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Changing consumer tastes, crazy raw material prices, and related policies and regulations are rapidly changing the supply chain of many nonwoven products. Many companies are reducing their reliance on traditional plastic-based fibers and seeking more bio-based feedstocks and natural fibers.

 

Although traditional plastic-based materials cannot be completely replaced in many applications, both in terms of tonnage and performance, these changes are undoubtedly changing the face of the global disposable hygiene products and wet wipes market, and more and more brands are focusing on telling the story of natural ingredients.

 

Manufacturers of both natural and synthetic fibers are responding to these changes by developing new products, improving production processes and partnering with companies focused on bio-based technologies, and looking for ways to create a greener image in their overall business.

 

 

"Sustainability is very important. What we do is recycle and remanufacture fiber, and more discussions about the circular economy. The market demand for sustainable projects and products continues to increase," said Bryan Tickle, Leigh Fibers account manager. "This makes us start to think differently about how to use all our Leigh capabilities to create new products to adapt to this greener world. More and more customers are asking how to dispose of their waste and make fibers from these waste materials, which will eventually be used to produce their end products."

 

Perhaps the biggest impact on nonwovens and nonwovens products will be the EU single-use plastics directive, which came into effect in July 2021, and similar measures in the United States, Canada and other countries are putting pressure on manufacturers of wipes and feminine hygiene products, who are the first products to be subject to regulatory and labeling requirements. Some companies have announced that they want to remove plastic-based raw materials from their products, and this reaction is common.

 

For Lanjing and many suppliers in the nonwovens industry, the first big challenge is the definition of plastic. "You can look at it from a lot of different perspectives-source of raw materials, renewable raw materials, end of life," said Tom Carlyle, commercial manager of nonwovens at the United States of America. "In addition, when they really delve into the complexity of the supply chain, it is difficult to define what is a single-use plastic."

 

Although the company's wood-based biodegradable VEOCEL fiber does not fall within the scope of the EU Single-Use Plastics Directive and is not considered plastic, the company continues to focus on improving sustainability through recent investment projects in Brazil and Thailand, as well as investments in existing Asian plants in China and Indonesia, where the focus is on achieving climate neutrality within the group. In 2019, Lanjing became the first fiber manufacturer to set the following goals: to reduce carbon emissions by 50% by 2030 and achieve net zero emissions by 2050.

 

In addition, the collaboration with Swedish pulp producer Södra marks another milestone in its efforts to achieve its ambitious climate and sustainable development goals. Two of the world's leading suppliers have been actively promoting the development of the circular economy in the fashion industry for many years. Together, the two sides will further promote this issue and make a decisive contribution to the global textile waste challenge. The two sides also plan to expand the capacity of pulp produced from post-consumer waste. The goal is to treat 25000 tons of textile waste per year by 2025.

 

Sustainability is not only a very important strategic element for Lenzing, but also a guiding principle for innovation and product development. Lenzing continues to expand its product offerings in the textile and nonwovens segment in 2021. The first Tencel made from orange wood pulp and sustainable wood™The release of the brand Lyocell fiber, is Tencel™New Tencel in partnership with Italian company Orange Fiber™Part of a limited edition program.

 

Weiyi Silk™Brand Launches First Zero Carbon Dimensional Silk in Non-woven Fabric Application™Lyocell fiber. The fiber in CarbonNeutral®Significant progress has been made in certification standards, which can support the majority of partners and product brands in the non-woven industry. Through the use of fibers with a net zero carbon footprint to reduce the impact on the climate, it will further strengthen the commitment of Lanjing and its partners to carbon neutrality.

 

Steven Tsai, Senior Commercial Director, Non-Woven Business Asia, Lanjing Group, said: "For our partners and brands, we launched the world's first CarbonNeutral this year.®Certified Zero Carbon Dimensional Silk™Fiber, partners such as certified zero-carbon dimensional silk.™fiber, which can help them meet the carbon reduction requirements of ESG Index scope 3. We are also actively working with the non-woven industry to assist partners in the transition to decarbonization processes and jointly achieve the goal of reaching zero carbon by 2050."

 

Rahul Bansal, Head of Global Business Development for Nonwovens at Birla Cellulose, said that cost and performance have been replaced by a combination of sustainability, performance and cost as key drivers for fiber selection. "Now, the choice of raw materials mainly depends on sustainability," he said. "When we talk about sustainability, it means that the procurement of raw materials, manufacturing, products and their end of life cycle will not harm or damage the environment, followed by the most important criteria for whether the raw materials are suitable for current non-woven technology."
 
Continuation of cotton fibers

Consumers know and like the look and feel of cotton, but now some synthetic fibers are doing very well in replicating this look and feel, and some consumers believe that its role in disposable products has become greater. This situation has changed in recent years, thanks to the efforts of companies led by Cotton Incorporated in consumer education, general consumer awareness and related legislation.

 

Cotton is not only sustainable, but also safe and healthy for the skin, and this natural fiber is hypoallergenic. This is especially important for people with sensitive skin and when designing products for more sensitive body parts, such as baby diapers, feminine hygiene products, and adult care products.

 

On the consumer side, the use of cotton fibers in wipes has been growing in recent years due to improvements in production lines and investments by nonwoven producers serving this market. Cotton fiber was originally only considered for baby wipes, but hydrophobic products, such as the TruCotton Wildwood Cotton Technologies, can now be used as an alternative to polyester or polypropylene in some applications.

 

At the same time, there has been a surge of interest in skin-contacting cotton-containing surfaces in the context of hygiene products. These products first appeared in feminine hygiene applications, but are now expanding into diapers.

 

At last year's Consumer Products Conference Hygienix, diaper startup Kudos won an innovation award for its diapers that use 100 percent breathable cotton to touch baby's skin. This product not only has less carbon emissions than any other disposable diaper, but is also a great boon for patients with skin rashes or eczema. Kudos diapers are also certified to the strictest safety standards OEKO-TEX Standard 100.

 

"We're here today because parents care about the ingredients in baby diapers," says founder and CEO Amrita Saigal. "They also care about the environmental impact of the products they buy."

 

Studies have shown that diapers in landfills take up to 500 years to degrade, and they produce methane and other toxic gases, and the volatile chemicals used eventually enter the ecosystem. "In the United States alone, 200,000 trees are used to make disposable diapers for babies each year. If all diapers were made the way Kudos did, 0.5 billion pounds of plastic would be replaced by clean, unbleached natural cotton. Every year, 2 billion pounds of diaper material originally derived from petroleum-based sources would be replaced by renewable sources."

 

The use of cotton fibers is growing, partly because of its softness and skin-friendly feel, and partly because of government requirements to limit the use of plastic materials in disposable products, which requires manufacturers to consider new materials when producing products such as disposable wipes and hygiene products.

 

As ingredient transparency becomes more and more important, especially for female consumers, the use of cotton fibers becomes more prominent in the hygiene field. This trend is continuing into big brands, such as Procter & Gamble's Always Pure brand, which contains a percentage of cotton.

 

Cotton growers are also working to increase yields and improve fiber sustainability. For the past 20 years, cotton growers have been committed to doing more with less. They have increased production without increasing water use, and global cotton uses only 3% of the total water used in agriculture.

 

Cotton farming uses only 0.6 per cent of the world's agricultural land in some 80 countries. Its natural drought tolerance, minimal irrigation requirements, and ability to grow in arid climates make it one of the most versatile crops on the planet, producing both fiber and food (cottonseed and cottonseed oil).

 

In the next 10 years, cotton growers aim to increase soil carbon and land efficiency, reduce soil loss and water and energy use, and cotton is already available in many forms-natural cotton, combed cotton, short wool, Short cut cotton and cotton lint.

Cannabis Expands Impact

Hemp fiber seems to have become a hot new fiber in women's care, with multiple companies launching or soon to launch products containing this ancient material. Although these fibers have historically been overlooked by the industry because of their inconsistency and difficulty in processing, recent technological advances have perfected the process of such fibers to meet the standards of nonwovens and disposable products.

 

"Consumers, brands and legislators are driving the shift from plastics to more sustainable materials and affecting all industries, not just non-wovens. Natural fibers currently account for only a small part of the nonwovens industry, but demand is growing exponentially. Our all-natural fibers are suitable for non-woven applications, from disposable wipes and hygiene products to durable non-woven fabrics for textiles, green construction and agricultural applications." said Lars Lauritsen, BAST Fibretech chief commercial officer.

 

In addition to working to develop processes that better serve the nonwovens industry, BFT is also focused on expansion. Earlier this year, the company acquired Georgia-Pacific Lumberton Cellulose LLC, a move that will allow the company to expand capacity to more than 30,000 tons per year, making BFT Lumberton one of the largest fully integrated natural fiber processing parks in North America.

 

"As changing consumer preferences and related legislation drive up demand for synthetic fiber alternatives, consumer brand companies are looking to use fibers with minimal ecological impact," said Jim Posa, CEO. "The BFT Lumberton plant will produce all-natural, clean, soft and compostable fibers that can replace synthetic fibers in many nonwoven and textile applications."

 

In addition to the planned capacity increase, the acquisition of the Lumberton plant has allowed BFT to diversify its natural fiber products into complementary product categories for cosmetic cotton, filtration, hygiene and other nonwovens applications. BFT's commitment to natural fiber innovation aligns perfectly with Lumberton extensive technical production experience, and upon completion of the acquisition, BFT will continue to provide excellent service to existing customers and begin site expansion to build new bast fiber manufacturing capabilities.

 

Recently introduced feminine hygiene products containing hemp fiber include Rif care(Regenerative International Female). The founder of the brand, Val Emanuel, sees cannabis as an excellent alternative to other plant options on the market. "The feminine care industry lacks alternative solutions as good as cotton," she said. "There are other products that use bamboo, bananas, and some even use pineapple fiber, but at the end of the day, we need a natural fiber ingredient to make a better product, and hemp fiber is also antibacterial."

 

Emanuel said that in less than a year, Rif care achieved 100 percent biodegradation in landfills or industrial compost. The wrapping material of the sanitary napkin is also made of sugar derivative material, which can protect the sanitary napkin without placing an additional plastic bag in the box.

 

In terms of sustainability, the carbon footprint of hemp is about 1/4 that of cotton, and in terms of comfort, many people think it is equivalent to cotton. "Cotton does have a place in specific nonwoven applications, and it blends well with BFT's sustainable fibers. However, bast fibers grow in a wider climatic zone than cotton and can be independent of irrigation," said Jason Finnis, chief innovation officer. "In addition, bast fibers yield much more per hectare than cotton, which makes them more effective at sequestering carbon. According to the EU, the carbon sequestration capacity of cannabis is almost twice that of most forests."

 

In addition to disposable products, hemp-based nonwovens are also used in durable applications such as insulation materials. In April, IND HEMP and Hempitecture announced a supply chain partnership to produce and manufacture non-woven Hempwool insulation made from natural hemp fibers. Hempwool insulation products have been called "the most sustainable and high-performance insulation material on the earth" in the past few years. They are currently building a factory to produce airlaid insulation materials in Jerome, Idaho.

 

"Hempitecture partnership with IND HEMP represents more than a key supply chain solution. It represents forward-looking innovation in sustainable materials. We look forward to innovating future building products with IND HEMP's hemp fiber." Hempitecture co-founder and CEO Mattie Mead said.

Plastic Persists

Plastics will always have a place in non-woven fabrics. Suppliers in the nonwovens industry agree. Generally speaking, it not only provides attractive prices and performance, but its supply is unparalleled. In non-woven fabrics and other industries, there is simply not enough fiber material to completely replace plastic fibers. Therefore, many believe that the ideal solution is not to replace plastic, but to focus on technological advances to make it more sustainable.

 

In April, Indorama Ventures Public Company Limited(IVL) announced at the IDEA show that its sanitary fiber business group has further strengthened its sustainable product portfolio with the launch of the Deja carbon-neutral polypropylene fiber series and significant progress in its bioconversion of polypropylene fibers. Deja's carbon-neutral polypropylene fibers were developed to meet customers' needs for sustainable solutions. After a fully approved life cycle assessment of its processes and materials, FiberVisions, a subsidiary of IVL Sanitary Fiber Business Group in Covington, Georgia, now offers this polypropylene staple fiber series, which is in cooperation with leading Strive to pass Proven carbon neutral projects to balance greenhouse gas emissions.

 

The company is also focused on the advancement of dual-solution bioconversion (PP), designed to be recyclable and time-biodegradable. This structurally stable polypropylene and stored and treated fiber non-woven fabrics can be recycled normally. If transferred to the environment, due to scientific design, it can be decomposed and biotransformed under natural conditions without leaving any toxins or microplastics.

 

At the same time, Indorama companies and Wellman International have been developing recycling technology for more than five decades. Recently at their plant in Murag, Ireland, they put the technology into use to recycle PET without compromising quality. Sister brands Auriga, IVL Asia and Trevira also offer a robust portfolio of recycled PET (rPET) fiber products to the hygiene industry. The IVL Fibers business unit's rPET product portfolio is represented by the Deja brand platform, a performance-led sustainable solution that helps customers achieve their sustainability goals while meeting end-consumer demands for transparency and environmental responsibility.

 

Recycling technology is nothing new to USFibers. The company has been recycling polyester since its inception in 1994. "Recycling is an area where we excel," said USFibers Vice President Teddy Oh, "and we have been making polyester staple fibers from recycled fibers since 1992."

 

However, the difference is that in the past, the recycling business was driven by economics, and now the focus is on providing truly sustainable products. "This allows us to focus on diversifying product supply and providing customers with'one-stop service'. Another focus is cost control to help offset rising raw material prices." Teddy Oh said.

 

The focus on biodegradability has led Fiberpartner to work Primaloft with a U.S. partner to commercialize biodegradation solutions using Primaloft Bio Biotechnology, which produces fibers that are biodegradable or chemically recyclable by hydrodegradation. These fibers are based on 100% PET.

 

Primaloft Bio will eventually leave no trace of microplastics after biodegradation. However, these fibers do not biodegrade during use. They are available in several varieties, are transported in ordinary packaging, have a fixed shelf life, and do not require special care or handling during storage and transportation.

 

Fiberpartner CEO Thomas Wittrup said that Primaloft is an excellent solution for non-woven manufacturers and processors, who want to get a more sustainable choice without sacrificing performance or modifying existing equipment. "The advantage of this technology is that it can be used on the original production line without modification or additional investment."

This article is from Nonwovens Industry Journal
作者：Karen McIntyre

Source: Jung-International Nonwoven Industry Business