Showing posts with label 1987. Show all posts
Showing posts with label 1987. Show all posts

Saturday, December 7, 2013

Tencel in Courtaulds Annual Reports (1981-90)

The Courtaulds Annual Reports contain concise statements of the progress of the Tencel development year-by-year.  These statements have been pasted into a series of 10 posts which can be read in sequence by scrolling down from here:

1981-82 - under "Research"
Technology is being developed in the use of novel solvents for the conversion of woodpulp to regenerated cellulose products, leading to lower effluent levels and reduced energy consumption in the manufacturing process.
1982-83 - under "Courtaulds Research"
 A pilot plant incorporating a process which directly dissolves cellulose ran successfully towards the end of the year.  First indications are that the process may provide a low cost route to novel types of fibres and films.
1983-84  - under "Courtaulds Research"
Development of the new process for directly dissolving and regenerating cellulose continued.  Samples of fibres, of fabrics made from them and of transparent films have been produced, all with interesting properties.
1984-85 - Under "Research"
The research progamme into the production of new fibres and films by direct dissolution and regeneration of woodpulp continued successfully.
1985-86 - under "Research"
The development of a direct solvent spinning system for cellulosic fibres and films continued successfully.  An expanded pilot plant will be available by the end of 1986.
1986-87 -  under "Fibres"
Research expenditure was again at a high level for all fibres, but especially in the development of the new solvent-spun cellulose fibre.  Its pilot-plant came on stream and good progress has been made on the next stage of production which will make commercial quantities available.
               - under "Research"
The programme to develop a new range of cellulosic fibres using a new direct solvent spinning system continued with the successful commissioning of an expanded pilot-plant and with engineering developments for further expansion.  The process gives significant improvements over existing fibre properties and environmentally.
1988-89 - under "Fibres"
The first commercial scale Tencel plant was commissioned during the year. Its capacity is modest and design work on larger units is now well underway.
                - under "Research"
Substantial work was undertaken to transfer expertise learned on the pilot plant...to the scaled up plant commissioned...at Grimsby.
1989-90 - under "Fibres and Films"
The new solvent spun fibre Tencel continued to progress well.

N.B.  (1) Tencel is not mentioned in the "Research and Technology" section in 89-90.
        (2) The Textiles business had been demerged and was no longer part of the Courtaulds Group.
        (3) Saiccor Pulp (the best pulp for making Tencel) had been sold in 1988 to fund acquisitions of US sealants and adhesives.
        (4) Bonded Fibre Fabric, the nonwoven business which had been modernised at the end of the eighties, was sold at the end of March.  (Tencel was showing great promise in nonwovens)
        (5) Prior to 1989-90, "Fibres" came immediately after the "Chairman's Statement" at the front of the Annual Report.   Here "Fibres" comes last after Coatings, Performance Materials, Packaging and Chemicals.  Furthermore it has been merged with the "Films" used in packaging - cellophane, polypropylene and polyethylene.  Maybe the continued development of Tencel clashed with the emerging strategy of getting out of Fibres and Textiles and was therefore downplayed.

Thanks to Ted Richards who provided the full set of Courtaulds Annual Reports from 1970 to 98

Friday, June 28, 2013

Innovation: Product Development with Tencel (1985-94)

Work with potential customers started in secret in October 1985 based on Coventry pilot plant Tencel.  All the developments to 1994 were organised by Courtaulds Research in conjunction with sales offices outside the UK and Tencel sales. 
There's a bias to nonwovens and technical textiles here because I have little information on the development of apparel textiles. Comments and additional information from those involved is welcome as always!

1985:
Products:  Hydroentangled dry-laid nonwovens, woven Tencel gauze
Markets:  Surgical Swabs (cotton gauze replacement)
Partners:  Chicopee USA,  Johnson and Johnson
Key Players:  Alton Bassett, Eric Attle (CNA)
Products:  Hydroentangled Coverstock (Topsheet)
Markets:  Diapers, Femcare
Partners:  Unicharm (Japan)
Key Players:  Migaku Suzuki,
1986:
Products: Hydroentangled Nonwovens
Markets:  Disposable Wipes
Partners:  Chicopee NV, Johnson and Johnson
Key Players:  Derek Rochford, John Elves
Products: Thermal bonded nonwovens
Markets:  Interlinings
Partner:  BFF Nonwovens
Key Players:  Taki Tyropolis, Bill Kennard
Products: Thermal bonded nonwovens
Markets:  Wipes
Partners:  J W Suominen
Key Players: Jorma Suominen, Esa Paltaala
Products:  Wet-laid nonwovens/Special Papers
Markets: Abaca replacement, tea-bags, food casings
Partners: JR Crompton (UK)
Key Players: Brian Tomkinson, Ivan Gbur
Products: Wet-laid nonwovens
Markets: Drapes/Gowns/Central Sterilising Room Wrap
Partners:  Dexter USA
Key Players: Alan Meierhofer
Products: Latex bonded nonwovens
Markets:  Disposable Wipes
Partners:  International Paper,
Key Players:  Zoltan Mate, Eric Attle (CNA)
Products: Thermal bonded (Powder Bonding)
Markets:  High Loft absorbents
Partners:  Bonar Carelle
Key Players:  ?
1987:
Products: Wet-Laid Nonwovens
Markets:  Wet-Wipes (Viscose replacement - low odour)
Partners:  Stora Kopparberg
Key Players:  Stefan Fors, Peter Fredericks
Products:  Modified Apertured Fabrics
Markets:  "J-Cloths" (polyester replacement), Swabs
Partners:  Johnson and Johnson (Canada)
Key Players:  Errol Tan
Products:  Hydroentangled Nonwovens
Markets:  Surgical drapes and gowns (polyester replacement)
Partners:  Chicopee USA,  Johnson and Johnson
Key Players:  Alton Bassett, Eric Attle (CNA)
Products: Tampons
Markets:  Femcare
Partner:  Johnson and Johnson (Germany)
Key Players:  Fritz Weinstrauch, Rolf Altdorf
Products: Tampons
Markets:  Femcare
Partner:  Tambrands (USA)
Key Players:  Ken Merrill, Eric Attle (CNA)
Products: Dry-Laid Nonwovens - various bonding
Markets:  Interlinings
Partner:  Freudenberg (Germany)
Key Players:  Gerhard Schaut, Johannes Knocke
Products:  Hydroentangled Nonwovens
Markets:  Surgical Dressings (cotton and polynosic replacement)
Partners:  Unicharm (Japan)
Key Players:  Migaku Suzuki, Kunihiko Tozaki (CJL)
1988:
Products:  Flame Retardant Tencel
Markets:  Workwear
Partners:  Albright and Wilson(UK)
Key Player:  David Cole, Les Pearson
Products: Dry Laid Thermal Bonded
Markets:  Floppy Disc Liners
Partners:  Freudenberg
Key Players:  Holger Buchwald
Products: Dry-Laid Latex Bonded
Markets:  Battery Separators
Partners:  BFF
Key Players:  Andrew Kelly
Products: Hydroentangled Coverstock
Markets:  Diapers/Femcare
Partner:  Kendall/International Paper
Key Players:  Drew Horn
Partner: J&J Personal Products
Key Player:  Beth Stern
1989:
Products:  Paper
Markets:  Security Papers
Partners:  Portals (UK), Tumba Bruk (Sweden)
Key Player:  Paul Howland,
Products: Wet-Laid Hydroentangled
Markets:  Industrial Wipes
Partners:  Molnlycke (Holland)
Key Player: Bernt Johannsen

(1990's developments follow)

Tuesday, September 11, 2012

David Cole's Tencel Processing Summary (1987)

Here's an early view of the Tencel processing issues from David Cole dated 2/10/1987.  Early concerns about fibrillation  in knits, good results from Courtelle blends and good prospects in air-jet spinning.

Monday, August 27, 2012

Tencel introduced to the Japanese market (1987)

Kunihiko Tozaki and I did not mention Genesis or Tencel during our tours of the Japanese nonwoven market until this August 1987 meeting with the Techncial Director of Unicharm, Migaku Suzuki.  


As mentioned in an earlier post, we'd arranged a blind trial with Tencel as part of the work to assess the Unicharm hydroentanglement system for BFF.  This resulted in the 'R134' nonwoven sample mentioned in the clip above.  (This remarkably soft and silky Tencel coverstock was also used to illustrate the fibre's coverstock potential at later meetings with P&G Research in Cincinnati.)

Seeing this clip again dredged up a series of recollections which probably should appear in a "BFF Saga blog" but I'll record them here before they disappear again.

Friday, August 24, 2012

Tencel in UK Speciality Papers (1987)

J R Crompton* (Bury) appear to have been the first speciality papermaker to report interesting results from their first trials with short-cut Tencel.  Brian Tomkinson, the Technical Manager, evaluated 5mm 1.7 dtex as a direct replacement for viscose in tea-bags and as a direct replacement for abaca (manila hemp).  He also evaluated 12-15mm 1.7 dtex as a replacement for polyester in medical papers.

Tencel disintegrated too easily in the abaca beating process and gave an unusably high Schopper Riegler value and a very highly swollen "gel" in a 5 minute treatment.  It clearly disintegrated much more easily than the abaca  fibre and they would need to optimise the beating process to make it usable.  

They were keen to follow up the polyester replacement, and we noted the need to study the beating properties of Tencel back in Research.

*Now Glatfelter UK

Wednesday, August 22, 2012

First public presentation of Tencel Nonwovens? - EDANA Index Show Geneva (1987)

This turned up while looking for something completely different for a client.  My earlier 1987 posts bemoaned the absence of press coverage of Tencel in 1987 but I'd clearly forgotten giving a paper at the International Nonwoven and Disposables Exhibition and Conference in Geneva in April that year, and the press appear not to have picked it up.  

It could be the first public paper covering the process and our early work on nonwoven applications with the fibre.  It covers thermal and latex bonding only.  The conclusions from the paper,  written with David A Smith and S.D.J. Williams, are given below:

Development of hydroentangled fabrics was well underway by this time but maybe the confidentiality agreements with companies like Chicopee prevented disclosure of the very good results.


Friday, July 6, 2012

Market Review 2/10/1987

This meeting was arranged at a time when we were beginning to introduce Genesis to Viscose Division customers and they were getting a little concerned that we might not all be singing from the same hymn sheet.  So not a proper Genesis meeting  but it contains some useful summaries of the activities at that time.  I'll probably post more later.



The following attended, and as I recall, only BSM, PAW, GRa, DJC, GRo, and CRW were active in Genesis Fibre development at that time.



Wednesday, July 4, 2012

Plant a Tree for Chemistry (1987)

This is the only published reference to Genesis (or Tencel or lyocell) I could find for 1987.  I guess this was the year of the construction of S25 at Grimsby and maybe we were keeping a low profile until sure that we could follow up on the interest generated by the Coventry-produced fibre.  Nevertheless the story of how we came to justify S25, its construction and start up would be well worth airing.


From "Plant a Tree for Chemistry", John Emsley New Scientist 8/10/1987 p 41