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

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)

Tencel Web Production Concept (1988)

At a time when the Tencel concept was being scaled up to produce basic  staple fibre, future machines which would be capable of extracting higher value from the technology were also being considered.  This 1988 diagram illustrates a possible layout for a machine capable of producing crimped staple fibre, tow and a range of bonded webs and nonwoven fabrics.

The proposal was first made for a viscose fibre in 1977 and involved a machine which would spun-lay tow onto a conveyor for washing, bonding and drying, the resulting dried and bonded web having 3 possible finishing processes.  Fully bonded heavyweight webs could be sold into the absorbent viscose needelfelt market, a category which included both external and internal feminine hygiene - major viscose staple outlets.  Bonded lightweights would become lint-free wipes. Temporarily bonded webs of discrete sinusoilally laid filaments could be pulled back into tow form after drying to give a highly crimped bulky tow which could packed and sold as a high quality tow or be cut to staple.

This "spun-laid" concept appeared to be easier using Tencel technology, where the vertically downward spinning system using large rectangular jets could be arranged to produce a ~3metre wide web on a conveyor-belt for washing.  By 1988 the hydroentanglement bonding system and high capacity through air dryers could provide the web options.  

EXODUS Part 1: COURTAULDS TO SELL SAICCOR DISSOLVING PULP INTERESTS TO SAPPI (1988)

As part of its aim to become a 'more focussed' growth company Courtaulds plc has signed unconditional agreements for the sale of its dissolving pulp interests, which include its interests in Saiccor (Pty) Ltd, South Africa, and Speciality Pulp Trading Ltd and supporting companies, Hong Kong, to a South African consortium represented by Sappi Ltd for £207 million. Sappi is also to purchase the 50% Courtaulds holding in unbleached kraft pulp producer Usutu Pulp Co. Ltd, subject to approval by the Swaziland government. Sappi estimates that the acquisitions will raise annual sales by 83% to 2.4 billion rand.


 Anon., Wall St. J., vol. VI, no. 117, 18 July 1988, p. 4

The cash realised was used to fund the purchase Product Research and Chemicals Corporation in the USA. It was part of the new strategy of reducing dependence on cyclical commodity businesses such as fibres in favour of the "stickies" - high-value polymers for paints and adhesives - and heralded a series of US acquisitions.  (Distancing Courtaulds from the "apartheid" troubles in South Africa were part of the reasoning at that time.)

VISCOSE AND THE ETERNAL SEE-SAW (1988)

The changing fortunes of viscose may present problems for producers in Europe and worldwide. European producers such as Courtaulds, Lenzing AG and Hoechst AG have trimmed annual output over the last decade and taken steps to improve performance while keeping prices down. There are now signs that viscose is becoming more popular in the contemporary climate of environmental concern as it is based on a regenerative natural resource and is biodegradable, causing a surge in demand. New developments in viscose are underway such as Fibrafinn MS, a high quality fibre for high performance spinning equipment from Sateri, and Courtauld's extra strong tencel fibres. The background to the situation at Avtex Fibre US, now supported by NASA is outlined. 

 Anon, UK Text. News vol. 5, no. 6, 1988, pp 10-11

This is one of the few releases using "tencel" and including it with new developments in viscose. The capital letter was dropped when we hoped to use "tencel" as the generic name for solvent spun cellulose, to avoid having to call it rayon.  

Here also Avtex Fibres USA are mentioned as being supported by NASA.  I think they were in Chapter 11 at this time but were the only qualified supplier of viscose for carbonising to make rocket exhaust cones.  Avtex were still using the viscose process and the factories installed by Courtaulds in the 30's which had to be transferred to US companies under Lend-Lease during the war.

TENCEL PLANT BEING ERECTED AT GRIMSBY (1988)

Commercial evaluation of the Tencel solvent spun cellulosic fibre from Courtaulds should be possible by the end of the year following completion of the company's Grimsby extrusion facility, part of the Genesis project. Trials comparing the fibre with viscose fibres report the following properties:

• stronger stiffer fabrics when bonded under conditions used for viscose rayon, 
• wet properties better than dry, 
• firmer handle than regular or high wet modulus viscose, 
• lower moisture uptake, and more efficient bonding in latex impregnated constructions. 
• The inherent strength of Tencel could result in fibre economies in some types of dry-laid fabrics.

Tencel is expected to find application in specialised, low-volume nonwovens where performance factors justify the extra cost of the fibre.

Anon, Nonwovens Rep. Int. no. 206, May 1988, p. 2

So, do we conclude that Genesis became Tencel in early 88?  

Maybe this one helps with Iain's question in his comment on the earlier release.

Apart from the "Genesis..forms a new range of clothes" in the ealier release I've found no PR for Genesis in textiles.  Can anyone recall any?

Please Click on "comments" below to reply.

COURTAULDS REFOCUSING 'GENESIS' ON NONWOVENS (1988)

The Courtaulds, UK, Genesis solvent spun cellulose process was not developed primarily for nonwovens production, but the company is emphasing how the process fits well with thermal bonding, hydroentanglement and latex bonding nonwovens technology. Courtaulds states that more possibilities of developing special fibres for nonwovens do exist.


Anon, Nonwovens Ind., vol. 19, no. 1, Jan. 1988, p. 15


This must have been at the time the problems with fibrillation in textile processing were slowing down development of the yarn/fabric route.  Maybe this also accounted for the relative PR silence in 1987.  Comments from those involved on the textile side would be valuable.

WHY INVESTORS UNDERESTIMATE COURTAULDS (1988)

Courtaulds shares are falling although November interim results were up to expectations. The company's development is traced from its initial breakthrough with viscose rayon to its present diversified range of products. In the 1960's a policy of acquiring textile and clothing companies to absorb its fibres production made it vulnerable to economic downturn. A management controlled business system now operates in the six main product sectors monitoring 'profit centres' for profitability. A modest acquisition policy is now being pursued in paints to bolster the declining marine market, and in brand name clothes. Genesis, a new fibre superior to viscose, forms a new range of clothes, and rapid growth in oriented polypropylene is bolstering the packaging group. Carbon fibres and acrylics are problem areas, as are dollar related textile imports. Analysts are optimistic that its strong balance sheet means a continuation of acquisitive growth. 

Bennett N, Investors Chron. vol. 83, no. 1040, 15-21 Jan. 1988, pp 18-19


There are no releases containing "Genesis" on the computer database for 1987 although I recall some coverage in New Scientist at that time, which I'll try to locate.  Does anyone have anything from 1987?