From the Sector

Hexcel announces its latest HexPly® XF surface technology that reduces shell manufacturing time within the wind blade surface finishing process. HexPly XF increases overall blade manufacturing efficiency by reducing time in the mold by up to two hours and by banishing surface defects that require rework before painting.

Hexcel’s HexPly XF surface technology has been formulated to address the limitations of current blade shell surfacing techniques whereby pinholes and other surface defects have to be repaired by hand to achieve the perfectly smooth surface required for painting.

HexPly XF surface technology introduces a new material format as the surface finishing layer, eliminating the need for a traditional in-mold gel coating process. HexPly® XF for infused rotor blades, is a lightweight non-woven semi-preg construction, comprising an epoxy resin matrix, that co-cures with standard epoxy infusion systems. The product has a successful track record in prepreg blades and has now been adapted for infusion processes.

Easy to handle and supplied in a ready to use roll form, HexPly XF can be quickly applied by hand or with semi-automated layup equipment. It features one self-adhesive, surface finishing side - indicated by a removable protective foil. This side of the prepreg is placed against a release agent treated mold surface. Once the material has been positioned, the lay-up of the blade shell structure can start immediately, and the laminate can be infused. After curing, the blade is de-molded with the manufacturer benefitting from a pinhole-free surface that needs minimal preparation before painting.

HexPly XF material is less than half the weight of a typical gel coat per square meter, reducing the overall weight of the blade. Additionally, the consistent areal weight and thickness of the prepreg film provide a completely uniform surface coating, ensuring blade weight distribution and balance are maintained, which is critical as rotor diameters continue to increase. With no need to handle or mix liquid chemicals as in the gel coat process, HexPly® XF also improves the health and safety working conditions on the shop floor.

The material has a shelf life of six weeks at ambient temperature, which also minimizes cold storage requirements and helps to reduce scrap.

Reinach, Switzerland, and Westlake, Ohio, 2 February 2021 - Archroma, a global leader in specialty chemicals towards sustainable solutions, today announced a strategic partnership with technology innovator CleanKore, aiming to advance sustainable dyeing processes throughout the denim supply chain.

The agreement will allow Archroma and CleanKore to promote the benefits of each other’s technologies. This includes Archroma’s robust catalog of dyes and specialty chemicals along with CleanKore’s patented process of dyeing yarns at the denim mill that completely eliminates the need for potassium permanganate (PP) spray and laser booster to achieve the bright white abrasion effect in the garment finishing process. The result is a large and circular bright white core with a small ring of indigo dye. The technology does not just eliminate the chemicals associated in the PP spray and laser process, which is much safer for denim workers, it also allows to save significant amounts of water and energy throughout the manufacturing process from fabric to garmenting.

CleanKore initially looked at eliminating potassium permanganate due to its being classified as hazardous if inhaled or ingested, or in case of contact with the skin or the eye. It is also considered very toxic to aquatic life. No new equipment or capital expenses are needed to implement the CleanKore technology, which works on all denim fabric, including dark indigo, sulfur top/bottom and sulfur black.

This is where Archroma comes into the picture. Its global technical team of denim coloration specialists will provide support to denim mills seeking to implement the CleanKore technology and develop the desired looks and effects - with the right colors and chemical systems for their production set-up.

CleanKore estimates that the technology allows to save up to 15 liters of water per garment, or the equivalent to the drinking needs of 5 people per day, and up to 0.51 kWh of energy per garment, or the equivalent of five 100-watt light bulbs on for 1 hour. The CleanKore technology also leads to a 10% to 20% increase in production throughput, as a result of a faster garment wash-down and the elimination of PP spray.

For CleanKore CEO Darryl Costin Jr., the announcement comes at an ideal time for CleanKore: "We have successfully proven the technology with mill partners such as Arvind and other denim mills in Pakistan, Bangladesh, China, Vietnam, Thailand and the United States. The response from the industry has been overwhelmingly positive. Having a partner in Archroma, one that is highly respected for their innovation and emphasis on sustainability throughout the industry, will allow us to take CleanKore to the next level.”

Umberto Devita, Global Indigo Manager at the Archroma Global Competence Center for Denim & Casualwear, adds: "CleanKore is perfectly aligned with the 3 pillars of 'The Archroma Way to a Sustainable World: Safe, efficient, enhanced'. 'Safe' through the elimination of a potentially harmful substance and the protection of the denim workers, 'Efficient' through the reduction of resource consumption, improved productivity and cost-effective profile. And 'Enhanced' through the gorgeous colors and effects allowed with Archroma's innovations and systems, in particular our aniline-free* Denisol® Pure Indigo and Diresul® sulfur dyes. We look forward to help promoting an innovation that will help with many of the challenges facing our denim customers throughout the world. Because it’s our nature."

Hexcel is pleased to announce Type Approval Certification of its HexPly® M9 prepreg materials by DNV GL. The addition of the HexPly M9 prepreg range to Hexcel’s already comprehensive DNV GL certified portfolio provides ship and boat builders with optimal prepreg processing options.

HexPly M9 prepregs enable short cure cycles at 100˚C and above and provide a balance between ease of processing and mechanical performance. Available in high tack and medium tack variants, HexPly M9 prepregs are available with a wide range of unidirectional, woven, and multiaxial reinforcements. Partnered with Hexcel’s own HexTow® IMC2 and HexTow® HM54 / HM63 fibers, designers and engineers can optimize highly loaded composite structures such as masts, wing sails, and foils with increased glass transition temperatures (Tg) and excellent long-term fatigue performance.
 
Hexcel has completed the DNV GL certification for HexPly M9 in response to the rapidly increasing demand for type-approved high-performance prepreg materials for large composite structures in the commercial marine craft.  

Hexcel’s collaboration with Chantiers de l’Atlantique on its new Silenseas cruise ship concept – a concept that uses composite Solid Sail® propulsion as well as dual-fuel engines to reduce emissions and operating costs – is one such application. In this case, DNV GL type approval provides third-party assurance of the product’s quality, performance and consistency, and also helps to streamline the approval of composite parts that replace traditionally metallic structures.

Hexcel has supplied advanced composite materials to the marine industry for more than 40 years and manufactures a comprehensive range of DNV GL certified products including woven reinforcements, multiaxial fabrics, prepregs, and adhesive films. Hexcel is committed to developing new composite technologies for the marine sector, helping builders evolve their designs to produce lighter, more fuel-efficient, and a sustainable craft for the future.

“Our latest Type Approval Certification is an important part of our strategy to provide the most complete package of DNV GL certified composite materials for the marine sector,” said Andreas Sageder, Product Manager at Hexcel. “With the addition of our M9 prepreg resin systems, mast, ship, and boat builders have an expanded range of processing and cure options available for parts requiring higher Tg and improved fatigue performance.”

Hologenix, creators of Celliant®, infrared responsive technology, and Kelheim Fibres, a world-leading manufacturer of viscose specialty fibers, have partnered to launch Celliant Viscose at ISPO Munich 2021. Celliant Viscose is a finalist in Best Products by ISPO and will be showcased in the Fibers & Insulations Category for ISPO Textrends, where realistic views and 3-D simulations will be available for each material.

The introduction of nature-based Celliant Viscose will be the first in-fiber infrared sustainable solution on the market and meets a consumer demand for more environmentally friendly textiles. An alternative to synthetic fibers and extremely versatile, Celliant Viscose blends beautifully with cotton, micromodal, lyocell, wool varieties including cashmere. It also has many applications across industries as it is ideal for performance wear, luxury loungewear, casual wear and bedding.

Celliant Viscose features natural, ethically sourced minerals embedded into plant-based fibers to create infrared products that capture and convert body heat into infrared, increasing local circulation and improved cellular oxygenation. This results in stronger performance, faster recovery and better sleep.

Celliant Viscose provides all the benefits of being a viscose fiber — lightweight, soft, highly breathable, excellent moisture management — as well as fiber enhancements from Celliant infrared technology. Celliant’s proprietary blend of natural minerals allows textiles to capture and convert body heat into full-spectrum infrared energy, resulting in stronger performance, faster recovery and better sleep. In addition, Celliant is durable and will not wash out, lasting the useful life of the product it powers.

An Affordable, Long-lasting Solution with Diverse Applications
As opposed to other IR viscose products which are coatings based, Celliant Viscose’s in-fiber solution increases wearability and longevity with a soft feel, durability from washing and longer life. The combination of Kelheim’s distinctive technology and the Celliant additives creates this unique fiber that provides full functionality without the need for any additional processing step — a new standard in the field of sustainable IR viscose fibers. This single processing also makes Celliant Viscose more cost-effective and time-efficient than coatings.

In addition, Kelheim’s flexible technology allows targeted interventions in the viscose fiber process. By modifying the fiber’s dimensions or cross sections or by incorporating additives into the fiber matrix, Kelheim can precisely define the fiber’s properties according to the specific needs of the end product.

Highly Sustainable
Celliant Viscose is a plant and mineral-based solution for brands seeking an alternative to synthetic fibers. It contains natural raw materials that are from the earth and can return safely to the earth.

Nature-based Celliant Viscose is certified by FSC® or PEFC™, which guarantees the origin in sustainably managed plantations, and is part of the CanopyStyle initiative to protect ancient and endangered forests. The production of Celliant Viscose takes place exclusively at the Kelheim facilities in Germany, complying with the country’s strict environmental laws and guaranteeing an overall eco-friendly product.

Backed by Science
Celliant is rigorously tested by a Science Advisory Board composed of experts in the fields of physics, biology, chemistry and medicine. The Science Advisory Board has overseen 10 clinical, technical and physical trials, and seven published studies that demonstrate Celliant’s effectiveness and the benefits of infrared energy.

For more information, visit www.celliant.com/celliant-viscose/

• The Bavarian Kelheim Fibres GmbH has become the first viscose fibre manufacturer worldwide to receive EMAS certification.

“Our aspiration is that our fibres offer an eco-friendly and high-performance alternative to synthetic materials”, says Craig Barker, CEO at Kelheim Fibres. “So, it’s not enough that our fibres are made from renewable resources and that they are fully biodegradable – our environmental awareness must include the whole production process and all that goes with it if we want to safeguard our credibility.

The EMAS certification proves that we take this responsibility seriously.” EMAS stands for “Eco Management and Audit Scheme” and is a standardised eco management certification system developed by the European Union. EMAS includes the globally applicable ISO 14001 standard and goes beyond its requirements by demanding more transparency and continuous improvement: Certified companies report in their annual EMAS Environmental Statement on their environmental goals and their progress in meeting them.

During the audit preceding the certification, the independent environmental auditor thoroughly investigated all departments of the company, from the production itself to the company canteen. He found no non-conformances and was impressed by the competence and the high sense of responsibility among Kelheim’s employees. In contrast to the EU Ecolabel and similar certifications, EMAS does not apply to individual products or services, but certifies the complete environmental performance of the company. This benefits not only the protection of the environment and climate, but also the improvement of a company’s ecoefficiency.

Craig Barker: “An efficient environmental management system ensures that economy and ecology go hand in hand – that gives us a decisive competitive edge.”

Archroma, a global leader in specialty chemicals towards sustainable solutions, has been recently ranked number 1 in the “industrial chemicals” list published by the Institute of Public & Environmental Affairs (IPE) for driving transparency in their supply chain.

Archroma also entered the Top 50 of companies in IPE’s Green Supply Chain CITI Evaluation, at the 47th position. The evaluation dynamically assesses brands on the environmental management of their supply chains in China.

With a wide array of products used every day, everywhere, the company is committed to operate along the principles of “The Archroma Way to a Sustainable World: Safe, efficient, enhanced, it’s our nature”. The Archroma team is therefore committed to sourcing safe and sustainable raw materials and intermediates from like-minded partners.

Heike van de Kerkhof, CEO of Archroma, recently delivered a message at the IPE 2020 Green Supply Chain Forum online, and commented: “As industry leader, we have the responsibility to keep on addressing the climate challenge, and to do everything we can together to reduce our impact on the environment. This is where the approach of the Institute of Public & Environmental Affairs supports us. They encourage us to challenge our suppliers in terms of safety, health and environment, and to go even beyond our own strict policies and processes.”

The Swiss Technology Award announced the 2020 prizes, and among all the notable finalist innovations of the year, HeiQ was bestowed the highest honor as First Prize Winner for its breakthrough antiviral textile technology HeiQ Viroblock.

Developed in record time and launched after the Swiss authorities announced the lockdown in March 2020, HeiQ Viroblock has had a major impact on the global textile industry and is being unprecedently adopted by mills around the world.

The technology that makes HeiQ Viroblock a unique innovation
What exemplifies HeiQ Viroblock is its ability to turn any fabric antiviral. It’s among the first textile technologies in the world to be proven effective against SARS-CoV-2 (COVID-19). HeiQ Viroblock consists of a combination of HeiQ’s patent-pending vesicle and silver technologies. The two mechanisms of attack result in an over 99.9% destruction of viruses in 5 minutes that is unrivaled in the industry. HeiQ Viroblock is a unique patent-pending formulation of 72% bio-based ingredients, made with 100% cosmetic-grade materials from the International Nomenclature of Cosmetic Ingredients list. HeiQ Viroblock is also a shining example of Swiss cooperation between academics and the industry. The silver technology was developed at ETHZ (Eidgenössische Technische Hochschule Zürich), the vesicle technology at EPFL (École polytechnique fédérale de Lausanne), and the production was scaled up at FHNW (Fachhochschule Nordwestschweiz).

HeiQ Viroblock has demonstrated unparalleled speed from laboratory to consumer
HeiQ launched the new antiviral textile technology HeiQ Viroblock on March 16, 2020 – two hours after Switzerland declared a state of emergency. This was made possible with the indispensable support of Swiss research Partner FHNW and the EPFL which helped accelerate product validation. The fast scale-up of production was enabled by the FHNW School of Life Sciences with their new Process Technology Center (PTC) by special permit. With its agile operations and global footprint, HeiQ also brought HeiQ Viroblock face masks and other PPE (personal protection equipment) to different corners of the world where are needed. Now, Swiss consumers can also acquire HeiQ Viroblock enhanced face masks online.

Reacting to the news of HeiQ Viroblock winning this year’s Swiss Tech Award, Co-founder and CEO Carlo Centonze says: “I am both amazed and honored that HeiQ has won this award a second time in just ten years, and from among some incredible tech innovation finalists. It confirms our resolve to push the boundaries and push innovations to help the world with its most pressing and imminent problems. This award is recognition for our company and team that have spared no efforts to develop and launch HeiQ Viroblock at such speed and make a valuable contribution to the global pandemic efforts. We remain true to our mission: enhancing the everyday lives of people with smart and efficient textile effects.”

Since the outbreak of the coronavirus pandemic, the worldwide demand for protective masks and apparel has resulted in a record number of new orders in the high double-digit millions of euros at Oerlikon Nonwoven. The meltblown technology from Neumünster is recognized by the market as being one of the technically most efficient methods for producing highly-separating filter media made from plastic fibers.

Protective equipment demands high-end nonwoven products
The rising demand for protective masks and other medical protective equipment since the start of the coronavirus pandemic and the associated global ramping up of production capacities has also resulted in an increase in the demand for nonwovens for the production thereof. Initially, this resulted in bottlenecks in the provision of meltblown filter nonwovens. To this end, there had until this point be very few producers of medical filter nonwovens outside China. Meanwhile, the demand for spunbond systems is also rising. “Due to the structure of our group, we are in the fortunate position to swiftly reallocate and free up our production capacities. This means that we are able to relatively quickly deliver not only meltblown systems, but also spunbond equipment”, explains Dr. Ingo Mählmann, Head of Sales & Marketing at Oerlikon Nonwoven, talking about the positive situation at the company.

The capacities for respiratory masks available in Europe to date are predominantly manufactured on Oerlikon Nonwoven systems. “Our machines and systems for manufacturing manmade fiber and nonwovens solutions enjoy an outstanding reputation throughout the world. Ever more manufacturers in the most diverse countries are hoping to become independent of imports”, comments Dr. Mählmann. The Oerlikon Nonwoven meltblown systems are being delivered to Germany, China, Turkey, United Kingdom, South Korea, Italy, France, North America and – for the very first time – to Australia until well into 2021.

Quality and efficiency in demand
Depending on the purpose of the application, medical PPE (personal protection equipment) should be breathable and comfortable to wear, protect medical staff against viruses, bacteria and other harmful substances and form a barrier against liquids. For these reasons, they are often made of either pure spunbond or of spunbond-meltblown combinations. Here, the meltblown nonwoven core assumes the barrier or filter task, while the spunbond has to retain its shape, while being tear-resistant, abrasion-proof, absorbent, particularly flame-resistant and nevertheless extremely soft on the skin.

All masks are not created equal – thanks to the ecuTEC+
Protection against infections such as coronavirus can only be guaranteed with the right quality.

The nonwovens can be electrostatically-charged in order to further improve the filter performance without additionally increasing breathing resistance. Here, Oerlikon Nonwovenʼs patented ecuTEC+ electro-charging unit excels in terms of its extreme flexibility. Nonwovens manufacturers can freely choose between numerous variation options and set the optimal charging method and intensity for their specific applications. In this way, even the smallest particles are still attracted and reliable separated by a relatively open-pored nonwoven. Nevertheless, mask wearers are still able to easily breathe in and out due to the comparatively loose formation of the fibers. To this end, it comes as no surprise that all meltblown systems currently destined for the production of mask nonwovens are equipped with the ecuTEC+ unit.

The AVK – Industrievereinigung Verstärkte Kunststoffe e.V. – has once again announced the winners of its prestigious Innovation Awards. Decided by an expert jury, the awards recognise and honour sustainable innovations in three categories: “Innovative Products/Applications”, “Innovative Processes” and “Research and Science”.

Overview of all the winners in the three categories:

Category “Innovative Products/Applications”
1st Place: “Directly-cooled electric motor with integral lightweight housing made of fibre reinforced polymers - DEmiL” – developed by the Fraunhofer Institute for Chemical Technology ICT, Pfinztal, Germany, in partnership with the Karlsruhe Institute of Technology and Sumitomo Bakelite Co., Ltd.*

2nd Place: “Intrinsically Reprocessable, Repairable and Recyclable (3R) thermoset composites for more Competitive and Sustainable Industries” – developed by cidetec, Donostia-San Sebastian, Spain*

3rd Place: “Fireproof composite metal hybrid structure – LEO® fire protection sandwich with integrated Hyconnect steel-glass hybrid connector” – developed by SAERTEX GmbH & Co. KG and Hyconnect GmbH.*

Category “Innovative Processes”
1st Place: “Robotised Injection Moulding (ROBIN)” – developed by Robin, Dresden with the Institute for Lightweight Engineering and Polymer Technology at the TU Dresden*

2nd Place: “Omega stringer from the roll” – developed by the German Aerospace Center, Braunschweig*

3rd Place: “Hybrid die-casting – manufacturing of intrinsic CFRP-aluminium composite structures in aluminium high-pressure die-casting” – developed by Faserinstitut Bremen e. V. with Fraunhofer IFAM, Bremen*

Category “Research and Science”:
1st Place: “New high-temperature resistant UP resins and toughening agents” – developed by Münster University of Applied Sciences with BASF SE Global New Business Development, Leibniz Institute for Polymer Research e. V., Saertex multicom GmbH*

2nd Place: “Scientific basis for the industrial application of the thermoplastic resin transfer moulding (T-RTM) process” – developed by Fraunhofer Institute for Chemical Technology ICT, Pfinztal*

3rd Place: “The material- and energy-efficient production of turbine struts by the integrative combination of thermoset fibre reinforced materials” – developed by the Institute of Polymer Technology, University of Erlangen-Nuremberg with the German Aerospace Center, Gubesch Group, Schmidt WFT, Siebenwurst, Raschig.

Award ceremony on the Internet for the first time
For the first time, due to the Covid-19 pandemic, the award ceremony took place as an online event on 12 November 2020. Many of the award winners’ innovations will be presented again in this year’s AVK Innovation Award brochure. This will be available online: https://www.avk-tv.de/innovationaward.php

*Please see attached document for more information.

• License agreement concluded for promising technology
• Integration into the digital spinning suite ESSENTIAL
• Implementation of digital strategy further advanced

The Rieter Group concludes a license agreement with WW Systems on November 5, 2020 and will integrate the Brazilian company's promising product into its digital spinning suite ESSENTIAL. "OptCotton" from WW Systems offers the only software system worldwide that enables an even blend of cotton for the spinning process. With this cooperation, Rieter is taking an important step forward in implementing its digital strategy and offering its customers further added value in yarn production.

"OptCotton" eliminates variations in quality between cotton blends that are being prepared for the spinning process. In this way, standardized quality yarn can be produced efficiently in the spinning process. From the arrival of the bales in the warehouse to their use in the blowroom line, “OptCotton” manages the entire blending process with no need for categorization. This results in increased efficiency in storage and logistics as well as machine performance.

Integration into the digital spinning suite ESSENTIAL
By integrating this solution, Rieter strengthens its digital spinning suite ESSENTIAL. Access to bale-related fiber data and raw material information opens up new possibilities for controlling the spinning mill. In combination with the existing modules ESSENTIALbasic, ESSENTIALmonitor, ESSENTIALmaintain and ESSENTIALpredict, this optimizes the entire spinning process and raises digital intelligence to a new level.