Collaborative Innovation for Textile Circularity

The project utilized Epson’s Dry Fiber Technology to transform textile waste into nonwoven fabric sheets, marking the first time such materials have been applied to zipper tape. Dry Fiber Technology allowed for the creation of these sheets for the first time in this specific application, overcoming previous manufacturing hurdles. Due to the unique properties of the material, the engineering team conducted rigorous studies to ensure secure element attachment. This included selecting a slider specifically designed for the rigidity of the nonwoven fabric zipper to maintain the high standards and ease of use associated with the EXCELLA® line. The integration of this technology into sustainable fashion France represents a practical step toward material upcycling in the luxury sector.

Technical Advancement in Sustainable Fasteners

This initiative addresses the global challenge of textile waste and the circular economy Japan is actively pursuing. Designer Nakazato’s exploration of used clothing management, particularly regarding the volume of garments entering countries like Kenya, served as a catalyst for the project. By supporting the circular economy Japan, YKK continues to build upon its existing initiatives, such as the NATULON® Fiber Sourced™ products which utilize recycled textile materials. By integrating this YKK sustainable zipper into luxury fashion, the company aims to leverage insights from this nonwoven fabric zipper development to meet the evolving needs of global customers. YKK intends to use the knowledge gained from this project to further enhance the value of its premium fastener series while promoting the reuse of clothing and materials that would otherwise remain unused.

The first shock arrives through energy. Synthetic fibres are, at their core, petrochemical products. When crude oil becomes volatile, textiles feel it quickly through feedstocks such as purified terephthalic acid and monoethylene glycol, the building blocks for polyester and PET-based materials. Even when fibre prices do not move in perfect lockstep with crude, the direction of travel matters because it changes buyer behaviour. Apparel brands working on thin margins tend to delay orders, renegotiate, or switch blends when input costs climb. Technical buyers, by contrast, are often purchasing to specification for protective performance, industrial processes or infrastructure projects, where substitution is harder and compliance timelines are less forgiving. That difference alone helps explain why the technical textiles boom can accelerate even as parts of conventional apparel trade slow.

Logistics risk amplifies the divide. Disruption across the Red Sea corridor and wider Middle East has forced vessels to reroute, adding time at sea, tightening effective capacity and pushing up freight and insurance costs. For commodity apparel, where speed-to-market and price competitiveness are paramount, that is a direct hit to profitability. For technical textiles, extended transit can still be painful, but demand is frequently anchored in longer-term supply contracts, replenishment planning, and mission-critical uses. In a world where reliability is priced in, specialised textiles gain an edge.

At the demand end, the drivers are becoming clearer. Defence and security procurement has become a powerful tailwind, pulling through ballistic and stab-resistant materials, flame-resistant fabrics, chemical protective suits, and advanced composites. Industrial safety programmes and stricter workplace standards add another layer of demand for high-performance protective textiles. Meanwhile, infrastructure spending—roads, rail, ports, flood control and coastal protection—continues to broaden the market for geotextiles and geomembranes, products that rarely enter mainstream consumer awareness but are indispensable for soil stabilisation and civil engineering.

Filtration is another underappreciated engine of growth. Whether driven by water scarcity, industrial air-quality requirements, or more stringent emissions controls, filtration media demand has remained resilient. Nonwovens, engineered membranes and specialty fibre structures sit at the heart of that market, and they benefit from the same war-economy logic: governments and industries rarely treat filtration as optional when it is tied to public health, factory uptime or regulatory compliance. As this segment scales, it contributes to the technical textiles boom in a way that is structurally different from fashion-led growth.

Regulation is also nudging the market toward technical solutions. Europe’s growing focus on PFAS in textiles illustrates why. The European Environment Agency has described PFAS as persistent chemicals that can hinder reuse and recycling and pose environmental and health concerns, noting the difficulty of tracking PFAS content across global supply chains and end-of-life systems. This matters because PFAS chemistry has historically delivered durable water and oil repellency across apparel and technical applications. As restrictions tighten and transparency expectations rise, the industry is being forced to innovate—developing PFAS-free barrier technologies, redesigning finishes, and creating new material architectures that deliver performance with a more future-proof chemical profile. In effect, compliance is becoming an innovation trigger, supporting the technical textiles boom by rewarding suppliers that can combine performance with chemical credibility.

The result is a rebalancing of what “good business” looks like in textiles. Volume apparel remains enormous, but it is more exposed to consumer sentiment, discounting cycles and freight shocks. Technical textiles are not immune to macro pressure, yet their demand is more closely tied to structural needs: defence readiness, industrial production, infrastructure resilience and environmental regulation. That makes them attractive not only for manufacturers looking to protect margins, but also for governments seeking domestic capability in strategically important materials.

For textile producers and converters, the playbook is changing. Competing in technical textiles requires investment in testing, certification, traceability and process control. It demands closer collaboration with end users, engineers and regulators. It often means smaller runs, higher complexity and higher accountability. But it also offers something the apparel market rarely provides for long: pricing power rooted in performance.

The next phase of the technical textiles boom will likely be defined by two questions. First, can the industry scale responsibly, without replicating the opacity and waste that have plagued commodity fashion supply chains. Second, can innovators deliver high performance while navigating a tightening regulatory landscape, particularly around chemicals of concern. Companies that can answer both will not just ride the boom; they will shape the next era of the global textile economy.

1. Nonwoven Roll Goods

Lenzing – LENZING™ Dualwipe

LENZING™ Dualwipe is a high-performance cleaning wipe crafted from regenerated cellulose using LENZING™ Nonwovens Technology. Its innovative dual-surface design integrates abrasion and absorbency in a single material, enabling efficient cleaning without relying on fossil-based synthetic materials, binders, or chemical additives. One side features a mechanically active surface for scrubbing away dirt, grease, and residues, while the other offers a soft, highly absorbent surface for liquid uptake and surface finishing. Designed for industrial, professional, and household applications, LENZING™ Dualwipe is compatible with existing converting and processing infrastructure, facilitating rapid adoption.

The jury praised LENZING™ Dualwipe for addressing the pressing industry challenge of combining performance with sustainability. By leveraging a novel web architecture of cellulose filaments, it eliminates plastics and microplastics while delivering high-efficiency cleaning. The innovation demonstrates how fiber-level design can create tangible environmental impact without compromising functionality, offering a scalable, market-ready solution that aligns with both regulatory and consumer demands.

Magnera Corporation – Next-Gen Fluid Barrier Technology

Magnera’s proprietary fluid barrier technology represents a major advancement in protective medical textiles. Designed for demanding surgical and clinical environments, it delivers durable liquid repellency against water, oil, and other fluids without intentionally added PFAS, chemicals traditionally used for this function. Evidence of PFAS persistence in the environment and possible associated health risks has prompted global regulatory action and growing demand for alternatives. Through advanced material engineering, the technology maintains the high-performance healthcare professionals require while aligning with evolving global regulatory expectations. By eliminating legacy chemistries and ensuring consistent barrier performance, it provides a safer and more environmentally responsible alternative to conventional PFAS-based materials.

The jury recognized Magnera for addressing a long-standing challenge in medical textiles: achieving reliable fluid resistance without harmful chemicals. Combining regulatory readiness, operational reliability, and sustainability, the innovation offers healthcare providers and manufacturers a credible, scalable solution for the future.  While healthcare remains a primary application, the underlying platform has potential relevance in other markets that require durable, PFASalternative liquid barrier solutions.

Woolchemy – neweFlex™ ADL

Woolchemy has developed neweFlex™ ADL, a plastic-free acquisition distribution layer containing neweFibre™ — Woolchemy’s hygiene-grade wool fibre that meets strict regulatory standards for non-sterile hygiene products while preserving wool’s natural functionality. Engineered as a plastic-free alternative to petroleum-based ADLs, neweFlex™ ADL is a blend between wool and plant-based fibres to deliver natural benefits including breathability, thermal regulation, and odour control — while being naturally compatible with skin. Wool is a keratin-based fibre — the same structural protein found naturally in human skin, making it an inherently gentle, renewable choice for disposable hygiene products such as diapers and sanitary pads.

The jury recognised neweFlex™ ADL for overcoming long-standing technical and regulatory barriers that previously prevented wool from being used in disposable hygiene products. By enabling wool fibres to run on standard carded spunlace nonwoven equipment, Woolchemy has created a plug-and-play solution for manufacturers seeking alternatives to fossil-based nonwovens. Demonstrated performance in hygiene layers, including fast liquid acquisition and low rewet, confirms that this renewable material can match synthetic materials while advancing the industry’s transition toward more sustainable, plastic-free hygiene products.

2. Finished products made from, or incorporating nonwovens – Single-use application

Corman – Organyc brand “Personalized Protection” Light Incontinence Pads

Corman’s new light incontinence pads deliver personalized protection through three key innovations. The Smart-Cotton™ cover with a citric acid buffer maintains an ideal skin pH of 5.5, reducing irritation. The patented Cotton-Balanced Absorbent Core channels liquid to superabsorbent polymers that lock in moisture and expand toward the body for superior leak protection. Natural odor control uses an organic ingredient to bind ammonia and slow odor formation, eliminating odor instead of masking it. Clinically proven, the pads address the three main concerns of light incontinence: leaks, odor, and skin irritation.

The jury recognized the product for its consumer-focused innovation, combining skin-friendly materials, adaptive absorption, and effective odor control in one solution. The patented absorbent core was highlighted as a market-first technical advancement. Supported by clinical evidence, the product enhances comfort, confidence, and dignity for users. Its impact is amplified by the brand’s sustainability initiatives, including reducing ocean plastics and improving livelihoods through the Plastics for Change partnership, demonstrating both social and environmental responsibility.

Teknomelt Teknik Mensucat – Fibrasiv®

Fibrasiv® Abrasive Spunlace is an application-driven nonwoven innovation developed to meet the growing demand for effective yet safe cleaning materials across multiple end-use sectors. The material functions by combining a soft, absorbent spunlace base with an integrated abrasive structure that enables controlled mechanical cleaning. This allows the removal of stubborn dirt, residues, and contaminants while minimizing the risk of surface damage.

The jury appreciated Fibrasiv® for redefining the functional boundaries of spunlace nonwovens. By embedding controlled abrasive performance directly into a soft, flexible fabric, the innovation transforms a traditionally gentle wiping material into a multifunctional cleaning solution. This approach improves cleaning efficiency, reduces reliance on harsh chemical cleaners, and simplifies cleaning processes by replacing multiple tools with a single material. Its combination of performance, usability, and sustainability makes Fibrasiv® a valuable advancement for both professional and consumer cleaning applications.

3. Finished products made from, or incorporating nonwovens – Durable application

Confitex Technology – Reusable Nonwoven Bed Pads

This new Confitex technology has enabled the world’s first machine-washable and tumble-dryable nonwoven bed pads, opening a significant new application for nonwoven materials. Using a proprietary fibre-stabilisation bonding technique, the innovation allows absorbent nonwoven structures to withstand more than 30 machine wash and tumble-dry cycles while maintaining performance. The fully nonwoven construction combines a fast-wicking top sheet with a highly absorbent core capable of holding over two litres of liquid. In addition, a bonded frame structure prevents leakage across the entire surface, including the edges, addressing a common weakness of stitched textile bed pads.

The jury particularly valued how this innovation unlocks a new market segment for the nonwoven industry. By making absorbent nonwovens fully laundry-compatible, the technology enables nonwoven suppliers to enter the rapidly growing reusable bed pad market, historically dominated by textile products. At the same time, the product delivers improved absorbency, leak protection, and ease of care for users, while supporting sustainability goals through reusability and the use of predominantly natural-based fibres.

DuPont Personal Protection – DuPont™ Tychem® 6000 SFR

DuPont™ Tychem® 6000 SFR garments represent a breakthrough in personal protective equipment, delivering unprecedented dual protection against chemical exposure and flash fire hazards. Designed to be worn over primary flame-resistant (FR) clothing, these garments use a lightweight, multi-layer fabric laminate to provide at least 30 minutes of barrier protection against more than 250 chemicals, including toxic industrial chemicals, and flammable organic solvents. By combining advanced chemical resistance with secondary flame protection, Tychem® 6000 SFR enables workers in oil & gas, chemical manufacturing, and emergency response to operate safely in high-risk environments without compromising comfort or mobility.

The award jury highlighted the innovation for its ability to address a long-standing safety challenge: protecting workers simultaneously from chemical and thermal hazards. Tychem® 6000 SFR protective coverall delivers the broadest chemical coverage in the lightest-weight secondary flame-resistant garment, while its engineered design self-extinguishes in flash fire scenarios. The jury praised the garment’s combination of multi-hazard protection, durability, and comfort, recognizing its significant contribution to improving occupational health and safety standards.

Pelsan Tekstil – Metabreathe™

Metabreathe™ is an advanced nonwoven-based thermal insulation composite designed to address a key challenge in cold chain logistics: combining high solar reflectance with breathability and recyclability. Unlike conventional covers that rely on glued aluminum foils or PET films, Metabreathe™ utilizes a proprietary process where reflective particles are precision-printed onto a high-performance breathable film, which is then integrated with a specially engineered nonwoven structural foundation. This unique composite approach preserves the fabric’s interstitial spaces and the film’s microporosity, allowing air and moisture vapor to pass through while reflecting over 90% of solar radiation. Scientifically proven to keep cargo 12-15°C cooler during extreme ramp exposure, Metabreathe™ is currently trusted by global logistics leaders.

The award jury highlighted Metabreathe™ for its practical and environmental impact This innovation represents a notable step forward for cold chain materials, reducing raw material consumption by 70% and demonstrating how nonwoven material science can reconcile performance, efficiency, and circular economy principles.

4. Raw materials or components of special relevance to the nonwovens and related converted products industry

Bostik – Kizen™ Miles 9.0

Bostik’s latest innovation, Kizen™ Miles 9.0, is the first adhesive designed for disposable hygiene article construction, that offers the unique feature of debonding on demand: when exposed to a specific chemical key, combined with controlled temperature and mechanical stress, the adhesive allows clean, rapid separation of plastic components in minutes. This process keeps the adhesive material on the substrate, preventing contamination for cleaner, more efficient hygiene article recycling. But during the lifetime of the hygiene article, this new material, based on up to 75% renewable materials, delivers exceptional bonding across a wide range of substrates—including PP, PE, and PLA—while maintaining stable performance over time and under wet conditions.

The jury praised Kizen™ Miles 9.0 for its combination of sustainability and functionality. By reducing carbon footprint by up to 90% per kilogram of adhesive (compared to fully fossil based adhesives, according to internal Bostik calculation) and enabling separation of complex hygiene article components, it addresses a critical bottleneck in diaper recycling. Its ability to maintain performance during use yet allow controlled disassembly after use was recognized as a breakthrough in circular economy solutions for absorbent hygiene products.

Fiberpartner – PolyPlant®

PolyPlant® is a PLA-based fiber engineered to overcome the traditional mechanical, thermal, and processing limitations of conventional polylactic acid. Its proprietary formulation enhances crystallization behavior, molecular stability, and fiber morphology while maintaining full biogenic carbon content. Without relying on synthetic additives, PolyPlant® delivers high-performance PLA fibers that are compatible with existing industrial equipment, enabling manufacturers to adopt renewable materials without sacrificing efficiency or product quality.

The award jury praised PolyPlant® for its scientific ingenuity and practical impact. By addressing PLA’s limitations, PolyPlant® provides a credible alternative to fossil-based fibers. Its intrinsic performance improvements, achieved without additives, ensure consistent product quality and reliable processing in real-world production lines. The jury highlighted its potential to accelerate the transition toward sustainable materials while maintaining industrial efficiency, marking PolyPlant® as a transformative innovation for the fiber and nonwoven sectors.

The Lycra Company – LYCRA® ADAPTIV fiber

Building upon its proven performance in apparel, LYCRA® ADAPTIV fiber now elevates hygiene garments with hybrid elasticity that adjusts to the body at rest and in motion. This results in products that stay in place, have a second skin fit and are easier to put on and take off. LYCRA® ADAPTIV fiber represents a material-led innovation that has the potential to enable consistent, inclusive user experience across expanded size ranges— addressing an industry-wide challenge.

The jury praised LYCRA® ADAPTIV fiber for addressing a key industry challenge: delivering a consistent wearing experience across expanded size ranges without adding SKUs. By dynamically adjusting to diverse body shapes, the fiber ensures comfort, support, and fit for users at all points of the size spectrum. This innovation helps manufacturers pursue scalable solutions that feel personalized across body types—while preserving SKU discipline and operational efficiency.

5. Innovation in machinery of special relevance to the nonwovens industry

Kansan – KM Hydroentanglement Filtration System

This innovation is a mechanical filtration system developed as an alternative to conventional chemical filtration units used in wetlaid and spunlace production lines.

Instead of complex filtration systems, flotation units, and chemical additives, the system utilizes dedicated mechanical filtration equipment to enable the recovery and reuse of water and fibers directly within the production process.

By eliminating the need for chemicals, the system provides a more sustainable, efficient, and process-integrated solution for water and fiber management in nonwoven production.

The jury recognized that through its multi-stage mechanical filtration concept, the system delivers substantial environmental and operational benefits: approximately 200 kWh of energy savings per hour, 20 cubic meters of water savings per hour, and up to 2 tons of fiber recovery per day. Its ability to significantly reduce chemical consumption, lower operational costs, and improve sustainability without compromising production efficiency impressed the jury as a truly forward-thinking solution.

Teknoweb Converting – OCEAN – Converting technology for high-performance, low-impact underpads

OCEAN is IMA Teknoweb’s advanced converting system for absorbent underpads, combining new manufacturing technology with a revised product design to improve performance while using fewer materials. The system features a drumless core formation process that builds the absorbent core directly on a carrier web, ensuring even distribution of fluff and SAP and enabling ultra-thin, lightweight underpads. It also supports multilayer structures, including optimized 5-layer designs and a patent-pending 4-layer configuration with integrated leakage barriers. This approach allows production of thinner, lighter, and more efficient underpads without affecting quality or output.

The award jury highlighted OCEAN for addressing industry challenges around material efficiency, product reliability, and sustainability. Its linear core formation and multilayer designs can reduce raw material use by up to 30% and lower energy consumption. By combining stable output with reduced environmental impact, OCEAN provides manufacturers with an approach that balances innovation, performance, and resource efficiency, responding to the market demand for high-quality, discreet absorbent products.

ZUIKO  – Converting machine for recloseable baby diapers

ZUIKO has developed a converting line to produce adjustable pull on pant diapers that address the challenge of achieving a secure fit around a baby’s waist and legs while maintaining softness and stretchability. The design of such a diaper combines the adjustability of open diapers with the stretch characteristics of pant diapers. Unlike conventional pant diapers, which are processed symmetrically, ZUIKO’s recloseable diapers are asymmetric, requiring a precise, glue-less attachment process during folding. Central to the production is ZUIKO’s patented “Stretch Re-pitch Drum™,” which regulates elastic tension and product spacing, allowing panel folding in line with the machine’s flow. This system enables the production of over 700 diapers per minute without the need for multiple folding units.

The jury recognized the technical ingenuity of ZUIKO’s approach, particularly how the machine merges two product attributes efficiently. They highlighted the asymmetric folding and tension-control mechanisms as practical solutions to a long-standing industry challenge. The innovation offers a new product format for consumers and provides manufacturers a method to produce it at scale without added complexity.

The winners in each category will be announced during a special ceremony at the INDEX™26 exhibition, the world’s leading nonwovens event, which will take place on the first day of INDEX™26, Tuesday, 19 May at 10:30 CET, on the EDANA stand. These awards serve not only to honor the ingenious engineering of the finalists but also to provide a roadmap for the future of the entire nonwovens supply chain.

Drawing on more than two decades of industry experience, the company’s latest development effort is designed to deliver a combination of effective odour and gas adsorption with low pressure drop, practical carbon integration and the level of documentation manufacturers increasingly need to support product approvals and risk assessments.

The timing reflects intensifying global attention on PFAS. In the European Union, regulators have progressed a wide-ranging proposal that would restrict broad PFAS groups under REACH. In the United States, ostomy pouches and related accessories are regulated as medical devices, placing accountability on manufacturers for material selection, risk management and compliance. Nonwovenn argues that adopting PFAS free filter media can help brands simplify international market access and protect future product portfolios as regulations evolve.

John Birkett, MediTech Business Director at Nonwovenn, said: “Demographic trends and regulatory changes are driving the need for next generation ostomy care technologies. We want to focus on delivering high-quality PFAS free filter media that can meet the practical and regulatory demands of modern ostomy systems.”

“Aging populations are driving greater demand for ostomy care, and we believe that reliable, discreet and comfortable pouch technology that offers effective control is incredibly important. Our customers, and the end users, are at the forefront of our minds as we continue to develop our products.”

Nonwovenn says its development programme is engineered without intentionally adding PFAS, aligning with emerging legislation while maintaining key functional requirements such as breathability and adsorption performance. The company notes that its measured performance targets reflect published gas and composition data, known odour drivers and clinical experience. Finished materials will be offered as roll goods or as cut filter inserts designed to fit common ostomy pouch formats.

Recent European research conducted by Ontex among more than 2,500 people living with incontinence shows that dermatitis and skin irritation remain widespread and have a meaningful impact on daily life. Almost 1 in 2 people living with incontinence have experienced dermatitis or skin irritation in the intimate area; with many describing significant discomfort and effects on confidence and wellbeing. Despite this high prevalence, “Around 80% of caregivers are not trained to recognize dermatitis. Education and better product design are key to preventing complications.” says Dr. Maria Panourgia, Geriatrician at the Milton Keynes University Hospital (UK).

These findings underline the urgent need for affordable, qualitative incontinence products that actively support skin health. The new Sensitive range has been developed precisely to answer this need—combining trusted protection with dermatological care to help prevent irritation and keep skin as healthy as possible.

To address the educational need, the Sensitive range is complemented with expert training advise on how to recognize, prevent and treat dermatitis related to incontinence. This is offered both through Ontex’s network of nurse advisors and through the online training platform Ontex Academy.

Sensitive range: powerful protection that respects the skin

The new Sensitive range combines proven incontinence protection with dermatological care.

Sensitive Pants offer:

• Topsheet enriched with botanical ingredients – helps to prevent skin irritation
• Innovative Y-core technology – for instant dryness
• Faster absorption – up to 2.5x faster than previous iD or Serenity pants
• Hypoallergenic design – gentle on fragile skin
• Odour control technology – for lasting freshness and confidence

Tatiana Bumachar Carvalho Pastori, Sr Marketing Manager Adult Care concludes: “the Sensitive range was developed to help people with incontinence to live their everyday life more comfortable. At the same time, it offers professional caregivers a product they can rely on, making it easier for them to deliver the best possible care, supported by our training opportunities.”

The collaboration focusing on identifying new, efficient ways to process Lenzing’s TENCEL™ Lyocell and Modal fibers with Micro Technology, made from the natural material wood, sourced from certified or controlled sources and manufactured using a responsible production process with a low environmental impact, on warp knitting machines, whilst demonstrating their suitability for high-quality textile applications.

TENCEL™Lyocell and Modal fibers produced with Micro Technology are characterized by their fine titers which enable the production of finer yarns, resulting in smooth and consistent fabrics that deliver softness and lightness for enhanced comfort, whilst yielding superior drape and movement.

Cellulose fibers offer consistent fiber length uniformity, forming the basis for high mechanical performance. Despite this advantage, the production of warp-knitted fabrics from cellulose fibers presents significant technical challenges. To address this complexity, the two partners joined forces to develop a new innovation project; Lenzing contributing extensive expertise in fiber production and yarn development, including the downstream spinning process, whilst KARL MAYER complemented with many years of experience in warp beam production from staple fibers and their processing on high-performance warp knitting machines. The manufacturer’s machines are renowned on the market for their maximum efficiency, reliability and quality.

Yarn Properties: Minimal Hairiness, Homogeneous Cross-Section
The first step within the project development was to select fibers and spinning technologies that would result in yarns with reduced hairiness. Low hairiness prevents contamination by lint or flying fibers during the beaming and warp knitting process.

In addition, a uniform yarn cross-section is important. A high level of homogeneity of the yarns ensures the tensile strength required to process several thousand threads at maximum speed on KARL MAYER warp knitting machines. Four different yarns were used, each made from two fiber raw materials and two spinning processes.

Specifically, the choice fell on:

1. TENCEL™ Modal with Micro technology, Ne 60/1 ( Nm 100/1) Ring Compact – from Gebr. Otto GmbH + Co. KG, 89165 Dietenheim (Germany)
2. TENCEL™ Lyocell with Micro technology, Ne 60/1 ( Nm 100/1) Ring Compact – from Gebr. Otto GmbH + Co. KG, 89165 Dietenheim (Germany)
3. TENCEL™ Modal with Micro technology, Ne 60/1 ( Nm 100/1) SIRO Compact – from Inovafil – Fiação, S.A., 4770-583 Vila Nova de Famalicão (Portugal)
4. TENCEL™ Lyocell with Micro Technology, Ne 60/1 ( Nm 100/1) SIRO Compact – from Inovafil – Fiação, S.A., 4770-583 Vila Nova de Famalicão (Portugal)

Processing: High Efficiency, Good Quality

The yarn material was warped to a high standard, particularly in terms of lint and used on a high-performance warp knitting machine in a gauge of E 28 with two guide bars. This resulted in three different articles for the clothing sector from each yarn: an open worked three-stitch tulle net, a close-knit fabric made counter-lapped open tricot lap and a fabric made from a counter-lapped atlas lap, also with a dense surface.

The processing tests revealed a clear winner: SIRO Compact impressed with significantly reduced hairiness, resulting in less fiber abrasion and less contamination of the machine.

Debut Showcase: Market Ready Solutions                           

The results of the innovation project will be presented to the textile world during Premiere Vision, Paris, 3rd-5th February, introducing a capsule collection as a mix of applications across lingerie, innerwear and lifestyle pieces for everyday wear.

The Lenzing team will be at the Lenzing stand 6P30 to welcome guests, engage in discussions on all the latest innovations across the Lenzing portfolio, whilst exploring the new applications across the capsule.

Innovation plays a crucial role in the future of the tissue and towel industry, as it aims to meet the growing consumer demand for softness, strength, and sustainability, while also enabling manufacturers to optimize their production processes.

As the demand for eco-friendly, high-performance products increases, innovation provides smarter solutions that minimize water, fiber, and energy consumption, boost operational efficiency, and support long-term environmental sustainability goals.

As part of this collaboration, Nalco Water will act as a strategic partner for ANDRITZ, utilizing their cutting-edge pilot tissue machine at TIAC. This partnership will allow Nalco Water to test and validate its advanced chemistries, as well as digital and automation solutions, in a controlled, large-scale environment. The increased access to the machine will accelerate the innovation cycles and facilitate quicker market entry for new tissue solutions.

“This partnership with ANDRITZ allows us to bring our solutions to life in a real-world setting, accelerating development timelines and enabling our customers to trial programs before implementation on their own machines,” said Ravi Raghavapudi, Senior Vice President & General Manager of Global Nalco Water Paper. “It is a significant milestone for Nalco Water and our tissue customers.”

The TIAC facility features a fully-equipped tissue production line with flexible configurations, including conventional, textured, and structured (TAD) tissue formats, complemented by advanced automation and monitoring systems. The collaboration will also present opportunities for joint development with leading global tissue producers and access to TIAC’s Metris digital innovation platform, which enhances process optimization.

Nalco Water’s involvement in this partnership was confirmed through a competitive evaluation process, where its chemistries showcased superior performance.

This alliance marks a significant step forward in tissue innovation, driving the industry toward more sustainable practices and enhanced product quality.

Nonwovenn, a leading company in the nonwoven fabric technology sector, has been officially acquired by CorpAcq, a firm based in Altrincham and backed by TDR Capital. This acquisition also marks a successful exit for BGF, the UK and Ireland’s most prominent growth capital investor.

Founded in 2003 by David Lamb, who serves as the current Chairman, Nonwovenn specializes in manufacturing custom technical fabrics for niche markets. The company’s dedication to harm reduction is evident in its range of products, which includes materials designed for protective clothing and wound care. Following a significant multi-million-pound investment in 2016, BGF has played a crucial role in supporting the company during its substantial growth journey.

The annual turnover for Nonwovenn has impressively surged from £19 million in 2016 to £46 million by 2025, with continued strong growth expected into 2026. The business has celebrated 19 consecutive years of profitability and is recognized as a significant exporter of its products. Additionally, Nonwovenn has recently invested £1.5 million in research and development to enhance its CBRN (chemical, biological, radiological, and nuclear) protective solutions.

David Lamb, Chairman of Nonwovenn, stated, “We’re proud to have delivered such consistent growth and strong profitability over two decades, whilst remaining committed to maintaining the highest quality and customer satisfaction across our product lines. Partnering with BGF has been instrumental in maximizing our potential – enabling us to strengthen innovation, diversify product lines, and expand internationally. We’re excited to build on these strong foundations in our next phase of growth as part of CorpAcq.”

The transaction process was led for BGF by Paul Oldham, with assistance from Louis Hall from BGF’s Bristol team, while Alantra provided advisory services to the shareholders of Nonwovenn.

Paul Oldham remarked, “Nonwovenn has gone from strength to strength since our initial investment in 2016, reflected in the outstanding returns delivered for BGF. This impressive management team has built a loyal customer base by providing consistently high levels of service and product development. Our nine-year partnership with the business has been hugely enjoyable and successful, and I look forward to seeing how the team builds on their success with the backing of CorpAcq.”

Stuart Kissen, Head of Acquisitions at CorpAcq, added, “Nonwovenn is an outstanding business with a leading market position, strong growth prospects, and a highly experienced management team. We see significant opportunity in the fabric technology space and are looking forward to establishing a long-term partnership with David and his team as Nonwovenn enters the next stage of its development.”

Since its establishment in 2003, Nonwovenn has been dedicated to producing top-quality technical fabrics that enhance product experiences. The acquisition by CorpAcq represents a transformative moment for Nonwovenn, pointing to an exciting future in the nonwoven fabric industry.

• Nonwovens represent 30-35% of global textile production but <5% of current recycling; market expansion potential substantial as collection infrastructure develops
• Medical nonwovens (surgical gowns, masks, bandages) and hygiene products (diapers, feminine products) represent primary nonwoven waste streams requiring specialized handling
• Fiber separation challenges in nonwovens (multiple fiber types bonded without clear structures) require different technology approaches than woven/knit textiles
• Nonwoven recycling facility capital investment (USD 8-15M for 50,000-ton capacity) exceeds woven recycling due to process complexity; offset by higher material value
• Automotive nonwoven applications (door panels, sound insulation, trim) provide established end-markets for recovered fiber with quality specifications
• Regulatory drivers (medical waste management, hygiene product waste directives) are accelerating nonwoven recycling infrastructure investment

The Underutilized Recycling Opportunity in Engineered Fabrics

Nonwoven textiles occupy distinct position in global fiber market: substantial production volume (approximately 30-35% of global textile production), diverse high-value applications, yet virtually no established recycling infrastructure. This position creates both challenge and exceptional opportunity as regulatory pressure, resource constraints, and circular economy requirements drive nonwoven recycling development.

Understanding nonwoven recycling potential requires first understanding nonwoven materials themselves distinct from conventional woven and knitted textiles in both manufacturing process and end-use applications.

Nonwoven Materials: Composition and Manufacturing

Nonwovens are engineered fabrics composed of fibers bonded together through mechanical interlocking, adhesive bonding, or thermal fusion. Unlike woven textiles created through interlacing yarns or knit textiles created through loops, nonwovens comprise fibers directly bonded without yarn intermediate.

This manufacturing difference creates distinct properties: nonwovens offer high porosity enabling fluid filtration, excellent barrier properties preventing particle passage, variable strength profiles optimizable for specific applications. These properties enable applications impossible with conventional textiles.

Nonwoven fiber composition varies by application: polypropylene dominates nonwovens for general applications (filtration, insulation, geotextiles); polyester, nylon, and acrylic serve specialized applications (sound absorption, thermal insulation); cellulose nonwovens serve medical and hygiene applications.

Primary Nonwoven Waste Streams

Medical nonwovens represent the most visibility but not the largest volume stream: surgical gowns, masks, bandages, wound dressings, sterilization wraps. This segment faced particular visibility during COVID-19 pandemic when millions of single-use masks entered waste streams daily.

Hygiene product nonwovens represent larger volume: diapers, feminine hygiene products, incontinence products. These products comprise 70-80% nonwoven by composition, generating substantial waste volumes. A single diaper contains approximately 5-7 grams of nonwoven fabric; global diaper waste exceeds 30 million metric tons annually.

Automotive nonwovens serve interior applications: door panels, sound insulation, trim components, seat padding. These applications generate pre-consumer manufacturing waste plus post-consumer vehicle end-of-life waste.

Industrial and filtration nonwovens include air filters, water filters, bag filters, geotextiles, and specialized industrial applications. This segment represents smaller volume but often higher-value material.

Technical Challenges in Nonwoven Recycling

Nonwoven recycling presents distinct technical challenges compared to conventional textiles. Primary challenge: multiple fiber types bonded together without clear structural organization. A surgical gown might comprise polyester fibers bonded with polypropylene through adhesive, plus elastic trim and waterproofing coating.

Separating bonded fiber structures is technically complex. Mechanical approaches (shredding, carding) cannot selectively recover individual fibers from bonded matrices. Chemical dissolution approaches must carefully select solvents dissolving specific fibers while preserving others, often proving inefficient or uneconomic.

Contamination represents second major challenge. Medical and hygiene nonwovens are frequently contaminated with biological matter requiring specialized decontamination before recycling is possible. Rigorous sterilization, chemical disinfection, or thermal treatment is necessary ensuring output material safety.

Adhesive contamination similarly presents challenge: adhesives bonding fibers cannot be easily removed and persist through many recycling processes, potentially degrading final product quality.

Emerging Technology Approaches

Despite challenges, solutions are progressively emerging. Thermal separation employs carefully controlled heating to soften thermally-bonded nonwovens selectively, separating fiber components. This approach works particularly well for adhesive-bonded nonwovens where temperature profiles can dissolve adhesive without damaging fibers.

Solvent-based approaches employ selective solvents dissolving specific fiber types. A polypropylene-polyester nonwoven might be processed using selective solvent attacking polyester, leaving polypropylene fibers intact. Subsequent fiber recovery and regeneration enables material reuse.

Pyrolysis and thermal processing decomposes nonwoven structures into basic chemical components monomers, oils that can be further processed. While not fiber-to-fiber recovery, this approach converts waste into processable chemical feedstock.

Enzymatic approaches employ specialized enzymes degrading specific polymers or adhesives selectively. This emerging technology offers potential for precise decomposition without harsh chemical processing.

Medical Nonwoven Recycling Challenges and Solutions

Medical nonwoven recycling requires specialized approaches addressing contamination and safety concerns. Surgical masks, gowns, and bandages likely carry biological contamination requiring thorough decontamination before recycling is possible.

Sterilization through autoclaving (high-temperature steam), chemical disinfection (hydrogen peroxide, quaternary ammonium compounds), or irradiation (gamma radiation, electron beam) eliminates biological hazards. Following sterilization, fibers can safely proceed to conventional recycling pathways.

Some medical facilities are implementing medical nonwoven collection and decontamination programs. The waste volume is enormous surgical masks alone represent millions of tons globally and dedicated processing can achieve scale supporting specialized facility investment.

Hygiene Product Nonwoven Recycling: The Diaper Challenge

Diapers present particular challenge: they contain not only nonwoven but also absorbent polymer (super-absorbent polymer, SAP), elastic components, and biological contamination. Separating these components and recovering fibers presents complexity exceeding surgical gown recycling.

However, approaches are emerging. Some companies are developing thermal processes decomposing diaper structures into recovering component materials. Recovered fibers can be processed into building materials, insulation, or lower-value nonwovens. Recovered superabsorbent polymers can be regenerated or processed into other applications.

The economic case for diaper recycling remains challenging given low material value relative to processing cost. However, landfill diversion benefits and regulatory pressure are driving investment.

Automotive Nonwoven Applications and Established Markets

Automotive nonwoven recycling faces more favorable economics than medical or hygiene segments. Vehicle end-of-life processing already involves systematic disassembly and material recovery. Nonwoven components (interior trim, insulation, panels) can be captured during this process.

Recovered automotive nonwovens have established end-markets: sound insulation for construction, carpet padding, automotive interior components for lower-cost vehicles. This established demand creates viable economic pathway supporting recycling.

Automotive manufacturers’ end-of-life responsibility regulations in Europe and emerging in other regions create explicit incentive for nonwoven recovery. Manufacturers must achieve specified material recovery percentages, driving nonwoven recovery infrastructure development.

Market Opportunity and Growth Trajectory

Current nonwoven recycling represents <5% of nonwoven waste despite 30-35% composition of global textiles. This gap represents exceptional growth opportunity as infrastructure develops.

Infrastructure investment requirements are substantial. A facility capable of processing 50,000 tons annually requires capital investment of approximately USD 8-15 million, exceeding conventional textile recycling facility cost due to technical complexity. However, higher material value of nonwoven products justifies capital investment.

Market projections suggest nonwoven recycling market reaching USD 2-3 billion annually by 2030, representing 5-10% of current nonwoven waste volume. This expansion represents 400-500% growth from current baseline.

Geographic concentration near major nonwoven manufacturing centers and automotive recycling infrastructure will likely characterize early facility development. Medical and hygiene product nonwoven recycling will follow as specialized collection and decontamination infrastructure matures.

Long-Term Viability and Circular Nonwoven Systems

As nonwoven recycling technology matures and infrastructure scales, genuine closed-loop nonwoven systems become feasible. Manufacturers designing nonwovens for recyclability, collection systems capturing end-of-life material, and processing technology recovering fibers, create circular nonwoven economy paralleling emerging circular systems in conventional textiles.

This circular transition will require design-for-recyclability investment by manufacturers, collection infrastructure development, and regulatory drivers creating economic incentive. These elements are progressively converging, positioning nonwoven recycling as high-growth circular economy segment through 2030s.

As member states begin to enforce extended producer responsibility (EPR) for textiles, the lack of distinction within the textile EPR directive is causing significant confusion, according to EDANA.

Currently, the specified combined nomenclature (CN) codes do not differentiate standard clothing from essential personal protective equipment (PPE) or medical devices.

The joint statement highlights that PPE and medical devices are specifically designed to protect users from hazardous conditions, including chemical, biological, and radiological threats. Due to their nature, these garments often become contaminated and are classified as hazardous waste, necessitating incineration (often with energy recovery) rather than recycling for safety reasons.

Integrating these products into standard textile EPR schemes poses substantial risks, including cross-contamination, regulatory conflicts, and limited circularity potential.

Mixing hazardous PPE waste with regular textiles jeopardizes both human health and environmental safety. The disposal of contaminated PPE is already regulated under Articles 13, 17, 18, and 19 of the existing Waste Framework Directive.

PPE accounts for less than 1% of textile waste, with 80-90% considered hazardous. The environmental advantages of recycling the remaining non-hazardous fraction are minimal compared to the extensive transport required to collect sufficient volumes.

The statement further urges for guidance on safety footwear. Like other personal protective equipment, these items encounter contamination issues that restrict recyclability. Manufacturers find it challenging to guarantee warranties or compliance for reused safety footwear, and the fee structure for heavier items, such as steel-toed boots, remains unclear.

Although the directive indicates that products posing safety or hygiene risks should be excluded from the EPR, this is being overlooked in national implementations by countries such as Spain and the Netherlands.

In light of these concerns, the signatories have called upon the European Commission to provide clear guidance to member states, affirming that products compliant with the PPE Regulation (2016/425) and the Medical Devices Regulation (2017/745) are outside the scope of the textile EPR directive.