Composite Machinery Innovations

Dornier offers the PROTOS® tape weaving composite technology

While ITMA remains an event with limited composites offerings, plenty of composite related innovations were to be found at ITMA 2023.

By Prateeti Ugale

The 19th international textile machinery show, ITMA 2023 was recently held in Milan. The “Olympics” of textile machinery exhibitions held every four years, has a 73-year history of displaying the latest technology for every single work process of garment making and textiles. Out of the many products specialized in various areas, this article focuses on the latest and existing machinery for textile reinforcement structures, composite processing machinery, and accessories for the same.

A composite is made up of at least two components that possess significantly different physical and chemical properties which when combined forms a material that possesses advantageous properties of all the base components. In textile reinforced composite, the two components are matrix, which is a polymeric bonding component and textile, which is a reinforcement. The resultant composite benefits from tensile strength of the textile reinforcement and compressive strength of the matrix. Common fibers used are carbon, glass, basalt, aramid, or natural fibers to provide strength to the material whereas, matrix resins include materials like epoxy, polyurethane (PU) and others which function as glue to hold the reinforcement in place1. Braiding, nonwovens, knitting, weaving production techniques can be used to obtain reinforcement architecture. Composites have infinite applications including automotive, sports, aerospace, medicine, construction, and many others. The composite manufacturing process usually includes:

• prepreg — fiber architecture achieved through careful placement of fibers also called tape laying;
• impregnation — fibers and resins are comingled to form a composite; and
• consolidation — intimate contact is made between layers of fibers or lamina.

Composites can also use fillers, additives, and surface finish coatings depending on end-use applications. Lamination technique or process is another class of composite which involves manufacturing a material with multiple layers to achieve end-use properties like appearance and strength.

Technical Textile Reinforcement Structures

Braided Reinforcement Structures — Braided composites are at the forefront of the composite market due to their structural integrity and cost efficiency. The France-based Interreg North-West Europe (NWE) Program supported COBRACOMP project aims to develop, test, and validate a new automated textile braiding process to produce preforms for composite materials reinforcement. The organization displayed a section of its braider at ITMA. Higher mechanical performance is achieved with the innovative multilayer 3D axial braid assembly with more axial yarn, fiber fraction, and homogeneity. Composites expert Georges Cahuzac invented new architecture that has no gaps between unidirectional (UD) fibers, a bias to UD ratio of 5:4 equal to 80 per-cent and introduces four UD sections per layer. Front crash cone is an application that illustrates that this braid can absorb lots of energy due to the presence of UD yarns which help resist crack propagation.

Zhejiang Benfa Technology Co. Ltd., China, showed a hose braiding machine at its stand. The braids produced from this braider are used as high-pressure wire hoses, Teflon hose, high pressure rubber hose and car air-conditioning hose, among other applications. Its machinery can braid using stainless steel and aluminum wire as well as nylon, polyethylene and composite yarn material.

Germany-based HERZOG GmbH displayed SE 1/32-432 and SE 1/32-266 rope braiding machines. Its GF 1/32-120 glass fiber braiding machine along with the take-up is used for producing fiberglass sleeving and for overbraiding hoses with fiberglass.

Nonwoven Reinforcement Structures — Germany-based AUTEFA Solutions converts carbon fiber waste by recycling carbon fibers to carbon fiber nonwovens. If the waste is resin-free it can be directly processed on AUTEFA machinery; if not, the resin needs to be removed using pyrolysis. The Aerodynamic Web forming Machine Airlay K 12 can produce a nonwoven with isotropic fiber orientation and medium fiber separation. Autefa Solutions’ Carbon Card can produce incredibly good fiber separation with UD orientation. The fiber orientation, surface weight and width of the nonwoven can be adjusted using Crosslapper TOPLINER in combination with the card. Its Needle Loom Stylus can process 100-percent carbon fibers and enable mechanical web bonding. By adding a thermoplastic, thermal bonded nonwovens can be produced using Thermobonding Oven HiPerTherm. Autefa is the key supplier for carded-crosslapped needlepunch lines, aerodynamic web forming technology, thermobonding lines and spunlace lines.

Dilo Group’s MicroPunch technology made its debut at ITMA 2023.

Germany-based Dilo Group demonstrated brand new MicroPunch technology as alternative to hydroentangling. This is a “green” needling technology for lightweight nonwovens right from bale opening to final winding step. The technology is classified green because the trimmed material can be recycled within the process therefore there is no fiber loss and no water is consumed. These lightweight nonwovens — in the range of 30 to 40 grams per square meter (g/m2) — may be used for applications including artificial leather and automotive, among other applications. Dilo’s inventions Hyperpunch and Cyclopunch have speed of 150 meters per min (m/min) and stroke frequency of 3,000 per minute. Dilo demonstrated the machine with a needle density of 45,000 needles per m per board, a barb depth of 20 to 40 microns, and throughput speed up to 140 m/min at 2,000 strokes/min. Dilo Group machines can also process aramids, glass fiber, P84® and polypropylene (PP), which is useful for composite applications.

Woven Reinforcement Structures — Germany-based Lindauer DORNIER GmbH’s A2 air-jet weaving machine debuted at ITMA 2023 and hence, its stall was very busy. This new machine provides improved efficiency, as well as enhanced flexibility and reliability to technical textiles. Electronically controlled systems monitor and control reliable weft insertion. DORNIER Composite Systems® is designed to produce high-quality reinforcement fabrics. World renowned, the P2 roving weaving machine produces reinforcement fabrics using carbon, glass and aramid fibers. Tritos® PP equipment manufactures multilayer textiles with complex structures for composite reinforcements using digital weave patterning, rapid rapier motion for low filamentation, and flexible shed geometry. Protos® TW is a tape weaving machine that can process strip-like materials such as fiber reinforcement tapes and films using zero twist feeder. Lastly, Protos® TP machine is used for UD tape which can be either be coated with a binder or impregnated with thermoplastic resin.

Switzerland-based Jacob Müller Group exhibited the Narrow Fabric Loom NFM 53 2/130, which can make spacer fabrics, tapes, rigid webbing and elastic ribbons with controlled thread transports suitable for all yarn types.

Knit Reinforcement Structures— COMEZ International, a member of the Jacob Müller Group presented the DNBF/EL-800, an electronically controlled raschel type warp-knitting machine that can produce 3D knitted fabrics, tubular fabrics and nets for the automotive industry. It operates at a higher speed compared to the previous models. Müller also offers the NH2 53 8/27 needle loom that uses the Z6 weaving system to make spacer fabrics suitable as reinforcements in lightweight composite materials and can provide good compressive stability by incorporating monofilaments.

Germany-based Karl Mayer Group showed new digital developments and applications of artificial intelligence to change patterns without making manual adjustments. It demonstrated the HKS 3-M ON, which is the fastest three-bar tricot machine and a compact warp knitting machine, as well as a warp knitting machine with magazine weft insertion to produce technical textiles with reduced weft yarn waste and increased working speed and width. The KM.ON dashboard is user-friendly and tackles the issue of global shortage of skilled workers. MULTI-MATIC® 32 Compact was the highlight in the warp preparation area. Karl Mayer also offers composite machines for producing biaxial and multiaxial textiles, fiber spreading lines and fiber reinforced thermoplastic tapes.

BIAXTRONIC® II can produce biaxial layer structures; COP MAX 4 can produce multilayer, multi-axial structures; MAXTRONIC® can produce high performance glass fiber composites; and COP MAX 5 can process carbon fibers and lightweight textiles. UD 500 AND UD 700 are fiber spreading machines that can produce fiber tapes from continuous filament yarns. SIM.PLY UD can produce tapes up to a width of 800 millimeters (mm).

IPCO’s ThermoPress HB —hybrid belts — double belt press for composite applications.

Impregnation, Coating, Lamination Lines For Prepregs & Composites

At ITMA 2023, Sweden-based IPCO AB highlighted its Thermo-Press Systems and Scattering Systems. IPCO’s scatter system can deposit powdered, granular and fibrous materials onto a carrier material up to 1800-mm-wide. Applications include composites, nonwovens and textiles. ScatterPro F can scatter fibers like glass and carbon uniformly using key features such as a special agitator for uniform distribution, optimized scattering roller to hold the fibers, a rigid or adjustable doctor blade, easy change of the brush roller and a scattering roller with digital position display to adjust the distance between the two rollers.

IPCO manufactures double belt presses used in composites produc-tion. Its presses include ThermoPress TB, which has Teflon®-coated belts and counter pressure elements to make multi-layered materials, mixed thermoplastics, carbon fiber, glass fiber, and composite sandwich sheets. ThermoPress CB is used in making fiber-metal composites. ThermoPress SB is a high-pressure steel belt-based double belt press technology used to make high performance metal-plastic composites. IPCO has a 1,600-square-meter center of excellence testing center in Germany that has a full range of processes from impregnation, lamination, and consolidation to tempering and cooling. The company can consolidate prelaminate sheets and impregnate fibers with resin which can be applied in liquid, film, or powder form on a felt or nonwoven material.

Germany-based BRÜCKNER Trockentechnik GmbH & Co. KG, exhibited innovations for textile coating and finishing at ITMA 2023. Its finishing line for glass mesh fabric and for construction reinforcements is the Techno-line TT glass fiber finishing line. OPTI-COAT KA/KC coating unit has a simple and com-pact design with combined floating knife-/knife against cylinder unit. Woven and knitted fabrics can be processed for end-use applications including technical lightweight protection materials and air bags.

Since 1949, Germany-based Maschinenfabrik Herbert Meyer GmbH has been making fusing, laminating, and scattering machines and presses. At its booth a Technical Sales representative mentioned that the company has bonding technology for composites like honeycomb sandwich sheets and fiber reinforcement composites; and for technical textiles like powder coating and impregnation. For prepregs, the flow behavior of the thermoplastic adhesive is important as the fibers need to be optimally encapsulated. Prepreg makes semi-finished products for end-use components. For this application Meyer has laminating machines that can generate high pressure linearly as well as surface wise. These prepregs can be used in televisions, notebooks, mobile phones, the aviation and automotive industries and for lightweight construction components. The KFK-P is a high pressure at elevated temperatures laminator used for processing fiber reinforced composites and other composites. Some technical highlights are hydraulic belt tension, hydraulic pressure by the means of pressure rollers and pneumatic surface pressure.

Meyer also offers a production line to make glass mats from glass rovings with the help of a cutting unit that cuts the roving into a defined length and spreads them evenly on a conveyor belt. Then a powder scatterer distributes the adhesive powder. An infrared preheating station helps fast melting of the adhesive to increase the production speed. Applications of the lamination and scattering machines are tempering and sintering of UD-/Machine Direction (MD)-layers, coating of UD-tapes, thermoconsolidation of UD-/MD-layers, connecting of single UD-tapes to large-area layers and, production of UD-/MD tapes in different effective direction.

Meyer’s thermoconsolidation press is suitable for carbon layers or any other material that requires high processing temperatures. The temperature can go up to 400°C.

Italy-based Matex S.r.l. has expertise in coating and finishing machines since 1973. At ITMA 2023, it showed a reverse cylinder coating head with features including independent driving system, tension control for adjustments with lightweight materials, trays for continuous recirculation, gap control using digital display, removable roller and cleaning tray which help with easy maintenance. The machines can do direct coating and transfer coating with a knife or rotating cylinder. Matex also has impregnation equipment such as Rotocomp for impregnation of composite substrates with carbon, glass, or aramid fibers. Rotocoat, Rotomark, Rotopharm, and Rotosplit are its lamination lines. End-use applications include soundproofing for offices, automotive and filtration.

Zappa Macchine S.r.l., Italy, was founded in 1860, and its long history brings experience and knowledge in hot melt lamination, coating, impregnation, calendaring, flock, prepreg and powder scattering. With coating head model HSM-2, blade in air and blade over roll coating is feasible. This technology is used in applications like prepregs, technical textiles and traditional textiles. The head can be customized per a customer’s requirements and has accurate blade gap settings. Width ranges from 500 to 6,000 mm, and mechanical speed is 0 to 40 m/min. The company also highlighted a rotogravure head that can coat different water-based resins on a fabric for the Brinatura “frosted” effect. It can apply micro-dots of resin using different engraved rollers. The head also may be used to apply special effects such as lamination with metallized film. The web width of this machine is 1,600 to 3,600 mm and mechanical speed is 0 to 40 m/min.

Italy-based COS.T.A. S.r.l. designs industrial lines for applications including synthetic leather, tannery, carbon fiber dip coating and furniture edge banding. COS.T.A. offers high-performance dip coating technology for carbon fiber, fiber-glass and Kevlar® that can be used for prepreg preparation. The company also has lab lines for research and development, self-adhesive technology, technical textile laminations and hot melt lines.

Germany-based A. Monforts Textilmaschinen GmbH & Co. KG presented the Montex®Coat coating unit which can coat using air knife, roller knife, magnetic doctor blade, rotary screen printing, paste and foam coatings — hence, can offer a lot of tailor-made solutions from one source. It has improved features including saving setting time, handheld control device, and automatic edge limiters for immediate adaptation to changing coating widths.

At ITMA, Van Wees had samples of high performance-fibers for the production of composites used in applications including sailcloth and flexible protection materials like bullet-resistant vests.
Source: Photo taken at Van Wees booth during ITMA

The Netherlands-based Van Wees UD and Crossply Technology B.V. entered the composite industry in 1994. The company is proud to be the only company to offer UD and multi-axial cross-ply technology. It manufactures UD thermoplastic resin impregnation machines, fabric prepreg (thermoset) impregnation machines, crossply machines, lamination lines, creels and other custom-built machines. It also offers product and development services at its Research and Technology Center (R&TC).

Van Wees displayed a variety of samples at ITMA including glass fiber PP, a crossply roll of carbon fiber PP; materials used for soft applications such as sailcloth and flexible protection materials like bullet resistant vests; and flax fiber reinforced polymer.

At Van Wees, technology offers a spreading section, impregnation section, and final winding using tension control on every yarn. The fibers that may be process on these machines are glass, carbon, aramid fibers and ultra-high-molecular-weight polyethylene (UHMWPE), which are converted to UD tapes using dispersion resin. These tapes are then used as raw materials for the multiaxial UD or crossply machines to make composites with various fiber orientations and layers.

The three machines Van Wees offers for impregnation of fibers and fabrics are dispersion impregnation, thermoset impregnation by reverse roller coater, and thermoplastic resin impregnation with inline extruder. The dispersion impregnation is stable with high impregnation due to easy penetration at the speed of 20 m/min. The thermoset prepregs are made in one step process by reverse roller coater at a speed of 3 to 10 m/min. For impregnation of thermoplastic resins, the film is made by melting the polymer in an extruder and metering the film thickness on impregnation roller at a speed of 3 to 15 m/min.

VanWees also has equipment for making flakes, which can be compression molded on a press to make make products. For flat panels, it has heated tables on which the materials is consolidated using vacuum pressure only. All the equipment used in-house is commercially available.

Van Wees also has expertise in testing and consultation, and has inspec-tion machines at its research facility, as well as drumwinders that can mimic the processes as it would take place in actual crossply and UD production.

Texmer creel
Source: Photo taken at Texmer booth during ITMA

Accessories For Enhancing Composite Production

Texmer GmbH & Co. KG, Germany, specializes in developing and supplying creels for all winding materials that can be pulled off both tangen-tially and overhead. A motor on the creel calculates and controls tension from full bobbin to empty bobbin. The company developed patented tension balancing systems that provide a substantial number of adjusting possibilities. Texmer has experience with high-quality pneumatically braked creels characterized by short response times, high operational safety and extremely low wear. Diameter control secures trouble-free operations. These creels are made for technical yarns and tapes. Specially coated guide elements help reduce carbon fiber damage to a minimum and increase process reliability. It is particularly important for low yarn tension glass roving creels to have exact control. Pneumatic mandrels have unrolling solutions for glass fiber roving without a twist. The yarn comes in minimum contact with the Texmer creel and can be drawn as far as possible without deflection. A polyacrylonitrile (PAN) precursor creel can hold bobbin diameters up to 1,000 nanometers and weight up to 500 kilograms (kg). All positions are individually controlled. Once the controlling unit of the electronically controlled creels is adjusted it will maintain a required thread tension by accelerating or decelerating the motor during operation.

Topocrom GmbH, Germany, offers Topocrom® surface structure for wear and corrosion protection that helps extend the service life of machine parts. It is challenging to process technical fibers such as carbon, aramid, glass and basalt fibers because they can be very abrasive. If the fiber filaments break, tear, stick or splice it can lead to interruptions in automated operations, which often happens because of the unsuitable surface of the guiding element. Topocrom employs a chrome electroplating process. Base materials suitable for chrome plating include steel, steel alloys, cast iron, stainless steel, copper, copper alloys, titanium and titanium alloys. The roughness of the surface can be changed by altering the current during electroplating and Topocrom coating can prevent splicing, wrapping, adhesion of filaments, reduce dust formation and increase wear resistance.
Van Wees also develops creels with features such as regulated yarn tension with manual or automated adjustment for each individual row or the entire creel. This is helpful when processing yarns like nylon, polyester, aramids, and UHMWPE. In the case of carbon fiber, it supplies special eyelets to avoid twisting the tows. Van Wees’ glass roving creel can handle heavy rolls up to 25 kg.

Switzerland-based Retech AG provides heat treatments for filament yarns with high-quality components, machines and in-process monitoring systems. The company demonstrated intriguing sustainable advancements for heated godets that are crucial in manufacturing synthetic yarns. Retech presented the new “blue line” tem-perature controller UCR-6/CR-7 and transmitter UTR-4 /UTR-4A. The new devices are sustainable as they con-sume less energy, which reduces the overall cost while producing exceptional results. Retech presented its innovation in a customized draw frame with godet, Internet of Things (IOT) technology and (super) slow speed drive concept. It presented vibration measurements, bearing temperature display and induction temperature measurement; and its demonstration unit explained the negative temperature effects and vibrations. The newly developed algorithms, monitoring devices and sensors can achieve higher productivity, less downtime and a longer lifetime.

Germany-based Osthoff-Senge GmbH & Co. KG demonstrated one of its singeing machines that often is a first step in finishing. Woven and knitted fabrics comprised of cotton, viscose and glass fibers may be treated. The display machine was five feet wide and ran at a speed of 100 m/min.

Conclusion

Textile composites play a significant role as innovations in lightweight performance materials used in sleeves for electron volt batteries or artificial leather for high-end fashion brands, among other applications. The theme for ITMA 2023 was “Transforming the World of Textiles” and the event featured 20 sectors of innovations including composites, although composite technologies remain a relatively small focus. Some companies specialize in composite technologies, while other companies are focused on manufacturing such as braiding, nonwovens, knitting and woven reinforcement that may be used in composite applications. At ITMA, several companies demonstrated the ability to process high-performance fibers on their machines, provide research and development consultation and testing and contract manufacturing. Overall, this year’s ITMA unveiled remarkable advancements in improving process sustainability by reducing waste and adding smarter and faster technologies to make machines more automated and efficient.

References:

1 Romeo RIM. (n.d.). What Are Composites? – Romeo RIM. Retrieved July 19, 2023, from https://romeorim. com/what-are-composites

Editor’s Note: Prateeti Ugale is a Ph.D. student in Fiber and Polymer Science and a research and teaching assistant at NC State University’s Wilson College of Textiles, Raleigh, N.C.

September/October 2023

 

Celebrating Georg+Otto Friedrich — KARL MAYER’s First Warp Knitting Customer

(right to left): Julian Schubert, sales manager at KARL MAYER; Philipp Seubert, executive board, GOF Industrial; Kai Trippel, executive board; and Jonas Menzel, Procurement from Georg+Otto Friedrich

OBERTSHAUSEN, Germany — September 27, 2023 — The KARL MAYER GROUP is proud of its long-standing partnerships. Some of them have been in existence since the very beginning, and one of them recently celebrated a round anniversary: the first warp knitting machine produced by the innovative textile machine manufacturer based in Obertshausen was sent on 10 September 1948 to Georg+Otto Friedrich, a leading producer of warp-knitted digital printing fabrics and technical textiles in the neighboring town of Groß-Zimmern. As a token of its solidarity, the loyal customer has donated an old treasure — the seventh machine built  to KARL MAYER’s Academy.

Setting trends in warp knitting

After the first investment 75 years ago, the two companies have grown continuously together and have advanced warp knitting. Georg+Otto Friedrich has tested many new KARL MAYER models in live operation in its workshops, thus helping them to be successful. In addition, valuable impulses for further developments came from the resourceful textile producer. “280″ were considered technically unfeasible for a long time. Today KARL MAYER builds even wider machines,” recalled Managing Director Kai Trippel of an example of this.

Today, Georg+Otto Friedrich is the largest customer of the model of KARL MAYER’s most modern generation of tricot machines, the HKS 3-M ON. Just in December 2022, the last machines of an extensive investment project were put into operation. The company produces around 650 tons of warp-knitted fabrics per month at its sites in Groß-Zimmern in Hesse and Limbach-Oberfrohna in Saxony. In Neresheim in Baden-Württemberg, there is a separate company for textile finishing. Thanks to the high technical level of the machines and the know-how of the employees, the textile products made by Georg+Otto Friedrich are of the highest quality.

Leadership position obligates

In addition to high quality, the company focuses on sustainability. “As the leading manufacturer of textile solutions in Europe and as the world market leader in the field of digitally printable warp-knitted polyester fabrics, we have a special responsibility for environmental and social issues,” explained Philipp Seubert, managing director of GOF Industrial. Georg+Otto Friedrich, for example, was a pioneer in the processing of recycled materials, starting with the first processing tests around ten years ago. It then took a good five years to develop the market for this new material.

“We first had to explain a lot why a PET recycled in Europe has a much smaller carbon footprint and what effort is involved in collecting, sorting, cleaning, etc,” said Philipp Seubert. Today, complete product lines and diverse articles made from recycled post-consumer PET are offered. Of particular note here is DecoTex Blue, a sustainable textile developed by Georg+Otto Friedrich together with the SEAQUAL® initiative. The fabric consists of more than 60-percent SEAQUAL polyester fibers, made from recycled marine plastic. By participating in the PLANT-MY-TREE® reforestation program, the manufacturer also aims to completely offset the CO₂ footprint of its recycled textiles within a few years. By August 2023, around 6,000 trees had already been planted.

In addition to recycling, Georg+Otto Friedrich focuses on the topic of energy. “The solutions to many of today’s problems require energy. It is important to us to save electricity and use renewable energy,” emphasized Jonas Menzel from purchasing. Looking over the hall roofs in Groß-Zimmern, it becomes clear that the company is serious about this: solar cells on the buildings as far as the eye can see. Around 30 percent of the energy required comes from the company’s own generation. The installed capacity can supply 800 households.

Georg+Otto Friedrich is therefore well positioned for the future. KARL MAYER Sales Manager Julian Schubert is looking forward to a continued bilaterally successful cooperation. He particularly appreciates the exchange at eye level.

Posted: September 27, 2023

Source: KARL MAYER GROUP

September/October 2023

Macy’s Inc. has joined the U.S. Cotton Trust Protocol, Memphis, Tenn.

PrimaLoft Inc., Latham, N.Y., recently launched PrimaLoft® Utility, a resilient, man-made insulation material designed to excel in harsh conditions and last longer.

Blue Ridge Home Fashions, Irwindale, Calif., has introduced a new basic bedding collection —comprised of filled pillows, comforters, mattress pads, mattress toppers and blankets — featuring CiCLO® sustainable textile technology from Intrinsic Advanced Materials LLC.

HanesBrands, Winston-Salem, N.C., has announced a multi-year licensing agreement for the design, production and distribution of Champion and C9 Champion outerwear in North America with New York City-based G-III Apparel Group Ltd.

Navis TubeTex, Lexington, N.C., is now a sales agent in Canada, Honduras and the United States for Germany-based SETEX a producer of controllers, sensors and software solutions for textile dyeing and finishing operations.

Cone Denim®, Greensboro, N.C., has joined the CIRCULOSE® Supplier Network. It reports it is the first U.S.-based denim mill to join the network, which comprises yarn and textile manufacturers committed to streamlining and increasing the production of Circulose, a cellulosic fiber made using waste material.

Switzerland-based electronic warp feeding system provider Crealet AG is celebrating its 20th anniversary.

Aurora Specialty Textiles Group, Yorkville, Ill., recently celebrated 140 years of continuously manufacturing products in the United States.

New York City-based denim brand Madewell has become a bluesign® System Partner.

Montreal-based Gildan Activewear Inc. recently published its 19th Environmental, Social and Governance (ESG) report, which highlights the companies 2022 performance against
key targets.

September/October 2023

September/October

Brent Hyder has joined Denver-based VF Corp. as chief people officer. He reports to President and CEO Bracken Darrell.

The Italy-based Association of Italian Textile Machinery Manufacturers (ACIMIT) has appointed Giorgio Calculli managing director. He replaces Federico Pellegata, who after 25 years as managing director, is moving into a role as CEO of ACIMIT Servizi S.r.l., a company that provides services to its associated member companies to help promote and support the Italian textile machinery at home and abroad.

The board of directors at Albany International Corp., Rochester, N.H., has named Gunnar Kleveland the successor to Bill Higgins as president and CEO. Higgins is retiring, but will remain on Albany’s board.

Tom Gyles is the new senior vice president, Global Distribution Network in Canada, for Portland, Ore.-based Columbia Sportswear Co.

Standard Fiber, Foster City, Calif., has named Trina Solomon to the new position of vice president, marketing and brands.

Daren Abney was recently named executive director of the U.S. Cotton Trust Protocol.

Dr. Sanjay Patel has joined Navis TubeTex, Lexington, N.C., to lead the chemical applications product line and strengthen the company’s commitment to providing sustainable chemical finishing solutions.

San Francisco-based Gap Inc. has named Chris Blakeslee president and CEO of Athleta.

Kontoor Brands, Greensboro, N.C., has appointed Pete Kidd executive vice president and chief human resources officer.

Cincinnati-based Standard Textile Co. Inc. has named Jonathan Simon executive vice president of Global Growth and Strategy.

Markku Koivisto, senior vice president, Europe and R&D at Helsinki-based b, has been named interim senior vice president, Americas. Lynda Kelly, senior vice president, Americas and Business Development, has left the company for medical reasons. The company has started the search for a new senior vice president, Americas.

September/October 2023

Soft, Sustainable ZZZs

Cotton Incorporated’s RESTech COTTON™ technology imparts increased softness, moisture management properties and durability to cotton sheeting for a more restful night’s sleep.

By Rachael S. Davis, Executive Editor

When polled by Cary, N.C.-based Cotton Incorporated as part of a Home Textiles Survey, 79 percent of respondents said quality is a priority when choosing sheets, 70 percent actively seek 100-percent cotton goods and quality bedding translates to better sleep according to 87 percent of people polled. In addition, 71 percent express a desire for environmentally friendly textiles.

Cotton Incorporated’s latest innovation, RESTech COTTON, uses advanced chemistry to create a 100-percent cotton sheeting solution that checks all the boxes to meet those consumer concerns and produce a restful night’s sleep. The company reports the technology brings comfort, durability and softness to sheeting products, while remaining an ecofriendly choice because it’s biodegradable and recyclable.

According to Cotton Incorporated, RESTech COTTON-treated sheets are up to 40-percent softer than untreated cotton sheets, with durability that beats polyester and rayon when tested against ASTM D3885 – Standard Test Method for Abrasion Resistance of Textile Fabrics. In addition, RESTech boosts the natural moisture management and thermoregulating properties of cotton, and  may dry up to 50-percent faster on the skin, thus providing cool comfort for hot sleepers. Cotton also is a naturally hypoallergenic fiber that is gentle on the skin for people with skin sensitivities.

The technology is applied as a finish using a standard pad-dry-cure application after the sheets have either been bleached to a finish white or dyed.

According to Mark Messura, senior vice president, global supply chain marketing for Cotton Incorporated, the cotton-specific innovation was designed for practical implementation and may be licensed from the company with the only requirement that it be used on 100-percent cotton fibers. However, there may be further applications for the technology that will be introduced in the future.

“RESTech COTTON technology takes the best attributes of cotton and cotton finishes to create a unique, durable product with non-fluorine technology,” noted Dr. Hongqing “Mike” Shen, vice president and managing director of product development and implementation for Cotton Incorporated. “It allows sheets to hold less moisture, dry more quickly, maintains remarkable softness and comfort. This combination makes it a triple threat.”

“With our RESTech COTTON technology, we’ve captured the timeless comfort of cotton and enhanced it with modern innovation, redefining the possibilities of a good night’s sleep,” said Jennifer Lukowiak, director, supply chain marketing, for Cotton Incorporated. “This technology is a perfect choice for those seeking not just better sleep but a more sustainable one. It’s another proud mile-stone in our continuous effort to promote the natural excellence of cotton.”

For more information on RESTech COTTON™ please visit cottonworks.com /restech-cotton.

September/October 2023

PAKA® Launches Performance ¾ Crew Socks

BOULDER, Colo. — September 28, 2023 — PAKA®, an innovator in alpaca fiber apparel, is excited to announce the launch of its new Performance ¾ Crew Sock. Since its launch in 2017, PAKA has been setting the standard for alpaca-based athleticwear. The Performance ¾ Crew Sock highlights their latest innovation with the natural fiber, incorporating the finest alpaca yarn diameter the company has ever used to create an ultra-soft and highly durable multisport sock.

Alpaca fiber is a performance powerhouse — it’s naturally odor resistant, moisture wicking and thermoregulating. Alpaca’s impressively low moisture retention rate of 8 percent (typical wool compares at an average of 18 percent) helps to keep feet dry and comfortable, and avoids the moisture and friction buildup that can lead to blisters. Alpaca fibers also contain a keratin protein with natural antibacterial properties that make it incredibly difficult to make these socks smell.

Paka takes these inherent features of the fiber to the next level with intelligent design. The Performance ¾ Crew Sock is crafted with a snug rib-knit design to avoid shifting and friction, a breathable mobility mesh where the ankle meets to the foot to promote ventilation, compressive arch support, and strategic extended heel padding for high-impact zones.

“We wanted to create a versatile performance sock that could stand the test of intense biking, hiking and backpacking. We went all the way back to refining the yarn in Peru, creating a much finer thread count that would knit into a high-compression rib,” said Kris Cody, PAKA Founder and CEO. “We went through probably 15-20 prototypes, sending them out on treks until the sock encompassed everything our community needed.”

The Performance ¾ Crew Sock is available for $24 in Black, Charcoal, Blue, Walnut, Quail and Forage colors

Posted: September 27, 2023

Source: PAKA

PT. Embee Plumbon Tekstil (Indonesia) Joins International Textile Manufacturers Federation (ITMF) As Corporate Member

ZURICH — September 27, 2023 — Since PT Embee Plumbon Tekstil started its operations in 1999 in Indonesia the spinning company has evolved into one of the leading spinning companies in the world. Embee pursues a customer-focused approach by continuously upgrading its technology, by producing in a skillful manner, and by conducting comprehensive training programs. This approach allows setting the highest standards in product and process development.

Christian Schindler, director general of ITMF, stated that: “ITMF is very fortunate to welcome such a renowned spinning company as a new Corporate Member in its membership. companies like Embee demonstrate how important it is to offer quality products that the markets demand at a competitive price. ITMF offers Embee an environment that can be seen as sounding board. This helps Embee to better understand the company’s position in the global competition, to learn about the prevailing trends in the global industry and to identify suitable suppliers and customers”.

Vijay Agarwal, president director of PT. Embee Plumbon Tekstil, commented that: “by joining ITMF we become a part of a unique universe of the global textile supply chain. It is important for Embee to look beyond the daily business and develop a feeling for the evolution of the industry. A forum like ITMF offers just that. To have access to ITMF’s data, survey, webinars, and its international network across the entire textile value chain provides intangible value for us. Engaging with colleagues from around the world in an atmosphere of trust is very valuable.”

Posted: September 27, 2023

Source: International Textile Manufacturers Federation (ITMF)

MAS Holdings’ Fabric Park Redefines Sustainable Manufacturing

THULHIRIYA, Sri Lanka — September 27, 2023 — In an era where environmental sustainability is transitioning from choice to necessity, MAS Fabric Park (MFP) stands out as a revolutionary force in Sri Lanka’s apparel industry. Nestled in the tranquil environs of Thulhiriya in the Kegalle District in Sri Lanka, this 165-acre privately owned apparel-intensive free trade zone is not just a manufacturing hub; it’s the result of the MAS Group’s unwavering vision for sustainability, a testament to the Group’s dedication and a shining example of business harmonizing with the environment.

A Vision for Positive Change

MAS Holdings, the parent company of Fabric Park, has long embraced a vision of sustainable growth and positive transformation within the Company’s ethos, which is seen throughout the organization and its initiatives. The belief is that sustainability goes beyond profit; it’s about fostering positive change in the world, making a difference for the communities around the locality, and leaving a lighter footprint on our planet.

Murad Rajudeen, CEO of MAS Fabric Park

MAS Fabric Park’s CEO Murad Rajudin explained that MFP provides partner plants with centralized utility services including treated water, raw effluent treatment for factory-discharged water, energy in the form of electricity distribution from the main grid, steam, and thermic heat, based on the location of the plant.

“MFP plays a pivotal role in the intricate supply chain of MAS Holdings. Firstly, it is a strategic hub for fabric development and value addition, contributing significantly to the vertical integration of the MAS supply chain. This integration is crucial in a global industry where speed, efficiency, and reducing carbon footprint have become paramount. By offering state-of-the-art infrastructure and facilities for fabric manufacturing right within Sri Lanka, MFP not only streamlines operations but also aligns with the global demand for responsible and sustainable manufacturing practices.”

Comprehensive Water Management, Waste Reduction, and Value enhancement

Sustainability is deeply ingrained in every facet of MAS Fabric Park’s operations, notably in its approach to IPZ’s overall water footprint management, centralized effluent treatment, and waste management operations. The Park introduced a uniquely designed centralized raw wastewater collection and combined treatment system, which strictly adheres to global-level Zero Discharge of Hazardous Chemicals (ZDHC) standards with respect to the fully treated discharges of the zone.

Water Treatment Plan at MAS Fabric Park

MFP General Manager (Hydro & Sustainability) Harsha Deraniyagala says, “MFP is leading the way in centralized water management systems, and centralized effluent treatment operations whilst meeting global standards with a present capacity of 9,000 cubic meters per day. These innovative systems, operating at such high capacity, eliminate the need for redundant in-house treatment plants for partner facilities, effectively optimizing resources and curbing environmental impact within the zone.”

In addition, MAS Fabric Park has pioneered the sustainable management of textile “sludge”, which is a globally concerned area related to the industry. Through sustainable solar and thermal drying-based reductions, and dried sludge co-processing for energy recovery leading to final eco-brick production, it has significantly reduced the waste footprint of the zone whilst ensuring circularity within the entity. Even the ultimate byproduct of textile wastewater treatment sludge finds purpose in products like the Eco Brick, used in constructing the chalets at MAS Athena and also across other construction needs of the entity, whilst biological waste is being diverted for composting for nurturing plants, aligning seamlessly with the concept of waste-to-energy and waste-to-value. These initiatives contribute for the significant reductions of respective Carbon Footprints usually linked with the water, wastewater, and resultant large-scale environmental engineering operations. The fully equipped, ISO IEC 17025 accredited water quality laboratory and the research center support the related quality assurance and compliance aspects throughout the respective value streams.

Solar Revolution – Clean Energy and Carbon Footprint Reduction

The path to sustainability at MAS Fabric Park was not without its share of challenges. In its early stages, the substantial investment required for clean energy battled with an unfavorable national electricity tariff, resulting in a low return on investment (ROI) for green projects. However, a turning point came with the introduction of the “Sooriya Balasangramaya” national solar initiative, which sparked a newfound interest in clean energy among investors, both industrial and domestic.

Nandana Dissanayake, Deputy General Manager of MAS Fabric Park

Deputy General Manager Nandana Dissanayake proudly affirms, “Our 24 MW solar capacity is a groundbreaking achievement in Sri Lanka’s renewable energy landscape, decreasing our carbon footprint by 20 tons annually.” MFP wholeheartedly embraced the shift towards clean energy, directly addressing its carbon footprint. Today, it stands at the forefront of rooftop solar installations with an impressive 24 MW of solar capacity spread across its facilities—a milestone that solidifies its status as the largest multi-site rooftop solar project in Sri Lanka under a single business entity.

Beyond Industrialization – Analog Forest and Biodiversity Restoration

One of the most striking aspects of MFP’s sustainability journey revolves around its “Thuruwadula” analog forest. Analog forests represent human-crafted natural ecosystems aimed at reclaiming land lost to agricultural expansion. Thuruwadula, spanning 9.7 acres serves multiple roles as a sanctuary for preserving biodiversity, a model for adapting to climate change and a valuable educational resource.

Within the confines of Thuruwadula, endangered endemic plant species have discovered a safe haven from extinction. The flourishing growth of Ayurvedic and medicinal plants not only benefits the environment but also has a positive impact on local communities. Furthermore, the forest provides a habitat for numerous animal species.

Thuruwadula also plays a crucial role in enhancing rural communities, both socially and economically, by promoting species that offer sustenance and marketable products. While it typically takes up to 80 years for an analog forest to evolve into a rainforest, Thuruwadula, situated in a dry zone, is already displaying approximately 20% of the characteristics of a natural forest. This unique ecosystem is home to an impressive variety of wildlife, including 25-35 bird species, 10 butterfly species and 15 snake varieties, as well as deer, mouse deer, porcupines, rabbits and other fauna.

Long-Term Commitment and Future Prospects

“MFP plays a critical role in not only the MAS Supply chain but also the Sri Lankan apparel industry’s supply chain,” says Rajudin. “Our commitment to sustainability is unwavering given that we have set ambitious goals to reduce Greenhouse Gas Emissions by 25% by 2025.” With an annual consumption of approximately 230 million kWh of electricity from the national grid, the shift towards clean energy has already made a substantial impact, reducing carbon footprint by 20 tons annually.

In an industry often criticized for its environmental impact, MFP is a role model of change. It is a reminder that we can reduce our carbon footprint, restore ecosystems and build a brighter future for generations. It’s a symbol of hope, proving that businesses can be forces for good and that a sustainable future is within our grasp.

As for MFP’s future, the journey is far from over. The Park plans to expand its solar capacity and continue its role as a leader in sustainable practices. It’s not just about meeting today’s environmental standards; it’s about setting new benchmarks for tomorrow.

Posted: September 27, 2023

Source: MAS Fabric Park (MFP)

PLEVA Gmbh: Weft-Straightening At ETV Textilveredlung

EMPFINGEN, Germany — September 27, 2023 — A high quality fabric is an essential requirement for any finisher who intends to ensure a consistency in quality and resource-efficiency. A particularly important quality criterion is fabric with straight weft and course.

The German textile finishing company ETV Textilveredlung produces for various areas of application a wide variety of articles and qualities. Their customers are from the automotive sector as well as from sportswear, building materials, protective clothing, home textiles, medicine and filtration. This implies the use of completely different fibers (cotton, polyester, mohair, polyamide, aramide and blends), different fabric weights from 80 to 800 g/m2 and different fabric widths in a range from 1000 to 2800 mm.

Despite the huge variety in the portfolio, the goal and claim of ETV Textilveredlung is to produce high quality, straightened fabrics without distortion at all times while maintaining easy, intuitive operation.

Fitted to these needs the well-known German manufacturer PLEVA gives with the automatic weft- straightener SL smart including the unique high- tech traversing camera technology the optimum solution and offers the finisher several advantages.

The user-friendly, self-explanatory interface displays all important information at one glance. This enables to work with maximum efficiency and to react to the complex portfolio with the integrated recipe management for sophisticated straightening. The well-established advanced traversing camera with many measuring points across the fabric width ensures the most accurate straightening. In combination with the fast reaction time of the rollers, it allows best straightening results. Furtheron the machine design is fitted to even the harshest working conditions and optimized for easy cleaning and low maintenance.

Dirk Tunney, COO ETV Textilveredlung is satisfied and said: “Very good straightening results have been achieved for all articles. Even in the case of very special fabric designs/structures, the stored recipes always deliver a good result. The positive experiences in the use and easy handling of the SL smart straightening machine (which is in use since 2021) have prompted us to install a new PLEVA high-tech straightening machine in March 2023. We can recommend PLEVA with a clear conscience.”

Besides those advantages, also a positive ecological impact is achieved: Due to the first-time-right-principle, only one round through the production line with the fabric is needed to produce directly the aimed result. This saves energy and valuable resources. In addition, due to the higher quality of the goods, there are no more costly readjustments or wasted fabrics and complaints can be reduced drastically. This is not only good for textile finishing companies and customers, but also for the environment.

Posted: September 27, 2023

Source: PLEVA GmbH

Techtextil And Texprocess Innovation Awards 2024 Submissions In Full Swing

Photo: Messe Frankfurt / Jean-Luc Valentin

FRANKFURT AM MAIN, Germany — September 27, 2023 — Looking forward with great anticipation to discover the sector’s latest and most technologically sophisticated products and processes, preparations for Techtextil and Texprocess from April 23-26, 2024, are in full swing. As integral parts of the two fairs, the Innovation Awards are genuine highlights. Two expert juries will select the latest, most intelligent and outstanding innovations from the sector thus ensuring that all award-winning companies and their best solutions are brought to the attention of all visitors to Techtextil and Texprocess 2024.

“We are proud to once again present the very latest innovations — the result of unrivalled research, products and technologies of the textile manufacturing and processing industry — at the coming Techtextil and Texprocess trade fairs. For our visitors, the Techtextil and Texprocess Innovation Awards are genuine highlights. Every two years, these innovations give a perfect demonstration of the future-oriented direction being taken by the industries in fields of development, such as efficiency, ultra-new materials, coatings and sustainable production, which incentivizes the market and illustrates the innovative power and spirit of the industries,” said Sabine Scharrer, director Techtextil and Texprocess.

The closing date for all entries for the 2024 Techtextil and Texprocess Innovation Awards is December 15, 2023. The awards are open to all companies, institutes, universities, polytechnics and individuals, regardless of whether they are exhibitors of Techtextil or Texprocess in 2024. The developments entered must have been on the market for max. two years, or be shortly before their market launch. From mid-December 2023, two juries of experienced international experts will thoroughly examine the products submitted and evaluate them in terms of criteria such as novelty, economic relevance, potential and creativity. The winning companies will be presented for the first time during a well-publicized ceremony during the first day of the fair in Frankfurt am Main on April 23, 2024.

Business relevant: Innovation Awards attract great attention

Award-winning companies and research institutes benefit from the high degree of attention for their innovations generated by the Techtextil and Texprocess Innovation Awards. For example, FibreCoat GmbH of Aachen, Germany, which received the Techtextil Innovation Award in the ‘New Technology’ category together with Deutsche Basalt Faser GmbH in 2022, reported: “Winning the Innovation Award represents a milestone for us because it has always been our ambition to be honored in this way. The Techtextil Innovation Award is the most prestigious award in the textile industry.” The two companies were chosen for the joint development of an aluminium-coated basalt fiber. According to FibreCoat, the new product means that electromagnetic shielding as wallpaper in buildings, such as hospitals or server farms, will be up to 20 times cheaper than conventional aluminium foil. Another attractive and particularly fast-growing market is shielding solutions for electric vehicles.

A positive response was also noted among the customers of Juki Central Europe after the company was selected for the 2022 Texprocess Innovation Award in the ‘New Technology’ category. The company won the award for its innovative AW-3S automatic bobbin thread winding and feeding device. The jury was impressed by the change from a manual to an automated process as another example of Industry 4.0 and said the device not only increases productivity but also reduces fatigue for sewing machine operating personnel.

Go-to-market boost for award winners

Italy’s Vérabuccia company was also one of the winners in 2022 and received the Techtextil Innovation Award in the ‘Performance Fashion’ category for its patented, innovative production process that enables fruit waste to be transformed into fashion highlights. In distinction to other vegetable leathers, which tend to imitate genuine animal leather, this process retains the original appearance of a pineapple skin. The jury honored the unconventional thinking of the Italian label whereby original fashions are created using unexpected materials. Currently, a year after receiving the award, Vérabuccia is working on opening up important markets with its patented process.

Starting shot for entries for 2024

Now, companies, institutes, universities, polytechnics and individuals have until December 15, 2023, to enter their inspiring, disruptive and innovative new products for the Techtextil Innovation Award 2024 or the Texprocess Innovation Award 2024 and have the opportunity to present their award-winning ideas on an outstanding platform in Frankfurt am Main during the first day of the fair on April 23, 2024. The juries are looking forward to judging the most innovative ideas emerging from the many exciting segments of the two industries.

Techtextil Innovation Award 2024

Submit entries at: https://www.techtextilaward.com/

Categories:

  • New Concept;
  • New Technology;
  • New Material;
  • New Application;
  • New Product;
  • New Approaches on Sustainability & Circular Economy;
  • New Technologies on Sustainability & Recycling; and
  • New Technology & Digitalization.

Texprocess Innovation Award 2024

Submit entries at: https://www.texprocessaward.com/

Categories:

  • Economic quality (cost minimisation, time / process optimisation, automation);
  • Ecological quality (climate protection, energy efficiency, sustainability, recycling, circularity);
  • Digitalisation and AI; and
  • Innovation for quality improvement.

The Techtextil and Texprocess trade fairs will be held from April 23-26, 2024.

Posted: September 27, 2023

Source: Messe Frankfurt Exhibition GmbH

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