future is fibres strategy

8/8/2019 Future is Fibres Strategy

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The Future is FIBRESVision and Strategy

Creating a Vibrant Fibre Sector in the Future Australian Economy
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CONTRI BUTI NG AUTHORS

Nigel Johnson Chief, CSIRO Textile and Fibre Technology

Keith Cowlishaw Head of School, Textiles & Fashion, RMIT

Xungai Wang Alfred Deakin Professor, Centre for Material and

Fibre Innovation Deakin University

Peter Kreitals Manager, Australian TCF Technology Network

Lachlan Caddy Network Officer, Australian TCF Technology

Network

ACKNOW LEDGEMENT

The authors would like to thank all the various parties that have contributed to thedevelopment of this paper, particularly the participants at the TCF Technology Networks2007 Strategy Workshop on 23 August and most notably the collective members of theNetworks Advisory Committee and Strategy Group, all of whom have generouslycontributed their thoughts, efforts and time:

Paul Cacioli, Gale Pacific

Sam Cassarino, Yakka

Robert Bell, Madison Filter

Steve McMillan, Melba Industries

Darren OLoghlin, Bruck Textiles

Thomas Seeger, Bruck Textiles

Sarah Beilby, ADA

Phillip Butler, Textor

Bill Humphries, CSIRO

Peter Cookson, Deakin University

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1. THE EVOLVING SOPHISTICATION OFTHE FIBRES SECTOR

Fibres are integral to all living things, fromthe twisted strands of our DNA to thecomplex fibrous structures that make up ourlargest mammals and trees. Life on earth

has evolved by assembling fibres and fibrouscomposites into complex materials with awide range of sophisticated properties.

To date, humankind has taken macro-fibresand developed textile materials, and thesehave become ubiquitous in our human-madeworld.

But we are nowhere near reproducing whatnature does with fibres. The emergingsciences that are enabling newnanotechnologies and biotechnologies aredriving a revolution in new materials, andfibres are poised to be at the centre of thatrevolution. Many future materials will bebased on fibres, including:

o Nanofibres

o Fibres from biopolymers (naturalor bio-derived)

o New nanofibrous composites(copying natural materialstructures)

o Complex hierarchical structuresengineered from fibrecomponents at nano, micro and

macro scales.

There are endless new applications and fibredevelopments underway, that will createnew business opportunities based on fibres.For example:

o Functional and protective apparel

o Biomedical materials including

replacement and/or regeneration ofmammalian body parts

o lightweight fibre compositesreplacing metal and concrete

structureso flexible consumer products replacing

hard plastic

o Intelligent materials from functionalfibres (eg conductive, sensory,responsive).

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Thus, the multitude of applications for fibres in todays modern economy are reflected below:


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2. FUTURE VISION FOR THEAUSTRALIAN FIBRES SECTOR

2.1.Global ActivitiesAround the world, new fibre businesses areemerging, through the efforts ofentrepreneurs exploiting scientific progress.However, stimulated by these opportunitiesand the pressures on their textilemanufacturing sectors, some first-worldcountries have already realised the emergingtrends for a more sophisticated andtechnologically advanced fibres sector, andare already taking steps to establish their

positions in a more strategic manner.

The USA has established a National TextilesCentre (NTC) that directs and supports fibreand textile research at a network of researchinstitutions. Europe has developed aStrategic Research Agenda, including 5 keyTechnology Platforms for textiles andclothing.

Australia also needs to take action. Suchactions must be lead by a vision of thefuture.

2.2.A Vision of Australias FutureFibres Sector

Australia has the potential to benefit from anexciting fibre future that could see Australianenterprises as:

o Producers of sustainable natural

fibres for global markets.

o Manufacturers of bio-derivedfibres from natural feed-stocks,using biotechnology.

o Niche manufacturers of specificnano-fibres and nano-composites, creating high value

materials and devices for exporto Manufacturers of several world-

leading textile technologiesdeveloped as innovativesolutions to Australias majorchallenges (eg in waterresources, energy, climateadaptation, transport,sustainable agriculture) andsubsequently exported to theworld.

o Specialist manufacturers thathave adapted overseas fibre and

textile advances for applicationto specific Australian issues,keeping various sectors ofAustralian endeavour in touchwith global advances.

The opportunities and benefits to theAustralian economy through such a futurefibre and fibre materials sector are profound.These are consistent with the four NationalResearch Priorities as shown in the diagram.(see over)

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Fibres Contributing Solutions to National Research Priorities

2.3 Australias ComparativeAdvantage

In broad terms, the authors believe thatAustralias relative advantages will comefrom three main drivers as highlightedbelow:

(1)Exploiting our Natural Resources

Australia has a sophisticated agriculturalsector that can provide raw materials to feeda fibres sector. For example, Australia has a:

o Demonstrable record as a worldleader in wool and cotton fibreproduction

o Proven potential to be a producer ofnext generation of sustainable fibres

o Capacity to successfully implementdemanding sustainability/greenpolicies

o Unique flora and fauna which can

provide new fibrous polymers

o Extensive experience as an early

adopter of biotechnologies forsynthesis of bio-derived fibre-forming polymers.

(2)Innovating to Meet Local andRegional Needs

Developing applications for specificAustralian needs, which can become world-class solutions that can subsequently beexported, eg:

o Water management solutions

o Climate adaptation tools

o Biomedical materials linked to ournational health needs and world-leading medical researchers.

o Fibre and textile pre-forms to createinnovative composite materials forour mining, aerospace, marinesecurity and sports technologysectors.

(3)Focussing and Redirecting ourExisting Capabilities

There is a real and significant role for a

strong fibres industry in Australia, as:

o Australia retains acomparative/competitive

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advantage in R&D in fibredevelopments

o It is needed to service local

needs

o There is scope to forge mutuallyadvantageous internationalpartnerships

o The resource base exists(human, scientific and naturalresources)

o There is a strong existingknowledge and skills base.

o High design element

o Protective and performanceapparel

o Industrial textiles

3. AUSTRALIAS POSITIONING IN THENEW WORLD OF FIBRES

This section highlights the potential forAustralia to achieve this vision of anemerging and significant fibres sector, bybuilding on the existing industry andresearch structure and capabilities.

3.1.Existing Industry CapabilityThe existing textiles/textiles product sectorprovides a strong base from which to buildthe new fibres sector. While the traditionalactivities of this sector are expected toultimately only constitute a relatively small

component of the future fibres sector, it isthe very inherent entrepreneurial nature andmarket astuteness of these traditionalplayers that will help enhance thetechnological benefits of the future fibresindustry.

Super-hydrophobic textile

surfaces out-perform the lotus

leafThe lotus leaf has an amazing capacity to keep

its surface clean and dry. By mimicking the

nano-structured surface morphology of the lotus

leaf, researchers at Deakin University have been

able to develop a range of super-hydrophobic

textiles. These textiles have a water contact

angle of over 170 degrees, which is much

higher than that of a lotus leaf. Super-

hydrophobic textiles can be used for both

apparel and outdoor applications. The method

developed at Deakin is a simple one-step

process that may be incorporated into an

existing fabric treatment process used in the

textile industry. Functionalising the surface of

conventional textiles adds significant value to

the products.

Cotton Wool

The current TCF industry has manystrengths, and that segment of industry stillsurviving has consolidated its position byexploiting these strengths, including:

o Design capability

o Fashion orientation

o Effective sourcing

o Brand management and globalsupply chain management

o Testing facilities and accreditationsystems

o Technical knowledge

o

Innovative and entrepreneurialattitude

The industry has restructured to takeadvantage of these strengths, assisted in nosmall part by the benefits of the TCFStrategic Investment Program (SIP).Companies have successfully transitionedinto brand/design/supply chain specialistsand manufacturers have found successfulniches - eg. in technical textiles, defence andhealth applications and protective textiles,and we have a textile design and fashionsector that has high profile due to itsinnovative design, niche marketing and, itsconnectivity with global supply chains.

But for the companies in this sector tobridge the gap and form part of the highpotential fibres sector of the future, a muchgreater focus will be required on innovation,R&D and commercialisation (see Figure).

A clear vision of a future fibre sector will

provide new direction and opportunities forthis creative business energy, as well asattract new investors and entrepreneurs.

The new direction needs to be sufficientlyaggressive to make use of the Research andInnovation capability within Australia tostimulate the existing TCF industry to buildon existing strengths (similar to the

European strategies) as well as nurture newstrengths of an emerging major Fibres basedsector (as offered by the NTC in the USA).This Vision extols a framework within whichboth potential new entrants and existingparties can participate, pursuing thoseopportunities which are of greatest relevanceto them, leading to renewed growth ofAustralias future fibre industry.

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Not all of the existing industry will have thecapability or desire to follow up on themarket and research developments but weneed to pursue a knowledge industryapproach and recognise that it will be adifferent industry.

New ways of processing and

using wool

The traditional ways of processing and using

wool have not changed much for well over a

century. To revitalise the wool industry, new

ways of value adding to this unique fibre must

be found.

Researchers at Deakin University and their

partners have been exploring different means

of converting wool and other natural fibres

into micro and nano particles. These fine

particles are much more reactive than theparent fibres and can be used in a range of

advanced applications.

Cotton fibre measurement

breakthrough

Scientists at CSIRO have developed an

instrument that more precisely measures

the fineness of ginned cotton fibres .

The development of the Cottonscan

technology brings the Australian and

international cotton industry significantly closer

to meeting a longstanding commercial

challenge.

Fine fibres are needed to make high-premium

lightweight fabrics but the industrys ability to

accurately grade fibre in a cost-efficient way

has presented a major problem.

Cottonscan benefits both cotton growers and

the textile industry by enabling high quality

fine Australian cotton to be correctly graded

and valued by the market.

A series of comparative tests and international

validation trials have demonstrated that the

Cottonscan instrument can quickly and

routinely measure the fineness and maturity of

cotton with high precision.

3.2.Research CapabilityAustralia is fortunate in having one of theworlds largest specialised fibre researchfacilities at CSIRO Textile and FibreTechnology, backed up by the Centre forMaterial and Fibre Innovation at DeakinUniversity and the textile, design, research

and education delivery at RMIT. In additionother Australian research institutions havebeen developing specialist researchcapabilities that involve the application offibre technology. A key feature will be thesefibre-focussed groups collaborating withresearchers and users in other fields to buildnew fibres, complex fibre composites, andspecialised applications.

Some examples of the activities of thisresearch capability that are relevant to thispaper are highlighted in the feature boxes.

3.3.Education & Training NetworkThe TCF sector has an effective establishednetwork of education and training providers,from vocational to undergraduate to postgraduate, who can adapt their training andeducation programmes to create theintellectual capital and skilled personnel topopulate this new industry.

4. STRATEGY FOR ACHIEVING THEVISION

This section has been compiled fromfeedback and ideas generated throughindustry workshops and meetings of theAdvisory Committee and Strategy Group.

Australia is well placed to capitalise on thevibrant new fibre-based developments,building on many existing and prospective

elements of comparative and competitiveadvantage.

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However, it is also important to appreciatethat Australia is in a global marketplace. Tobe competitive, our future fibre innovationswill need to be relevant to global markets toachieve the economies of scale to be pricecompetitive in both local and internationalmarkets. Since most other countries are alsolooking at many of the broad opportunitiesidentified in this paper, Australias focusmust be in areas where we have a realedge/expertise and Australia can establishitself as a world leader. Action is now neededto pursue focussed partnership projects

between industry and researchers to turnthese research priorities into commercialreality.

To best capitalise on our strengths weshould be seeking to pursue collaborativeprojects between key firms in the industry toensure the appropriate research anddevelopment occurs. An effective wayforward would be to establish consortia ofcompanies that are non-competing todevelop new strategies.

Industry will require innovations that willlead to a successful commercialisation and itwill be important to ensure that innovative

projects are supported by sound marketanalysis. ie it is vital that the commercialopportunities are real.

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Textiles encourage tissue grow th

Tissue engineering support structures known as

scaffolds are artificial devices designed to

encourage cell attachment, proliferation and

migration through the porous structure. CSIROis tailoring fibrous scaffolds for particular tissue

types. Scaffolds act as templates for attached

cells, where new tissue forms gradually and can

be implanted into the body. For a tissue

engineering scaffold to work effectively, its

structural and mechanical properties must be

suitable for the type of tissue being grown.

Using knitting, weaving, nonwovens and

electrospinning technologies, CSIRO is able to

produce fibrous scaffolds that are tubular or flat

for a variety of purposes.

This also means that we need to identify thekey regional markets that we wish topursue. For example, in general the Asianmarkets are easier for Australia to penetratethan say the US or European markets,although of course this will vary dependingon the specific product.

Some specific market opportunities arediscussed in relation to each of the threedrivers.

4.1.Exploiting our NaturalResources

Australia should seek to position itself as amajor source of unique and niche orientednatural fibre products, eg:

Maintain our position as the worldsleading supplier of apparel wool, and themost efficient cotton producer

Build on success of introducing woolfibre into unique applications, notablyprotective and performance apparel andtarget Asia with these products asAustralian products have a goodreputation there (especially in firefighting and protective wear)

The US market is also receptive toAustralian wool product wool is anoutstanding versatile fibre. (activewear/performance wear utilising wool

fibres are potential areas for innovation).

Explore scope for adding value to rareanimal fibres such as alpaca, cashmere,and mohair. These are true high fashion,high value fibres, that are produced inAustralia that offer some degree ofcomparative advantage.

Develop innovative new fibres based onour natural resources, biodiversity, andbiotechnology skills.

4.2.Innovating to Meet Local andRegional Needs

Sectors where Australia has an establishedexpertise that has a need for fibre andtextile innovations are:

- Medical devices and health

- mining industry

- automotive

- built environment and

- sustainability.

Significant R&D is already being undertaken

in Medical applications. Greater TCF industryinvolvement/participation needs to beencouraged into this sector. Increasingly the


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focus will shift to broader scale monitoring ofhealth, the prevention of cross-infection andmanaging an ageing population. Thedevelopment of textile materials throughfibre technology and the application ofsurface coatings offer innovative solutions.

The mining and minerals processing sectorsare also a significant market in Australia withall technical services divisions of the worldslargest mineral processors being based here.Fibres and textiles applications can be foundin mining operations/refineries/smeltersfrom filters to conveyor belts to protectiveapparel.

Note: A number of firms have alreadyindicated that they would be interested incollaborating on a joint project targeting themining sector. In addition, the CSIROflagship Minerals Down Under is seeking

innovative solutions for this sector.

Automotive textiles are an importantsegment with OEM manufacturers preparedto look at innovative solutions. Textiles are

used for upholstery, head lining, seats, seatbelt webbing, acoustic materials and highperformance pressure hoses. Compositetextile and fibre materials are increasinglybeing used in auto manufacturing.

Easy-breathe air filters

CSIRO has developed an electrostatic filter

that removes potentially hazardous particles

from the air.

Intermediate size particles (those with

diameters typically between 0.2 and 10

micrometers) can linger in the lungs forextended periods, during which they can

cause poisoning (if the are toxic) or allergicreactions.

Electrostatic filters have an advantage overcommonly used mechanical filters because of

the low airflow resistance. With co-funding

from Australian Wool Innovation Ltd, CSIROhas developed an electrostatically-charged

wool filter medium, which consumes little

energy, is highly efficient and makesbreathing easier.

The material has a high dust-holding

capacity and therefore a long life. It issuitable for use in air conditioning systems,

personal respirators and many other

industrial applications.

Built environment is a major fibre and textilesegment that includes domestic textiles andindustrial textiles. Advanced materials thatmake use of carbon fibres and aramids forsuperior strength are now common place.Australia has a carbon fibre and carbon

nanotube research capability that can beutilised to develop innovative applications forthe built environment, as well as in thebroader composite materials sector.

The development of products that willprovide an environmentally sustainable

outcome represents an important areawhere Australian industry can take globalleadership. Fibre recycling, development ofwater filtration and conservation, conductivefibres for renewable energy, fibrecomposites for lower weight and windturbines are some examples of sustainabilityend uses for Fibre innovations.

4.3. Focussing and Redirecting ourExisting Capabilities

The fibres sector represents an opportunity

for innovation through collaboration betweenthe Research and Innovation institutions andthe existing fibre and textile industry. Anaction plan to capitalise on the opportunitiespresented in this paper would need toaddress:

Cleaner w ater storage

A collaborative project between CSIRO, GalePacific, East Gippsland Water (EGW), and

Superspan has demonstrated the benefits of

textile covers for protecting potable waterstorages. In a two-year study, four drinking

water basins were covered with suspended

high-density polyethylene shade cloths,while two other basins were left uncovered

as controls. The study showed that the semi-

permeable covers successfully blocked lightto prevent toxic algal blooms from

photosynthesising and reduced evaporation

by 90 percent. Other benefits includedelimination of weed growth in the basins,

saving labour costs and reduction incontamination from water birds and wind

borne debris.

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an ongoing process to facilitatecollaboration between the research andinnovation institutions and industry. Thisprocess would probably best be servedby an entity that could channel fundinginto innovation projects

Identify what research is alreadyhappening, so this can be highlightedand promoted to industry

Initiate market research to identifywhere there are commercial marketopportunities. Industry needs to haveconfidence in innovation projects. eg:

(Original fabric) (Faded fabric)

UV protection to keep colour in

the fabric of life

Colour fading is a critical problem that

continues to plague the textile industry,

especially for products such as flags, awnings

and car upholstery that are exposed directlyto sunlight. Through an ARC Linkage project,

Deakin University has established research

partnership with Micronisers Pty Ltd and

Bruck Textiles Pty Ltd to develop improved

nano zinc oxide formulations that will give

o A market research document onthe industry sectors highlightedin section 4.2 would be highlyvalued.

o Surface finishing relevant tofilter fabrics and to industrial

fabricso Looking for next polymer that

will take over from existingsynthetic polymers

o An assessment of environmentalopportunities eg mulch matsare made out of polyethylenebecause of price factors, but it isnot environmentally friendly.

Identify innovation projects thatcould be developed and facilitatecollaborative partnerships toimplement an innovation project (egThe TFIAs CAPES Group provides a

good base to develop a collaborativeproject in relation to ProtectiveApparel).

Virtually all of the innovative new fibres aredeveloped outside Australia, and thereforewe need to forge close links/partnershipswith international fibre producers. Access tothe right fibre is vital for our processors andglobal networking will be an essentialcomponent of a successful Fibres innovationstrategy. Some issues that industry hasstressed that need to be addressed indeveloping a successful fibre outcome are:

The need for either a local pilot plant fordeveloping new fibres or alternatively aTechnology Agreement with a major

international fibre producer Focus must be on producing fibres that

address key Australian problems, wherewe have the recognised expertise. Thereality is that it will probably best toengage a yarn/fibre producer overseas,and then look to further processing and

finishing in Australia. Australias strength lies in developing

fibre derivations/new products and then

collaborating on these. This is somethingthat can also be accomplished with

shorter lead times (eg in fabric finishingtechnology, Australia can achieve quickgoals).

Much of the industry infrastructure hasdisappeared over time, especially withthe supply side eg strong linkages will

need to be re-established with thechemical sector

4.4Research and Education Needs

Australia has an educational infrastructure inplace that is well placed to meet industryneeds and provide vocational and higher

education graduates who can meet therequirements of a high technology fibres andmaterials industry. However, as thetraditional textiles industry has declined,industry has focused on costs andmaintenance of traditional skills and notinvested in graduates. The educationalinstitutions servicing the TCF industry haveresponded to industry restructuringpositively with an emphasis on design andsupply chains as a source of competitiveadvantage whilst continuing to providevocational , undergraduate and postgraduate programs in Textiles. To support a

robust fibre sector the technological and

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managerial base will need to be much moresophisticated.

This means the industry will need to attractnew people, with new skill sets. Goingforward the industry will need people thatare well versed in:

o Biotechnology

o Nanotechnology

o Materials engineering

o Product design

o Supply chain management

Much of this can be achieved through closerlinks with educators in other disciplines, bystimulating their interest in the excitingfuture for fibres in Australia, and by

providing specialist fibre and textile trainingto build on their existing knowledge.

In the research area, Australia is fortunateto have had an extensive and world classtextile research capability in CSIRO and atseveral Universities, developed largely to

service the Australian woolgrowing industry.Although this has declined steadily over thelast two decades, the remaining capacity isstill world class, and the key groups havealready re-aligned their activities to thevision outlined in this paper.

For Australia to fully realise the potential

opportunities outlined above, these researchgroups will need to be rejuvenated andexpanded.

A mechanism is also needed to bring CSIROand University research groups more closelytogether, to further develop and promotesynergistic effect in their research anddevelopment activities.

Carbon nanotubes could go

antiballistic

CSIRO has been granted funds under the

Defence Capability and Technology Demonstrator

Program to demonstrate the capabilities of

carbon nanotubes as strong, lightweight

antiballistic materials.

Carbon nanotubes (CNTs) are amongst the first

of the new wave of nano-structured materials

and offer extraordinary properties of strength,

stiffness and lightness.

The challenge is to capture the potential of these

new materials at the macro level. CNTs are fibres

of pure carbon that are only 1 to 100 nanometres

in diameter but up to millimetres in length.

Synthesising and manipulating these myriad tiny

fibres into ordered structures requires acombination of novel processing skills coupled

with a fundamental understanding of fibre

behaviour.

CSIRO has established a capability to produce

very highly specified CNTs with the unique

characteristic of being able to be drawn directly

into yarn. This in combination with other

advanced materials will form the basis of the new

antiballistic structures.

No single material has all of the properties

required for ballistic protection, so a successfulapplication of CNTs would see them as part of an

integrated system with greater strength and

flexibility and reduced weight.

We have a solid foundation already for avibrant new fibres sector in Australia. Thereis a lot more that fibres can offer to manyexisting industry sectors. With this visionand the right catalyst, the future is trulyfibres!

Functional bi-component

nanofibres

Researchers at Deakin University have

pioneered a technology for producing side-by-

side bi-component nanofibres from different

polymers (T. Lin &, HX Wang and XG Wang,

Advanced Materials, 17 , 2699-2703, 2005).

This technology further enhances thefunctionality of nanofibres for certain

applications and also allows the production of

the finest nanofibre materials by dissolvingone of the polymer components.

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The next generation in work wear fabric

Performance combined with durability and comfort

Bruck Bionic Gemini was developed using existing knowledge and adapting it to Australian

conditions. In Europe, the main focus is to keep the body warm without overheating. In many

parts of Australia, throughout most of the year, the main challenge is to keep the body cool. It is

clear intelligent garment construction plays a very important role in meeting that challenge, butfabric also plays a very important role.

Bruck Bionic Gemini is an intelligent fabric construction with the following features:

Fast drying

Soil release

Antimicrobial

Anti odour

High visibility

In addition to the selective use of chemicals it was crucial to test the functionality of these fabrics. Extensive tests in climate chambers and field tests conducted over several months have confirmed

that Bruck Bionic Gemini:

Releases humidity 25% faster than a similar weight100% cotton fabric

Dries 40% faster than a similar weight 100% cotton fabric

Similar cooling properties compared to a similar weight cotton fabric

All of these improvements are most importantly achieved with chemicals, which have OEKOTEX

STANDARD certification. Therefore Bruck Bionic Gemini in addition to being a high performance

fabric is also environmentally friendly and a much healthier option for theAustralian workforce.

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future is fibres strategy

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