OFC SNWApril-May-2020_HD_SustainableNewsMagazine07/04/202014:08Page1 TechnicalPractice Best InnovationIndustry and F Nonwovens sector an essential partner in coronavirusin fight Nonwovenspartner essential sectoran bedrock of geotextiles of bedrock i r Nonwovens as the as Nonwovens m
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EDITORIAL
Editorial office MCL News & Media, Hallcroft House, Castleford Road, Normanton, West Yorkshire, WF6 2DW, UK. Tel: +44 (0) 1977 708488 Fax: +44 (0)1924 897254 E-mail: [email protected] Appropriate response Web: www.nonwovensnews.com
As the nonwovens industry steps up to Alliance using research underwritten by the plate to help deal with the pressures companies like Novolex - one of the Editor Haydn Davis | [email protected] of the coronavirus global pandemic, a country’s largest manufacturers of plastic familiar issue is rearing its head. film and packaging - and groups like the Consulting editor Such has been the ramping up of American Chemistry Council (ACC), Adrian Wilson [email protected] | [email protected] personal protective equipment which represents the world’s largest production such as masks, gloves, fossil fuel and chemical companies. Deputy editor Tony Whitfield | [email protected] gowns, head covers, and even shoe The vast numbers of PPE currently covers, that the amount of waste being used by health workers around the Consulting editor Calvin Woodings | [email protected] generation of single use plastics, albeit world are single-use in nature as it isn’t essential SUPs, is unprecedented. safe for them to be reused or recycled Global advertising David Jagger | [email protected] However, a knock-on effect of the because of fears over contamination. The virus has been the delay to key legislative result is that sustainability and waste Subscriptions & sales Paula Jones | [email protected] introductions on plastic prevention. generation will inevitably become a Governments and manufacturers are lower priority for the time being. Design Gavin Gibson | [email protected] developing contingency plans which However, as Edie, the climate change means that the implementation of and sustainability business publication EDITORIAL ADVISORY PANEL environmental legislation will inevitably notes, it is here where the key Dr George Kellie, Kellie Solutions have been placed on the backburner just distinctions within the debate need to Vanessa Knowles, Pebble International Ed Krisiunas, WNWN (Waste Not, Want Not) as many countries were poised to be reinforced. John Mowbray, Ecotextile News implement bans on single-use plastics, or As we have reiterated many times in Colin Purvis, Purvis Consulting SCS. introduce new systems to collect plastics. these pages, it is not necessarily that Stephen J. Russell, Nonwovens Research Group, University of Leeds. In the US, for example, both New York plastics are unrequired and unwanted, Dr Karl-Michael Schumann, InnovatorenGruppe and Maine have had to delay various with the current situation clearly Larry C. Wadsworth, US Pacific Nonwovens bans and charges on single-use plastics, demonstrating the benefits of Vicki Barbur, Advanced Innovation to April and January respectively. plastic-based nonwovens and the Subscriptions These delays are completely industry’s admirable and demonstrable Sustainable Nonwovens understandable. However, more ability to scale up production when Published six times per year in magazine and digital format. worryingly, a new briefing from demand rockets. Thankfully, many are Includes all digital back issues, premium web access, a weekly e-bulletin and access to our mobile app. Greenpeace USA claims that some urgently just wanting to ramp up Price starts from £160.00 including global airmail delivery industry groups are using the Covid-19 productivity to assist with the global E: [email protected] crisis to lobby that bans on plastic bags, responses to the pandemic. Electronic storage or usage for example, should be suspended. The warning signs are there though Permission of the publisher is required to store or Described as exploiting people’s fears that some elements within the plastics use electronically any material contained in this journal, including any article or part of an article. around Covid-19, Greenpeace says that industry are pushing to exploit loopholes the plastics industry and its surrogates to create pushbacks on legislation. Notice No responsibility is assumed by the publisher for any commercial have utilized older, industry-funded The balance surely comes in ensuring loss as a matter of products liability, negligence or otherwise, studies to publish op-eds and stories that new plastics production doesn’t or ideas contained in the material herein. claiming that reusables are somehow do what it historically has done, harm more dangerous than other options in the natural environment and drive ISSN: 2049-9043 grocery stores and elsewhere, despite climate change. new research from the National Institutes of Health, CDC, UCLA, and Princeton University showing that Covid-19 can live on plastic surfaces longer than others, for as long as two to three days. According to Greenpeace, this plastics www.mclnews.com industry PR push has been carried out by organizations like the Manhattan © Published by MCL News & Media 2020. Institute, the Competitive Enterprise All rights reserved. Institute, and the American Energy Haydn Davis, Editor Printed on PEFC™ certified paper.
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Insight: 24 Staple developments Expanding the processes for natural, renewable or recycled staple fibre-based nonwovens and the products made with them is currently a hot topic in the industry, writes Adrian Wilson.
Features 29 Pollutant prevention Electronics giant Sony has developed rice husk fabrics for advanced filtration.
30 Firm foundations Needlepunched polypropylene nonwovens are the bedrock for the range of functional geocomposites manufactured by the UK’s GEOFabrics.
34 Fabrics on four wheels Nonwovens featured prominently in a recent conference exploring all aspects of textile materials for the automotive industry. Adrian Wilson reports. 39 Home comforts Sustainability and functionality are the key trends currently dominating the home and contract textiles market.
44 Perfect particles Martin Brunner, Christophe Roux and Michael Knerr of Omya International outline the company’s development of calcium carbonate designed for PP spunmelt and dry-laid nonwovens.
46 Sandler boosted by capacity expansion Nonwovens manufacturer Sandler has outlined its performance over the last year while also updating on its latest expansion activities following on from its 140-year anniversary.
Every issue 12 Nonwovens News 48 Material Matters 54 News Extra 56 People 57 Trade shows and conferences
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CONTENTS
Key feature Collaboration is key in fight against COVID-19 The nonwovens and related industries are proving to be essential partners in the global fight against the coronavirus pandemic. Starts on page 4
April / May 2020 / May April 48
SUSTAINABLE NONWOVENS 46
Collaboration is key Nonwovens sector an essential partner in coronavirus fight
Firm foundations Fibre technologies Home comforts Nonwovens as the Natural, renewable Latest developments bedrock of geotextiles and recycled staple fibres in the home textiles sector
Published by Technical Innovation and Industry Best Practice
FRONT COVER: Image: © LuckyStep | shutterstock.com 34 44
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24 39
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Collaboration is key in fight against Covid-19
Nonwovens and other related industries are proving to be essential partners in the global fight against the coronavirus pandemic.
DANA, the European nonwovens Industries are proving to be an essential the coronavirus is not always possible. industry association, has been partner in the fight against the corona Healthcare workers are therefore urged working closely with the services virus pandemic,” said EDANA general to apply standard precautions consis- Eof the European Commission to manager, Pierre Wiertz. tently with all patients – regardless of find solutions for the continued provision Nonwoven protective clothing was their diagnosis – at all times. These of essential medical and protective widely deployed to deal with previous include basic hand hygiene, respiratory equipment and to any bottleneck in the epidemic scares, including the 2003 hygiene, safe injection practices and the supply chain in the fight against the SARS outbreak, the wave of Bird Flu that use of personal protective equipment coronavirus pandemic. swept through south-east Asia in 2005 In its response, the European It has also requested European and during the Swine Flu panic of 2009, Commission confirmed it has created a Commission support in working with when the demand for face masks, in strategic rescEU stockpiling – a common Member States to ensure that all particular, exploded on a global scale. European reserve - of medical production facilities where these products “During 2014 and 2015, major equipment such as ventilators, personal are manufactured are kept fully manufacturers of nonwoven protective protective equipment, reusable masks, operational in the interest of public health. clothing for healthcare workers worked vaccines and therapeutics and laboratory The letter to the Commission notes around the clock to meet fresh demand supplies. The Commission is currently that the availability of disposable hygiene in response to the Ebola threat before it collating information about providers’ and medical products to the general was eventually brought under control offers, which it will then share with public, hospitals and care homes, is an using such recognised public health Member and Participating States. essential element in the fight against containment measures,” the letter says. As a means of increasing European Covid-19. “In these unprecedented “Like in the case of the Ebola virus, early production capacities of personal times, the Nonwovens and Related identification of patients infected with protective equipment, the Commission
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and the European Standardisation Organisations agreed on 20 March that CURRENT SITUATION IN THE PRODUCTION all the relevant European harmonised OF MEDICAL FACE MASKS standards will exceptionally be made freely and fully available for all interested companies. This action will help both EU and third-country companies to manufacture these items without compromising health and safety standards and without undue delays. On 24 March, the Commission also adopted decisions on revised harmonised standards that will allow manufacturers to place on the market high performing devices to protect patients, health care professionals and citizens in general. The revised standards play a pivotal role because they relate to critical devices such as medical facemasks, surgical drapes, gowns and suits, washer- disinfectors or sterilization. The harmonised standards will cover equipment such as medical facemasks, personal eye protection, medical gloves, protective clothing as well as respiratory protective devices.
Masks While the European Commission is A key task here has been mapping the masks, and reminding officials that currently looking at mapping the need capacities of meltblown nonwovens in depending on mask types they are for masks in the Member States, EDANA Europe that are being or can be generally made of 3 to 5 layers of notes that first estimates show that no additionally supplied to masks converters. nonwovens, including the ‘meltblown’ less than 250 million medical masks and “Our message though, to the nonwoven layer, which is particularly 30 to 40 million personal protective European Commission on any action important in providing masks with the equipment (PPE) masks will be needed impacting international trade is in line necessary filtration performance to on a monthly basis in the EU alone for with that of MedTech Europe, namely protect people (one way or both ways) the battle against the pandemic. that any export ban or restriction would from infectious agents. EDANA staff In this context EDANA is working be potentially counter-productive, since emphasised that the global supply- closer than ever with its partners ESF, the in the short and medium term, whether demand balance was reportedly European Safety Federation and one likes it or not, the supply of medical extremely tight, in particular since the EURATEX, the European Apparel and face masks and personal protective beginning of the Covid-19 outbreak in Textile Confederation. The result is that equipment in the EU heavily depends on China. Supported by an expert group, the European Commission is receiving third countries, in particular from Asia,” EDANA launched a quick survey within the necessary information to accelerate EDANA says. the industry to identify available capacity the procurement of medical face masks Building on many years of relationship of meltblown nonwovens, including pilot and protective masks in the EU. The with the European authorities, EDANA lines, and alternative solutions. partnership is also matchmaking contacted the European Commission An estimate of the average quantities suppliers of materials needed to create early March to support the initiative of of meltblown and other layers required medical face masks and personal incentivizing European companies in masks was put together, allowing a protective masks with existing or involved in the entire supply chain of forecast of the capacities that would be prospective manufacturers. medical and protective face masks, in a needed for every additional million In its efforts to reach out and share proactive effort to accelerate and masks produced. information EDANA is also working increase their production in the EU - all Together with the ESF, European Safety together with MedTech, the European within the limits of a trade association’s Federation, potential matchmaking trade association for the medical remit and applicable competition law opportunities have been initiated technology industry including diagnostics, Time was dedicated to analysing the between the suppliers of nonwovens and medical devices and digital health. different steps of the supply chain of the manufacturers of masks, with each V
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association taking the lead for contacts in its respective field. These are, at ESF, representing the Personal Protective Equipment industry, Henk Vanhoutte, and at EDANA, representing the nonwovens industry, Jacques Prigneaux EURATEX, in cooperation with ESF and EDANA, has also published an online tool on their website to collect needs and proposals from material suppliers and finished device converters. The BYD plant is now running at full capacity and is able to produce five million masks a day. Each association is promoting this online collecting tool to their as the meltblown nonwovens are also Buffet, has announced that it has rapidly respective networks. welcome and encouraged to contact created the world’s largest mass- Companies, where they are suppliers EDANA and inform on their availability. produced nonwoven face masks plant. or converters, have been invited to The plant is now running at full submit their offers through this simple Production capacity and is able to produce five tool. Suppliers of nonwovens related Looking at production, BYD, the Chinese million masks a day, in addition to alternative technologies that could electric vehicles and smart phones 300,000 bottles of disinfectants, in produce materials with similar properties manufacturer which is backed by Warren response to the severe shortages that have affected hospitals and agencies across China in the face of the global Reicofil speeds up delivery Covid-19 outbreak. In late January a special task force was for meltblown lines established consisting of leaders from TROISDORF – Reifenhäuser Reicofil reports that in order to become more independent from different BYD business divisions and China in medical supplies such as face masks, a number of countries are looking to set up their more than 3,000 engineers involved in own production. research and development, design, In order to implement such projects as speedily as possible, the company is shortening the processing and other roles. delivery times for its meltblown lines – with which to produce the crucial middle material layer The task force moved with incredible for face masks – to just 3.5 months. speed and in less than two weeks had “Quick and reliable solutions like this are needed in the corona virus crisis,” says Reifenhäuser finished work that normally takes two Reicofil CEO Dr Bernd Kunze. “In the current situation, we are gladly departing from customary months to complete. It reportedly procedures because sticking to standards in a non-standard situation is out of place. It goes completed both the R&D and manufac- without saying that we will do everything in our power to serve these new needs quickly turing process of mask production without sacrificing the high quality our customers are accustomed to.” equipment within seven days, whereas The first contract with the new delivery time has already been concluded and the 1.6 metre-wide on the market, it would normally take Reicofil meltblown line is scheduled to start operation in August 2020. With an annual output of 15 to 30 days to fully manufacture a 550 metric tons, the plant will produce H99 filter material for up to 1.8 million face masks a day. mask-producing machine. At the same Reifenhäuser Reicofil also supplies technology for the production of other medical protective time, BYD also completed the R&D of clothing, such as surgical gowns. These products are made of a SMS nonwoven structures and the medical-grade hand sanitizers in six Reicofil composite lines for manufacturing them can be delivered within ten to eleven months. days, which were then shipped to www.reifenhauser.com medical staff on the front lines of the epidemic after just eight days. On February 8, the newly-built production lines in one of BYD’s industrial parks in Shenzhen started to produce these critical supplies, with hundreds of staff working both day and night shifts on machines working around the clock. BYD’s strong R&D capabilities, combined with its manufacturing facilities and creativity, have enabled the firm to mass-produce quality masks in a short period of time. Mask production requires impeccably clean and sterile environments and equipment, and BYD’s dust-free V
6 | Sustainable Nonwovens | April / May 2020 SHAPING 13 October 2020 TOGETHER Dolce Hotel | La Hulpe Brussels THE CIRCULAR CIRCULAR ECONOMY ECONOMY FOR IS ON EVERYONE’S AGENDA. NONWOVENS NGOs, companies across all sectors, European regulators and legislators alike strive for a shift towards a circular economy. The new Circular Nonwovens Forum is dedicated to addressing challenges and collectively fi nding opportunities in order to accelerate this transition.
JOIN US IN BRUSSELS AND PARTICIPATE IN THIS UNIQUE AND INTERACTIVE FORUM TO: Learn from stakeholders’ concerns Hear from experts on latest technologies and trends Exchange views and ideas on issues and solutions Inspire and get inspired in the roundtable discussions Identify topics for future cooperation on common initiatives
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rooms, previously used for the assembly along with the reserve of professional the most pertinent challenge was the of smartphones, are particularly well- and technical manpower, has given BYD rapid expansion of its production suited for this. During the Spring Festival strong capabilities and rich experience capacity to meet demand for these period, the company was unable to in large-scale precision manufacturing much-needed items. obtain mask-making equipment rapidly over the years. With the company making about five enough, so it set about making its own “For BYD’s electronics business, the to ten new mask-producing machines on machines. BYD can now make more than high-end mobile phones that we a daily basis, the number of masks a dozen of these machines a day. produce have high requirements in terms produced by BYD is increasing at a rate “A production line for high-quality of quality, waterproofing and other of approximately 300,000 to 500,000 face masks requires about 1,300 parts aspects,” said Zhao Jianping, general units per day. By mid-March it had a total for various gears, chains, and rollers, manager of BYD’s Quality Division. “This production capacity of five million masks 90% of which are BYD’s self-made also comes with our high standards for per day, which is equivalent to a quarter parts,” said Sherry Li, director general of moulds, automated equipment, of China’s entire production capacity in BYD’s President Office. manufacturing processes, and more. In early February. Since its founding, BYD has set up a other words, the equipment that we specialised team to conduct R&D and already have offers precision and quality Capacity manufacturing for its equipment, and that is much higher than what is Japan’s Mitsui Chemicals, meanwhile, the team has been engaged in the commonly required to produce masks.” has doubled the capacity for industrial- independent R&D and manufacturing of According to the Chinese use meltblown nonwovens at its Sunrex complex production lines and government’s quality inspection Industry wholly-owned subsidiary. equipment, such as electronics, department, the quality of BYD’s masks The subsidiary started manufacturing batteries and new energy vehicles. Its is significantly better than similar masks at the new Sunrex facility in January and own machining centres, for example, in the industry. has now added a second line there. have a variety of high-precision As a multitude of orders have come In addition to its Syntex-branded equipment like grinding machines and after the company announced its materials for face masks which are moulds. This collection of hardware, production of masks and disinfectants, currently highly in demand, Sunrex also makes meltblown grades for car seats and agricultural sheeting as well as Web Industries allocates medical filter media. Materials from the new line are based material converting capacity on superfine fibres, no more than several MARLBOROUGH - Web Industries, Inc., the US-based precision converter and contract manufac- hundred nanometres in diameter. turing organization (CMO), is prepared to develop nonwoven and material converting solutions and is offering production capacity to support the manufacture of disposable medical products Thermoforming for the Covid-19 crisis. Converting is an important step in the supply chain in which materials Sencorp Thermoforming, a division of are formatted so that they can be run more efficiently on automated manufacturing lines. SencorpWhite, is modifying its thermo- Certified under ISO 14001 and ISO 9001, Web has multi-color, high-speed printing, slitting and forming machines to make face masks traverse winding, or spooling, lines at its factory in Fort Wayne, Indian., the company’s Center for medical professionals combating the of Excellence for converting personal and home care products. Covid-19 pandemic. The recently expanded facility has state-of-the-art equipment for converting nonwoven So far, the Massachusetts-based materials. Web’s team is available to discuss how it can support manufacturers of personal company has successfully modified three protective equipment (PPE) and other medical consumables. Most disposable PPE products, machines, each with the ability to such as surgical masks and protective gowns, are made of nonwoven materials. produce around three million face masks Currently, Web converts ties and bindings for surgical masks at the Fort Wayne facility, per week. They are being delivered to a which predominantly processes nonwoven materials for diapers and other personal and major US supplier of protective home care products. equipment, where they be operational in “We are available to discuss how we can use our converting lines and expertise to help a cleanroom environment in just days. manufacturers meet demand for disposable medical products needed for the Covid-19 Like elsewhere, medical workers and response,” said Adrienne Green, director of sales, personal and home care. “Our engineers are first responders in the, USA are short on skilled at devising solutions for working with a wide variety of materials and converting them the supply of N95 protective face masks into formats that can be efficiently and seamlessly integrated into the end-product and shields. These essential components manufacturer’s operations.” of personal protective equipment (PPE) Web Industries’ Fort Wayne, Ind., plant has high-speed equipment capable of converting help safeguard clinicians from accidental nonwoven medical materials. Its team is ready to discuss how the factory can support droplets containing coronavirus as they manufacturers in need of formatted materials for personal protective equipment and other tend to patients, work in labs, and assist medical applications. at drive-through testing facilities. The coronavirus is more contagious than the
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flu, and it is critical that these first Sencorp Thermoforming is modifying its thermoforming responders get the medical supplies they machines to make face masks for medical professionals. desperately deserve. “We received a call from a large PPE manufacturer of face masks to see if we could respond quickly to the unprece- dented global demand,” said Brian Golden, Sencorp vice president. “We converted two 2500 style machines typically used for consumer products in the plastic industry to run the material used in the production of the N95 masks. Our staff of machine builders stepped up to the challenge. With necessary modifi- cations two machines were prepped for shipment in less than a week. Each machine is capable of producing about A research team at KAIST has now developed a nano- three million face masks per week.” filter that maintains Brian Urban, Sencorp’s president and excellent filtering efficiency even after hand washing. CEO, also credited the company’s skilled workforce for their dedication during this national emergency. “Despite concern for themselves and their families, our dedicated employees are working in staggered shifts to meet this unprecedented demand,” Urban said. “These sophisticated thermo- forming machines require a large skilled workforce that SencorpWhite has in place. In addition, unlike others, we are washing, through the development of orthogonal nanofibres by controlling their self-sufficient and manufacture parts in- proprietary technology that aligns alignment. This structure can minimise house so we can quickly respond in nanofibres with a diameter of 100-500nm delivery of the pressure towards the air urgent situations like this. Our machines in orthogonal or unidirectional directions. filter and maximise the filtration efficiency. are proudly Made in America right here Professor Il-Doo Kim’s nanofibre Existing masks also fail to maintain on Cape Cod.” filtered mask will maintain its robustness their air filtering function because their SencorpWhite has several product lines and filtering function even after being electrostatic function disappears when that are critical in the supply chain across washed more than 20 times and is now exposed to water and as a consequence, America, including vertical carousels awaiting final approval from the the filtering efficiency is reduced signifi- used within hospital pharmacies, medical country’s Ministry of Food and Drug cantly, making it almost impossible to supplies distribution, and grocery pickup. Safety to be brought to market. reuse them. Medical pouch and tray sealing machines Professor Kim used an insulation block The new nanofibre is was proven to be protect medical devices, consumables, electrospinning process to manufacture water resistant, with more than 94% V and clinical supplies and our software drives efficiency in the distribution and manufacturing supply chain. Ahlstrom’s Italy plants remain open Washable STOCKHOLM - Ahlstrom-Munksjö has confirmed that its plants in Italy are not affected by the In South Korea, the government is now Italian government’s lock-down of all non-essential industrial and commercial operations. rationing disposable nonwoven N94 or The decree entered into effect on 23 March and as we go to press, is still in place. However, N95 face masks to two per person per the decree excludes certain industries and activities. “The paper and nonwoven industries are week, due to the supply shortages specifically excluded from the lock-down according to the decree,” Ahlstrom-Munksjö’s said. associated with the Covid-19 outbreak. “Production plants in Italy, Turin and Fabriano, are currently operating and are not directly A research team at the Korea Advanced affected by the decree.” Institute of Science and Technology All 45 Ahlstrom-Munksjö manufacturing facilities worldwide are therefore currently operational (KAIST), however, has now developed a although the company said it was closely monitoring the situation and was taking strict health nano-filter that maintains excellent and safety precautions at all sites to protect the wellbeing of its employees and all stakeholders. filtering efficiency even after hand
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filtering efficiency in 20 repeated 80% of 600-nanometer particles even US legwear manufacturer Kayser-Roth bactericidal tests with ethanol. The after undergoing a bending test more is also planning to add the technology nanofibre mask also showed no than 4,000 times.” to its new product, Ghluv hands deformation in its nano-membrane Professor Kim established his start-up protector, while Lufeng from China is structure, despite the 20 hand washes. In company, the Kim Il-Doo Research evaluating the technology on other particular, it was confirmed that there Institute, last February. It can currently types of fabric used for garments. were no deformations in the membrane, produce 1,500 nanofibre filters per day. “HeiQ strives to help improve the lives even after soaking in ethanol more than of people through bringing three hours. Treatment breakthrough innovations to textiles,” “We believe that this mask can be HeiQ is launching Viroblock NPJ03 as an said Centonze. “We have pushed hard reusable for about a month even after antiviral and antimicrobial textile treatment to bring the HeiQ Viroblock technology washing in ethanol,” said Professor Kim. which has tested effective against to reality to assist at this time of urgent The inner filter cam be replaced and we coronavirus when used in face masks. need for society around the world.” found that the mask filters out up to The tests proved the treatment signifi- HeiQ Viroblock NPJ03 is a unique cantly improves the antiviral log reduction combination of vesicle and silver of 2.90 for untreated face masks to 4.48 technologies designed to inhibit the Radici inspires – an over 99.99% reduction of virus growth and persistence of bacteria and infectivity (a log reduction of 2 is viruses. The HeiQ vesicle technology support from equivalent to 100 times the effectiveness). targets lipid-enveloped viruses, such as “Virologist Dr. Thierry Pelet of HeiQ’s coronavirus, providing rapid virus China to Bergamo Scientific Advisory Board brought us a deactivation, while the HeiQ silver BERGAMO - Radici Plastics Suzhou, a profound depth of knowledge and technology inhibits the replication of RadiciGroup company specializing in accelerated our efforts to address the both bacteria and viruses. HeiQ engineering polymer production and urgent problem of a global pandemic,” Viroblock NPJ03 can be applied to a based in Jiangsu Province in China, has said HeiQ Group CEO Carlo Centonze. wide spectrum of textile surfaces joined a fund-raising drive promoted by “Our goal is to prevent textiles from including face masks, air filters, medical the Italian community in Shanghai to send becoming a host surface for propagating gowns, curtains, drapes etc. a Bergamo over 20,000 masks and other harmful viruses and bacteria and Both 229E and Covid-19 are two of medical devices. contribute to reduce the risk and speed seven types of human coronaviruses. The campaign has already seen a raft of of contamination and transmission.” Besides testing on human coronavirus equipment arrive at its destination, the Chinese protective masks producer (229E), HeiQ Viroblock NPJ03 also Papa Giovanni XXIII Hospital. Suzhou Bolisi is the lead adopter of HeiQ demonstrates dramatically improved In addition to the donation from Radici Viroblock NPJ03 and the treated masks reduction of virus infectivity against Plastics Suzhou, the employees of the will be available on the market as early influenza types H1N1, H5N1, H7N9, and company (about one hundred strong) also as this April. respiratory syncytial virus (RSV). SNW wanted to participate in the drive by HeiQ is launching joining the initiative of the Italian Viroblock NPJ03 as an antiviral and antimi- community in Shanghai coordinated by crobial textile treatment which has tested effective some native Bergamascans who live and against coronavirus when work in the city. A total of over €35,000 used in face masks. was collected to help the Bergamo area cope with the coronavirus emergency with further aid expected to arrive soon. “This is evidence that, in this severe global scenario, collaboration among the various organizations located all over the world will become even more valuable,” RadiciGroup said. “In compliance with local laws and regulations, all RadiciGroup companies and the Bergamo headquarters, in particular, have immediately adopted measures to prevent the spread of infection and are continuously staying up to date on the evolution of the emergency to further the aim of strengthening the Group safety culture.”
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April / May 2020 NEWS LATEST INDUSTRY NEWS FROM WWW.NONWOVENSNEWS.COM
Neenah acquires Vectorply ALPHARETTA – Neenah is to expand its technical products platform by acquiring Vectorply Corporation from MSouth Equity Partners, for US$155 million. With annual sales of over $70 million, Vectorply is a leader in the manufacture of high-performance composite materials used in a variety of growing end markets which has been experi- encing strong, double-digit growth in its sales and profitability over the past few years. The company is focused in North America, with its customers and supply chain predominantly in the USA and operates out of a single manufacturing facility Phenix City, Alabama. “Vectorply is well-known for its product capabilities, utilising product-enhancing fibres such as carbon, glass and aramid to produce purpose-built, nonwoven reinforcement fabrics,” said Nennah CEO John O’Donnell. “The acquisition broadens our businesses in 2004 and has grown significantly in the field of technical products platform, adding new capabilities that will technical nonwovens in recent years. further accelerate our ability to grow in existing, as well as new In February this year, the company announced an increase in end markets.” production capacity for its Cranemat wet laid nonwoven Neenah came into existence following the spin-off by membrane substrates at its plant in Pittsfield, Massachusetts, to Kimberly-Clark of its technical products and fine paper support continued strong growth in water filtration.
INDEX 20 exhibition postponed October GENEVA - The INDEX 20 exhibition has been postponed October to 20 - 23 October 2020. A statement from organisers EDANA reads: “By ordinance entering into force on 28 February 2020 at 10:00 am, the Swiss Federal Council has prohibited all events bringing together more than 1,000 people. In the current circumstances, the situation is qualified as a force majeure event. As a result, taking into account the negative evolution of the situation, INDEX™20 is postponed to 20 - 23 October 2020. “The situation has recently significantly deteriorated with the appearance of the first confirmed cases of coronavirus in Switzerland. The organisers had no other choice than to review their assessment of the situation and to act in strict compliance with the ordinance of the Swiss Federal Council.” “We sincerely regret this situation, as large numbers of people around the world have invested in ensuring that the event takes place. However, the well-being and health of all INDEX exhibitors, visitors, and exhibition staff, as well as their business needs and expectations, remain our highest priority. We trust that all participants will understand this forced decision,” said Pierre Wiertz, EDANA General Manager. “The world continues to discover the important role of nonwovens in protecting healthcare staff and patients through medical devices and personal protective equipment, such as surgical masks, respirators, gowns, drapes and coveralls. It is of course unfortunate that the biggest nonwovens trade show ever, with over 730 exhibitors and covering 24,700m2, has had to be postponed because of the largest epidemic in decades. “PALEXPO and EDANA remain at disposal for any further information. Please consult www.indexnonwovens.com and www.edana.org for any updates.
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Cranemat is the registered trademark name for Neenah’s line of polyester and polyolefin wet laid nonwoven membrane substrates, designed for the liquid filtration and membrane Mondi new line for separation sectors. Known for its reliability and uniformity in the biodegradable nonwovens membrane casting process, Cranemat contributes to enhanced membrane performance and efficiencies. VIENNA – Mondi Group, a leading international manufacturer of Other key Neenah production centres include the Weidach packaging and paper products, has developed a new carded airlaid Mill in Feldkirchen-Westerham, Germany, which is equipped carded (CAC) line to create more sustainable three-layer nonwovens with two wetlaid machines and three meltblown machines, for personal hygiene and cleaning wipes. along with three saturators and lamination and finishing The new line, which is being built at the company’s plant in Ascania, equipment. A second plant in Munising, Michigan is equipped Germany, will use 100% cellulose content, including viscose and with two wetlaid machines and eight calenders. pulp from certified sources, resulting in a nonwoven material that is During 2017, a filtration machine (which was converted from fully biodegradable. a fine paper machine) and adjacent saturating plant began The new technology makes it possible to combine three layers of production in Appleton, Wisconsin, a site also shared with the nonwovens into a highly functional and stable composite material to company’s fine paper and packaging business. deliver optimal absorption and lotion load for high-quality In June 2014, Neenah acquired Crane Technical Materials biodegradable wipes and uses fewer resources than comparable from Crane & Co. for $72 million. Crane, headquartered in carded mono-structures. The technology will be able to produce the Dalton, Mass., has been the sole manufacturer of dollar bill entire sustainable nonwoven material in-line, while enabling hydro- substrates since 1879, while its paper-making facility at Tumba embossing to increase softness and improve cleaning power. near Stockholm in Sweden has been operating since 1753, and “The innovative technology means we can produce 100% today is one of the most advanced in the world. biodegradable, high-performance nonwovens for wipes that are more Crane Technical Materials brought a wide range of materials accessible, and we are looking forward to introducing this to the to Neenah, primarily for industrial applications from glass, market.” explained Kelly Wright, Mondi’s product expert for personal synthetic and natural fibres. care and components. The new line is set to be fully operational by 2021. Web: www.mondigroup.com Andritz to supply The line features the best-in-class technologies available on a turnkey spunlace the market and will be installed in a dedicated new building, meeting the highest hygiene and environmental standards. line to BCNonwovens Due to its versatility, it will enable BCNonwovens to widen GRAZ - International technology Group Andritz has received their product portfolio and process a broad range of raw an order from BCNonwovens, Spain, to supply a neXline materials, including sustainable fibres. spunlace line as a turnkey project to meet growing needs from This line will also be equipped with Andritz’s self-developed customers globally. Metris UX platform, enabling predictive maintenance based on The line is scheduled for start-up early in 2021. Andritz’s new Vibe sensors and the risk-based maintenance app. This new state-of-the-art line will help BCNonwovens to It will improve the line’s efficiency by reducing downtime and better serve its customers and position the company for current therefore help BCNonwovens to achieve its strategic objectives and changing requirements in the marketplace. in terms of quality and sustainability. “With its wide range of “The choice of spunlace line supplier was based on a applications, Metris will assist us in our operating activities, and thorough evaluation of the technologies available on the we can already envisage a wide range of new possible market,” said Marko Rajamaa, General Manager of developments with this extremely powerful Andritz tool,” BCNonwovens. “The combination of Andritz process engineers’ added Rafael Dufour, Strategy and Business Development expertise and our in-depth market knowledge has enabled us to Director of BCNonwovens. define the appropriate line configuration for current and future Miguel Vinas Pich, CEO of BCNonwovens, said: “Andritz has market needs. The fully equipped Andritz spunlace pilot line been a major partner for almost two decades. This new line will and expertise have played a key role in the order being awarded be an essential investment to help our customers achieve to Andritz.” growth and serve demanding markets.”
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Overall, growth in the sector is augmented by developments Medical disposables in nonwovens production technology, a rise in focus towards preventing hospital acquired infections (HAIs) and the market to reach US$14b production of high-quality fabrics for safety purposes provided NEW YORK - The Medical nonwoven disposables market is by nonwoven material. Moreover, a significant increase in projected to reach US$14,134 million by 2025, growing at a geriatric population, government regulation toward health CAGR of 7.4% from 2018 to 2025. and hygiene, and rise in health awareness will further boost The new report from Allied Market Research notes that the market growth. market value of the sector in 2017 was $7,910 million with the The report also notes, however, that concerns regarding the surgical product segment accounting for more than half of the disposable of nonwoven products and the increase in total market share. popularity of less-invasive surgeries are anticipated to hamper The surgical product segment is also expected to maintain the market growth. this dominance throughout the forecast period. This is North America was the leading revenue contributor to the attributed to the increased use of surgical products in hospitals, global market in 2017, owing to presence of high demand for clinics, and other medical services to inhibit contaminations and incontinence products along with a well-established healthcare avoid infection transmissions. infrastructure and technological advancements in patient care. However, the incontinence segment is expected to register Asia-Pacific is expected to witness the highest growth rate the highest growth rate during the forecast period, owing to throughout the forecast period, due to increase in baby rise in demand for disposables incontinence products such as boomer population, upsurge in disposable income, and rise in disposable underwear, panty shield, cotton pad, and others. patient awareness toward incontinence products. Borealis producing certified renewable polypropylene LINZ – Borealis has started to produce polypropylene (PP) based on Neste’s renewable feedstock at its production facilities in Kallo and Beringen, Belgium. After producing renewable propane using its proprietary NEXBTL technology, Neste is selling the renewable propane to the Borealis propane dehydro- genation plant in Kallo. Then it is converted to renewable propylene and subsequently to renewable PP at the Kallo and Beringen plants. Recently finalized audits carried out by an independent third party have resulted in an ISCC Plus certification for the renewable PP produced at both Kallo and Beringen plants. This certification encompasses the entire value chain scope and verifies that the renewable feedstock used is certified as being 100% renewable and sustainably produced, including traceability to point of origin. Downstream partners from a variety of industries such as consumer packaging, automotive, healthcare, and appliance industries can now commer- cialise their end-use products with a lower carbon footprint based on renewable propylene and PP. In response to increasing demand, Borealis is working with value chain partners to expand availability. Henkel, a global market leader in the adhesives sector, will be including renewable PP content in the packaging of a major brand over the course of the year, in its efforts to reduce its use of fossil fuel-based virgin plastics by 50% by 2025. “Producing renewable PP based on renewable feedstock for the first time in history is another concrete step towards a more sustainable carbon future,” said Lucrèce Foufopoulos, Borealis executive vice president. “Working closely with partners like Neste and Henkel is key to shaping a better tomorrow. Thinking circular means capitalising on growth opportunities that accelerate the transformation to a circular economy.” “It is great to see, for the first time in history, a propane dehydrogenation facility using renewable propane to replace fossil feedstock, enabling Borealis to produce mass balance certified renewable polypropylene for sustainability-focused brands like Henkel,” added Mercedes Alonso, Executive Vice President at Neste. “This is an exceptional example of collaboration across the value chain making a positive sustainability impact on the polymers sector.” www.borealisgroup.com
14 | Sustainable Nonwovens | April / May 2020 GoodNature-210x297mm.pdf 1 3/23/20 10:37 AM
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1: THE GENERATION AND AQUATIC BIODEGRADATION OF MICROFIBERES PRODUCED FROM LAUNDERING FABRICS. Zambrano, M., et al. NC State University, Raleigh, NC, USA. Cotton Incorporated, Cary, NC, USA.* 76% in waste water after 250 days with continued degradation projected. 2: Accumulation of Microplastic on Shorelines Worldwide: Sources and Sinks. Mark Anthony Browne, et al. Environmental Science & Technology 2011 45 (21), 9175-9179. DOI: 10.1021/es201811s Nonwovens News April-May 2020_HD_Layout 1 09/04/2020 13:40 Page 16
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secretariat, production of nonwovens in Europe reached Hydroentanglement 2,782,917 tonnes. This compares with 2,774,194 tonnes in 2018 when the annual growth was 1.5%. Despite these two sets the pace in low growth years, the European production recorded an nonwovens growth average growth rate of 4.4% over the last decade. Commenting on the results, EDANA noted that a more in- BRUSSELS - The hydroentanglement sector recorded the highest depth analysis will be necessary to draw any definitive growth rate in 2019, at slightly more than 5.5%, according to conclusion, as diverging trends have been observed in different the latest statistics from EDANA. European countries, and between the various production The latest report from the industry body shows that other processes and market segments of nonwovens. Jacques bonding processes within the drylaid technologies (thermally, Prigneaux, EDANA’s Market Analysis and Economic Affairs air-through, chemically bonded and needled punched), as well Director, stated: “In terms of apparent growth rates, airlaid as wetlaid nonwovens witnessed either flat or negative growth nonwovens has been in line with the long-term trend this year, rates in 2019. but it is actually the hydroentanglement process that has Overall, as a result of the recent economic conditions and, in recorded the highest growth rate, at slightly more than 5.5%. particular, the downturn in several end-use sectors, figures for “However, other bonding processes within the drylaid Greater Europe (Western, Central and Eastern Europe, Turkey, technologies (thermally, air-through, chemically bonded and Belarus, Ukraine and Russia) show that the overall production of needled punched), as well as wetlaid nonwovens witnessed nonwovens has been flat in both weight (+0.3%) and in surface either flat or negative growth rates in 2019. Spunmelt area (+0.5%) compared with 2018. nonwovens production, compared to its performance of 2018, According to figures collected and compiled by the EDANA recorded a growth of 0.6%.”
Web Industries introduces functional ink printing capability MARLBOROUGH - Web Industries has developed a new functional ink printing capability for communicating changes in a garment’s or material’s condition such as incontinence wear and diapers. The technology enables two- or three-part ink chemistries to be printed on nonwovens, paper, tissue, films, or textiles to signal a change in material condition. It is designed for personal care items including incontinence wear, diapers and feminine hygiene products, but also has potential uses in industrial applications. Functional ink refers to printed coatings that register a change when exposed to reagents such as moisture. The change could involve fading or becoming a different color, releasing a telltale odor or triggering an increase or decrease in temperature. Web Industries says that its printing facility can apply functional ink coatings to a variety of materials on behalf of manufacturing customers. “Functional ink is all about providing information to product users,” says business development manager Courtney Robinson. “Garments or materials printed with functional ink indicate changes and can prompt corrective actions. Personal care product manufacturers, for example, can employ functional inks to indicate the status of incontinence wear, where the ink will fade or alter color when exposed to moisture, alerting caregivers to change the garment.” Functional ink coatings also have a wide range of industrial uses. “The ability to build chemical or bio-reactive markers directly into personal protective equipment or other product components can provide an added level of awareness and safety for first responders and other users,” Robinson notes. “For instance, a tailored coating could be applied to specific areas of single-use hazmat suits that would change color to indicate the presence of specific levels of a contaminant. By providing passive monitoring during an emergency situation, these ‘sensing areas’ would allow the wearer to focus on their specific task while knowing that their exposure to harmful chemicals or bio-agents was being assessed.” “Another high-potential use is in industrial control systems,” Robinson added “For instance, an electrically-conductive functional coating could be applied to a substrate that breaks down in the presence of excessive heat. Used as a sensor component, an overheating condition would cause the material to degrade, breaking the electrical connection and signaling the equipment’s PLC/computer.”
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The main end-use for nonwovens remains the hygiene market with a 29% share of deliveries, amounting to 792,620 tonnes, a growth of 1.5% in 2019. The most significant increases in percentage in 2019 were in table linen (+12.3%) and electronic materials (+6.8%). In contrast, several important sectors in terms of volumes sold showed limited (and sometimes negative) growth rates: e.g. personal care wipes (+1.6%), building/roofing (-0.3%), civil engineering (-1.5%) and automotive interiors (- 2.5%). Additionally, major declines were noticed in medical applications, garments, interlinings and wall covering. “Without the help of participating companies,” Jacques Prigneaux noted, “these figures couldn’t be compiled, and we would like to thank them again for their efforts in sending their input to us, especially during the tumultuous period of the first quarter 2020. “Thanks to a convergence of efforts of the participating companies, to an improved ISO definition of nonwovens and to the continuous monitoring of EDANA staff, these statistics are more and more relevant for planning and benchmarking purposes within member companies.” Only EDANA members receive the full report, as part of one of their most valued membership benefits and will soon get their complimentary copy of the report “2019 European Nonwovens Production and Deliveries”. Nonwoven producers who are member companies of EDANA will receive detailed data, in recognition of their participation. The 2019 statistics will be also available through the EDANA Statistics App and at http://edanastatapp.org. “As the world continues to discover the important role of nonwovens in protecting healthcare staff and patients through medical devices and personal protective equipment, such as surgical masks, respirators, gowns, drapes and coveralls during the Covid-19 pandemic, our ongoing commitment is to work with partner associations throughout the world, also to harmonise nonwoven production and sales statistics, and our positions on trade classification rules,” said Pierre Wiertz, general manager, EDANA. “This, together with the now improved ISO nonwovens definition, should give the whole industry the visibility it deserves.”
Kelheim Fibres achieves low risk rating KELHEIM - Kelheim Fibres’s current viscose fibre supply chain has been confirmed as a low risk of sourcing wood from Ancient and Endangered Forests or other controversial sources. The German fibre manufacturer joined the global CanopyStyle initiative, which closely documents supply chains and is actively supported by numerous leading fashion brands, such as H&M, Zara and Levi Strauss, in 2019. The confirmation follows the company’s first audit from CanopyStyle and third-party auditor NEPCon. “Canopy congratulates Kelheim Fibres for its low risk audit results,” said Nicole Rycroft, Canopy’s Executive Director. “Producers are increasingly hearing from brands that they will no longer V
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source Ancient and Endangered Forest textiles by the end of 2020. This audit result is a validation of Kelheim’s efforts in that direction and positions it well in a competitive market place.” Key findings of the audit include: • The company is at low risk of sourcing from Ancient and Endangered Forests; • The company has a limited fibre basket and uses a significant proportion of FSC-certified fibres in its viscose products; and • The company has begun supporting forest conservation solutions in key areas of Ancient and Endangered Forests. “Future-oriented fibre materials cannot come at the cost of Ancient and Endangered forests and other valuable resources,” said Craig Barker, CEO of Kelheim Fibres. “Therefore, we are committed to focus on sustainability at every step from raw material sourcing and state-of-the-art closed-loops production processes.” Sage acquires Adient’s He continued: “As a small producer, we are proud to have accomplished low-risk audit results. We welcome the recommen- interiors business dations the audit report has given us for further improvements GREENVILLE – Asahi Kasei company Sage Automotive Interiors is to and we will actively work towards implementing them.” acquire the automotive fabric business of Adient for $175 million, In the spirit of continuous improvement, Canopy subject to regulatory approval. recommended that the company increase the proportion of This move follows quickly on from Adient’s sale of its automotive FSC-certified fibre, and make efforts to source 100% FSC, as interior trims and NVH (noise, vibration and harshness) subsidiary well as continue to invest in research and development of low- Futuris Automotive to Supreme Group – one of India’s largest and impact alternative fibres, with the goal of launching a fibre line most diversified nonwoven manufacturers in February. that contain these products. In January, Adient also released its 30% ownership share in Yanfeng The audit, which reflects a snapshot in time, is to be Automotive Trim Systems for $379 million. conducted annually to ensure that Kelheim continues to meet Headquartered in Plymouth, Michigan, USA, and registered in Dublin, the expectations of the CanopyStyle initiative. The audit Ireland, Adient has supplied roughly 25 million seats each year and findings contribute to Hot Button Issue Report. claimed a 32% share of the global automotive seating market, slightly The public report from Kelheim Fibre’s audit evaluations is ahead of its competitor, Lear Corporation. available for download here: The company only came into existence as an independent company in www.kelheim-fibres.com/en/sustainability/certificates/ October 2016 as a result of the separation of the automotive seating Kelheim Fibres GmbH is the world’s leading producer of and interiors businesses of Johnson Controls International, of viscose speciality fibres and the most important supplier of Plymouth, Michigan, but has been plagued by operational issues and viscose fibres for the tampon industry. About 90.000 tons of also ongoing costs related to the spin-off. viscose fibres are produced every year at Kelheim in South With this latest acquisition, Sage Automotive significantly expands its Germany from the renewable raw material wood. These are capacity for automotive interior products to the European market. used in most diverse applications – from fashion, hygiene and “Europe continues to be a key growth area for Sage Automotive medical products to nonwovens and speciality papers. Interiors,” said Dirk Pieper, CEO of Sage Automotive Interiors. “In Web: www.kelheim-fibres.com addition, the technology and capabilities that will now be part of Sage Automotive Interiors will strengthen our ability to serve customers from our current locations in Europe and the rest of the world.” Following its acquisition in July 2018 of Sage Automotive, Japanese Teijin to open conglomerate Asahi Kasei is looking to triple its current annual sales of around €1 billion to the automotive industry to €3 billion by 2025. European centre for Sage also owns the Italian company Miko, which it acquired in April 2015. Miko artificial leather materials for automotive interiors have automotive R&D been very successful in Europe and Sage is now able to use Asahi’s TOKYO - Teijin is set up a new research and development centre global network to expand their adoption around the world. Miko’s in Europe aimed at exploring and developing next-generation artificial leather substrates are now being dyed and finished for North components for the company’s automotive composite business. America, signaling a move by Sage into the luxury car market. Similarly, The Teijin Automotive Center Europe GmbH (TACE), which Miko fabrics are also being dyed and finished for China and Asia at the will be based in Wuppertal, Germany, will handle concept, Sage plant in Wuhan. designing, prototyping, evaluations, marketing and technical http://www.sageautomotiveinteriors.co.uk/ research utilizing the Teijin Group’s capabilities to provide multi- material solutions for next-generation vehicles.
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According to Teijin, the TACE will allow the company to strengthen and advance its solution capabilities by establishing First US state law a strong platform for collaboration within the Teijin Group’s European automotive composite bases. It is expected to speed mandates for up concept, designing, prototyping and the evaluation of technological proposals developed by each base. Do Not Flush labeling Later, TACE will develop marketing and research functions to CARY - Washington has become the first state in the US to explore opportunities for new technologies and M&A, aiming to pass a law mandating Do Not Flush labeling for certain wipes. accelerate joint development with European automakers and The law, spearheaded by Rep. Fitzgibbon, Chairman of the respond to demands for greater design freedom, productivity Washington House Environment and Energy Committee, and cost efficiency as well as weight reduction and strength. At represents a months-long cooperative effort between a the same time, the company will pursue opportunities to coalition of Washington wastewater and municipal sector establish bases for automotive composite technical functions in stakeholders led by the Association of Washington Cities and the USA and China to satisfy demands in these markets to strive INDA, the trade association representing the wipes industry. to steadily strengthen its position as a global solution provider. The groups came together to tackle the problem of Backed by such initiatives, Teijin is targeting automotive consumers flushing baby wipes, surface cleaning wipes and composite business sales of approximately €1.7 billion by 2030. other “nonflushable” wipes that are not designed to be Amid the ongoing shift toward Connected, Autonomous, disposed in sewer systems. The law requires packages of these Shared, and Electric (CASE) automobiles, the automotive wipes to carry prominent “Do Not Flush” labeling to help guide industry is urgently transforming its business models to realize consumers to dispose of them appropriately in the trash. more lightweight and multifunctional next-generation vehicles. Washington Representative Joe Fitzgibbon joined the Teijin acquired Continental Structural Plastics (CSP) in 2017 to Association of Washington Cities and INDA, Association of the become a Tier 1 supplier focused on multi-material automotive Nonwoven Fabrics Industry, in applauding Governor Inslee’s composite. In Europe, CSP’s French operation will open a new signing of HB 2565, the law intended to address the labeling of sheet molding compound plant and Teijin has acquired leading certain disposable wipes. automotive-composite suppliers Inapal Plásticos of Portugal and “I introduced this legislation in response to concerns voiced by Benet Automotive of Czech Republic. Washington sewer system operators that consumers are flushing “To leverage these recent moves, Teijin has now decided to certain categories of wipes that are not intended to be,” said further strengthen its multi-material capabilities in Europe and Fitzgibbon. “I was pleased to sponsor legislation that brought organically link the development and marketing functions of its together municipalities and industry to find a common sense European automotive composite bases to satisfy automakers’ solution to this problem and am proud that Washington is the demands in the forthcoming CASE era,” the company said. first state in the nation to tackle this issue in a meaningful way.”V
Berry confirms new line start-up and coronavirus update EVANSVILLE - As it begins commercial shipments from its new Spinlace line in the US, Berry Global has updated its latest actions in the work against the spread of coronavirus, highlighting measures that include shifting capacity to supply maximum output in response to increased demand for healthcare materials. Berry manufactures nonwoven fabrics, which are then sold to converters who produce infection prevention items such as face masks, N95 respirators, and protective apparel. At the end of January, the company reported the prioritization of healthcare production in its Chinese facilities in response to the increased demand for coronavirus prevention. Concurrently, the company has responded to this increased demand across North America and Europe. In the US, Berry has shifted capacity to supply maximum output in response to increased demand for healthcare materials; these include materials for hard surface disinfectant wipes and face masks. In Europe, the company’s meltblown lines are running around the clock to produce materials for face masks and other healthcare applications, such as materials used in blood filtration. “We are proud to be a part of this fight,” said Tom Salmon, Berry Chairman and CEO. “Many don’t realize the role plastics play in protecting us from infection and the spread of disease, when in fact, they are a critical component. Our leadership position and global scale allow us to create increased supply when encoun- tering a pandemic such as this.” In addition to its nonwoven capabilities, Berry also provides packaging for a number of in-demand items, such as disinfectants, hand sanitizers, and soaps. Berry has also announced the commercialization of its new Spinlace production line in Mooresville, North Carolina. A $50 million investment, the asset is running at full production rates, providing an incremental 17,000 metric tons of annual capacity to the marketplace. The Spinlace asset is focused on various wipes applications serving the healthcare, hygiene, household cleaning, foodservice, and industrial markets and, says Berry, is key to underpinning its leadership position in the manufacturing of hard surface disinfectant wipes. “We are very excited to begin commercial shipments from our third proprietary Spinlace asset in the United States. The technology provides customers with the ability to design customized products imparting flexibility in strength, image or branding, functionality, raw materials selection and much more,” said Mark Siebert, EVP & GM of Berry’s Health and Specialties, United States and Canada.
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Peter King, CEO of the Association of Washington Cities added: “Improperly flushed wipes can be a contributing cause to sewer clogs and wastewater spills. This bill was a collabo- rative effort between government and industry, which will provide consumers with clear disposal direction and protect the public’s sewer and wastewater systems.” INDA’s President Dave Rousse said: “Baby wipes, cosmetic wipes and other disposable wipes provide tangible benefits to Montefibre invests consumers, while hard surface antibacterial and disinfecting wipes are an indispensable tool for household cleaning and in carbon fibre reducing exposure to viruses impacting public health as we’ve MIRANDA DE EBRO – Montefibre Carbon is investing €16.2 million at seen recently. However, unlike wipes labeled “flushable,” these its plant in Spain, €11.5 million of which will come from the Spanish kinds of wipes were not designed nor marketed to be disposed Ministry of Industry, to produce polyacrylonitrile (PAN) precursor for in the toilet. conversion to carbon fibre with semi-aerospace quality and to build a “We would like to thank Representative Fitzgibbon for his flexible carbonization line. leadership and the Washington cities and wastewater The new PAN precursor fibre will have a tensile strength of 700 ksi and community for their constructive engagement on legislation that will be marketed as M700. The new carbonization line will be one of the will go a long way to ensuring that consumers understand which most advanced lines in the industry to serve as a development and wipes are ‘Do Not Flush’ and require disposal in the trash can.” demonstration of Montefibre’s carbon fibre and will be able to work with fiber from 80K to 480K, up to a capacity of 100 tons per year. The carbonization line will be operational by the end of 2021 and will serve as a key hub prior to commercial production scale and will Essity acquires generate market-development volumes of carbon fiber, as part of a project to transform part of Miranda facilities into a collaborative medical solutions firm research center. STOCKHOLM - Hygiene and health company Essity has signed Montefibre’s carbonization line will be the first owned by a Spanish an agreement to acquire an majority stake in Swedish medical company and the second to be installed in Spain at Miranda de Ebro – solutions company ABIGO Medical AB. the first being the line built by Hexel in Illescas in 2008). The company Gothenburg-based ABIGO Medical, develops, manufactures will also become the third leading European producer of carbon fibre and markets products including the Sorbact technology, which after SGL in Germany and Solvay in Belgium. is a clinically established innovation for advanced wound care. “The support of the Spanish Public Administration is essential to achieve Founded in 1989 by the brothers Jan G and Leif Smith, the the success of a project of the magnitude of Montefibre Carbon, which company has about 170 employees and reported net sales of will be key to the industrial competitiveness of Spain, Castilla y León and approximately SEK 403 million in 2019. Miranda de Ebro,” said Alfonso Cirera Santasusana, CEO and President Following completion of the deal, Jan G. Smith will retain a of Montefibre. 25 per cent stake in the company and remain as chairman of The company is currently adapting four of its seven spinning lines to bring the board. to market some 17,000 metric tons per year of its large-tow PAN precursor The company, which is currently a key partner and sub-supplier for conversion to carbon fibre. The first precursor to reach the market is an to Essity, is valued at SEK 900 million on a debt-free basis. 80K tow in two industrial qualities, M500 (with a tensile strength of 500 “The acquisition is a good strategic fit for Essity and strengthens ksi) and M600 (with a tensile strength of 600 ksi), which will be available the innovation capacity of our Medical Solutions business,” said this year. The M700 aerospace-grade 80K precursor will follow. Magnus Groth, president and CEO of Essity. “ABIGO Medical has The experience of more than 40 years as world-leader in the leading innovations in advanced wound care that reduce the development of textile acrylic fibre and speciality acrylic fibres has spread of bacteria without increasing resistance to antibiotics.” allowed Montefibre Carbon to develop a proprietary technology for the Jan G. Smith said: “Essity’s values and strategy are well production of polyacrylonitrile (PAN) carbon fiber precursors. aligned with ABIGO’s ambitions for the future and with Essity as Montefibre also has the support of the Spanish technology centre Leitat a partner, we believe there is great potential to continue our and has cooperative research and development agreement with the U.S. shared journey of growth.” Department of Energy’s Oak Ridge National Laboratory in the United Sorbact is a technology that Essity, through ABIGO Medical States. Additionally, the company is a member of the Institute for AB, already uses in its wound care products to prevent and treat Advanced Composites Manufacturing Innovation, the US-based national infections. It does this using a natural mode of action that binds advanced composites consortium with over 150 members. bacteria and fungi. Sorbact does not contain antiseptics or The Miranda de Ebro plant employs currently 112 people who have been other toxic substances, which is positive for both the patient producing samples and industrial tests of precursor fibres that have been and the environment. tested in carbon fibre development centres around the world. The completion of the transaction is subject to customary www.montefibrecarbon.com regulatory approvals and closing is expected to take place during the second quarter of 2020.
20 | Sustainable Nonwovens | April / May 2020 dominocommunication.it
DIAPER TECHNOLOGY LINE
Advanced Tension Controlled Unwinding Technology for Hygiene Sector Applications
BTSR - Via S. Rita - 21057 Olgiate Olona (VA) - Tel. +39 0331.323202 - Fax +39 0331.323282 - [email protected] - www.btsr-hygiene.com Nonwovens News April-May 2020_HD_Layout 1 09/04/2020 12:26 Page 22
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achievement from FTSE Russell, approved as a member of the IVL recognised for FTSE4Good Index Series which is designed to measure the performance of companies in environmental, social and CSR achievements governance (ESG) practices.” Bangkok - Fibre producer Indorama Ventures Public Company In addition, IVL received a B Rating in Climate Change for the Limited ( IVL), has been selected as a member of the FTSE 4 fourth consecutive year by The CDP, an international non-profit Good Index Series for the fourth consecutive year following the organization in climate change that drives sustainable December 2019 index review. economies covering over 1,000 companies worldwide. With an increase in overall score from 4.3 in 2019 to 4.6 in “Being recognized by global organizations reflects IVL’s 2020 - the highest ESG score out of all chemical companies, IVL continuous development in sustainability and our commitment has been notably acknowledged in areas including corporate to economic, social and environmental responsibility towards governance, pollution & resources and climate change, standing the benefit of all stakeholders,” Richard added. “By focusing on at the top amongst included chemical companies. recycling development, lowering the carbon footprint, IVL has also been highly ranked in risk management and gas increasing renewable energy sources, developing human capital, emissions reduction from an international non-profit organi- and innovative products, we aim to fulfill a circular economy zation in climate change area for the fourth consecutive year. and efficiently serve the needs of our customers.” Mr. Richard Jones, senior vice president, Head of Corporate IVL has also announced its corporate strategy for 2020 till Communication and Sustainability at IVL, stated: “IVL 2023 which focuses on five pillars: Cost Transformation via commences our sustainability performance in 2020 with an Olympus, Asset Full Potential, Adjacency Growth, Recycling Leadership, and People. In combined PET, IVL says it aims to strengthen its cost Techtextil North America advantage while also driving the circular economy for PET by building a leading recycling business. rescheduled for In fibres, the company has outlined a focus on operation efficiency, asset integration, and innovation to meet October 2020 customer’s evolving needs, resulting in a business that delivers Atlanta - Messe Frankfurt has confirmed new dates for the Techtextil North double-digit ROCE. America & Texprocess Americas shows. “Going forward, IVL will continue to pursue our strategic Earlier this month, the organizers of Techtextil North America and Texprocess themes, with the ambition of achieving double-digit ROCE, Americas announced that the co-located events, initially scheduled for May strong cash flows across the cycle and above average returns to 12 - 14, 2020 would be postponed to December 2020 due to the COVID-19 shareholders,” Mr. Aloke Lohia, Group CEO of Indorama pandemic. Today, the organizers have announced that the postponement Ventures, said. “Historically, we have always remained strong has been rescheduled, and the co-located events will now take place from through the peaks and troughs of the chemical cycle and expect Thursday, October 1 until Saturday, October 3, 2020. to continue to outperform thanks to our highly experienced and In an announcement that was relayed first to exhibiting companies on professional management team.” Friday, Show Director Kristy Meade said: “Although not ideal, the [December] dates provided were the only viable option at the time of our postponement inquiry to the Georgia World Congress Center (GWCC). However, we shared the concerns of many of our exhibiting and visiting Georgia-Pacific signs companies regarding the holidays and year-end processes, and after tireless communication between our team and those at the GWCC, we have been agreement to add hemp able to secure the new dates of October 1-3, 2020 for Techtextil North VICTORIA - Canada’s Bast Fibre Technologies and pulp and America and Texprocess Americas. paper company Georgia-Pacific have entered into a global The new dates are more suitable for both local and international exhibitors.” licensing agreement for a suite of patents related to the The new dates have received an overwhelmingly positive response from the application of intact plant-based bast fibres in a variety of exhibitor base so far, organisers said, adding that the team was looking nonwoven products and processes. forward to aiding in the global recovery of the Technical Textiles, Under the terms of the agreement, under licence from Georgia- Nonwovens, and Sewn Products industries by providing a platform where Pacific, BFTi will develop, process and market the ‘next generation’ industry professionals can once again gather to exchange knowledge, new of sustainable nonwoven fibres, part of the industry’s transition ideas, and business. away from synthetic materials towards natural solutions. Registration will remain open, with the Advanced Pricing deadline extended Bast fibre, also called phloem fibre, is collected intact from until September 1, 2020. All event registrations will remain intact, and will the inner bark of the bast family group of plants including be transferred to the new dates. hemp, flax, jute and kenaf. The essential role of the fibre in the For more information and access to the most recent program updates, plant’s life cycle – the transportation of nutrients while deadlines, pricing information, and more, visit www.techtextilna.com or supporting the structure of the plant – also provides key www.texprocessamericas.com. performance benefits such as high natural absorbency and wet strength, critical for many nonwoven products.
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NONWOVENS NEWS
With many countries set to introduce strict legislation aimed at significantly reducing single-use plastics, the nonwoven New adult diaper industry has recognised the urgent need to find alternative fibres that are natural and fully sustainable. The recent passing line from Andritz of favourable hemp farming legislation in Canada and the USA GRAZ - Andritz Diatec is extending its portfolio with the launch is expected to provide future hemp fibre supply volumes that of a new adult pants converting machine. will be required to support the transition away from synthetic to With the acquisition of Diatec in 2018, Andritz enlarged its natural fibre for many single-use nonwoven markets. product portfolio to include the latest converting lines for the Enhanced labeling requirements will also soon inform hygiene, lamination, medical and food pad sectors. consumers in many countries about the appropriate disposal of The company was seen as an excellent complement to the synthetic nonwovens and the negative impacts single-use already well-known Andritz solutions for spunbond, spunjet, air- plastics have on the environment. through bonding, or spunlace technologies. From fibre “Over the last few years we have been working very closely preparation to the finished diaper or sanitary napkin product, the with our farming and supply chain partners who share our goal customer can now have almost everything from a single source. of transitioning the nonwoven industry away from synthetic The latest launch is the new adult pants line D-TECH Adult fibres to natural bast fibres,” said Noel Hall CEO and Chairman pant, which offers high quality components and an innovative BFTi. “Displacing man-made synthetic fibres with all-natural fibres technology process. such as hemp requires an intimate knowledge of agronomics, “The growing market for adult incontinence products has natural fibre processing and deep technical knowledge of both resulted in a state-of-the-art process with highest quality nonwoven manufacturing processes and market opportunities. standards, such as the development of ultrasonic side seam “Georgia-Pacific’s foresight in recognizing the potential of solutions with excellent results in terms of bond strength and bast fibres in the nonwoven market is to be applauded. system reliability,” Andritz said. “The machine speed no longer Georgia-Pacific appreciated that we were best placed to limits quality bonds. As a result, operations and size changes are maximise the global potential of its bast fibre IP while allowing faster and easier. The modern forming system for higher SAP Georgia-Pacific to focus on serving its core customers in the concentration and the turning and placing system guarantee North American food service, industrial and club segments with maximum process stability and put customers’ adult pants at their own portfolio of bast fibre products.” the top of the adult hygiene market.”
Investkonsult Sweden AB Consultants to the nonwoven and absorbent hygiene industries
Investkonsult Sweden is one of few companies in the world solely devoted and focused on these two sectors. Over the years we have developed an extensive and ever-growing network of contacts within the industry. Our main services Customer benefits G G Project management An objective outside eye G G Market and customer analysis Flexible, adaptive and creative G G Mergers & Acquisitions A safe zone G G Valuations & Assessments Accessibility G G Matchmaking Confidentiality
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Image: © Lenzing Image: Staple developments
Expanding the processes for natural, renewable or recycled staple fibre-based nonwovens and the products made with them is currently a hot topic in the industry, writes Adrian Wilson.
ad the INDEX 2020 nonwovens collection and disposal coming into place drive manufacturers and consumers show taken place as originally in December 2024. towards these materials, considering scheduled from March 31st to According to the current definitions of them to be ‘green alternatives’. In the H April 4th in Geneva, rather than plastics, the key raw materials that are longer term, this may result in an increase being pushed back to October 20-23 left to work with in order to avoid the in wet wipe consumption and flushing as due to the coronavirus, a clear trend legislation include wood pulp, starches, consumers are told that the products are would have been evident. cotton, cellulose derivatives, flax/hemp/ environmentally friendly, with increased With the imminent arrival of the sisal etc., PHA, proteins and viscose and environmental damage as a result. European Single-Use Plastics Directive lyocell. “The SUP was a flagship achievement (SUP), and with similar legislation of the previous European Commission. It planned in North America, there is a Lyocell and viscose would be both disappointing and a lost rush to expand the processes for However, in January this year, a report opportunity to address problems natural, renewable or recycled staple by consultancy Eunomia for the EU, associated with single use plastic items if fibre-based nonwovens and products What is Plastic?, questioned the non- those placing single-use products on the made with them. inclusion of lyocell and viscose under market were able to evade its core goals the current definition of plastic in as a result of the way that exemptions Action Europe’s legislation. are specified. It is crucial that producers The SUP will take action against the ten “Our researchers focused on the take fuller responsibility for the impact products most commonly found materials found in wet wipes, specifically that their products have on the discarded on European beaches and the lyocell and viscose, finding that the environment – ensuring that legislation is list is 99% certain to include both evidence that these materials are as watertight as possible is the first step nonwoven wipes and feminine hygiene substantially less harmful in the natural towards that goal.” products, when finalised in July 2020. environment compared to synthetic In July 2021, laws will come into force plastics is currently lacking,” said lead Response requiring such products to carry author of the report Joe Papineschi. “The EDANA, the European Disposables and prominent warning labels, with extended report raises a serious concern that, if not Nonwovens Association, while producer responsibility for their clean-up, addressed, the loophole in the SUP will welcoming the SUP, responded with
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TABLE 1: EXAMPLES OF RECENT AMERICAS Current European STAPLE FIBRE TECHNOLOGY EXPANSIONS legislation, as well as technical expertise, concludes that lyocell Company Technology Location Operational and viscose are not chemically Ahlstrom-Munksjö Drylaid Madisonville, Kentucky 2018 modified natural polymers and Autoneum Needlepunch San Luis Potosi, Mexico 2017 as such should be excluded from Berry Global Airlaid Benson, North Carolina 2015 the definition of plastics. EDANA Bondex/Andrew Industries Spunlace Trenton, South Carolina 2016 Bouckaert Industrial Textiles Spunlace Woonsocket, Rhode Island 2017 concern to the Eunomia report, Carolina Nonwovens 2 X airlay lines Maiden, North Carolina 2015 asserting that as man-made cellulose Carver Nonwovens 2 X airlay lines Fremont, Indiana 2016 fibres, lyocell and viscose are simply not plastic materials. Fibertex (Mogul) Spunlace Gray Court, South Carolina 2016 “Current European legislation, as well Fibertex Personal Care Printing Asheboro, North Carolina 2017 as technical expertise, concludes that Fis Fiber 2 x needlepunch lines Naucalpan, Mexico 2017 lyocell and viscose are not chemically modified natural polymers and as such Foss Needlepunch Rome, Georgia 2018 should be excluded from the definition Foss (AstenJohnson) Needlepunch Hampton, New Hampshire 2020 of plastics,” the organisation said in a Freudenberg Filter media Hopkinsville, Kentucky 2017 statement. “Furthermore, there have been multiple independent studies done Glatfelter Airlaid Fort Smith, Arkansas 2017 by scientific experts to demonstrate the H&V Absorbent glass mat East Walpole, Massachusetts 2016 biodegradability and flushability of both H&V Filter media Floyd, Virginia 2015 lyocell and viscose in several environments and to show that they are Jacob Holm Spunlace Candler, North Carolina 2015 more sustainable than fossil-based McAirlaid's Airlaid Rocky Mount, Virginia 2019 plastic fibres.” Norafin Spunlace Mills River, North Carolina 2018 Staple fibre technologies Nutec Ceramic spunmelt needlepunch Huntersville, North Carolina 2016 Whatever the outcome of this debate – Owens Corning Glass nonwovens Gatonia, North Carolina 2016 and it is unlikely that the EU will act on Pantex 3 X Air-through TB lines Simpsonville, North Carolina 2015-2016 the Eunomia report in respect of its definition of plastics – responding to the Polyvlies Needlepunch Winston-Salem, North Carolina 2019 SUP completely favours the use of drylaid Porcher Needlepunch Altavista, Virginia 2018 or wetlaid manufacturing processes over Precision Custom Coatings Airlaid Totowa, New Jersey 2015 higher speed spunmelt options. According to a number of forecasts, Sandler Not disclosed Perry, Georgia 2016 including those from EDANA and North Sandler Not disclosed Perry, Georgia 2020/21 America’s industry association INDA, around 11.8 million tons of nonwovens Scavone Needlepunch Itatiba, Brazil 2020 were produced in 2019. Shalag Carded TB Oxford, North Carolina 2017 While the growth of spunmelt Spuntech Spunlace Roxboro, North Carolina 2015 (spunbond and meltblown) nonwovens made from polymer resins has been Suominen Wetlaid Bethune, South Carolina 2016 dramatic in the past couple of decades, Technical Fibre Products Wetlaid Schenectady, New York 2019 58% of the market (6.8 million tons) is TenCate Needlepunch Pendergrass, Georgia 2016 still based on staple fibres manufactured via either dry or wetlaid technologies. Ten Cate Geosnthetics Needlepunch Jefferson, Georgia 2019 The nonwoven technologies Tenowo Multiknit stitchbond Lincolnton, North Carolina 2017 originating from the textile industry Thrace-Linq Needlepunch Summerville, South Carolina 2018 manipulate staple fibres (or chopped filaments) in the dry state, usually by US Cotton Spunlace Gastonia, North Carolina 2015 carding and then bonding by a variety of Vita Nonwovens Needlepunch/Thermobond High Point, North Carolina 2019 methods – needlepunching, WPT Drylaid Kentucky, Ohio 2018 thermobonding, chemical bonding, V
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hydroentanglement with high pressure head, a fibre feeding system and a water jets etc. Over the last few years, we hammer mill designed for high capacity Airlaying technology also involves have been working very closely and robust forming processes and fibres that are manipulated in their dry with our farming and supply configured as the company’s patented state but is a process technology which chain partners who share our airlaid beater forming technology. originated from the paper industry and goal of transitioning the “In addition to the traditional involves converting soft, random-laid types of fibres, the new line can also nonwovens industry away from fibres made from wood pulp or synthetic process recycled or biodegradable fibres fibres – or most often a combination of synthetic fibres to natural from one millimetre up to thirty the two – into sturdy and absorbent bast alternatives. millimetres in length and uses signifi- webs, using air instead of water to Noel Hall, cantly lower energy than similar transfer the fibres. CEO and chairman BFTi systems,” said Jens Erik Thordahl, a partner in the company. “Having our Wet-laid technology “The general properties of airlaid own testing facility means that we can Paper-based nonwoven fabrics are fabrics are high isotropicity. high loft (if be even better at advising our customers manufactured with machinery designed required), high porosity, high absorbency on new products. Our customers can see to manipulate short fibres suspended in and wicking rate, a soft handle, adequate immediate results even from as little as a fluid and referred to as ‘wet-laid’. tensile strength, good resilience and high kilo of raw material.” The use of the wet-laid process has thermal resistance,” Tipper explained. been confined to a very small number of “These properties make airlaid Bast fibres companies, being extremely capital nonwovens the ideal materials for AHPs Atlanta-headquartered Georgia-Pacific – intensive compared to drylaid or airlaid and wipes, as well as other products such which appears to be focusing largely on operations that can be relatively small as meat pads, filters, insulation felts and its paper and tissue businesses having scale, involving little more than a card or automotive components.” sold its European airlaid operations to airlay machine and a needling machine Glatfelter in October 2018 – has also or heated calender. Airlaid trials granted a license to Bast Fibre The downside of such modest Denmark’s Campen meanwhile reports Technologies Inc., (BFTi) for its suite of operations, of course, is their inability to that its just-opened new test centre in patents related to the use of bast fibres meet the needs of mass markets such as Hornslet near Aarhus has already been in nonwovens production. absorbent hygiene products (AHPs) or visited by three Fortune 500 companies “Over the last few years, we have consumer wipes, which is exactly where looking to trial new ideas for the been working very closely with our the alternatives to synthetic fibres are development of more environmentally farming and supply chain partners who being demanded today. friendly products via airlaid production. share our goal of transitioning the The new test centre’s technology nonwovens industry away from synthetic Preoccupations consists primarily of an airlaid forming fibres to natural bast fibres,” said Nevertheless, in the build-up to the postponed INDEX show, a number of TABLE 2: EXAMPLES OF RECENT announcements indicated the current ASIA PACIFIC STAPLE FIBRE EXPANSIONS preoccupations of the nonwovens Company Technology Location Operational industry, as confirmed by Matt Tipper, Autotech Needlepunch Gujurat, India 2016 business director at NIRI (the Nonwoven Innovation and Research Centre) based Dalian Ruiguang Carded spunlace Dalian, China 2017-2018 in Leeds, UK. DDN Beijing Dongfang Dayuan Spunlace Beijing, China 2015 “With the EU Directive on Single-Use Plastics, the nonwovens industry is Freudenberg Headliner nonwovens Suzhou, China 2016 focused on experimenting with processes Fujiang Nonwovens Spunlace Nanping, China 2018 that work towards increased sustain- ability.” he said. “Manufacturers are Hangzhou Xiaoshan Phoenix Spunlace Hangzhou, China 2016 exploring airlaid technologies as these Huafon Microfiber, Needlepunch (ten lines) Jiangsu, China 2016-2017 use a high percentage of natural fibres – predominantly fluff pulp, which is both JNC Corporation Air through bonded Moriyana, Japan 2017 cost-effective and sustainable, Nan Liu Undiclosed Yancho, Taiwan 2018 biodegradable and renewable.” Nbond Wetlaid spunlace Hangzhou, China 2015 NIRI itself has just installed a Dan-Web airlaid machine at its prototyping facility Zhejiang Yanpai Filtration Needlepunch (3) Tiantai, China 2020 that is used by both consultancy clients Zhejiang Huajiang Spunlace/needlepunch (2) Hangzhou, China 2017 and industrial partners.
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Noel Hall, CEO and chairman BFTi. “Displacing man-made synthetic fibres TABLE 3: EXAMPLES OF RECENT EMEA with all-natural fibres such as hemp STAPLE FIBRE TECHNOLOGY EXPANSIONS requires an intimate knowledge of Company Technology Location Operational agronomics, natural fibre processing and deep technical knowledge of both Afitex Needlepunch Champhol, France 2018 nonwoven manufacturing processes and Ahlstrom-Munksjö Drylaid Turin, Italy 2018 market opportunities. “Georgia-Pacific appreciated that we Ahlstrom-Munksjö Microglass Turin, Italy 2020/21 were best placed to maximise the global Akinal (AS Nonwovens) Wetlace Gaziantep, Turkey 2016 potential of its bast fiber IP while allowing Georgia-Pacific to focus on Albaad Wetlaid, spunlace Dimona, Israel 2015 serving its core customers in the North Autefa Needlepunch Linz, Austria 2019 American food service, industrial and club segments with their own portfolio Berry (Avintiv) Carded Terno, Italy 2015 of bast fiber products.” CMC Consumer Medical Care Spunlace Germany 2015 The recent passing of favourable hemp farming legislation in Canada and EcoTechnilin Needlepunch Tychy, Poland 2018 the US is expected to provide future ELG Carbon Fibre Needlepunch Colseley, UK 2016 hemp fibre supply volumes that will be required to support the transition away Fibertex Nanofibres Aalborg, Denmark 2018 from synthetics for many single-use Grupo Sari Needlepunch Rubi, Sain 2019 nonwoven markets. H&V Nanofibre nonwovens Hatzfeld, Germany 2015
CAC production Hassan Tekstil Needlepunch Istanbul, Turkey 2018 In February, Mondi Group, headquartered in Vienna, Austria, Hassan Merkas Needlepunch Istanbul, Turkey 2018 announced the commissioning of a new Kimberly-Clark Wetlapping (rebuild) Coblenz, Germany 2016 line for the creation of cellulosic three- layer nonwovens for personal hygiene Low and Bonar Drylaid Tivadar, Hungary 2018 and cleaning wipes in Ascania, Germany. Low and Bonar Glass mat Ivanka pri Nitre, Slovakia 2018 The new CAC (carded-airlaid-carded) line is using 100% cellulose content, Manifattura Fontana (Sioen) Needlepunch Venice, Italy 2019 including viscose and pulp from certified Mogul Spunlace Luleburgaz, Turkey 2016 sources, resulting in nonwovens materials that are fully biodegradable. Novita Spunlace Zielona Gora, Poland 2020 The new CAC technology makes it Rexcel Skapafors, Sweden Airlaid (upgrade) 2018 possible to combine three layers of Rusvata Spunlace Ryazan, Russia 2017 nonwovens into a highly functional and stable composite material. This Saint-Gobain Adfors Wetlaid Litomyšl, Czech Republic 2021 construction delivers optimal absorption Sandler Undisclosed Germany 2016 and lotion load for high-quality biodegradable wipes and uses fewer Sandler Undisclosed Germany 2020-21 resources than comparable carded Solar Nonwovens Proprietary Tamworth, UK 2017 mono-structures. The technology will be able to produce the entire sustainable Sapro Spunlace Istanbul, Turkey 2016 nonwoven material in-line, while Technical Absorbents Needlepunch Grimsby, UK 2015 enabling hydro-embossing to increase softness and improve cleaning power. Technical Fibre Products Wetlaid Burneside, UK 2015 “This latest technology means we Technical Fibre Products Wetlaid Burneside, UK 2019 can produce 100% biodegradable, high-performance nonwovens for wipes Texfelt Drylaid Bradford, UK 2017 that are more accessible, and we are Texsus Airthrough bonding Poland 2020 looking forward to introducing this to the market,” said Kelly Wright, TTL Needlepunch Lörrach, Germany 2017 Mondi’s product expert for personal VTT Foam technology Jyväskylä, Finland 2020 care and components. V
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P&G technology Consumers love textiles made from absorbency in skin care applications such Procter & Gamble – as the global leader cotton fibres, the company observes, as cosmetics and baby wipes. in AHPs – has meanwhile granted an appreciating the soft and natural touch “All of these nonwovens receive their exclusive worldwide license to Italian not only in garments but also in other particular properties from the special machine builder Teknoweb Materials to products coming in contact with the skin. fibre blends used,” says Sandler, “The commercialise its in-house developed Fibre fineness – usually in the range of raw materials selected not only maximize and patented Phantom technology. between 3-5.5 microns – along with functionality but also enable a reduction P&G’s Phantom is described as a strength and absorbency make cotton in basis weight.” drylaid alternative technology for fibers an ideal material for single-use dry manufacturing products such as wet and wet wipes, but there are two Renewable PP wipes from pulp and polymer fibers, reasons for the fibre’s limited popularity However, while all of this work on the which compared to conventional existing in single-use nonwovens. processing of staple fibres is taking place, processes is said to offer superior Firstly, cotton is usually more expensive spunmelt nonwovens made from performance, with both cost advantages than viscose/polyester blends. Secondly, polymer resins may yet find a new way and more eco-friendly products. cotton fibers are natural products and to respond to the call for more This technology dispenses with their quality can vary significantly – both sustainable processing and products. hydroentanglement, rendering the regionally and from year to year. Borealis has just started to produce subsequent drying of the material Trützschler proven line technologies polypropylene (PP) based on Neste’s redundant and targeted process for cost effective cotton nonwovens are renewable feedstock at its production management allows the optimal setting even able to reliably turn cheap cotton facilities in Kallo and Beringen, Belgium. of relevant product parameters such as comber noils, as well as short or After producing renewable propane softness, tenacity, dirt absorption and unbleached cotton fibres into using its proprietary NEXBTL technology, liquid absorption. high-value products. Neste is selling the renewable propane to Another route to providing consumers the Borealis propane dehydrogenation Oerlikon airlaid with eco-friendly, sustainable and plant in Kallo. Then it is converted to Teknoweb also partners with Oerlikon affordable single-use nonwoven products renewable propylene and subsequently Nonwovens for the development of is via the combination of wetlaying and to renewable PP atthe Kallo and new technologies for hygiene products spunlacing (WLS) technology. Trützschler Beringen plants. and wipes. builds complete WLS lines in partnership Recently finalised audits carried out by Oerlikon has also developed an airlaid with Voith. an independent third party have resulted process for turning pulp or cellulose in an ISCC Plus certification for the fibres into nonwovens said to have ADL renewable PP produced at both Kallo and virtually unrivalled environmental Germany’s Sandler has recently Beringen plants. This certification performance. Oerlikon confirms that introduced a number of new materials encompasses the entire value chain scope there is now a huge demand for including an acquisition and distribution and verifies that the renewable feedstock manufacturing such high-quality, layer (ADL) for absorbent hygiene used is certified as being 100% lightweight airlaid nonwovens with products (AHPs). All of its components renewable and sustainably produced, economically attractive production can made from renewable or recycled including traceability to point of origin. speeds and system throughputs. raw materials and its performance Downstream partners from a variety of The patented Oerlikon Nonwoven properties – such as absorbency, fluid industries such as consumer packaging, formation process – which also allows distribution and storage capacity – can automotive, healthcare, and appliance the homogeneous mixing of the most be fine-tuned to the requirements of industries can now commercialise their diverse raw materials, while simulta- each individual product. end-use products with a lower carbon neously guaranteeing evenness and The company is also introducing a footprint based on renewable propylene homogeneous fibre laying – is now nonwoven made from 100% and PP. In response to increasing setting new standards in the low running unbleached cotton at the show, suitable demand, Borealis is working with value meter weights it can achieve, the for use as both a wipes substrate and for chain partners to expand availability. company says. topsheet applications in AHPs. Henkel, a global market leader in the The benefits of this technology are adhesives sector, will be including also increasingly gaining significance in Flax renewable PP content in the packaging sustainable recycling applications. In addition, Sandler is now combining of a major brand over the course of the flax and viscose for materials with year, in its efforts to reduce its use of Cotton enhanced softness for skincare products, fossil fuel-based virgin plastics by 50% A focus of nonwovens technology while its 100% viscose BioWipe features by 2025. manufacturer Trützschler is currently on a special embossed design, which not Quite how renewable PP will be enhancing the conversion of cotton into only adds visual appeal, but adds bulk categorised within any definition of nonwovens for AHPs and wipes. and enlarges the surface to optimize plastics is, as yet, unclear. SNW
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FILTRATION Pollutant prevention Electronics giant Sony has developed rice husk fabrics for advanced filtration.
well known quick-fix for mobile In addition to its micro-pores of 2nm or The first step in the production process phones that accidentally fall in less which are found in conventional for Triporous is to carbonize the rice water is to encase them in a activated carbons, it also contains husks by clearing the large amount of Aplastic sachet of rice. mesopores of 2-50nm and macropores of silica accumulated between the cells of Now that same absorption principle is approximately 1µm – all of which exist in the husks. Next, the silica is etched to being exploited in a new material called a multiplex. form large macropores, and then Triporous – introduced by Japanese As a result, it can easily absorb large mesopores and micropores are electronics giant Sony at the recent 2020 substances at larger molecular weights developed in a high-temperature water ISPO sports show – has the potential to that have been difficult to absorb with vapor activation process. become widely employed in high conventional technologies. This includes It can be manufactured to order in performance nonwoven media for the organic molecules such as humin and different shapes and granularity filtration industry. poisonous algae blooms that cause water according to the application. It was for its equally-convincing odour pollution, as well as allergens, viruses and Sony has obtained end-to-end patent absorption properties, however, that small proteins such as enzymes. It is also protection on the material and Triporous was being promoted in capable of quickly absorbing low investigated the possibility of commer- outdoor apparel ranges at ISPO 2020, molecular weight compounds such as cialising and mass-producing it itself but held in Munich from January 26-29. organochlorides and pesticides. has now decided to make the material Its development dates back to 1991, As a consequence, Triporous provides available through third party licenses. when Sony became the first company in new value for various products, including the world to commercialise a environmental filters that remove ISPO 2020 rechargeable lithium ion battery and has pollutants from the air and water. Some 2,850 exhibitors took part in ISPO continued advancing its R&D efforts in Other applications include toiletries 2020 and around 80,000 people from pursuit of improving its performance. such as deodorants, odour removers, and 120 countries visited the. The countries During this development work, other anti-bacterials, as well as with the largest number of visitors were Triporous – a material that exhibits a applications in cosmetics, pharmaceu- Germany, Italy, Austria, France, greater and faster rate of absorption of ticals and clothing and textile products. Switzerland, Great Britain and the various substances than existing Russian Federation. activated carbons – was stumbled across. Sustainable story The ratio of visitors from outside Approximately two million tons of Germany climbed to 70%, with increases Structure rice husks are disposed of annually in from France, Japan, South Korea and It consists of a unique finely structured Japan alone and over 100 million tons New Zealand. porous carbon material derived from worldwide every year, so the product The next ISPO Munich will be held surplus biomass such as rice husks has a compelling story when it comes from January 28 to 31, 2021. including silica. to sustainability. www.sony.net/triporous SNW
Triporous was promoted in outdoor apparel ranges at ISPO 2020.
Triporous is to carbonize rice husks.
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www.nonwovensnews.com Firm foundations
Needlepunched polypropylene nonwovens are the bedrock for the range of functional geocomposites manufactured by the UK’s GEOFabrics.
uTex is a new geocomposite rootstalks can push through asphalt, Knotweed must be treated as controlled product developed by Geofabrics building foundations, cracks in concrete, and it can cause excessive costs for specifically to deal with Japanese retaining walls and even drains. remediation and lead to prosecution CKnotweed and other aggressively The plant out-competes other species, and/or compensation claims, especially invasive plants. impacting on landscaping programmes from neighbouring sites. Native to Japan, Taiwan, China, and and accumulating litter in its dense the Korean peninsula, Japanese thickets which encourage vermin and Copper ions Knotweed was introduced into Europe in increase the maintenance costs of The Geofabrics solution, CuTex, is a the mid-19th Century as an ornamental buildings. It can also disturb local permeable geocomposite root barrier plant and has subsequently thrived in ecosystems by blocking the migration of system consisting of a copper sheet fertile European soils – it has a high native plants and animals which can add mechanically encapsulated between high growth rate of up to two metres in 30 huge costs to development and strength nonwoven and woven days and is now classified as an regeneration schemes and additionally, polypropylene geotextiles. aggressive weed species with a is capable of obscuring railway signals Once installed, its impact is based on significant negative impact on the and road signs as well as causing rip the safe release if Cu2+ ions which inhibit environment where it occurs. hazards in paving. root growth. The copper ions create a The stout Japanese Knotweed Soil contaminated by Japanese localised zone of inhibition which when approached by root tips causes them to undergo a progressive collapse. The copper acts as a signal layer that all plants avert their growth from. CuTex only releases minute quantities of the copper ion and is a safe, yet effective root growth blocking material.
Testing In order to independently assess the effectiveness of CuTex, The Centre for Plant Sciences at the University of Leeds used a range of approaches with different plant species.
CuTex, is a permeable geocomposite root barrier system consisting of a copper sheet mechanically encapsulated between high strength nonwoven and woven polypropylene geotextiles.
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Schematic of how TrackTex effectively deals with the problem of mud pumping around railways lines
Testing in a sterile culture using Arabidopsis Thaliana demonstrated how CuTex creates its zone of inhibition roots with up to six metres wide, as well as wide growing towards this zone ceasing at a width lamination, sheet extrusion and distance of approximately 1.5cm from vacuum forming, Leeds, UK-based the composite. Even when seedlings Geofabrics has developed a range of were established at different distances all The stout Japanese geocomposites as solutions to specific roots stopped at the zone, and seedlings Knotweed rootstalks can push problems in infrastructure. trying to establish within the zone failed through asphalt, building They also include TrackTex, a patented to do so. foundations, cracks in anti-pumping geocomposite which was CuTex in soil will effectively form a concrete, retaining walls the result of over a decade of research by chemical barrier as the Cu2+ ions diffuse and even drains.. railway engineers and materials scientists. into the soil and it is believed its Subgrade pumping has always been a effectiveness increases with time. This was problem in ballasted railway track, partic- tested by pre-incubating CuTex in an agar support the development of the plant, ularly on weakly cemented mudstones or media for a period of four weeks, after and thus the long-term growth and over consolidated clays. These soils have which seeds were sown. The plates where survival of the plant depends on a high shear strength and as such do not the CuTex had been allowed to incubate growing through the CuTex. The need a deep trackbed to support track indicated a much stronger and larger experiment was conducted using a loading. If unprotected though, the zone of inhibition abolishing the growth number of plant species, including upper surface degrades easily to a slurry of the seeds. Japanese Knotweed, with the CuTex when directly exposed to water. being assessed against a control fabric. The open texture of ballast allows free Bio-safety Confocal laser scanning microscopy water to come into contact with the The bio-safety of CuTex was tested by and differential contrast interference exposed formation. When the exposed assessing how it affects the overall microscopy were also used to analyse the surface contains fine grained particles, health and growth of plants. morphology of root tips grown in the these can be readily eroded by the water Whilst CuTex prevents plants from presence and absence of CuTex. The accumulating in the voids, forming growing through the composite and results demonstrated that when root tips weak, highly mobile slurry. This slurry is within the zone of inhibition, the effects approach the zone of inhibition they then ‘pumped’ up into the overlying were shown to be relatively localised. undergo a progressive collapse. The ballast by each passing axle load. CuTex was not shown to negatively dividing cells at the very tip of the root Contamination of the clean ballast layer affect the biomass of surrounding plants. (the meristem) die off and the cells above by the fine soil particles in the slurry very The most effective demonstration of the meristem differentiate. quickly reduces the load-bearing CuTex was a set-up using an upper layer properties of the ballast and leads to loss of vermiculite and a lower compost Mud pumping of track alignment in the affected area. layer separated by CuTex. The With the ability to manufacture Mud pumping results in ballast failure, vermiculite contained no nutrients to needlepunched geotextiles in widths of that weakens the track modulus, and V
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consequentially reduces the bearing GEOfabrics manufacture cuspates from quality high density polyethylene or polypropylene, which is extruded capacity. Under extreme conditions the into a range of different thickness membranes. ballast will become unmaintainable within a very short time post-installation.
Multilayer TrackTex is a multilayer composite with a unique microporous filter media protected by specially engineered protective nonwoven geotextiles. The filter is an orientated microporous polymeric film long service life due to its high puncture with a series of microcells and intercon- Over half a million square resistance, high elongation to break, necting pores, characterised by its relative metres of TrackTex have so far superior abrasion resistance, excellent strength and ability to transmit vapour. been installed under live railway filtration characteristics at all strains and TrackTex can effectively facilitate the tracks around the world. high UV resistance. passage of liquid under pressure, but the pores are such that the passages of clay Cuspates fines are not prohibited. Without intense compression and decompression Cuspates are polymeric sheet materials pressure, water cannot pass through the cycles. The foundation, being subjected that have been vacuum formed into filter, therefore any underlying clay to this fatigue stresses, can undergo either a stud or cup to provide a void formation will, over time dry out and fracturing up to the point of collapse. space for the passage of liquid or gas. have an improved modulus. Under these conditions, both very thick They are available in a range of heights Rain water is unable to penetrate the layers of aggregate and frequent and to suit design requirements. microporous filter and is drained laterally to expensive maintenance are required and It is common for a cuspate to be used the side of the track. Pore water below the although these maintenance costs are as a component in a geocomposite, in geocomposite is relieved upwards under high, by far the most important cost conjunction with a geotextile filter. They cyclic loading which aids residual slurry to factor is the reduction in revenue caused are commonly used in gas protection dry out as the pore water is dissipated. by the disruption of services. systems, cut off walls around contam- Over half a million square metres of RK4 laid on the base of the railway inated land, at the rear of bridge TrackTex have so far been installed in live ballast, constrains the aggregate by abutments and retaining walls, and tracks within Europe, Australia and the laterally confining it, and creating the around buried structures. United States. necessary trackbed stiffness. GEOfabrics manufacture cuspates from The geotextile also acts as a filter to quality high density polyethylene or RK4 prevent the intermixing of soils, with the polypropylene, which is extruded into a Also widely employed in railway track ballast layer maintaining the integrity of range of different thickness membranes. construction projects is RK4, consisting the drainage system. The sheet is formed in an extrusion of a bi-axial geogrid heat laminated to a RK4 uses RK1 needlepunched process in which semi-molten polymer is robust needlepunched nonwoven nonwoven which is specified by extruded through a flat die, with normal geotextile. RK4 is designed to provide engineers due to its robustness and its thicknesses from 0.4 to 2mm. ballast confinement and filtration and proven ability to function in the most These impermeable membranes are separation between the track ballast and demanding conditions which is especially vacuum formed into geocuspated cores the subgrade. important under dynamic loading between 6mm and 40mm thick, The rapid passage of trains applies beneath track ballast. Extensive testing depending on the mechanical and dynamic loads to the soil resulting in very has demonstrated RK1’s robustness and hydraulic properties required. Vacuum forming is a simplified version With the ability to manufacture needlepunched geotextiles in widths of of thermoforming, in which a sheet of up to six metres wide, Leeds, UK-based Geofabrics has developed a range of geocomposites as solutions to specific problems in infrastructure. plastic is heated to a forming temperature, stretched onto a single-surface mould, and forced against the mould under vacuum. An alternative to vacuum forming involves a continuous process where semi-molten polymer is formed between two corresponding rollers with male and female forming points. This process allows the company to control the quality from the polymer source through to finished cuspated drainage core. SNW
32 | Sustainable Nonwovens | April / May 2020 NEW CERTIFICATIONS. SCIENTIFIC BREAKTHROUGHS. MORE CONSUMER DEMANDS.
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www.nonwovensnews.com Fabrics on four wheels
Nonwovens featured prominently in a recent conference exploring all aspects of textile materials for the automotive industry. Adrian Wilson reports.
he 1st Textile Opportunities in a Luxury E-mobility Changing Automotive Industry In an opening keynote, a design team In examining the impact of e-mobility on (TOAI) conference took place from Jaguar Land Rover spoke of a textiles and nonwovens, Silke Brand- Tfrom February 5-6 2020 at the slowly accelerating shift in the Kirsch of the German consultancy Jaguar Experience Centre in Castle perception of what constitutes luxury, as Schlegel and Partner said it was just one Bromwich outside Birmingham in the UK. consumers increasingly consider sustain- of four current disruptive megatrends, Jaguar Castle Bromwich built Spitfire ability in their purchasing decisions. with the other three being sustainability, planes in the 1940s and now assembles The interiors of the auto brand’s autonomous driving and new business Jaguar vehicles there, and conference vehicles have traditionally been leather, models such as shared mobility. delegates got the chance to tour the which is still the default choice for Legislation, technology and lowering highly automated plant during their visit. premium vehicles for many consumers, costs are the key incentives for the Slated for closure back in 2008, the but various Jaguar Land Rover models adoption of e-mobility and the Castle Bromwich plant has instead had a now offer optional alternatives, based on production of battery electric vehicles renaissance following investments of combinations of Kvadrat wool textile (BEVs) climbed from 1.6 million units in around £600 million in the past few panels and Miko’s Dinamica, the high- 2018 to 2.2 million in 2019, representing years, including the latest in advanced end nonwoven leather alternative. growth of 35%. At the same time, this industrial robots. “We still need to gain more advocacy production represented only a 2.5% The sold-out TOAI event featured a for sustainable materials,” said Amy share of the approximately 89 million diverse range of presentations on Frascella, the company’s design director light vehicles produced last year. applications for textiles in the automotive for colour and materials. “We are The most optimistic of forecasts puts industry, with nonwovens particularly working hard to embed a new concept annual growth rates for BEVs of 15%, to well represented. of what constitutes luxury.” see them claim a 24% share of the Delegates visited the highly automated Jaguar Castle Bromwich plant during the two-day conference.
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overall market by 2030. Schlegel and Jaguar Land Rover designers (left to right) Amy Frascella, Louise Thorburn, Sarah Kate Fraser and Partner’s own forecast is for annual Nicola Keers discussed the growing influence of growth of 8%, giving them a 10% share sustainability in consumer purchasing decisions. of the market in ten years’ time. Other forecasts, however, are for growth as low as 4% annually.
Growth The consumption of textiles in light vehicles has grown significantly over the past 20 years, from 20kg per vehicle in 2020 to 25kg at present. Between 2007 and 2018 meanwhile, the average content of nonwovens in vehicles climbed from 3kg in 2007 to 8kg in 2018, largely as a accelerate internal research, in order to thermal insulation components for result of lightweighting issues and gain a competitive advantage and the first Leyland Mini, Autins now new applications. generate intellectual property (IP) that is supplies around an annual 20 million Around 30 square metres of commercially exploitable. It’s also often insulation parts to over 160 different nonwovens are now to be found in light beneficial to share the risk of a project customer locations. vehicles, with the layers in underbodies and these aims should in theory be With four operations in the UK and wheel arches being two recent metal achieved at reduced cost.” and others now in Sweden (opened in and plastic substitutions which have The three-stage process she advised for 2012) and Germany (opened in 2013), added an average eight square metres ensuring both partners are fully protected the company’s product range is between them. involves an initial audit in respect of based around: There are a number of applications for patents, registered designs, trademarks, • Nonwovens as lightweight, ultra-micro textiles on traditional cars, however, know-how and non-disclosure fibre-based acoustic absorbers. which are no longer required in BEVs, agreement (NDA) requirements. • Mono-material polyester nonwovens such as outer dash components, engine The preparation of the agreement with application-specific scrims. liners, encapsulation materials, under should then clearly define what each • Injection moulded PUR open/ engine shields, various filter systems and party will bring to the collaboration as semi-open/closed cell foams. tunnel components. well as the background IP and which • Layered barriers and absorbers tuned Nevertheless, there are new sources ~ parties will have ownership of what. to specific applications. of noise in BEVs that are likely to “There could be pitfalls if joint • Low density PUR foam with application- require NVH (noise, vibration and ownership is intended, in respect of who specific scrims and heat shields. harshness) shielding. will file and pay for the IP, how it will be Beresford’s team employs software called “E-mobility will favour textiles over exploited and who benefits,” Maxwell Alphacell to predict and tune the other solutions for acoustics while said. “The solution could be that one acoustic behaviour of multi-layer autonomous driving and car sharing will party is to own it and grant the partner a materials and a separate software have an impact on interior design, so favourable licence, which often turns out programme called Rokcell to calculate there are many opportunities,” Brand- to be much more straightforward.” the parameters governing viscous and Kirsch concluded. “Nevertheless, there is There should then follow a thorough thermal dissipation in porous materials. enormous price pressure on Tier 1 and review of the project in respect of what Such testing has recently proven, for Tier 2 suppliers, while the so-called falls within the scope of the background example, that compared to back-injected ‘Dieselgate’ emissions scandal leaves no IP and the new developments. PU foam, the company’s special Neptune room for further failure.” Naturally, the conclusion was to seek nonwovens can reduce the weight of a legal advice early. spring (decoupling) layer in electric Legal aid vehicles by 35%, while maintaining the Patent and design attorney Deborah Acoustics equivalent sound reduction. Maxwell of Potter Clarkson spoke of the Two papers explored the use of necessary legal steps that companies nonwovens and textiles as automotive Neptune should take when entering into collabo- insulation, with Kathy Beresford Neptune is a new high-performance rative projects. explaining the acoustic modelling and nonwoven made from a combination of “There are many sound reasons for material classification involved in her polypropylene microfibres in the weight companies to collaborate,” she said. work for Autins. range of 0.3-10µm and PET staple fibres “These can include access to external Founded in 1966 in Rugby, UK, of around 23µm. expertise, perhaps to supplement and originally as a supplier of acoustic and The combined fibre web has a V
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corrugated finish and nonwoven and Thermashield, with maximum In testing, lightweight spunbond covering scrims provide a smooth, operating temperatures ranging from fabrics have been loaded with activated aesthetic surface. Neptune nonwovens 600°C to higher than 1,000°C. carbon and metal organic framework have a high sound absorption at a low A key application field for these particles (MOFs) using the technique, weight, with exceptional low-frequency materials is in exhaust system applications with a significant improvement in both absorption, along with excellent where they are employed as heat shields adsorption capacity and airflow compression and recovery. They also both at the hot and cold end of a vehicle. efficiency. At the same time, the cost of provide advantages for thermal Silcosoft and Silcosoft+ mats are based the adsorbent material can be reduced, insulation with low thermal conductivity on alumina silica fibres and extremely as well as the actual size of the product. and are cost competitive to alternative soft and pliable, allowing them to be cut NIRI’s process is fast and involves no products in the industry. Neptune into irregularly-shaped parts. The adhesives, with the particles effectively nonwovens are already approved for use Thermashield products meet the held inside the materials purely by in the vehicles of BMW, Fiat-Chrysler, requirements for insulation in the end mechanical agitation. Ford, Jaguar Land Rover and Volvo. cones of a vehicle’s catalytic converter and are based on near-respirable long Light Fast Car Thermal insulation fibres with close to zero shrinkage. Mark Dohmen introduced Archroma’s Jean-Marc Senecot, head of global R&D Now under development is SilcoSoft range of treatments for automotive for Porcher Industries outlined his Ultra which is promising to provide a interior fabrics, including Light Fast Car, a company’s range of products for thermal 25% reduction in thermal conductivity system for keeping fabric colours, deep, insulation in vehicles. performance while withstanding temper- vibrant and bright. With an annual turnover of €330 atures of up to 1,100°C. Polyester fibres, he explained, contain million and 16 industrial sites, 33% of the “As battery shielding for electric oligomers produced during manufac- French-headquartered company’s sales are vehicles, SilcoSoft Ultra is flexible and turing which migrate out of the fibres to the automotive sector and in addition simple to apply and can achieve a during acid dyeing at high temperatures, to needled mats and manufactured parts, considerable reduction in weight depositing white crystals on the yarn or it specialises in weaving and 3D weaving, compared to thin gauge steel shields or fabric, or into the machine. fabric and yarn treatments, laid scrims, other alternatives,” Senecot said. These deposits cause serious problems twisting and cabling. The company is further developing a at all stages of automotive textile This broad range of services allows the technology called Tex-Tronic for printing processing and impact on the produc- company to provide powertrain belts, directly onto fabrics to provide new tivity of dyehouse and weaving or brake hoses, clutch discs, airbags, car functions such as heating, lighting and knitting mills. body reinforcements and solutions for touchscreen capabilities. The Light Fast Car alkaline dyeing tyres to the automotive sector, in addition system with Archroma’s Dorospers dyes, to chassis, door and seating materials. Particle inclusion UV absorbers and dyeing auxiliaries is Ross Ward of NIRI in the UK spoke of the said to solve this problem to significantly Exhaust systems potential for enhanced cabin air filter reduce both processing times and Porcher’s nonwoven automotive systems with the company’s new particle operating costs. insulation materials are branded Silcosoft inclusion technology for nonwovens. Textilise Jean-Marc Senecot, head of global R&D for Porcher Mica NanoTech, a spinout from Limerick Industries, which University, introduced another finishing manufactures a wide range of fibre-based materials for technology called Textilise for improving the automotive sector. interior hygiene via particle binding to both textiles and surfaces. It can provide antimicrobial, hydrophobic, anti-static, odour and stain resistance to fabrics, in addition to flame retardant properties. Company founder Patrick Cronin explained that the company’s process anchors a nano-coating to the fibre surface via an ionic inter facial bind, creating a far superior bond than traditional finishing techniques due to the generation of significantly stronger surface energies. In the development of Textilise, Cronin
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said the objective was to develop a more sustainable textile finishing process that would fulfil the requirements of any expected future regulatory changes on the use of nano-materials, while maintaining the productivity and efficiencies necessary in modern textile manufacturing processes. As such, Textilise can be used to apply coatings to a wide range of substrates, including cotton, viscose rayon, polyester, nylon, acrylic and polyolefin and in addition to its effective mechanical bonding mechanism it provides a durability increase in washing of more than 90% over pad-cure approaches. detailed three projects the car maker has technologies and the process eliminates In automotive applications, it is partic- undertaken to replace metal components the wires and plastic substrates found in ularly effective at dealing with biofouling with carbon fibre composites, with existing wearables. – an issue likely to be of increasing varying degrees of success, while Screen printing is used to build-up significance with the rise of shared Friedrich Suchomel spoke of the fibre layers of ink, including one or more vehicles that is being predicted. producer’s involvement with Rinspeed in electrically conductive layers, onto a Switzerland on a number of advanced substrate. The conductive layers are Haptic concept cars, including this year’s shape- encapsulated between two electrically Haptic, developed by Huafeng Textile shifting micro-SNAP. insulating ink layers. An adhesive layer is Technology Solutions in China, is an added to form a conductive transfer, additive manufacturing technology for Printed circuits which can then be heat-pressed onto fabric surface finishing that has been used Marck Catchpole, creative director of any surface. The transfer film is finally to date on 25 million pairs of sports shoes Conductive Transfers, based in Barnsley, peeled off, leaving the ink-stack bonded for brands such as Adidas and Nike. UK, demonstrated a range of products to the substrate. Huafeng’s director of innovation enabled by the company’s advanced The most successful product to date Thomas Schmidt explained that the screen-printed circuits, including a for the company’s technology has been water-based PU treatment is applied via heating layer for automotive seating with in Innovo shorts developed for treating advanced screen printing with high extremely rapid heating up action, as well bladder weakness in women by Atlantic material finishing and no cutting waste. as lighting and touchscreen materials. Therapeutics of Galway, Ireland. Many different effects can be achieved The company’s circuits are stretchable Atlantic describes Innovo shorts as the such as 3D touch effects via coating and can be washed when printed onto only non-invasive pelvic floor exerciser thicknesses of 0.2-1.2mm that can be flexible substrates for use in wearable that treats the root cause of bladder very effective in automotive interiors. weakness – a weak pelvic floor – rather March Catchpole, These include the generation of fine lines creative director of than just managing the symptoms. They Conductive Transfers, and small dots, high or low gloss areas, demonstrated a range of can be worn like a normal pair of shorts products enabled by the semi-transparent coatings for see-through company’s advanced and use electrical muscle stimulation effects and multiple printed surfaces. screen-printed circuits. (EMS) to generate 180 contractions In terms of hand, the surfaces that can across the entire network of pelvic be created range from extremely soft floor muscles, which control bladder leather-like surfaces to sandpaper function, during every 30-minute textures and the process can be applied session. The shorts are controlled using a to a wide range of natural fibres, as well hand-held device. as synthetics. Further speakers at the conference included representatives from the Light and smart companies Bcomp (Switzerland), Borealis Other presentations at TOAI centred on (Austria), imat-uve (Germany) Kobleder reducing weight and meeting the (Austria), Sinterama (Italy) and Trevira challenges of sustainable manufac- (Germany), as well as the research turing, as well as smart textiles and institutes CeNTI (Portugal), the integrated electronics. Automotive Technology Centre of Galicia Alice Swallow of Ford, for example, (Spain) and EURECAT (Spain). SNW
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AUTOMOTIVE Autoneum bracing itself for heavy losses Despite the anticipated benefits of its new restructuring program, Autoneum has warned of a difficult year following the impact of Covid-19.
ith further details of its innovative components that are designed comprehensive restructuring to help automobile manufacturers and cost cutting program produce quieter, lighter and more Wemerging, automotive environmentally friendly vehicles. component specialist Autoneum has The multifunctional, lightweight posted a much-anticipated loss in its components are suitable for vehicles with latest financial update. all types of drives. “This is a great Revenue in 2019 grew organically by advantage for car manufacturers in both 2.5%, significantly outperforming the pre-development as well as series declining market, the company said. production of models and makes Revenue rose slightly to CHF 2,297.4 Problems have been further Autoneum a sought-after supplier of million. However, as previously exacerbated by the coronavirus acoustic and thermal management announced, operational inefficiencies in pandemic. The temporary plant closures solutions,” the company said. North America and impairments on fixed at almost all customers in all regions will With battery undercovers made of assets in that region had a particularly result in a revenue decline in the current Ultra-Silent, for example, Autoneum has strong impact on profitability and led to a year, the extent of which cannot yet be adapted this textile underbody net loss of CHF –77.7 million. estimated, the company said. In addition technology for use in electric vehicles for Following an extremely challenging to the ongoing cost-saving programs, the first time. These battery undercovers year for the automobile industry in 2019, Autoneum has therefore decided on a act as insulators helping to reduce sound the Swiss firm announced at the end of comprehensive set of measures to further that enters the passenger cabin as well as last year that it intends to relocate its increase the flexibility of personnel and pass-by noise. Competence Center New Mobility from material expenses. Noise-reducing components are also California USA, back to its headquarters This includes staff adjustments, e.g. by essential in electric models. External and in Winterthur, Switzerland. reducing the number of temporary internal noise sources such as electric The move is part of a wider restruc- employees in plants. In addition, short- drive elements, fans and pumps are more turing and cost cutting exercise that will time work at the Group’s headquarters in audible in this vehicle category due to the also see job cuts although precise Winterthur and at the Sevelen plant, as lack of engine noise and therefore impact numbers have not been confirmed. well as short-time work in some other driving comfort. As Autoneum notes, the continuing European countries and temporary “Thanks to their light weight, battery weakness of the global economy, closures of production facilities in various undercovers made of Ultra-Silent also ongoing trade disputes and the regions are being implemented. help to ensure a greater driving range,” increasing regulation of mobility had a Despite the above-mentioned counter- Autoneum said. “In view of increasing negative impact on vehicle demand, a measures and in light of the advancing pass-by noise regulation around the situation which has contributed to a spread of the coronavirus, Autoneum world, Autoneum now offers customers reevaluation of the Group’s performance does not expect to achieve its targets for the multifunctional Alpha-Liner over the short- to medium-term. the business year 2020. Due to the wheelhouse outer liner, which is In Business Group North America, for considerable uncertainties regarding the highly effective in reducing tire example, the operational and commercial course and duration of the pandemic, no noise and allows noise absorption problems have proven more extensive updated outlook is provided for 2020 for to be customized for the specific than originally assumed. As a result, the the time being. requirements of the vehicle model. turnaround program launched in spring Made primarily of recycled PET fibers 2019 was replaced at the beginning of Innovation and fully recyclable, Alpha-Liner 2020 with a dedicated and far more Despite the financial results, 2019 once wheelhouse outer liners are particularly comprehensive program. again saw Autoneum launch various environmentally friendly.” SNW
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HOME TEXTILES Home comforts Sustainability and functionality are the key trends currently dominating the home and contract textiles market.
ne of the outstanding qualities bedrooms, living rooms and dining Colcore Sonic. Colcore uses EconCore’s of nonwovens is that they can rooms, high-quality nonwovens can continuous, high-volume production be extremely durable, if that’s ensure practical, comfortable, safe, process for lightweight thermoplastic Owhat’s needed, or be single-use, hygienic and attractive solutions for honeycomb sandwich panels and is limited-life fabrics. Beyond this, modern home life. deliverable on a roll, rather than as a nonwovens possess limitlessly versatile rigid panel. The new product concept qualities like super absorbency, resilience, Honeycomb was developed during 2018, with a liquid repellency, stretchability, strength, An example of this new technology series of testing, learning and further softness, flame retardancy, cushioning, comes from Low & Bonar which has optimisation. Relevant industry qualifi- washability, bacterial barriers, filtering combined thermoplastic honeycomb cation tests were achieved to and sterility. technology with its nonwovens in a new demonstrate the product meets and With an ability to combine these leveling underlay for hard floors with a exceeds industry standards. qualities in innumerable ways, unique combination of lightweight, Colcore Sonic is lightweight and thin nonwoven manufacturers are able to strength and acoustic performance. but with a high compression strength. It create home textile products with the The company has signed a license has excellent soundproofing and unique, specific characteristics agreement with EconCore, for the use of outstanding leveling characteristics and is requested or needed by a client. its honeycomb technology and launched also very easy to handle, store and install. Nonwoven fabric is ideally suited for the new underlay flooring product, called As the first underlay that provides V carpet construction enhancement, for A close-up view of Colcore Sonic, showing the relaxed example, by being able to extend the honeycomb core with nonwoven performance fabrics. life of a carpet, by protecting the integrity of the product, and by reducing the chances for mold development or bacterial buildup, with proper use and deployment. New developments in nonwoven fabrics also help create home furnishing products that are good at repelling dirt, help against dust mites, and provide antimicrobial characteristics. Nonwovens are also seeing increase use in the wallpaper sector; nonwoven fabrics used in wallpaper have no seam A click flooring system sitting on top of the separation issues (like other materials Colcore Sonic underlay with an inset of a roll of used for the exact same purpose) and the new product, demonstrating its lightness. are easier to remove than other types of wallpaper. Furthermore, nonwovens are ideally suited for properties in great disrepair and in need of extra care since these types of wallcovering materials offer high stability, strength, versatility and cost-effectiveness. Nonwovens are also used in a multitude of household applications that range from filtering and cleaning to providing aesthetic enhancements to a home. When used in kitchens,
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excellent effective soundproofing and nonwoven composite produced from texture to create a beautiful ombre leveling capacity in a single product, it plastic waste to create its felt-like effect,” said Shannon Cochran, vice can be used with a range of hard construction. By utilizing recycled plastic president of creative and design for flooring types such as vinyl click bottles that have been converted into Patcraft. “The Patcraft design team systems, flexible vinyl, laminate, PET fibre, Dichroic has approximately sought to design a collection that hardwood and ceramic flooring. 70% recycled content (both post- resembles the effect of glass “Even with the latest generation of consumer and post-industrial), which is transparency. The two different shapes leveling compounds, preparing subfloors equivalent to 18 (0.5L) bottles in each play with optical perceptions using a prior to the installation of vinyl click 24”x 24” tile. series of solid gradients.” flooring is time-consuming,” said Joo Products are Cradle to Cradle Certified Bovenschen, new technology manager at Bronze and are backed by Patcraft’s Needlepunched Low & Bonar. “Unrolling, cutting and Environmental Guarantee specifying that Every year, more than 100 million square positioning this high-performance the company will reclaim and recycle the metres of primarily needlepunched underlay system is all it takes to smooth product at the end of its useful life. nonwoven carpet is manufactured for out uneven surfaces in minutes rather The Dichroic collection combines trade fairs and employed in corridors, fair than hours or days.” shape and color for multiple design stands, entrance halls and other event Independent testing found that options that support colour blocking and spaces. Because it contains latex, Colcore reduced impact sound by 20 dB zoning spaces within commercial however, it cannot be sustainably and airborne sound transmission is 57 interiors. The rich polyester face fibre recycled and most of it ends up in an dB, both defined as the noise perceived contributes to enhancing sound incinerator or as landfill, according to in a room below. Radiated walking absorption, and the collection is Belgium’s Beaulieu International Group sound, defined as walking noise in the designed and tested to meet Patcraft’s (BIG), which says it has the answer. same room, registered at 56.4 Sone (a high standard for performance flooring. The company has unveiled Rewind, as unit of loudness), considered to be a Dichroic is constructed with EcoWorx a unique latex-free carpet designed to comfortable sound level. The results backing, and products are backed with help the trade show and special events demonstrate that the product is ideal for limited lifetime warranties against stain, industries go greener. More than simply flooring of both, commercial and colorfastness to light, static and abrasive a product, Rewind is a concept that residential buildings. wear for maximum performance and offers both economic and ecological appearance retention. advantages as part of a strategy centred Composite With rich colorways that encourage on corporate social responsibility, the Patcraft, the US manufacturer of high- optical depth and aid in the design of company says. performance commercial flooring, has warmer, optimistic spaces, the Rewind is 100% polyolefin, which launched its first nonwoven composite collection’s sweeping color gradation means it is 100% latex-free. flooring collection, Dichroic. Designed to creates a compelling ombre effect. Consequently, the production process is create an innovative platform for Dichroic is available in facet tiles to offer very environmentally friendly. Compared commercial flooring, the Dichroic a variety of installation options. with traditional carpet, no water is used collection incorporates the warmth of “The soft visual of the Dichroic and gas consumption is cut by 83%. This soft surface and the durability and collection develops from tonal stripes production process reduces total CO2 cleanability of hard surface. that fade and shift across a space, emission by 35%. Dichroic features a multilayer, mimicking the subtle variation of a felted In the current economic climate,
Patcraft has launched its first nonwoven quality and efficiency also play a big role. composite flooring collection. Rewind proves its added value here and is described as strong and durable, with low VOC content and with Bfl fire classi- fication. Thanks to a lower total weight, the rolls are easier to handle and more ergonomic to install, the company says. The unique composition of Rewind also offers logistical advantages – less storage space and transport. Because Rewind contains no latex, it can be fully recycled into a pure recyclate that can be re-used as a raw material for the injection molding of new, high grade products. “As the market leader in needlefelt floor coverings, we are proud to be at
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the forefront of this technologically One of the Xeikon production lines. innovative product,” says Wim Coppens, general manager for needlefelt at BIG. “Rewind is the result of collaborative efforts by our employees across all divisions. More than a product, it is a philosophy in which economy and ecology merge. That ensures that Rewind creates added value for every stakeholder and the environment, at every stage of its lifecycle.” components: a Xeikon Digital Wallpaper Press, a dedicated workflow, application- As mentioned, nonwovens are also specific toners, process optimization playing an increasing roll in the wallpaper tools and pre- and post-press solutions. Under its ADVApaper brand, which is sector, particularly when combined with “We have seen an excellent 2018 ideally suited for the production of digital printing. A key recent development performance of our Wall Decoration nonwovens for wallpapers, the company in this sector is that Ahlstrom-Munksjö’s segment, both in terms of production has developed specially designed Wallstar Digital nonwoven wallcovering volumes at our existing customers and polyester fibres with modified cross- media is now suitable for use on digital new installations of Xeikon production sections and coloured, binder fibres. printing technology firm Xeikon. lines in the field,” said Dimitri Van Since the early 90’s, the company has a The compatibility with Xeikon’s Gaever, Business Development Manager, large portfolio of customized products technology, which focuses on the colour Xeikon. “We are pleased to be adding with more than 35 individual fibre types printing of labels and packaging as well the Wallstar Digital media to our for nonwoven wallpapers, exceeding the as the graphic arts printing industry, catalogue of qualified wallcovering increasing demands of the customers. follows a new collaboration between the substrates. The BR9708 grade from According to Advansa, the wet and dry two companies announced at this year’s Ahlstrom-Munksjö is a textured high- strength, tear strength and the Heimtextil exhibition. quality grade. We were impressed by its dimensional stability (in wet condition) in Wallstar Digital nonwoven wallpapers luxurious, textile-like appearance and its papers and wet-laid nonwovens have have been specifically developed for natural, esthetic and fibrous tactile been improved through partial substi- digital printing technologies, offering a touch. We expect to see good market tution of the pulp; a perfect base for the range of benefits such as homogeneous uptake of this exceptional wallcovering nonwoven wallpaper, which is moisture- print results while also being PVC-free. substrate, especially with the growing resistant due to the polyester fibre The range features smooth, structured, demand for customized interior décor content and also remains durable. coated and non-coated substrates, solutions, both among interior The removal of the wallpaper is also from 110gsm to 180gsm, which are said decorators and consumers.” said to be more straightforward as the to ensure very easy handling and fibre ingredient prevents a tearing; excellent dry stripability. Ahlstrom- Polyester ensuring a dry peel off the wallpaper. Munksjö also reports high customer Fibre specialist Advansa has been Elsewhere for the home market the satisfaction, especially regarding the supplying the nonwoven wallpaper company has also developed its first soft-touch feeling. industry with special polyester fibres for duvets which have been certified as The latest addition, the BR9708, is the more than 20 years. back-friendly. For the first time, duvets V only matt fibrous option on the market. Advansa has been supplying the nonwoven wallpaper It opens up a whole range of new industry with special polyester applications and design opportunities for fibres for more than 20 years. Xeikon customers and prospects. The long-standing cooperation between Ahlstrom-Munksjö and Xeikon gathered pace last year when the nonwoven manufacturer and printing specialist worked together to qualify a range of papers for Xeikon presses. This includes Xeikon’s Wall-Decoration Suite. It enables cost-efficient production of high-quality wall decoration for commercial, retail and residential purposes. It consists of five major
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featuring Aerelle Cool Night filling fibres needed to activate the effect in fabrics. the Belgian firm developed a masterbatch and Climarelle nonwovens have been The World Health Organization (WHO) technology for in-yarn solutions. Devan certified as proactive products by in Geneva, Switzerland, says that more was also the first company to introduce Aktion Gesunder Rücken (AGR, than 80% of urban residents are probiotics in textiles (2010). Campaign for Healthier Backs), which exposed to high levels of outdoor and In 2019 Devan presented its first bio- can preventively reduce painful indoor air pollution and estimates this based solution (Bio-flam) and now they muscular tension in the back. causes seven million deaths a year will launch another two: a bio-based worldwide. Meanwhile, another study antimicrobial (BI-OME natural) and bio- Mattresses has found that the concentration of based PCMs (Tones of Cool Bio). Founded in 1987, Totowa, N.J.-based VOCs is generally higher in indoor than A drive towards the use of more Precision Textiles, a supplier of coated outdoor air. Not all VOCs are harmful, sustainable products has led to the fabrics, nonwovens and laminations for but the WHO says that some, including introduction of more alternative solutions the bedding, automotive, health care and those noted above and the semi-volatile to solve the discomfort of malodours and home furnishings industries, has polycyclic aromatic hydrocarbons, have to reduce the allergens of dust mites. developed a new nonwoven textile detrimental effects on health. Many plants and flowers produce designed as cleaner alternative to FR socks The technology has been adopted by antimicrobial chemicals as a defence currently used in roll-pack mattresses. home furnishing retail giant IKEA which mechanism towards threats like bacteria, The company’s patented EcoFlex is a has introduced a range of Gunrid- fungi and moulds with natural antimi- glass-free, chemical-free barrier designed branded curtains based on the HeiQ crobials also used in food and cosmetics to tolerate the rolling and packaging Fresh AIR technology. A survey conducted as a preservative. required for boxed beds. on behalf of IKEA found that indoor Plant based, non-persistent, low EcoFlex, which is OekoTek Standard VOCs come from a number of sources toxicity pesticides have been used for 100-certified, is made with inherently including outdoor air, furniture, paints many years in agriculture and in flame retardant rayon. The material and household cleaning products, as well industrial kitchens. According to Devan, offers four-way stretch and recovery that as being generated during cooking. these natural, biocidal ingredients resists breakdown when tested on To quantify the performance of its inspired the company to develop a new rollators or rolled for packing. Designed treated fabrics, HeiQ worked with range of odour control technology and to be laminated to the underside of Professor Detlef Bahnemann, head of anti-dust mite products. mattress ticking, EcoFlex eliminates the Photocatalysis and Nanotechnology at BI-OME Natural for example, is a need to apply FR socks in the manufac- the Leibniz University Hannover, natural, bio-based antimicrobial solution turing process, the company said. Germany, resulting in four new norms that guarantees an optimal freshness and “As the industry continues to embrace being established: hygiene for textiles. The active ingredients the growing boxed bed trend, we seized • The Geneva, Switzerland-based are the well-known Linseed oil, obtained the opportunity to develop a more International Standards Organization from the dried, ripened seeds of the flax effective and cleaner FR solution to help (ISO)’s ISO 22197-1 for NO. plant and Chrysanthemum, derived from our manufacturing partners deliver high- • ISO 22197-2 for acetaldehyde. the seeds of the flowers of the daisy. quality sleep solutions,” said Keith • A modified version of ISO 17299 The active ingredients in BI-OME Martin, vice president of Precision for the measurement of the Natural are organic, GMO free, Textiles. “As a glass-free, chemical-free percentage reductions of VOCs. biodegradable and recyclable. barrier, EcoFlex changes the FR game • A modified version of ISO 10678 The bedding industry is also planning with its streamlined application process for rapid quality-control testing in to invoke regulations on recyclability, and skin-friendly materials proven to textile mills. therefore technologies such as BI-OME hold up and retain its FR efficacy.” Natural, which are recyclable, could gain Natural antimicrobial more interest over time, says Devan. Air purification Devan Chemicals, the Belgium-based Also available is Tones of Cool Bio, a Chemical specialist HeiQ is now developer of finishing technologies patented cooling technology which promoting a new mineral-based additive for textiles has developed two ~bio- stimulates the textile to dissipate which can be infused into fabrics to help based solutions, which complements redundant heat from the body and to purify indoor air. the bio-based flame retardant it instantly reduce the body temperature. The additive works as a photocatalyst launched last year. The PCMs used in Tones of Cool Bio are and combines with radiation from Sustainability has always been a focus derived from sustainable, natural sources. sunlight in the wavelength range 315– topic for Devan, even long before it The PCMs have the form of a 400 nm (also known as UVA) to break- became an urgent issue. In 1995 the crystalline wax or oily liquid (depending down pollutants considered harmful to company launched Eco-flam, the first on temperature) and is 100% plant health, such as VOCs such as halogen-free flame retardant. Four years based. In addition, Tones of Cool Bio has acetaldehyde and formaldehyde, and later they commercialized a non- a lower flammability than traditional nitrogen oxide (NO). No power source is migrating antimicrobial solution. In 2001 paraffin based PCMs. SNW
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SUSTAINABLE NONWOVENS Technical Innovation and Industry Best Practice
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Perfect particles
Martin Brunner, Christophe Roux and Michael Knerr of Omya International outline the company’s development of calcium carbonate designed for PP spunmelt and dry-laid nonwovens.
alcium carbonate can be found back in the 1950s when Omya introduced of calcium carbonate. Sheets for thermo- everywhere in daily life. It is used the first surface coated calcium carbonate forming, PP raffia tapes and injection widely as a coating agent for for PVC applications. Since then the molded articles typically contain up to Cpaper and paperboard as well as mineral has become an integral part of 40% of mineral. Shopping bags or for paints, as an additive in food/- many formulations for wire and cables, T-shirt bags used in packaging are pharma and cosmetics, as a soil fertilizer pipes, conduits and profiles. loaded with 5% to 30%. The improved in agriculture, for water remineralization, Later, more and more applications in performance with calcium carbonate is for flue gas desulfurization and many other polymers such as PS, UP, PUR, PA, used to down-gauge film thickness. other applications. ABS or PET were established. BOPP films take advantage of the In plastics the first applications date Polyolefins are also a major application cavitation functionality of the carbonate
HOW TO INCORPORATE OMYAFIBER 800 INTO THE PP NONWOVEN FABRIC MASTERBATCH FIBRE AND NONWOVEN COMPOUNDING PRODUCTION
100% Omyafiber® 70% Omyafiber® in PP masterbatch Virgin PP plus Omyafiber® masterbatch
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RAW MATERIALS
particles. Voids created with 7% to ® 25% calcium carbonate particles help to PP MULTIFILAMENT FIBERS CONTAINING 10% OMYAFIBER reduce density down to 0.5 g/cm3 and 800 SHOWING PERFECT MINERAL DISPERSION boost the opacity of the films. If the addition rate of calcium carbonate is increased further to 40% to 60%, an open cell structure can be achieved. This effect is used to produce breathable hygiene films for baby diapers and adult incontinence products. The membrane function is charac- terized by a high water vapor transmission rate (WVTR) in combination with a good water column even for very thin films down to 8 g/m2. produced in an intermediate Omyafiber 800 on industrial lines. Such demanding applications require compounding step. To ensure good The trials were conducted with different specific properties of calcium carbonate processability and product quality, the technologies. Spunbond nonwovens powder. It is therefore essential to compounding technology needs to have been produced with thermal develop tailor-made solutions to fulfill the provide perfect dispersion of the mineral. calendering. Further trials with specific requirements of these markets. To dilute the masterbatch concentrate spunlacing or hydroentanglement as Omya works within these established pellets must be mixed with virgin PP and bonding step have been conducted. applications and introduces novel fed to the nonwoven process. A typical Trials with PP staple fibers which products to open new markets. Key to formulation may contain around 14% were carded and hydro-entangled have this success has been addressing all masterbatch with Omyafiber 800. The PP been done. aspects along the value chain from raw is typically a homopolymer with a melt In all trials 10% Omyafiber 800 was materials, formulations, compounding, flow rate (MFR) of 25 to 35 g/10 min at incorporated in the nonwovens via the converting down to the requirements of 230°C and 2.16 kg. addition of 14% masterbatch. Scanning the end application. electron micrographs of PP multifil- A good example of Omya’s innovation Value aments containing 10% Omyafiber 800 is the development of the new Raw material savings are substantial are shown above. Omyafiber 800 calcium carbonate for PP although cost savings are not the only The trials proved that Omyafiber 800 spunmelt and dry-laid nonwoven fabrics. attraction. In spunlace and carded caused no die build-up at the spinneret This product is specifically designed to nonwoven fabrics it creates natural nor any extrusion pressure evolution provide an attractive solution which cotton like haptics and softness. At high during processing. The processes ran creates value for customers. It is a fine and low basis weight fabrics it improves stable without fibre breakage. The ground calcium carbonate that is tensile strength and elongation. Higher evaluations helped to establish the naturally very pure. whiteness with Omyafiber 800 allows know-how to optimize the process. More The particle size and the particle size savings in titanium dioxide (TiO2). During detailed technical results are available distribution are tailored to achieve processing and on the final fabric the from Omya for further discussion. outstanding processability and fibre static charge is reduced. To realize all beneficial features properties. A new and improved Omyafiber 800 is also beneficial from a with Omyafiber 800 it is important proprietary surface treatment is applied sustainability perspective as it has a to ensure high quality along the to the calcium carbonate to achieve substantially lower carbon footprint then value chain from raw material excellent dispersion of the mineral PP resin; it improves the CO2 balance. producer via the compounders to the particles in the polymer matrix. It allows The value proposition is not only seen nonwoven producers. enhanced processability and optimized in internal lab investigations. Extensive Therefore, it is crucial that all compatibility. The product is food technical evaluations have been done stakeholders work together to make the contact approved according FDA and with well-known research institutes. In development a success. actual EU regulations. recent years processing trials have been Omya is a global producer of industrial done at the European Centre of minerals – mainly fillers and pigments Concentrate Innovative Textiles (CETI) in Tourcoing, derived from calcium carbonate and To successfully apply the new product, France. Further trials on a Reicofil 4 dolomite – and a worldwide distributor the whole value chain must be nonwoven line have been conducted at of specialty chemicals. considered. Omyafiber 800 is produced the Sächsische Textilforschungsinstitut Founded in 1884 in Switzerland, Omya by Omya as a calcium carbonate powder. (STFI) in Chemnitz, Germany. has a global presence extending to more To apply this mineral to PP nonwovens, a The successful trials were essential to than 175 locations in over 50 countries masterbatch concentrate must be ensure the outstanding processability of with 8,000 employees. SNW
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MANUFACTURING Shaping the future
Sandler has outlined its performance over the last year while also updating on its latest expansion activities following its 140-year anniversary.
espite challenges regarding raw highlighted an expansion of its usage of material prices in some markets, alternative raw materials. which resulted in price demands “Sustainable business practices for the Dfrom some customers, Sandler benefit of staff members, the people in says was able to keep its turnover the region, business partners and users constant at €322 million and ensure of Sandler products has always been one solid earnings in its last fiscal year. of the cornerstones of the company’s This positive year-end result created philosophy – in the economic, social and the basis for further growth in the ecological sense,” the company said. dynamic market environment of the “Sandler also takes up the task of nonwovens industry, the company said. installing a new manufacturing line for creating new product solutions which “From a local wadding factory for nonwovens for hygiene applications contribute to the conservation of upholstered furniture to a high-tech which is scheduled to start production in valuable resources by increasing the use nonwovens producer, last year, Sandler autumn of this year. of alternative raw materials. Already was proud to celebrate 140 years of With the creation of 70 jobs, Sandler today, the company uses about 30% company history, being managed today says that the expansion of the plant will renewable and recycled raw materials.” in the fourth generation by Dr. Christian help its growth in the local market. Noteworthy here is how Sandler has Heinrich Sandler,” the company said in a “Sandler nonwovens made in USA allow once again been nominated for an statement. “Continuity in leadership, us to continuously develop and advance INDEX Innovation Award in the Roll openness to new ideas and continuous our longstanding business relationships Goods category. Every component of the development in products are the basis to companies in the North American company’s new ADL (acquisition and for this Upper Franconian success story. market,” said Tobias Baumgaertel, distribution layer) for absorbent hygiene Bavaria’s Prime Minister Dr. Markus President of Sandler Nonwoven products (AHPs) can be made from Söder, MdL, emphasized this particularity Corporation. “The investment in the renewable or recycled raw materials, in his speech on occasion of the USA strengthens Sandler’s position as making it an ideal alternative for a company anniversary celebration, stating one of the largest nonwovens manufac- number of hygiene products that the that ‘a company can only shape the turers worldwide.” industry is currently seeking. In addition, future if they continue to evolve—just as its performance properties – such as Sandler does’.” Portfolio absorbency, fluid distribution and storage Over the past year, the 880 Sandler capacity – can be fine-tuned to the Investments employees in both Schwarzenbach and requirements of each individual product. In 2019, the company again invested Perry have developed a range of new Sandler is increasingly placing its heavily in its production facilities. nonwovens products, steadily expanding emphasis firmly on the use of sustainable A double-digit million euro investment the product range and the company’s raw materials and at INDEX 2020, now has enabled the expansion of the position in the global market. scheduled for October 2020, it will company headquarters in Schwarzenbach New developments have included introduce a nonwoven made from 100% with two new nonwovens manufacturing heat-insulating and sound-absorbing unbleached cotton which is suitable for lines increasing production capacity in materials for the construction industry use as both a wipes substrate and for technical applications as well as providing and room acoustics; efficient filter media hygiene topsheet applications. a basis for the further expansion of for clean air in buildings and vehicles; In addition, the company is combining the business. soft upholstery materials for furniture flax and viscose for materials with Sandler is also gradually expanding and bedding; skin-friendly materials for enhanced softness for skincare products, its U.S. subsidiary – Sandler Nonwoven hygiene products; absorbent wipes while its 100% viscose BioWipe features Corporation in Perry, Georgia – substrates for cosmetics and household a special embossed design that not only into a competence centre for as well as sound insulating nonwovens adds visual appeal, but adds bulk and nonwovens manufacturing. for more driving comfort in automobiles, enlarges the surface to optimise its As well as a new 135,000 square foot buses and trains. absorbency in skin care applications such building on the site, Sandler is also As part of its annual update Sandler also as cosmetics and baby wipes. SNW
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Mann-Filter air filters made from recycled plastics make another FILTRATION significant contribution towards the conservation of resources.
Forward-thinking filters
Mann+Hummel is ramping up its sustainable options for the filtration sector.
iltration specialist Mann+Hummel In addition to spunbonded fabric plant, There is also an emphasis on sustainability has developed a number of a recycling plant has also been built from the company with its Mann-Filter spunbonded nonwoven fabrics where edge trim and rolls of defective packaging: each green-yellow box consists Ffor the automotive industry material from the production process are of about 80% to 95% recycled fibres. which include sustainable filters and reprocessed into granulate and reused packaging manufactured with resource- As a result, the facility is nearly waste- Committed saving methods. free and highly sustainable. For the European market, more than The company’s spunbonded fabric 4,800 filter elements are now available plant is being used to produce synthetic Recycled plastics for over 48,000 vehicles and machines, filter media under its Mann-Filter brand Mann-Filter air filters made from including more than 12,000 cars and at its site in Marklkofen, Bavaria. recycled plastics make another transporters, more than 9,100 lorries and The combination of spunbonded fabric significant contribution towards the buses, nearly 1,000 motorcycles and production processes and integrated conservation of resources. One square 25,500 applications in off-highway furnaces for thermally bonding the metre of C 24 005 filter medium vehicles and industry. nonwoven material is new, the company contains recycled plastic from about two In addition to using environmentally says, compared to previously applied 1.5-litre PET bottles. Moreover, thanks friendly filter media and packaging in processes such as melt blowing. to its high dirt-holding capacity the air these products, Mann+Hummel points The new production method enables filter only requires 30% of the filter out that it has been committed to annual process energy savings of up to media surface area of traditional air sustainable forestry for many years. 70% compared with current production filters with cellulose media. Further air As well as complying with technical techniques. This amounts to a CO2 filters using the innovative medium are specifications, the company says it also reduction of more than 4,000 tonnes currently in development and will be strives to operate in a sustainable and per year. available soon. environmentally friendly manner. For this Material and process energy reason, Mann+Hummel has had its efficiency at the Marklkofen site. production site in Zaragoza certified pursuant to the guidelines of the Forest Stewardship Council (FSC) so that it can manufacture products that contain wood from certified sources. By also using modern lighting (LED) and intelligent lighting control, switching compressors and other measures, the company was able to reduce its CO2 emissions by around 3,300 tonnes in 2018. “All these measures aim to continually reduce our CO2 footprint and all aspects of the value chain and to ensure that natural resources are used responsibly,” the company said. SNW
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Freudenberg unveils first ever 100% biodegradable padding
WEINHEIM - Freudenberg Lyocell is a cellulose Performance Materials produced from natural raw Apparel has launched the materials in an environ- Freudenberg Performance feather and as efficient as first fully biodegradable mentally friendly production Materials Apparel, adding that synthetic paddings. The padding made from process using eucalyptus the EU has presented the thermal insulation provides sustainably produced wood from sustainable process with the European warmth and is both soft and cellulose fibre that completely forests. The solvent used to Award for the Environment. highly breathable. Thanks to degrades in soil within just obtain the fibres is almost “As an ecologically responsible its excellent moisture under 60 days. completely reused in the manufacturer of special fibres management, the padding This comfortemp Lyocell production cycle, which is a from the renewable raw also absorbs body moisture up padding, which also meets all clear advantage over other material wood, the Lenzing to 45 per cent and therefore requirements for high- cellulose fibers such as Group is a perfect partner minimizes perspiration. performance thermal viscose, Freudenberg says. for Freudenberg.” The thermal insulation is insulation for sports and “This innovation is the result The fine fibres created from also water-repellent, dries outdoor clothing, is the result of intensive research and close the natural raw material and quickly, is antistatic and of a cooperative venture with cooperation between the subsequent manufac- conforms to the OEKO-TEX fibre manufacturer Lenzing Freudenberg and Lenzing,” turing process are said to 100 standard. Consequently, and was unveiled at the said Benoit Cugnet, head of ensure that comfortemp comfortemp Lyocell padding recent ISPO exhibition. Global Strategic Marketing at Lyocell padding is as light as a meets the high demands placed on clothing for sports and outdoor use. “Although Oeko-Tex recognition for Unicharm the end consumer usually TOKYO - Unicharm Corporation has been awarded the Oeko-Tex Standard 100 safety certification for its Natural rarely sees or even thinks Moony brand of premium disposable diapers. about the padding, it makes a The brand has been certified with Product Class I, the most stringent product standard for infants and babies, decisive contribution. After all, the first disposable baby diapers in Japan to be recognised with this standard. it needs to offer protection in Oeko-Tex Standard 100 only certifies the products which fulfilled the stringent standard as a result of analytical all weathers and be able to experiment on over 350 kinds of hazardous chemical substances. In order to use this certification label, all handle all kinds of sporting materials and chemical substances used in the product must satisfy the experimental standard. activities,” Cugnet added. Oeko-Tex Standard 100 Certification also corresponds to initiatives for eliminating hazardous chemical The cohesive padding also substances as is stated in SDG (Sustainable Development Goals) #3 - Good health & well-being for all people prevents fibre migration and #12 -Responsible production & consumption. through the outer fabric and “For protecting the babies and their future, we are proactively working on Project Orgabits using organic cotton, is offered by the meter. This a sustainable activity that is friendly not only to their skins but also to the earth, with our Natural Moony,” the means less time and cost for company said. “Accordingly, in order to have as many mums and dads as possible use our products with a peace the industry and no cold of mind more than ever, we have acquired Oeko-Tex Standard 100 Certification.” bridges at the seams for the end consumer.
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MATERIAL MATTERS
tively. This is to simulate an Valmont’s composite utility TFP announces new extreme wildfire. In addition poles successfully passed all to this, the utility poles must the fire testing, maintaining application for Tecnofire achieve a V0 rating in fire test their integrity under load UL94 to be classified as “self- during the simulated Burneside - Tecnofire fire expert, was used in which extinguishing” and have a Wildfire Test, as well as materials from nonwoven the utilty pole is enclosed flame spread index of 25 or passing pre- and post-burn manufacturer Technical Fibre within a steel culvert and less as per the ASTM E84 structural testing via Products are now being used subjected to 1150°C / 2100°F Class 1 rating. the ASTM D1036 Pole to offer fire protection for for 2 and 3 minutes respec- With the help of Tecnofire, Bending Test. utility poles. TFP’s Tecnofire materials PRE-TEST DURING TEST POST-TEST provide effective fire protection in a wide variety of applications and have been specified for use in construction products, aircraft, bridges, buses, trains and architectural fire doors. The latest successful application for Tecnofire is composite utility poles, manufactured by Valmont Industries, Inc., a leading producer of utility structures. The composite poles are used as transmission and distri- bution poles and have to withstand rigorous fire testing to ensure that they maintain their integrity in the event of a fire. This requires them to pass the USA Utility Company Consortium Fire Tests and Valmet launches recycled withstand temperatures of and renewable roll covers 1150°C / 2100°F without significant structural loss. TIMRA - Textiles and nonwovens machinery manufacturer Valmet says it is the first company in the world to Valmont incorporates one offer roll covers based on biomaterials and recycled materials for pulp making, board, paper and tissue. of TFP’s infusible Tecnofire These new composite covers for press, guide and calender rolls use bio-based resin and hardener in the polymer grades into their composite matrix. The reinforcing fibre and filler originate from recycled consumer plastic and glass. Depending on cover structure which is fabricated type, the content of recycled or bio-based raw materials is 75-96 per cent. New materials are being tested using centrifugal casting and continuously, and the target is to reach 100% as soon as possible. filament winding. Roll covers used in paper, board, tissue and pulp making need periodical renewal and therefore consume tons of The Tecnofire will activate in materials. A major part of the raw materials of traditional roll covers has been manufactured from fossil-based the event of a fire to produce materials, which has been refined and processed from crude oil. a stable insulating char and Valmet says that its R&D work focuses strongly on enhancing raw material and energy efficiency and promoting thereby ensure the structural the use of renewable raw materials. It has therefore set strict criteria for the bio-based raw material in the integrity of the pole. covers. Only renewable materials derived from non-food chain plants or plant parts are used, in order to prevent Photos from the fire testing the effect to global food production. Cultivation and harvesting of plants must not endanger the growth of are shown and include before, natural forests either. during and after images. “In best cases, bio-based materials can be produced from plant parts that would otherwise be waste. For There is no specific example, lignin, carbon black made of lignin and nanocellulose can be utilized as reinforcing fillers in roll standard for the simulated covers,” explains Jani Turunen, R&D Manager for Polymeric Roll Covers, Valmet. “Our customers do not have to Wildfire Test carried out; in compromise in product performance either, as the results have shown that in some applications the performance this case the set up devised is even above the traditional offering.” by Mark Ackerman, a forest
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New HT veils from TFP
BURNESIDE – Technical Fibre temperature of above 260°C Products (TFP) is introducing – significantly higher than new polyimide and basalt other polymers such as nonwoven veils. polyester and PPS. It was They are the latest developed as a high- additions to the company’s performance insulation OPTIVEIL range and have material for space been developed specifically applications, designed to to expand the company’s offer the temperature selection of high stability necessary to temperature materials. withstand missions to temperature stable quality of dispersion makes The polyimide veil is the Mercury and the Sun, where alternative to standard E & the materials suitable for a highest temperature stable spacecraft experience ECR glass veils. It is stable up wide range of composite polymer veil that TFP extreme temperatures. to 850°C and retains its applications including surface manufactures, with a The basalt veil has been integrity when in contact finish, improving resin flow, maximum service developed as a more with an open flame, making adhesive carriers and it suitable for applications imparting functionality where requiring a fire barrier. required, in this case high Basalt, like glass, has a high temperature stability. resistance to acid and alkali, TFP will also be exhibiting which makes it ideal for use some new Tecnofire in corrosive environments. developments for the fire As well as increased protection of composite temperature stability these structures. The latest E8AI new materials also offer the Mat is formulated with AES uniformity and surface quality fibre, which has a classifi- synonymous with TFP’s cation temperature of Optiveil and Optimat ranges, 1,100°C to 1,300°C and which include carbon, glass, also offers improved metal coated, aramid, temperature stability for fire Enhanced filtration recycled carbon and thermo- protection applications. efficiency from Fibertex plastic nonwovens. This www.tfpglobal.com AALLBORG - Fibertex has developed a range of advanced pleatable products for air filtration, based on in-house produced nanofibre layers, which are combined with tailored nonwovens, to support the benefits Donaldson iCue provided by nanofibre materials. The Fibertex Pleatex filter media product range – which can be pleated on launched in Europe all types of pleating machines – is said to offer the highest efficiency and LEUVEN – Donaldson is and associated lowest pressure drop on the market, through pure mechanical filtration. expanding its iCue production lines. Pleatex media do not lose their efficiency due to electrical discharge in the connected filtration service, • Lower maintenance costs presence of moisture and air pollutants, like electret meltblowns. launched in September for labor and parts, Additionally, these products do not contain any harmful, small fibre shreds, 2019 in North America, including longer filter as is the case with conventional fine glass fibre-based filtration products. to Europe. replacement intervals, and All products in this range conform with new ISO 16890 requirements The service monitors • Better management of dust and also adhere to the lowest energy consumption standards in industrial dust collectors in collector tasks and ventilation systems, the company says. real time to help facility compliance reporting data. Pleatex filter media containing nanofibres can achieve filtration teams improve dust Based on research Donaldson efficiencies up to HEPA 13 level according to EN 1822 and ISO 35H collection management has performed, 65% of according to ISO 29463. and early adopters have surveyed facilities reported All Fibertex filtration products can also be treated with permanent plasma reported benefits in three they would experience coating or non-permanent impregnations, to enhance hydrophobicity, main categories: production downtime if their oleophobicity or hydrophilicity. Anti-static treatment is also available. • Reduced downtime for collector failed due to dust collection equipment maintenance oversights.
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“Dust collection systems Access to the live play an important role in customer assistance team. New phthalate free helping manage airborne “Facility managers tell us contaminants and that actively monitoring their range from Sabic emissions,” said Bart dust collectors’ performance RIYADH - Sabic has launched aimed to help our customers Robbeets, industrial air is a challenge, in terms of a new portfolio of polyolefin- to produce safe and pure filtration sales director. “The both time and technical based products designed for materials for advanced iCue service provides real- knowledge,” said Wade personal hygiene and functionality and softness time insights that can help Wessels, global director of medical applications. for nonwovens and hygiene facility teams troubleshoot connected solutions at Sabic PureCares is films, all are ultimately issues earlier and keep a Donaldson. “Our iCue described as a combination of aim to support consumer collector up and running. This service automates two words 'pureness' and wellbeing, convenience and added intelligence helps our monitoring and provides 'care', representing PHF comfort in compliance of customers drive efficiency, simple, actionable data that (phthalate free) and TNPP hygiene regulations." reduce costs, and improve helps our customers manage ((tris (nonylphenyl) phosphite)) As a strategic material their production uptime.” their equipment with - free technologies. solutions provider to the The iCue monitors key confidence and ease.” "PureCares’ tells our sector, Sabic says it is also operating metrics on a dust The compact iCue device customers and final working with its customers to collector, with additional and wireless connection is consumers about the story create hygiene products by sensors available to meet simple to install, requires no behind our materials’ offering a broad portfolio of specific needs. Users have IT integration with an offerings,' the company says. polymers for nonwovens, film access to service features internal automation "PureCares product family is and laminates. that include: network, and is compatible Real-time alerts e-mailed with major dust collector directly to facility teams for brands. An annual assessment and action. subscription includes An easy-to-use dashboard hardware, automated detailing all dust collectors on reports, real-time the service. maintenance alerts, and an Automated historic online interface for more performance reports on each detailed analysis. dust collector. www.donaldson.com Shedding weight with kenaf KARIYA – Toyota Boshoku has supplied nonwoven reinforcements made from kenaf for the door trims of Toyota Motor Corporation’s new LQ electric concept car. They are being consolidated with Covestro’s Baypreg F NF technology polyurethane into panels that are said to be 30% lighter than existing alternatives. Kenaf is a member of the hibiscus genus grown in regions such as South East Asia, Bangladesh, India and Africa and the bast fibre obtained from it is attracting increasing attention as a cost-effective raw material with good mechanical properties. Toyota Boshoku has employed kenaf- reinforced components for its vehicles for a number of years now. The kenaf fibre-reinforced polyurethane foam composite for the LQ, however, has an area density of less than 1 kg per square metre and high strength, making it the lightest to date. It was developed in close cooperation between Toyota Boshoku and Covestro’s recently renovated Japanese Innovation Centre. “Our joint development makes an important contribution to the design of particularly lightweight and sustainable vehicles,” says Hiroaki Ido, Covestro’s head of polyurethanes application development for transportation in Japan. “It is also a good example of our company’s focus on using alternative raw materials and establishing a circular economy.”
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our customers have become resources which are non- Bioplastic dog pads accustomed to, our male renewable. Bioplastic is dog solution, the stay-put 100% recyclable and works WESTPORT - WizSmart from Krister Holm, General tabs and our pads stay dry exactly like regular plastic.” Petix has expanded its Manager of WizSmart all day. WizSmart by Petix product line to include a new explained: “Our new “The key difference is that transforms more than 120 dog pad made with bioplastic WizSmart Earth Friendly Dog we are using bioplastic in the million unused baby diapers from sugar cane and unused Pads have all the features, packaging and liner of this each year into an innovative baby diapers. benefits and performance new Earth Friendly line. super absorbent blend for Bioplastic is made from sugar their thick and soft dog pads. cane which is a renewable These dog pads are a 24 hour Award finalists announced source. When sugar cane solution, which means less grows it captures CO2, plastic, less waste and better for 2020 World of Wipes reducing carbon footprint. for the environment. CARY – INDA, the Association of the Nonwoven Fabrics Industry, has We help save fossil energy Web: https://www.wizsmart.com announced the three World of Wipes Innovation Award Finalists who will present their innovations at the 14th edition of the World of Wipes (WOW) International Conference. As it stands, the event is still on scheduled for 2020, June 22-25 in Minneapolis, USA. “While cognisant of the evolving Covid-19 situation, we are proceeding with plans for an exceptional event in late June including three strong contenders for this years’ prestigious World of Wipes Innovation Award. We applaud the ingenuity and creativity shown by Berk International, LLC, Lonza LLC, and ITW Pro Brands in advancing the wipes market sector,” said Dave Rousse, INDA President. Finalists for the World of Wipes Innovation Award are: Berk International, LLC: Food Fresh liners are the first nonwovens that can absorb accumulated moisture in sealed produce packages and reduce wilting and spoilage. The product reduces consumer produce waste by keeping produce fresher for a longer period of time. ITW Pro Brands: The DETEX Metal Detectable Scouring Pad is designed to be detected by metal detectors currently in place in most food production facilities and minimize the risk of foreign object contami- nation. The base is a nylon needlepunched nonwoven within a resin system with abrasive particles sprayed onto the web. Lonza LLC: The NUGEN NR Disinfectant Wipe is designed to be a one- step no-rinse food contact surface disinfectant, cleaning and New sustainable disinfecting the surface without detergent pre-clean or potable water- rinse requirements. Also, the wipe kills a broad set of bacteria and options from Advansa viruses such as Norovirus – a key food safety gap not addressed by pre- HAMM - Advansa, the finest fibres are available at saturated food contact surface sanitizing wipes. manufacturer of technically the range of 1.6 dtex. advanced & sustainable The binding fibres are polyester fibres has developed used in combination with ADVA MegaBond, part of the crystalline PET fibres. company's new product This gives the nonwoven a family of binder fibres. self-reinforcing property These products are charac- which is triggered by terised by an amorphous thermal treatment. The end polymer structure, which product can be moulded provides thermal formability, into any shape to fit the and are designed for drylaid technical needs. and wetlaid nonwoven The articles manufactured processes. Among its in this way, says Advansa, are portfolio, Advansa offers stable and can be exposed to very fine fibre linear density, high temperatures. The which – so far - are rarely technology can replace for available on the market. The example injection moulding.
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new microfibre for the nonwovens industry. With a diameter of only 8 µm (0.6 dtex), the fibres are partic- ularly soft. A special surface treatment provides hydrophilicity, so that an immediate moisture transport can be ensured. The fibres are crimped and suitable for dry laid processes. The stability of the nonwoven can be achieved through needle punching, hydroentan- glement or heat setting. This It can also be used for chemical binders, products after their life cycle, could new fibre type is suitable applications such as fine- made of pure polyester are be reintroduced to the especially for hygiene pored filters. particularly suitable for recycling system. products, medical textiles and In contrast to products recycling. Both, industrial The company has also filtration. They can also be containing bi-component or waste and finished products launched ADVA Staple, a used in contact with food.
RKW ramps up production FRANKENTHAL – RKW has expanded its production capacity for waste bags at its facility in Echte with the commissioning of two new production lines with a capacity of 3,000 tonnes per year. This brings the film manufacturer’s total stock to ten lines with an annual capacity of 15,000 tonnes for the manufacture of FFS films, shrink films and ready-made bags. RKW’s facility at Echte has seen significant investment since 2013, mostly centered around an increased workforce and and increasing the efficiency of its processes and products. The capacities for garbage bags alone have been expanded in the past two years with investment totaling around €1.6 million. With both premium and premium plus products manufactured here, RKW has enjoyed a close partnership with key customer Emil Deiss KG for many years and has taken over additional capacity after a competitor, who also supplied Deiss, recently ceased production. “We are pleased that we have been able to increase the production of waste bags by a further 3,000 tonnes,” said Dr. Markus Brinkmann, director, Echte site. “This underlines the close partnership with Emil Deiss KG and the importance of the garbage bag as a sustainable product for our location.” The plant in Echte specializes in the development and manufacture of environmentally friendly and resource-saving industrial packaging solutions and waste bags. “Sustainability is a special differentiating feature of the films,” Brinkmann said. “Waste bags are produced in genuine materials with a high percentage of regenerated material. With its investment policy, RKW has also been optimizing energy efficiency for years through continuous process improvement and modern technologies.” RKW is a major supplier in the areas of hygiene and agricultural films, films for the beverage industry and packaging for powdery goods. In addition, the company makes films and nonwovens for medical applications, for the chemical and converting industries as well as for the construction sector.
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Many exhibitors praised the high-quality interactions they FiltXPO draws over 1,300 had with senior-level decision makers they met on the floor for the first time. These new acquaintances were seriously looking attendees to Chicago for new materials and solutions to current design challenges CHICAGO - More than 1,300 business and product they are facing. “The ability to forge new connections with developers converged at Chicago’s Navy Pier for the inaugural first-time attendees in new business areas provided strong edition of FiltXPO, North America’s only exhibition and technical value that will generate high returns,” said Doug Brown, conference dedicated exclusively to filtration and separation President, Biax-Fiberfilm. products and processes. A sampling of the many new technologies on the FiltXPO Well over 100 exhibitors (several exhibitors from China had to show floor included: withdraw due to the COVID-19 situation) displayed their • TSI International demonstrated automated filter testers. products and services to an inquisitive crowd that included • Albarrie representatives discussed new designs and presented many first-time attendees, and the concurrent Technical fabric samples for air and liquid filtration. Conference featured seven distinct sessions and 31 outstanding • Ahlstrom-Munksjö shared their new approaches on presenters during the three-day event February 26-28. protecting the environment and people with its industrial filtration offerings. • Air Techniques International tested filter media on site for efficiency and resistance. The Technical Conference, chaired by Behnam Pourdeyhimi, Ph.D., Associate Dean at North Carolina State University and Executive Director of its Nonwovens Institute, featured sessions on Biopharmaceutical Filtration, Membrane Filtration, Air & Gas Filtration, Nanofiber Filter Media, Water Filtration, Macro/Nano Modeling and Separation & Filter Media Technology. Conference attendees were impressed with the caliber and content of the speaking professionals. The two-day Filter Media Training Course, conducted by Chris Plotz, Director of Education & Technical Affairs at INDA, the Association of the Nonwoven Fabrics Industry, drew the
Supreme acquires Adient business MAHARASHTA – Supreme Group – one of India’s largest and most diversified nonwoven manufacturers – has acquired the automotive interior trims and NVH (noise, vibration and harshness) business of Futuris Automotive, a subsidiary of Adient. The acquisition is being made through Supreme’s majority-owned Thai subsidiary Supreme Feltol Thailand. Supreme Feltol began just-in-time deliveries from its greenfield plant located at the Eastern Seaboard in Thailand to Ford Motors and Auto Alliance Thailand in September 2019. This acquisition provides it with a second plant in Eastern Seaboard, bringing employees there up to 230. “This acquisition further reaffirms Supreme Group’s commitment to our global automotive OEM customers,” said MD Amit Kavrie. “We continue to focus on our core business areas and with the investments in Thailand the company is on course for a geographical expansion. “The timing is perfect as the automotive industry is going through a major technological shift. Our strong R&D base and next-generation, nonwoven material technologies together with competent engineering resources places us in a strong position to benefit from opportunities arising out of this shift. Over the next few months, the company will explore further opportunities for growth with auto OEMs in Thailand and South East Asia. We expect the Thailand subsidiary alone to generate annual sales revenue of US$50 million within the next five years.” Supreme Treon’s major customers of include Ashok Leyland, Force Motors, General Motors, Honda, Hyundai, John Deere, Mahindra and Mahindra, Maruti Suzuki, MG Motors, Nissan-Datsun, Renault, SML Isuzu, Tata Motors, Toyota and Volvo Eicher, in addition to Ford. Supreme Treon has 14 manufacturing plants strategically located across automotive manufacturing hubs and supplies to over 100 different passenger and commercial vehicle models. http://www.supremegroup.co.in
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NONWOVENS NEWS
maximum of 35 attendees who were extremely pleased with the level and quality of the instruction provided. FiltXPO replaces the International Filtration Expo and Conference, which was organized annually by INDA for 27 consecutive years and, in the later years, alternated between Chicago and Philadelphia. FiltXPO is intended to be broader in scope, covering separation and membrane technologies, processes, and equipment. FiltXPO will be fixed in location at the Navy Pier in Chicago and take place every 18 months, with the next edition taking place October 12-14, 2021. For updates, visit FiltXPO.com
Texon targets zero waste MILAN –Texon, the manufacturer of nonwoven saturated felts Salad days for the and materials used primarily for structural support components in footwear, has announced new sustainability targets as it UK’s Anglo Recycling strives to become a zero waste company. As part of its Zerofootprint strategy, the company has LANCASHIRE - Anglo Recycling Technology is on course to deliver no outlined ambitious plans to ensure 90 per cent of its waste is less than a million of its special nonwoven mats for hydroponically recycled or reused, its carbon footprint and utilisation of virgin growing herbs to a major customer in the Middle East this year. materials is halved and water usage and waste water is cut by The Growfelt-branded products arose from the discovery back in the 20 per cent, all by 2025. late 1990s by Anglo Recycling’s owner Simon Macaulay, that the “At the start of a new decade, we’re renewing our commitment Sussex-based retail supplier of salads, Van Heineken Brothers (now to sustainability and pledging to do more in collaboration with our Vitacress), used nonwoven felts on which to grow its cress. customers and supply base,” Texon’s CEO, Jelle Tolsma, has said. “I drove down to see the company’s production manager, Chris Texon develops footwear components and performance Moncrieff, and discovered they were indeed growing cress on felts, but fabrics for the likes of Adidas, Nike, Reebok, Timberland and they were made from virgin materials and he liked the idea of maybe Vans, serving 90 countries with annual production outputs of using a blend of virgin fibre offcuts of cotton, wool and more than 30 million square metres of fabric. polypropylene,” he explains. “That’s how Growfelt was born. For the As a defining decade for the textile and fashion industries first six years we supplied exclusively to Vitacress and in return they gets underway, Texon has reiterated its commitment to helped us to bring our factory up to food grade standard and to set in accelerating sustainability progress within its supply chain with place a testing regime for Salmonella E-Coli coliforms and listeria.” timebound targets to achieve within the next five years. In recent years, however, Anglo Recycling, which is based in Eliminating waste takes precedence, as the company vies to live Whitworth, near Rochdale in the UK, has significantly broadened its up to a mantra of ‘Zero Waste by 2025’. That said, the company customer base. It now offers a core of three growing media products has set the target of ensuring 90 per cent of its production waste to meet the differing needs of customers across Europe, the Middle is either reused or recycled – perhaps a benchmark that the East and the Far East, whether for retail presentation and appearance company will vie to achieve as a very minimum. or for water holding. Halving its carbon emissions and reliance on virgin materials is “As we continue to expand our customer base, we are constantly also an ambition of the firm, along with cutting water and being set new challenges,” says the company’s managing director wastewater by 20 per cent. Tolsma insists: “As a business we’ve Andy Hall. “A customer in the Philippines, for example, wanted a mat identified a series of sustainability goals that will further accelerate 10mm thick, since the ambient temperature in that region demands our journey to becoming a world class sustainable company and increased water availability for growing herbs. Our customer in the drive us closer towards our ambition of zero waste.” Middle East is meanwhile seeing the demand for fresh salads In-line with work to cut its dependence on virgin fibre, Texon increasing significantly and is expanding so rapidly orders have grown says “pioneering new solutions” in the pipeline should curb any from 360,000 pads for all of 2017 to this latest order at the start of reliance on virgin cellulose. In terms of water consumption: 2020 for a million.” “We’re going above and beyond to limit what we use. Where “We’re also undertaking trials to find a fully biodegradable product we do use water, we make sure we recycle and return it back to that meets micro and growth challenges but also allows customers to nature even cleaner than when it came out so it can be reused.” reduce their landfill costs,” adds Simon Macaulay. “It’s not proving Finally, locating factories closer to key markets and re-strate- easy, but we’re sure we’ll solve it. There’s already a pretty convincing gising how it ships stock, it’s hoped, will offset emissions. sustainable argument, with our Growfelt pads allowing herbs for “Zerofootprint will serve as a constant reminder to us, and to salads to be grown and sourced locally, rather than being flown in our customers, that there is always more that companies can do from the other side of the world.” - collectively and individually,” Tolsma concluded.
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People
A new Secretary With immediate effect, Harald Späth Stephanie Kniep, Head of Investor General has been has been appointed president and Relations, will leave Lenzing, effective chosen by Cematex, general manager for the Original as of April 30, 2020 to pursue the European Equipment business unit. He succeeds new endeavors. Committee of Textile Kurk Wilks, who was appointed Machinery Manufac- president and CEO of the Jones Family of Companies has turers. Cornelia Mann+Hummel Group in January 2020. appointed Matt Buck as vice president of Buchwalder has Cornelia Buchwalder. Harald Späth currently holds the position Sales and Business Development. Matt is served on an interim basis since June of Senior Vice President Original a graduate of Bowling Green State 2019, following the retirement of Maria Equipment Europe, which he will University and most recently served as Avery, and was elected to the continue in addition to his new role. Director of Sales for Performance permanent position by the Cematex Materials at Thrace-LINQ. Prior to Board on March 12. Ernesto Levy, senior vice president, Thrace-LINQ, Matt served as the National Buchwalder has a wide knowledge of Americas business area and a member Accounts Manager for Owens Corning. the global textile equipment sector, of Suominen’s Executive Team, has Buck comes to Jones with more than having managed the Swiss Textile decided to pursue career opportunities 15 years of experience in the Industrial Machinery Association since 2013 and outside the company and will leave Market Sector. He has spent the majority been closely involved in organizing Suominen on April 6, 2020. He has of his career focusing on technical sales participation at the major global trade worked for Suominen since 2015, and sales leadership with the aim of shows and various international events. previously heading the Convenience developing new markets for organi- Her experience takes in the ITMA business area. zations. While at Thrace-LINQ, Matt exhibitions in Europe at Milan (2015) Lynda Kelly will act as interim SVP, significantly grew their sales in the and Barcelona (2019), as well as three Americas business area in addition to industrial sector such as automotive, ITMA Asia + CITME fairs, in 2014, 2016 her role as SVP, Business Development. construction, and flooring. and 2018. “I would like to thank Ernesto for his She will continue to combine the two contribution to the company both in his Thrace Plastics has announced that posts as Secretary General of both Swiss previous role in heading Convenience Dimitris Malamos, executive member of Textile Machinery and of Cematex. business as well as in his new role in the Board of Directors, will assume the Americas business area. I also want to duties of the deputy group chief Josef Parzhuber, President and General thank him for his valuable contribution executive officer. Malamos who has held Manager of Mann+Hummel’s in the Executive Team,” said Petri Helsky, the position of Group CFO since 2010, Automotive Aftermarket, will leave the president and CEO of Suominen. has extensive experience in strategy, company effective April 30, 2020. financial analysis and internal restruc- Parzhuber has been with Stephan Trubrich has turing, has demonstrated his managerial Mann+Hummel since 2011 and has a assumed the new skills and has acquired significant played a significant role in developing role as vice president expertise and experience in the organi- the global automotive aftermarket Capital Markets, zation, operation and the activities of business during his tenure. effective as at March both the company and the Group. The search for a successor for his 01, 2020 at Lenzing. The position of group CFO will now be position is still ongoing. In his capacity, who has held senior management From 2012 to 2016 Parzhuber, born in Trubrich will oversee Stephan Trubrich. positions for many years in a reputable Bavaria, worked in Singapore as Group the Lenzing Group’s capital markets audit firm and has significant and Vice President and CEO for activities, including Investor Relations valuable expertise in providing financial, Mann+Hummel Asia Pacific. In March and ESG (Environmental, Social & audit and consulting services that will be 2016, he assumed global responsibility Governance) Reporting. He will report used to improve the organization, for the aftermarket business unit based directly to Stefan Doboczky, Chief effectiveness and operation of the in Ludwigsburg/Germany. Executive Officer of the Lenzing Group. company’s and Group’s corresponding The Supervisory Board and the Stephan Trubrich has more than nine divisions and departments. Management Board Committee thank years of experience in the field of equity Josef Parzhuber for his contributions research with Kepler Cheuvreux, Incontinence product company over the past nine years and wish UniCredit and Deutsche Bank. For many Principle Business Enterprises, Inc. him all the best for the future. Until years, he has been Austria’s top ranked (PBE) has announced the addition of further notice, Kurk Wilks, President equity analyst. Trubrich holds a Master’s Matt Ross, vice president of Strategic and CEO, will take the lead of the Degree in Science in Accounting and Ventures, and Carmie Maloney, vice Automotive Aftermarket business unit Finance from Aston Business School, UK. president of Quality Assurance and on an interim basis. He is also a CFA Charterholder. Product Development.
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TRADE SHOWS AND CONFERENCES
MCL NEWS & MEDIA APP AVAILABLE TO DOWNLOAD ON Visit: www.mclnews.com/mobile-apps
June 2020 July 2020 29-30 RISE (Research, Innovation & Science for 3-5 14-16 Engi abrics) China International Nonwovens Expo Absorbent Hygiene Training September 2020 Shanghai, China INDA Headquarters Raleigh Web: https://cine- Cary North Carolina shanghai.hk.messefrankfurt.com North Carolina USA www.riseconf.net www.inda.org 9-10 Elementary Nonwovens Training 21-2 INDA Headquarters Inter Nonwovens Training October 2020 Cary, North Carolina INDA Headquarters 1-3 USA Cary, North Carolina USA & Techtextil North America www.inda.org The Nonwovens Institute, North Carolina State University Atlanta 17-1 Raleigh Georgia, Fund in Filtration North Carolina USA USA EDANA training course Web: www.inda.org www.techtextilna.com Brussels Web: www.inda.org September 2020 20-23 22-23 INDEX 20 WIPES Academy 9-10 Palexpo Co-located with WOW 2020 Absorbent Hygiene Products Geneva EDANA training course Hyatt Regency Switzerland Minneapolis, Brussels Web: https://www.indexnonwovens.com/en/ Minnesota USA Web: www.edana.org www.inda.org
22-25 23-25 November 2020 World of Wipes (WOW) Outlook 16-19 International Conference The world’s premier nonwovens Hygienix Hyatt Regency personal care and hygiene & wipes The Roosevelt New Orleans Minneapolis, products conference New Orleans Minnesota Corinthia Hotel, USA Lisbon, Portugal Louisiana USA Web: www.worldofwipes.org Web: www.edana.org Web: www.hygienix.org
Although every care is taken over the compilation of this diary to ensure accuracy of the dates, these can sometimes be changed due to local circumstances. It is therefore advisable to check with the appropriate organisers before travel arrangements are made.
April / May 2020 | Sustainable Nonwovens | 57 Where nonwoven innovations happen
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