4M Carbon Fiber Announces Launch Of 50-Ton Plasma Oxidation Qualification Line To Accelerate Revolutionary Carbon Fiber Technology

KNOXVILLE, Tenn. — November 13, 2024 — 4M Carbon Fiber, an innovative carbon fiber manufacturer, is excited to announce the commencement of its 50-ton per year plasma oxidation qualification line project. This strategic initiative marks a critical step in demonstrating 4M’s patented oxidation technology, which promises to revolutionize the carbon fiber industry by significantly improving efficiency, reducing costs, and enhancing material properties.

4M Carbon Fiber Announces Launch of 50-Ton Plasma Oxidation Qualification Line

The $4.5 million project, which has already secured initial funding, will serve as a platform to showcase the scalability of 4M’s groundbreaking plasma oxidation process. With this line, 4M will be able to produce material for large-scale qualification projects, a key factor in securing licensing agreements and equipment sales. The technology is designed to triple throughput, cut oxidation energy consumption by 75%, and deliver up to 50% savings in capital costs and 30% in operating expenses compared to current industry standards.

“We are thrilled to launch this 50-ton qualification line project, which represents a significant milestone in our journey to transform the carbon fiber industry,” said Dr. Truman Bonds, CTO of 4M Carbon Fiber. “This project is an essential step in getting our technology to a commercial scale, and also opens the door for expanded partnerships with key players across various sectors. Our goal is to make carbon fiber more accessible and cost-effective, and this line will allow us to demonstrate the full potential of our revolutionary process to prospective customers and partners.”

The qualification line will also enable 4M to engage more closely with companies that are already showing strong interest in adopting the technology. Multiple major carbon fiber manufacturers and new market entrants have expressed readiness to proceed with qualification projects and licensing agreements once the technology is proven at this scale. Furthermore, the line will support ongoing development projects with domestic oil companies and other industry partners, who are looking to establish their own carbon fiber production capabilities using 4M’s patented process.

“This investment in our qualification line is about more than just expanding production capacity; it’s about setting a new standard for the carbon fiber industry,” added Bonds. “Our plasma oxidation technology has the potential to disrupt traditional manufacturing methods, offering not only cost savings but also superior carbon fiber properties. We are excited to work with our partners to bring these benefits to market.”

Posted: November 13, 2024

Source: 4M Carbon Fiber

Innovation For An Industry In A Waiting Position

Feedback on STOLL’s performance demonstration during ITMA ASIA + CITME 2024 for the flat knitting industry

TW Special Report

During ITMA ASIA + CITME in October 2024, the KARL MAYER GROUP also showcased solutions for the flat knitting sector under the motto “Master the Change”.

At the global player’s trade fair stand and at a simultaneous in-house show at KARL MAYER (CHINA), STOLL presented an exclusive selection of its high-performance machines, market-effective textile developments and inspiring fashion items that enable flat knitting companies to tap into the potential of the changes of our time.

My TEXTILE NEWS editor Ulrike Schlenker spoke to Michael Händel, vice president, sales & Service, at KARL MAYER STOLL Textilmaschinenfabrik GmbH, to find out how the comprehensive exhibition program was received.

Michael Händel (second from right)

Schlenker: Let’s start with the most important question: Are you satisfied with the results of the trade fair?

Händel: In terms of visitor numbers, our overall summary is positive. We were able to welcome a large number of our customers and new interested parties from China. However, the number of visitors from India, Bangladesh and South-East Asia fell short of our expectations. This certainly has to do with more difficult travel conditions and other consequences of the current global geopolitical and financial tensions.

Schlenker: How was the quality of the exchange with your guests?

Händel: For the most part, we were able to hold very goal-oriented and project-related discussions and talk in detail about the machines on display. Various customers from China and Hong Kong came to us with concrete plans for the future. The discussions with our customers from Bangladesh, among others, were also about coordinating the finalization of projects that had already been negotiated in advance. In addition, the exchange during the trade fair gave us an even clearer picture of the situation in our markets and competitors.

Schlenker: Let’s stay with the market situation for a moment. What is the mood among your customers?

Händel: We are feeling the uncertainty among our customers. They are suffering from constantly rising costs with reduced margins and currently lack the confidence to make investments. In our important market of Bangladesh, the current unstable political situation is also having a negative impact on expansion and modernization plans in the flat knitting world.

Schlenker: With which exhibits were you able to score particularly well with trade fair visitors in this difficult environment?

Händel: The biggest crowd pullers were certainly our machines, including the CMS 703 ki knit and wear and the CMS 503 ki L in the fine gauge E 18. These machines impress with their strong focus on market demand in China. Fine articles are increasingly in demand here. The CMS 503 ki L offers this and also exceptionally high productivity with a working width of 50”. For some time now, we have also seen a growing trend towards the manufacture of finished products and thus towards our STOLL-knit and wear® technology. The CMS 703 ki knit and wear in particular is efficient, attractively priced and unrivaled in flexibility. The production repertoire includes finished articles as well as fully-fashion products. With their working widths, the two CMS machines cover the usual range of sizes in the clothing sector in important target markets such as the USA.

We will continue to consistently pursue the path we have taken towards price optimization. In Turkey in particular, there are clear indications that customers are looking for affordable machines. We are currently working at full speed on a new series with an excellent price-performance ratio for the volume market.

Schlenker: That sounds exciting. We will certainly be able to report on this innovation on my TEXTILE NEWS soon. Thank you for the informative interview.

Posted November 12, 2024

Lindauer DORNIER Appoints New Technical Managing Director

(left to right): Dornier’s CTO Dr. Holger Niemeier, CEO Andreas Kückelmann and CFO Franz-Peter Matheis

LINDAU, Germany — November 8, 2024 — Lindauer DORNIER GmbH is strengthening its management team. Dr Holger Niemeier has taken over the position of chief technology officer (CTO) as of November 1, 2024, and will thus be responsible for the technological developments of the internationally operating machine and plant manufacturer in the future.

With a doctorate in mechanical engineering, Dr. Niemeier possesses comprehensive in mechanical engineering and many years of international experience in special machine construction, particularly in the areas of film and flexible packaging. At DORNIER, he will be responsible for the areas of research and development, production and digitalization with a focus on AI.

“With Dr. Holger Niemeier, we are gaining a renowned mechanical engineering expert with comprehensive technical knowledge and excellent international industry expertise,” stated Andreas Kückelmann, CEO of DORNIER. “His extensive experience will help us to consolidate and further expand our position as market and technology leader in the business areas of weaving machines, film stretching systems and production systems for the fibre composite industry.”

Dr. Niemeier said: “As a mechanical engineer, I am very familiar with the high quality, flexibility and reliability of Lindauer DORNIER’s machines and systems. Over more than seven decades, the traditional family-owned company has built up a strong international market position in the areas of fabrics, films and composites. I look forward to continuing this successful development with a particular focus on product development and digitalization.”

Posted November 12, 2024

Source: Lindauer DORNIER GmbH

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YKK Achieves Major Sustainability Milestones In 2024 Integrated Report

TOKYO — November 12, 2024 — YKK Corporation has released “This is YKK 2024” Integrated Report showcasing notable progress in its journey toward climate neutrality and environmental stewardship. The company has slashed its greenhouse gas emissions by more than half since 2018, while dramatically expanding its use of sustainable materials across its global operations.

Key Achievements

  • Emissions Reduction: Cut direct emissions (Scope 1+2) by 56.2% from 2018 levels
  • Renewable Energy: 37 facilities now running on 100% renewable energy
  • Sustainable Materials: 38% of materials now from sustainable sources, up 12 percentage points in one year
  • Water Conservation: Reduced water consumption by 22.1% since 2018
  • Waste Management: Achieved 91.9% waste recycling rate

YKK’s Sustainability Vision 2050 aims for climate neutrality and coexistence with nature by 2050. The company targets 10 SDGs through themes of climate change, material resources, water resources, chemical management, and respect for people. Progress is detailed in the Integrated Report, with additional data on environment, society, governance, and finance in the Data Book.

Innovation Highlights

  • Copper and Zinc Recycling: Developed proprietary in-house recycling technology for copper and zinc alloys used in YKK® zippers
  • Sustainable Packaging: Switched to Forest Stewardship Council® (FSC®)-certified packaging at the Kurobe Manufacturing Center
  • Chemical Management: AcroPlating® technology now accounts for 25% of brass slider sales, a 7-point increase from last year.
  • Product Longevity: Launched the Revived Renewal Series to extend zipper lifespan

Environmental Recognition

The company’s dedication to biodiversity has been acknowledged with the designation of YKK Center Park’s Furusato-no-Mori (Hometown Forest) as a Nature Coexistence Site, underscoring YKK’s leadership in corporate environmental stewardship.

Looking Forward

Building on these achievements, YKK has revised its Sustainability Vision 2050 to strengthen its focus on three critical areas:

  • Climate change mitigation
  • Biodiversity protection
  • Resource recycling

The company plans to further accelerate its sustainability initiatives throughout its supply chain, working closely with partners to address environmental challenges in the garment industry.

Full List of FY2023 Initiatives for Achieving Sustainability Objectives

Climate change

  • Scope 1+2 GHG emissions: 238,812t (56.2% reduction from FY2018 baseline)
  • Scope 3 GHG emissions: 587,848t (32.7% reduction from FY2018 baseline)
  • Renewable energy usage: 56.5%
  • 37 locations are powered entirely by renewable energy.
  • Ten new solar power generation facilities in operation (28 total)

Material resources

  • 38% of materials now from sustainable sources, up 12 percentage points in one year
  • 31% of packaging is now sustainable
  • YKK JAPAN Company (Kurobe Manufacturing Center) replaced the main outer packaging cardboard for fastening products with packaging which uses paper certified by the Forest Stewardship Council® (FSC®)
  • Waste recycling rate: 91.9%
  • Conducted a survey of suppliers that already do business with YKK, or plan to do business with YKK, to determine whether they are certified with The Copper Mark
  • Launched the Revived Renewal Series of products that contributes to the longevity of garments life cycle
  • Established in-house recycling technology and operational flow for copper and zinc alloys used in YKK® zippers
  • YKK Center Park’s Furusato-no-Mori (Hometown Forest) designated as a Nature Coexistence Site

Water resources

  • Water intake: 8.898 million t (22.1% reduction compared to FY2018)
  • Water intensity: 13.1% reduction (compared to FY2022)
  • Introduced manufacturing equipment designed to reduce water consumption.
  • Conducted wastewater management studies based on ZDHC Wastewater Guidelines
  • Analyzed water risks at each manufacturing site

Chemical management

  • Informed suppliers about the YKK RSL (2023 version) and conducted compliance surveys (1,663 companies)
  • Conducting annual revisions of in-house standards (YKK RSL) (2024 version) based on social and customer needs
  • Conducted tests to monitor status of compliance with the OEKO-TEX®[4] STANDARD 100 certification and the AFIRM RSL
  • Globally deployed the ZDHC MRSL compliance level assessment system
  • Selected alternative materials for non-compliant materials in the YKK RSL (2023 version) and promoted the development of materials, manufacturing processes, etc.
  • Conducted fluorine testing of all purchased materials and switched to materials that are alternatives to per-and polyfluoroalkyl substances (PFAS) wherever possible
  • AcroPlating® technology unit sales volume as a percentage of brass sliders: 25% (+7 points year-on-year)

Respect people

  • Implemented YGCC self-checks/audits at all applicable locations (ongoing)
  • Based on the results of implementation, identified issues to be addressed and developed plans for implementation

Posted: November 12, 2024

Source: YKK Corporation of America

Sourcing And Logistics Challenges In The Textile Value Chain During Peak Season

By Rohit Dev Sethi

The textile industry, particularly in countries like India, thrives during festive seasons. These periods represent a peak in consumer demand, driven by cultural celebrations and the heightened propensity for shopping. Whether it’s Diwali in India, Eid in the Middle East, or Christmas in the Western world, textiles — ranging from garments to home décor — experience a significant surge in demand. However, while this increased demand brings lucrative opportunities for textile manufacturers and retailers, it also intensifies several sourcing and logistics challenges throughout the value chain.

Surge in Demand and Lead Times

Festive seasons are characterized by a sudden spike in demand, which can strain the textile value chain. Lead times, or the time taken from placing an order to receiving it, are usually extended due to the higher volume of orders during festivals. Manufacturers often experience delays in securing raw materials, including cotton, yarn, dyes, and other inputs required for production.

Material Shortages

The textile industry relies heavily on natural and synthetic fibers, and festive seasons can create temporary shortages due to a sudden surge in orders. For instance, cotton — a key raw material for garments — might see inflated prices and supply shortages during peak seasons, particularly if the sourcing region is experiencing adverse conditions such as weather issues or geopolitical instability. This can result in either delayed production schedules or inflated costs that impact profit margins for both manufacturers and retailers.

Supplier Lead Times

The textile value chain includes various tiers of suppliers — raw material providers, yarn producers, fabric manufacturers, and garment assemblers — each facing increased pressure to meet deadlines. The upstream suppliers often struggle to ramp up production to meet the festive demand. This creates cascading delays that trickle down the value chain, affecting the lead times for finished products. The result is a bottleneck where manufacturers may have to resort to expedited shipping options, increasing costs further.

Logistical Bottlenecks

Logistics plays a critical role in the textile value chain, from moving raw materials to transporting finished goods to retailers. During festive seasons, several logistical bottlenecks arise due to the increased load on transportation networks, warehousing, and distribution systems.

Congestion in Ports and Transportation Hubs

One of the primary challenges during festive seasons is congestion at ports and transportation hubs. Textiles, especially those involving international trade, face delays due to crowded ports, customs backlogs, and limited availability of shipping containers. Countries with major textile industries, such as India, Bangladesh, and China, see their ports overwhelmed during these peak periods. The congestion isn’t limited to ports; transportation hubs like railway stations, truck depots, and cargo airports also experience similar delays. Transport companies often struggle to balance the demand, and this can result in slower-than-expected delivery times, missed deadlines, and increased freight charges due to the urgent nature of shipments.

Warehousing and Inventory Management Challenges

During festivals, retailers and manufacturers stock up on inventory to meet increased consumer demand. However, managing this inventory surge poses a logistical challenge. Warehouse capacities may not be equipped to handle the temporary spike, and inefficient stock management can lead to stockouts or overstock situations. Moreover, warehousing during festive seasons is also impacted by labor shortages. In many cases, warehouse workers take leave during holidays, leaving businesses short-staffed during a critical period. As a result, there are delays in picking, packing, and dispatching orders.

Last-Mile Distribution

The last-mile distribution—the process of delivering the finished product from a transportation hub to the final consumer or retail store—faces its own set of challenges. Traffic congestion, particularly in urban areas where festival shopping reaches its peak, can slow down deliveries and increase fuel costs. In addition, e-commerce platforms, which are integral to the textile retail sector today, experience an exponential increase in home delivery orders during festivals. Ensuring that last-mile deliveries happen on time without compromising service quality becomes a significant logistical hurdle.

Managing Supply Chain Complexity

The textile value chain is inherently complex, involving multiple stakeholders, from fiber producers and fabric mills to garment manufacturers, distributors, and retailers. This complexity is amplified during the festive season due to heightened coordination efforts required at every step of the process.

Global Sourcing and Lead Time Variability

A key aspect of supply chain complexity is global sourcing, with textile raw materials and finished goods often sourced from multiple countries. For instance, while raw cotton may be sourced from India or the United States, synthetic fibers may come from China, and dyes and chemical treatments from European suppliers. Each country has its own set of logistical constraints, leading to variability in lead times. During festive seasons, the globalized nature of the textile industry leads to intricate coordination challenges. Delays at any one point in the global supply chain can disrupt the entire production schedule. Given the interconnectedness of the supply chain, disruptions in one country, such as port strikes, regulatory changes, or political instability, can have ripple effects throughout the value chain.

Vendor Relationships and Coordination

Festive seasons put additional pressure on relationships with vendors and suppliers. Maintaining transparent communication and close coordination with suppliers becomes essential for avoiding delays. However, some suppliers may prioritize long-term clients over smaller orders, leading to challenges for newer or smaller textile players.

Moreover, disputes over timelines, payment terms, and quality control can escalate during this high-stakes period. Contractual disagreements may also arise due to unfulfilled commitments, as some suppliers might be tempted to overcommit to meet the increased demand.

Technological Integration and Traceability Challenges

One of the emerging trends in the textile industry is the use of technology for real-time tracking, transparency, and traceability in the supply chain. However, the festive season complicates this process. The increased volume of orders often leads to data overload, with companies struggling to keep accurate tabs on inventory, shipments, and deliveries.

Inconsistent Data Across Systems

The use of multiple technology platforms across different suppliers can lead to inconsistent or inaccurate data. This is especially challenging when dealing with cross-border transactions, where different countries may use different logistics management systems. Integrating these disparate systems to provide end-to-end visibility across the supply chain is difficult even in normal times, and it becomes more so during festive periods.

Blockchain and Traceability

While blockchain technology offers a solution for traceability in the textile industry, ensuring ethical sourcing and transparency, its widespread implementation remains a challenge, particularly in regions where the supply chain is not fully digitized. During festivals, the rush to meet demand can lead to lapses in traceability protocols, raising concerns about sustainability and ethical practices in sourcing and manufacturing.\

Cost Pressures and Profit Margins

Logistical inefficiencies during the festive season translate into increased costs. Expedited shipping, overtime labor, and higher transportation fees all add up, placing pressure on the profit margins of textile companies. Retailers, too, face rising costs due to stockouts, backlogs, and the need for faster delivery options to keep customers satisfied. Balancing these cost pressures while maintaining competitive pricing is a delicate challenge that textile companies face during festivals.

Conclusion

The festive season presents a double-edged sword for the textile industry. On one hand, it offers immense opportunities for growth, with heightened consumer spending. On the other, it brings a range of sourcing and logistical challenges. From raw material shortages and extended lead times to transportation bottlenecks and inventory management hurdles, companies across the textile value chain must adopt innovative strategies to navigate these challenges. The key to success lies in enhanced coordination, better supply chain visibility, and technological integration that can mitigate the risks and capitalize on the festive fervor.

Editor’s Note: Rohit Dev Sethi is managing director, India-based ColossusTex

November 12, 2024

Moss Promotes Elissa Decker To Vice President, Global Procurement & Textile Development

Decker

FRANKLIN PARK, Ill. — November 12, 2024 — Moss Inc., a provider of high-quality graphics and tension fabric structures, is pleased to announce the promotion of Elissa Decker to the position of vice president, Global Procurement & Textile Development. In her new role, Decker will provide strategic leadership and direct oversight of the Moss global procurement organization. Her responsibilities will encompass the rationalizing and sourcing of raw materials, outsourced procurement manufacturing and services, and vendor diligence. Elissa will also lead the company’s development and maintenance of global procurement systems, policies, and reporting, ensuring governance and consistency across all regions.

“Our ability to secure the highest quality and widest range of raw materials is a key differentiator,” said Jason Popp, president and CEO of Moss.  “Elissa has an innate understanding of our core products, their performance characteristics and the associated global supply chains that deliver our raw materials to Moss around the world.”

Decker holds a bachelor’s degree in textile design from Philadelphia College of Textiles and Science and has been an instrumental leader at Moss for 16 years, significantly contributing to the development and procurement of core textile offerings. Her achievements in procurement are notable; she has spearheaded initiatives at Moss that led to substantial cost savings, quality enhancements, and the establishment of global supplier agreements.

“Our global procurement team members are so talented and I’m excited to lead this group through our next phase of growth at Moss,” Decker said.  “We will keep scouring the globe to get the best supply base for our customers.  The focus of our global procurement team is also on ensuring a robust supply chain with suppliers from multiple countries and sources for each of our core raw material categories.”

With Decker’s expertise spanning across textiles and substrates, aluminum, and OEM manufactured parts, her skills are well-suited to help drive Moss’s procurement strategy and material offerings to new heights, enhancing the company’s ability to deliver innovative and sustainable solutions for clients worldwide.

Posted November 12, 2024

Source: Moss Inc.

 

American Flock Association Announces New Leadership

CHERRYVILLE, N.C. — November 12, 2024 — Following last week’s annual meeting, the American Flock Association formally announced that Megan Rossomme, President of EIS Fibercoating, Inc., has been named Association Chairperson. Rossomme has served on AFA’s executive committee since 2019 and stepped into the chairperson role in September. AFA represents flock manufacturers and their suppliers in North America.

At the annual meeting, Rossomme named Eric Honkamp, Sales Manager for Cellusuede Products, Inc. of Rockford, Ill., as the association’s Vice Chair.

Rossomme said her focus on the AFA executive committee will include acting as a sounding board for the association’s management and working on projects that help industries throughout North America learn about flock and the flocking process.

EIS Fibercoating, which is ISO 9001 certified and located in Logansport, Ind., opened in the early 1980’s serving the North American auto industry. Automotive continues to be one of the company’s primary markets but under Rossomme’s leadership, EIS has expanded into a wide variety of other industry sectors.

“I have been connected to flocking my entire life,” said Rossomme. “I look forward to working with the rest of our AFA team, the majority of whom are also second generation, in continuing to promote both the value and beauty of flock.”

Cellusuede Products recently went through a major expansion with the acquisition of Engineered Fiber Technologies, Inc., (EFT) of Shelton, Conn. Founded in 1998, EFT specializes in making precision, short-cut fibers for technical markets. For example, carbon fibers made by EFT are used on the Mars Rover to help prevent fires.

“First, I want to thank Raj Shah, our outgoing Chairperson, for his years of service to the association,” said Steve Rosenthal, AFA’s managing director. “And we look forward to working with both Megan and Eric in their new leadership roles as the North American flock industry moves forward.”

Posted: November 12, 2024

Source The American Flock Association (AFA)

Active Apparel Group Secures B Corp Certification, Achieves Major ESG Milestone

CULVER CITY, Calif.   — November 12, 2024 — Active Apparel Group (AAG), manufacturer of performance apparel for the leisure/lifestyle and active market, has attained B Corp Certification, solidifying their role as one of a select few pioneers in environmental, social, and governance (ESG) practices for their industry, customers, and partners.

AAG achieved a score of 84.9 points on the rigorous B Impact Assessment (BIA), exceeding the 80-point threshold required for B Corp certification. This demonstrates Active Apparel Group’s dedication to workers, customers, community, and the environment, all part of the brand’s dedication to using business as a force for good.

The strongest areas represented in this score were Governance (17.6 pts), Workers (24.9 pts) and Customers (4.1 pts), which are significantly higher vs country, sector, and size benchmarks for similar B Corp certified companies.

“We’re proud to be recognized as a B Corp, which is a natural extension of our commitment to building a more sustainable and equitable business,” says Active Apparel Group CEO Henry Jones. “It sets us apart as a premium service provider and manufacturer in the global marketplace, assuring all stakeholders of our compliance with global best-practice standards. These standards also encourage continuous sustainable innovation, drive valuable operational efficiencies, and enhance our ability to attract and retain top talent.”

A highlight of Active Apparel Group’s certification was the achievement of hard-to-earn Impact Business Model (IBM) points for their practices in Toxin Reduction / Remediation. This recognition highlights AAG’s deep commitment to reducing harmful chemicals in their production processes through the use of 100% OEKO-TEX certified inks and responsible chemical management practices.

AAG already pays all workers a living wage. In 2023, an audit by third-party Bureau Veritas of AAG’s factory in China, Ningbo Longson Garments Co. Ltd (Longson), confirmed a 100% pass rate. Employees received wages exceeding the calculated living wage, 29% above the local minimum wage and 140% greater than the poverty line in Ningbo. Remuneration at this level remains a rarity in the manufacturing industry in China.

AAG has also committed to a structured approach in reducing its environmental impact across its global operations through an Environmental Management System (EMS). The EMS, built using the ISO14001 Standard Framework, incorporates key environmental policy commitments and has set targets and strategies to reduce the carbon footprint of its operations across China, Australia and the USA.

B Corp certification places AAG’s environmental, social, and governance practices in the company of a select few manufacturers in the performance apparel manufacturing industry, giving all AAG customers the confidence that they are partnering with a global leader in this space.

Posted: November 12, 2024

Source Active Apparel Group

KARL MAYER Warp Knitting Draws Positive Results At ITMA ASIA + CITME 2024

OBERTSHAUSEN, Germany  — November 11, 2024 — Warp knitting companies in Asia are also facing fundamental changes and challenges considering the tense global economic and geopolitical situation. During ITMA ASIA + CITME in October 2024, KARL MAYER showed how these can be mastered: with innovations that are primarily aimed at greater profitability, flexibility and sustainability.

The exhibition was a major crowd puller at the KARL MAYER GROUP stand in the Shanghai National Exhibition and Convention Center. Around 40% of all visitors with specific inquiries came from the warp knitting sector. The number of guests was significantly higher than at the previous ITMA ASIA + CITME, especially on the second and third days of the event, and all major customers were present.

Christof Naier, President of the Warp Knitting Business Unit at KARL MAYER, is delighted with the high level of response, but also with the quality of the exchange. “For the most part, we had very in-depth, goal-oriented discussions and conversations about many projects. Our customers are cautious but optimistic about the future,” says Christof Naier.

The visitors were particularly interested in the HKS 2-S presented in the new gauge E 44, its advantages in the production of sun protection clothing and the diverse textile and application show with its potential for more business.

In addition to the ITMA stand, a performance demonstration of selected machines at the in-house show accompanying the trade fair at KARL MAYER (CHINA) was also impressive, with two premieres. New in Asia and an attraction were the Elastomeric RE 4-1 with the 190” working width and E 36 configuration and the DM 6/2-6 EN, a double raschel machine with an excellent price-performance ratio.

Machines for markets with potential

With its efficiency and fine textile products, the HKS 2-S in E 44 brings new drive to the outdoor wear segment. At a maximum speed of 3,200 rpm, the high-performance tricot machine can produce up to 200 kg of fabric per day, extremely reliably and with the highest quality. The E44 articles in the HKS 2-S range are uniquely light, soft and supple, breathable and particularly suitable for use in sun protection clothing, i.e. for outdoor activities. Their UV protection factor more than doubles that of circular knitted fabrics with a comparable fabric weight. This is due to the dense surface structure.

The RE 4-1 is predestined for the extremely efficient production of highly elastic textiles. The machine offers an excellent price-performance ratio and therefore benefits that are particularly evident in the production of fine underwear items for the volume business thanks to the new 190” E36 combination.

With the DM 6/2-6 EN, KARL MAYER has further differentiated its range of double raschel machines and thus better tailored them to market requirements. With a speed of 850 rpm, the new machine works just as fast as its range neighbours, the RD 6/1-12 EN and RD 7/2-12 EN. However, thanks to a special technical focus on the production of lightweight 3D warp knitted fabrics, it is significantly cheaper. This makes the DM 6/2-6 EN a top production machine, especially when it comes to the highly efficient production of spacer fabrics for the luggage and furniture sector.

New textile developments with a focus on growth

KARL MAYER machines are not only extremely productive and reliable, but also open doors to new business with the right textile products, as demonstrated by a highly acclaimed textile innovation show at KARL MAYER’s ITMA stand in Shanghai. The most important highlight was certainly a chic sun protection outfit made from an E-44 fabric from HKS 2-S. However, inspiration and ideas for new articles and applications were also provided by the other exhibits, including functional, fashionable sportswear for the growing yoga trend and clothing fabrics with the look of typical cotton fabrics, an E40 warp knitted fabric as an outer fabric for thick down jackets, a comfortable casual wear outfit, lace with a uniquely high approximation to the Leavers Lace standard, a RASCHELTRONIC® article made of silk and stylish spacer fabrics for clothing and shoes.

Posted: November 12, 2024

Source: KARL MAYER Verwaltungsgesellschaft AG

Spinner Ibrahim Fibres Of Pakistan Expands With Trützschler TC 30Si Carding Machines

MÖNCHENGLADBACH, Germany  — November 11, 2024 — Ibrahim Fibres operates nearly 200 Trützschler cards, which is more than any other business in Pakistan. The leading yarn and Polyester Staple Fiber (PS) manufacturer has partnered with Trützschler for over two decades – and recently wanted to start processing long polyester and viscose fibers. It’s an unusual request that brings unique challenges. Our R&D team worked closely with the customer to find the optimal solution: Our TC 30Si carding machine.

From left to right: Gerold Gonska, Regional Sales Manager at Trützschler; Nico Sieben, Area Manager Pakistan at
Trützschler; and Zafar Iqbal, General Manager of R&D and New Projects at Ibrahim Fibres.

Pakistan is the eighth largest exporter of textiles in Asia and has the third largest spinning capacity in the continent. Ibrahim Fibres, located in Faisalabad, is a big contributor to that economic strength – and a powerful partner for Trützschler. The pioneering company produces a wide range of yarns for woven, and knitted fabrics. This includes various blends of cotton, viscose and polyester in different proportions and combinations with yarn counts ranging from Ne 8 to Ne 50. Ibrahim Fibres uses its own polyester via 240,000 spindles at four factories, mainly to produce poly-viscose and poly-cotton combed yarn. In total, the company manufactures 1,200 tons of PSF per day and consumes around 100 tons of its own materials per day. The remaining material is sold to other textile manufacturers.

Ibrahim Fibers is using the Trützschler Autoleveller Draw Frame TD 10 because of its high efficiency and its space-saving design with advanced self optimizing features.

Trützschler’s long relationship with Ibrahim Fibres is driven by a shared passion for continuous improvement, constant innovation and leading the push for more sustainability in the textile industry. “Our experience with Trützschler has been exceptional,” says Zafar Iqbal, General Manager R&D and New Projects at Ibrahim Fibres. “Their high-quality machines, advanced technologies, and 360-degree analyses, along with innovations like MY MILL have been pivotal in our zero-man spinning and Industry 4.0 initiatives. Their excellent after-sales service over the past twenty years has built our trust and satisfaction. We eagerly anticipate continuing this successful partnership and exploring new opportunities together.”

An unusual challenge

Teams from Ibrahim Fibres often approach Trützschler with fresh ideas and new expectations. They recently set the challenge of producing top-quality yarns from unusually long polyester and viscose fibers. These fibers are used for luxury textiles, high-performance fabrics, fine bedding and advanced nonwoven materials. The end products benefit from the fibers outstanding strength and durability. Often, people in the textile industry talk about the problems with processing short fibers. But long fibers also present difficulties because they have a tendency to wrap or clog carding elements. Their length also makes them more tightly bound, which means they are more difficult to open.

What was the answer to this unusual challenge? Collaboration! Experts from Trützschler worked closely with partners at Ibrahim Fibres to explore potential solutions. “Our technical teams regularly collaborate with Trützschler’s R&D department to enhance production using Industry 4.0 principles, Al, and the latest technology,” says Zafar Iqbal. “We’ve now developed a method for handling longer fibers that improves yarn consistency, end-product performance, and cost efficiency, while reducing waste. Our ongoing partnership with Trützschler continues to drive innovation and efficiency in our operations.”

TC 30Si is here to help…

Ibrahim Fibres wanted to process 51mm polyester with 51 mm viscose fibers. In line with these requirements, Trützschler engineers optimized the TC 30Si carding machine for processing long polyester and viscose fibers. This machine is specifically customized for man-made fibers and can process these fibers more effectively due to its larger drum diameter, which results in a 14 % extended carding length. The machine also has 35 % more active flats. It has one licker-in and its cylinder, doffer wire, flat tops and stationary flats are all designed for processing man-made fibers.

As a loyal customer for more than twenty years, Ibrahim Fibres now operates nearly 200 carding machines from Trützschler – and recently purchased another eighteen TC 30Si cards.

“We chose TC 30Si for its advanced features, such as its 1400 mm cylinder diameter, extended carding lengths, and the automatic T-GO gap optimizer,” says Zafar Iqbal. “These attributes support our Industry 4.0 goals by enhancing technology integration, data use, and operational efficiency, making it ideal for modernizing production and staying competitive in the textile industry.” And Ibrahim Fibres has even more reasons for choosing the TC 30Si: “It has user-friendly software and an intuitive Human Machine Interface (HMI), making it easy to maintain with minimal adjustments. This card boosts productivity and reduces energy consumption, while also improving consistency and reducing defects.”

Long fibers, long partnership

This shared success is the latest milestone in the long relationship between Trützschler and Ibrahim Fibres. It’s also a powerful example of how we work together to keep pushing the boundaries of what’s possible. Based on strong test results, the customer placed an order for eighteen TC 30Si carding machines in June 2024. In this way, the company can move ahead with its big ambitions for processing unusually long fibers – and move ahead with the next phase of its long partnership with Trützschler too.

Posted: November 12, 2024

Source: Trützschler Group SE

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