Evolution yarns: r-Starlight in Recycled Polyester and Cornleaf in PLA
Evolution yarns :r-Starlight in Recycled Polyester and Cornleaf in PLA Roberto Parenzan R&D Manager PET Yarns
RadiciGroupRadiciGroup is one of the most active chemicals companies at an international level. Itsdiversiﬁed businesses operate worldwide and are focused on Chemicals, Plasticsand Synthetic Fibres.The Group has total control over its production chain, from chemical intermediates,such as adipic acid and polyamide 6 and 66, to engineering plastics, and man-madefibres.RadiciGroup’s products are exported all over the world, and are the starting-point fordevelopments in the clothing, sport, furnishings, automotive, electrical/electronic andappliances sectors. 3,500 employees 1,238 million euros 2011 Turnover Radici Partecipazioni
A World-wide PresenceEUROPEMendrisio (CH)Stabio (CH)Podborany (CZ)Overath (D)Hamburg (D)Lüneburg (D)Reutlingen (D)Tröglitz (D)Viernheim (D)Selbitz (D)La Carolina (ES)Saint Priest (F)Szentgotthard (H)Andalo Valtellino (IT)Ardesio (IT)Casnigo (IT) AMERICA ASIAChignolo d’Isola (IT)Gandino (IT) Buenos Aires (RA) Noida (IND)Novara (IT) Rio Grande (RA) Shanghai (CN)Trivero (IT) Araçariguama (BR) Suzhou (CN)Villa d’Ogna (IT) São José dos CamposSavinesti (RO) (BR)London (UK) Gastonia (USA) Wadsworth (USA)
Sustainability According to RadiciGroup1) Organizational Models ISO 9000, ISO 14000, OHSAS 18000, SA 8000, ISO 50001, ISO 14064.2) Certifications (mandatory and voluntary) along with R&D efforts• REACH• LCA applied to all main products.• Eco-Profiles, EPDs, Ecolabel, Oekotex3) Kyoto protocol parameters : 20/20/20 +20% recycled materials.4) Sustainability as an approach to corporate governance, an approach based on GRIGlobal Reporting Initiative protocol.
What does it mean to be a manufacturer of sustainable yarn ?Making yarns that customers want using eco-sustainable polymers and processesRadiciGroup’s goal is to build a portfolio of sustainable products with the sameflexibility and properties as standard ones.In pursuing this target, we have worked on many aspects of production technologyand product development, including:• Support documentation• Base polymers• Production flexibility• Product range• Solution dyeing and additivationWe want to give our customers the opportunity to start their projects with yarns tomeet their design objectives already on hand.
Recycled Polyester Brand It’s a continuous polyester filaments yarn made with 100 % Recycled PET from bottle. With this brand we sell POY and FDY productsFriction text – Air text - Warping Once the POY yarn is transformed, the final product becomes r-Radyarn
Why is r-Starlight different ? Certifications Product range FlexibilityCertificates Wide product range Meeting customerguaranteeing product encompassing all demand in terms oforigin and safety are conceivable quantity and productavailable combinations of type colours and performance characteristics
Why is r-Starlight different ?CertificationsGRI ( Global Reporting Initiative )In 2011 RadiciGroup decided to certify its system according to the Global ReportingInitiative, an internationally recognized sustainability reporting system that hasalready been adopted by the major brand names in the apparel industry, such asAdidas, Nike, Puma, Timberland and The North FaceLCA ( Life Cycle Assessment )A Life Cycle Assessment (LCA) for both r-Starlight and r-Radyarn products wasperformed with the aid of an external organizationProduct certification : 100 % post-consumer PETThe production cycle is monitored by DNV, a leading certification body, which checksthat all the products sold with a “recycled” label have actually been made incompliance with applicable standards and guarantees that 100%post-consumer polymer has been used
LCA ( Life Cycle Assessment ) Standard PET GER Gross Energy Requirement 72 MJ eq 134,4 MJ eq … more than 40 % reduction GWP Global Warming Potetial 3,5 CO2 eq 5,3 CO2 eq … more than 30 % reductionData Source : RadiciGroup LCA Study conducted by ICA - 2012
Audit Certification Process Purchase request 100% post consumer Declare to Recycled PET chips DNVSpinning Spinning100% R-PET 100 % R-PETr-Starlight r-StarlightFDY type POY Declare to DNV per Material Balanced month Check DNV product Customers certification
Why is r-Starlight different ?CertificationsOEKO-TEX Standard 100All r-Starlight and r-Radyarn polymers are OEKO-Tex certified as free of substancesharmful to the healthREACHAll substances used, including colours and additives, comply with REACH safetyregulationsEuropean productIn order to better achieve a low LCA value, all the recycled polymer is made frombottles collected in Europe. We are already working on further improving the systemby reducing the distance between the collection site and the place where the polymeris transformed firstly into granules and then into yarn
Why is r-Starlight different ?Product rangeProduct typeOur recycled yarn is available in : POY, FDY, DTY, ATY, Twisted, Beams. As luster we canproduce full-dull, semi-dull, bright with different cross section like round, trilobal,octolobal, hollow, multi channelCountWe have a complete range of count from final 22 to 600 dtex as POY and FDYand from 22 up to 2500 dtex as ATY, DTY combined with twistedColors and additivesTo colour our yarn, we use solution dyeing, and we have thousands of coloursavailable, which have been developed to meet customer needs.During extrusion we can add other functions, beside colour, such as antibacterialaction or UV resistance, in any combination
Solution Dyeing Technology• Dyestuff and additive embeddedwithin the filaments• Maximum color fastness• Color reproducibility guaranteed • Reduced consumption of water and energy compared to traditional dyeing systems.
Why is r-Starlight different ?FlexibilityFit the customer specificationsThe yarn is produced according to customer specifications on count, lustre, colour andadditional functionalities. There is no standard product, as each yarn is developed togive the customer the opportunity to create items based on a set of specific needs.QuantityThe flexibility of our plant allows for a minimum quantity of only 200 kg for eachproduct/colour. This minimal amount facilitates using the yarn for new projects orniche markets.Color matchingCustomers can ask us to develop solution-dyed yarn using their own colours. A sampleof the requested colour, already consisting of the final yarn type, will be sent to thecustomer, so that on approval it can be implemented immediately in productionwithout introducing any new variables
r-Starlight in sportswear socksIn collaboration with Intersocks Srl, we havedesigned and manufactured special runningsocks using r-Radyarn.For this product, we use either black or opticalwhite dtex 78/66 DTY solution-dyed yarn,together with an additive providingbacteriostatic action.Solution dyeing has allowed us to achieveoptimal washing fastness equal to 5 on thegrey scale for both colours after 200 washes.Mass additivation of antibacterial agentshelps to eliminate bacteria from the yarn,while keeping yarn performance unchangedup to 200 washes at 65°C
r-Starlight in sportswearPresented at ISPO 2012 this zip longsleeve,made in collaboration with Heiq, Youngoneand Mapp, combines the sustainability ofr-Starlight and the natural touch of merinowool.Outside a yarn r-Starlight dtex 78f66 DTY FTdope dyed grey with embedded bacteristaticeffect. Good performance in terms of odorcontrol, color fastness, low pilling, goodtranspiration and nice touch.Inside pure merino wool to keep the body atthe perfect temperature during winter.A perfect project to join the technology andthe sustainability of recycled polyester withnatural fibers.
r-Starlight technical applicationIn collaboration with Diatex fabrics forfiltration aeraulics was made with r-RadyarnThe yarn used is a dtex 78f24 DTY FTFThe eco characteristic of this fabric can beused in buildings with low environmentalimpact, thus satisfying all the demands of themarket for new standard with recycledmaterials
Why PLA ? A real alternative coming from renewable resource and not from oilRadiciGroup started working on this polymer in 2001 and has developed a largevariety of products since then.Using this product, it is possible to manufacture yarn that combines standard textilecharacteristics with the use of renewable resources.Today PLA polymer is produced not only from corn, but also from a variety of otherproducts such as sugar cane, beets, wheat, and, in the future, agricultural waste. Thecorn used is less than 0.1% of total corn production and thus it has no effect on thefood chain. ( Source NatureWorks LLC)We believe that PLA has excellent potential in the textile industry because it is both agreen product and a compostable one.Thanks to our know-how and production flexibility, PLA has become a versatilematerial for any textile application..
PLA ( polylactic acid ) Brand It’s a continuous PLA filaments yarn made with PLA polymer. With this brand we sell POY and FDY productsFriction text – Air text - Warping Once the POY yarn is transformed, the final product becomes Radyarn CornLeaf
CornLeaf : key points Tenacity Between 3 and 4 cN/dtex Elongation Between 22 and 38 % Shirkage ( 100°C x 2 min ) Between 3 and 9 %The difference in the values depends on the process: DTY, ATY, FDY or Twisted Specific weight - 10 % compare to PET FR properties LOI >26, does not release toxic fumes Certification OEKO-TEX standard 100 Physical characteristics The yarn’s physical characteristics over time are over time guaranteed both on yarn and finished fabrics. No influence due to humidity on yarn performance (Guideline has to be followed)
Yarn’s physical characteristics over timeStudies were conducted over a 3-year period to determine any changes occurring inthe yarn’s physical characteristics over time
CornLeaf : available productsType POY, DTY, ATY, FDY, TwistedLuster Bright, Semi Dull, Full DullCount From 50 to 300 dtex for POY,FDY and up to 2000 dtex for DTY, ATY and twistedDPF From 1,6 to 7 dtex/filamentColors Because of the high temperatures involved, the use of a yarn or piece dyeing process tends to cause deterioration in the mechanical properties of the yarn, and consequently solution dyeing is recommended. Hundreds of colours are available and we can create recipes for customized colours on customer requestQuantity 200 kg min for each product/color
Example of useDornbirn Conference bag Yarn used : -Warp : DTY dtex 200f48 x 2 DTY FTF intermingled - Weft: ATY dtex 480f96 The fabric of this bag has inside all technologies to a be an alternative to the standard PET or PP bags. Renewable polymer, solution dyeing process without water and chemicals harmful to the health. Adding a bacteriostatic performance is possible Shopping bags for food can be made adding bacteriostatic proprieties. This permits to have an heavy, safe place where to put food avoid any contact with bacteria.
Environmental impact comparison betweentextile shopping bags : Cornleaf Std PET consumption for unit. bag dimension cm 37 X 27 X 6 37 X 27 X 6 bag weight gr 85 85 water lt 6 15emission (GWP CO2 eq) Kg 0,6 1,1Energy (GER Mjeq) MJ 14 22 oekotex standard -- YES possible 100 (CLASS1 certificate) bacteriostatic activity -- possible possible recycling -- possible possiblebiodegradability time compost – days 90 unknow ISO14855biodegradability time soil – ISO17556 years 1 100-1000
Example of useSustainable officeIn this building more than 1400 roller curtains are made with CornLeaf yarn, based ondtex 167f48.CornLeaf fits perfectly the idea of the building, made using sustainable products andenergy.
Example of useEmbroidery fabrics intimate wearYarn used :-Dtex 120x2 FDY twisted Dope Dyedwith bacteristatic effectIn collaboration with our partnerRitex Spa, we have created a lacefabric for intimatewear, 100% madefrom CornLeaf.Intimatewear items made with thisproduct ensure that the skin touchesan anallergic, bacteriostatic yarn witha soft hand.
Key points to remember for r-Starlight and CornLeaf r-Starlight • low LCA value • Safe and certified 100 % post consumer PET from bottle CornLeaf • yarn form renewable resources, it’s not made from oil • compostable materials For both yarns • Wide product range • Minimum lot of 200 kg for each product/color • Solution (Dope) Dyeing process to save water • Sustainable approach for all process/product ( GRI)
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