Rishi Gurnani, Ph.D., Director of Software & Algorithms, Matmerize

The steam engine, the light bulb, and the Internet; these are among the handful of technologies that have shaped every industry, including nonwovens. With each passing day, it appears increasingly likely that artificial intelligence (AI) will leave a commensurate mark.

AI has already improved the development of novel materials and chemical formulations in academia and industry. To fully harness AI's potential, strategic investments and planning are needed in a few key areas, including digitalization, data capture and management, as well as AI algorithms and their limitations. This presentation provides a comprehensive overview of those areas, culminating in impactful and value-added use cases in the nonwovens and polymeric materials domain.

Don Walter, Director of R&D, Darling Fibers

Polyester has been an integral material in society for many years. Its properties can be engineered as tire cord for its strength and stability, designed for safe packaging for food and drink, and formed into various denier textiles for use in a myriad of end uses. Additionally, the low-cost and flexibility of polyester has made it a popular choice in many single-use products. Its durability is an asset in many cases but also creates a concern as products reach end-of-life. Untreated polyester does not degrade effectively in landfills which creates long-term environmental issues.

Sustainable technologies for PET are expanding quickly, and it is unlikely that any one method will optimally handle the variety of ecological challenges. This presentation will focus on recycling, and discuss the practical challenges and benefits of the leading options. It will also layout some of the key hurdles in rPET production and usage in the near term.

Carmen Covelli, Technical Laurate, Celanese

Neolast™ fiber is designed to offer elevated stretch performance while helping address sustainability challenges (including recyclability) associated with elastane, which is commonly referred to as spandex. Apparel designers can now create more sustainable power-stretch clothing that also delivers elite performance. Deolast(TM) fiber is melt spun using thermoplastic copolyester elastomer which is classified under the generic category of elastoester. The thermoplastic nature of the polymer enables melt processing, allowing fiber formation without the need for solvents. Celanese expertise in thermoplastic copolyester elastomer chemistry and formulation has led to innovation of two new grades of Neolast™ polymer created for fiber spinning.

Katrina Knauer, Ph.D., Senior Researcher & CTO of BOTTLE, National Renewable Energy Laboratory (NREL)

The plastic pollution crisis is intrinsically tied to an energy crisis, with projections indicating that roughly 20% of fossil fuel consumption will be allocated to plastic production by 2050, accounting for nearly 15% of global greenhouse gas emissions (twice that of the aviation sector). Existing polymerization processes offer limited potential for efficiency enhancements and reducing energy demand. Moreover, reliance on mechanical recycling, the predominant method at scale, is hampered by its finite life cycles due to polymer degradation and contamination. In light of these challenges, the most promising avenues for decarbonizing the U.S. plastic industry necessitate comprehensive systemic transformations.

This involves integrating bio- and waste-based supply chains and establishing a circular economy loop for plastics through innovative recycling techniques aimed at reclaiming plastic waste. At the forefront of these efforts is the Bio-Optimized Technologies to keep Thermoplastics out of Landfills and the Environment (BOTTLE™) Consortium, a multi-organization initiative led by the U.S. Department of Energy. The consortium is dedicated to pioneering new chemical upcycling strategies for current plastics while concurrently designing future plastics with recyclability as a core tenet. This presentation will showcase the flagship technologies developed by the BOTTLE Consortium, including low-energy plastic deconstruction methods, innovative upcycling approaches for waste intermediates, and the development of recyclable-by-design (RBD) polymers poised to revolutionize the plastic industry landscape.

Wes Fisher, Director of Government Relations, INDA

In 2022, the United Nations Environment Assembly approved a resolution to "develop an international legally binding instrument on plastic pollution, including in the marine environment." This action officially kicked off the negotiations colloquially referred to as the UN Global Plastics Treaty, formally titled the "Intergovernmental Negotiating Committee to develop an international legally binding instrument on plastic pollution, including in the marine environment."

While the title of the pending treaty may indicate a focus on plastic pollution, the negotiations held so far have included NGOs and high-ambition countries calling for a drastic reduction in the use and production of plastic polymers, with other nations and industries favoring an application-based approach. INDA director of government affairs Wes Fisher, who has served as an accredited observer on behalf of INDA at two in-person negotiation sessions, will explain the history of the treaty, where we are in the process, the outcome of recent negotiation sessions, and the outlook for what will happen at the final session to be held this November in South Korea.

Tony De la Hoz, Director – R&D, Hills, Inc.

We are witnessing a significant surge in developmental efforts within the nonwovens sector aimed at crafting the next generation of materials. This momentum spans various segments of the industry, including hygiene, medical, filtration, apparel, furniture, acoustics, insulation, and more. Amidst this fervor for innovation, it is crucial to recognize that sustainability has emerged as the primary driving force propelling technology and materials forward.

In light of this paradigm shift, let us contemplate the implications of integrating bicomponent extrusion capabilities. This advancement not only facilitates the introduction of sustainable solutions or materials to the market but also enhances value proposition. By leveraging bicomponent extrusion, we can elevate innovation to unprecedented levels, augmenting product performance, durability, and efficiency. Furthermore, this technology holds the promise of reducing carbon footprints, conserving energy, and boosting production rates, thereby reshaping the landscape of the industry – a true game changer.

It is imperative to acknowledge that with the incorporation of bicomponent extrusion, the conventional approach to polymer utilization undergoes a fundamental transformation. Rather than viewing polymers in isolation, it becomes imperative to comprehend the synergistic potential inherent in combining distinct materials through bicomponent extrusion.

As a foremost authority in multicomponent extrusion technology, Hills takes pride in contributing to this pivotal juncture in history, where sustainability ascends to the forefront of industry priorities.

Ross Ward, Ph.D., CCO, NIRI

The need for PFAS replacement is disrupting the nonwoven industry. Revised EU and US regulations are on the horizon, and there is growing evidence that exposure contributes to organ disease, cancer, and reduced fertility. Companies are now challenged to explore options to reduce or eliminate their dependency on PFAS while maintaining product performance. This is no small undertaking, as no single route to PFAS replacement exists. Potential solutions will likely incorporate PFAS-free additives or coatings, intelligent fibre designs, and textile constructions.

This presentation will focus on strategies for intelligent fibre and nonwoven design, which can serve as a reference for manufacturers wishing to exploit application development approaches for PFAS replacement. NIRI is helping companies develop PFAS-free materials in the automotive, medical, filtration, construction, and performance clothing sectors. Case studies and performance data will be provided where applicable to show the potential strategies.

Christophe Morel-Fourrier, Ph.D., Global Sustainability Leader, Bostik, Inc.

In a world facing considerable environmental challenges, it's important to strive to reduce environmental impact, and in particular carbon footprint, for all products and processes that we control, and contribute to a more sustainable planet for generations to come. As Arkema's adhesive solutions segment, Bostik has invested resources into understanding how to create adhesives that decrease the environmental impact of the product they are used in and to measure the carbon footprint of adhesives.

While there are several ways adhesives can do this, reducing the impact of the adhesive itself is one of them. And using bio-based materials in adhesive formulations is one approach our company has taken. But moving to bio-based materials is not relevant if it does not come with improved performance or reduced carbon footprint. This presentation will discuss how our Nuplaviva™ adhesives, which contain up to 90% bio-based materials, offer improved adhesion on natural fibers vs. traditional adhesives as well as can enable material recycling and how these capabilities help absorbent hygiene manufacturers reduce carbon footprint.

Additionally, it will cite how our 80% bio-based polyamide adhesives for nonwoven composite applications offer better properties than oil-based adhesive equivalents, further proving why bio-based adhesives can in fact reduce carbon footprint while meeting or exceeding performance requirements and, in some cases like with Arkema's Rilsan®, even without oil-based material equivalents. The right adhesives can enable both excellence in performance and reduced carbon footprint (compared to traditional alternatives) at the same time.

John Rose, Ph.D., Development Director, Technical Absorbents (UK)

SAF technology is already proven as a water-blocker within applications such as the cable industry. Yarns and tapes containing these unique fibres are present in some fibre optical and power cables and swell to prevent further water ingress/damage should the outer sheath be breached, and moisture enter the cable. Technical Absorbents is now actively looking at how this capability to absorb, block and prevent further damage can be applied within large scale geo and construction applications.

Its needlefelt fabric technology provides rapid absorption and extremely high levels of retention. This, coupled with the fact its fabrics are lightweight, clean, and easy to handle, means that the technology offers a wide range of benefits to end users. Its fabric technology is currently undergoing rigorous testing with a view to commercially launching its technology into this sector during the next twelve months. This paper will take a closer look at the benefits of a SAF needlefelt fabric in such applications and will also share validated performance test data.

Olaf Isele, Strategic Director of Product Development, Trace Femcare, Inc.

Across continents and cultures, Cannabis sativa L. has intrigued and fascinated with its medicinal potential for centuries. While its therapeutic compounds have garnered attention worldwide, a pivotal question arises: Do the remarkable medical benefits of the plant extend to its fibers? This talk will briefly delve into the intricate processes of extracting fibers from hemp stalks akin to the methods used for flax.

Exploring the nuanced composition of hemp plants, with a focus on the stalk, bast, and fiber, our investigation analyzes the mysteries surrounding their inherent antimicrobial properties. The implications of our findings resonate deeply within the industrial hemp and fiber industry, casting new light on the products made from the versatile plant of industrial hemp.

Melissa Coolich, Ph.D., Principal Product Development Engineer – Sustainability Technical Partner, Amcor Flexibles

Join Amcor and sustainability packaging expert Melissa Coolich in a comprehensive session exploring sustainable packaging solutions for flow wrap and pet food pouches. Contrast the strategies in design for recycling based on product needs, incorporation of post-consumer recycled materials (PCR) and the benefits of downgauging for improving sustainability