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| Issue date:01/06/2008 |
| ATA Journal for Asia on Textile & Apparel - Jun 2008 Issue |
| Source:Journal for Asia on Textile & Apparel |
| by Adrian Wilson |
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| Processors of European flax and hemp fibers need value-added alternatives to conventional textiles. Are composites the answer? |
The European market for technical fabrics in 2005 was 4.8million tonnes, of which approximately 2 million tonnes, or 42%, were then employed in composite materials, according to the European Confederation of Flax and Hemp (CELC).
Approximately 50% of the fibers used in these materials, primarily glass, could be replaced by flax or hemp. The confederation believes, including 600,000 tons as reinforcement fibers in components for the key areas of transportation, construction/civil engineering and packaging.
The current estimated consumption of flax and hemp for these applications is estimated to be around 20,000 tonnes, which corresponds to less than 4% of the potential market.
Linum is a multi-stemmed and branched wild species, which has been grown for over 3,000 years for the production of flax and linen cloth.
Longer fibers are used for spinning into yarn and making textiles, with shorter flax fibers not long enough for the linen process, although they can be suitable for spinning into yarns, often mixed with cotton, but also have other novel uses, including packaging materials, reinforcements for plastics and concrete, asbestos replacement, panel boards, lining materials for vehicles and alternatives for fiber glass and insulation.
Flax fiber is hollow and able to absorb up to 12% of its own weight in water, and its strength increases by 20% when wet. It also dries quickly, and is anti-static. For some applications, it is a suitable substitute for synthetic fibers such as heavier fiber glass. The fibers are twice as strong as those of cotton and five times as strong as those of wool.
Flax fiber (upper) is hollow and able to absorb up to 12% of its own weight in water, while widespread production of hemp fiber is hindered by its narcotic property.
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Hemp has an equally long history of providing both fiber for clothing, ropes and sail cloth, as well as oil for lamps. It is also, of course, the source of the narcotic marijuana. Modern varieties grown in the west are low in the narcotic agent tetrahydrocannabinol (THC) and provide fiber for a range of uses, although there have been some trials with the controlled production of higher THC varieties to evaluate the pharmaceutical properties. This narcotic "legacy" has, over the last century, been an obstacle to the more widespread production of hemp.
Hemp, however, produces 25% more valuable long fiber than flax.
A wide range of uses can be found for flax and hemp plants, with around 30% of the crop being turned into fibers for both wovens and nonwovens, as well as in compound form.
European flax and hemp production continues to be heavily subsidized by the European Union. The latest European Council Regulation number 247/2008 issued in March 2008 sets aid available for the processing of long flax fiber at 160 euros per tonne for the 2008/09 marketing year and at 200 euros per tonne from 2009/2010 onwards.
Short fiber flax and hemp containing not more than 7.5% impurities and shives will receive aid of 90 euros per tonne in 2008/09.
The CELC promoted the use of flax and hemp at JEC composites show |
According to figures produced by CELC at the Natural Fibers Forum on April 1 at the JEC Composites show in Paris, France is the most effective manufacturer of flax fibers in the world, with 2005 production of 136,500 tonnes grown on 81,500 hectares.
It is followed by Russia, which in 2005 grew 35,000 tonnes on 112,000 hectares and China, which produced 30,000 tonnes, but over an area of 200,000 hectares.
Natural fibers go into automotive sector
In recent years, French manufacturers of flax and hemp-based materials have been particularly targeting the automotive sector, where the use of natural fibers has been on the increase.
In 2003, for example, the German automotive sector used 45,000 tonnes of natural fibers, not including cotton or wood, most notably in the Mercedes E-Class, and the figure five years on is likely to be considerably higher.
"Natural fibers are a key element in enabling us to convincingly present our strategy for sustainable mobility, and we already have natural fiber components in some of our series production vehicles," said Professor Heinrich Flegel, head of production and materials technology at the vehicle body and drive systems research unit of DaimlerChrysler, owner of Mercedes. "The current Mercedes A-Class, for example, has 26 components containing renewable raw materials such as abaca, flax and hemp – the share of such natural materials is significantly higher than in the predecessor model. Nevertheless, using such natural fibers wouldn't be justified if they didn't offer technical and economic benefits."
China's automotive industry is also now increasing its use of components with a natural fiber base, appreciative of their high performance, good stability and no bursting in the event of a collision, in addition to their lower price and the potential for reducing fuel consumption.
French producers picking up opportunities
French companies such as Techni Lin and AFT Plasturgie are spearheading this trend.
Techni Lin, based in Valliquerville, started supplying the automotive industry with parts back in 1993, following investment in a nonwovens manufacturing line after a search for alternative markets for its flax fibers, other than conventional textiles.
The 2008 Mercedes B-Class feature components from natural naterials of Flax, cotton, and coconut fibers |
It invested in a second line in 2007 and now has the capacity to produce an annual 3,000 tonnes of flax felt mats in weights ranging from 150gsm to 3,000 gsm, equating to over a million items a year. The company's turnover has now reached 4 million euros.
The mats are often employed in door panels due to their good resistance and because they can be subjected to thermocompression.
Techni Lin's first big delivery was in 1997, an 800 tonnes-per-year deal to supply for the Opal Astra made by General Motors.
The company's products are now also used for rear parcel shelves and the headliners of cars such as the Renault Twingo.
Techni Lin processes ordinary scutched tow and bleached tow, using a to-be-patented process. The company also has a thermoforming line in order to react swiftly to the demands of automotive customers and is currently testing the blending of four separate natural fibers, as well as the use of glass fibers in its manufacturing processes, in response to market expectations.
The company's mats are also used as geotextiles in farming and horticultural applications.
Another French company, AFT Plasturgie, based near Dijon, is a specialist in composite materials reinforced with hemp fibers, and also manufactures nonwoven hemp mats, with the majority of its annual 6,000-tonne capacity going to the automotive sector.
The company has managed to improve the thermal stability of these products to 155°C, compared to 90°C for polypropylene products, which means they can be used in a car engine without deteriorating. The behaviour of these components in the event of rupture due to a collision is said to be excellent, since they absorb energy and shock and deform without breaking. They are also isoptropic, with low shrinkage levels, resulting in parts with a high level of geometric stability.
Full supply chain in need
Flax and hemp prices have been very stable in recent years, says CELC, in contrast to fossil-based resources and in specific sectors such as construction, bast fibers are forging a reputation for high levels of comfort and financial savings.
However, Europe's flax and hemp industry faces challenges and the fibers are still under-exploited for a number of reasons.
There is a lack of a proper supply chain and of a standard product marketed on a large scale.
Soil and crop rotation for flax is a restriction, with six or seven years between two flax crops on the same plot required. Flax and hemp also have to counter competition from exotic natural fibers such as kenaf and sisal, which have benefited from recent expansion in their shipment by sea.
New market chances in composites
The global composites industry is now worth an estimated 53 billion euros annually, with the majority of its products supplied to two key sectors, namely construction/civil engineering and transportation, which have 30% and 26% shares of the market respectively.
Inevitably, environmental regulations and recycling issues are having an impact on the composites industry, most notably in Europe and Japan in respect of VOCs emissions, carbon dioxide (CO2) emissions and directives relating to electrical and electronic equipment and vehicles. The latter are not yet in place in the USA or China, and in fact the only restriction China currently faces is very minor legislation in respect of CO2 emissions.
This may be one contributing factor to China's anticipated growth from representing 16% of the total 8.2 million tonnes produced in 2005 to a 32% market share in 2015 at an estimated market size of 88 billion euros, with a total of 12 million tonnes.
With the restrictions in place, the market is primed for natural fibers to claim a much bigger market share of the technical textiles employed in the future of European composites production.
While the aim of the flax and hemp industry of supplanting the use of glass fibers in composites may be a little too ambitious, there is doubtless scope for further progress to be made in this industry.
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| Copyright © Adsale Publishing Limited. Any party needs to reprint any part of the content should get the written approval from Adsale Publishing Ltd and quote the source "ATA Journal for Asia on Textile & Apparel", Adsale Textile English Website - www.AdsaleATA.com. We reserve the right to take legal action against any party who reprints any part of this article without acknowledgement. For enquiry, please contact Editorial Department. |
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