From the Sector

• Borealis’ EverMinds™ ambition moves industry one step closer to plastics circularity thanks to new recycling technology and improved recyclate
• Borealis also announces significant material improvements to existing Purpolen® recyclate materials

Borealis, a leading provider of innovative solutions in the fields of polyolefins, base chemicals and fertilizers, announces the introduction of a new plastics recycling technology, Borcycle™. This evolving technology will be used to produce high-quality compounds made of recycled polyolefins (rPO) such as the newly-launched Borcycle™ MF1981SY, an rPO with over 80% recycled content intended for use in visible appliance parts. Borealis also announces a series of significant material improvements to existing recyclates in the established Purpolen™ brand portfolio. These market launches and product improvements are important technology advancements and thus accelerate the transformation to a circular economy of plastics. Borealis and its wholly-owned subsidiary, mtm plastics, will showcase the new Borcycle technology and recyclate innovations at the K 2019 in October.

Borealis is leading the industry by applying its Visioneering Philosophy™ to the development and implementation of novel polyolefins-based solutions that enable plastics reuse, recycling, and recovery, and by designing for circularity. These wide-ranging activities are gathered under the symbolic roof of EverMinds™, the Borealis platform dedicated to promoting a more circular mind-set in the industry. By capitalising on its profound expertise in virgin polyolefins and collaborating with value chain partners, Borealis keeps discovering new opportunities for business growth within the circular economy.

Advancing technology to bring about polyolefin circularity

The new technology, Borcycle, transforms polyolefin-based waste streams into recyclate material such as pellets. As a transformative technology, it complements the existing Borealis virgin polyolefins portfolio with a range of pioneering, circular solutions. It unites state-of-the-art technology with the profound Borealis polymer expertise gained over decades.

As a scalable and modular technology, Borcycle has been developed to meet growing market demand for high-quality recyclate. Leading appliance brand owners, for one, have pledged to increase the amount of recycled plastics in their goods. Yet until recently, producers have not been able to rely on a consistent supply of high-quality recyclate. The Borcycle technology will help address this challenge. Compounds made using the Borcycle technology deliver high performance, add value and offer versatility. Producers and brand owners in a range of industries will profit from the availability of high-quality recyclate that helps them meet environmental and regulatory challenges.

“Advancing technology is crucial if our aim is to implement value-creating solutions in the circular sphere,” claims Maurits van Tol, Borealis Senior Vice President, Innovation, Technology & Circular Economy Solutions. “‘Building tomorrow together’ means innovating, collaborating, focussing on the customer, and above all – taking action. The launch of our new recycling technology Borcycle is tangible proof of our commitment to achieving plastics circularity.”

New and improved recyclate for high-end applications

Borcycle™ MF1981SY is the first of several upcoming launches of rPO solutions made under the umbrella of the Borcycle technology. Borcycle™ MF1981SY will be available to Borealis customers in Europe. The compound is an exciting addition to the rPO portfolio because it is a 10% talc-filled compound that contains over 80% recycled material. It offers an ideal balance between stiffness and impact. The compound is especially suited for use in visible black parts, for example in small appliances.

Like its relatives in the mtm plastics family of recyclate materials, Borcycle™ MF1981SY is a truly sustainable offering. Recyclates from mtm save approximately 30% of CO2 emissions compared to virgin materials.

A number of significant improvements have been made to existing recyclate grades in the Purpolen portfolio.

“Mechanical recycling is presently a most eco-efficient method to implement the principles of the circular economy,” explains Guenter Stephan, Head of Mechanical Recycling, Borealis Circular Economy Solutions. “Borealis and mtm plastics are leveraging their respective areas of expertise to make significant progress in achieving polyolefin circularity by upscaling recycling output and ensuring the reliable supply of high-quality plastics recyclate for European producers, in particular.”

• Lenzing sets net-zero CO2 emissions target by 2050
• Reduction of specific CO2 emissions by 50 percent until 2030
• Investment of more than EUR 100 mn to combat 1.3 Mt of CO2 emissions
• Commitment to follow the Science Based Targets concept

Lenzing, member of the CEO Climate Leaders Group of the World Economic Forum and a signatory to the United Nations Fashion Industry Charter for Climate Action, will drastically reduce its CO2 footprint. The Lenzing Group will invest EUR 100 mn over the coming years to reduce carbon emissions both inside its operational boundaries (scope 1+2) and in its supply chain (scope 3). Due to its ambitious CO2 emission reduction strategy, the Lenzing Group will further contribute towards helping customers to transition their business to a lower CO2 base.

A first milestone is set for 2030, when Lenzing plans to reduce CO2 emissions per ton of product by almost 50 percent (scope 1+2 and 3) compared to a 2017 baseline. The total CO2 reduction of all the planned initiatives will yield 1.3 Mt.

Kornit Digital market leader in digital textile printing technology, announced Kornit Konnect, its new cloud-based, mobile workflow software platform that enables businesses to maximize productivity of their digital printing solutions. This is the first phase in Kornit’s implementation of its industry vision of textile design, decoration and production being fueled by data-driven insights and performance metrics.

STAMFORD, Conn. – At this year's Paris Airshow [Le Bourget, June 17-23] Hexcel will promote a range of carbon fibers and composite materials used to manufacture high-performance weight-saving structures in civil aircraft, engines, helicopters, and space applications.

Visitors to the Hexcel stand will see an Integrated Wing Panel demonstrator and an I-beam, both made with HiTape® carbon fiber reinforcements. HiTape® dry carbon reinforcements were developed for the automated lay-up of preforms and to complement a new generation of HiFlow™ resin systems, producing high-quality aerospace structures using the resin infusion process. The reinforcements incorporate a toughening veil to enhance mechanical properties and meet the structural requirements for aerospace parts. The I-Beam was manufactured using C-RTM (Compression Resin Transfer Molding) and was injected with Hexcel’s RTM6 resin in a process taking less than five minutes.

Hexcel honeycomb saves weight and enhances stiffness in composite structures, and the company provides a range of engineered core solutions that enable highly contoured parts with precision profiling to be produced to exact customer specifications. A sample part made from aluminum FlexCore® that is CNC machined on both sides and formed and stabilized with both peel ply and flyaway layers of stabilization will be on display.

Another honeycomb innovation is Hexcel’s Acousti-Cap® broadband noise-reducing honeycomb that significantly improves acoustic absorption in aircraft engine nacelles. The acoustic treatment may be positioned at a consistent depth and resistance within the core or can be placed in a pattern of varying depths and/or resistances (Multi-Degrees of Freedom and 3 Degrees Of Freedom), offering an acoustic liner that is precisely tuned to the engine operating conditions. These technologies have been tested at NASA on a full engine test rig and meet all 16 design conditions without trade-offs.
Another Hexcel technology to benefit aircraft engines is HexShield™ honeycomb which provides high-temperature resistance in nacelles. By inserting a thermally resistant material into honeycomb cells, Hexcel provides a core product with unique heat-shielding capabilities that allows for the potential reuse of material after a fire.

With 50 years of experience behind its comprehensive range of high-strength, high-strain PAN-based carbon fibers, Hexcel continues to innovate and is introducing two new fibers to its portfolio. HexTow® HM50 combines high modulus and high tensile strength, making it ideal for commercial and defense aircraft and engines. HexTow® 85 was developed specifically to replace rayon-based carbon fiber for ablative applications.

Another area of expertise that uses HexTow® carbon fiber is additive manufacturing, where Hexcel uses PEKK ultrahigh performance polymers and HexAM™ technology to manufacture carbon reinforced 3D printed parts. This innovative process provides a weight-saving solution for intricate parts in highly demanding aerospace, satellite and defense applications. HexPEKK™ structures offer significant weight, cost and time-to-market reductions, replacing traditional cast or machined metallic parts with a new technology.

Later this year Hexcel will open a joint research and development laboratory in Les Avenières (Isère), France with Arkema to develop carbon fiber-reinforced thermoplastic prepreg tapes for aerospace, space and defense applications. A spool of thermoplastic prepreg tape will be on display on Hexcel’s stand to showcase this cost-effective technology that enables lightweight parts to be produced in faster production cycles for future generations of aircraft.

Hexcel’s stand is located next to Hexcel’s official distributor for aerospace products, Groupe Gazechim Composites. In 2018, Hexcel and Gazechim formed a joint venture, HexCut Services, to provide aerospace and defense customers with customized kitting services that include Hexcel’s innovative carbon fiber prepreg, fabrics and adhesives. Pre-cut kits save customers time and investment, reduce inventory and minimize material losses through scrap reduction.

TINTEX Textiles announced its acceptance as a participant of the United Nations Global Compact initiative - a voluntary leadership platform for the development, implementation and disclosure of responsible business practices. A real demonstration of the “Naturally Advanced” ongoing commitment to responsible business action. Expertly controlled processing, and advanced dyeing and finishing solutions drive material innovation to create responsible supply chains to transform fashion systems.
 
“Being part of the UN GLOBAL COMPACT means to publically commit with all the principles that are the basis of our business” – [ Ana Silva Tavares Head of Sustainability ]

Assuming social responsibility and acting sustainably has been Autoneum's focus since it became an independent company. In order to achieve the best results possible, the Company last year has defined a number of quantitative and qualitative targets in the areas of “Sustainable Products and Production Processes”, “Fair and Attractive Workplace”, “Good Corporate Citizenship” and “Responsible Supply Chain Management” for 2025. In all these areas Autoneum has achieved important successes already in 2018.

Through the consistent implementation of environmental efficiency projects – a total of over 80 worldwide – Autoneum reduced its environmental impact further in 2018. For example, both the amount of waste (–5.9%) and water consumption (–13.4%) have fallen sharply. At the same time, various plants – particularly in Asia and North America – have expanded their recycling capacity, significantly increasing the amount of production waste reused in the manufacturing process (14.9%).

To further improve working conditions especially in production, measures were taken in all Business Groups in 2018 to enhance occupational health and safety and well-being in the workplace. A global employee satisfaction survey conducted in fall last year has confirmed the first positive effects of these measures.

A complete overview of all targets and activities during the past year can be found in the Corporate Responsibility Report 2018 and is available at www.autoneum.com/corporateresponsibility/.

The last frontier of innovation in racing suits made with yarns in Metamicro is the model Prime SP-16+, designed in collaboration with the Team McLaren Honda F.1

The spinning mill Filidea, joint venture between Marchi & Fildi spa and Abalıoğlu Holding A.Ş specialized in technical and high performance yarns with natural and synthtic fibers, is parter of Sparco, italian Company leader for the production of automotive components and technical apparels for the most important world Championships. The cooperation between the two Companies located in Piedmont, northern Italy, is focused on the supply of yarns with Metamicro in an exclusive composition, that are used for the production of the racing suits Sparco of the Premium range for Formula 1 and the World Rally Championship. The fire resistant yarn Metamicro based on aramidic fibers are a product of the latest generation, for their production it is necessary a special spinning line. The production is following the strict Sparco standards. Sparco controls all the production chain of racing suits, from Filidea, who has the competence to dye all the yarns with aramidic fibers in its own dyeing plant, to the woven fabric, produced and dyed in its own plant, to the woven fabric made by the italian Company TAT, till the production of garments. The process is always improved and tested.

Metamicro yarns are made by an high peformance spinning process. They are used for the production of fire resistant fabrics, that make a protection barrier for the body against flames and high temperature. The very fine micronage allows the production of very light fabrics with thick texture, the perfect base for light and comfortable suits. These features assure easier movements to the driver and the maximum protection from fire, keeping high breathability.

Filidea has invested on its production capacity of corespun yarns with XLANCE® technology, fiber used for the production of longlasting workwear apparel with an excellent fitting.

The spinning mill Filidea, joint venture between Marchi & Fildi spa and Abalıoğlu Holding A.Ş specialize in technical and high performance yarns with natural and synthtic fibers, is increasing its production of blends with XLANCE®.

XLANCE® is the innovative elastolefin fibe, elastic, chlorine and UV resistant. It finds application on workwear and outdoor clothing, with natural and comfort fitting. The comfort stretch feature follows the the body’s natural movement during the day-to-day work. Workwear clothing are so light, resistant and with a contemporary look. Resistance to abrasion and to frequent industrial laundry cycles with chemical products meet the needs of several professional sectors. XLANCE® is produced by ©Xlance srl, Company located in Varallo Pombia (province of Novara – Piedmont – Italy) that found in Filidea the perfect partner for the development of specific yarns, that are getting more and more requested. An innovation that is getting more important thanks to the cooperation of the two textile Companies located in Piedmont. Filidea has been producing XLANCE® yarns since 2009 and has now a great know-how. The Company to strengthens its leadership in technical yarns, for the main applications on protetictive garments, workwear, sportswear, racing and automotive. Filidea has developed and consolidated several partnerships for the creation of complete supply chains and the collaboration with ©Xlance is a perfect example.

• BASF’s photopolymer materials for advanced manufacturing applica-tions qualify for early development access in new WAV™ technology
• BASF’s Ultracur3D ST 45 reactive urethane photopolymer fulfills the re-quirements of functional applications

BASF 3D Printing Solutions is to provide innovative additive manufacturing materi-als to Paxis LLC for their new WAV™ technology. This is currently in development and is designed to meet the needs of additive manufacturing users, advanced manufacturing as well as traditional manufacturing markets. The WAV™ (Wave Applied Voxel) process was created with the end-user firmly in mind in an effort to solve trapped volume issues of current liquid resin-based technologies.

"The combination of BASF materials and Paxis’s system will revolutionize the way end-applications are designed, manufactured and integrated into production", states Arnaud Guedou, Business Director Photopolymer Solutions, BASF 3D Printing Solutions. "With the new WAV™ technology, Paxis extends the application possibilities of additive manufacturing to a much broader scope than current technologies allow. What’s more, equipment and processes can be adapted to requirements that were previously unimaginable in additive manufacturing. BASF’s innovative photopolymer materials are a perfect match for Paxis's WAV™ technology."

BASF’s Ultracur3D ST 45 reactive urethane photopolymer for tough applications has been designed to fulfill the requirements of functional applications for high accuracy and mechanical strength, where existing 3D printing materials often reach their limitations. Ultracur3D ST 45 can be used to produce high performance functional parts by using a wide variety of equipment, such as stereolithography (SLA), digital light processing (DLP), or Liquid Crystal Display (LCD).

Lectra has been awarded by a jury of experts the Texprocess Innovation Award 2019 in the New Process category for its latest ground-breaking offer, Fashion On Demand by Lectra.

Fashion On Demand by Lectra automates the entire personalization process, from order reception and product development to the final cutting stages. Resulting from a four-year research-and-development process, the digital solution for on-demand production was developed based on Industry 4.0 principles.

"We are very proud to receive this prestigious award at Texprocess, the biggest international event for all fashion players. Fashion On Demand by Lectra allows companies to produce personalized clothing at the same speed as ready-to-wear and avoid overstocking by producing in precise quantities,” states Holger Max-Lang, President, Northern & Eastern Europe, Middle East, Lectra.

Fashion On Demand by Lectra is available in the form of two packages, one dedicated to made to measure, with pattern adjustments, and the other to customization, with product characteristic alterations. This turnkey solution automates on-demand production right from order reception to production development stages and the cutting room. Companies can define their desired product personalization criteria for each item depending on the package, and launch production processes right from the get-go, without interfering with their standard workflows.

"This innovative cloud-based platform solution ensures efficient made-to-measure and customization production processes and facilitates nearshoring for companies that offer individualized products. This technology is up and running and can be used by the fashion industry on a plug-and-play basis," say the jury experts. “Since 2011, the Texprocess Innovation Award has been honoring remarkable achievements and new developments in the Texprocess product range under two categories: new technology and new process. The winners are selected based on criteria such as degree of innovation, choice of materials and environmental sustainability."

C.L.A.S.S ‘takes action’ and shares the very smartest textile and material innovations available globally today as part of a carefully curated space to be unveiled at the 10th anniversary of the Copenhagen Fashion Summit. This two-day event will take place from the 15th - 16th May at The Copenhagen Concert Hall.

With education right at the heart of this unique presentation, C.L.A.S.S will share valuable insights and physical examples of some of the most sustainably responsible innovations available on the market today, empowering the next generation of designers as well as those from leading design houses, with the chance to experience first-hand how they might work towards a circular design economy.

Located within the Design Studio area, key members of the C.L.A.S.S ACTIVATE team will be on hand to share valuable insights gleaned from over 12 years of research and development within this area helping to provide visitors including new designers, start-up’s, and established designers with everything needed to make ‘smart’ choices that work vertically through the supply chain from merchandising right through to consumer facing communication campaigns. From trends, new R&D concepts, and the latest buzzwords, C.L.A.S.S has it covered.