SÃO PAULO — August 30, 2024 — Pulp producer Suzano today announced the completion of its acquisition of a 15 percent stake in Lenzing AG, the Vienna-listed leading global supplier of sustainable premium cellulosic fibers for the textile and nonwovens industry, from B&C Group. As announced in June this year, the transaction value is 230 million euros (or 39.70 euros per share). The agreement was subject to regulatory approval, which was granted without restrictions.
The long-term partnership between Suzano and B&C Group establishes that Suzano has the right to hold two seats on Lenzing’s Board and the option to acquire an additional 15 percent stake from B&C Group until the end of 2028. Following the sale of the 15 percent stake, B&C Group now holds 37.25 percent of Lenzing’s share capital.
Lenzing is a global supplier of premium wood-based cellulosic fibers (lyocell, modal, and viscose) for the production of clothing, home textiles, hygiene products, and non-woven materials.
Beto Abreu, CEO of Suzano, said: “Lenzing’s unparalleled track record of innovation and best-in-class technology make it a global leader in developing sustainable solutions from wood. With this transaction, we intend to build our expertise in the textile market and identify how we can help strengthen the company’s competitive position.”
The purchase of the stake in Lenzing is aligned with two of Suzano’s key strategic goals — “Expand Boldly into New Markets” and “Play a Leading Role in Sustainability”. Its completion does not have a material impact on Suzano’s overall financial leverage and/or indebtedness.
NEUMÜNSTER, Germany — September 2, 2024 — At FILTECH, the trade fair for filters and filtration systems in Cologne, November 12-14, Oerlikon Nonwoven will be presenting its market- and customer-oriented system solutions for filtration applications. The Neumünster-based plant engineering company for nonwoven production technology will be offering trade fair visitors the opportunity to meet the team in hall 8, stand B18 and immerse themselves in the company’s comprehensive product and process expertise.
Filtration: Meltblown solutions for the highest demands
Oerlikon Nonwoven meltblown technology enables the efficient and simple production of unique and highly sophisticated nonwovens for filtration, insulation and sorption applications. The polymers used for the production of filter media and membranes are just as diverse as their areas of application. The spectrum ranges from classic polyolefins (PP, PE) through PET, PLA, PBT and PA to speciality plastics such as PPS and TPU. All these and other raw materials can be safely processed using the Oerlikon Nonwoven Meltblown process.
The Oerlikon nonwoven hydrocharging technology hycuTEC for meltblown systems impresses with maximum filtration efficiency combined with low pressure loss.
With the Edana Filtrex Innovation Award-winning hycuTEC hydrocharging technology for the production of highly efficient electret filter media, the pressure loss of a typical FFP2 filter medium can be reduced to less than a quarter. “Filtration efficiencies of over 99.99% are easy to achieve with typical filter media of around 35 g/m² with a maximum pressure loss of 35 Pa,” explains Dr Ingo Mählmann, Director Sales & Marketing Oerlikon Nonwoven. “What’s more, this innovative process eliminates the need for an additional drying process for the production of high-separation electret filter media for most applications,” he continues.
Spunbond solutions: High-performance technology for filter applications
Spunbond products are becoming increasingly important in filtration applications – both as backing materials for filter media and as the filter media themselves. Thanks to a nonwoven structure tailored to their specific tasks, customer-specific requirements for different functions can be realised; it is also possible to combine different functions in one layer. In particular, many years of experience in the field of bicomponent spinning processes enable the design of completely new nonwoven structures and thus the fulfilment of different functions in one material. With the Oerlikon Nonwoven Bico spunbond process, different fiber cross-sections can be combined, but also different fibers can be produced simultaneously from one or different polymers on one system. The spectrum ranges from classic core-sheath and side-by-side bico filaments to splittable fibers and so-called mixed fibers.
Posted: September 2, 2024
Source: Oerlikon Polymer Processing Solutions Division / Oerlikon Group
BANGKOK, Thailand — September 2, 2024 — Indorama Ventures Public Co. Ltd., a global sustainable chemical producer, through its direct subsidiary – IVL Dhunseri Petrochem Industries Ltd. – and Dhunseri Ventures Limited have formed a joint venture with Varun Beverages Limited, PepsiCo’s second-largest bottling company globally outside the US, to establish several greenfield state-of-the-art PET recycling facilities in India. This strategic alliance marks a substantial move towards meeting the increasing demand for recycled content throughout India, representing the companies’ collective dedication to sustainability.
The joint venture has already begun the construction of two PET recycling facilities, planned for completion within 2025, with potential for more. One facility is in Kathua within the Jammu Division of the Indian Union territory of Jammu and Kashmir, situated in Northern India, while the other is in Khurdha within the State of Odisha, located in Eastern India. The aim is to reach 100 kiloton annual capacity of recycled PET (rPET) across all the facilities when combined.
This initiative aligns with the escalating demand for rPET content in India, driven by both regulatory mandates and a collective effort towards a circular economy for PET. The surge in demand reflects a significant shift, with projected volumes increasing from approximately 400 kilotons in 2025-2026 to over 1 million tons by 2031. Mandates such as the Indian government’s compulsory requirement of 30 percent recycled plastic content in plastic packaging by 2025-2026, escalating to 60 percent by 2028-2029, underscores the urgency and importance of this transformation. Moreover, this move aims to effectively cater to the needs of India’s beverage Brand Owners, many of whom have established ambitious sustainability goals in line with regulatory directions.
Yash Lohia
Yash Lohia, representative of IVL Dhunseri, and executive president Petchem Special Projects, and chairman of the ESG Council of Indorama Ventures, stated: “We at IVL Dhunseri are delighted to collaborate with Varun Beverages, in the establishment of these mechanical recycling facilities in India. As the world’s largest recycler of PET, this partnership underscores our steadfast commitment to sustainability and our support for the region’s escalating demand for rPET content. Anticipated to substantially diminish plastic waste, these new PET recycling facilities will convert post-consumer PET bottles into valuable resources. This initiative exemplifies the shared dedication of Indorama Ventures’ and Varun Beverages to creating a circular economy, promoting environmental sustainability, and meeting the rising consumer demand for eco-friendly products.”
The amalgamation of the three industry leaders bodes well for bolstering the region’s recycling infrastructure. As regulatory frameworks increasingly advocate for heightened usage of recycled content, the joint venture is positioned to play a pivotal role in meeting these evolving requirements.
Indorama Ventures is the world’s largest producer of recycled PET resins widely used in food and beverage packaging. Since 2011, the company has operated PET recycling facilities, gradually expanding its global footprint. In 2023, Indorama Ventures achieved a significant milestone, recycling over 100 billion PET bottles. Progressing towards its target of recycling 750,000 tons or 50 billion bottles annually by 2025, the company remains dedicated to advancing circular economy practices.
Varun Jaipuria
Varun Jaipuria, executive vice chairman of Varun Beverages Ltd., added: ” As part of our long-term vision and in line with PepsiCo’s global PEP+ objectives, we remain committed to sustainability and environmental stewardship. We are making investments that emphasize using green energy as well as reuse of PET which will be instrumental in mitigating environmental impact. These endeavors are aligned with our pledge to the environment and reflect our ambition to nurture a greener future. Our collaboration with Indorama Ventures represents a strategic foray for Varun Beverages into the recycling market. We believe this joint venture will yield environmental dividends and generate substantial value for our stakeholders. As India’s recycling landscape undergoes a paradigm shift, we take pride in spearheading this transformation alongside Indorama Ventures. Through this joint venture, we endeavor to harness our expertise to cater to the escalating demand for sustainable packaging solutions.”
ROCHESTER, N.H. — August 30, 2024 — Albany International Corp. announced today that its board of directors has appointed Merle Stein as president of its Machine Clothing business segment, and elected him an officer of the company effective September 1, 2024, to succeed Daniel Halftermeyer, who has stepped down from the position to focus his time and energies on the continued integration of the Heimbach acquisition and the successful transition to Stein.
Stein has considerable experience in the paper and pulp industries and significant knowledge of the Machine Clothing business and a strategic understanding of the markets it serves. He comes to the role with considerably broad leadership experiences, particularly in operational and customer-facing operations. Since April 2024 he has served as Division COO for the business segment where he oversaw all operational aspects of the business and led the Sales & Marketing, Operations, Procurement and Human Resources functions. Prior to that, since 2022 he was the vice president, Sales & Marketing/Applications for Americas, after having served in various other sales and marketing leadership roles since joining the company in 2011, including vice president Sales MC – North America, Regional Business director and Sales & Service engineer. Prior to joining the company, Stein managed papermaking operations at Essity’s green field papermill in Alabama where he had risen to the position of Papermill Manager following roles as a process engineer, and machine superintendent. Stein holds a Bachelor’s degree in Chemical Engineering and a Master of Business Administration, both from Auburn University.
Gunnar Kleveland, company president and CEO, said: “I am happy to have Merle join our senior leadership team and take over the reins of the Machine Clothing business. He has broad industry experience and an intimate knowledge of our Machine Clothing business and its customers. This experience and knowledge will be a competitive advantage, ensuring that the business will remain the industry leader while pursuing its strategic goals. At the same time, I want to recognize Daniel for his 37 years of wide-reaching and impactful service to Albany International and thank him for his continued dedication to the success of the Company by implementing this succession plan. I am confident that he will continue to drive the Heimbach integration plan while assisting Merle in the transition.”
Stein said: “I am proud to be a part of the Albany team and honored to be given this opportunity. I thank Daniel for his mentorship over the years and look forward to working with the Machine Clothing team as we continue to develop new technologies, empower our team and deliver value to our customers and other stakeholders.”
Halftermeyer said: “I am grateful to have had the opportunities given to me at Albany International for so many years, and proud of what my team and I have accomplished. Merle will be taking the helm of a great business run by a strong and experienced team, which will continue to have my support.”
Board Chair John Scannell said: “I also wish to thank Daniel for all his service and dedication to the Company. His record of leadership and success at the Machine Clothing business is remarkable. As part of Daniel’s team, Merle has great familiarity with the business, and will continue its exceptional performance. I wish them both continued success in their new roles.”
BRIXEN, Italy — August 30, 2024 — Mirage Group, the official representative and certified service company for global manufacturers of machines, consumables and media for wide format digital printing and finishing machines, has been confirmed as a new partner for Vanguard Europe.
The far-reaching agreement between Vanguard Europe and Mirage Group, which has its headquarters in the commercially strategic Bulgarian town of Ruse, involves sales, distribution, service and consumables.
In addition to covering Bulgaria where the group has warehouse and office premises in Ruse, Sofia, Plovdiv, Varna and Burgas, subsidiary company Mirage MT Ltd will represent Malta from Handaq, while Mirage Group MK — based in Skopje, Macedonia — has responsibility for North Macedonia. It also has a branch company in Serbia.
Mirage Group, which provides end-to-end solutions for digital printing and finishing, including software, has been selling digital printing machines since its inception in 2006 and has closed more than 400 deals across its territories. The 70-strong team includes 16 qualified and certified service technicians and more than 20 sales staff. It also has ISO 9001: 2008 quality management certification.
Yiannis Apostolidis, Vanguard Europe’s Business Development director, said: “With an impressive, proven track record in the large format digital machine sales, Mirage Group is a welcome new addition to our growing network of partners. The agreement covering the territories of Bulgaria, Malta and North Macedonia is another important strategic as we continue to grow business profitably together for our growing number of customers. We see a lot of opportunities ahead through meeting and anticipating all their needs in a partnership approach.”
Lyubo Parashekov, Mirage Group owner, said: “Having had a successful start to the new year, we were delighted to have started discussions with Vanguard Europe during FESPA, which has now resulted in a formal agreement. As an established player in the flatbed market, we are proud to have secured another partnership that will benefit both parties. Indeed, the fantastic Vanguard products — high quality, industrial speed machines that are competitively priced — are already proving highly We have already achieved first sales and we expect to announce further details soon.”
Vanguard Europe has committed to grow its operations quickly and efficiently as part of its mission to continue to replicate the success of its parent company Vanguard Digital Printing Systems, which has installed over a 1,000 printing systems across the Americas. Vanguard has been part of Durst Group since 2020, with its European headquarters in South Tyrol, Brixen, Italy.
NEW YORK CITY —August 29, 2024 — Abercrombie & Fitch, a division of Abercrombie & Fitch Co. is excited to announce the continuation of its partnership with the National Football League (NFL) for the fall 2024 season. The partnership, which includes releases of licensed graphics apparel as well as content creation and social media collaborations with NFL players, serves as an organic evolution to the popular relationship between the two brands over the past two years.
As a natural next step for Abercrombie’s collaboration with the NFL, the brand is featuring four NFL athletes for the fall 2024 NFL collection, including TJ Watt, linebacker for the Pittsburgh Steelers, who expressed his excitement for the collaboration stating, “Outside of football, I’ve always been a fan of Abercrombie. I didn’t even realize how much product of theirs I wear until my wife let me know.” He continued on, “The NFL Tees have a cool vintage look and feel.” Additional players include Nick Chubb, running back for the Cleveland Browns; Fred Warner, linebacker for the San Francisco 49ers; and Rome Odunze, wide receiver for the Chicago Bears. The players can be seen wearing merchandise of their respective teams throughout the campaign.
“We are excited to expand upon our successful Abercrombie x NFL franchise with an expanded assortment across men’s, women’s and kids for this upcoming season. This collection has consistently exceeded our expectations, and we are thrilled to continue to innovate and expand our product offerings with this program, particularly with our authentic partnership with NFL players,” says Corey Robinson, chief product officer of Abercrombie & Fitch Co.
The expanded assortment features all 32 NFL teams and includes hoodies, sweatshirts, t-shirts, outerwear, and hats. The NFL by Abercrombie fall 2024 campaign and collection is now available in-stores and online.
SEOUL —August 29, 2024 — With the intention of creating a world where vibrant colors blend effortlessly with stretchy comfort, Birla Cellulose, a global leader in viscose staple fiber (VSF), and Hyosung, a comprehensive sustainable textile solution supplier and the world’s largest manufacturer of spandex under the CREORA® brand, have co-created a collection of vibrant cellulosic knits made possible with CREORA Color+ Spandex.
“The fusion of science and style is at the heart of this initiative,” said Abir Chakrabarti, joint president, Grasim Industries Limited- Pulp & Fiber, the flagship company of Aditya Birla Group that operates Birla Cellulose plants in India. “Our research and development teams are tirelessly working to achieve the perfect balance between spandex’s elasticity and dye absorption. This blend requires meticulous testing, tweaking, and reimagining traditional processes to create a fabric that retains its stretch while embracing a full spectrum of color.”
As regular spandex does not take color well, it is a challenge to achieve all-over, rich color when dyeing it with natural fibers such as cotton, rayon, and modal. As a result, Hyosung created CREORA Color+ Spandex, a special reactive dyeable spandex developed for natural blended materials. CREORA Color+ has the same performance stretch characteristics as Hyosung’s flagship CREORA Power Fit Spandex, with the added benefit of providing deeper, richer, all-over color in natural and cellulose fabrics without grin-through — an attractive fiber blend for leading intimate, activewear and ready-to-wear brands.
“Dyeable spandex knit fabrics open worlds of possibilities for designers and creators across multiple end-uses,” said Dinesh Keswani, Hyosung director Technical and Business Development, India. “As a comprehensive provider of textile solutions dedicated to assisting our partners throughout the entire value chain in addressing complex material challenges, we are delighted to collaborate with esteemed Birla Cellulose in bringing this progressive innovation to fruition.”
“In this age of conscious consumerism, sustainability takes center stage,” Chakrabarti said. “Our fabric isn’t just about aesthetics — it’s about reducing environmental impact. By developing man-made cellulosic dyeable spandex knit fabric, we’re minimizing water usage, energy consumption, overall waste reduction with enhanced shade depth. It’s our commitment to a greener, cleaner planet as a step forward.”
According to Birla Cellulose, the road to innovation is paved with challenges, but every obstacle is a chance to learn and grow. The company is excited about its progress so far and eager to share the new cellulosic knit collection made with CREORA Color+ Spandex with customers soon.
FERNDALE, Wash. —August 29, 2024 — Samson, a developer of high-performance synthetic rope solutions and services, is excited to announce a new partnership with Applied Fiber. Samson will have an industrial license for Applied Fiber’s industry-leading end fitting technology. The collaboration between these two companies will allow users to expand their operational capabilities by pairing Samson’s synthetic rope design and production excellence with Applied Fiber’s proprietary termination solutions, enabling fiber rope use in previously incompatible systems and increasing opportunities for existing applications.
This technology provides high efficiency termination of synthetic rope with attachments similar to steel wire rope fittings and at a more compact size than traditional eye splices. Samson is eager to install the production equipment and implement training for operations at its Ferndale, Wash., facility. Ahead of this, Samson will continue to support end-user needs for these termination solutions through our partnership with Applied Fiber and its facility in Havana, Fla.
“Providing a technology beyond the traditional methods for termination of high-performance fiber rope allows optimization of operations for those experienced in synthetic rope use or interested in replacing steel wire,” highlighted Dustin Heins, Samson’s Product manager for Innovation. “Applied Fiber’s technology provides an exciting tool for Samson’s design engineers and end-users alike to improve the function of synthetic tension solutions!”
“Samson’s commitment to excellence and their forward-thinking approach to rope technology make them an ideal partner. Advanced terminations unlock rope constructions that can achieve higher levels of performance. This collaboration underscores Applied Fiber’s alignment with industry leaders to push the boundaries of synthetic fiber rope technology,” said Richard Campbell, CEO of Applied Fiber.
WATERLOO, Belgium —August 29, 2024 — BASF’s Performance Materials division reveals its strategic roadmap toward achieving carbon neutrality by 2050 and highlights key milestones on its way to a circular economy. With that, the division, which brings together BASF’s entire materials know-how regarding innovative and customized plastics, positions at the forefront of the much-needed sustainability transformation in plastics.
“We want to enable our customers’ transformation by offering a portfolio with lower carbon footprint and diverse circular solutions. We work through the entire lifecycle of plastics to make them more sustainable: from how to produce plastics more resource-efficiently, to how to improve their use, to how to give them a new life” said Martin Jung, president, BASF Performance Materials. “We call this transformation #ourplasticsjourney. With our roadmap, we are laying an important foundation to make this transformation go faster.”
Accelerating the journey towards carbon neutrality and climate protection
BASF has set clear targets to reduce carbon emissions by 25 percent by 2030 compared to 2018 (scope 1 and 21) and by 15 percent compared to 2022 for the scope 3.12, with the goal of achieving carbon neutrality by 2050. The first and imperative step of the company’s carbon management strategy is to increase the use of green electricity.
“In 2023 already, more than one-third of our Performance Materials sites worldwide were running on green electricity and we are making relentless efforts to switch them all completely by 2025,” Jung said.
Green electricity also plays an essential role earlier in BASF’s value chain, particularly in the scope 3.1. One of BASF’s suppliers, 3B Fibreglass, supplies the company with glass fibers that are used as reinforcement for thermoplastic and thermoset polymers. By utilizing solar panels to generate electricity, 3B Fibreglass significantly reduces its carbon emissions. As a result, the glass fiber’s reduced product carbon footprint is transferred to BASF’s products and ultimately to its customers. This showcases the potential of a circular economy when all stakeholders are committed to sustainability.
Supporting customers with certified sustainable solutions
BASF is actively certifying its manufacturing sites globally with the International Sustainability and Carbon Certification (ISCC) PLUS and REDCert². Most Performance Materials sites are certified in at least one scheme and additional sites will be certified in all regions by the end of 2024.
These schemes certify the amount of renewable raw materials that is attributed to biomass balanced (BMB) products. These renewable feedstocks replace a part of the fossil raw materials necessary for the production at the very beginning of the value chain. The process ensures identical product quality and properties. Thus, customers can use the materials as drop-in solutions. The same applies to chemically recycled feedstocks like pyrolysis oil from scrap tires or mixed plastic waste.
“Today, a majority of our product portfolio is already available based on renewable feedstocks and with significantly lower or even net-zero product carbon footprints. We want to support customers as early as possible on the journey to meet their sustainability targets and offer diverse circularity options,” added Matthias Scheibitz, head of Sustainability, BASF Performance Materials.
Ambitious target for a more circular product portfolio
To increase the use of circular feedstock in its product portfolio, BASF is looking into the most promising mass balance solutions, thereby meeting customer expectations from all industries. On its sustainability journey, BASF Performance Materials commits to reaching at least 20 percent of circular economy sales by 2030 (via products that support the substitution of fossil by circular feedstock by at least 20 percent). A strong contributor to this target already is BASF’s biopolymer portfolio which is the optimal solution for certified compostable packaging and agricultural applications. Biopolymers contribute to closing the biological loop by reducing food waste, increasing organic recycling of organic waste, returning nutrients to the soil and avoiding the accumulation of microplastics in agricultural soil.
Wide range of commercially available sustainable solutions and co-creations
BASF Performance Materials views co-creation with customers and partners from all along its diverse value chains as the cornerstone of sustainability efforts within the plastics industry. “For us, it is essential to offer our customers commercial and series-ready, sustainable solutions and inspire them with what is possible today,” Jung said.
Circularity needs to be deeply embedded into the product design phase. As an example, BASF Performance Materials has recently developed an innovative polyurethane (PU) foam technology that enables simplified and scalable mechanical recycling. First steering wheel prototypes using this new technology were recently presented publicly in Europe and in China.
The Siemens SIRIUS 3RV2 circuit breaker is the first electrical safety product to include components from biomass-balanced plastics where fossil feedstock at the beginning of the value chain is replaced by biomethane derived from renewable sources such as agricultural waste. In a similar way, BASF collaborated on the Steelcase’s Flex Perch Stool using plastics derived from a chemical recycling process, preventing incineration or landfill. In other cases, bio-based and recycled raw materials are used complementarily. Developed with Mercedes-Benz AG, the door handle and the crash absorber of the Mercedes-Benz S-Class combine pyrolysis oil from scrap tires and biomethane from organic waste to replace fossil raw materials in manufacturing these plastics with virgin material properties.
For the packaging industry, BASF is also offering a way to increase the use of renewable feedstocks. Its portfolio of certified compostable biopolymers now includes a biomass-balance grade. Next to being organically recyclable, it also shows a 60-percent lower Product Carbon Footprint (PCF) than the respective standard grade.
Finally, a comprehensive portfolio of engineering plastics and polyurethanes with a significantly reduced carbon footprint (PCF) is available. Some of these LowPCF products reach a CO2 footprint close to zero, proving once again that a sustainability future with plastics is within reach.
REMSCHEID, Germany—August 29, 2024 — More than 15 million tons of CO2 savings in 20 years — that is the balance sheet of e-save — the sustainability program of today’s Oerlikon Polymer Processing Solutions Division. As a supplier of manmade fiber plant technologies, the company has been developing, producing and launching its products and services with sustainability in mind since 2004: ‘Energy’ savings and ‘Efficiency’ of systems, machines and components, ‘Environment’ relief and improved ‘Ergonomics’ for optimal machine operation are the four e-save topics that have provided fiber and yarn manufacturers with significant added value in terms of economy, safety and process handling right from the start. The pioneers of today’s brands Oerlikon Barmag, Oerlikon Neumag and Oerlikon Nonwoven were already true pioneers in terms of sustainability.
The e-save logo is awarded to components and machines from Oerlikon Barmag, Oerlikon Neumag and Oerlikon Nonwoven that are significantly more sustainable than the market standard or predecessor models.
Rising energy prices, scarce resources, an ageing society, a shortage of skilled workers and lower profit margins in many industries prove Oerlikon’s e-save mission right. For 20 years, the technology leader in man-made fiber production has been scoring points with significantly lower energy consumption compared to the market standard, the competition or its own predecessor models. Fiber and yarn manufacturers around the world appreciate this, as investments in new systems developed according to e-save criteria pay for themselves in a much shorter time.
“Topics such as energy efficiency and the careful use of resources have become increasingly important for all our customers in recent years, not least due to stricter legal framework conditions,” said Georg Stausberg, CEO of the Oerlikon Polymer Processing Solutions Division. “Our e-save sustainability program and the associated technology development over the last two decades has often given us the decisive advantage in numerous investment decisions on the customer side and thus the edge over the competition.”
More than 15 million tons of CO2 saved since the introduction of e-save
The Oerlikon Polymer Processing Solutions Division and its business units have been subject to DIN ISO certification for decades, they realize the CE marking and consistently implement the strict guide-lines for machine safety, especially in terms of protecting employees on the customer side. At the beginning of the millennium, however, this was no longer enough. The company and its managers wanted to voluntarily do even more with a view to the future. As a result, the e-save program was launched in 2004.
Since its introduction, hundreds of man-made fiber spinning mills worldwide have been equipped with technology solutions from Oerlikon Barmag, Oerlikon Neumag and Oerlikon Nonwoven. Around half of the currently installed production capacity for polyester, polypropylene and nylon is based on Oerlikon technologies. According to an estimate by the publication “The Fiber Year 2024”, this corresponds to almost 40 million tons of fibers and yarn annually. The corresponding CO2 balance is impressive: The e-save certified customer installations saved, cumulatively over the last 20 years, over 15 million tons of CO2. This is roughly equivalent to the emissions generated by around 15 million intercontinental passenger flights per capita, or the amount that a forest with a surface area of 300 km² — roughly the size of Munich, Germany — can store.
Efficient heating and cooling creates energy-saving potential
What did the engineers focus on in the beginning? Heat is a crucial factor in polymer spinning systems. Polyester melt is conveyed from the polycondensation plant to the spinning system at temperatures between 280 and 290 degrees Celsius. The hot filament coming out of the spinnerets is then cooled in the quenching unit before being drawn on hot godets, depending on the process.
Jochen Adler, CTO of the Oerlikon Polymer Processing Solutions Division.
“All of this has the potential to optimize energy consumption: WINGS POY (Winding Integrated Godet Solution) revolutionized the man-made fiber industry at ITMA 2007. The completely new winding concept already showed the potential to turn the entire industry upside down. All market participants were enthusiastic from day one,” says Jochen Adler, CTO of the Oerlikon Polymer Processing Solutions Division. Chinese companies in particular already saw the technology that would make them global pioneers in the manmade fiber industry. Five years later, WINGS FDY conquered the market with even more e-save advantages, especially in the area of energy savings. The Oerlikon Barmag innovation achieved over 40-percent lower energy consumption compared to the industry standard at the time. The return on investment (ROI) was and still is achieved very quickly. The best technology with the highest quality is therefore also worthwhile from an economic point of view. In addition to the Oerlikon Barmag core technology WINGS — today an indispensable part of a modern man-made fiber spinning mill — the company has set standards over the years with other components in the field of energy savings.
Benchmark market in the industry
The SP8x spinning head series, for example, is based on a reduced heat-radiating surface with significantly improved insulation, resulting in more than 40-percent less heat loss compared to its predecessor models. In concrete figures, this means energy savings of around 200,000 kWh per year for a system with 36 positions. The component therefore remains the benchmark in the industry.
“The EvoQuench radial quenching system is a real cash cow thanks to its up to 80-percent lower air conditioning requirement. In combination with the WINGS take-up system, up to 46-percent energy and around 50 percent waste can be saved compared to conventional technology, depending on the process,” said Adler. The latter is mainly due to the ergonomically unique concept of the take-up unit: The component is placed at eye level in record time; only one operator is required.
The sister company Oerlikon Neumag also contributed corresponding e-save components at an exceedingly early stage. For example, the BCF tangle unit RoTac3 enables high energy savings through its targeted use of compressed air. Tangle knots are created with a pulsating rather than a continuous airflow, as is the case with conventional tangle processes. This means that compressed air is only ever used when a tangle knot is to be created. This significantly reduces the required volume flow or compressed air consumption — by up to 50 percent compared to conventional tangle units, depending on the yarn type. The component is naturally installed in Oerlikon Neumag’s BCF S8 carpet yarn system, the most modern of its kind in the world. It makes a significant contribution to the energy-efficient production of carpet yarns. However, the system also convinces with impressive data thanks to the overall concept: Plant efficiency of 99 percent, higher throughputs of up to 15 percent and energy savings of up to 5 percent per kilogram of yarn.
Less energy – more productivity
Compared to standard DTY machines, the Oerlikon Barmag eAFK Evo offers 30-percent higher productivity with 20-percent less energy consumption per kilogram of textured yarn. The significant increase in machine speed and the 50-percent shorter texturing zone compared to a conventional machine ensure an exception-ally stable texturing process that enables maximum productivity and the lowest operating costs. The core component of the machine is the EvoCooler, whose sustainable cooling principle is based on the evaporation of water. This active cooling technology with direct contact to the yarn is independent of the ambient temperature and requires no additional energy. In addition, the low heat emission to the environment reduces the requirements for hall air conditioning. The collected coolant is recirculated and can therefore be recycled.
“Precisely coordinated process steps in the textile value chain also offer potential in terms of efficiency. One example is the WINGS POY HD and eAFK Big V high-titer concept, which is designed for a carpet and home textile product range that uses particularly soft and bulky polyester yarns with BCF-like properties. The aim here is to produce yarns with a maximum count of 1200den with over 1000 filaments. As standard, DTY yarns up to 1200den with up to 1152 filaments from four POY bob-bins 300den/288f are spun together on a DTY machine,” said Jochen Adler. However, the process has a fundamental disadvantage: half of the available winding positions on a texturing machine re-main unused. This is where the spinning concept with a WINGS POY HD take-up unit in combination with an automatic eAFK Big V multi-spindle texturing machine offers a highly efficient solution — currently the only one on the market.
Water – a contested resource
The most recent example of sustainable e-save technology is the Oerlikon Neumag EvoSteam staple fiber system. Here too, the relevant process steps in terms of sustainability were already addressed during development.
The most recent example of a sustainable e-save technology is the Oerlikon Neumag EvoSteam staple fiber plant. Here, too, the relevant process steps in terms of sustainability were already taken into account during development. The innovative process does not require water baths. The result: water savings of up to 3.5 million liters per year, significantly lower consumption of drying energy and preparation, and ultimately a reduction in the CO2 footprint of up to 20 percent. An optimized draw point release makes the EvoSteam staple fiber system up to 12-percent more efficient than previous concepts. Overall, the EvoSteam process reduces production waste by up to 50 percent while at the same time saving up to 8 percent energy.
Another example: the pollution of water by dyeing textiles is a much-discussed topic. With the help of the 3DD mixer technology once developed at Oerlikon Barmag, manmade fiber production offers the injection of color pigments as a masterbatch as early as the melt preparation stage — this really is an exceptionally clean alternative. A nice side effect: the dyeing of these spun-dyed yarns is much more uniform than bath dyeing of bobbins or textile surfaces, and the color fastness is unsurpassed. In addition, the spun material retains its color almost forever.
Last but not least — the entire textile industry is striving for solutions for a functioning and all-encompassing circular economy. Together with its joint venture partner BB Engineering, Oerlikon Barmag already has at least one solution for a zero waste man-made fiber spinning mill on offer. With the help of the VacuFil technology, production waste can be reprocessed to a high quality in the spinning mill so that the waste material can be directly reintroduced into the melt flow.
On top: bluesign® certification
A good 20 years after the introduction of the e-save label as a voluntary commitment by Oerlikon, the company is following suit and is also subjecting itself to the assessment of independent institutes such as the Swiss bluesign Technologies AG as part of the ESG criteria that have been legally binding for a few years now.
Last year, the Oerlikon Neumag EvoSteam staple fiber plant was awarded the bluesign® VERIFIED DATA label. The label includes the verification of impact data such as water, spinning preparations, thermal and electrical energy as well as the CO2 footprint by means of a plausibility check of the supporting records for the EvoSteam draw frame, the central element in the EvoSteam process. For yarn manufacturers, this means that all polyester staple fibers produced with the EvoSteam process will actively contribute to the bluesign SYSTEM in the future.
Georg Stausberg, CEO of the Oerlikon Polymer Processing Solutions Division and CSO of the Swiss Oerlikon Group.
“The trend towards greater sustainability is no longer just a trend, but a must for the industry and all market participants worldwide. With a view to the European Green Deal, we are creating even more transparency for our customers through external certifications such as bluesign in addition to our own e-save label. In this way, we are intensively strengthening trust in all our products and services,” explainsedGeorg Stausberg, who in addition to his role as division CEO is also chief sustainability officer (CSO) of the Swiss Oerlikon Group.
Posted: August 29, 2024
Source: Oerlikon Group / Oerlikon Polymer Processing Solutions Division
SÃO PAULO — August 30, 2024 — Pulp producer Suzano today announced the completion of its acquisition of a 15 percent stake in Lenzing AG, the Vienna-listed leading global supplier of sustainable premium cellulosic fibers for the textile and nonwovens industry, from B&C Group. As announced in June this year, the transaction value is 230 million euros (or 39.70 euros per share). The agreement was subject to regulatory approval, which was granted without restrictions.
Lenzing is a global supplier of premium wood-based cellulosic fibers (lyocell, modal, and viscose) for the production of clothing, home textiles, hygiene products, and non-woven materials.
