Daniele Dossi, Noyfil SA, RadiciGroup AICTC Conference : Polyester production and processing - Como May 30, 2014

1. “From LCA to Enviromental product certification
through PCRs”.
Daniele Dossi, Noyfil SA, RadiciGroup
Como May 30, 2014AICTC Conference :
Polyester production and processing

2. ABOUT RADICIGROUP
RadiciGroup is one of the most active Italian chemicals companies at an
international level. RadiciGroup's diversified businesses operate worldwide
and are focused on Chemicals, Plastics, Synthetic Fibres and Nonwovens.
3,200employees1,045million euros
Radici Partecipazioni
Sales Turnover 2013
About RadiciGroup
RadiciGroup's products are exported all over the world, and are the
starting-point for developments in the clothing, sport, furnishings,
automotive, electrical/electronic and appliances sectors.

3. It was back in 1941 that Pietro Radici established the company Tessiture
Pietro Radici in Val Gandino, a narrow valley embraced by the Orobic Pre-
Alps. With Pietro's son, Gianni Radici, RadiciGroup began a process of
horizontal diversification in the 1950s, progressing from blanket producer
to the production of rugs, fabrics, carpeting and car mats.
Today the Group is managed by
the president Angelo Radici,
the vice-president Maurizio Radici
and Paolo Radici
A group owned by a family
In the '80s, we are witnessing the
development of the business of plastics
and polymers (1981) and chemicals
(1986).

4. IN EUROPE AND AROUND THE WORLD
EUROPE
Mendrisio (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)
Chignolo d’Isola
(IT)
Gandino (IT)
Novara (IT)
Trivero (IT)
Villa d’Ogna (IT)
Savinesti (RO)
London (UK)
AMERICAS
Buenos Aires (RA)
Rio Grande (RA)
Araçariguama (BR)
São José dos Campos
(BR)
Wadsworth (USA)
Greenville (USA)
ASIA
New Delhi
Shanghai (CN)
Suzhou (CN)

5. PET PRODUCTION PLANTS
Noyfil SpA - Andalo Valtellino (Italy)
Continuous polyester yarns, semi-dull and bright,
flat, sized beams for weaving and warp-knitting
beams. Micro and multifilaments and special
yarns.
Noyfil SA - Stabio (Switzerland)
POY dope dyed or raw, FDY dope
dyed or raw; POY for stretch yarns
(PBT); UV resistant, antibacterial and
flame retardant yarns; PLA
Biopolymer yarns.
Noyfil SpA - Chignolo d’Isola (Italy)
Texturing, air-jet, twisting, air-mingling of
polyester yarns raw white, dope and yarn
dyed suitable for weaving and knitwear.
27,000 tons – spinning capacity
10,000 tons – texturizing/taslan/entwining
6,000 tons – warping capacity
2,600 tons – package dyeing

6. RADYARN ®
STARLIGHT ®
Customer care and
technical assistance
WARP KNITTING AUTOMOTIVE WEAVING CONVERTERS
Industry team
FINAL APPLICATIONS
Apparel, automotive, technical-industrial, home and
furnishings…
ADDITTIVATED
SOLUTION DYED
YARN DYED
POY
FDY
HOY (SY type)
TDY
ATY
FDY/HOY TWISTED
TDY TWISTWD
FLAT OR
TEXTURED
ON BEAMS
PRODUCTION
WARP KNITTING
SIZED FOR
WEAVING
MARKETING
POLYESTER YARN PRODUCTION
91 million euros ; Sales (2013)
340 employees

7. MAIN BRANDS
Raw-white and
solution or yarn-dyed
polyester available in
additivated versions
(Flame Retardant,
bacteriostatic,
UV protection),
microfibre,
supermicrofibre and
bicomponent
(PA/PET).
Raw and solution-
dyed polyester yarn
available in
additivated versions
(FR, bacteriostatic,
UV protection) ideal
for applications,
from apparel to
furnishings, medical
and automotive
sector.
Continuous polyester
filament derived from
post-consumer
recycled polymer
available in dope-
dyed, bacteriostatic
and UV stabilized
versions. Versatile
product for a wide
range of applications.
Eco-sustainable
polyester yarn
produced from post-
consumer recycled
PET bottles;
sustainable solution
for a vast range of
applications from
apparel to
technical/industrial
sectors.
Raw or solution-dyed
yarn, available with
antimicrobial
functionality, made
from Ingeo™ polylactic
acid (PLA) 100%
natural biopolymer
derived from
renewable sources.

8. POLYESTER FILAMENT YARN: PRODUCTION CHAIN
RadiciGroup companies employ in
their modern production chains the
latest technologies.
Thanks to modernized production
plants and automation of all
departments, the company regularly
assures quality and consistency of
products.
RADICIGROUP HAS CONTROL
ON THE ENTIRE POLYESTER
PRODUCTION CHAIN,
INTEGRATED FROM THE RAW
MATERIAL TO THE FINAL YARN.

9. THE VISION MISSION VALUES OF A FAMILY GROUP
VISION
MISSION
VALUES
To be one of the leading chemical groups in the polyamide, synthetic fibres and engineering plastics production
chain.
To promote the development of our businesses while pursuing our Group values and culture.
To pursue our vision by valorising and optimizing our human resources, establishing strategic alliances and
searching for new markets, including niche markets.
To embed sustainability into new product and application development.
Putting people at the centre of everything we do and respecting their right to physical and cultural integrity.
Efficiency and effectiveness of our management systems to improve our business.
Fairness and transparency of our management systems in compliance with all applicable laws and
regulations.
Attention to the needs and expectations of our stakeholders in order to create a feeling of belonging
and satisfaction.
Reliability of our management and operating systems to ensure the safety of our employees, our
communities and the environment.
Our responsibility as a company for our workers, production sites and communities.
SUSTAINABLE DEVELOPMENT

10. GLOBAL THINKING, LOCAL ACTION
2003: RESPONSIBLE CARE® PROTOCOL
2004:
PUBLISHING OF 1st SUSTAINABILITY REPORT
2010:
RADICIGROUP PROJECT FOR SUSTAINABILITY
2011-2012 : GLOBAL REPORTING INITIATIVE
LCA STUDIES - LIFE CYCLE ASSESSMENT
PCR PREPARATION - PRODUCT CATEGORY RULES
1997
2004
2010
2011-2012
2003
2013-2014
2013-2014:
EPD - ENVIRONMENTAL PRODUCT DECLARATION
OEF/PEF - ORGANIZATION/PRODUCT ENVIRONMENTAL FOOTPRINT
SUSTAINABLE DEVELOPMENT

12. SUSTAINABLE DEVELOPMENT GUIDELINES
3. Kyoto Protocol 20/20/20 + 20% recycled material. Sustainability
becomes the Group's guideline by following the Global Reporting Initiative
protocol;
2. certifications (voluntary and mandatory), Research & Development:
Reach,
LCA: main product measurements,
Eco-Profiles, EPDs, Ecolabel, Oekotex,
PEF and OEF.
1. ISO 9000, ISO 14000, OHSAS 18000, SA 8000, ISO 50001 and ISO 14064
become RadiciGroup's organisation models;
4. Sustainability as an approach to corporate governance,
an approach based on GRI - Global Reporting Initiative

13. GRI SUSTAINABILITY AS A SYSTEMIC STANDARD
• ECONOMIC INDICATORS - EC
• HUMAN RIGHTS INDICATORS - HR
• LABOR PRACTICES AND DECENT
WORK INDICATORS - LA
• SOCIETY INDICATORS - SO
• ENVIRONMENTAL INDICATORS - EN
• PRODUCT REPONSiBILITY
INDICATORS - PR

14. From LCA to OEF/PEF through EPD/PCR
2) EPD – Environmental Product Declaration
1) LCA – Life Cycle Assessment
4) OEF – Organization Environmental Footprint
3) PCR – Product Category Rules
5) PEF – Product Environmental Footprint

15. Why LCA analysis?
ISO 14040 Environmental management
Life cycle assessment – Principles and framework
LCA analysis
-Improve environmental performances of products at various points in their life cycle
-Inform users about planning and developments
-Selection of relevant indicators of environmental performances
-Marketing, implementing in Ecolabel scheme, EPD, OEF/PEF certifications
Awareness in environmental protection
Understand and address environmental impacts

16. LCA certification
1) EPD – with refernce to PCR product category rules
2) PEF – with reference to recommendation 2013/179/UE
4 aprile 2013

17. Sustainability development @ RadiciGroup
LCA
Life cycle
assessment
PCR
EPD
PEF
GRI
Sustanability
report OEF
From LCA to OEF/PEF through EPD/PCR

19. LCA Study steps (ISO 14040 – 14044)
2) Inventory analysis
1) Goal and scope definition
4) Interpretation
3) Impact assessment
- Reporting e critical review
- Limitations
- Relationship between the LCA steps
- Condition of value choices and optional elements

20. LCA Studies @ RadiciGroup – Polyester yarn
Assess the key impact indicators for the production of polyester filament
yarns in different types of products, POY, FDY, HOY, flat textured, dyed
and yarn dyed in standard versions made by virgin polymer and
versions made by post-consumer recycled polymer.
Goal and scope definition

21. LCA Studies @ RadiciGroup – Polyester yarn
GER = Gross Energy Requirement
expressed in MJ; expresses the consumption of primary energy resources
GWP = Global Warming Potential
expressed in kg CO2 eq; expresses the global warming potential of
each greenhouse gas
Eutrophication: total effect of eutrophication,
expressed in kg PO4 eq ˉ ³, due to substances released into the waters
(in particular the compounds containing nitrogen and phosphorus).
Water consumption : water demand (additional info)
expressed in liters, due to the demand and consumption of water

22. LCA studies @ RadiciGroup – Polyester yarn
Inventory analysis.
The study refers to the
cradle-to-gate scope. The
overall analysis includes raw
materials, additives, dyes,
auxiliaries, their
transportation to the
production site, packaging
material, all emissions (direct
and indirect), and process
waste. Transportation to
customers and end of life are
not considered.
Starlight ®
Radyarn ®
Raw
materials
Transportation
Energy
Emissions
Discharge
Waste
End of life
Sales
External
processes
Manufacture

23. Textiles &
Clothing
NOYFIL
Petrochemicals
PET
Recycle (bottles)
r-PET
Spinning
Texturization
Twisting
Yarn dyeing
Weaving
Finishing
Manufacture
Distribution
Use
End of life
Donations
Reuse
Disposal
Recycle

24. LCA studies @ RadiciGroup – Polyester yarn
Impact assessment
The functional unit considered in studies is 1 kg of product
NOYFILRaw materials
Polymers (chips) ; vergin PET, post consumer r-PET
Master batches, additives, spin finishes, auxiliaries, dyes
Packages, tubes, boxes, pallets, polyethilene bags,
Transportation
Energy/Utilities
Waste
Distance
Type
Electricity
Oil, gases
Water
Waste
Emissions
Discharges
Source : Analisi Studio ICA Bergamo 2012
Banche dati : Ecoinvent,ETH-ESU96,
Edimat2001, Industry data 2.0 (Plastic Europe),
ELCD, USLCI

25. Impact assessment
STARLIGHT ®
LCA studies @ RadiciGroup – Polyester yarn
Production processes analysed
NOYFILFilament Spinning
Logistics, handling
Drying
Extrusion
Texturizing
Standard yarn dyeing
Additivation
Dope dyeing
Master batches preparation
Drying
Cooling – Spin finish dosage
Winding
Packaging, handling
Dosing
RADYARN ®
Logistics, handling
Friction texturizing
Air texturizing
Twisting
Packaging handling
Scuring
Dying
Drying
Preparation
Drawing

26. LCA studies @ RadiciGroup – Polyester yarn
Interpretation
GER total contribution

27. LCA studies @ RadiciGroup – Polyester yarn
Interpretation
GWP total contribution

28. LCA studies @ RadiciGroup – Polyester yarn
Interpretation
GWP total contribution

29. Standard yarn dyeing
Polymer Transportation Spinning Dope dyeing Texturing
GER GWP GER GWP GER GWP GER GWP GER GWP
++ ++ -- -- ++ ++ - - +++ +++
++++ ++++ -- -- + + - - + +
+++ + -- -- ++ ++ - - ++ ++
r- Radyarn®
Radyarn®
Cornleaf
GER GWP Eutr. Water
+++ ++ +++ +++++
++ + +++ +++++
r- Radyarn®
Radyarn®
Final
GER GWP Eutr. Water
107 4,4 3,5 84
170 6,1 3,5 84
Final
GER GWP
72 3,6
135 5,3
101 3,8
LCA studies @ RadiciGroup – Polyester yarn
Interpretation
GER – GWP process contribution

30. Environmental impact : r-Radyarn® solution dyed vs dyed Radyarn®
yarn
Water (lt/Kg)
GWP (CO2eq/Kg)GER (Mj/Kg)
Eutrophication (mgPO4ˉ³
eq/Kg)
- 90% - 50%
- 55% - 40%
Interpretation
LCA studies @ RadiciGroup – Polyester yarn

31. LCA studies @ RadiciGroup – Polyester yarn
Interpretation
GER – GWP processes contribution ; standard yarn dyeing / dope dyeing

32. Interpretation
Yarn pakage dyeing / solution dyeing : main advantages.
Environmental impact
Sampling - Reciping
Small quantity
Color intensity
Yarn mechanical properties
Color fastness
Oligomer releasing
LCA studies @ RadiciGroup – Polyester yarn

33. Interpretation Natural fibres comparison
LCA studies @ RadiciGroup – Polyester yarn

34. From 1950 to 2020
1950-60-70-80-90-00-10-20
■ wool – ■ cotton – ■ manmade
Interpretation
LCA studies @ RadiciGroup – Polyester yarn
Natural fibres comparison

35. 0
20
40
60
80
100
120
1980
1982
1984
1986
1988
1990
1992
1994
1996
1998
2000
2002
2004
2006
2008
2010
2012
2014
2016
2018
2020
2022
2024
Acrylic
Olefin+ speciality
Cellulosic Total
Nylon Total
Polyester Staple
Polyester Filament
cotton
Millions of Metric Tonnes
POLYESTER : WORLD MARKET TRENDS
World: Mill comsumption – by fibre with cotton
Source: Radici Partecipazioni Spa
Interpretation
LCA studies @ RadiciGroup – Polyester yarn

36. r- Starlight ® – r- Radyarn® : product certification
Reference : from internal procedure to National standard UNI 11505 : 2013

37. r- Starlight ® – r- Radyarn® : LCA certification
Next steps :
Updating LCA analysis
PEF Certification
Availability in further textile
processes

38. Thanks for attention!
Follow us on:
LinkedIn YouTube Slideshare
Twitter