Melt spinning of sustainable fibres for belts and straps in outdoor applications

AI Quick Summary

The Institute of Polymer Engineering FHNW has the infrastructure for melt spinning of polymer fibers.The plant is used for fiber development for sustainable, plastic-based product and process innovations in the field of high-performance polymers and fiber composites. Fibers are the basis of textile structures and fiber composites. The development and investigation of new bio-based or recycled fiber materials as well as their production is the starting point of the textile process chain. Thematic focusThe focus of the project is to develop sustainable solution for textile application based on bio-based fibers. Many applications in the textile sector are mixed petroleum-based materials and cannot be recycled. The company Sulzer as an equipment and process provider of polymerisation plants for PLA (https://www.sulzer.com/en/shared/news/220113-sulzer-pla-bioplastics-production-technology-selected-for-natureworks-new-plant ) and the company Mammut (https://www.mammut.com/ch/de/support/sustainability) as end user from the textile sector will be supported by the FHNW ( https://www.fhnw.ch/de/die-fhnw/hochschulen/ht/institute/institut-fuer-kunststofftechnik/newsletter-polymer-technology/schmelzspinnanlage). The objective is to apply design thinking starting by formulated end user demands for sustainable fiber solutions backwards to the spinning process, back tonew biobased polymers. In this regard, polylactic acid (PLA) is a biodegradable as well as recyclable polyester made from renewable feedstock. The idea will be to investigate if a connector element (strap and buckle, see main figure) which is used in backpacks for instance can be designed with different PLA grades. We have chosen PLA as promising candidate because different grades are available which might fit for melt spinning (fibers for the strap) but also for injection moulding (buckle) allowing the development of an end-use product from the same feedstock. Beside other polymers like PEF, PHAs… PLA is commercially available, and our goal is to identify the gap to bring PLA into such load carrying applications. Mammut has signed the UN Fashion Industry Charter for Climate Action in 2018 and verified its climate targets in 2021 by the Science-based Targets Initiative as an absolute reduction of 55% by 2030.Sulzer’s sustainability strategy is composed of three pillars – minimizing our carbon footprint, enabling a low-carbon society, and engaging our employees and communities to build a more inclusive and sustainable future. Degree of innovationThe novelty of the approach is that end user knowhow / demand, processing and polymer formulation (and scaling) are covered by the competences of the partners. The idea was initiated by Sulzer and FHNW. The team was extended by Sophie from Mammut during and after the workshop. EffectMammut has committed to do three actions. First to reduce CO2-emissions within our value chain, second to compensation through conventional carbon offsetting in a transition phase and third to compensation through carbon removal in line with net-zero. The project supports the first action by phase out coal and other fossil fuels across the value chain and accelerate the transition to renewable sources of energy which is based on an analysis of 2018. Mammut’s generated emission are 75% (41’413 t CO2 eq) based on goods and services. This means around 600t of PA and 360t of Polyester which must be replaced by bio-based materials. The selected application, the connector element with a textile and a hard plastic part, is representative for different application from Mammut. The goal of the pilot project is to build up development know-how and a production network for bio-based textiles made from PLA. Thanks to the knowledge gained in the pilot project, Mammut hopes to achieve significant time savings in the development of innovative, bio-based fabrics made from PLA and thus gain a market advantage over the competition in achieving its to become NetZero by 2050. Methodological qualityThe funds will be used by FHNW to enable melt spinning of selected, newly defined /or modified PLA grades. These grades will be characterised by DSC, MFR, process parameters will be derived, initial fibers will be processed, characterised and compared to the requirements of Mammut. By the discussion including all partners a starting point for further development can be reached which is the starting point for an innovation project including all partners. FHNW has all the knowhow and equipment necessary for characterisation, fiber spinning and 3D-printing, Sulzer has the knowhow about the polymer and has the equipment for modifications and Mammut has the know-how about and access to fabrication of the application. By frequent updates and coordination, we can make most efficient use of the funds. Gender and DiversityThe project includes the following contact points and respects both genders. · Sophie Renot, Innovation Manager, Mammut Sports Group AG, · Dr. Ulla Trommsdorff, Manager Polymer R&D and Applications & Technology, Sulzer Chemtech Ltd· Dr. Greta Giacobazzi, Polymer R&D and Applications & Technology, Sulzer Chemtech Ltd· Prof. Dr. Christian Brauner, Delal Arslan FHNWScope and TasksThe scope will be to produce and test fibers and to fabricate a demonstrator piece made of strap and 3D-printed buckle The work packages will be: WP1: Definition of requirements and specification (Mammut)WP2: Selection of polymer grades, initial characterisation (Sulzer, FHNW)WP3: Initial melt spinning of fibers, characterisation of this fibers, 3D Printing of the buckle, (FHNW)WP4: Discussion of results, drafting of further steps along the supply chains (Mammut) and for polymer development (Sulzer) Budget and Co-Funding Yes, we would like to get support by the Innobooster / external expert We would ask for 25000CHF funding which will be used by FHNW (WP 2,3). 10% of the third-party contribution will be paid by Mammut to buy materials in the project. 10% of the third-party contribution will be given by Sulzer to the Innobooster. Sulzer will add 2500CHF, Mammut 2500CHF of internal cost into the project. This means the total budget of the project will be 27500CHF.

Project Idea Metadata

• Project Idea Name: Melt spinning of sustainable fibres for belts and straps in outdoor applications
• Date: 3/25/2022 9:29:09 AM
• Administrators:
  • Christian Brauner

Project Idea Description

Thematic focus

The focus of the project is to develop sustainable solution for textile application based on bio-based fibers. Many applications in the textile sector are mixed petroleum-based materials and cannot be recycled. The company Sulzer as an equipment and process provider of polymerisation plants for PLA (https://www.sulzer.com/en/shared/news/220113-sulzer-pla-bioplastics-production-technology-selected-for-natureworks-new-plant ) and the company Mammut (https://www.mammut.com/ch/de/support/sustainability) as end user from the textile sector will be supported by the FHNW ( https://www.fhnw.ch/de/die-fhnw/hochschulen/ht/institute/institut-fuer-kunststofftechnik/newsletter-polymer-technology/schmelzspinnanlage).

The objective is to apply design thinking starting by formulated end user demands for sustainable fiber solutions backwards to the spinning process, back tonew biobased polymers. In this regard, polylactic acid (PLA) is a biodegradable as well as recyclable polyester made from renewable feedstock. The idea will be to investigate if a connector element (strap and buckle, see main figure) which is used in backpacks for instance can be designed with different PLA grades. We have chosen PLA as promising candidate because different grades are available which might fit for melt spinning (fibers for the strap) but also for injection moulding (buckle) allowing the development of an end-use product from the same feedstock. Beside other polymers like PEF, PHAs… PLA is commercially available, and our goal is to identify the gap to bring PLA into such load carrying applications.

Mammut has signed the UN Fashion Industry Charter for Climate Action in 2018 and verified its climate targets in 2021 by the Science-based Targets Initiative as an absolute reduction of 55% by 2030.

Sulzer’s sustainability strategy is composed of three pillars – minimizing our carbon footprint, enabling a low-carbon society, and engaging our employees and communities to build a more inclusive and sustainable future.

Degree of innovation

The novelty of the approach is that end user knowhow / demand, processing and polymer formulation (and scaling) are covered by the competences of the partners. The idea was initiated by Sulzer and FHNW. The team was extended by Sophie from Mammut during and after the workshop.

Effect

Mammut has committed to do three actions. First to reduce CO2-emissions within our value chain, second to compensation through conventional carbon offsetting in a transition phase and third to compensation through carbon removal in line with net-zero. The project supports the first action by phase out coal and other fossil fuels across the value chain and accelerate the transition to renewable sources of energy which is based on an analysis of 2018. Mammut’s generated emission are 75% (41’413 t CO2 eq) based on goods and services. This means around 600t of PA and 360t of Polyester which must be replaced by bio-based materials. The selected application, the connector element with a textile and a hard plastic part, is representative for different application from Mammut.

The goal of the pilot project is to build up development know-how and a production network for bio-based textiles made from PLA. Thanks to the knowledge gained in the pilot project, Mammut hopes to achieve significant time savings in the development of innovative, bio-based fabrics made from PLA and thus gain a market advantage over the competition in achieving its to become NetZero by 2050.

Methodological quality

The funds will be used by FHNW to enable melt spinning of selected, newly defined /or modified PLA grades. These grades will be characterised by DSC, MFR, process parameters will be derived, initial fibers will be processed, characterised and compared to the requirements of Mammut. By the discussion including all partners a starting point for further development can be reached which is the starting point for an innovation project including all partners.

FHNW has all the knowhow and equipment necessary for characterisation, fiber spinning and 3D-printing, Sulzer has the knowhow about the polymer and has the equipment for modifications and Mammut has the know-how about and access to fabrication of the application. By frequent updates and coordination, we can make most efficient use of the funds.

Gender and Diversity

The project includes the following contact points and respects both genders.

· Sophie Renot, Innovation Manager, Mammut Sports Group AG,

· Dr. Ulla Trommsdorff, Manager Polymer R&D and Applications & Technology, Sulzer Chemtech Ltd

· Dr. Greta Giacobazzi, Polymer R&D and Applications & Technology, Sulzer Chemtech Ltd

· Prof. Dr. Christian Brauner, Delal Arslan FHNW

Scope and Tasks

The scope will be to produce and test fibers and to fabricate a demonstrator piece made of strap and 3D-printed buckle

The work packages will be:

WP1: Definition of requirements and specification (Mammut)

WP2: Selection of polymer grades, initial characterisation (Sulzer, FHNW)

WP3: Initial melt spinning of fibers, characterisation of this fibers, 3D Printing of the buckle, (FHNW)

WP4: Discussion of results, drafting of further steps along the supply chains (Mammut) and for polymer development (Sulzer)

Budget and Co-Funding

Yes, we would like to get support by the Innobooster / external expert

We would ask for 25000CHF funding which will be used by FHNW (WP 2,3). 10% of the third-party contribution will be paid by Mammut to buy materials in the project. 10% of the third-party contribution will be given by Sulzer to the Innobooster. Sulzer will add 2500CHF, Mammut 2500CHF of internal cost into the project. This means the total budget of the project will be 27500CHF.

The Institute of Polymer Engineering FHNW has the infrastructure for melt spinning of polymer fibers.

The plant is used for fiber development for sustainable, plastic-based product and process innovations in the field of high-performance polymers and fiber composites. Fibers are the basis of textile structures and fiber composites. The development and investigation of new bio-based or recycled fiber materials as well as their production is the starting point of the textile process chain.