Author: dev@ifgdev

To recycle PA, the waste from IFG’s production is collected and sent to a specialised recycling company. They clean the collected waste and put it through a process of depolymerisation, where large polymer molecules are broken down into smaller units called monomers. After cleaning the material to remove impurities, they repolymerise it. Once this process is complete, the recycled polymer is returned to IFG. Afterwards, we proceed with fibre spinning and incorporating necessary additives tailored to meet our customers’ specifications. 

Compared to virgin PA, recycled PA offers a significant decrease in CO2 emissions – at IFG, its carbon footprint is lowered by 78 %! Certificates confirming the carbon footprint values of our fibres are available upon request. 

Despite this reduction, the recycled PA retains the same qualities as the virgin PA. This enables their versatile use across all PA6 applications, demonstrating our commitment to sustainability without compromising performance or customization options. 

To continue with the important topic of sustainability at IFG, we are committed to offer not only recycled polypropylene (rPP), but also recycled polyamide (rPA).

During July 2024, Vladimir Vykoukal joined the team at IFG Asota, Linz, Austria as an intern.

Early in July, Vladimir introduced himself:

“I am 22 years old and I come from the Czech Republic. I study international business as the University of Economics and Business in Prague. Besides my studies, I enjoy playing sports like tennis or football. I am also always eager to learn new things!”

We asked him about how he had found his first week:

“The first week working here at IFG Asota was really interesting. The team welcomed me warmly and we started working on a couple of projects focused on promoting sustainability at IFG. We have also started working on enhancing the website. It has been really rewarding to apply the knowledge I gained from my studies in a real company setting, and I am very excited to see what the rest of my internship has in store!”

During Vladimir’s second week, we asked him his general thoughts on sustainability in business – it’s always interesting to hear new views on the subject. Here’s what he had to say:

“These days, “sustainability” is often overused and is used in a lot of marketing campaigns of big companies. For me personally, it is important that it is not just a marketing strategy, but that the company really follows a sustainable path.

There is no doubt that climate change is a real thing, and we need to act to prevent it. It is not an issue that could be solved by one person alone, it requires collective effort. While consumers can make a difference by sorting waste, choosing eco-friendly products, and reducing energy and water usage, a lot can also be changed by businesses.”

 

In week 3, Vladimir shared more of his thoughts on the sustainability practices at IFG:

“I’ve been really impressed by what IFG is doing to be more sustainable. The R&D team is continuing to come up with more sustainable innovations. IFG is using more and more recycled and bio-based materials in their production. It’s important that companies are starting to apply changes like this.

Now, these actions seem complicated, they may be more expensive or time consuming, but in the future they will be worth it.

During my internship, I learnt a lot about IFG’s different fibres. As I am working on the Sustainability Promotion Project, my focus was on the recycled and bio-based fibres.

To get a better overview, the Asota team and I tried to summarise the key characteristics of sustainable fibres in a graphic

While learning more and more about sustainable fibres, I realized that there is a clear trend à higher sustainability and performance comes at a higher cost.

To be more sustainable, companies need to invest more. This could decrease their short-term profitability, but as I already said last week, these actions will pay off in the future.”

Finally, we asked Vladimir to summarise his time at IFG.

“My father works as a representative for IFG and was able to introduce me to them. It’s important whilst studying International Business to get real-time experience at a company that operates internationally, and for me to see first hand how it works. I have gained some valuable inside experience of business issues experienced in the real world.

I have largely focused on marketing, which will play its part in any future role I have, even if it’s not my sole focus. The key things I have noted during my experience is the attention to detail required in marketing to ensure the company is represented correctly and that we are presenting facts in any campaigns that the company runs. IFG really cares about the work they do and want to be the best in the industry.

Chemistry and Physics aren’t necessarily my strong point, however R&D leader Andreas really helped me to understand the technical details of the fibres.

Most of my time was spent with Debby – we got on really well, and with her experience we worked together and came up with some really good ideas – together we worked on presenting some suggestions to the wider marketing team, of how things could be improved. We also worked on some case studies of real life applications of IFG’s fibres.

IFG Asota is a small team with a friendly atmosphere, everyone was very welcoming and friendly.

I would definitely recommend IFG Asota as a place to undertake an internship. The team is welcoming, products are interesting and as they have a lot of uses, their fibres are really important in industry. It was great to get experience in both business and learn more about the technical aspects of fibre production.

The key takeaway is attention to detail – marketeers really need to consider how their writing can influence the perception of information.

I am really grateful for the opportunity that IFG gave me. It has been a really nice experience being in Linz for a month, living in a different country. I met new people, had many new experiences. We will keep in touch and I hope our paths cross again in the future.”

Vladimir’s blogs and social content ideas will be rolled out over the coming months, we thank him for his time spent at the company and his valuable contribution.

With over 30 years’ experience in the sector under our belt, IFG’s fibres can create durable and hard-wearing surfaces for use both inside and out. We can design and produce fibres for a variety of indoor and outdoor applications, all fully colour-customised with UV resistant additives with a carefully selected range of colour pigments to provide the full range of shades required. Examples of our work include sports and utility surfaces, children’s play areas and swimming pool areas. 

IFG PP and PE fibres are melt-spun and specially developed for processing into a wide range of products. These fibres are suitable for being processed into needled and thermo-bonded felts and yarns. Today there is a growing market for technical applications in both nonwovens and spun. 

Additional UV protection is required for certain applications to help increase the lifetime of the final product. Here at IFG we offer a wide range of UV grades and protection, including: 

• No Additional UV stability – This type of fibre is mostly used in applications where there is no exposure to sunlight, such as composites in “non-visible” products, which are widely used in automotive products such as wheel arches and compartment liners. 
• LOW UV stability – Fibres in this version of UV-stability have UV-stabilisers added to meet the requirement of a certain lifetime of the final product. This meets the majority of applications; it is associated with a half-life of the fibre strength of a minimum of 1000 hours, meaning that after 1000 hours of exposure, the fibre still retains at least half of its original strength. 
• MEDIUM UV stability – Fibres with medium UV stability have a higher content of additives, which makes it possible to obtain products for outdoor applications, like sports surfaces or artificial grass. Half-life time reaches 3000 hours. 
• HIGH UV stability – Due to various climatic conditions with extreme UV radiation, we see a demand for super UV-stabilised fibres with a long service life. In these cases, we have developed a synergistic blend of UV stabilisers that can give a half-life time up to 4000 hours. 

 

All our UV packages and tailored formulas are available with both natural and coloured fibres and can be used along with other performance additives. 

We are delighted to be exhibiting at Techtextil in Frankfurt from the 23rd to 26th April 2024. Please do come and visit the team in Hall 9.1 Stand number D50. We look forward to seeing you there!

Techtextil is the leading international trade fair for technical textiles and nonwovens, which IFG have been exhibiting at since 1986. As a result we are delighted to be being honoured as a founding exhibitor on Wednesday 24 April at 09:00 a.m. in the Techtextil Forum in Hall 9.1, Stand E70.

What are they, what are they for, and why are IFG’s the best? 

Low melt binder fibres are fibres with a low melting point. When they are utilised without any pigment being introduced, they produce a clear melt effect. Low melt binder fibres are mainly used for floor coverings, for example carpets. 

Historically the preferred material for binder use was latex, but this is becoming less popular due to not being recyclable and therefore having a poor environmental impact. Using melting binder fibres as a latex substitute improves the recyclability of the end product. IFG’s binder fibres are made from 100% low melting polymer derived from PP and PE (Polypropylene and Polyethylene) 

Depending on construction and specific product requirements, the blending ratio of PE fibres with for example PP fibres can vary. A thermal treatment of approximately 125°C is required to create a bonding effect. 

At IFG, our unique approach to colouring allows us to match any given colour to our fibres, using a range of tried and tested techniques, and the best colourists in the industry. We use a mixture of pure pigments and computer assistance to develop our coloured fibres. This results in us both meeting and exceeding customer expectations, setting us apart from our competitors. 

Once the colours are developed, their application to client specific products is tested on our pilot line – the samples provided show the customer how the pigments harmonise and gives them the chance to view the fibres before they go into production. 

We’ve seen colour trends change significantly over the last few years, with a growing demand for more muted tones as opposed to the strong and vibrant colours we saw historically. Our ability to shift our colour production processes in line with industry trends is another way we set ourselves apart from the competition. 

We also need to make sure that our colours work well with other fibres additives as these develop – UV filters, water repellents and antimicrobial properties are regularly requested, and it’s important that the colour additions work well alongside. 

We are able to colour across our range of PP, PE, PA and PLA and offer customised solutions. We continue to invest in research and development across our entire offering, bringing us in line with our customers exacting expectations. 

Richard Hart started at IFG Drake (Huddersfield, UK) as Production Manager in July 2023.  Bringing with him a wealth of experience from a range of manufacturing firms, Richard has implemented a series of changes since his arrival, all with the aim of improving IFG’s manufacturing processes. 

We chatted to Richard about his first few months in the role, the best practice he has brought to the company, and his plans for the future: 

Tell us a bit about life before IFG. 

“Before starting with IFG in July 2023, I was working for a company that specialised in PVC compounding and extrusion.  Given that the extrusion process was similar to that at IFG, it was all very familiar!  Prior to that I have worked for a number of food & FMCG manufacturing companies, including HJ Heinz, McVities and Nice-Pak International.  They all have Lean manufacturing processes embedded in various stages, and the Lean process is something I am developing further with the IFG team, using the most appropriate practices taken from my experience.” 

How are you implementing Lean Manufacturing into IFG’s processes? 

“The key thing is to work out where the company is at on its Lean journey, what’s working and what’s not, and make changes and additions which complement and enhance what’s already in place. All staff are encouraged to bring ideas and suggestions to contribute to improvements.  Because of this engagement there is lots of enthusiasm amongst the teams for the new ways of working and implementation of related projects, with an overall goal of achieving a Lean Culture.” 

What training have the team had to undergo to facilitate this transformation? 

“Utilising an external Lean specialist, we have 10 delegates from the company undertaking a 12-month Level 2 Lean Operative Manufacturing course, including four shift managers and their deputies. This is due to finish in Summer 2024.  Part of the course includes each delegate implementing a Lean improvement project, which is leading to many improvements as a result of the training.” 

 What are the key components of a Lean Culture? 

 “We are concentrating on two elements that will give us the biggest leap forward in terms of a Lean culture. These are 1) Leader Standard Work, and 2) Daily Accountability Improvement Process.  

 1) Leader Standard Work (LSW) involves defining the key activities that a leader needs to undertake on a day-to-day basis.  This includes elements of safety, quality, people, process and production management, utilising a pre-defined worksheet.  The benefits of this ensure that the key tasks required to have a successful day or shift are completed, and it also gets all managers working in the same way.  Adopting LSW throughout the production teams reinforces structure, consistency and routine to manage effectively.  Knowing that the basics to achieve a successful shift are covered, it frees up leaders to be more creative, adding value via Lean improvement projects. 

 2) The Daily Accountability Improvement Review is a review of the preceding 24 hours’ production in a very structured meeting.  By discussing a number of performance metrics versus targets and standards we are able to identify whether production and its associated metric are on track or not.  In the event of a metric deviating from target or standard, an improvement will be agreed to rectify the deviation.  Since we started this process 3 months ago, more than 60 improvements have been raised and implemented.  One of the benefits of focusing on improvements as opposed to issues is that it creates a positive culture of accountability rather than a blame culture.” 

 What benefits have you seen from implementing these processes since you started? 

 “It’s clear that there is already a very positive and collaborative working environment within IFG, and everyone works together and supports each other.  The structure that comes about from implementing these processes allows for a calmer, more organised workplace with clear indication as to whether we are on target or not.  The way of working that has been created allows the senior management team to focus more on strategy and ‘the bigger picture’ without getting too involved in the detail.  The team are encouraged to work autonomously which generates a positive atmosphere throughout the business.  The team are able to achieve a high degree of job satisfaction by seeing their ideas put into action.” 

 So what are your next plans? 

 “Over the next 12 months we are introducing a new training programme, to improve the skillset of the production team.  We will introduce a ‘topic of the month’ in which all the team members will be trained.  In total we have over 40 people taking these training modules which range from health and safety, environmental and HR topics.” 

 Are you enjoying the role? 

“The role is a really motivating one and it is a very interesting time to join this organisation where it is, on its Lean journey.  The way to advance the organisation rapidly is to make many small improvements, via a structured improvement process, and never stop learning. This advances the maturity of the company in terms of Lean with everyone pulling together and moving forward. 

 The team here are truly receptive to change and improvement.  Long may it continue!” 

Dear IFG Customer,

Due to a continuation of rising inflation throughout 2023, we find it necessary to implement a price increase on the sale of IFG products for 2024, to ensure we maintain the high level of product quality, service, and innovation we provide to our customers.

We aim to do this in a fair and transparent manner and undertake to continually monitor the situation throughout the year.

We appreciate that this will not come as welcome news in the continuing difficult climate. However, we hope you understand the justification behind this decision and thank you for your understanding through these still challenging times.

Your sales representative will be in touch with you to provide further detailed information and answer any questions you may have.

Yours sincerely

 

Richard Barker-Poole

Group Sales Director

International Fibres Group

Introducing Rachael Doran, HR Manager at IFG Drake, Huddersfield, UK 

September 2023 saw IFG Drake in Huddersfield welcome Rachael Doran as HR Manager. With four short weeks under her belt, we caught up with Rachael to find out more about her. 

Rachael’s recent roles included working for a UPVC window manufacturer, and previously for an automotive manufacturing company, who were a direct customer of IFG, so she had some previous knowledge of the business and what it does. Her previous company were supplied with IFG fibres as raw material to manufacture into car components including wheel arches and heat shields. 

Having had some previous experience of IFG as a supplier, alongside a strong manufacturing background, when Rachael saw the opportunity for a part-time HR Manager at Golcar, she leapt at the chance. The role tied in perfectly with her desire for an improved work-life balance that would allow her to continue a career she loves, whilst also caring for a young family. 

So how have the first four weeks been? 

“The people here are lovely and so helpful”, says Rachael, “They really can’t do enough for you. It’s such a good culture here, with multiple team members who have been here for their whole working lives. The company promotes development from within, and has seen staff start at factory level and work their way right through the company into management positions. This enables organic growth of people and the company itself, whilst maintaining the industry knowledge that goes with a huge breadth of experience within the organisation.” 

“People who work at IFG are hugely passionate about what they do. Everyone is empowered, and encouraged to suggest improvements wherever they can, especially in Health and Safety and Production. Any new starter here can easily see the opportunity for personal development, with a clear development platform to climb the career ladder and go as far as they would want within the company.” 

Rachael is currently recruiting for two posts – for more information on those visit the careers page here: Careers – IFG – International Fibres Group 

IFG Exelto (Belgium) are delighted to have received the BQA Certificate of Quality Management for Recycling and Production Companies – QA-CER system 2 in honour of our development, production and sales of recycled staple fibres.

BQA is an accredited certification body with a focus on system certifications for SMEs, both active in industry and services. The expertise of their auditors in the various sectors, their reliability and their independence form the basis of their approach.

BQA QA-CER Recycled Content is an international, independent, third-party certification system based on EN 15343 following the principles of ISO 9001, including chain of custody. It goes beyond ISO 14021, in that it identifies all possible waste streams that can be recycled so that it offers a comprehensive system.

‘Recycled content’ refers to a product that contains recycled materials. Recycling is an essential part of the circular economy and is grounded in the belief that our planet has only a finite amount of resources.

Rising economic activity and growing demand for materials make the familiar linear economic model unsustainable. Therefore, there is an urgent need to shift to a circular economic model based on the continuous reuse of materials and products in the economy. Repair, reuse and recycling are essential elements in this economic model and are an intrinsic part of IFG’s commitment to a sustainable future.

A company certified to QA-CER recycled content proves to independent and expert auditors that they have implemented a monitoring system for their production sites that allows them to determine the recycled content of their products. Those companies must be able to prove this continuously to independent auditors.

What does QA-CER recycled content mean?

the possibility of building a relationship of trust between companies and customers regarding recycled content

a tool for companies to demonstrate their efforts and ambitions to add value to the circular economy by using recycled content in their products

a tool that allows consumers to make informed purchasing decisions in order to contribute to a circular economy

For more information on the requirements of the certification, download the pdf here:

https://www.bqa.be/en/system/files/attachments/requirements_qa-cer_v3_e_1.pdf