From the Sector

The combination of high strength and rigidity with sustainability and a neutral carbon footprint makes flax the ideal raw material for natural fibre-reinforced plastics. vombaur offers composite textiles made of this natural fibre for the automotive, wind power, construction or sports industries and many other sectors.

Flax fibres are rigid and tear-proof. They have natural bactericidal properties, are virtually antistatic, stain resistant and easy to spin. Humans have taken advantage of these properties to manufacture robust, stain-resistant and lint-free textiles. Between the late 19^th and late 20^th centuries, cotton largely replaced natural fibres. Because flax can be grown in Europe and consumes less energy and water than cotton production, the material's importance is currently growing again, for both clothing and composites. Regional textile value added chains in Europe – flax makes them possible.

Ideal mechanical properties
vombaur makes the mechanical properties of flax usable for lightweight design. Because flax fibres are particularly rigid and tear-resistant, they ensure great stability in natural fibre-reinforced plastics (NFRPs). And thanks to their low density of 1.50 g/cm3, the fibres weigh virtually nothing. On top of this, fibre-reinforced plastics are less prone to splintering than glass fibre-reinforced plastics.

Excellent carbon footprint
The cultivation of flax binds CO₂ and the production of natural fibre-reinforced plastics (NFRPs) generates approximately one third less CO₂ emissions compared with conventional fibre-reinforced plastics. Energy consumption is substantially lower. This saves resources. The use of flax fibre tapes by vombaur in lightweight design applications also improves the product's carbon footprint and contributes to a secure, regional supply chain.

Recycling without impacting on quality
Flax offers another sustainability benefit: more recycling cycles than glass- or carbon fibre-reinforced plastics – without impacting on quality. Thermoplastic fibre-matrix prepregs are melted and reused in the recycling process. The natural fibres can be used in other products such as natural fibre-reinforced injection moulded parts.

Sustainable product developments for many industries
"Orthoses for high-performance sports, high-tech skis, wind turbines, components for the automotive industry or aerospace, but also modern window profiles – the application scope for our lightweight design flax tapes is amazingly diverse", as Carl Mrusek, Chief Sales Officer at vombaur explains. "After all, wherever flax tapes are used, three key properties come together: light weight, strength and sustainability".

OCSiAl, a leader in graphene nanotube technologies, has been granted a construction permit for a nanotube production facility near Belgrade, Serbia. The new nanotube synthesis plant will be launched in 2024 and will have an initial annual capacity of 60 tonnes of graphene nanotubes. Over the next two years, the capacity of this plant will be increased to 120 tonnes per year. “The project will facilitate logistics and lower supply chain costs. European-produced nanotubes and nanotube derivatives will be primarily supplied to our customers in central and western Europe, North America, and Asia,” said OCSiAl Group Senior Vice President Gregory Gurevich.
 
In addition to synthesizing nanotubes, the facility will manufacture nanotube suspensions for lithium-ion battery manufacturers in Europe, the US, and Asia – enough to enhance the performance of more than 1 mln electric cars with an average battery capacity of 75 kWh per car. OCSiAl nanotubes create long and robust electrical networks between active material particles, improving key battery characteristics, including cycle life, lower DCR, C-rate performance, and cohesion between active battery material particles, making the battery electrodes more durable. Graphene nanotubes unlock new battery technologies, including high-silicon content anodes, thick LFP cathodes, fast-charging graphite anodes, and more. They can be applied in both conventional and emerging battery tech, such as a dry battery electrode coating process, and solid-state batteries.
 
As well as synthesizing nanotubes and producing suspensions, OCSiAl project includes manufacturing of nanotube concentrates for high-performance polymers. The project has passed environmental impact assessment and it is 100% powered by green energy. It enjoys support from Serbian municipal and national governments. The plant is planned to be certified in accordance with ISO 9001, ISO 14001, and ISO 45001, and to be compliant with the IATF 16949 automotive industry standard. The project will create more than 200 job opportunities for engineers, scientists, managers, operators, and administrative staff.
 
Currently, OCSiAl has an extensive manufacturing system of nanotube-based products in the regions of highest market demand, such as China, Japan, Sri Lanka, Brazil, Malaysia, and other countries. The Serbia nanotube hub will operate in conjunction with the company’s operational R&D center and planned graphene nanotube synthesis facility in Luxembourg.

At this year’s Techtextil India, the Polymer Processing Solutions Division of the Swiss Oerlikon group will be presenting the trade audience with new applications, special processes and sustainable solutions focusing on the production of industrial textiles. Between September 9 and 12, the discussions at Jio World Convention Centre (JWCC), Mumbai, will be concentrating on airbags, seat belts, tire cord, geotextiles, filter nonwovens and their diverse applications.

More polyester for airbags
The yarns used in airbags are made predominantly from polyamide. As a result of increasingly diverse airbag applications and also the increasing size of the systems used, polyester is today used as well, depending on the application requirements and cost-benefit considerations. Against this background, the Oerlikon Barmag technol-ogies make an invaluable contribution. In addition to high productivity and low energy consumption, they particularly excel in terms of their stable production processes. Furthermore, they comply with every high quality standard for airbags, which – as in the case of virtually all other textile products used in vehicle construction – must provide the highest level of safety for vehicle occupants - without any loss of function in any climate and for the lifetime of the vehicle

Buckle up!
Seat belts have to withstand tensile forces in excess of three tons and simultaneously stretch in a controlled manner in emergencies in order to reduce the load in the event of impact. A seat belt comprises approximately 300 filament yarns, whose individual, high-tenacity yarn threads are spun from around 100 individual filaments. “With our unique, patented Single Filament Layer Technology, we offer a sophisticated and simultaneously gentle high-tenacity (HT) yarn process for manufacturing these lifesavers and other applications made from industrial yarn”, explains André Wissenberg, Head of Marketing.

Road reinforcement using geotextiles
Low stretch, ultra-high tenacity, high rigidity – industrial yarns offer outstanding properties for the demand-ing tasks carried out by geotextiles; for instance, as geogrids in the base course system under asphalt. Normally, geotextiles have extremely high yarn titers of up to 24,000 denier. Oerlikon Barmag system concepts simultaneously manufacture three filament yarns of 6,000 denier each. Due to the high spinning titers, fewer yarns can be plied together to the required geo-yarn titer in a more cost- and energy-efficient manner.

hycuTEC –  quantum leap for filter media
In the case of its hycuTEC hydro-charging solution, Oerlikon Neumag offers a new technology for charging nonwovens that increases filter efficiency to more than 99.99%. For meltblown producers, this means material savings of 30% with significantly superior filter performance. For end users, the consequence is noticeably improved comfort resulting from significantly reduced breathing resistance. With its considerably lower water and energy consumption, this new development is also a future-proof, sustainable technology.

Toray Composite Materials America, Inc. headquartered in Tacoma, Washington, has been awarded the "Boeing Supplier of the Year" award, a leadership-nominated award given to supplier companies that support and propel Boeing's strategic objectives through risk-sharing and enduring partnerships. This year, 12 companies were selected from among 11,000 Boeing suppliers worldwide, and CMA was selected as one of them for the Alliance Award. This is Toray's second award from Boeing, receiving the Supplier of the Year Excellence Award in 2019.

Toray began supplying Boeing in 1975 when it first qualified TORAYCA™ T300 carbon fiber for commercial application on the Boeing 737. Since then, Toray has provided high-performance carbon fiber and highly toughened, primary structure carbon fiber composite prepreg on various programs.

The trophy was presented by William A. Ampofo II, Vice President of Parts & Distribution Services and Supply Chain for Boeing Global Services and Chair of the Supply Chain Operations Council to CMA.

The FoxCore founding team and the ITM at TU Dresden aim to usher in a new era for fastening solutions in lightweight construction with the start of the Exist research transfer project FoxCore. The project started on June 1, 2023, and will run until November 30, 2024, with support from the German Federal Ministry of Economics and Climate Protection (BMWK) and the European Social Fund (ESF).

The innovative company is to develop and offer new and customer-oriented fastening solutions for lightweight construction applications. Safety and performance of lightweight solutions in various industries are to be increased. FoxCore's objective is to take a leading role in fastening technology.

Daniel Weise, Philipp Schegner, Michael Vorhof and Cornelia Sennewald form the FoxCore team; they will work closely with the Institute of Textile Machinery and Textile High Performance Materials (ITM) at TU Dresden. Together, they will develop optimal manufacturing technologies and establish a widespread network of customers and suppliers.

Using recovered resin from discarded car bumpers, Autoneum’s sustainable Re-Liner technology transforms a previously unusable waste product into lightweight and durable wheelhouse outer liners. In addition to their high recycled content, the eco-friendly components require significantly less energy to produce than conventional alternatives. The innovation presents another important step towards a more sustainable circular economy and has now been nominated for the 2023 PACE Award.

Autoneum has been selected as one of the finalists for the 2023 Automotive News PACE Awards. Entering its 29th year, this prestigious award honors superior innovation, technological advancement and business performance among automotive suppliers.

Re-Liner is based on a core of polyolefins recovered from post-consumer bumpers and has a textile top layer made of fibers from recycled materials. “Autoneum has recognized the untapped potential of recovered resin from automotive bumper covers as a resource and is giving this former waste product a second life,” explained Dan Moler. “The core resin of Re-Liner is 100% automotive post-consumer recycled material, not just a filler or additive to a virgin material. Lightweight, durable, and sustainable wheelhouse outer liners based on this technology are expected to reduce waste generated by bumper covers by nearly one million kilograms in 2023.”

For more than a quarter century of a century, the PACE Award has honored innovations driven by automotive suppliers. The award is known in the global automotive industry for identifying and recognizing the latest game-changing innovation: from the plant floor to the product to the showroom. In 2000, Autoneum (then Rieter Automotive) already received a PACE Award for its Ultra-Light technology. In addition, two of the Company’s technologies have also been nominated as finalists in the past: Ultra-Silent in 2010 and Theta-Fiber in 2012.

PrimaLoft, Inc., a leader in advanced material technology, is expanding its  Active Insulation Range by adding four new Active Evolve styles, reaffirming its commitment to providing cutting-edge solutions that meet the evolving needs of consumers.

Originally launched in 2018, PrimaLoft Active Evolve is a line of insulating fabrics that is designed to evolve performance, design, and sustainability. Combining the lightweight warmth of insulation with the breathability of fabric, this technology is developed to perform in a wide range of activities, regardless of intensity or season. From pushing yourself during a cross country ski tour, to working up a sweat hiking to the next peak, PrimaLoft Active Evolve keeps you in your comfort zone – even when you’re pushing yourself out of it.

Several products in the Active Evolve line can be used as a next-to-skin fabric. This enables brands to forego liner fabrics, which means heat and moisture are more efficiently managed, breathability is supported, and user comfort is maintained. In addition to achieving optimal performance during aerobic activity, this yields a wider utility and year-round use, all while allowing brands to use less overall material when designing a garment, reducing footprint and waste.

PrimaLoft Active Evolve offers several advantages to designers. It enables them to utilize the full spectrum of color, incorporate unique patterns, and provides greater flexibility in fabric selection. Additionally, Active Evolve eliminates the need for quilting in the design process. Products within the Active Evolve line are made from up to 100% post-consumer recycled content, including three of the four new styles.

With more than a dozen brand adoptions thus far, PrimaLoft Active Evolve’s adaptability for the user, range of use across activities, and seasonal timing, is quickly making this one of the most versatile products in the PrimaLoft portfolio. For Fall/Winter 2023-2024, key partner brands beside Sitka and Löffler will include CP Company, Eddie Bauer, Endura, Martini Sportswear, OMM, Quiksilver, Ziener and more.

Viscose speciality fibre manufacturer Kelheim Fibres, nonwoven producer Sandler, and hygiene product manufacturer pelzGROUP have jointly developed a new panty liner that is plastic-free according to the European Single-Use Plastics Directive (SUPD). This innovative solution is a step towards reducing the amount of plastic in hygiene products – and thus also a contribution to tackling the problem of plastic pollution.

According to a UNEP study on marine litter and microplastics, eight million tons of plastic end up in the oceans every year. A significant portion of this pollution comes from single-use plastic products, including conventional period products such as pads or panty liners.

The partnership between the three companies was formed under the Open Innovation principle, which allowed for creative idea exchange and facilitated the development of an innovative product. According to Jessica Zeitler, R&D Specialist at Sandler, “Our collaboration with Kelheim Fibres and pelzGROUP is a great example of how companies can work together to create solutions that benefit both the environment and consumers. We are proud to be part of this project and the opportunities it offers.”

For hygiene product manufacturer pelzGROUP, it is important to combine sustainability and performance to achieve broad acceptance in the market. “Our panty liner meets the strict requirements of the European Single-Use Plastics Directive (SUPD) while also matching the performance of conventional synthetic products. At the same time, our new panty liner has a completely European supply chain. This means short distances and therefore low CO2 emissions, and – especially in times of global disruption – reliability for our customers,” emphasizes Dr. Henning Röttger, Head of Business Development at pelzGROUP.

"Our viscose speciality fibres are an environmentally friendly and high-performance alternative to synthetic materials," says Dominik Mayer, Project Manager Fibre & Application Development at Kelheim Fibres. "They are at the very beginning of the product value chain and yet have an enormous impact on the functionality of the end product. Open innovation allows us to bring all partners in the value chain to the table, to find the best solution together in a very short time and bring it to commercialisation - the collaboration with Sandler and pelzGROUP is an important milestone in our AHP journey."

• Iconic 200 Series fleece to be the first fabric made from this new process.

Polartec®, a Milliken & Company brand, announces Polartec® Shed Less Fleece, a new milestone in its industry-leading efforts to reduce textile fiber fragment shedding. Shed Less is a process that combines yarn construction, knitting, chemistry, and manufacturing to reduce home laundry fiber fragment shedding by an average of 85%. The first fabric to receive this new technology is the brand’s iconic Polartec® 200 Series Fleece, the modern version of the original PolarFleece® launched in 1981, and in 1993, the first performance fleece knit from yarn made from recycled plastic bottles.

The Shed Less process works by engineering the lofted fibers that give fleece its soft hand the ability to resist breaking and rubbing off during home laundering, cited as one contributing factor to the spread of fibers fragments (commonly referred to as microfibers). Polartec® Shed Less Fleece achieves this while maintaining all of the attributes that continue to make Polartec fleece a staple of midlayer collections - lightweight, breathable and warm.

The brand used the AATCC (American Association of Textile Chemists and Colorists) TM212-2021 test method for fiber fragment release during home laundering. This test was conducted with large sample sizes to account for variability. The testing concluded that Shed Less Fleece reduced fiber fragment shedding by an average of 85% compared to the baseline fabric.

“In 2016 we began looking into how we might test for fiber loss because there wasn’t a lot of research on the issue.” said Aimee LaValley, Polartec Textile Development, Dye and Chemistry Manager. “This led to new products like Polartec Power Air™, new manufacturing processes, as well as our participation in the TextileMission workgroup to study the issue on an interdisciplinary basis.”

TextileMission was a three year collaborative initiative of academia and industry to reduce the impact of textile microplastics funded by the German Federal Ministry of Education and Research. Founding partners include The Association of the German Sporting Goods Industry, Hochschule Niederrhein - University of Applied Science; TU Dresden - Institute of Water Chemistry; Vaude Sport; WWF Germany; Adidas AG; Henkel AG; Miele & CIE; and Polartec, LLC.

Polartec® Shed Less Fleece will be initially launched in the United States and will be available to customers beginning March 1, 2023. The brand plans to apply the Shed Less process to many other industry-leading fabric platforms and manufacturing facilities around the world.

• Registered in majority as a class 1 medical device  

CELLIANT -  a performance textile that converts body heat into infrared energy - is designated as a Class 1 Medical Device in Australia, Canada, the EU and European Economic Area (EEA), Japan, New Zealand, the United Arab Emirates, the United Kingdom and the United States. CELLIANT is cleared to market in China, India, Indonesia, Korea, Malaysia, Mexico, Peru, Philippines, Russia, Saudi Arabia, Singapore, South Africa, Taiwan, Thailand and Vietnam, with more countries and regions to follow.

In 2017, the FDA determined that products containing CELLIANT are medical devices as defined in section 201(h) of the Federal Food, Drug and Cosmetic Act and are general wellness products because they are intended to temporarily increase blood flow and local circulation at the site of the application in healthy individuals.
 
At Hologenix®, whose CELLIANT® infrared technology is an ingredient in world-class brands across many categories, science matters. The company has a distinguished Science Advisory Board composed of experts in the fields of photobiology, nanotechnology, sleep medicine, diabetes and wound care. The Science Advisory Board has overseen nine peer-reviewed published studies that collectively demonstrate CELLIANT’s effectiveness and the benefits of infrared energy. This claim set provides the basis for products containing CELLIANT to be designated as a Class 1 Medical Device in 38 countries and cleared to market in 15, with more countries and regions to follow. This elevated status in 53 countries translates to CELLIANT being an ideal partner for global companies who are seeking innovation in textiles to distinguish their products.   

“We have laid the groundwork for our partner brands to capitalize on the benefits of our infrared technology and to enhance their ability to do business,” said Seth Casden, Hologenix co-founder and CEO.  “We firmly believe that regulatory status matters and that is why we have grown the number of countries we have such relationships with by over a third in the last three years. It is definitely a competitive advantage of our company and CELLIANT.”

“Globally, the awareness of the benefits of infrared textiles, which absorb body heat and reflect it back as therapeutic infrared energy, has grown exponentially over the last 10 years,” continued Casden. “And in the United States infrared is gaining a strong foothold.”