Textile World July/August 2021

Rieter’s E 90 Comber Face Covering Testing Mosquito-Resistant Clothing ■

■

July/August 2021 Founded 1868

Shawmut Corp.

Investing In Advanced Materials

Show Previews • INDEX™20 • FloorTek Expo 2021

Nonwovens Focus • Technology Roundup • COVID-19 — Lessons Learned?

• QFOM: Suominen’s BIOLACE®Ultrasoft

Make the Difference

E 90 – Highest sliver quality, economically produced The comber E 90 impresses thanks to its state-of-the-art technology components, increased productivity, and greater flexibility in terms of possible applications.

The machine ensures a consistently high yarn quality at low conversion costs.

www.rieter.com

July/August 2021 TextileWorld.com

A

Founded 1868

Publication

Features 12

INDEX™20 ShowPreview: Global Triennial Nonwovens Show Returns Originally scheduled in early 2020, INDEX™20 is confirmed to move forward with a new October 2021 date.

14

FloorTek Expo: Back To Business After canceling the 2020 event because of the pandemic, FloorTek Expo heads back to the Dalton Convention Center in September.

28 Standardizing Barrier Face Covering Testing Standardized testing of face coverings may be beneficial in reducing public confusion and misinformation about performance.

34 Norfil Benefits From Flexible Production With Comber E 90 Rieter’s Comber E 90 offers consistent quality thanks to reliable, real-time information with Rieter Quality Monitor.

ON THE COVER: Innovations for the nonwovens industry, such as Germany-based DiloGroup’s 3D-Lofter, will be in the spotlight at the upcoming INDEX™20 show in October.

Nonwovens/Technical Textiles 15

Shawmut: Investing In The Future Of Advanced Materials No stranger to innovation and change, Shawmut is committed to helping customers rapidly solve pressing business challenges.

18

COVID-19 — Lessons Learned?

Manufacturing innovations will provide more reliable, affordable and adaptable protection in the face of the next pandemic.

22 Innovations For Nonwovens Production

Departments 4

From The Editor

6

News

8 Business & Financial 10

Yarn Market

36

People

37

Bulletin Board

38

Quality Fabric Of The Month

Nonwovens technologies can be used to produce an array of products for an ever-increasing number of end uses.

Dyeing,Printing & Finishing 31

News

Knitting/Apparel 32

Mosquito-Resistant Clothing Prevents Bites In Trials Patent rights to mosquito-resistant clothing developed at NC State has been licensed by startup company Vector Textiles.

VOL. 171, No. 4 / TEXTILE WORLD (ISSN 0040-5213) is published bimonthly by Textile Industries Media Group, LLC, PO Box 683155, Marietta, GA 30068, and incorporates Modern Textiles, Textile Industries, Fiber World and Knitting/Apparel magazines, which remain the property of Textile Industries Media Group, LLC. Copyright 2021, Textile Industries Media Group, LLC Title registered with the U.S. Patent Office. All rights, including translation into other languages, reserved. Subscription rates for one year are: $65 (US); $85 (Canada and Mexico); $130 (Other International). Single copy rates are: $15 per copy. All prices are in U.S. dollars and all orders must be prepaid. Questions may be submitted to jdavis@textileworld.com. To obtain electronic copies of print articles, please contact ProQuest at www.proquest.com. To obtain microform copies, please contact NA Publishing at www.napubco.com.

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From The

Editor

Demand, Demand,

Demand — Inflation

WW

ith large sums of money chasing too few goods — you guessed it — inflation is on track and gaining steam. CNBC recently reported: “Consumer prices increased 5.4 percent in June from a year earlier, the biggest monthly gain since August 2008.”

There are more factors at play than meets the eye. On the demand side, consumers — having sheltered in place for the past year — have money to spend and a year’s worth of consuming to catch up on.

And whether you support the policy or not, 35.2 million families just received $15 billion in the first of six child tax credit payments — $300 per month for children under the age of six and $250 for those between the ages of 6 and 17. These are monthly payments, the last of which is scheduled for December 10 — just in time for Christmas with pressure on congress to renew the tax credits before the year’s end.

According to CNBC: “There’s no limit on the number of eligible children who can receive the credit. For example, a family with three children ages five, eight and 10 who qualified for the full credit would get $800 per month.

“The full credit is available to eligible households with adjusted gross income less than $150,000 for married couples filing jointly and $75,000 for individuals. The enhanced credit phases out for married couples filing jointly making $170,000 annually and individuals earning $95,000, though they’d still qualify for the regular child tax credit.”

There hasn’t been much said about this flow of funds to families with children, and its impact could be incredible on the demand side of the economy.

It is different from the normal tax deduction plans — people without income will be receiving funds. The timing is such that the initial payments are just in time for the back-to-school rush. This could be a bright

sign for retailers and the apparel supply chain which is already being squeezed.

The U.S. Census Bureau recently noted: “Retail trade sales were up 0.3 percent (±0.5 percent) from May 2021, and up 15.6 percent (±0.7 percent) above last year. Clothing and clothing accessories stores were up 47.1 percent (±2.8 percent) from June 2020.”

However, inflation comes with lack of supply, shortages and kinks in the supply chain.

Energy prices are soaring and a trip to the gas pump will cost 43-percent-more than last year. Keep in mind the driving season has hardly started.

New car and truck prices make up a strong part of rising inflation with computer chip shortages limiting supply and driving used car prices higher.

So, in the wake of the recovery and barring a new shut down because of the COVID-19 Delta variant — or some other mutation yet unnamed — is this the time to invest?

It would seem possibly so. Recently textile industry machinery supplier Rieter, Switzerland, posted an increase of 289 percent in year-over-year order intake. The company characterized the increase as widely global in scale. In Asian countries, Rieter increased sales 57 percent for the first half of the financial year 2021. In China, sales rose by 85 percent with spinning mills investing to improve competitiveness. India had a significant increase of 188 percent, while sales in Turkey improved slightly by 17 percent. Sales increased by 94 percent in North and South America, driven — according to Rieter — by a considerable increase in demand in Latin America.

Inflation? Yes. But, demand? Oh yes!

James M. Borneman jborneman@TextileWorld.com

A

Publication

EDITOR IN CHIEF EXECUTIVE EDITOR TECHNICAL EDITORS

James M. Borneman Rachael S. Davis Dr. Lisa Parillo Chapman Dr. Peter J. Hauser Dr. Trevor J. Little Dr. William Oxenham Dr. Behnam Pourdeyhimi Dr. Abdel-Fattah Seyam Dr. Andre West

ECONOMICS EDITOR YARN MARKET EDITOR CONTRIBUTING EDITORS

Robert S. Reichard Jim Phillips Jim Kaufmann Stephen M. Warner

INTERNET CONTENT EDITOR CIRCULATION MANAGER ADVERTISING BUSINESS MANAGER

Rachael S. Davis Julie K. Brown-Davis Denise Buchalter

ART & PRODUCTION MANAGER

Julie K. Brown-Davis

OWNER/PUBLISHER

James M. Borneman

ADVERTISING REPRESENTATIVES UNITED STATES/CANADA

Turner Marketing & Media, LLC

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News Mannington Commercial To Buy AtlasMasland Assets Mannington Commercial, Calhoun, Ga., reports it has entered into an agreement to purchase select assets of The Dixie Group company’s commercial flooring business AtlasMasland — including existing product lines, and tufting machinery and other equipment assets from The Dixie Group’s Atmore, Ala., facility.

The Atmore plant is not part of the transaction, and Mannington will relocate and install the assets at its facility in Calhoun upon the close of the transaction.

During the transition, AtlasMasland will continue to produce products for Mannington until the purchased assets are fully operational in Calhoun.

“Today marks an important day for Mannington Commercial’s future and for our customers,”said Mannington Commercial President Tom Pendley.“We will be adding significantly more sales and carpet manufacturing capacity to meet the continued demand for our commercial product line. We are also gaining proven product lines that are well-established within certain commercial segments where we see expanded growth opportunities. Taken together, we will be accelerating our growth and better serving our customers with a more comprehensive set of floor covering solutions.”

6

Standard Textile Announces Expansion Standard Textile has announced plans to expand capacity at its Union, S.C., operation with an investment of $15 million. The expansion is anticipated to be complete by October 2021 and will create 45 jobs.

It was reported that the Coordinating Council for Economic Development has approved job development credits related to this project, and also awarded Union County a $400,000 Rural Infrastructure Fund grant to assist with related project costs.

“We are excited about the expansion of our facility in Union, S.C.,” said Bradley Fry, COO and CFO, Standard Textile.

“In addition to meeting growing demand, this expansion allows us to create a state-of-the-art rapid prototyping center for the development of innovative products and a showroom to share the company’s innovation history and unique products.”

Messe Stuttgart Expo To Collocate With IFAI Expo 2022 Germany-based Messe Stuttgart has announced its new Sun Shading Expo North America that was planned as a collocated event with IFAI Expo 2021 will now make its debut October 12-14, 2022, as a collocated event with IFAI Expo 2022 in Charlotte, N.C.

JULY/AUGUST 2021 TextileWorld.com

Tidal Vision, Leigh Fibers Form Partnership Bellingham, Wash.based Tidal Vision Products Inc. has announced a partnership with Leigh Fibers Inc., Wellford, S.C. Tidal Vision produces a line of water-based textile treatments formulated using chitosan — a biodegradable, non-toxic, abundant biopolymer — that is extracted from crab and shrimp shells that are unwanted byproducts of the seafood industry.

The treatments may be applied using dip, spray or coating methods to fibers, yarns or fabrics; and are cured by simply removing the water through drying.

The partnership includes a new Tidal Vision 24,000-square-foot-facility inside Leigh Fiber’s 1-million-square-foot headquarters location in Wellford.The cooperation offers economies of scale and Tidal Vision hopes to offer its biobased solutions at a lower price.

During IFAI Expo 2021 — to be held November 2-4, 2021, at the Music City Convention Center in Nashville, Tenn. — Messe Stuttgart will provide expertise in sun shading systems by the way of expert talks and discussions, as well as present its Sun Shading Expo concept.

“A large number of international R+T exhibitors have already shown their interest in the North American market,”said Roland Bleinroth, president

“In the textile industry, to have the biggest impact it made sense to start with fibers treated at the top of the supply chain,” said Craig Kasberg, CEO,Tidal Vision. “Leigh Fibers was our ideal partner since their mission, values and business model are so synergetic with ours. Both of our companies produce sustainable solutions by upcycling byproducts that would otherwise end up in landfills, and through vertical integration we provide high performance products out of what was previously considered waste.”

“Partnering with Tidal Vision is a win-win for our company, our customers, and the environment,” said Eric Westgate, senior vice president of Leigh Fibers.

“Their Tidal-Tex product line delivers the key benefits that our customers look for in textiles at a lower price and is made from sustainable materials in the USA.”

of Messe Stuttgart.“In our capacity as a professional trade fair organizer, our objective is to offer all participants planning security in particular along with a high-quality and successful presentation platform. After analyzing the currently valid general conditions and in view of the long-term success of the new trade fair brand, we decided to stage Sun Shading Expo North America as a co-location to IFAI Expo 2022.” TW

Business & Financial Textile Activity At A Glance DEMAND

*Latest

Previous

Year Ago

(Federal Reser ve Board [FRB], 2017=100)

PRODUCTION

Textile mill Textile product mill Apparel

74.1 67.7 78.3

72.9 68.4 75.6

56.0 58.5 55.3

(Dept. of Commerce [DOC], millions)

MANUFACTURING SALES

Textile mill Textile product mill Apparel Apparel retail

$2,230 $1,862 $859 $25,247

$2,275 $1,875 $861 $29.521

$1,771 $1,583 $761 $8,407

(FRB, 2012=100)

CAPACITY

Textile mill Apparel

92.8 60.9

92.8 60.8

93.4 64.9

(FRB, 2012=100)

OPERATING RATE

Textile mill Apparel

70.8 78.3

70.5 75.6

STOCK/SALES RATIO Textile mill Textile product mill

1.38 2.08

1.33 2.07

1.67 2.27

57.2 55.3

83.7

80.1

57.1

(DOC)

COSTS (cents/lb)

(Bureau of Labor Statistics [BLS], $/h)

HOURLY EARNINGS

Textile mill Textile product mill Apparel

PRICE INDEXES 146 145 144 143 142 141 140 139 138 137 136 135 134

$22.67 $21.80 $21.83

$22.64 $21.91 $21.46

$22.96 $21.52 $21.41

(December 2003=100)

Previous

Year Ago

140.4 155.5 142.4 172.8 165.6 180.4 145.5

140.0 152.6 140.7 171.1 165.8 179.8 145.4

127.5 136.9 138.3 161.6 168.6 176.3 145.3

$8,175 $1,890 $6,285

$9,061 $2,005 $7,056

$5,144 $1,003 $4,141

(BLS, 2011=100)

103.4

103.2

98.5

(BLS, 2005=100)

107.8

107.7

106.6

95.9 105.9 93.4

95.3 106.6 92.6

Man-made fibers Processed yarn & threads Greige goods Finished fabrics Home furnishings Carpet Apparel

INTERNATIONAL TRADE (DOC, millions)

Imports Exports Trade Deficit IMPORT PRICE

Textile mill Textile product mill

EMPLOYMENT

(BLS, thousands)

Textile mill Textile product mill Apparel

PROFITS Textile Apparel

$759 $2,517

Textile Apparel

8.1 12.9

3.6 -4.1

*Latest

Previous

Year Ago

5.8

6.1

13.3

$19,277

$17,380

$16,699

1,572

1,517

1,046

269.2

267.1

256.4

224.4

217.5

188.6

Factory utilization rate 75.8 Industrial production (2017=100) 99.9 Production capacity (2012=100) 104.9

74.4 99.0 104.9

63.9 85.8 104.8

(BLS)

Housing starts

(DOC, thousands)

Consumer Price Index (BLS, 1982-84=100)

Producer Price Index, all (BLS, 1982=100)

AGGREGATE J

A

S

O

N

D

2020 February – May = preliminary

JULY/AUGUST 2021 TextileWorld.com

J

F

M

A

M

J

2021 June = estimated

$305 $-776

8.3 13.4

(DOC, billions)

`

$743 $2,621

(census, quarterly per $ of sales)

MARGINS

Unemployment Rate Disposable income

Textile Mills Price Index

87.3 99.8 80.2

(census, millions per quarter)

MACROECONOMIC FACTORS

Textile Product Mills Price Index

J

8

*Latest

(BLS,1982=100)

TEXTILE & APPAREL

SUPPLY

Cotton

PRICES

(FRB)

* all figures are for the latest available month as of TW’s press time, except for profits where only quarterly data are available.

YarnMarket Inquiries Improving, But Concerns Remain In Costs, Labor

TT

By Jim Phillips, Yarn Market Editor

he U.S. economy continued to improve over the first half of the year, and as of early July, was at approximately 93 percent of pre-pandemic levels. Spinners and others across the fiber/textile/ apparel complex reported significant increases in activity compared to the first half of 2020.

Strong holiday sales forecasts have resulted in a flurry of activity. Economists expect total U.S. holiday retail sales in 2021 to rise 2.7 percent to almost $1.1 trillion. “Orders and inquiries have been strong so far, and we expect business to be solid for the remainder of the year,” said one executive. Others said they also expected business to remain strong. However, spinners continue to experience issues affecting production and pricing.

“One of the biggest issues at the moment is talent,” said a well-placed business analyst. “A lot of people lost their jobs during the pandemic, and some are not coming back into the workforce.”

Added an industry specialist: “We were having trouble keeping enough resources to run a full schedule before the pandemic. Since the

10

pandemic, it has become even harder to recruit the right people.”

Some employers pointed the finger at supplemental federal unemployment compensation. But more than half of the states in the country ended the program early. “Yet,” one manager noted, “there are still more jobs available than people willing to fill them.”

LinkedIn, which tracks job postings, noted a decline in available jobs early in the pandemic. However, as of July, manufacturing job postings were up 56.88 percent when compared to the pre-pandemic week of February 12, 2020.

Another area of concern for spinners, as well as others across the manufacturing sector, is the rapid rise in some raw materials costs. Energy costs, for example, have increased by almost 25 percent over the past 12 months, according to the U.S. Bureau of Labor Statistics.

“The rapid rise in energy costs — especially petroleum — places a heavy burden on yarn manufacturers,” said one operating officer. “We’ve been hit in multiple areas, such as in the cost to keep the lights on and the cost of materials for some of

JULY/AUGUST 2021 TextileWorld.com

our product offerings.

Making yarn can be a low-margin business. Now, it is costing us more to operate, but our customers don’t want to pay more.”

Consumer Prices Up, But So Is Consumer Confidence Across the entire economy, the Consumer Price Index for All Urban Consumers rose 0.9 percent in June, according to the labor statistics bureau.

Increases were noted in used cars and trucks, new vehicles, airline fares, and apparel. Prices have increased 5.4 percent over the past 12 months.

Despite rising costs, consumers are increasingly confident in the economy and expect to have more disposable income than in past months. The Conference Board Consumer Confidence Index® improved further in June, following gains in each of the previous four months.

The Index now stands at 127.3 (1985=100), up from 120.0 in May. The Present Situation Index — based on consumers’ assessment of current business and labor market conditions — rose from 148.7 to 157.7.

The Expectations Index – based on consumers’

short-term outlook for income, business, and labor market conditions – improved to 107.0, up from 100.9 in May. “Consumer confidence increased in June and is currently at its highest level since the onset of the pandemic’s first surge in March 2020,” said Lynn Franco, senior director of Economic Indicators at The Conference Board.

“Consumers’ assessment of current conditions improved again, suggesting economic growth has strengthened further in Q2. Consumers’ short-term optimism rebounded, buoyed by expectations that business conditions and their own financial prospects will continue improving in the months ahead.”

Cotton Prices Inch Up Average spot quotations for the base quality of cotton (color 41, leaf 4, staple 34, mike 35-36 and 43-49, strength 27.0-28.9, and uniformity 81.0-81.9) averaged 83.59 cents per pound in the seven designated markets measured by the USDA. The weekly average was up from 83.18 cents the previous week and from 59.91 cents reported the corresponding period a year ago. TW

Color 41, Leaf 4, Staple 34, Mike 35-36 and 43-49, Strength 27.0-28.9, Uniformity 81.0-81.9 COTTON FIBER (BASE GRADE)

Spot Market, ¢/lb.

CURRENT

6 MO. AGO

1 YR. AGO

83.59

77.4

57.62

Ring-Spun 100% Carded Cotton

CARDED COTTON

Open-End Spun 100% Carded Cotton

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

10/1 18/1 24/1 30/1 12/2 20/2

2.01 2.04 2.21 2.22 2.58 2.66

1.94 1.96 2.10 2.15 2.53 2.57

1.73 1.84 1.89 1.96 2.31 2.49

4/1 10/1 16/1 18/1 20/1

1.18 1.23 1.28 1.34 1.43

1.13 1.17 1.22 1.28 1.36

1.02 1.04 1.20 1.25 1.27

Ring-Spun 100% Combed Cotton COMBED COTTON

POLYESTER/ CARDED COTTON

ACRYLIC & RAYON

Ring-Spun 50/50% Polyester/Combed Cotton

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

18/1 26/1 30/1 38/1

2.74 2.82 3.11 3.18

2.70 2.78 3.07 3.14

2.65 2.73 2.98 3.06

20/1 30/1

2.29 2.35

2.20 2.26

1.98 2.08

Ring-Spun 50/50% Polyester/Carded Cotton

Open-End Spun 50/50% Polyester/Carded Cotton

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

20/1 30/1

2.15 2.22

2.03 2.10

1.83 1.90

12/1 14/1 18/1 24/1 28/1

1.09 1.22 1.42 1.46 1.50

1.08 1.11 1.30 1.34 1.43

0.97 1.09 1.19 1.23 1.33

Open-End Spun 100% Acrylic (worsted count)

Open-End Spun 100% 1.2 Denier Rayon

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

1/12 1/18 1/24 1/28 1/32

3.10 3.15 3.22 3.27 3.48

3.10 3.15 3.22 3.27 3.48

3.03 3.07 3.13 3.19 3.40

20/1 30/1

4.56 4.79

4.56 4.79

4.52 4.74

Ring-Spun 100% Polyester (whites only) SPUN POLYESTER

Ring-Spun 100% Polyester (dyed)

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

8/1 16/1 20/1 22/1 30/1

2.19 2.31 2.44 2.54 2.92

2.16 2.28 2.41 2.51 2.89

2.13 2.25 2.39 2.48 2.85

8/1 16/1 20/1 22/1 30/1

3.36 3.57 3.63 3.71 4.08

3.25 3.46 3.51 3.59 3.95

3.20 3.41 3.45 3.55 3.92

Filament Polyester Partially Oriented Yarn (POY)

Textured Nylon

MAN-MADE FIBERS/ FILAMENTS

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

70/2 100/2

3.45 3.58

3.45 3.58

3.38 3.51

70 denier 100 denier 150 denier

2.20 2.14 2.08

2.20 2.14 2.08

2.09 2.03 1.97

Textured Polyester (knits)

Man-Made Staple Fiber

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

YARN TYPE

CURRENT

6 MO. AGO

1 YR. AGO

70 denier (dyeable) 70 denier (whites) 100 denier (dyeable or whites) 150 den. (dyeable) 150 den. (whites)

2.01 1.93 1.72

1.96 1.88 1.67

1.96 1.88 1.67

Polyester (1.5 denier) Acrylic (3.0 denier)

2.22-2.36 2.08-2.24

2.22-2.36 2.08-2.24

2.18-2.32 2.02-2.16

1.67 1.65

1.62 1.58

1.62 1.58

All yarn prices in U.S. dollars per pound & asking prices only. Prices compiled from 7/13/21 See TextileWorld.com for archived Yarn Market data.

Textile World JULY/AUGUST 2021

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INDEX™ 20 PREVIEW

Global Triennial Nonwovens Show Moves Ahead

TT

ypically, once every three years Belgium-based EDANA — the international association serving the nonwovens and related industries — and show organizer Palexpo bring together the entire nonwovens industry at the INDEX™ trade show. The event, with its unique nonwovens focus and highly vertical format, offers four intensive days of insights, networking and rewarding business activities, according to EDANA. But the year 2020 was anything but typical, and INDEX 20 did not escape the upheaval and uncertainty caused by the global COVID-19 pandemic. Originally planned for March 31-April 3, 2020, the show was initially postponed and tentatively rescheduled.

The Swiss Federal Council authorized large-scale public events and trade shows to take place again beginning in July. This allowed EDANA and Palexpo to reschedule and plan INDEX 20, albeit much later than planned and with strict health measures in place to ensure the event is enjoyable and exhibitors and

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JULY/AUGUST 2021 TextileWorld.com

Originally scheduled in early 2020, INDEX™20 is confirmed to move forward with a new October 2021 date.

unpredictability of the pandemic and its effect on the attendance figures,” said Magali Fakhry Dufresne, INDEX exhibition director. “Under normal conditions, we would expect in the region of 12,000 to 12,500 visitors over the four days, and more than 750 exhibitors.”

TW Special Report

Can’t Attend In Person? attendees will be able to conduct business in a safe atmosphere.

Therefore, after three reschedules, organizers are excited to confirm that INDEX 20 — the 13th consecutive edition of the show to be held in Geneva, Switzerland at the Palexpo Exhibition and Conference Centre — will take place October 19-22, 2021.

Exhibitors, Attendees At the event held in 2017, 666 exhibitors from 41 countries showed their wares to a total of 12,758 visitors who made their way through the doors of the exhibition center. Participation in the October show is harder than usual to predict, however.

“This year’s edition is going to be difficult to gauge, owing to the

The organizers understand that with some international travel restrictions still in place, corporate travel bans in effect and reluctance from some people who are not yet ready to travel, not all willing participants will be able to go to Geneva for the show. To combat this problem, for the first time INDEX will include an interactive virtual platform where visitors anywhere in the world will be able to watch more than 80 presentations, arrange live video meetings and chats with speakers, as well as interact with exhibitors and other participants using the digital tool to gain a taste of INDEX. “We are confident that this will further increase our visitor numbers and help extend the awareness and reputation of the

The Palexpo Exhibition and Conference Centre, Geneva, Switzerland, will host INDEX™20 October 19-22, 2021.

event to new audiences,” Fakhry Dufresne noted.

On Site Happenings The event focuses on six sectors: Filtration; Geotextiles & Civil Engineering; Hygiene & Cleaning; Medical: Infection Prevention; Transportation; and Packaging.

INDEX 20 will feature a Sector Seminar Programme on-site comprising six half-day seminars on topics including Infection Prevention, Smart Nonwovens, Nonwovens and Sustainability, Geotextiles, Filtration and Transportation. The free seminars will be held live in person and also broadcast in parallel on the virtual platform. All participants will have an opportunity to interact with speaks and ask questions during the Q&A sessions.

In person visitors also have the opportunity to explore the INDEX Innovation Lab. The lab is dedicated to showcasing the level of innovation and imagination residing in the nonwovens industry, aimed to inspire.

The Innovation Lab includes research poster displays, demonstrations of experiments and testing equipment, and a display with samples to illustrate the benefits of nonwovens in daily life and their myriad of uses.

The exhibition is open October 19-21 from 9 a.m. until 6 p.m., and on October 22 from 9 a.m. until 4 p.m. Organizers are offering a fourday ticket option only at a cost of 100 euros ($118). No daily tickets will be available. Participation in the virtual event will be free to all.

Facemasks are not required, but visitors will need to prove they are fully vaccinated; provide proof of a negative PCR test conducted within the preceding 72 hours, or an antigen test performed within 48 hours of attendance; or provide proof of immunity.

“We were indeed much relieved when the Swiss Authorities decided to end the restrictions on public and trade fairs at the end of June this year, following the uncertain times which we have all been through over the past 18 months,” Fakhry Dufresne said. “We are all very much looking forward to holding INDEX™ again, and to extending the event’s offer with the addition of a rich virtual offering too!” TW For more information about INDEX 20 including details about the seminars, events and virtual options, please visit indexnowovens.com.

INDEX™ 20 Awards The INDEX 20 Awards normally would be announced during the trade fair. But owing to the delayed in person event, EDANA decided to honor the seven award winners back in October 2020 during an online ceremony.

Entries were judged by a panel of industry representatives, members of the nonwovens press and EDANA officers. Winners of each category were announced as follows: • Nonwoven roll goods — Jacob Holm for Sontara® Dual cellulosic wipe substrate • Finished or composite products made from, or incorporating, nonwovens — DuPont de Nemours for Tychem® 2000 SFR chemical garment technology • Raw materials or components

(e.g. fiber, binder, polymer, tape) of special relevance to the nonwovens industry and related converted products — Beaulieu Fibres International for UltraBond sustainable needlepunched fabrics.

• Innovation in machinery of special relevance to the nonwovens industry — GDM for its Expanding Welding Wheel.

• Most original marketing campaign for a product made from, or incorporating, nonwovens — Berry Global’s J-Cloth® Plus Biodegradable Communication Campaign • Sustainable product — Ahlstrom-Munksjö for Fiber+ Green Capsule Top Lid and Compostable K-cup filter • Sustainable process or management practice — FaterSmart Used Absorbent Hygiene Products Recycling Technology A “People’s Prize” also was awarded to Omya International for its Omyafiber® 800. The company was chosen after its video received the most “likes” on the INDEX Nonwovens LinkedIn page.

All winning submissions will be explained and displayed where possible in the INDEX Innovations Lab.

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FLOORTEK EXPO 2021 PREVIEW

fill our commitment to our motto and serve the entire floor covering industry,” Manis said.

“We feel people are ready to get back together as an industry,” Manis added. “FloorTek is here to help you reconnect. The show will feature more than 16 new cutting-edge technologies to enhance your business.

Come experience the future of the industry. Additionally, AFA will have a new member program to be unveiled at the show.”

AFA Floorcovering Industry Scholarship

FloorTek Expo: Back To Business After canceling the 2020 event because of the COVID-19 pandemic, FloorTek Expo heads back to the Dalton Convention Center September 14-15, 2021.

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n June 2020, the American Floorcovering Alliance (AFA) unfortunately announced the cancellation of the FloorTek Expo 2020 that was scheduled for September of that year. Looking back, with all the unknowns facing the nation and the world at the time, there really was no other solution. AFA noted, “The uncertainty related to the COVID-19 pandemic and potential restrictions which may be placed on travel and public events has made planning for the event difficult for AFA, potential exhibitors and attendees.”

At that time, Stephanie Manis, AFA executive director, stated she was very disappointed at having to cancel

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the expo because several new and exciting events were planned to coincide with the event. “We are going to use the time between now and the expected 2021 Expo in September or October to create even more cuttingedge events to help the industry thrive during these changing times.”

AFA was delighted to recently announce it will hold FloorTek Expo 2021 September 14-15, 2021, at the Dalton Convention Center in Dalton, Ga. “With the vaccine distributions, lowering infection rates and hopeful ‘herd immunity’ by late summer, we are optimistic that fall 2021 will be a good time for FloorTek and will move us in a positive direction to ful-

AFA will hold a golf tournament in conjunction FloorTek Expo 2021 with proceeds benefiting the inaugural 2021 AFA Floorcovering Industry Scholarship.

According to the AFA, all FloorTek VIP participants are invited to play in the FloorTek Open golf tournament on September 13, the day before the expo begins. Individuals can play for $125, and teams of four may register for a $500 fee. The deadline to sign up to play is August 6, 2021. There are also sponsorship opportunities for interested parties.

Back To Business The FloorTek Expo is a distinctive industry event that responds to the uniqueness of Dalton’s identity as the “Carpet Capital of the World.”

The close proximity of many of the most significant floorcovering manufacturers and the event’s aggregation of key suppliers makes for a very efficient expo opportunity.

“With the nonexistence of trade shows for 2020 and few in 2021, we are ready to resume networking opportunities for exhibitors and attendees,” Manis said. “The format will be an ideal opportunity for every flooring professional from every level to explore avenues for growing their business.” TW For more information about FloorTek Expo 2021 and to register for the event and associated golf open, visit floor-tek.com.

COMPANY PROFILE

An N95 Particulate Respirator manufactured by Shawmut

Shawmut: Investing In The Future Of

Advanced Materials No stranger to innovation and change, Shawmut is committed to helping customers rapidly solve pressing business challenges.

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ounded in 1916, West Bridgewater, Mass.-based Shawmut Corp. is no stranger to innovation and change. The fourth-generation, family-run, global company is the largest independent laminator for technical fabrics in the United States, and offers advanced materials solutions for the automotive, health and safety, military and protective and custom lamination solutions markets. Shawmut employs more than 700 employees worldwide, operating 10 manufacturing plants and seven commercial offices across North America, Europe and Asia.

A History Of Change What started in the location of America’s oldest woolen mill producing braided fabric and man-made yarn, has transitioned over time into a business that creates a range of soft composite materials and technical textiles,

and provides lamination solutions.

Throughout the years, Shawmut has supplied diverse products from branded knitted children’s apparel to yarns used by the U.S. military during World War II for parachute shroud lines, knitted blankets, field jackets and bomb parachutes. In the 1950s, the company focused on flame lamination to use with its jersey cloth, a process that continues today. In the mid-1980s, Shawmut relocated to its present West Bridgewater headquarters to focus on product development processes in advanced material technologies.

“Since our founding 105 years ago by my grandfather Rudolph Wyner, Shawmut always had the ability to adapt to changing markets and create innovation,” said CEO James Wyner. “Our history gives us a broad materials knowledge and expertise to engineer our own production techniques and capabilities that set us

ahead of our competition. Our customers tell us that we can develop solutions to their challenging requests much faster and with higher-quality output than our competition. We embrace what we’ve learned but are always looking to innovate to create better solutions.

Our purpose of ‘materials innovations for a better world’ may sound a bit aspirational, but we really do try to apply it to everything we do.”

An Automotive Leader Shawmut is a global supplier in the automotive market supplying everything from laminated headliners to pillars, roller shades, seating, door and trim laminations, sun visors, package trays and parcel shelves. A few years ago, the automotive headliner and specialty industrial fabrics business of Glen Raven Technical Fabrics (GRTF) merged with Shawmut after an 18year strategic partnership between the two companies. The merger fully integrated Shawmut’s composite development capabilities and global lamination platform with Glen Raven’s specialty industrial fabrics operation. About the venture, Shawmut said at the time: “Our recent merger with the specialty industrial business unit of Glen Raven Technical Fabrics represents the combining of forces between two longtime partners.

We now offer the full suite of automotive interior and industrial solutions, from durable high-performance knit fabrics to flexible multi-layer laminated composites.”

Shawmut recently announced plans to introduce a brand-new customer-focused Technical Center at the Burlington, N.C., Park Avenue facility that houses the merged operations. The Park Avenue Technical Center will offer customers unparalleled access to Shawmut’s advanced design, engineering, and production expertise, multiple quality and testing labs, along with state-of-the-art cus-

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repurposed and recycled by external sustainability operations.

Investing In Health, Safety

Top: Shawmut invested in the world’s most advanced meltblown filter media production system from Germany-based Reifenhauser Reicofil GmbH & Co. KG. Inset: Shawmut CEO James Wyner (left) with the Fallon Co. CEO Joe Fallon who was a majority investor in Shawmut’s face mask operation.

Bottom: Shawmut retrofitted 70,000-square-feet of space to accommodate production for its Health & Safety business unit.

tomer collaboration tools, all under one roof. The development of the Technical Center helps to meet Shawmut’s goal of accelerating the timeline of the finished product with even greater quality production leading to an enhanced experience for the

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customer. The Park Avenue Technical Center is also the first Shawmut facility to be ISO 14001 certified and is a 100-percent-landfill-free facility meaning that less than 1 percent of the waste that comes out of the facility goes to a landfill. Waste is mainly

In early 2021, Shawmut announced the creation of a new Health & Safety business unit, which was a strategic expansion into markets where Shawmut already had a foothold. According to the company, the new unit, applies “the company’s trademark advanced materials, textile manufacturing, and process innovation techniques to produc[e] high-quality, U.S.-made, health and safety products, including its Protex™ line of U.S.-made personal protective equipment (PPE).”

For decades, the company has produced medical-grade barrier and filtration fabrics, orthopedic medical devices, and certain inflatable medical devices. In the spring of 2020, Shawmut broadened its focus to produce PPE during the COVID-19 pandemic.

The company rapidly developed its Protex™ N95 Particulate Respirator, and now also manufactures medical isolation gowns and surgical barrier fabrics. With these additional product lines, the timing was right to bring on board additional personnel with health and safety expertise and launch the new business unit.

“This is a very exciting time in Shawmut Corporation’s 105-year history, as we delve deeper into the healthcare solutions space,” Wyner noted. “We’re making a significant, long-term commitment to developing innovative U.S.-made — and Berry Amendment-compliant — health and safety products not only for this period of great need, but well beyond so that our country never faces a critical PPE shortage again.”

Making Room, Starting Up According to Shawmut, the company retrofitted nearly 70,000square-feet of space in its West Bridgewater manufacturing facility to produce isolation gowns and N95 respirators. Shawmut acquired nearly 60 tons of specialized, high-precision meltblown machinery from Germany-based Reifenhauser Reicofil

GmbH & Co. KG, which was fasttracked and shipped on an expedited timeline to the Port of Boston. In addition, Shawmut installed a fully automated and flexible production system to support its N95 particulate respirator line, and installed roughly 50 new assembly lines for gowns and masks, some of which are augmented with advanced robotics capabilities.

The multi-million-dollar investment enables Shawmut to help customers meet demand and rapidly respond to their evolving business needs.

A Military Focus Most recently, Shawmut announced another strategic expansion with the creation of a new Military & Protective Materials business unit. The unit will produce high-quality, U.S.-made, ultra-high-specification and high-performance technical fabric solutions, many of which will also be Berry Amendment-compliant.

Shawmut’s military and protective solutions feature waterproof, windproof, flame-resistant, and chemical and biological protection properties, and are ideal for high-stakes usages required in military and in-the-field professionals who need high-performance gear to safely do their jobs.

With new business development leadership on board focused on highperformance materials solutions, the division integrates Shawmut’s textile manufacturing, dyeing, finishing and lamination capabilities to develop game-changing new technologies that will further establish Shawmut as a key player within the high-performance U.S. textile and garment industry.

Providing Protection Shawmut’s leadership position in lamination technology has resulted in multiple applications in protective gear including products in the highspec utility workwear market; fireretardant fabrics area; and chemical, biological, radiological, and nuclear protection markets. Shawmut’s ability to manufacture high moisture vapor transmission laminates provides solu-

Clockwise from top left: One of Shawmut’s original locations; Shawmut makes products for the global automotive market; Shawmut’s new Health & Safety business unit is producing U.S.-made PPE such as medical isolation gowns; Shawmut recently created a Military & Protective Materials business unit that will produce ultra-high-specification and high-performance technical fabrics.

tions for firefighters’ gear; surgical gowns; and waterproof, breathable utility and outdoor gear, among other applications. The waterproof, but breathable attributes also extend into products like footwear, military outerwear, as well as boots for hunting, hiking and military use.

Clean Water Shawmut leverages its advanced process technologies and technical fabric expertise to deliver customengineered materials solutions and solve complex challenges. Its global team believes that no challenge is too great, and they have a long history of solving a wide variety of industry needs through dynamic and innovative textile approaches. As an example, Shawmut is part of the worldwide push for innovative textile water filtration technologies as a producer of tricot knit technical fabrics that are used as permeate carriers in salt and brackish water reverse-osmosis filtration processes and systems. Shawmut reports its nonwoven filter fabric is U.S. Food and Drug Administration (FDA)-compliant and certified by the National Sanitation Foundation.

Looking Forward In this day and age, a fourth-generation, family-run international company is not commonly found, and Shawmut is by no means a common company. Drawing upon more than 100 years of experience in fabric formation and lamination, Shawmut uses materials innovation, engineering expertise, advanced processes, and global supply chain strategies to help rapidly solve customers’ advanced material design challenges, truly distinguishing itself from the conventional New England textile company stereotype. Shawmut’s story is rooted in agile technology application, advanced processes, performance testing, and quality — all while keeping the needs of the customer front and center.

“We’re excited to leverage our expertise in textile engineering, process innovation and commitment to excellence to produce the highest quality materials for the highest performing individuals,” Wyner noted when speaking about the new Military & Protective Materials business unit. This excitement, commitment, and problem solving is at Shawmut’s core. TW

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NONWOVENS/ TECHNICAL TEXTILES

Current respirators and facemasks center on two key technologies: fine, meltblown fibers; and an electrostatic charge.

(Sylwia Bartyzel/Unsplash)

COVID-19 — Lessons Learned?

Manufacturing innovations will provide more reliable, affordable and adaptable protection in the face of the next pandemic.

By Behnam Pourdeyhimi, Technical Editor; Simon Schick; and Robert Groten

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he World Health Organization (WHO) recently released the findings of its investigation into what went right and wrong as the world was faced with the coronavirus pandemic. An 86-page report noted that there were “weak links at every point in the chain of preparedness and response.” A 13-member panel appointed by the WHO called the COVID-19 pandemic a “preventable disaster.”

Some of the recommendations resulting from the investigation included: • Creating an improved system for disease surveillance and alerts, at a speed that can combat viruses like the one that causes COVID-19, along with authority for WHO to publish information and to dispatch expert missions immediately.

• The ability to produce vaccines,

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diagnostics, therapeutics and supplies and secure their rapid and equitable delivery as essential global common goods.

• Production of and access to COVID-19 tests and therapeutics, including oxygen, should be scaled up urgently in low- and middle-income countries.

Vice President Kamala Harris and U.S. Ambassador Linda ThomasGreenfield recently opened a dialogue on pandemic preparedness aimed at learning the lessons learned from COVID-19, which was cohosted

by Argentina, Norway, Japan, South Afria and the United States.

“The takeaway from this past year is clear: the world barely withstood this pandemic,” said Thomas-Greenfield addressing the global group comprised of political, public health and non-governmental organization

leaders. “We must be ready for the next. We cannot continue to underinvest — after outbreaks, epidemics, and now a pandemic — in our capacity to prevent, detect, and respond to infectious disease threats.”

Note that the WHO does not specifically address the challenges with personal protective equipment (PPE), but focuses on challenges with therapeutics, among other solutions.

The second bullet point above is a key point — having the ability to produce what is needed quickly and deliver these supplies globally and equitably.

When it comes to such products as facemasks for example, it is difficult to produce them quickly and distribute them equitably to low- and middleincome countries. A paradigm shift is needed, and cloth masks are not the solution

Background Protective mouth and nose coverage can be traced back to the beginning of the 20th century. In 1897, Carl Friedrich Flügge discussed the possibility of droplet infections originated by coughing and, interestingly, first identified the importance of social distancing1,2. The airborne transmission of cholera, plague, and cerebrospinal meningitis were discussed and the importance of wearing a “mouth bandage” — a single layer of cotton gauze — was recognized 1 .

Cotton-based facemasks were subsequently widely used during the Spanish flu pandemic of 1918-1920.

In contrast to this simple clothbased technology, current respirators and facemasks center on two key technologies: fine, meltblown fibers; and an electrostatic charge. Meltblowing itself extends back to 1941 when the process was first invented3.

It was immediately recognized that meltblowing can produce very fine fibers relative to traditional fiber melt spinning4. Meltblowing is a very economical, large-scale process that cre-

Inertial Impaction

Interception

Brownian Diffusion

Electrostatic Attraction

Figure 1: Filtration mechanisms

ates fiber diameters that range from sub-micron to a few microns.

Electrostatic charge enhances the particle interception efficiency of such fibers while producing a significantly lower overall pressure drop — a measure of the resistance that the air meets as it flows through the mask, which should be low enough that the effort required to breath is as normal as possible.

Other critical technologies focused on ensuring that the charge density was initially high and, more importantly, stable. The first “modern” mask was introduced in 19675 while the first respirator was patented in 1976. A critical development was the application of electrostatic charge to meltblown webs in 1980 6 . Key patents leading to the current widely used N95 respirators soon followed.

The first such patent was issued to Saint Paul, Minn.-based 3M Co. in 1980 when a meltblown structure was charged to form a high efficiency electrostatic filter 7 . In 1985, 3M developed the first modern, cupshaped molded respirator8.

Ideal Filtration Aerosols are a suspension of solid or liquid particles in a gas ranging in size from 2 nanometers (nm) to 100 micrometers. Bioaerosols are aerosols of biological origin, including viruses, bacteria and fungi. An ideal filter removes only the unwanted aerosol particles from the air and does it without creating a large pressure drop. There are four primary aerosol filtration mechanisms9 (see Figure 1).

The air stream bends as it moves around the fibers. Large particles are trapped by inertial impaction. Large

particles have a high probability of impacting with a fiber because inertia causes them to deviate from the streamline. Inertial impaction is for large micro particles and becomes important at high and medium velocities. Very small particles also have a high probability of hitting a fiber due to Brownian motion. Brownian motion comes about as the particles collide with gas (air) molecules that are much smaller than the particles. This leads to a chaotic movement that is disordered and abrupt, which leads to diffusion. The capture mechanism for particles less than 100 nm is mainly due to diffusion.

However, larger sized particles — from approximately 100 nm to 400 nm with roughly 300 nm representing the most challenging particle size to capture — normally follow the airflow streamlines and are the most difficult to capture. The capture mechanism is due to interception as the particles may be intercepted by a fiber. This is where the electrostatic attraction becomes important. Oppositely charged particles are attracted to a charged fiber. This collection mechanism does not favor a certain particle size particularly but is most significant for the particles most difficult to capture.

Fiber size becomes critical for the interception capture mechanism. If the fibers are of the same size or smaller, they have a tendency to be more effective in intercepting the particles. This, together with high electrostatic attraction, leads to high filtration collection efficiency in today’s respirators and medical masks that reply upon charged meltblown structures.

Cloth masks produced from regular textile fibers employ much larger fibers — greater than 15 microns in most cases — lack electrostatic charge and the structures create large gaps or holes. These gaps lead to localized areas that have a much lower pressure drop and therefore the air stream will flow naturally to these areas, carrying the aerosol particles through the structure. These masks offer almost no respiratory protection. They are useful however in reducing the number of expelled particles from the wearer, which may result in reducing the spread of a virus even though they may not offer much protection to the wearer. Thus, cloth masks are useful as a means of source control for individual wearers by reducing the number of expelled droplets and aerosols from the wearer’s nose and mouth into the air10.

References: 1 Flügge, C. Ueber Luftinfection. Zeitschr. f. Hygiene. 25, 179–224 (1897). https://doi.org/10.1007/BF02220473 2 C. Flügge, The spread of phthisis through dusty sputum and through droplets that are sprayed out when coughing, Journal of Hygiene and Infectious Diseases volume 30 , pages107 - 124 ( 1899 ) 3 JG McCulloch, The history of the development of melt blowing technology International Nonwovens Journal, 1999 4 Wente, V.A. , Naval Research Laboratory, Report 4364, Manufacture of Superfine Fibers. May 25, 1954.

5 U.S. Patent 3,333,585 6 U.S. Patent 3,971,373A 7 U.S. Patent 4,215,682A 8 U.S. Patent 4,536,440A 9 Pourdeyhimi, Schick and Groten, The Filtration Efficiency of Single-Layer Textiles for Respiratory protection, The Journal of Science and Medicine, Vol 3 No 2 (2021) 10 Pourdeyhimi, Schick and Groten, Respiratory Effectiveness of Cloth Masks, The Journal of Science and Medicine, Vol 2 No 4 (2021)

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Challenges During COVID-19 Mask filters are almost exclusively made from electrostatically charged polypropylene (PP) meltblown (MB) nonwovens. MB filters have fibers in the range of 0.5 to 5 microns in size and are therefore, fragile and must be protected by layers of spunbond (SB) PP made up of larger fibers — 15 to 25 microns — which provide mechanical protection for the MB filter layer.

The overall supply chain consists of the following: 1. MB fabric manufacturers; 2. SB fabric manufacturers; 3. Mask converters who assemble the MB and SB fabrics into masks.

The dual challenge faced in the United States and globally during the COVID-19 pandemic was the limited production of MB fabric and the lack of infrastructure needed to convert the fabrics into masks.

MB and SB production facilities are always custom built, are large and expensive and require significant infrastructure. The lead time for setting up new capabilities is typically greater than 10 months at a cost of more than $10 million for a small, 1.6meter-wide meltblowing machine.

Therefore, even in high-income regions in North America and the European Union, plants could not be deployed any faster. In other regions of the world, it would be impossible to ramp up quickly, and this is why there needs to be a paradigm shift. In contrast, mask conversion is more readily available, is relatively inexpensive and does not require special infrastructure.

MB machines are a lot more expensive that the sum of their components. Engineering know-how and in some cases, intellectual property, create barriers to entry. Meltblowing, for example, is rather simple as a process. The key to the technology is the die tip that controls the uniformity of the fibers produced. The rest of the components are off-the-shelf.

However, the nonwoven industry is built around large volumes, high

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speed and low production costs, and automation. This is why the nonwoven industry continues to lead the world in productivity and innovation.

What is needed for such products as facemasks and respirators is a different solution. The mask conversion is also a fully automated process,

Much of the new machinery installed in the United States for mask production is for the three-layer surgical mask, not the N95 mask. (Brian McGowan/Unsplash)

and the width requirements range from 19.5 centimeters (cm) to 32 cm at most. Note that mask converting does not require special infrastructure such as high bay space, for example. If a MB machine was designed that is only say 40 cm wide, the process will still be fast enough to supply many mask converting machines while the costs will be low, and no special infrastructure is needed. Take for example, the Biax Fiber Film pilot line which measures 15 inches (38 cm) in width. With a few minor changes, this can become a super mask filter production machine that can also be collocated with the mask converting equipment.

There are other examples of such smaller footprint lines that are primarily used as pilot lines. Such designs can be replicated and reproduced easily as needed.

Lack Of Know-How, Equipment Availability Another major challenge during the pandemic was lack of know-how.

Meltblown structures require additives as charge enhancers and charge stabilizers. While some masterbatches are commercially available, some work and some do not. Also, while meltblown machinery is fully automated, the resulting fabric is impacted by process variables and therefore, a trialand-error approach is required to establish the process conditions that lead to the desired performance characteristics. While there were companies in North America producing other meltblown products, switching to filter media was not a simple task.

Another challenge faced in North America was that no one was producing mask converting machinery before the pandemic. This was not because of a lack of expertise or capabilities, but rather driven by simple economics.

Asian-made machines sold for as little as $30,000 to as much as $120,000 and could be delivered in a few weeks. The cost of the components in North America would be higher than the finished product and given that the machines look similar and operate similarly, the tendency has been to lean toward Asian-made machinery. Lack of technical support, an inadequate supply of parts, and the unreliability of the machinery, often led to delays and much higher production costs.

Some sixteen months later, the situation has changed. There are a few new installations for meltblowing and according to the Cary, N.C.based Association of the Nonwoven Fabrics Industry (INDA), there are more than 70 companies who have invested in mask converting equip-

ment since the beginning of the pandemic. Much of the new machinery, however, is for the production of the classical three-layer surgical mask.

With cheap Asian surgical masks flooding the market over the past six months, it is questionable whether many of the companies that made investments will be able to compete.

This, in turn, will lead to challenges for the MB capacity installed.

There are far fewer N95 machines installed. In addition, medical masks and respirators are regulated by the National Institute for Occupational Safety and Health (NIOSH), the U.S. Food and Drug Administration (FDA) and the Occupational Safety and Health Administration (OSHA), and another barrier to entering the market today is the long lead time required for certification. Many companies have been waiting for certification for many months and the queue is not getting shorter. Certification also requires the development of a quality management system such as International Organization for Standardization (ISO) or good manufacturing practice (GMP) certification — additional barriers to market entry.

age situation in the United States likely will be no different. In the absence of democratized manufacturing, low-income countries will continue to be at a disadvantage.

The status quo of PPE manufacturing is not advanced enough to shield the United States from the next viral outbreak definitively. Further manufacturing innovations are the path forward to more reliable, affordable,

adaptable protection. Cloth masks will not be the solution, and will be regulated perhaps using the new ASTM 3502 or its equivalent.

The Nonwovens Institute, Raleigh, N.C., and its partners are developing manufacturing strategies and educational programs to help establish definitive minimum standards for manufacturing that would be scalable and easily reproducible. TW

What About The Next Pandemic?

It is not a question of if, but when, another global pandemic happens. In the absence of policies that encourage domestic manufacturing of PPE and other critical products, the shortEditor’s Note: Dr. Behnam Pourdeyhimi is associate dean for Industry Research and Extension, William A. Klopman Distinguished Professor of Materials, professor of Chemical and Biomolecular Engineering and Biomedical Engineering, and executive director, The Nonwovens Institute (NWI), Wilson College of Textiles, North Carolina State University, Raleigh, N.C.; Simon Schick was a masters student at NWI and NC State; and Robert Groten is a professor with Germany-based Hochschule Niederrhein University of Applied Sciences, Germany, and an adjunct professor at NC State.

Ultrasonics for Faster Production, Uncompromised Quality Meeting high demand for nonwoven PPE and hygienic products requires increased productivity BOE VODPNQSPNJTFE RVBMJUZ 8JUI FOFSHZ FGàDJFOU Branson™ ultrasonic welding solutions from Emerson, manufacturers can bond even delicate nonwovens without thread or adhesives, continuously and contamination-free. The result is faster, more DPTU FGàDJFOU QSPEVDUJPO BOE HSFBUFS UISPVHIQVU backed by real-time weld quality assurance and all the resources of Emerson’s global network.

Learn more at: Emerson.com/Branson

The Emerson logo is a trademark and a service mark of Emerson Electric Co. © 2021 Emerson Electric Co.

NONWOVENS/TECHNICAL TEXTILES

DiloGroup’s 3D-Lofter is an additive manufacturing process that can deposit additional fiber in specific areas on a flat needlefelt.

Innovations

For Nonwovens Production Nonwovens technologies can be used to produce an array of products for an ever-increasing number of end uses.

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vidence suggests the earliest means of turning fibers into cloth was through felting, which makes use of the scaly structure of wool to firmly interlock the fibers together. Some of the manufacturing techniques employed in today’s nonwovens industry are derived from this ancient fabric formation method, while other techniques are a product of modern engineering developed to work with man-made materials. The origins of today’s modern nonwovens industry are not clear, but according to the Nonwovens Institute, Raleigh, N.C., the term “nonwoven fabrics” was first used in 1942 when fabrics were manufactured by bonding fiber webs using adhesives.

In the decades since the term was coined, the innovations have turned into a dazzling array of technologies for making products for filtration, automotive, medical, hygiene, geotextile, agrotextile, floorcovering and even apparel applications, to name just a few of the applications. Here, Textile World presents information on some of the newest technologies available to producers of nonwoven fabrics and products.

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DiloGroup Engineered nonwoven systems manufacturer DiloGroup, Germany, offers a unique additive manufacturing process called the 3D-Lofter, which was originally introduced as a prototype at ITMA 2019. The process essentially uses a separate sliver feed mechanism that functions in a similar manner to a digital printer. The sliver is fed into an aerodynamic webforming unit, which allows additional quantities of fiber to be placed three dimensionally in specific locations on a flat needlefelt. The added fiber can be placed to avoid thin areas and build up stress points, alter textures, build mountains or fill valleys in the base web, and even allows for colored or patterned designs in the resultant web. Dilo reports the technology offers a fiber saving potential of up to 30 percent of the total fiber mass because once the even, flat needlefelt is created, only the fibers required are then used. The resulting web may be compacted and consolidated using needling and/or thermofusion. Applications include formed needlefelt parts for automotive interior linings, upholstery and mattress

products, apparel and shoe applications, and floor coverings with colored patterns.

DiloGroup also offers the IsoFeed single card feeder technology — an aerodynamic system featuring numerous 33-millimeter-wide individual web forming units placed over the card’s working width. These units can dose web or fiber strips in the running direction where they are needed to combat mass variation in the web.

According to Dilo, the IsoFeed can produce web mats from the card feeder with an improved CV value of approximately 40 percent. Additional advantages of IsoFeed include fiber consumption savings when the same minimum weight is the basis for a comparison between traditional and IsoFeed feeding; and the web is visually improved and more homogeneous. Web mats from the IsoFeed process are suitable for card feeding, for feeding aerodynamic web forming units, or may be used directly in needling or thermobonding processes.

Oerlikon Nonwovens, Teknoweb Materials Germany-based Oerlikon Nonwoven offers comprehensive technologies for meltblown, spunbond and airlaid nonwovens. For meltblown products, Oerlikon offers stand-alone mono and bicomponent equipment or the option of “plug & produce” inserts positioned between an upstream and downstream spinning system, such as spunbond, to manufacture products with a barrier or liquid impervious layer. Oerlikon Nonwoven reports its airlaid technology is perfectly suited to producing nonwovens from pulp or cellulose fibers. Its process also permits homogenous mixing of diverse raw materials and is gaining attention for use in sustainable recycling applications.

The latest offering from Oerlikon Nonwovens is the Procter & Gamble

(P&G) PHANTOM patented technology. Teknoweb Materials — Oerlikon’s partner for hygiene products and wipes — has an exclusive license from P&G to distribute this technology worldwide. Developed by P&G for hybrid nonwovens, Phantom combines airlaid and spunmelt technologies for wet and dry wipe products.

According to Oerlikon Nonwoven, the two processes are merged into one step to combine cellulose fibers, long fiber including cotton, and possibly powders with man-made fibers. No hydroentanglement means it is not necessary to dry the nonwoven, which offers cost savings. The process can be adjusted to optimize required product characteristics including softness, strength, dirt absorption and liquid absorption. Phantom technology is perfectly suited for wipes production, but also may be used for absorbent core products such as diapers.

An Andritz Laroche recycling line

ANDRITZ Nonwoven

Oerlikon Nonwoven’s airlaid technology is suitable for use in recycling operations.

Austria-based ANDRITZ Nonwoven reports its key competencies lie in drylaid, wetlaid, spunbond, spunlaced, needlepunched nonwovens, including converting and calendering.

Andritz offers technology for producing biodegradable, sustainable nonwovens including spunlace lines, Wetlace™ and Wetlace CP. The lines can process wood pulp, short-cut cellulosic fibers, viscose, cotton, hemp, bamboo and linen without the use of any chemical additives. The company offers customized trials in its advanced technical center in Montbonnot, France, which recently was updated with an innovative pulp application system for carded-pulp wipes.

Andritz’s latest technology for biodegradable wipe nonwoven production is its neXline wetlace CP.

This innovation combines two forming technologies — inline drylaid and wetlaid web forming — with hydroentanglement for bonding.

According to the company, natural fibers such as viscose or pulp, can be processed smoothly to produce a high-performance and cost-efficient carded-pulp wipe that is fully biodegradable.

The company recently acquired France-based Laroche S.a.s., which adds additional drylaid fiber preparation technology — including opening, blending, dosing, airlay web forming, textile waste recycling and bast fiber decortication — to the Andritz portfolio. The acquisition adds value in the recycling sector with complete recycling lines for post-con-

sumer and industrial waste, which can produce fibers for respinning and nonwoven end-uses. As part of the Andritz Group, the company is now known as ANDRITZ Laroche S.a.s.

Allertex Of America In the United States, Andritz Laroche is represented by Allertex of America Ltd., Cornelius, N.C. According to Allertex’s Technical Sales & Business Development director Jason Johnson, Laroche’s technology is perfectly suited to the rapidly emerging U.S. hemp fiber market.

“We see a huge interest currently in the decortication, cottonization and refining of hemp fiber in nonwovens for building materials, wipes, automotive uses, furniture and compos-

A schematic showing a Trützschler CP line including a HydroFormer for producing the wetlaid web layer and an NCT high-speed card for creating the carded web layer.

HydroFormer (Voith)

High-Speed Card NCT

AquaJet

Multi-Drum Dryer

Mather Roll Winder

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Brückner’s Supra-Flow BA air-through thermofusion oven for lightweight nonwovens Replacement components from Reifenhäuser Enka Tecnica are fully compatible with all globally installed meltblown and composite lines.

ites,” Johnson said. “Combined with Laroche opening, blending and airlay technology, as well as Schott & Meissner’s Thermofix technology, the sky is the limit!”

The Thermofix-TFE double-belt press flatbelt laminator from Germany-based Schott & Meissner Maschinen- & Anlagenbau GmbH uses a combination of contact heat and pressure. The product to be processed passes through the machine between two Teflon ™-coated conveyor belts. Once heated, the material moves through one or more calibrated nip rollers into a cooling area to thermoset the material. The Ther-

mofix-TFE is suitable for textiles used in outerwear, reflecting strips, artificial leather, furniture, glass mats, filters and membranes, among other applications. Thermofix is available in two models and three different sizes for handling varying capacities.

Allertex specializes in supplying recycling and nonwovens technologies including opening and blending, web forming, bonding, finishing, bast fiber processing, and lamination from a variety of companies.

Trützschler Nonwovens With an increased demand for high-quality, single-use cleaning wipes, Germany-based Trützschler Nonwovens has introduced a carded pulp (CP) solution for producing a sustainable, non-man-made-fiber nonwoven more affordably Graf + Cie’s Hipro card clothing can boost throughput by up to 10 percent, according to the company.

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using its AquaJet spunlaced technology. Trützschler along with partner Germany-based Voith GmbH & Co. KG introduced the WLS wetlaid/spunlaid environmentallyfriendly wipe process to the market in 2013-14. The WLS lines use cellulose-based blend of pulp from plantation wood and short lyocell or viscose fibers, which is dispersed in water then wetlaid and spunlaced.

Trützschler Nowovens’ latest CP development advances the WLS concept one step further by combining a wetlaid, pulp-based web with a carded web made using longer viscose or lyocell fibers. The wetlaid pulp provides the required absorbency and additional volume to the nonwoven, while the web enhances the softness and wet strength. The AquaJet’s highpressure water jets bond both layers into a functional nonwoven.

The CP production line features an NCT high-speed card between Voith’s HydroFormer wet web former and the AquaJet. This configuration is flexible — the card may be bypassed to produce a WLS nonwoven using only the HydroFormer and AquaJet; the wetlaying process may be omitted to produce a classic carded, hydroentangled nonwoven; or the HydroFormer, NCT card and AquaJet may all be utilized to produce a two-layer CP nonwoven.

According to Trützschler Nonwovens, its Poland-based customer Ecowipes has seen strong demand for the nonwovens produced using a CP line that was installed in the fall of 2020.

Reifenhäuser Reicofil, Reifenhäuser Enka Tecnica Germany-based Reifenhäuser Reicofil GmbH & Co. KG — a specialist in spunbond, meltblown and composite lines, and a business unit of Reifenhäuser GmbH & Co. KG — offers sustainable options for producing nonwovens. According to the company, its Reicofil lines can process up to 90-percent polyethylene terephthalate (PET) from post-consumer waste for use in industrial applications. The company also offers

technologies for producing hygiene products using sustainable materials such as diapers made using biobased raw materials.

In addition, Reifenhäuser Reicofil has solutions for medical protective items such as face masks. The company recognizes the need for 100percent reliable fabrics for such applications and guarantees highly reliable machinery for producing nonwovens with filtration efficiencies of up to 99 percent to meet N99/ FFP3 standards. West Bridgewater, Mass.-based Shawmut Corp. recently acquired nearly 60 tons of specialized, high-precision meltblown machinery for its new Health & Safety business unit from Reifenhauser Reicofil (see “Shawmut:

Investing In The Future Of Advanced Materials,” TW, this issue).

“In applications in the hygiene, medical and industrial sectors, we regularly set benchmarks for productivity and end-product quality,” said Markus Müller, sales director, Reifenhäuser Reicofil. “In addition, we offer our customers the option to produce sustainable nonwovens from bio-based raw materials or recycled material. We support our customers in leveraging the opportunities offered by the global shift to sustainability — or in other words: Next Level Nonwovens.”

Germany-based Reifenhäuser Enka Tecnica specializes in customdesigned replacement smart spinning beams, cassettes and spinnerets that are compatible with any existing spunbond or meltblown line. Its capabilities allow a manufacturer to upgrade existing lines and enter new markets including hygiene, medical or filtration. Enka Tecnica reports the high caliber of the nozzle tips and capillaries assure consistent product quality and precision. Its meltblown spinning beams also incorporate an optimized sustainable energy concept for reduced preheating times and increased heat output.

“Our primary concern is the satisfaction and success of our customers,” noted Wilfried Schiffer, managing

Idrosistem has developed specialized technologies to solve the water filtration problems faced by producers of spunlace nonwovens.

A Saueressig Surfaces’ pilot line for 3D embossing and apperturing

director, Reifenhäuser Enka Tecnica.

“That’s why a personal relationship with our customers is just as important to us as the punctual delivery of our very high-quality products. A long-term cooperation based on trust means more to us than turning a quick profit,” Both Reifenhäuser Reicofil and Reifenhäuser Enka Tecnica are represented in the United States by Fi-Tech Inc., Midlothian, Va.

Graf + Cie. Switzerland-based Graf + Cie. — a member of the Components Business Group of Rieter — is a manufacturer of clothing for flat and roller cards. For the nonwovens industry, Graf offers its Hipro Metallic Card Clothing. According to Graf, an innovative geometry used in the design may boost throughput by up to 10 percent in nonwovens applications compared to conventional clothings. The Hipro teeth feature a specially designed hump at the front, which increases fiber retention, according to Graf. An optimized web transfer from the cylinder to the doffer increases production by up to 10 percent, and fewer failures occur in

the web thanks to a precise fiber transfer to and from the cylinder.

The clothings, suitable for both high-performance and conventional cards, are available in a variety of steel alloys and a choice of surface finish so they may be tailored to the application and the fibers to be processed. Hipro Card Clothings are designed for all man-made fiber types processed in the nonwovens industry and are compatible with different rollers including workers, doffers and condenser rollers. Graf reports Hipro is ideally suited for applications in the hygiene, medical, automotive, filtration and floor covering markets.

BRÜCKNER Over the past few years, Germany-based BRÜCKNER Trockentechnik GmbH & Co. KG has developed its nonwovens portfolio considerably. The company offers ovens and dryers for nonwovens applications including: • Supra-Flow BX — an air-through double-belt thermofusion oven for high-loft nonwovens used in mattress insulation, seat cushions and upholstery;

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SAUERESSIG Surfaces

Sonobond’s SeamMaster® Ultrasonic Sewing machines meet requirements for barrier seams in nonwoven materials used for medical gowns, facemasks and other nonwoven medical supplies.

• Supra-Flow BA — an air-through thermofusion oven for lightweight nonwovens used in hygiene applications; • Supra-Flow BE — an air-through dryer for lightweight nonwovens used for abrasive cleaning pads, kitchen wipes, surgical tablecloths and feminine care products, among other applications; • Supra-Flow BH — an air-through dryer for high-speed spunlace lines; and • Power-Frame — an air-impingement tenter for thermal treatment/drying of needlefelts, bitumen carriers for roofing membranes, high-temperature filters and geotextiles.

In addition, Brückner’s nonwovens product range comprises impregnation units, coating units, accumulators, calibration calenders, lamination calenders, cutting machines and winding machines. Brückner has a technology center at its headquarters location in Leonberg, Germany, where customers may run trials.

Brückner is represented in the United States by Fi-Tech.

Idrosistem The quality of the water used in spunlace manufacturing processes is important. Italy-based Idrosistem S.r.l. specializes in water filtration systems for spunlace lines that remove fibers from the water to avoid issues with injectors and finished product

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quality. The company’s latest offering was designed to control bacteria in the water loop during wet wipe production. The technology uses a chlorine dioxide water sterilization system to keep toxic matter, in particular chlorides and bromate-based products, out of the production water.

Idrosistem reports that the sterilization system maintains its efficiency independently from the pH of the water and can reach the lowest limits for bacteria control required in terms of colony forming unit per millimeter (CFU/ml). The system also acts as a powerful algaecide, bactericide, virucide and sporicide, according to the company. Idrosistem is represented

by Fi-Tech in the United States.

Germany-based Saueressig Surfaces, a Matthews International Corp. company, is an established designer and manufacturer of sleeves and embossing rollers for decorating spunbond and thermally bonded nonwovens. The company uses the latest laser-engraving methods as well as evolved molettage techniques.

Hardened rollers, microporous shells, basic and structure dams expand the customization options. Recent developments include new 3D embossing and apperturing options offline using high-precision heated rollers with complex and exact engraving patterns; or inline during the hydroentangling process using nickel sleeves. These developments make designs with 3D effects possible with improved tensile strength and elasticity, and high air/liquid permeability. Saueressig also can produce 3D samples — taking base material, engraving pattern, basis weight and color into account — so customers can develop optimal solutions for their end products.

Saueressig Surfaces is represented in the United States by Fi-Tech.

Ultrasonic Bonding Technology: Sonobond Ultrasonics

Nonwovens are non-traditional fabrics and traditional cut-and-sew methods may not be the most effective way to produce end products using nonwovens. The onset of The Branson DCX F by the pandemic and need for perEmerson with real-time sonal protective equipment data output and Fieldbus (PPE) in particular created communications. increased interest in ultrasonic technologies — those that use high-frequency sound waves to heat and plasticize man-made fiber nonwoven fabrics.

According to West Chester, Pa.-based Sonobond Ultrasonics, ultrasonic bonding technologies can quickly create strong, sealed edges and secure barrier seams that meet regulatory requirements. These high-quality

bonds at pressure points create fin- Emerson between two layers of nonwovens ished products without stitch holes, St. Louis-based Emerson offers and guides the stretched elastic glue gaps, fraying or unraveling. No Branson ultrasonic equipment that through the tunnel. The fabric is then thread is needed, and production can slit, bond, seal or quilt man- welded in specific bonding areas tends to be fast for greater output. made fiber nonwovens for medical before it is cut and relaxed. The new Sonobond offers bonding, seaming, and non-medical applications. The anchoring process may be executed slitting, cutting and trimming equip- company reports a major advance- continuously or intermittently. ment and often, more than one func- ment is the ultrasonic welder’s ability According to the company, the tion may be performed on the same to monitor and record welding data method simplifies elastic handling, unit in a single step. Sonobond’s in real time. This enhances the cus- reduces the risk of breakage, increases SeamMaster ® Ultrasonic Sewing tomer’s quality control capabilities the process window and lowers proMachines are the company’s most and allows for continuous improve- duction costs. Herrmann reports it popular technology. SeamMaster ments even in automated lines. has successfully tested a range of offers continuous, patented material combinations, difrotary operation for strong, ferent size elastics and elonsealed, smooth and soft gations, and varying speeds. seams. According to the “This new process, we company, the machine can call ‘Anchoring’, will supbe used in a wide variety of port our North American assembly applications since customers even better, as more than one function may they strive to create products be performed at one time. that are softer and more For example, with the necessustainable,” said Uwe sary tooling, the SeamMasPeregi, president, Herrmann ter can bond, seam and trim Ultrasonics Inc. in one quick step. Sonobond Herrmann also has reports the speed is up to updated its ULTRABOND four times faster than when ultrasonic generator with using a traditional sewing new controls that can trigger machine and up to 10 times the ultrasonic vibrations faster than adhesive A magnified cross-section of the elastic thread fixed in a tunnel quickly and in the right place machines. The machine also built between two ultrasonically welded layers of nonwoven instead of generating a conis configured similar to a tra- fabric using Herrmann Ultrasonics’ “Anchoring” process. tinuous signal. This update ditional sewing machine, so makes format-dependent minimal operator training is required Another recent advance is the tools, such as a format anvil drum, to operate the SeamMaster. addition of Fieldbus capabilities in unnecessary. Herrmann notes that Applications for Sonobond’s tech- Branson’s DCX F ultrasonic welding overall equipment efficiency is nology in the medical nonwovens system, which allows multiple weld- improved with reduced tool costs and market include face masks; surgical ing systems to connect to each other less time required for format changes. gowns; disposable shoe, pillow and and communicate directly with a Combining the Ultrabond generator mattress covers; and lint-free wound programmable logic controller. Field- signal with its MICROGAP technoldressings. Filtration products that bus allows the user to control weld ogy — which controls the gap in the may be made using Sonobond’s parameters for an individual ultra- bonding area — allows multi-dimenultrasonic technologies include sonic welder and also monitor the sional process monitoring to ensure pleated HVAC and HEPA filters; air, status of a multi-welder production consistent bonding quality and direct liquid and gas filters; heavy-duty fil- system using an electronic dash- system feedback. ter bags; and spill clean up cloths and board. In this manner, the user can All of the latest nonwovens innooil containment booms. optimize the production process and vations are sure to be on display at To help a customer decide on the address issues as they arise. the upcoming INDEX ™ 20 nonwovens event in October 2021. The best technology for their application, expo also will be available in a paralSonobond offers a free Ultrasonic Herrmann Ultrasonics Herrmann Ultrasonics Inc., lel virtual format for attendees who Bonding Viability Test using the customer’s nonwoven materials. The Bartlett, Ill., offers a new ultrasonic are unable to be there in person. See customer then has the opportunity to technology for anchoring elastic “Global Triennial Nonwovens Show see the results and understand the threads in diapers. The company’s Moves Ahead,” TW, this issue, to innovative process creates a tunnel learn more about INDEX. TW capabilities of the available products.

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NONWOVENS/ TECHNICAL TEXTILES

At the beginning of the pandemic, the textile community, as well as home sewers, responded to the need for barrier face coverings.

Standardizing

large droplets of saliva and/or mucus, while also being reasonably comfortable to the wearer.4 The evaluation places a focus on the filtration efficiency, breathability, fit and expected usage conditions.5 This article reviews the importance of standardized test methods, and some of the key issues related to face coverings. At the same time, it should be noted that even with standardized testing to quantify performance, individual use factors — such as wearing the mask correctly, facial fit, usage time and other factors — also impact the efficacy of the barrier covering performance. These factors are beyond the scope of this article.

Barrier Face Covering Testing

Why Test Standards Are Needed

Standardized testing of face coverings may be beneficial in reducing public confusion and misinformation about performance.

The increased use of face coverings during the COVID-19 pandemic led to a surge of studies on the filtration efficacy of various face coverings and materials. In September of 2020, a paper was published detailing a “simple optical measurement method” using an expanded laser beam and a cell phone camera to evaluate the efficacy of different masks.6 The study examined a variety of samples and ranked the relative droplet count emerging from the coverings. The study authors concluded that “speaking through some masks — particularly the neck gaiter — seemed to disperse the largest droplets” causing an increase in droplet count compared to the “no mask” control. The authors concluded that smaller droplets dispersed from larger droplets remained airborne for longer periods of time, suggesting that the use of neck gaiters may be counterproductive to the wearer. Even though limitations of the detection method were discussed in the article, many news outlets reported on the implication that in some cases, a neck gaiter may be worse than no mask at all.7,8,9,10

(Pixabay/Phimchanok Srisuriyamart)

By Dr. Davis Lee; Dr. Erin Kirkpatrick; Dr. Emily Fitzharris; Dr. Ariana Levitt; Michael Posson, M.P.H., CIH; Ryan Siskey M.S.; and Dr. Mark Roberts

DD

uring the pandemic, there has been a sharp increase in demand for face coverings to reduce the risk of infection by the novel coronavirus (SARS-CoV-2), creating both opportunity and challenge for textile manufacturers. As a result, there is growing awareness that a clear regulatory difference exists between personal protective equipment (PPE) used in an occupational or healthcare setting — N95 respirators and surgical masks for example — and barrier face coverings that may be used by the general public such as the face coverings as described by the Centers for Disease Control and Prevention (CDC).1 While established standards and requirements already exist for many types of PPE, this was not the case for the barrier face coverings that have been in wide-use by the general public in response to the COVID-19 pandemic.2

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The textile community responded to the need for barrier face coverings in unprecedented fashion. This has in turn driven the need for standardized testing to help educate the public and to reduce confusion about performance. Many universities, companies and testing laboratories have developed novel approaches for evaluating the efficacy of barrier face coverings, with particular emphasis on inexpensive and easy to implement methods. Standardized methods for evaluating face covering efficacy have also emerged. ASTM F3502-213 for example, was developed and published in just eight months in response to the critical need for objective test methods. The purpose was to provide a test method that evaluates the ability of a face covering to act as a barrier to the transfer of aerosolized particles and

These media conclusions have since been disproven by a number of different studies showing that neck gaiters can be effective at blocking a range of particle sizes, especially when worn as a double layer. 11,12 Moreover, the higher number of particles detected in the initial study have led some to speculate that this was the result of fibers shedding from the fabric. 13 However, even with these new results, the controversy of “Gaitergate” left the public confused over the efficacy of face covering options during a time when supply chain constraints were making it necessary for the general public to use all available options.

Key Issues Efforts to evaluate the performance of textile face coverings — for filtration efficiency and breathability, for example — have shed light on the importance of standardizing the methods used to evaluate these coverings.

Standardized methods for evaluating face masks help to ensure the availability of consistent methodologies for comparing barrier face covering technologies. They also help to assess the various parameters that can affect both performance results and variability.

The following points represent examples of product and test parameters that can affect the performance results of barrier face coverings: • Textile Construction: Numerous studies have shown that fiber content and fabric structure can significantly impact filtration efficiency and breathability.14,15,16 For example, researchers compared the performance of two cotton samples with different weave densities, or threads per inch (TPI), and found that the denser weave had a higher filtration efficiency.17 While this is not surprising, many studies do not describe the structure and fiber content of textile coverings, making it difficult to interpret the results and compare the results within and between studies. The new ASTM F3502-21 requires the primary materials of construction,

(Air Techniques International/atitest.com)

Mask integrity tests for ASTM F3502 follow the NIOSH procedure for sodium chloride aerosol testing.

including the materials and fiber content to be printed legibly on the product packaging.

• Sample Conditioning: It is common practice to pre-condition textile samples to minimize test variability. This is done by preconditioning test samples to a standard humidity and tempera-

ture for a prescribed period of time prior to testing. ASTM F3502-21 requires pre-conditioning test samples at 85 ± 5% relative humidity and 38 ± 2.5°C for 25 ± 1 hour.18,19 This is particularly important for textile face coverings, as temperature and humidity may influence the per-

References: 1 “Recommendation Regarding the Use of Cloth Face Coverings, Especially in Areas of Significant Community-Based Transmission” Centers for Disease Control and Prevention, reviewed 3 April 2020, www.cdc.gov/coronavirus/2019ncov/prevent-getting-sick/cloth-face-cover.html. Accessed 21 April 2020.

2 “Global Collaboration to Advance Personal Protective Equipment (PPE) Safety, Quality, and Innovation” ASTM White Paper, February 2021, https://www.astm.org/ABOUT/PPE-White-Paper-R2.pdf. Accessed 25 May 2021.

3 ASTM F3502-21, Standard Specification for Barrier Face Coverings, ASTM International, West Conshohocken, PA, 2021, www.astm.org.

4 Plotz, Chris, INDA, Director of Education & Technical Affairs, personal communication.

5 Peachman, Rachel. “New Standards for Everyday Masks will Help People Pick Covid-19 Face Coverings.” The Washington Post, 1 March 2021. https://www.washingtonpost.com/health/new-covid-19-cloth-mask-standards/2021/02/26/307aa398-730e-11eb-85fa-e0ccb3660358_story.html. Accessed 25 May 2021.

6 Fischer, Emma, et al. “Low-Cost Measurement of Face Mask Efficacy for Filtering Expelled Droplets During Speech.”

Science Advances, 2 September 2020. 10.1126/sciadv.abd3083.

7 Morris, Emily. “Facial Masks that Miss the Mark.” The Oakland Post, 17 February 2021. https://oaklandpostonline.com/34628/opinion/facial-masks-that-miss-the-mark/. Accessed 25 May 2021.

8 Kelleher, Suzanne. “Neck Gaiters Do Not Curb COVID-19, Study Finds.” Forbes, 11 August 2020. https://www.forbes.com/sites/suzannerowankelleher/2020/08/11/neck-gaiters-do-not-curb-covid-19-studyfinds/?sh=5086abdd204d. Accessed 25 May 2021.

9 Chiu, Allyson. “Wearing a Neck Gaiter May Be Worse Than No Mask At All, Researchers Find.” The Washington Post, 11 August 2020. https://www.washingtonpost.com/lifestyle/wellness/mask-test-duke-covid/2020/08/10/4f2bb888db18-11ea-b205-ff838e15a9a6_story.html. Accessed 25 May 2021.

10 Baskar, Pranav. “How Should I Cover My Face? A Deeper Look Into Neck Gaiters and Face Shields.” NPR, 14 August 2020. https://www.npr.org/sections/goatsandsoda/2020/08/14/902244060/how-should-i-cover-my-face-adeeper-look-into-neck-gaiters-and-face-shields. Accessed 25 May 2021.

11 Pan, Jin and Marr, Linsey. “Neck Gaiters.” Civil and Environmental Engineering, Virginia Tech, 15 August 2020. https://drive.google.com/file/d/1GNXt-SWSsPTp8nv0MtqpvUmVQI8g-7WE/view. Accessed 25 May 2021.

12 Lindsley, William, et al. “Efficacy of Face Masks, Neck Gaiters and Face Shields for Reducing the Expulsion of Simulated Cough-Generated Aerosols.” Aerosol Science and Technology, 7 January 2021.

10.1080/02786826.2020.1862409.

13 https://twitter.com/CappaSnappa/status/1296494910355451905 14 Konda, Abhiteja, et al. “Aerosol Filtration Efficiency of Common Fabrics Used in Respiratory Cloth Masks.” ACS Nano, 24 April 2020, 10.1021/acsnano.0c03252.

15 Zhao, Mervin, et al. “Household Materials Selection for Homemade Cloth Face Coverings and their Filtration Efficiency Enhancement with Triboelectric Charging.” Nano Letters, 2 June 2020. 10.1021/acs.nanolett.0c02211.

16 Zangmeister, Christopher, et al. “Filtration Efficiencies of Nanoscale Aerosol by Cloth Mask Materials Used to Slow the Spread of SARS-CoV-2.” ACS Nano, 25 June 2020. 10.1021/acsnano.0c05025.

17 Konda, Abhiteja, et al. “Aerosol Filtration Efficiency of Common Fabrics Used in Respiratory Cloth Masks.” ACS Nano, 24 April 2020, 10.1021/acsnano.0c03252.

18 ASTM D1776-04, Standard Practice for Conditioning and Testing Textiles, ASTM International, West Conshohocken, PA, 2021, www.astm.org.

19 ASTM F3502-21. See ASTM F3502-21, Standard Specification for Barrier Face Coverings, ASTM International, West Conshohocken, PA, 2021, www.astm.org.

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formance of substrate materials — such as polyester, nylon or cotton — differently.

• Air Flow Rate: Air flow rate has been shown to affect the measured efficiency of textile face coverings. A slower flow rate typically results in improved filtration efficiencies.20,21 Ideally, the test flow rate should be standardized and should mimic respiratory rates so that test results are realistic. Pressure drop across the textile face covering is a related parameter that can affect both filtration efficiencies and breathability. ASTM F3502-21 specifies a flow rate of 85 + 4 liters per minute, and if the sample is lying flat in a filter holder adjusting the flow rate to achieve a face velocity of 10 + 0.5 centimeters per second.22 • Mask Fit: In use, mask fit is critical to the overall performance of the textile face covering as gaps between the wearer’s face and the textile allow respiratory droplets and aerosols to escape.23,24 Quantifying and standardizing mask fit is especially challenging and is often not sufficiently examined.

ASTM F3502-21 addresses the importance of mask fit with a leak-

age assessment (Vera Davidova/Unsplash) that is described in the method.

The standard also permits supplemental quantitative testing to determine the leakage ratio based on ASTM F3407: Standard Test Method for Respirator Fit Capability for Negative-Pres- Standardized testing for barrier face coverings, such as sure Half-Face- homemade masks, may help reduce public confusion and piece Particulate misinformation about performance.

Respirators.25 • Charge Neutralizing Aerosol tice used in standards evaluating Particles: Charged particles can filtration efficiency, such as EN impact filtration efficiency due to 1822 31 , ISO 29463 32 , ASTM electrostatic interactions with the F3502-2133, and NIOSH No. TEBmask material and other nearby APR-STP-0059.34 26,27,28 particles.

For instance, aerosols that contain moisture can Conclusions change diameter during testing, While test methods for evaluating influencing the measured particle the efficacy of PPE face masks have size distribution of the filtered existed for years, they are only just particles and the filtration effi- emerging for barrier face coverings. ciency. 29,30 In order to mitigate Standardized testing may be benefithese effects, particles need to be cial in helping to reduce public concharge neutralized and dried prior fusion and misinformation about to testing. This is a common prac- performance. Standardized tests, such as ASTM F3502-21 that address key technical issues, such as References: 20 Kumar, Amit, et al. “Evaluation of Filtration Efficacy of Various Types of Facemasks Using Ambient and PAO the few examples identified in this Aerosols Following with Different Sterilization Methods.” MedRxIv, 27 October 2020. 10.1101/2020.10.23.20218073. article should provide both manu21 Stevens, Gregory and Moyer, Ernest. “’Worst Case’ Aerosol Testing Parameters: I. Sodium Chloride and Dioctyl Phthalate Aerosol Filter Efficiency as a Function of Particle Size and Flow Rate.” American Industrial Hygiene Associafacturers and consumers with tion Journal, May 1989. increased clarity on the performance 22 See ASTM F3502-21, Standard Specification for Barrier Face Coverings, ASTM International, West Conshohocken, PA, 2021, www.astm.org. of face coverings. TW 23 Aydin, Onur, et al. “Performance of fabrics for home-made masks against the spread of COVID-19 through droplets: A quantitative mechanistic study.” Extreme Mechanics Letters, 11 August 2020. 10.1016/j.eml.2020.100924.

24 Zhao, Mervin, et al. “Household Materials Selection for Homemade Cloth Face Coverings and their Filtration Efficiency Enhancement with Triboelectric Charging.” Nano Letters, 2 June 2020. 10.1021/acs.nanolett.0c02211.

25 ASTM F3407-20, Standard Test Method for Respirator Fit Capability for Negative-Pressure Half-Facepiece Particulate Respirators, ASTM International, West Conshohocken, PA, 2020, www.astm.org.

26 Rule, Ana et al. “Comment on Aerosol Filtration Efficiency of Common Fabrics Used in Respiratory Cloth Masks: Questioning Their Findings. ACS Nano, 22 September 2020. 10.1021/acsnano.0c05265.

27 Freitag, Steffen et al. “Why simple face masks are unexpectedly efficient in reducing viral aerosol transmissions.”

MedRxIv, 4 December 2020. 10.1101/2020.12.03.20243063.

28 Mueller, Amy et al. “Quantitative Method for Comparative Assessment of Particle Removal Efficiency of Fabric Masks as Alternative to Standard Surgical Masks for PPE.” Matter, 2 September 2020. 10.1016/j.matt.2020.07.006.

29 Rule, Ana et al. “Comment on Aerosol Filtration Efficiency of Common Fabrics Used in Respiratory Cloth Masks: Questioning Their Findings. ACS Nano, 22 September 2020. 10.1021/acsnano.0c05265.

30 Mueller, Amy et al. “Quantitative Method for Comparative Assessment of Particle Removal Efficiency of Fabric Masks as Alternative to Standard Surgical Masks for PPE.” Matter, 2 September 2020. 10.1016/j.matt.2020.07.006.

31 EN 1822: High Efficiency Air Filters (Efficient Air Filters (EPA), High Efficiency Air Filters (HEPA), Ultra Low Penetration Air Filters (ULPA)). ICS 13.040.40. 14 January 2019.

32 ISO 29463: High-Efficiency Filters and Filter Media for Removing Particles in Air, September 2017, www.iso.org.

33 ASTM F3502-21, Standard Specification for Barrier Face Coverings, ASTM International, West Conshohocken, PA, 2021, www.astm.org.

34 National Institute for Occupational Safety and Health. “Determination of Particulate Filter Efficiency Level for N95 Series Filters Against Solid Particulates for Non-Powered, Air-Purifying Respirators.” NIOSH Procedure No. TEB-APR-STP-0059, Rev. 3.2, 13 December 2019.

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Editor’s Note: Dr. Davis Lee is senior managing scientist, Dr. Erin Kirkpatrick is managing scientist, Dr. Emily Fitzharris is associate and Dr. Ariana Levitt is a scientist in the Polymer Science & Materials Chemistry practice of Exponent Inc. — a multi-disciplinary engineering and scientific consulting firm. Ryan Siskey, M.S., is the principal and office director of Exponent’s Biomedical Engineering & Sciences practice. Michael Posson, M.P.H., CIH, is senior managing scientist and Dr. Mark Roberts is principal scientist at Exponent’s Health Sciences practice.

Dyeing,Printing & Finishing Pulcra Acquires Devan Germany-based Pulcra Chemicals has acquired Belgium-based Devan from private equity fund Pentahold.

“We are thrilled to make this announcement with our mutual trust to grow our business as a Solution Specialist for our customers across broad range of textile markets,”said said Ümit Yaldiz, CEO of Pulcra Chemicals Group.“The acquisition of Devan will support our vision of being the leading international benchmark for sustainable chemistry. Both organizations have deep histories of creativity, innovation excellence and a shared commitment to care for our communities. With our combined platform, Pulcra will become a stronger partner for our customers, uniquely positioning us to address our customers’evolving needs.”

Coloreel Raises 70 Million Swedish Krona Sweden-based Coloreel reports it has raised 70 million Swedish Krona ($8.1 million) that will be used to support the market expansion and

growth of its unique patented technology for dyeing textile threads digitally and on-demand. The technology offers embroidery providers an number of benefits including creative freedom, high embroidery quality, and no thread or water waste. Existing embroidery heads may be equipped with Coloreel’s technology. The company is represented in the United States by Hirsch Solutions, Peachtree City, Ga., which has already installed the technology at several U.S. customers.

“In parallel to this [private placement], we now receive more and more new expressions of interest from additional investors which feels very exciting,”said the company’s founder and main owner Joakim Staberg.

Gavin Supports AATCC Foundation With $100,000 Gift In honor of the Research Triangle Park, N.C.-based American Association of Textile Chemists and Colorists’(AATCC’s) 100th anniversary this year, Charles E. Gavin III

made a generous donation of $100,000 to the AATCC Foundation.

According to AATCC, this contribution will fully endow two graduate fellowships as permanent sources of textile student support, which helps the organization get much closer to its goal of endowing all existing Foundation scholarships.

In 1997, Gavin was the first donor and was instrumental in establishing AATCC Foundation Inc. Over the years, he has also created and supported several Foundation scholarships and fellowships for both undergraduate and graduate students — providing not only financial assistance, but also guidance and encouragement.

“I would like to thank the Gavin family for their generosity in giving this scholarship, and AATCC for the dedication of their member corporations to continuing the education of Polymer and Fiber science in the U.S. Thank you!”said Jonathan Shaheen, recipient of 2021-2022 Charles E. Gavin III Family Scholarship.

Avient Acquires Magna Colours

Polartec® Removes PFAS From Its DWR Treatments Andover, Mass.-based Polartec®, a Milliken & Company brand, recently announced it has eliminated the use of per- and polyfluroalkyl substances (PFAS) in durable water repellent (DWR) treatments used for its line of performance fabrics including Hardface®, Power Shield®, Power Shield Pro, NeoShell® and Windbloc®.The change is part of Polartec’s EcoEngineering™ initiative, and the company reports the new non-PFAS treatment imparts zero loss of durability or water repellency when compared to PFAS treatments. Polartec also will be used on fleece and insulation treat-

ments for improved moisture-management properties on products such as Thermal Pro® and Alpha®.

“Trial results have exceeded even our expectations,” said Mike Rose, Polartec vice president of Product Development. “There is no loss of performance from a water repellency or durability standpoint.”

“Achieving non-PFAS treatments within our product line is an important milestone in our commitment to sustainably made performance fabrics,” added Steve Layton, Polartec president.

“It’s the latest step on our journey to an even more sustainable Polartec.”

Cleveland-based Avient recently acquired Magna Colours Ltd., England, for $48 million. The MagnaColours® water-based ink technologies for textile screen printing will be added to Avient’s specialty ink portfolio joining brand such as Wilflex® and Rutland®.

“Magna represents an important investment in sustainable solutions, as brand owners seek alternatives to legacy technologies,”said Robert M. Patterson, chairman, president and CEO, Avient.“We are thrilled to have Magna join Avient. We expect our collective inks portfolio will grow substantially as the threat of COVID subsides, people can safely attend sporting and other live events in person, and travel increases.” TW

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KNITTING/APPAREL

Testing showed that even very thin fabrics protected the wearer from mosquito bites as long as the fabric had a very small pore size.

(Image Matt Bertone, NC State)

Patent rights to mosquito-resistant clothing developed at NC State has been licensed by startup company Vector Textiles.

By Laura Oleniacz

Mosquito-Resistant Clothing Prevents Bites In Trials

NN

orth Carolina State University researchers have created insecticide-free, mosquito-resistant clothing using textile materials they confirmed to be bite-proof in experiments with live mosquitoes.

They developed the materials using a computational model of their own design, which describes the biting behavior of Aedes aegypti , the mosquito that carries viruses that cause human diseases like Zika, Dengue fever and yellow fever.

Ultimately, the researchers reported in the journal Insects that they were able to prevent 100 percent of bites when a volunteer wore their clothing — a base layer undergarment and a combat shirt initially designed for the military — in a cage with 200 live, disease-free mosquitoes. Vector Textiles, an NC State startup company, has licensed the related patent rights and intends to make clothing for commercial sale in the United States.

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The researchers think their computational model could be used more widely to develop clothing to reduce transmission of diseases.

“The fabric is proven to work — that’s the great thing we discovered,” said study co-author Andre West, associate professor of fashion and textile design at NC State, and director of Zeis Textiles Extension for Economic Development. “To me, that’s revolutionary. We found we can prevent the mosquito from pushing through the fabric, while others were thick enough to prevent it from reaching the skin.”

To develop the computational model to design textile materials that could prevent A. aegypti bites, researchers investigated the dimensions of the head, antenna and mouth of A. aegypti, and the mechanics of how it bites. Then, they used the model to predict textile materials that would prevent bites, depending on their thickness and pore size.

Researchers said they believe the materials could be effective against other mosquito species in addition to A. aegypti because of similarities in biology and biting behavior.

“There are different uses for clothing,” said the study’s first author Kun Luan, postdoctoral research scholar of forest biomaterials at NC State.

“The idea is to have a model that will cover all possible garments that a person would ever want.”

Testing The Model To test the accuracy of their model, the researchers tested the materials predicted to be bite-proof. In experiments with live, disease-free mosquitoes, the researchers surrounded a blood reservoir with plastic materials made according to parameters predicted by the model. They then counted how many mosquitoes became engorged with blood.

One material they initially tested was very thin — less than one mil-

limeter thick — but had a very small pore size to prevent the mosquito from sticking its mouth parts, or proboscis, through the material. Another material had a medium pore size to prevent the mosquito from inserting its head through the textile far enough to reach the skin; and a third material had larger pores, but was sufficiently thick that the mosquito’s mouth still couldn’t reach the skin.

In a subsequent test, the researchers chose a series of knitted and woven fabrics that met the biteproof parameters determined by the model, and validated they worked in experiments using both the blood reservoir and human volunteers. The researchers tested the number of bites received by volunteers when study participants inserted an arm covered by a protective sleeve into a mosquito cage. The researchers also compared the fabrics’ ability to prevent bites and repel mosquitoes to fabrics treated with an insecticide.

From what they learned in early experiments, researchers developed the bite-resistant, form-fitting undergarment made with a thin material, as well as a long-sleeved shirt, which was initially envisioned as a combat shirt for the military.

When a volunteer wore the garments sitting for 10 minutes and

standing for 10 minutes in a walk-in cage with 200 hungry mosquitoes, the volunteer found the combat shirt was 100-percent effective at preventing bites. In the first trial testing the base layer, the volunteer received bites on the back and shoulders — seven bites from 200 mosquitoes. The researchers attributed the bites to the fabric stretching and deforming, so they doubled the material layer around the shoulders, and were ultimately able to prevent 100 percent of bites. They also tested the clothing for comfort, and to see how well it trapped heat and released moisture.

Results “The final garments that were produced were 100-percent biteresistant,” said Michael Roe, William Neal Reynolds Distinguished Professor of Entomology at NC State.

“Everyday clothing you wear in the summer is not bite-resistant to mosquitoes. Our work has shown that it doesn’t have to be that way.

Clothes that you wear every day can be made bite-resistant. Ultimately, the idea is to have a model that will cover all possible garments that person would ever want — both for the military as well as for private use.”

The study, “Mosquito-textile physics: A mathematical roadmap to

A shows the human arm in cage bioassay covered with fabric sleeve during testing; and B-D are predicted safe fabrics that were tested. B is an ultrafine, thin man-made knit fabric with small pores; C shows two layers of the fabric shown in B; D shows a thick 3D warp knit fabric.

insecticide-free, bite-proof clothing for everyday life,” was published online July 13, 2021, in the journal Insects . It was authored by Luan, Roe, West, Charles Apperson, Marian McCord, Emiel DenHartog, Quan Shi, Nicholas Travanty, Robert Mitchell, Grayson Cave, John Strider and Youngxin Wang from NC State University; and Isa Bettermann, Florian Neumann and Tobias Beck from Aachen University, Germany. The study was supported by the National Science Foundation, the Department of Defense Deployed War Fighter Program, Natick Contracting Division of the U.S. Department of Defense, the Chancellor’s Innovation Fund at NC State, the Southeast Center for Agricultural Health and Injury Prevention, PILOTS and the NC Agriculture Research Experiment Station. TW Editor’s Note: Laura Oleniacz is Public Communications Specialist at NC State News Services.

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WEAVING & SPINNING

Norfil Benefits From Flexible Production With

Comber E 90 SS

Rieter’s Comber E 90 offers consistent quality thanks to reliable, real-time information with Rieter Quality Monitor.

TW Special Report

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witzerland-based Rieter reports that its latest comber E 90 achieves a high level of productivity. Combined with its high raw material utilization capability and economical energy consumption, the lowest production costs per kilogram of combed sliver may be achieved.

In addition to these E 90 capabilities, Rieter’s customer Brazil-based Norfil S.A. Indústria Têxtil was particularly impressed by the continuous monitoring of the sliver quality. This makes unpleasant surprises in the yarn a thing of the past.

The comber E 90 produces up to 100 kilograms of combed sliver per hour. The high combing speed of 600 nips per minute, as well as the stable and fault-free running behavior of the machine, enable this high standard of productivity. In addition, the E 90 delivers all quality levels with high consistency from yarns with low noil extraction to fine yarns in a class of their own, according to Rieter.

Rieter’s E 90 comber offers a high level of productivity.

High Flexibility, Consistent Quality Flexibility was also an important factor for Norfil when it was considering the E 90 comber. Norfil is a family-owned business in the state of Paraiba founded in 1989. Thanks to continuous investments in technology and automation, the company now produces 2,400 tons of yarn per month. Using raw material from its own cotton plantation, Norfil manufactures high-quality yarn for the apparel industry, with combed cotton yarns as its main product. The company was looking for a comber that could not only deliver consistently high quality, but would also have the capability to produce different quality levels with high consistency. Norfil’s new Rieter E 90 comber meets these expectations.

The operating unit is very easy to use, which enables Norfil to flexibly change the quality requirements. The new technology components devel-

Norfil Owner Fabio Borger appreciates the reliable real-time information provided by the Rieter Quality Monitor.

oped for the E 90 significantly reduce the noil extraction and lead to improved raw-material utilization.

Real-Time Information On Sliver Quality Production at Norfil takes place with total control over the sliver quality thanks to the Rieter Quality Monitor (RQM) technology. This proven Rieter draw frame technology is now also fully integrated in the E 90 comber. A sensor continuously monitors the sliver quality produced by the comber and constantly delivers exact and reliable information regarding the current quality level.

This allows deviations in sliver weight and sliver evenness to be detected early. As a result, unpleasant surprises in the yarn due to changed settings in the comber are a thing of the past at Norfil.

“The new comber E 90 takes many things off our hands so that we can concentrate on our priorities,” said Norfil Owner Fabio Borger.

“This is mainly due to the Rieter Quality Monitor (RQM). It is easily adjustable, and we can trust the settings. The comber delivers the promised quality very consistently at a high productivity rate.”

Quick Change Of Noil Level Another requirement of Norfil for its new comber was the ability to quickly change the noil level. Using Rieter’s E 90, Norfil can quickly change from 14 percent to 24 percent, which extends the company’s working range and saves raw material. The company can now produce sliver with a low noil level of 14 percent with maximum consistency for Ne 30 at a rate of 550 nips per minute — with enough headroom to easily accelerate to 600 nips per minute if needed (see Figure 1) .

Thanks to the huge noil savings with the E 90, Norfil also managed to cut costs while maintaining quality.

Figure 1: The comber E 90 delivers consistent CV-values at a lower noil level compared to the former model E 62 and E 66.

Rieter has developed new technology components for the E 90 that significantly increase the range of applications of the top comb and circular comb. With this new development, it is possible to reduce the noil extraction amount by 3 percent without the need to change the settings of the top comb and circular comb. As a result, raw material utilization is improved significantly with low noil extraction. Maximum output

remains consistent even when producing high-quality yarns.

Norfil is very satisfied with the ongoing support from Rieter technicians throughout the E 90 installation project. In cooperation with Rieter technologists, Norfil was able to implement new ideas, resulting in a new combing process designed for their specific needs. The comber E 90 is the best solution for Norfil and the company has already ordered the next batch of combers. TW

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People HanesBrands, WinstonSalem, N.C., has named LaTonya Groom vice president, Talent and Diversity. The company also recently named William S. Simon to its board of directors.

Moira Murray has joined the Textile Division at Spartanburg-based Milliken & Company as the residential sales and market director for the specialty interiors business.

with an eye on reducing the environmental impacts of the textile industry. She will receive a $5,000 award each year for a total of $20,000 over her four years of study.

The scholarship is open to sons or daughters of NCTO Fiber Council member company employees.

Mimaki, Japan, has promoted Arjen Evertse to general manager sales, EMEA, effective September 1, 2021.

Jürgen Eizinger, vice president of Austriabased Lenzing’s Global Nonwovens Eizinger business, was appointed to the board of governors of Belguimbased EDANA — the international association serving the nonwovens and related industries.

Sweden-based Coloreel has recruited Sven Öquist as its new vice president of sales.

England-based technical Nonwovenn has appointed Prabhat Mishra sustainability director.

MagnaColours®, England, has named Mark Taylor regional sales manager.

The Washington-based National Council of Textile Organizations’ (NCTO’s) Fiber Council has announced Rachel Crouse as the recipient of the 2021 Paul T. O’Day Scholarship Award. She is the daughter of Sandra and Martin Crouse, who is a Unifi Inc. employee. She will attend NC State in the fall to pursue engineering

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Champion Thread Co., Gastonia, N.C., has added John Saunders Saunders to its team as manufacturing manager.

New York City-based J.Crew Group has named Brendon Babenzien Babenzien creative director for J.Crew Men’s.

Atlanta-based Beaver Paper Group has promoted Allen Wheeler to the newly created position of TexSewn® product manager.

Spring City, Pa.-based technical textiles company Davlyn Group has named John Rutt vice president of business development.

Avgol, a subsidiary of Bangkok-based Indorama Ventures Public Co. Ltd. (IVL), has named Tommi Bjornman CEO. He replaces Shachar Rachim who will focus on a broader role as CEO of IVL’s Hygiene vertical in its Fibers segment.

Austria-based Borealis has named Wolfram Krenn executive vice president of Base Chemicals & Operations and a member of the executive board.

Sammy Dobbs has joined Glen Raven Technical Fabrics , Glen Raven, N.C., as director of New Business Development for the company’s GlenGuard® brand of flame-resistant and arc-resistant fabrics.

Carhartt, Dearborn, Mich., has appointed Todd Corley senior vice president of Inclusion and Sustainability. He reports directly to Linda Hubbard, president and COO.

Josephine “Josie” Cranfill is the winner of the 2021 American Association of Textile Chemists and Colorists (AATCC) Outstanding College Graduate Award. Cranfill is a

JULY/AUGUST 2021 TextileWorld.com

student at NC State and will graduate with a degree in Polymer & Color Chemistry Science with an Operations concentration and Spanish minor. She was honored with a plaque and $1,000 from AATCC. Joey Smith has joined the team at MMI Textiles Inc., Westlake, Smith Ohio, as director of Business Development.

Daniel Rüfenacht was named CEO of Switzerland-based bluesign technologies ag, an SGS Group company.

Unifi Inc., Greensboro, N.C., has hired James Cooper Jr. as sustainability manager; and Sara Porter brand sales manager of Global Business Development, Nonwovens, Films and Rigid Packaging Seoul-based Hyosung has named Claire O’Neill European marketing manager, and appointed company veteran Julia Nam U.S. marketing manager.

Culp Inc., High Point, N.C., has appointed Jeff Tsacoumangos head of Global Strategic Transformation, Supply Chain and Service for Culp Home Fashions (CHF). In addition, Jeff Veach was named vice president of sales and marketing for CHF. TW

BulletinBoard England-based James Heal has a new microsite, located at performance. james-heal.co.uk, which is dedicated to testing performance and technical textiles.

San Jose, Calif.-based Livinguard has introduced a line of odor-neutralizing T-shirts and polo shirts featuring its hygiene technology.

The U.S. Cotton Trust Protocol, Memphis, Tenn., recently added the following new members: Montreal-based Gildan Activewear; United Kingdom-based retailer Tesco; and San Francisco-based

Levi Strauss & Co. along with its legacy brands Levi’s®, Dockers®, Denizen by Levi’s®, and signature by Levi Strauss & Co.™ Houston-based Ascend Performance Materials received the General Motors (GM) 2020 Supplier Quality Excellence Award for its Pensacola, Fla., nylon 6,6 plant. The award recognizes GM suppliers who meet or exceed the company’s quality performance criteria and support multiple functions across GM’s organization.

Israel-based Delta Galil Industries Ltd. recently

announced a global licensing agreement with Wolford to create, produce and market new women’s lingerie and swimwear collections available Spring/Summer 2022. Delta Galil also signed a global licensing agreement with adidas for men’s and women’s underwear collections sold under the adidas Badge of Sport and Originals labels.

The collections will launch in Spring 2022.

Milliken & Company, Spartanburg, S.C., was named Partner of the Year by IFB Solutions, Winston-Salem, N.C. The award is given to the

partner company that stands out as an organization in its support of opportunities for people who are blind.

After many years in development, Los Angelesbased Hologenix® recently introduced pure white Celliant® fibers.

The new fiber expands the applications for Celliant into white and pastel colored products.

Italy-based Themore® recently introduced Ecodown® Fibers Genius, a hybrid product in between free fibers and rolled insulation that bridges the gap between the two products. TW

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BIOLACE® Ultrasoft features a viscose/lyocell fiber blend and can be produced using a “big dot” pattern.

Quality Fabric Of The

Month By Rachael S. Davis, Executive Editor

Effective,

Sustainable Softness Suominen’s BIOLACE® Ultrasoft is the company’s latest addition to its sustainable nonwoven fabric portfolio.

CONTACTS:

For more information about BIOLACE® Ultrasoft, contact Johanna Sirén, johanna.siren@ suominencorp.com; suominen.com.

Go online to TextileWorld.com for archived Quality Fabric articles.

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HH

elsinki-based Suominen is a producer of nonwoven roll goods used for wipes and other applications. Baby wipes, flushable wipes, household wipes, medical wipes, workplace wipes … name it, and Suominen has the market covered.

The company’s global manufacturing platform comprises eight production plants on three continents including three manufacturing locations in the United States — Bethune, S.C.; Green Bay, Wis.; and Windsor Locks, Conn.

On its website, the company states: “… we don’t just exist to make things. Our purpose is also to develop nonwovens and expand their possibilities. We make nonwovens better.” And in 2019, the company pledged to focus on improving its profitability through innovative and sustainable nonwoven products.

The latest addition to Suominen’s sustainable product portfolio, BIOLACE® Ultrasoft, was developed with sensitive skin as well as sustainability in mind. The fabric — made using plant-based, biodegradable and compostable materials — is aimed at personal care and baby products. Suominen reports that the nonwoven remains soft to the touch when it is both wet and dry and offers excellent absorbency.

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“Our strategy is put into action with the new innovative and sustainable products such as BIOLACE Ultrasoft,” said Lynda Kelly, senior vice president, Americas & Business Development.

“In 2020, the sales of sustainable products increased by more than 20 percent compared to the base year of 2019.”

BIOLACE Ultrasoft is made using a viscose/lyocell blend, its basis weight range is 50 grams per square meter and it can be customized with a “big dot” pattern. The product also is certified Standard 100 by OEKO-TEX®.

According to the company, testing showed the structure and composition of BIOLACE Ultrasoft enables a 25-percent higher cleaning efficiency compared to a product with the same basis weight made using 100-percent viscose spunlace, and a 38-percent higher cleaning efficiency compared to a polyester wipe.

“BIOLACE Ultrasoft with viscose and lyocell fibers performs better than a typical spunlace wipe made using only viscose because of the blend and the manufacturing process we are using,” said Johanna Sirén, manager, Category Management.

“BIOLACE Ultrasoft is a sustainable product with great cleaning efficiency and exceptional softness,” Sirén added. “It is a perfect solution for baby and personal care products, such as cosmetic wipes and baby wipes. The softness makes it also suitable for gentle skin products.” TW

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