Oerlikon Technologies Will Be Able to Convert Virtually Any Raw Material into an Ecologically Attractive End Product
Remscheid, Germany / Shanghai, China – October 19, 2023 – This year’s presence of the Oerlikon Group at the ITMA Asia + CITME 2023 trade show will prioritize the pressing challenges faced by the textile industry. Key areas of focus include establishing a circular economy within the textile value chain, offering energy-efficient technologies, utilizing digital solutions to support sustainable production, exploring new materials, ensuring product traceability, and promoting the recycling of raw materials. In addition, the trade fair attendees can expect a wide range of other topics to be addressed by Oerlikon’s experts at booth A55 in hall 7. Oerlikon welcomes visitors to engage in a constructive dialogue and aims to provide comprehensive solutions to current and future concerns within the textile industry. The booth, spanning over 225 m², promises to deliver answers to the most urgent questions of today and tomorrow.
Georg Stausberg, CEO of the Polymer Processing Solutions Division and Chief Sustainability Officer of the Oerlikon Group, emphasizes the significant role Oerlikon plays in advancing resource-efficient practices across global manmade fibre spinning mills. Oerlikon’s innovative technologies are dedicated to minimizing waste generation and are already widely adopted in the industry. Stausberg commits to further expanding the zero-waste production strategy as part of Oerlikon’s commitment to meeting both its customers and its sustainability objectives. The company’s vision is rooted in striving towards a more sustainable future and actively contributing to the achievement of its sustainability goals. The assertion is made by one of the foremost providers of machinery and plant solutions for the production of synthetic fibres, not just for this exhibition. Moving forward, their focus will exclusively revolve around developing sustainable advancements.
Circular Economy and Recycling? Empowering Customers to accomplish more with less
The pollution caused by textiles is growing at an alarming rate. European policymakers are taking the lead in addressing this issue by formulating a holistic approach to establishing regulations for a circular economy. The textile sector is also contributing by introducing innovative techniques to recycle synthetic fibres. Despite these efforts, creating a sustainable textile industry remains a significant challenge that requires considerable progress. One thing is clear: We need to find effective solutions to tackle the ever-increasing piles of discarded clothing and establish a world that prioritizes sustainable practices in the textile industry.
The European Environment Agency reveals that the textile industry has become the EU’s fourth most significant contributor to environmental and climate change issues. This alarming trend is mainly attributed to the relentless expansion of the textile sector. The Ellen MacArthur Foundation reports that global textile production nearly doubled between 2000 and 2015. To make matters worse, the European Environment Agency predicts that the annual consumption of clothing and footwear will surge by 63 per cent by 2030, reaching a staggering 102 million tons.
Oerlikon is actively engaged in the development of the market, particularly through its partnership with Worn Again Technologies. The focus is on a solvent-based recycling technology that converts end-of-life textiles made of polyester and polycotton blends, as well as PET plastics, into circular raw materials and fibres such as polyester and cellulose. To demonstrate the effectiveness of this technology, a large-scale system capable of upcycling 1,000 tons of textiles per year is being created in Switzerland.
Oerlikon believes in supporting technological innovators like Worn Again Technologies because their solution shows great promise and encourages collaboration among all stakeholders in the value chain. Oerlikon recognizes that effective recycling requires cooperation in a circular system. Looking ahead, they are eager to discuss closed-loop strategies and sustainable technologies at ITMA Asia + CITME 2023.
Oerlikon also has high sustainability goals for its operations and practices. They have been implementing pilot initiatives and aim to achieve CO2 neutrality across all locations by 2030, inspired by their successful implementation in Liechtenstein. Oerlikon’s other goals include sourcing 100% of electrical energy from renewable sources and maintaining the standard of “Zero Harm to People.”
Closing the loop in the textile industry requires not only regulatory initiatives but also technical innovation. Fibre-to-fibre recycling is a crucial circular technology, which has great potential to increase the recycling rate from the current one percent to 18-26 percent by 2030. However, automation is needed to replace manual processes, and there are challenges in sorting and separating mixed fibres. Despite these obstacles, promising solutions are emerging, although commercial exploitation may still be some way off.
Oerlikon Barmag is presenting cutting-edge technological options for rPET that empower clients to achieve substantial CO2 reduction every year. A novel recycling line, designed exclusively for customers in China and Asia, was introduced by Oerlikon Barmag in 2022. This ingenious system allows for the consolidation, extrusion, homogenization, and melting of bottle flakes and film waste, resulting in the generation of high-quality polymer melt or chips. The flexibility of this recycling line enables the customization of recycled bottles or film waste to meet the precise requirements of various downstream extrusion or injection moulding processes, ensuring optimal polymer quality.
The VacuFil system from BB Engineering, a joint venture between Oerlikon Barmag, offers yet another solution for rPET. This PET recycling line stands out for its ability to achieve consistently exceptional rPET melt quality through gentle large-scale filtration and targeted intrinsic viscosity (IV) regulation. An exciting development in 2022 was the introduction of the patented Visco+ filter, a key component of the VacuFil system. This separate and easily integrable upgrade enables precise IV adjustment and delivers a pure melt using vacuum technology. IV is a crucial quality factor in PET recycling and rPET processing, influencing melting performance, end product properties, and the overall recycling process. The Visco+ process is not only reliable and verifiable but also 50% faster than traditional liquid-state polycondensation systems.
Energy Efficiency? The EvoSteam process revolutionizes polyester staple fibre production
The demand for textile fibres is skyrocketing due to various factors like population growth, fast fashion, and other contributing factors. Global studies indicate that the demand for polyester staple fibres will reach 20 million tons by 2025, marking a significant increase of approximately 33% compared to the production volume in 2013. With the evident climate change impacts on society and the economy, it has become crucial to adopt resource- and environment-friendly manufacturing methods for the future.
However, high production costs pose challenges for fibre producers, with rising energy and polymer prices, as well as the scarcity and expense of water resources. Addressing these concerns, Oerlikon Neumag will introduce its new EvoSteam process at ITMA Asia + CITME 2023 in Shanghai. This innovative development is viewed as a catalyst for more sustainable production of staple fibres, aiming to reduce operating expenses and carbon footprint while ensuring exceptional fibre quality and maintaining high production volumes. By minimizing the consumption of energy, water, and polymer, this process seeks to fulfil the demands of downstream processes and secure a brighter future for the industry.
New Materials?
Reflecting on the policies governing the European Union, notable hurdles lie ahead concerning novel materials. Addressing this concern, the achievement of the Green Deal hinges on the establishment of robust European Union frameworks that assure prospective investments.
The polymer processing industry is actively working towards creating a sustainable and self-contained circular economy for packaging materials and textiles. One of the key objectives is to significantly enhance the recycling of the materials utilized, while also exploring the potential of new materials. As a machine manufacturer and plant engineering company, we are determined to seize the opportunities presented by these innovative materials. Nevertheless, when compared to non-biodegradable polymers like PE, PET, and PP which are derived from petrochemicals, the prices of bio-based polymers such as PA 5.6 and biodegradable polymers like PLA, PBAT, and PBS still lack competitiveness. On the other hand, bio-based materials used in consumer products, especially in the packaging industry, are already displaying competitive properties. Although compostable textiles may remain a niche market, Stausberg clarifies.
According to Stausberg, it can be said with certainty that by utilizing both existing Oerlikon technologies and upcoming innovations, the possibility to convert any type of raw material into an environmentally appealing final product exists. Ultimately, it will be the consumers who will determine the answers to the economic concerns. Once again, technology is empowering us to establish a more prosperous world.
Digitalization and Traceability?
The EU is aiming to lead the way in the global circular economy by adopting a sustainable and closed-loop textiles strategy. By 2030, the EU plans to promote textile products that are more durable, recyclable and made mostly from recycled fibres. These products must also be free from hazardous substances and manufactured in a socially responsible and environmentally friendly manner. To support these goals, the EU will introduce a digital product passport and amend the European Textile Labeling Act. This will require stakeholders in the textile value chain to provide detailed information about the composition of their products, ensuring adherence to the closed-loop principle and other environmental requirements. Oerlikon will showcase its digital technology solutions, as well as partnerships that have resulted in innovative advancements for Oerlikon technologies.
Unlocking the Future: Harnessing the Power of Oerlikon Barmag’s Digital Twin
The term “digital twin” originated in 2014 through the work of Michael Grieves and John Vickers from NASA. Its usage and interpretation vary across different scenarios. The most basic form of digital twins involves mapping a digital inventory list of a physical machine. This enables a precise supply of matching spare parts for a customized plant. On the other hand, advanced digital twins can incorporate the kinematics and dynamics of a machine or plant. During ITMA Asia + CITME 2023, Oerlikon Barmag will be showcasing a comprehensive WINGS POY winding head as a kinematic model, serving as a digital twin. The model encompasses all crucial machine components, which are connected through joints and contact bodies in a rigid body representation. By simulating forces and moments to imitate real-world actuators, and using contact and collision bodies for sensor emulation, the model replicates the entire operation of a winding head in a virtual environment. This innovation allows customers to access faster and more cost-effective production solutions.
Digital Academy – It’s just the beginning
The modern training concept at the Digital Academy in Oerlikon offers interactive and customized learning experiences that are adaptable and flexible in terms of time. This innovative approach ensures that training sessions can be accessed independently of location and timing, catering to the specific needs and general conditions of each student. The content of these training sessions is tailored to provide relevant information and guidance. Through the myOerlikon.com e-commerce platform, the digital online training centre offers a range of role-based e-learning modules focused on operating, maintaining, and repairing Oerlikon Neumag BCF S+ and S8 machines. This comprehensive training program is designed for operating staff, process engineers, technicians, and quality assurance officers. The learning contents available at the Digital Academy are specific to the Oerlikon Neumag BCF S+ and BCF S8 systems, with plans to continuously expand the content and make it accessible to all customers.
Oerlikon Barmag ACW WINGS
How can the POY yarn manufacturing process quality of Oerlikon Barmag be enhanced while also reducing energy consumption, waste, time, and personnel? Oerlikon will unveil their highly anticipated upgrade, the ACW WINGS drawing fields, at the upcoming ITMA Asia + CITME 2023 exhibition. Oerlikon recognizes that even established technologies can be further improved. Initially introduced in 1998, the Advanced Craft Winder (ACW) impressed the industry with its advanced modifications for string-up and yarn transfer. However, in 2007, WINGS set a new standard and became the preferred choice. Despite this, given the longevity of Oerlikon Barmag technology, many ACW and WINGS winders continue to operate side-by-side in certain locations. In response to customer demand, Oerlikon has developed a solution: integrating WINGS drawing fields onto ACW winders. This hybrid setup will be showcased at ITMA Asia + CITME 2023, demonstrating the combination of a WINGS drawing field with the virtual ACW Winder.
Oerlikon Barmag Wiping Robot
Ensuring the spin packs are regularly wiped is crucial for maintaining process stability and ensuring high-quality yarn. Implementing Oerlikon Barmag’s wiping robots, which can be easily integrated into various spinning plants, offers significant advantages. Notably, these robots contribute to a remarkable 30% reduction in yarn breakage, leading to improved process stability and reduced downtime. Moreover, the use of wiping robots indirectly aids in waste reduction as it substantially decreases reliance on silicone oil spray cans by 90% and lowers total silicone oil consumption by 15% to 20%. Embracing this automated approach guarantees enhanced efficiency and better sustainability in the spinning industry.
Oerlikon Nonwoven HycuTEC
Oerlikon Nonwoven’s HycuTEC inline charging technology has garnered recognition for its ability to produce top-quality charged melt-blown filtration media. Having received the esteemed 2022 FILTREX™ Innovation Award, HycuTEC stood out due to its exceptional efficiency. By utilizing this technology, the melt-blown media necessitates 40% less polymer (fabric weight) compared to untreated nonwoven material, all while maintaining the same level of filter effectiveness. This accomplishment simplifies the attainment of filter specifications while minimizing waste during production. Different from alternative hydro-charging approaches, HycuTEC substantially decreases water and energy consumption since it eliminates the need for an additional drying process and results in reduced pressure drop within the filter material. A notable advantage of HycuTEC is its suitability for easy retrofitting into existing systems, presented as a readily deployable component for effortless installation and operation.
Captions:
Innovations at ITMA Asia + CITME 2023: the revolutionary new Oerlikon Neumag EvoSteam staple fibre process (left) and the Oerlikon Barmag ACW WINGS upgrade (right).
Georg Stausberg, CEO of Oerlikon Polymer Processing Solutions Division
About Oerlikon Polymer Processing Solutions Division
Oerlikon is a renowned provider of comprehensive solutions for polymer processing plants and equipment for high-precision flow control components. Within their division, they offer a range of solutions including polycondensation and extrusion lines, spinning solutions for man-made fibre filaments, texturing machines, BCF and staple fibre lines, and nonwoven production systems. Additionally, they specialize in developing and manufacturing advanced hot runner systems and multi-cavity solutions for the injection moulding industry. These hot runner solutions cater to various sectors such as automotive, logistics, environmental, industrial applications, consumer goods, beauty and personal care, and medical.
Furthermore, Oerlikon stands out for its customized gear metering pumps which find applications in the textile, automotive, chemical, dyes, and lacquer industries. Through their engineering expertise, Oerlikon strives to deliver sustainable and energy-efficient solutions for the entire polymer processing value chain, adopting a circular economy approach.
The Oerlikon Polymer Processing Solutions Division operates globally, serving customers in approximately 120 countries through their technology brands – Oerlikon Barmag, Oerlikon Neumag, Oerlikon Nonwoven, and Oerlikon HRSflow. As part of the publicly listed Oerlikon Group, which is headquartered in Switzerland, they contribute to the group’s overall success. In 2022, the Oerlikon Group achieved sales of CHF 2.9 billion and employed over 13,000 individuals.
