From the Sector

•    First production supercar created with Hypetex coloured carbon fibre
•    Paint-replacement technology reduces weight to enhance performance

British car manufacturer Briggs Automotive Company (BAC) has created a unique Hypetex coloured carbon fibre version of its Mono R, reducing the weight by removing the need for paint.  

The original BAC Mono R was created to be lighter and more powerful than the standard model, with 343bhp and 555kg total weight, equating to a power-to-weight ratio of 618bhp-per-tonne. By removing the need for paint coatings in this version, the net weight of the exterior is reduced compared to a painted shell, resulting in a further improved overall performance.

The car’s body was created using Hypetex’s titanium carbon fibre twill, and finished with a crystalized lacquer, offering a unique aesthetic finish. The ultra-lightweight supercar can accelerate from zero to 60mph in less than 2.5 seconds.  

Hypetex’s paint-replacement technology retains the visible weave, allowing for a bold design and a choice of colours without technical compromises, perfectly aligning with BAC’s initiatives to maximise performance whilst creating bespoke supercars. Paint generally adds 138 grams per metre squared, whereas Hypetex adds just 17 grams for the same area, offering an 8x weight saving.
This bespoke version of BAC’s single-seater Mono R was subject to BAC’s renowned BAC Bespoke programme, which ensures that no two Monos are the same. The client, a US-based collector, worked with BAC’s design team to design the car to their personal taste.   

Born out of Formula 1 technology, Hypetex offers manufacturers sustainable aesthetic materials with technical and efficiency benefits. This collaboration is an all-British success story, with the Hypetex carbon fibre body built by Formaplex, a leading UK-based manufacturing company who manufacture lightweight engineered solutions for top tier customers in Automotive, Aerospace and Defence markets. BAC’s supply chain is 95% UK-based.  

Hypetex continues to expand its growing portfolio of the use of coloured carbon fibre to add personalisation to the automotive field, with its material recently featured on the 2024 Ford Mustang Dark Horse.  

The combination of high strength and rigidity with sustainability and a neutral carbon footprint makes flax the ideal raw material for natural fibre-reinforced plastics. vombaur offers composite textiles made of this natural fibre for the automotive, wind power, construction or sports industries and many other sectors.

Flax fibres are rigid and tear-proof. They have natural bactericidal properties, are virtually antistatic, stain resistant and easy to spin. Humans have taken advantage of these properties to manufacture robust, stain-resistant and lint-free textiles. Between the late 19^th and late 20^th centuries, cotton largely replaced natural fibres. Because flax can be grown in Europe and consumes less energy and water than cotton production, the material's importance is currently growing again, for both clothing and composites. Regional textile value added chains in Europe – flax makes them possible.

Ideal mechanical properties
vombaur makes the mechanical properties of flax usable for lightweight design. Because flax fibres are particularly rigid and tear-resistant, they ensure great stability in natural fibre-reinforced plastics (NFRPs). And thanks to their low density of 1.50 g/cm3, the fibres weigh virtually nothing. On top of this, fibre-reinforced plastics are less prone to splintering than glass fibre-reinforced plastics.

Excellent carbon footprint
The cultivation of flax binds CO₂ and the production of natural fibre-reinforced plastics (NFRPs) generates approximately one third less CO₂ emissions compared with conventional fibre-reinforced plastics. Energy consumption is substantially lower. This saves resources. The use of flax fibre tapes by vombaur in lightweight design applications also improves the product's carbon footprint and contributes to a secure, regional supply chain.

Recycling without impacting on quality
Flax offers another sustainability benefit: more recycling cycles than glass- or carbon fibre-reinforced plastics – without impacting on quality. Thermoplastic fibre-matrix prepregs are melted and reused in the recycling process. The natural fibres can be used in other products such as natural fibre-reinforced injection moulded parts.

Sustainable product developments for many industries
"Orthoses for high-performance sports, high-tech skis, wind turbines, components for the automotive industry or aerospace, but also modern window profiles – the application scope for our lightweight design flax tapes is amazingly diverse", as Carl Mrusek, Chief Sales Officer at vombaur explains. "After all, wherever flax tapes are used, three key properties come together: light weight, strength and sustainability".

Die AZL Aachen GmbH, bekannter Innovationspartner für Industriekooperationen auf dem Gebiet der Leichtbautechnologieforschung, startet eines neuen Projekts mit dem Titel "Trends und Designfaktoren für Wasserstoffdruckbehälter". Das Projekt wird Fragestellungen der Industrie in Bezug auf die Wasserstoffspeicherung adressieren.

AZL Aachen GmbH, a recognized innovator in lightweight technologies research and industry collaboration, announces the initiation of a new project titled "Trends and Design Factors for Hydrogen Pressure Vessels". The project aims to address industry needs surrounding hydrogen storage.

Hydrogen has gained significant attention as a key technological solution for decarbonization, with high pressure storage and transportation emerging as vital components. Its applications extend from stationary storage solutions to mobile pressure vessels employed in sectors such as transportation and energy systems.

The AZL team, renowned for its high reputation in providing market and technology insights as well as developing component and production concepts in the format of Joint Partner Projects seeks for companies along the whole composite value chain interested in further developing their application know how in this economically highly relevant field.

The project will provide an in depth exploration of market insights, regulatory standards, and intellectual property landscapes. Beyond this, there is a dedicated focus on staying updated with state of the art and advancements in design, materials, and man ufacturing techniques.

An integral component of the project involves the creation of reference designs by AZL´s engineering team. The reference designs will encompass a variety of pressure vessel configurations and will consider a diverse range of materials and production concep ts.

With the scheduled project start in October 2023, and a project timeline of approximately nine months, AZL encourages companies active across the composite value chain to participate. Companies interested in participating or seeking further information should reach out directly to the AZL expert team.

Beaulieu International Group will turn the spotlight on geotextile products with sustainability benefits to support progress in resilient civil engineering projects at the 12^th ICG Rome from 18^th -21^st September 2023, presenting options to target fossil carbon reduction by choosing PP-based staple fibres or woven geotextiles that are among the lowest in carbon footprint for geosynthetics.

For manufacturers of nonwoven geotextiles, Beaulieu Fibres International (BFI) offers PP fibres with > 25% carbon footprint reduction compared to the European standard PP fibres, generating 1.48 kg CO₂/kg PP fibres. A step further is to accelerate the replacement of fossil carbon in engineered fibre applications by choosing its ISCC Plus certified bio-attributed MONO-PP with a negative carbon footprint.

For construction projects, nonwoven geotextiles made with high-tenacity HT8 fibres are proven to secure a longer service lifetime and reduce the environmental impact, as they offer high mechanical performance at a reduced weight.

Beaulieu Technical Textiles' (BTT) woven geotextiles provide a wide range of functions, including separation, filtration, reinforcement and erosion control, and are among the most sustainable in the industry. Depending on weight, the carbon footprint of its woven geotextiles (m²) ranges between 0.37 and 1.40 kg CO₂ eq./m². They also minimize the use of natural resources for more sustainable infrastructure development. Case studies such as at the Ostend-Bruges airport highlight significant CO2 reduction on the jobsite by replacing the transport of 960 trucks of gravel with 3 trucks of woven geotextiles, and by extending the runway’s life span.

The ICG launch of its new line Terralys MF woven filtration geotextiles with monofilament boosts the performance of a common solution in building layers that require high water flow rates. High-tenacity extruded polypropylene tapes and monofilaments are interwoven to form dimensionally stable and highly permeable geotextiles. These new filtration geotextiles provide greater resistance to dirt and biological clogging. They allow water to travel freely while reducing soil erosion when employed as a separation and stabilizing layer.

As of September 2023, all PP staple fibres and woven geotextiles will have Environmental Product Declarations (EPD) based on LCAs. Each EPD is an essential tool for communicating and reporting on the sustainability performance and helps carbon-conscious customers in their purchasing and decision making. Registered EPDs are globally recognized, publicly available and free to download through EPD Libraries.

The Lenzing Group, a leading provider of specialty fibers for the textile and nonwoven industries, has made significant technical improvements to its Purwakarta site (PT. South Pacific Viscose). Lenzing has invested more than EUR 100 million since 2021 to convert existing production capacity to specialty viscose. With the imminent completion of the investment, Lenzing is in a better position to serve the strongly growing demand for specialty fibers.

Lenzing is striving for certification according to the standard of the internationally recognized EU Ecolabel1. The product portfolio would thus include LENZING™ ECOVERO™ branded fibers for textiles and VEOCEL™ branded fibers for nonwoven applications. In the course of these substantial investments, Lenzing has set the goal of significantly reducing emissions at the site. Moreover, the site started to obtain renewable grid electricity and promotes a changeover to biomass in line with Lenzing's goals of reducing carbon emissions per ton of product by 50 percent by 2030 and achieving carbon-neutral production by 2050.

“Demand for specialty fibers with low environmental impacts continues to grow structurally. We see enormous growth potential in Asia in particular. Through our investments in Indonesia and also at other Lenzing sites worldwide, we are in a better position to serve this growing demand. At the same time, we continue working tirelessly to make the industries in which we operate even more sustainable and to drive the transformation of the textile business model from linear to circular,” says Stephan Sielaff, Chief Executive Officer of the Lenzing Group.

• Sales up 1.9% year-on-year to €560.5 million with stable adjusted EBITDA of €88.0 million
• Strong business performance of the Graphite Solutions, Process Technology and Composite Solutions businesses
• Sales and earnings decline at Carbon Fibers due to weakness of wind market
• Impairment at Carbon Fibers of €44.7 million

Despite the increasingly difficult economic environment, SGL Carbon was able to increase sales in H1 2023 from €549.8 million in the previous year to €560.5 million. Adjusted EBITDA (EBITDApre) remained almost unchanged at €88.0 million (H1 2022: €87.9 million). The expected good business performance of the Graphite Solutions business unit and the better-than-expected sales and earnings development of Process Technology and Composite Solutions compensated the drop in demand in Carbon Fibers.

In particular, the Graphite Solutions (GS) business unit contributed to the stable development of the Company with a 15.3% increase in sales to €280.6 million (H1 2022: €243.4 million) and a 20.6% improvement in adjusted EBITDA to €65.1 million (H1 2022: €54.0 million). GS benefited especially from the high demand of the semiconductor industry. The semiconductor and LED market segment now accounts for around 45% of GS revenue (H1 2022: around 35%).

With a 30.9% increase in sales to €64.4 million (H1 2022: €49.2 million) and a significant rise in adjusted EBITDA from €4.1 million to €11.9 million, the business performance of Process Technology (PT) was significantly above the original planning. Composite Solutions (CS) also reported a higher-than-forecast sales increase of 14.4% to €79.6 million in H1 2023 (H1 2022: €69.6 million) and an improvement in adjusted EBITDA of 26.8% to €12.3 million (H1 2022: €9.7 million). By contrast, the business performance of the Carbon Fibers (CF) unit was not in line with expectations, with a 28.9% decline in sales to €125.1 million (H1 2022: €176.0 million) and a 78.4% drop in earnings to €6.1 million (H1 2022: €28.2 million).

An important market segment for the Carbon Fibers business unit is the wind industry. Demand for carbon fibers for the wind industry has declined sharply since the beginning of the year. According to current estimates, the expected recovery in demand in H2 2023 will not materialize. SGL Carbon expects customer demand from the wind industry to pick up in 2024.

As already announced in the ad hoc release of July 24, 2023, an impairment loss of €44.7 million was recognized on the assets of Carbon Fibers as of June 30, 2023.

Results situation
SGL Carbon's adjusted EBITDA (EBITDApre) remained almost stable in a half-year comparison at €88.0 million (H1 2022: €87.9 million). Due to the lack of demand from wind industry, CF's production capacity utilization decreased and idle capacity costs weighed on adjusted EBITDA. By contrast, higher margins from product mix and volume effects in the other three business units had a positive impact on adjusted EBITDA.

Non-recurring items and one-off effects not included in adjusted EBITDA totaled minus €46.9 million in the first half of 2023, of which €44.7 million resulted from an impairment loss in the CF business unit.

In addition to the above-mentioned effects and nearly unchanged depreciation and amortization of €29.1 million (H1 2022: €28.9 million), the decline in EBIT resulted in particular from the impairment loss already described (€44.7 million). After €69.6 million in H1 2022, EBIT amounted to €12.0 million in the reporting period.

Taking into account the slightly improved financial result of minus €15.8 million (H1 2022: minus €16.6 million), consolidated net income for the first six months of the current financial year amounted to minus €10.0 million, compared to €48.8 million in the first half of the previous year.

Net financial debt and equity
To complete its refinancing, SGL Carbon issued convertible bonds with a volume of €118.7 million in June 2023 and drew an existing term loan facility of €75 million in July 2023, which was used together with cash of the Company on July 28, 2023 to repay the corporate bond (outstanding as of June 30, 2023: €237.4 million). Accordingly, cash and cash equivalents increased to €310.5 million as of June 30, 2023 (€227.3 million as of December 31, 2022) and financial debt temporarily increased to €480.4 million (€398.1 million as of December 31, 2022). Net financial debt remained nearly unchanged at €169.9 million as of June 30, 2023 (Dec. 31, 2022: € 170.8 million).

Despite the impairment loss of €44.7 million in Carbon Fibers, shareholders' equity amounted to €565.2 million as of June 30, 2023, only slightly lower than at the end of 2022 (Dec. 31, 2022: €569.3 million). This corresponds to an equity ratio of 36.1% (Dec. 31, 2022: 38.5%).

To reach its goal of being the world’s leading supplier of enhanced recycled polyethylene terephthalate (PET), gr3n is signing a binding Memorandum of Understanding (MOU) with its shareholder Intecsa Industrial to set up a Joint Venture.

gr3n together with Intecsa Industrial will join forces and build a “First-of-a-Kind” manufacturing facility able to produce 40.000 tons of virgin-like PET, commencing EPC phase in Q4-2024 and aiming to be operational in 2027. gr3n’s chemical recycling technology is capable of processing PET from various industries including textile waste, closing the loop for hard-to-recycle PET applications.

The world’s first industrial-scale MADE PET recycling plant will have the capability to process post-industrial and post-consumer PET waste including hard-to-recycle waste, to produce approximately 40.000 tons of virgin PET chips from the recycled monomers saving nearly 2 million tons of CO2 during its operating life. The post-consumer and/or post-industrial polyesters will be both from bottles (colored, colorless, transparent, opaque) and textiles (100% polyester but also mixtures of other materials like PU, cotton, polyether, polyurea, etc. with up to 30% of presence in the raw textile).

The technical concept of the MADE plant is to break down PET into its main components (monomers) so they can potentially be re-polymerized endlessly to provide brand new virgin PET or any other polymer using one of the monomers. Polymers obtained can be used to produce new bottles/trays and/or new garments, essentially completely displacing feedstock material from fossil fuels, as the recycled product has the same functionality as that derived traditionally. This means that gr3n can potentially achieve bottle-to-textile, textile-to-textile, or even textile-to-bottle recycling, moving from a linear to a circular system.

gr3n’s process has the potential to change the way PET is recycled worldwide, enabling huge benefits for both the recycling industry and the entire polyester value chain. Many efforts have been made in the past to transfer enhanced recycling from research laboratories to the manufacturing industry, but the economics and skepticism of the first adopters have constantly blocked the progress of the proposed solutions. Thanks to the MADE technology developed by gr3n, this approach is now feasible and makes gr3n one of the few companies with the potential to provide a reliable enhanced recycling solution that closes the life cycle of PET, and also offers food grade polymer material, processes a large variety of waste and reduces the carbon footprint of these materials usually destined for incineration or landfill.

DOMO Chemicals, a global leader in polyamide-based engineered material solutions and services, has published its latest annual Sustainability Report, detailing progress on its sustainability journey, including notable reductions in greenhouse gas emissions. DOMO’s mission is to engineer polyamide solutions that contribute to a better, more sustainable world. In publishing its second annual Sustainability Report, DOMO enters a new phase in its decarbonization quest, with confidence in its long-term aspiration to set the standard for sustainability in the industry by 2030.

Notably, the Sustainability Report details DOMO’s achievements in 2022 toward realizing its 2030 sustainability goals. In terms of decarbonization and broader environmental achievements, against a 2019 baseline, the company:

• Reduced scope 1 and 2 greenhouse gas emissions by 27%, making significant progress toward its target of 40% reduction by 2030 and carbon neutrality by 2050
• Increased renewable electricity throughout operations to 12%
• Reduced waste by 24%
• Lowered water intake by 4.5%

In addition, as a provider of polyamide-based sustainable and circular solutions, DOMO:

• Achieved more than 11% of engineered materials sales based on sustainable feedstock, making excellent progress toward its 2030 target of 20%
• Allocated 25% of research and development resources to enhanced recycling

Moreover, fostering talent and ensuring the well-being of its workforce as a responsible employer is essential for sustainable growth, and 2022 highlights include:

• Increased share of women in senior positions from 22% in 2021 to 30% in 2022
• Providing a safe and inclusive working environment that encourages personal and professional development as well as a global safety culture

As part of Sappi Europe's full scale decarbonisation roadmap, Gratkorn mill is expanding the share of biomass to be used as an energy source, further driving the move away from fossil fuels as part of the mill’s contribution to the European roadmap. The project follows the recent modernisation of the power plant boiler which enabled the shift from coal to a combined approach of biomass and natural gas.

The mill is now embarking on a next step, enhancing its infrastructure and therefore capacity in order to handle the delivery, sorting and processing of increased biomass levels. This increased utilisation requires an improved biomass handling system at the mill as well as decentralised intermediate storage terminals within the surrounding regions.

"With our long-standing competent wood sourcing partner Papierholz Austria, we will continue our journey to move away from fossil fuels at Gratkorn mill and work towards a climate-neutral future”, says Peter Putz, Managing Director of Sappi Austria GmbH.

For the near term, Sappi’s decarbonisation roadmap includes close to 80 projects being carried out across its European mills by 2025.

“Our 2025 roadmap identifies the path we have embarked on towards a carbon-neutral future,” explains Sarah Price, Director Sustainability of Sappi Europe. The objective is to reduce emissions of specific greenhouse gases (Scope 1 and 2) by 25 per cent and to increase the share of renewable energy in Europe to 50 per cent by 2025 (compared to 2019). Additionally, Sappi’s 2030 science-based target is to reduce carbon emissions by 41.5% per ton of product. “We’re already making good progress towards these targets, with a large number of projects already well-underway or completed”.

Archroma, a leader in specialty chemicals towards sustainable solutions, is teaming up with COLOURizd™, an innovator specializing in sustainable textile dyeing technologies, to set a new standard for the eco-friendlier production of sustainable textiles.

The new collaboration will enable fabric mills and brands to combine Archroma pigment coloration solutions with the COLOURizd™ QuantumCOLOUR™ yarn-coloring technology to produce high-quality, high-performance textiles with maximum consumer appeal and minimal environmental impact.

Conventional fiber-reactive methods of dyeing cellulosic and synthetic yarns are multi-step resource-intensive processes that use up to 95 liters of water per kilograms of colored yarn and discharge approximately 94 liters of effluent.

In contrast, the innovative QuantumCOLOUR™ process injects pigment and a binder directly into the yarn, using only 0.95 liters of water per kilograms of colored yarn while producing zero effluent. This represents an unprecedented reduction of 98% in water consumption alongside zero wastewater discharge, zero discharge of harmful chemicals, 73% decrease in carbon footprint and 50% reduction in energy use.*

With Archroma, textile manufacturers and apparel brands can add further value to the QuantumCOLOUR™ process with tailor-made system solutions, including JUST COLOR. This formaldehyde-free** pigment coloration system is based on Archroma’s revolutionary Printofix® pigment dispersions and Helizarin® binders to deliver exceptionally soft fabrics with high fastness and durability, while also enabling energy and chemical savings and higher productivity.

* As tested by Peterson Control Union
** Below limits of detection according to industry standard test methods