Earth", precisely to emphasize the intent to focus on the Earth and future generations.

In the context of a complex and constantly changing scenario, the Group has therefore decided to capitalize on the goals achieved and look beyond them with a plan defining the medium-term targets and the actions to be taken to fulfil them and covering all areas considered to be "material”, i.e., relevant from the point of view of ESG and financial risks, opportunities and impacts. Indeed, the ultimate goal of "From Earth to Earth" is to support business continuity and the growth of the company and all its stakeholders.

The project was the result of a multi-year collaboration with Deloitte, which contributed an external and objective viewpoint on the definition of the material targets and themes. However, it was not an armchair exercise, but the result of an extensive listening process involving internal and external stakeholders, all of whom were sustainability experts who helped define a shortlist of strategic themes for both the Group and its main stakeholders. These issues were then analysed in detail using working tables on the different themes to identify the objectives in Environmental, Social and Governance areas and the related concrete actions needed to achieve them, in line with the European decarbonization and energy transition policies and the
United Nations Sustainable Development Goals, a global blueprint for sustainable growth.

In particular, RadiciGroup’s environmental goals include: a 20% increase and differentiation in renewable source electricity consumption, an 80% reduction in total direct greenhouse gas emissions by 2030 compared to 2011, attention to water consumption to limit the impact on local communities and biodiversity, the extension of Life Cycle Assessment (LCA) methodology to measure the environmental impact of 70% of the products (in terms of weight) manufactured by the entire Group, collaboration among the various actors in the supply chain from an ecodesign perspective and the search for increasingly more sustainable and circular packaging solutions.