Jim Rowan recalls making PEEK tubes for Mobile (1993)

I was employed by Courtaulds Research in the Composites Research group and we worked in labs in 72 Lockhurst Lane.  Our manager was Charles Holleyman.  Our work was directly in support of Courtaulds Structural Composites, and was funded by Courtaulds Advanced Materials, so I reported to Charles and to Ed Trewin in CSC.  My role was in filament winding R&D, to develop materials and processes and make prototypes and one-off components.  

I helped manufacture, in Coventry, by filament winding, a tube of PEEK and glass fibre that was needed for the Alabama factory to make Tencel. We were told that the plant could not start up without this tube. I think it was to go in the flow line prior to the spinnerette and was part of a metal detector system. It had to be non-metallic yet very chemically resistant and strong. No other material could fulfil the requirements at the time, and almost nobody world-wide had the technology to make this unique structure. 

The job was something of an experiment as we had only done a limited amount of development to establish a process and some materials data because of the urgency to produce the tube.  All our previous years of R&D had been on carbon/PEEK, which processes differently from glass/PEEK, and we had never made anything remotely this big.  So it was a rather stressful 42 hour marathon requiring non-stop attention.  For example, we were winding a single 6 mm x 0.125 mm tape of glass/PEEK onto an irradiated rotating mandrel at about 300 degrees C and could not stop the process without overheating the product; the tape came on spools of limited length, so every few hours we had to weld the end of one tape onto the start of the next tape (using a soldering iron and paper clips) aided by a mechanism that accumulated enough tape to allow us just enough time to stop the spool while the winding continued. 

I have located the attached document which is a very brief summary, probably for someone like Jim Ratcliffe (who went on to greater things...)

Tencel Dinner at Mancetter Manor (1993)

There had been a project review meeting in Courtaulds Research in Coventry during the day and this dinner was arranged, I think by Robin Thomas, at nearby Mancetter Manor.  From left to right, Calvin Woodings, Glenys Thomas, Robin Thomas, ??, Glyn Raven (US) , Clive Knee (US), ??, Pat White, Alan Jones, ??, Bob Feil (US), Omori-san.  

(If anyone can replace the ?? with names or knows who took the photo please comment.)

Tencel in Courtaulds Annual Reports (1992-93)

In "Chairmans Statement"

...Best of all, Tencel came of age with the commissioning in Mobile Alabama of the first major plant.  The origins of Tencel go back to the late 1970's and over the years since then those responsible for its development have nurture it with a skill and confidence which have owed much to Courtaulds massive experience with cellulosic fibres and technology since the start of the century. Tencel is now a product with a very exciting potential...

In "Chief Executives Review"

However the most important event of the year has undoubtedly been the successful start-up of the Tencel plant in Mobile, formally opened on 2 December 1992. Initial market reception of the product matches, or even exceeds, expectations and a key decision in the coming year will be the timing and scope of investment in further capacity in this core area.  The credit due to all those who have made this success possible cannot be overstated.

In "Fibres and Films"

Tencel, the new solvent spun cellulosic fibre, was commissioned on schedule at the Courtaulds Fibers facility in Alabama.  By the end of the year it was running at 80% of nameplate capacity, and such was the interest in the fibre that demand outstripped supply.  Tencel is capable of producing effects which are not available in other fibres and this, combined with high processing efficiencies is stimulating great interest amongst innovative customers.  In the final quarter, 50% of Tencel fibre was exported, principally to Japan, and Tencel was operating profitably.  

In Japan a consortium of textile mills focussed the development of Tencel into fabrics for fashion apparel.  A key feature has been the wide use of finishing techniques to develop a variety of fabrics with unique aesthetic effects.  Market reaction has been excellent and Tencel is leading the 1993 Spring/Summer collections.

N.B There was no "Research and Technology" section in this report.

Tencel in Courtaulds Annual Reports (1993-94)

- In "Chairmans Statement" (Sir Chris Hogg)

The company's balance sheet is sound and we are well placed for funding capital requirements in the foreseeable future, including those for Tencel and the Far East expansion.

-In "Chief Executives Review: Strategy" (Sipko Huismans)

We brought our new Tencel fibre into full production and turned it into a commercial success.  In November we announced a second US plant, more than doubling capacity, and we hope to make a start on a European plant in the present financial year.

-In Finance Directors Review (Michael Pragnell)

...expenditure plans for the coming year remain at the 1993-94 level*: in addition the next phase of US investment in Tencel is already underway.

*£143m representing 1.7 times depreciation.

-In "Fibres and Chemicals"

The common theme of these businesses is the transformation of cellulose and other material into fibre or film and the use of R&D and market development to create product differentiation.  Tencel, the world's first solvent spun fibre, with exceptional versatility and environmental compatibility, is an outstanding example.

Tencel made a notable contribution to profit in 1993/94 despite an increased level of investment in research and market development.  Manufacturing continuity and yields improved throughout the year.  Dependence on the Japanese market lessened as both US and European demand increased, and by the end of the year sales were equally balanced between all three geographic regions. Construction of a second Tencel plant in the US, which will more than double capacity, commenced in January 94.  It is expected to be on stream by mid-95.

More to come...

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)

Lenzing's Patent on Filmtruder use for Lyocell (1992)

This is the lyocell patent Lenzing claimed Courtaulds infringed in building the US Tencel plant.  They sued Courtaulds in 1993 and the case was summarily dismissed in the USA in 1995.   Courtaulds was awarded costs.  Lenzing later appealed.

The 1995 Judgement appears here.

United States Patent	5,094,690
Zikeli ,   et al.	March 10, 1992

**Please see images for: ( Certificate of Correction ) **

---

Process and arrangement for preparing a solution of cellulose

Abstract There is disclosed a process for preparing solutions of cellulose in aqueous tertiary amine oxides from a suspension of cellulose in an aqueous solution of the tertiary amine oxide by supplying heat at a reduced pressure. The suspension is transported over a heating surface, spread in layers or coats, until a homogenous solution of the cellulose has formed, which has a viscosity of between 50 and 15,000 Pas.s. Feeding of the suspension and drawing-off of the homogenous solution are carried out continuously. The solutions are prepared in an indirectly heated evacuatable vessel provided with a stirring device. The vessel is designed as a cylindrical container including a centrically mounted stirring shaft having agitators joined thereto, the radial distance of the agitators from the internal wall of the container being 20 mm at the most. There are provided an intake for the cellulose suspension in the upper part of the container and an outlet for the homogenous collulose solution in its lower end.

---

Inventors:	Zikeli; Stefan (Regau, AT), Wolschner; Bernd (Vocklabruck, AT), Eichinger; Dieter (Vocklabruck, AT), Jurkovic; Raimund (Lenzing, AT), Firgo; Heinrich (Vocklabruck, AT)
Assignee:	Lenzing Aktiengesellschaft (Lenzing, AT)
Family ID:	25597486
Appl. No.:	07/742,093
Filed:	August 2, 1991

Tencel will be a mass market fibre, but... (1993)

Who said of Tencel "I think it will be a mass market fibre but not before the middle of the 21st century".  Read on to find out.

Courtaulds catches cold, but defends core business (1993)

Another memorable quote, this time from the FT of November 18th 1993.  

The UK is now the favourite location for manufacturing in Europe (presumably with the proposed EU Tencel plant in mind) because "Germany provides an outmoded socialist environment.  That country has a long way to go to reach the efficiency levels of the UK".

In the same paper "Courtaulds Catches Cold": shares fall by 9%.

Dethroning King Cotton? (1993)

This is from the Financial Times, Jan 5th 1993, and comments on the magnitude of the marketing task faced by Tencel and Alan Jones.  New technology, new product and new market, i.e. the luxury apparel market chosen for the launch. 

• "The technical strengths and unusual properties of the material will sell it".
• The Courtaulds approach stands in contrast to ICI's conservative approach with Tactel: Launch in a market you understand and when the properties of the fibre are well understood, relaunch in fashion.

David Pike (Seydell-Wooley and Co Inc) recalls the first sizing of 100% Tencel in 1993

Here's the first contribution from one of the multitude of non-Courtaulds people who contributed to the successful  development of uses for the new fibre.  

If we get more I'll start a new page of credits.

I can help as I was the first person to size 100% Tencel at the old Greenwood Mills - Lindale Plant - Lindale Ga. location in 1993 & 1995 and 65/35 tencel/cotton in 1995. Email me at davidmpike@dpgenterprises.com and I will assist. I was working with SEYDEL-WOOLLEY & CO. INC. at the time and still have all the technical papers from the slashing of the yarns on an old West Point Foundry slasher #4 with West Point Foundry 863 Equi-Squeeze boxes/ medium pressure (5 ton) for research by Courtalds out of Axis, Alabama plant.

The people I dealt with were from the Axis, Alabama plant.  One of the engineers called me one day a few years later for some information on slashing/sizing techniques but I don't remember his name.  A I said, I have all my old notes from each warp sizing trial I conducted for 10 years while at SEYDEL-WOOLLEY & CO. INC.  I am still friendly to my my old company and the president Mr. Steve Adams and I am sure I could secure some of that other additional lab bench work info if a paper or history was ever put together.  

My best memory was the 65/35 Tencel/Cotton trial we conducted in 1995.  We were told it was basically a RAYON so we used that as a basis point but that was not the case at all.  We set the slasher up for a stretch of 4% which is standard for RAYON and low and behold it turned to rubber bands.  Our 100% Tencel trials went off without a hitch but the 65/35 was a different animal all together with a stretch more in line with cotton.  It turned out that Tencel was more like cotton and once we determined that away we went.

From: David M. Pike of DPG ENTERPRISES, INC.

Tencel capacity doubles in Mobile (1993)

Here's another Exodus story from The Independent of 18th November 1993 which also mentions the Mobile Tencel expansion and "another 4 plants in the Far East" (?!)

COURTAULDS, the chemicals and fibres group, yesterday surprised the City with a plan to shut down six manufacturing plants with a loss of 650 jobs in Europe.

The cuts were announced as Courtaulds reported taxable profits of pounds 96m, up from pounds 88m, for the half year to 30 September. Earnings rose from 18.1p to 19.5p and the dividend has been improved from 3.8p to 4p.

However, the results were below expectations and news of the closures and a dismal trading outlook led analysts to downgrade full-year profit estimates. Martin Evans of Hoare Govett slashed his taxable forecast by pounds 30m to pounds 150m before exceptional items. The shares dived 44p to 432p.

Courtaulds said the closures would cost about pounds 52m this year and were prompted by difficult trading conditions and falling exports to the Far East, which was becoming increasingly self-sufficient.

As a result it was accelerating its plant closures in Europe and would also integrate the aerospace sealants business with its coatings arm. The changes will reduce the number of coatings factories by a third to 12. Most of the job losses will be in Continental Europe although about 100 could be lost in Britain.

The group is expanding in other sectors. It is building a second factory to produce Tencel, a synthetic fibre, at a cost of pounds 90m, to meet growing demand in the US and Japan. The plant will more than double production capacity. Separately, it is also setting up four plants in the Far East.

Sipko on the merger of Fibres with Hoechst and Tencel in US (1993)

Sipko Huismans, Courtaulds' chief executive, observed: 'If you want to be in Eastern Europe, you have to start by positioning yourself in Germany,' as he announced the group's decision to merge its European fibre interests with those of Hoechst. Courtaulds is scarcely about to storm the Urals in pursuit of profits, but Mr Huisman's point about the importance of geographical positioning is well made.

Size brings not only savings of scale but makes it easier to exploit new products. One of the main reasons Courtaulds concentrated on the US rather than Europe when it came to releasing Tencel, its latest fibre, was that its stronger base in the US made for a safer launch-pad.

So Courtaulds' neat alliance with its German competitor, in which it will clearly be the dominant force, strengthens its Continental hand considerably, catapulting it into near pole position - aptly enough for a company that sponsors Ayrton Senna's Marlboro McLaren racing team.

Courtaulds closing 6 coatings plants, expanding Tencel (1993)

COURTAULDS, the chemicals and fibres group, yesterday surprised the City with a plan to shut down six manufacturing plants with a loss of 650 jobs in Europe.

Courtaulds said the closures would cost about £52m this year and were prompted by difficult trading conditions and falling exports to the Far East, which was becoming increasingly self-sufficient.

As a result it was accelerating its plant closures in Europe and would also integrate the aerospace sealants business with its coatings arm. The changes will reduce the number of coatings factories by a third to 12. Most of the job losses will be in Continental Europe although about 100 could be lost in Britain.

The group is expanding in other sectors. It is building a second factory to produce Tencel, a synthetic fibre, at a cost of £90m, to meet growing demand in the US and Japan. The plant will more than double production capacity. Separately, it is also setting up four plants in the Far East.

NEIL THAPAR , the independent

 

THURSDAY 18 NOVEMBER 1993

COURTAULDS TO EXPAND US TENCEL PLANT, HINTS AT EUROPEAN PRODUCTION (1993)

Courtaulds is to install a second production line for Tencel solvent spun cellulosic staple fibre at its plant in Alabama, USA, at a cost of $134m and may build a production facility in either the UK or Germany. The current line has capacity of 18,000tpy and this will be increased to 43,000tpy when started up in August 1995. Tencel is the most commercially successful of the lyocell fibres currently available and is most used in women's clothing, denim jeans and chambray shirts. It is produced by dissolving woodpulp in solvent, which is then recovered, and has high wet strength and excellent fibrillation possibilities when subjected to high energy water jets. This fibrillation capability means that spunlaced constructions may be formed by bonding with other fibres, which then have high strength and good filtration properties.

Anon., Nonwovens Rep. Int., no. 273, Dec. 1993, p. 3

The mention of the possibility that an EU Tencel plant could be built in Germany might have been to encourage the UK government to provide a grant for Grimsby.  

DAVID COLE: ENZYME FIBRILLATED TENCEL IN APPAREL FABRICS (1993)

By 1993 fibrillation was firmly established as the unique selling point for Tencel in apparel thanks to the Japanese development of enzyme treatment which dissolved the outer "cuticle" of the fibre and allowed the microfibre structure to be raised in finishing.  The resulting peach-skin texture was highly fashionable and the demand for Tencel led to the new Mobile plant rapidly reaching capacity,

Courtaulds' new cellulosic fibre Tencel exhibits properties superior to those of existing man-made cellulosics and is made by an environmentally compatible solvent spinning process. Of highly crystalline composition Tencel shows high dry and wet strength and has a high modulus. The concept of Tencel is completely different from that of viscose fibres, reflecting the innovative employment of enzymes to change the character of fabrics. The fibrillating character of the fibre can be exploited to create different aesthetics. Indigo dyeing represents just one example of the creation of a totally new fabric type based on Tencel's unique properties.

Cole D., Paper presented at 32nd International Man-Made Fibres Congress held at Dorubirn, Austria, 22-24 Sept. 1993, no. 62, 9pp [Vienna, Austria: Osterreichisches Chemiefaser-Institut, 1993]

The full paper is available here

LENZING TO DISTRIBUTE FIBER IN JAPAN THROUGH EXCLUSIVE AGREEMENT (1993)

A rare mention of the Akzo invention of lyocell fibre and an early mention of Lenzing licencing the Akzo technology presumably to accelerate their commercialisation of the fibre.  (Lenzing's acquired the BASF viscose plant - formerly Akzo - in Lowland Tennessee, which they modernised at a cost of ~$90m.)

Moririn Co. Ltd of Japan has acquired exclusive rights to import solvent spun cellulosic fibre from Lenzing AG into Japan. The fibre competes with Tencel fibres from Courtaulds and produces no pollution during manufacture, as solvents used may be recovered completely after extrusion. It is suitable for use where wet strength is important (e.g. medical applications), for battery separators and pre-moistened wipes. It has excellent dyeing capabilities. It was developed under licence from Akzo Fibers BV of Holland, holder of the basic patent, and will be launched in Japan in 1994. The fibre is profiled and has micro-crimps, which improve elasticity and smoothness when woven. Moririn also acquired exclusive import rights for high wet modulus cellulosic fibre.

Anon., Nonwovens Mark., vol. 8, no. 12, 4 June 1993, p. 8

COURTAULDS AND HOECHST LINK TO PROMOTE NEW FIBRE (1993)

Courtaulds's Tencel fibre will be promoted in Europe via a joint venture formed by the merging of Courtauld's viscose and acrylic fibre operations with those of the German chemicals group, Hoechst. Courtaulds will have a £238m share of the £369m combined sales of the operation. Success in the Japanese market has brought Tencel into profit. The material looks like denim but feels like silk. Despite being developed in the UK, it is manufactured in Alabama, USA. Courtauld's profits for the year ending March 1993 were up from £186.3m to £192.7m. The merger is subject to the approval of the European Commission but will put Courtaulds into a leading position in Europe if it goes through.

Sivell G., The Times,  no. 64,655, 27 May 1993, p. 27 

(News to me!  I had no idea Tencel was part of the logic for acquiring Kelheim.  However several other sentences don't ring true so maybe its a cub reporter - or abstractor - at work.)

JIM JAMES: THE TENCEL STORY (1993)

This paper looks at the development of Courtaulds Fibres' solvent spun cellulosic fibre Tencel. Tencel is the first commercially available cellulosic in the new lyocell classification. The first Tencel plant has been in operation in the US since 1992 supplying Tencel fibre to the major markets of the US, Europe and Japan. A major property of Tencel is its high modulus both in the wet and dry state which is determined by the fibrillar structure of the fibre. The strength of Tencel allows for effective blending with other fibres and leads to  high fabric stability. By selecting specific processing and finishing conditions, a large variety of different features such as handle, yarn regularity and fluidity can be imparted to the fabric.

James J.,  Paper presented at Microfibres - the State of the Art and their Future held at Ghent, Belgium, 19-20 Oct. 1993, 6 pp 

DAVID BERTRAM: CELLULOSIC FIBERS IN HYDROENTANGLEMENT (1993)

This paper considers how a broad range of fibres behave in hydroentanglement. It is based upon results from a new pilot line at Courtaulds Research in the UK which uses the Perfojet hydroentanglement system. The fibres studied were cotton, polyester, rayon and Courtaulds new solvent spun cellulosic fibre Tencel. The experimental procedures of the study and the trial results indicating fibre performance in hydroentanglement are detailed. The influence of fibre type, length, cross-section and fineness are discussed. The hydroentanglement efficiency of all the cellulosic fibres was good. Tencel fibre gave good wet and dry fabric properties in comparison with the other cellulosic fibres studied. Polyester fibres tended to be more difficult to entangle, resulting in bulky, less well consolidated fabrics but with good wet strength.

Bertram D., INDA J. Nonwovens Res., vol. 5, no. 2, Spring 1993, pp 34-41 

COURTAULDS HAS DESIGNS ON TENCEL FOR THE NEXT CENTURY (1993)

This is the first announcement of SL2, the Mobile plant expansion.  Clearly some aspects of the release failed to get across.  The fact that SL1 made a profit in its first year thanks to Japanese marketing, fashion and "shaping in acid baths" - whatever that was - is notable though.  I guess the "twice as much" referred to fabric not fibre costs.  If the original article surfaces it will be posted.

A new plant costing $134m manufacturing Tencel is to be built by Courtaulds in Alabama USA. Tencel costs twice as much than its rivals to produce but is proving popular within Japan and amongst certain fashion houses. It is very strong and can be shaped by treatments like acid baths; it is proving so popular that it made a profit in its first year of commercial sales. This new installation will increase Courtauld's production of Tencel from 18,000 to 43,000tpy, with another site planned in Europe in 1994.

Gilchrist S., The Times, no. 64,084, 18 Nov. 1993, p. 30