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Covestro Expands Its Circular Economy Portfolio to All Major Regions

Petra Löwer (Germany)
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Covestro Expands Its Circular Economy Portfolio to All Major Regions

Covestro Expands Its Circular Economy Portfolio to All Major Regions

  • Covestro’s third-largest site, Baytown, Texas, USA receives ISCC PLUS certification
  • Focus on mass balanced products using recycled and bio-attributed raw materials
  • Already hundreds of products made from alternative raw materials in the circular “CQ” portfolio

With the ISCC (International Sustainability and Carbon Certification) PLUS certification of its production site in Baytown, Texas (USA), Covestro is significantly expanding the reach of its product portfolio for the circular economy. The Baytown site is the company’s largest operating facility in North and South America and its third-largest production site worldwide. This most recent achievement is significant, with all of Covestro’s major sites now certified by the internationally recognized ISCC PLUS standard. In addition to Baytown, certified sites include Leverkusen, Dormagen, Krefeld-Uerdingen (Germany), Shanghai (China), Changhua (Taiwan), Map Ta Phut (Thailand), Antwerp (Belgium) and Filago (Italy).

“Thanks to this new milestone, Covestro will soon be able to serve even more customers around the world with an easily accessible, more sustainable product portfolio,” says Sucheta Govil, Chief Commercial Officer of Covestro. “Customers in North America can now reduce their carbon footprint and Scope 3 emissions with drop-in, mass-balanced materials derived from recycled and bio-attributed products.”

Covestro is the first manufacturer of polyurethane and polycarbonate raw materials to receive this certification in the United States. The certification is an important milestone for both Covestro and the industries it serves, including the automotive, construction, comfort, electronics and appliance industries, which will now have access to ISCC PLUS-certified products made from more sustainable raw materials in North America.

To underscore how the products support both the company’s vision to become fully circular and its customers’ journey to greater sustainability, Covestro has introduced a specially branded product line with the suffix “CQ”. CQ, which stands for ʺCircular Intelligenceʺ, is a portfolio of products with attribution of at least 25 percent alternative raw materials derived from biomass or recycled plastics.

Covestro is also introducing the name Evocycle CQ for all evolutionary recycling processes. The first project of this kind is called Evocycle CQ Mattress and denotes an innovative chemical recycling technology for polyurethane mattress foam. Covestro currently has more than hundreds of CQ products and is continuously expanding this portfolio.

The polycarbonate production plant is part of Covestro’s Baytown site.

The ISCC PLUS certified products produced at Covestro’s Baytown facilities will include:

  • Methylene diphenyl diisocyanate (MDI) – used primarily in the production of rigid polyurethane foam for efficient insulation of refrigeration equipment and buildings
  • Toluene diisocyanate (TDI) – used in the production of flexible foam for the automotive and furniture industries
  • Makrolon RE – polycarbonate, a high-grade plastic used in the automotive, electronics and medical industries, among others
  • Hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPDI), Desmodur W and Desmodur Z – used in various coatings and adhesive applications

Covestro expects to begin supplying select ISCC PLUS-certified products from its Baytown facility in the second half of 2023.

The products will be produced using a mass-balance approach. Sustainable raw materials will be accounted for throughout both the value chain and production process, allowing for an accurate attribution in the end products. The existing production infrastructure will be utilized while reducing the carbon footprint of the final products.

ISCC is an internationally recognized sustainability certification for biomass and bioenergy. The standard applies to all stages of the value chain and is recognized worldwide.

www.covestro.com

 

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The Beginning of a New Era

Petra Löwer (Germany)
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The Beginning of a New Era

The Beginning of a New Era

Leibinger to introduce new Coding & Marking System at the interpack fair

Leibinger, the global innovation leader in Coding & Marking Systems, will be presenting an all-new Coding & Marking System at the interpack in Düsseldorf from 4-10 May 2023. With the ground-breaking innovation, the company is raising the benchmark and promising a new era in the marking of, for example, best-before dates and other codes on a wide range of materials.

“Especially in the case of cost-sensitive applications, such as in the F&B sector or in the Fast Moving Consumer Goods (FMCG) segment, it is decisive that the marking runs smoothly and without any interruptions. We have developed an entirely new Coding & Marking System that delivers exactly what it promises: absolutely worry-free printing. We will be bringing our innovation to life at our interpack trade fair stand,” reveals Christina Leibinger, CEO of Paul Leibinger GmbH & Co. KG and explains: “Also worthy of mention is the fact that the new system boasts the lowest operating costs in the industry. Just one of the reasons we are talking about a new era.”

 

For more information, visit www.leibinger-group.com.

 

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Lanxess Increases Sales and Earnings Significantly in Fiscal Year 2022

Petra Löwer (Germany)
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0
Lanxess Increases Sales and Earnings Significantly in Fiscal Year 2022

Lanxess Increases Sales and Earnings Significantly in Fiscal Year 2022

  • Sales up 32.6 percent year-on-year at EUR 8.088 billion
  • EBITDA pre exceptionals increase 14.1 percent to EUR 930 million
  • Acquired Consumer Protection businesses make positive contribution
  • Dividend proposal for fiscal year 2022: EUR 1.05 per share
  • Guidance for fiscal year 2023: Earnings expected to be at the 2022 level
  • Guidance for Q1 2023: EBITDA pre exceptionals of EUR 180 million to EUR 220 million expected
  • CEO Matthias Zachert: “Our strategy has stood the test – LANXESS has successfully managed a year with many adversities.”

In an environment characterised by many upheavals, LANXESS closed fiscal year 2022 successfully. The specialty chemicals company’s sales and earnings have increased significantly.

Group sales amounted to EUR 8.088 billion in 2022, up 32.6 percent on the previous year’s figure of EUR 6.101 billion. EBITDA pre exceptionals increased by 14.1 percent to EUR 930 million compared with EUR 815 million a year earlier. Earnings were therefore within the recently forecast range of EUR 900 million to EUR 950 million.

LANXESS passed on the significantly increased costs for raw materials and energy to the market in full via a successful increase of selling prices. The growth was especially driven by the Specialty Additives and Consumer Protection segments. The latter benefited in particular from the contributions from IFF’s Microbial Control business acquired at the beginning of July 2022 and from the U.S. company Emerald Kalama Chemical acquired at the beginning of August 2021. Lower sales volumes, especially in the final quarter of 2022, had a negative impact on earnings.

“We mastered 2022 successfully and increased our earnings despite the adverse conditions. This shows that LANXESS is weatherproof. Our strategy has stood the test. Thanks to our products’ leading market positions, we passed on the extreme cost increases in full. In addition, we sharpened our focus on specialty chemicals and reinforced our presence in North America. This provides additional stability and growth,” says Matthias Zachert, CEO of LANXESS. “However, 2023 will not be easier. The reduced demand that we already felt in the final quarter of 2022 is currently continuing in the new year. But I am convinced that we will make it through this economic slump thanks to our stable positioning.”

The EBITDA margin pre exceptionals reached 11.5 percent, against 13.4 percent a year ago. The decline resulted from the passing on of significantly increased costs and lower sales volumes.

Net income from continuing operations increased considerably by 60.0 percent and amounted to EUR 184 million, against EUR 115 million a year ago. This does not include the results of the High Performance Materials business unit, which was spun off and reported as a discontinued operation.

For 2023, LANXESS expects EBITDA pre exceptionals to be at the level of the previous year. At the same time, the Group anticipates a recessionary business environment in the first half of the year. The persistently high energy prices from the fourth quarter of the previous year will also make an impact at the start of 2023. The repercussions of the war in Ukraine and changes in raw material and energy costs remain sources of uncertainty. For the first quarter of 2023, LANXESS expects EBITDA pre exceptionals of between EUR 180 million and EUR 220 million.

www.lanxess.in

 

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Intelligent E-Mobility Solutions – Dieffenbacher at Jec World 2023

Petra Löwer (Germany)
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Intelligent E-Mobility Solutions – Dieffenbacher at Jec World 2023

Intelligent E-Mobility Solutions – Dieffenbacher at Jec World 2023

German machine and plant manufacturer Dieffenbacher will present intelligent plant concepts for producing composite components for e-mobility at booth M81 in Hall 5.

The company will highlight efficient and sustainable production solutions for components such as battery housings, battery box and underbody covers and protection sheets. Solutions will feature technologies ranging from SMC to LFT-D/GMT to wet molding, all with the hydraulic press as the core element of the production process. The new digital platform Evoris complements the forward-looking Dieffenbacher Jec World presence.

Marco Hahn, Director Sales of the Forming Business Unit at Dieffenbacher, will describe the company’s latest advances in a speech in Hall 5 on Wednesday, April 26, at 3:00 p.m. In “Turnkey plants and solutions for the production of composites components for E-Mobility,” Hahn will focus on SMC technology, wet molding, hybrid thermoplastic technologies and Evoris.

With Evoris, Dieffenbacher introduces a new approach to the digitization of hydraulic press systems and complete plants that takes advantage of artificial intelligence’s self-learning capabilities. With apps for condition monitoring and process analysis, plant operators gain transparency throughout the entire plant, can make important decisions more quickly and thereby improve processes, enhance machine availability and optimize maintenance. The results are production capacity increases and higher-quality components.

Additionally, visitors to the Dieffenbacher booth can expect to see a wide range of solutions for saving materials and energy. For example, Dieffenbacher short-stroke presses are designed for minimum energy consumption, high press forces and short cycle times. Presses close with small cylinders until just before the position where forming takes place. Thereafter, large cylinders act with the corresponding press force. This makes it possible to reduce the oil volume by 88% compared with conventional concepts. Adaptive accumulator management also optimizes energy consumption by automatically determining during the first press strokes the exact energy required for forming. For subsequent production cycles, the hydraulic drive accumulator is charged only to the corresponding required pressure level.

The special nesting method of the Dieffenbacher Fiberforge tape laying system helps plant operators use valuable raw materials as efficiently as possible. The Fiberforge can cut UD tapes at any angle between -45° and 45° to produce a contour with minimum waste. In one sample application, waste was reduced from 50% to 6.7% compared to using organo sheets. Dieffenbacher’s fully automatic SMC cutting and packaging system also reduces material consumption. By combining length and width cuts, it can generate all conceivable cutting patterns. In accordance with the desired lay pattern, the intelligent nesting control determines the cutting pattern and optimizes material use.

Nesting, Evoris and fully automated processes also ensure that Dieffenbacher plants effortlessly meet the high output requirements of e-mobility. “High output, best quality and reproducible manufacturing processes are the core requirements for e-mobility,” explains Marco Hahn. “We do not stop there. Our systems are also characterized by a consistent and uniform control concept for all line participants, cycle time optimization, maximum reliability, a unique visualization system and smart digitalization solutions,” he adds.

“We invite everyone to come and see our solutions at Jec World. We are looking forward to once again meeting our customers, partners and friends in person at our booth. Plus, we have an important milestone to celebrate. Founded in 1873, Dieffenbacher is celebrating its 150th anniversary this year,” Hahn concludes.

 

 

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One Year of Digital Print Folders: Hubergroup Print Solutions Takes Stock

Petra Löwer (Germany)
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One Year of Digital Print Folders: Hubergroup Print Solutions Takes Stock

One Year of Digital Print Folders: Hubergroup Print Solutions Takes Stock

About a year ago, ink manufacturer hubergroup Print Solutions launched the digital print folder for its offset portfolio, which is intended to enable customers to benefit from faster and more efficient production, among other things. Now the international ink specialist is taking stock: according to hubergroup, the reaction of customers to the digital solution was consistently positive, and they were impressed by the high colour accuracy that is possible thanks to the integration in the company’s own colour management system HDCC. In the meantime, the ink manufacturer has therefore already connected four hubergroup sites in Europe and North America to the production of digital print folders and switched a large number of customers to the digital solution.

Heinz Aumüller, who is responsible for prepress and process standardisation at hubergroup, recounts: “At the beginning, we expected that we would have to convince our customers to test the digital print folders – but the opposite has been the case: almost all the customers we have approached so far were immediately willing to test our digital print folder and switched to it after a short time. Some have even approached us proactively. The quality and colour accuracy of the digital print folders, combined with the more efficient and flexible production process, are simply convincing.”

The special feature of the hubergroup solution is the complete integration into the company’s own colour management system HDCC. This means that the digital print folders go through the same quality control processes as analogue print folders and are also verified against their analogue reference. In addition, customers benefit from a faster and more efficient production process, which is particularly noticeable in the creation of multiple copies and multi-site productions.

One of hubergroup’s biggest customers in Northern Germany that has already switched to digital print folders is the printing company H.O.Persiehl, which specialises in printing high-quality packaging. Marco Erdmann and Soehnke Schildt, Managers Sheet Printing Department at H.O.Persiehl Norderstedt, explain: “The digital print folders did not only convince us with their very high colour accuracy but also with their long durability without physical changes. Furthermore, the quick availability, even in larger quantities, and the fast response time is a great advantage for us in everyday life.”

To meet the demand for digital print folders, hubergroup is setting up a global network of locations. Currently, the inks manufacturer produces digital print folders at four sites: Celle (Germany), Nottingham (UK), Arlington Heights (USA) and Mississauga (Canada).

Heinz Aumüller adds: “Our global network of production sites and their centralised access to our HDCC opens up completely new possibilities for flexibility and resource availability. Especially in global colour projects, we benefit from location independence and digital print folder output at the destination. The next site integrations are already being planned so that our customers can benefit even more from our flexibility and efficiency.”

 

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Get in the Loop at Interpack 2023

Petra Löwer (Germany)
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Get in the Loop at Interpack 2023

Get in the Loop at Interpack 2023

Windmöller & Hölscher, specialist for machinery in the flexible packaging market, will present new developments regarding the industry’s hot topics: Efficient production, Circular Economy, and Digitization. The W&H slogan “Get in the Loop” and the infinity symbol illustrate the way these three topics influence each other and contribute to the success of sustainability.

W&H will highlighting new packaging solutions ready for the Circular Economy. On the booth there will be examples that are made for recycling as well as solutions that use high percentages of recycled materials. All solutions have been extruded and printed with W&H lines and have been tested for their practicability with W&H sack making lines or with converting partners. The subsidiary GARANT Maschinenhandel, a specialist in paper bag machines will focus on its technical developments in the field of paper packaging solutions for tomorrow. GARANT will also provide a comprehensive understanding of the innovative machines and their applications at an IN-HOUSE EXPO at the GARANT technical center in Lengerich. This will take place on May 4, 5, 8 and 9, 2023, from 10:00 a.m. to 3:00 p.m. each day.

Highlights from W&H

Circular Economy – Solutions ready for recycling
Recyclable pet food bags: W&H is showing two different approaches to this recyclable packaging solution, that is trending in the market: a blown film with a co-extruded EVOH barrier layer and one made with a functional barrier coating during the printing process.

Recyclable Coffee Pouch: A stretched MDO PE-film with an EVOH barrier layer combined with PE sealing film. With a total amount of only 2% EVOH this solution exceeds the current recycling regulations, while at the same time providing the barrier properties for oxygen and water vapor required for this kind of packaging.

Circular Economy – Solutions using recyclates

PE Valve Sack: All new film recipe with 30 % post-industrial material that displays similar mechanical properties as a conventionally produced film.

DIGITIZATION

RUBY App: With the IoT system RUBY from W&H, the value chain can be digitized and the data used to monitor, automate and improve packaging production. Now it’s even easier with the new RUBY app: keep an eye on the production – no matter wherever you are.

Highlights from GARANT Maschinenhandel

As a servo champion, GARANT’s carrier bag machine TRIUMPH 5-F6 produces high-quality carrier bags with flat or twisted handles with significantly reduced changeover times and increased output.

With the e.BAG series, GARANT offers demand-oriented machines especially for e-commerce packaging. Whether flat and satchel bags, block bottom bags or cross bottom bags – the e.BAG series offers the possibility to select a machine that meets the requirements for paper shipping and return mailer bags.

The highlight of GARANT’s technical developments is the exclusive premiere of the latest cross bottom bag machine (based on the renowned TRIUMPH 5-F6). It carries cost effectiveness for compact cross bottom bags to a new level, with over a dozen options for additional modules. The cross bottom paper bags are ideal for applications in the hygiene sector and are compatible with common filling stations.

www.wuh-group.com

 

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Interpack 2023: Constantia Flexibles Highlights Its Materials’ Runability

Petra Löwer (Germany)
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Interpack 2023: Constantia Flexibles Highlights Its Materials’ Runability

Interpack 2023: Constantia Flexibles Highlights Its Materials’ Runability

Constantia Flexibles, a leading provider of packaging solutions, is proud to announce its contribution to the trade fair INTERPACK from May 4-10, 2023, in Duesseldorf. The company will demonstrate the performance of its materials in collaboration with 30 renowned international machine suppliers, highlighting its commitment to delivering quality products that meet the needs of its customers.

Constantia Flexibles will highlight its 360-degree material approach for the Pharma and Consumer business during the trade fair. “We are excited to collaborate with 30 machine suppliers at INTERPACK and demonstrate the capabilities of our materials,” said Marc Rademacher, Executive Vice President Consumer Commercial. “Our team has worked hard to develop high-quality substrates that deliver exceptional performance, and we look forward to sharing our expertise with the trade fair audience. With our product range Ecolutions, we can prove that sustainability and performance go hand in hand,” Marc Rademacher adds.

Visitors will have the opportunity to see the materials in action and learn about their benefits, such as increased efficiency and recyclability. Highlights of the show will be:

Designed for the PE recycling stream: Our EcoLam product family

EcoLam laminates are based on polyethylene (PE) compounds developed by Constantia Flexibles. Oriented polyethylene (OPE), barrier OPE, and metalized high barrier OPE (in combination with the appropriate sealant PE) will replace non-recyclable laminates such as PET/PE, PA/PE, or even PET/ALU/PE.

Several characteristics make the mono PE laminate EcoLam more sustainable and efficient than other products in its league: they are lighter than others, have a solid thermal resistance, and use a lower barrier polymer content due to the combination of processes and resins. Another advantage of the EcoLam Range is that its barrier properties can be customized to the product. All EcoLam grades are certified by RecyClass and are compliant with all existing sorting and recycling technologies commonly used at an industrial scale in Europe.

Based on mono PP: The EcoVer family

EcoVer is Constantia Flexibles’ mono polypropylene (PP) offer which is available in different barrier grades: EcoVer, EcoVerPlus, and EcoVerHighPlus. Applicable on VFFS and HFFS lines, its high transparency, low initial sealing temperatures, its heat resistance, and stiffness facilitate the use for beverages, snacks, dairy, confectionery, home and personal care (HPC), pet care or processed food. EcoVer, a PP mono structure, is recyclable in the mixed PO stream.

 

Based on aluminum: die cut lids that combine sustainability and versatility

Constantia Flexibles has already laid the groundwork to revolutionize the lid market. EcoPeelCover is the thinnest possible aluminum / coex die cut lid which lowers the material use and weight but still guarantees an easy peel for consumers. The new smooth-finish-embossing pattern significantly enhances the aesthetic appeal compared to traditional embossing techniques. Moreover, this advancement ensures perfect pick-and-place operations on the packaging machinery, further optimizing the process. At the same time, the reduced material thickness still provides seal-through properties and a high puncture resistance.

Constantia Flexibles strives for a 360-degree-approach consequently, in addition to the aluminum-based EcoPeelCover, has developed specifications with multiple other substrates and is delighted to present die cut lids based on these materials running live on packaging lines at INTERPACK. Highlights are the PPCover, a metal-free die cut lid based on polypropylene, paper-based EcoPaperLid, and another more sustainable solution which is the rPETLid die cut lid that is created from recycled plastic to reduce virgin feedstock.

 

Based on paper: The EcoPaper family

The EcoPaper family consists of a wide range of recyclable paper-based packaging solutions. EcoPaperPlus is dedicated to medium-barrier applications. It is particularly suitable for products that require aroma and grease barriers, such as confectionery, snacks, and even home and personal care (HPC) applications. The material is available with a smooth or rough surface shine and is printable by Rotogravure, Flexo, or Digital. Paper FSC or PEFC certification is available on demand.

Constantia Flexibles also demonstrates its solutions in the Pharma sector:

Based on aluminum: Blister solutions for pharmaceuticals

NORMA is a high-performance lidding foil for pharmaceutical blister packaging.

NORMA is our benchmark for lidding foils. It has been successfully utilized for more than 50 years in the pharmaceutical packaging market, not only protecting the integrity of pharmaceutical products but also supporting the preferred packaging format by patients and medical staff alike. A very versatile product that can be manufactured with different heat seal coating- and lacquer systems and printed with all in- and offline printing systems. Additional protection can be achieved by including our child-resistant or anti-counterfeiting features that help protect curious children and patients from potential harm.

 

PERPETUA: sustainable packaging solution with high barrier properties

PERPETUA is made of recyclable polypropylene-based mono-material. Its excellent barrier properties make it ideal for pharmaceuticals. PERPETUA protects products in the best conceivable way from oxygen, water vapor, and light. This is essential to maintain the efficacy of medicines. Additionally, the product line is cyclos-HTP certified, meaning its recyclability is between 90 and 96%, depending on the individual material specification. PERPETUA ALTA is a high chemical resistance variant of recyclable laminates approved by RecyClass.

VELAR is the packaging for pharmaceutical flow wrap and overwrap laminates based on PET/ALU/PE. It is designed to provide exceptional barrier properties against light, oxygen, and water vapor. VELAR is recommended for the packaging of medical and pharmaceutical products such as blisters, inhalers, plastic vials, and diagnostic devices.

 

www.cflex.com

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That’s a Wrap. Mondi and ATS-Tanner Launch Paper Band for Food Bundles and Multipacks

Petra Löwer (Germany)
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That’s a Wrap. Mondi and ATS-Tanner Launch Paper Band for Food Bundles and Multipacks

That’s a Wrap. Mondi and ATS-Tanner Launch Paper Band for Food Bundles and Multipacks

  • Mondi has partnered with Swiss converter ATS-Tanner to create new kraft paper
    bundle packaging.
  • The innovative solution is strong enough to replace plastic on single or bundle
    packages and ideal for drink, fruit and vegetable and eCommerce end-uses.
  • The band is recyclable in existing paper recycling streams.

Mondi, a global leader in sustainable packaging and paper, has collaborated with Swiss converter ATS-Tanner to create an innovative paper band, which can hold individually labelled products or bundles reducing unnecessary plastic. ATS-Tanner uses Mondi’s kraft paper Advantage MF SpringPack and converts it into a band by adding a functional barrier on both sides of the paper. The paper is then sealed using ultrasound, eradicating the need for any adhesive. This ensures that the products are secured with minimum packaging, reducing waste and delivering a cost-efficient solution.

ATS-Tanner markets the coated bands under the brand name TruePaper. The strength of Mondi’s kraft paper means it can hold weights of up to 20 kg, making the band perfect for fruit and vegetable bundles as well as multipacks of bottles and other consumer goods. The paper ensures excellent printing results meaning brand, product, return and responsible waste management messaging can be communicated to the end user. Mondi’s kraft paper used for the paper band is made from renewable, responsibly sourced and certified materials. It is recyclable in existing paper recycling streams across Europe, even fulfilling Germany’s ratio of 95/5.

Carsten Breiter, International Key Account Manager Speciality Kraft Paper, Mondi says: “By combining world-leading expertise in sustainable packaging with ATS-Tanner’s machinery and skills, we have together created a system that offers great product protection while reducing unnecessary plastic. This is the perfect example of strong collaboration producing a new solution that does just that.”

Serge Tanner, Owner & CEO, ATS-Tanner says: “We trialled various paper grades and Mondi’s kraft paper offers the required strength to substitute plastic packaging with this paper band. TruePaper is a resource efficient solution that can – depending on the banding machine used – wrap products measuring up to 1300 x 500 mm and is convenient to store. Using paper instead of plastic is not the only advantage: an ultrasonic banding machine from ATS-Tanner consumes 98% less energy than it would take to pack a like-sized delivery using a shrink wrapping machine.”

www.mondigroup.com

 

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Textiles Recycling: The Sorting Challenge

Petra Löwer (Germany)
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Textiles Recycling: The Sorting Challenge

Textiles Recycling: The Sorting Challenge

To this day, only a tiny fraction of discarded textiles is recycled. While the clothing industry has doubled production in the last 15 years, the time garments are worn has fallen by more than 30%. At the same time, the rising demand for low-cost fast fashion is driving a decline in the quality of the materials, which makes them
more difficult to re-use or recycle. According to the Ellen MacArthur Foundation, it is estimated that 114 million tonnes of textile waste are generated every year. Of the clothing that is collected for recycling, 12% is downcycled into lower-value applications such as insulation material, and less than 1% is used to make new clothing in a closed-loop circular economy. The high content of polyester in fast fashion also means that an increasing quantity of discarded textiles are incinerated in waste-to-energy plants because of its high calorific value.

 

The environmental impact of textile waste

The rising consumption of clothing, coupled with the decreasing wearing time and increasing use of synthetic materials such as polyester and nylon, is worsening the negative impact on the environment. Large quantities of plastic microfibres shed through the washing of textiles are leaked into the ocean, accounting for 35% of microplastic pollution. Improper disposal can also result in flat textiles released into the environment, endangering wildlife on land and marine life.

Regulatory drive for the development of textile recycling

Policymakers have a key role to play in driving an increase in recycling. In Europe, in 2022 the Commission presented an EU Strategy for Sustainable Textiles, which includes extending the lifetime of textiles by recycling the materials they contain into new quality products. The revised Waste Framework Directive requires EU member countries to establish systems for separate collection of textile waste by the beginning of 2025, and at the same time, new collection and recycling targets will kick in. The infrastructure for collecting, sorting and recycling these materials will need to expand fast in readiness for the new regulations.

The textile sorting challenge

Clothing is made of different fabrics, fixtures and accessories, such as buttons or zips, and they contain a variety of raw materials – combinations of natural and synthetic fibres, plastics and metals. This makes disposing of it sustainably a complicated matter. “The recycling industry requires pure fractions or very specific mixtures,” explains Annika Ludes, Engineer for Digital Solutions at STADLER. “This means removing the fixtures and accessories from the fabric. The different materials in the garment – the outside fabric, the lining, the seams – need to be separated, then the different fibres in each fabric (cotton, elastane, polyester, etc.) must be sorted.”

Today, textile sorting is done manually, and only a small portion of the output material is suitable for recycling. However, research is ongoing on automating the process with the aim of producing the high-quality fractions required to address the recycling challenge.

Automated sorting: the path to a textile circular economy

STADLER – a leading supplier of sorting plants for the recycling industry – is researching automated sensor-based solutions for textile sorting. In 2017, in artnership with TOMRA, it has designed and built a small pilot project plant in Avesta, Sweden, in the second phase of the government-funded Swedish Innovation Platform for Textile Sorting (SIPTex) project, which aims to develop a sorting solution tailored to the needs of textile recyclers and the garment industry. This was followed in 2020 with the third phase of the project: the first industrial-scale fully automated mixed textile waste plant in the world, which is capable of achieving the purity and recovery required for recycling and reutilization. This facility, located in Malmö, processes pre-consumer waste from textile producers (clippings and rejects) and post-consumer waste, which consists of clothing and household textiles, and may contain non-textile parts such as buttons and zippers. The material is delivered in bales weighting from 350 to 500 kg and is sorted whole. The plant has the capacity to process up to 4.5 tonnes/hour in one line.

The textile sorting process

The process developed by STADLER with the cooperation of TOMRA in the SIPTex project starts with the waste textiles entering the plant in batches, dosed, fed by conveyor belts into four sensor-based TOMRA AUTOSORT units.

“Because of the nature of the textile material fed into the plant, the feeding system and dosing are very important to the success of the sorting process,” explains Dr. Bastian Küppers, Engineer for Digital Business Development at STADLER. “The STADLER dosing drum features mechanical components specially designed to handle the soft, flexible textile materials, of various shapes and unpredictable sizes, prone to tangling. Similarly, the design and layout of the conveyor belts, hoppers and chutes need to be designed to avoid tangling of long pieces of fabric.”

The TOMRA NIR (Near Infrared) sorting technology is also key to the process and capable of recognizing and differentiating various types of textiles in a first step. A second optical sorter is added for further cleaning of impurities.

Towards a textile circular economy

As the textile industry is moving towards a circular economy, driven by public opinion and legislation, the demand for textile sorting equipment is set to grow at an accelerated pace. STADLER has already seen an increase in interest for textile sorting plants and has been approached by companies in the recycling sector. “At STADLER we are seeing many interested parties who would like to visit the textile sorting plant we designed and built in Malmö,” comments Annika Ludes.

STADLER is uniquely well placed to meet this new demand, bringing to the table its extensive know-how in the design and construction of sorting plants and the specific experience it has acquired through the SIPTex project, as well as the expertise of its technological partners such as TOMRA. With its holistic approach, it is able to develop complete solutions tailored to the requirements of the individual customers.

For more information, visit http://www.w-stadler.de

 

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Hasco Award for Innovative Products

Petra Löwer (Germany)
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Hasco Award for Innovative Products

Hasco Award for Innovative Products

In a competition held by the trade journal Modern Plastics India, HASCO India, which is based in Bangalore, was able to convince the jury with its innovative new products in two categories.

Tool and mouldmaking:

HASCO Loc Check enables fast localisation of moulds

The new HASCO Loc Check A5900/… makes it possible at any time to establish the location of a mould worldwide, wherever GSM network is available. With the GSM tracking, the location can be called up via an easy-to-use web interface. Maximum data security is guaranteed through the use of certified servers. A battery charge lasts for more than 3,000 transmission cycles, which, depending on the transmission frequency, corresponds to an operation period of up to three years. With a magnet attachment, the Loc Check A5900/… can be easily mounted directly on the mould.

Hot runner technology:

HASCO Streamrunner – the first additively manufactured hot runner

The additive manufacturing technology offers maximum design freedom and breaks through the previous limitations in the design of hot runners. Developed with state-of-the-art technologies for innovative, future-oriented solutions, the Streamrunner stands out through its compact design, perfect balancing, particularly gentle passage of the melt and excellent colour change characteristics. Every Streamrunner is designed individually to deal with a particular task and is optimised on the basis of rheological simulations.

HASCO Support in India

General Manager Rajnikant Patel looks proudly at the award presented to him. “For us, this is motivation to make the day-to-day work of tool and mouldmakers in India easier with the help of innovative products and top service.”

As an internationally leading standard-component specialist, HASCO has been active in India since 1998. It first entered the market as a branch of HASCO Singapore Pte Ltd. The growing success of the branch enabled HASCO India to be founded as an independent, limited liability company in 2003. Currently, a ten-member HASCO team with in-depth toolmaking expertise serves around 1,200 mouldmakers across India.

www.hasco.com

 

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