Innovating for sustainability > Twaron® with recycled content
Twaron® with recycled content
Teijin Aramid is proud to highlight a major milestone in our sustainability efforts: The successful completion of an industrial-scale production trial of Twaron® made with recycled feedstock. This high-performance filament yarn, derived from recycled materials, retains the exceptional strength and durability synonymous with our Twaron® filament yarn. It builds on our longstanding commitment to sustainability.
A significant milestone
This development showcases our progress toward incorporating a higher percentage of recycled content. The successful industrial-scale trials conducted by our material experts bring us closer to the commercialization of a more sustainable Twaron®.
Vision for 2050
Our venture into producing Twaron® with renewable material reinforces our dedication to fostering a circular economy within the aramid industry. It aligns with the European Union's Green Deal, aiming for a resource-efficient economy with zero net greenhouse gas emissions by 2050. This achievement demonstrates progress in our pursuit of a fully sustainable and circular aramid value chain, building on our longstanding practice of mechanically recycling end-of-life para-aramid products.
Innovating for sustainability > Tire manufacturing: A circular approach
Tire manufacturing: A circular approach
As the global demand for vehicles continues to increase, the tire industry faces a dual challenge: managing the disposal of approximately three billion tires annually (a figure projected to rise to five billion by 2030) and addressing the environmental impact of traditional disposal methods. Considering these issues, we feel responsible and are trying to contribute by developing recycling technologies to recover aramid from used tires and convert it into a useful form.
Aramids in tire performance
Aramid fibers, though constituting only 1% to 3% of a tire's total weight, play a crucial role in enhancing the performance of tires. They are primarily used in the capply, a layer beneath the tread, providing tire uniformity, dimensional stability, and better handling performance. This makes them ideal for conditions involving high speed or heavy loads, contributing significantly to the tire's performance. By including aramid in the tire, customers benefit from a reduction in CO2 emissions of 2g/km/car, and rolling resistance is reduced, leading to further benefits.
Embracing circularity
For over two decades, we’ve been committed to mechanical recycling, transforming post-industrial and post-consumer aramid materials into Twaron® pulp. However, we recognize the unique challenge of extracting aramids from end-of-life tires, highlighting the urgent need for a truly circular economy. Our vision is focused on more than just reducing carbon emissions; it's about creating a sustainable loop of material reuse. By dissociating business growth from raw material consumption, we're working towards a more sustainable future.
United efforts for sustainable recycling
We’re committed to transitioning to renewable raw materials by 2050. These raw materials may include recycled feedstock, such as PET, or they can be sourced from bio-based alternatives. This effort toward raw material transition is distinct from our ongoing initiatives to recycle aramids. This will reduce the reliance on virgin fossil resources, paving the way for a more sustainable tire industry.
Collaboration is essential in our quest to recycle aramid materials effectively. This journey begins with collecting waste aramid materials, sorting, separating, and cleaning them to prepare for recycling. The goal is to give these materials a second life through one of the three recycling routes, which presents significant challenges and opportunities for innovation.
Overcoming recycling challenges
The first major hurdle is removing rubber particles from the tire textiles, where the rubber, bonded through an RFL-dip process, leaves contaminants and particles intertwined with the textile fibers.
Secondly, the diversity of materials in tire textiles, including nylon, rayon, and polyester, complicates the process of isolating aramid fibers, which are present in smaller quantities compared to other textiles.
The third challenge involves purifying the aramid tire textiles to a degree that meets the stringent quality standards required for producing new aramids, ensuring that all contaminants are removed effectively.
Innovating for sustainability > Life protection: Dope-dyed fibers
Life protection: Dope-dyed fibers
Dope dyeing transcends being just a technique; it represents a significant stride toward cost efficiency and color durability in protective apparel. This innovative method stands out for its lower energy consumption, reduced water use, and considerable cut in carbon emissions compared to traditional dyeing processes. Dope-dyed fibers not only maintain their color longer but also contribute to prolonged garment life and cost benefits for our customers.
Teijinconex®: The preferred choice for garment makers
Teijinconex® has become the go-to fiber for manufacturers seeking to meet strict safety standards without compromising on quality or sustainability. Offering a range of fiber types and colors through dope dyeing, it's uniquely suited for protective gear requiring resistance to heat, flames, and chemicals. The sustainable advantages of dope-dyed fibers also extend throughout the production and usage phases.
The advantages of dope-dyed fibers
Fabric manufacturers report numerous benefits of dope dyeing:
- Cost savings on dye and finishing, thanks to reduced or eliminated dyeing stages;
- Quicker production lead times;
- Compatibility with various fibers, potentially lowering overall fabric costs;
- Enhanced quality and durability due to minimized processing, ensuring garments last longer and maintain their color.
Dope-dyed fibers are not only cost-effective and high-quality, but they also make the fabric-making process more efficient. By cutting down on traditional dyeing, we greatly reduce the environmental impact. The durability and longevity of color in our fibers mean garments enjoy a longer lifecycle, further reducing their ecological footprint.
Innovating for sustainability > BuschPRO: Ballistic helmets from Twaron® with recycled content
BuschPRO: Ballistic helmets from Twaron® with recycled content
Demand for sustainable yet high-quality materials in ballistic protection has increased. We've dedicated ourselves to proving that environmental responsibility and superior protection can go hand in hand.
We’ve been recycling end-of-life ballistic vests for many years. In 2023, in collaboration with Busch PROtective, we unveiled the first-ever helmet shells crafted from Twaron® prepreg, enriched with yarn from recycled content.
This initiative used Twaron® filament yarn derived from recycled materials to create a fabric suitable for the rigorous demands of ballistic protection. The helmets underwent extensive testing, demonstrating exceptional ballistic resistance that meets the high standards set by our virgin Twaron® material.
“We are continuously looking for partnerships within the value chain to scale up these developments. Our clear focus is to prove that ballistic performance and reliability can go hand in hand with making the defense and security business more circular.”
Martin Klang, Sales Account Manager - Ballistic Protection
Innovating for sustainability > FibreMax: Offshore wind energy
FibreMax: Offshore wind energy
In 2023, Teijin Aramid and FibreMax received a €4 million grant from the Just Transition Fund Groningen-Emmen (JTF). This funding supports the Floating Wind project: a forward-thinking initiative harnessing wind energy through floating turbines. As part of this project, we're developing tendons made from circular synthetic fibers. These specialized tendons offer a more sustainable alternative to traditional steel cables, helping to secure the turbines to the seabed and furthering the cause of renewable energy.
Setting a new standard in offshore wind energy
The essence of a floating wind turbine lies in its stability: essential for withstanding oceanic wave movements and wind forces. Our advanced tendons, developed through FibreMax's unique endless winding technology, deliver unparalleled strength and durability.
These cables are characterized by their rigidity and resistance to fatigue. They’re specifically designed to meet the demanding conditions of floating offshore wind farms. Sander van Helvoort, Director of Renewable Energy at FibreMax, emphasizes the capability of these tendons to unlock wind energy potential in deep-sea environments, beyond 60 meters, where traditional methods fall short.
Pioneering a greener future
This project not only sets new benchmarks in the industry but also aligns with our collective commitment to accelerating the energy transition, bolstering the labor market, and endorsing sustainable practices. The use of circular fibers in the tendons underscores our dedication to environmental stewardship. Endorsed by the Ministries of Social Affairs and Employment and Economic Affairs and Climate Policy, Floating Wind epitomizes our shared vision for a sustainable future. With significant backing from the JTF and additional support from the province of Fryslân, we are poised to make a lasting impact on renewable energy and sustainable development.
Innovating for sustainability > MACRO Industries and KLM: Recycled air cargo container panels
MACRO Industries and KLM: Recycled air cargo container panels
Our partnership with MACRO Industries and KLM began with the recycling of air cargo container panels. Over time, it has grown into a multifaceted collaboration.
Taking back end-of-life cargo panels
Our journey with KLM began when they searched for a partner to recycle air cargo container panels. These panels, containing aramid, presented a unique recycling challenge we were eager to tackle. Our initial efforts involved manually cutting out panels for processing at our Research and Innovation Center, leading to the successful extraction and purification of aramid.
Advancing safety and sustainability
The dialogue with KLM naturally evolved, spurred by regular interactions and a shared concern for safety, particularly regarding the transportation of lithium-ion batteries. Our collaboration with MACRO Industries in the U.S. led to the development of fire-resistant panels, with Twaron® at the forefront, enhancing the safety of KLM's flights by containing fires for extended periods.
Lighter panels, greater impact
Our pilot project with KLM and MACRO Industries not only showcased the durability of MACRO Lite panels but also aligned with KLM's sustainability goals by allowing for the recycling of replaced panels. The partnership extended to another significant project aimed at reducing CO2 emissions through the use of lighter Endumax® panels in KLM's Airbus A320 fleet. Despite Endumax® being phased out, we ensured a seamless transition for KLM.
Ben Rolink
Global Market Manager for Aerospace
"We've already received several responses, including from companies in Britain, Japan, and the United States. It's exciting to see what opportunities may arise from these interactions in the long term. Within the aviation sector, Teijin Aramid is now perceived as a company actively engaged in sustainability, even when dealing with materials that have reached the end of their life cycle."
