Technical Textiles: Creating Value for Spunbond Textiles: Creating Value for Spunbond Nonwovens Presented at: THE SOUHTERN GUJARAT CHAMBER OF COMMERCE INDUSTRY, SURAT,

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  • Technical Textiles:Creating Value for Spunbond

    Nonwovens

    Presented at: THE SOUHTERN GUJARAT CHAMBER OF COMMERCE & INDUSTRY, SURAT, INDIA

    MARCH 24, 2014

    Uday Turaga, Vinitkumar Singh, and Seshadri Ramkumar

    Nonwovens and Advanced Materials Laboratory, Texas Tech University, USA

    Email: s.ramkumar@ttu.edu

  • Technical Textiles?

    Where is money in technical textiles?

    How to grow the industry and make money?

  • Answers

    The answer lies in the THREE major product categories:

    1. Consumer tech products

    2. Institutional tech products

    (infrastructure, hospital or major bulk procurement items)

    3. Government procurement products

    Source: New classification pertinent to developing countries developed by Seshadri Ramkumar, Texas Tech University, USA.

  • Textile materials and products manufactured primarily for their technical performance and functional properties rather than their aesthetic or decorative characteristics.

    Textile terms and definitions

    The Textile Institute

    Technical Textiles-Industry Definition

  • Technical Textiles are value-added textile products that provide added functionality and applications other than regular fiber-to-fashion supply chain products

    These technical textiles encompass high performance fibers, yarns, woven, knitted, nonwoven, braided and composite structures

    What are Technical Textiles ?

  • Thrust

    Thrust will be to grow the sector that produces products that are close to end-users or where the

    value is!!

  • Are Nonwovens Technical Textiles? Most of the nonwovens are technical textiles as they have not yet penetrated into the apparel sector

    Nonwovens are predominantly disposable and semi durable goods

    All nonwovens are technical textiles but all technical

    textiles are not nonwovens

  • Technical textiles can be any fibrous material and their combination with other items which have NON-APPAREL applications, excluding paper

    Technical Textiles Simple Understanding

  • Raw cotton with bark, seed coats and trash is a TECHNICAL TEXTILE!

    Situations create new technical textile products

    Generally, margins are high

    Amazing Reality

    Oil Absorption by FiberTect

  • Current Status of Indian Textile Industry

    Indias current textile and apparel market size is estimated to be USD 90 billion

    It is projected to reach USD 220 billion by 2020

    Adequate focus on value-addition and value-enhancement will enable India to be a textile power house

    Source: Seshadri Ramkumar, TexSnips, January 7, 2014

  • Global Nonwoven Market Scenario

  • Global nonwovens consumption was

    estimated to be 161.3 billion (square

    meters) in 2010 and is projected to be

    250.4 billion (square meters) by 2015,

    with a CAGR of 9.2%

    Global Market for Nonwovens

    Source: The Future of Nonwov ens to 2015: Global Market Forecasts, New PIRA International Market Report,http://www.smitherspira.com/core/downloaddoc.aspx?documentid=4971

  • Global Market for Medical Nonwovens

    Majority of the market

    will be driven by

    increased demand

    for wound care, adult

    incontinence and

    health care wipes

    Source: The Future of Medical Nonwov ens to 2018, New PIRA International Market Report, https://www.smithersapex.com/market-reports/nonwovens/medical-nonwovens-industry-forecasts.aspx

  • Worldwide: Demand for Technical Textiles

    Source: IFAI Specialty Fabrics Review, February 2012 and Transparency Market Research, USA, July 5, 2013

    Asia Pacific Region

    Real Power Engine for Global

    Technical Textiles Market

  • Asias Influence on the Global Technical Textiles Market

    Source: IFAI

    Key Markets

    China

    India

    South Korea

    Taiwan

    Key Sectors

    Automotive

    Infrastructure

    Agriculture

    Protective textiles

    Medical & Health Care

    Asian Technical

    Textiles Market Share

    in Global Technical

    Textiles Market

    In 2011, 45%

    In 2018, 61%

    (expected)

  • Outlook for Worldwide Nonwovens Production (millions of tonnes)

    Source: INDA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)

    2006 2011 2016Growth Rate

    2006-2011 (%/Year)

    Growth

    Rate2011-2016 (%/Year)

    NAFTA 1.61 1.87 2.2 3.00% 3.30%

    Europe 1.56 1.95 2.6 4.60% 5.90%

    China 0.97 1.65 2.82 10.50% 12.00%

    Other Asia

    Pacific 0.51 0.59 0.78 3.00% 5.70%

    Japan 0.33 0.33 0.35 0.00% 1.20%

    Middle East 0.26 0.32 0.45 3.60% 7.70%

    Rest of

    World 0.44 0.9 1.88 16.60% 14.60%

    TOTAL 5.68 7.61 11.08 6.00% 7.80%

  • Outlook for Worldwide Nonwovens Production

    Source: INDA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)

    1997 2002 2011 2016

    Growth Rate

    1997-2010

    (%/Year)

    Growth Rate

    2011-2016

    (%/Year)

    Dollars

    (billions)$11 $15 $26 $37 6.2% 7.8%

    Sq Meters

    (billions)61 93 205 305 8.7% 9.0%

    Tonnes

    (millions)2.7 4.0 7.6 11.1 7.7% 7.8%

  • Growth Prediction of Technical

    Textiles in India

  • Technical Textiles Growth in IndiaGeneral Idea

    Cover Story in Modern Textiles, April/May 2008

    Nonwoven and Technical Textiles, January/March 2008

    13.3 % CAGR for India

  • Diversification into Non-commodity Textiles

    Indian textile industry should go on a higher gear in diversifying into unconventional textiles

    Even after 30 years of organized sector status, the nonwoven and technical textile industry is growing at a rate of 6 % in USA and Europe

    This sector is at infancy in India and offers tremendous growth and opportunities until 2050

  • 2011 Asian Nonwovens Market 2.6 million tonnes

    Source: INDA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)

  • Technical Textile Scenario in India

    Technical textiles consumption in India is one-fifth of total Asian consumption

    Employs about 800,000 people and 55% of employment needs technically skilled manpower

    Employment is expected to grow at an annual rate of 13% to reach

    2.6 million by 2016-17

    Source: Seshadri Ramkumar, TexSnips, July 3, 2013

  • Technical Textile Scenario in India

    Indian nonwoven textile production is just 3% of Asian production

    Technical Textiles Sector in India to Reach $ 26 Billion

    Expected annual growth rate- 20%

    Source: Seshadri Ramkumar, TexSnips, July 3, 2013

  • Consumption Of Nonwovens/TT in India Vs. GDP Per Capita

    (Assuming An Increase Of 13.27% In Per Capita Every Year)

    GDP per capita source: World Bank

    YEAR GDP PER CAPITA (US$) CONSUMPTION OF NONWOVENS/TT (kg)

    2005 733 0.08

    2010 1374 0.15

    2015 2563 0.27

    2020 4780 0.51

    2025 8912 0.95

    2030 16618 1.77

    2035 30985 3.31

    2040 57773 6.16

    2045 107720 11.49

    2050 200850 21.43

  • Consumption Of Nonwovens/TT in USA vs. GDP Per Capita

    (Assuming An Increase Of 4.6% In Per Capita Every Year)

    YEAR GDP PER CAPITA (US$) CONSUMPTION OF NONWOVENS/TT (kg)

    2005 42499 3.5

    2010 52435 4.32

    2015 65656 5.41

    2020 82213 6.77

    2025 102943 8.48

    2030 128901 10.62

    2035 161404 13.29

    2040 202103 16.64

    2045 264705 20.84

    2050 331452 26.10

    GDP per capita source: World Bank

  • India vs. USA Per Capita Nonwoven/TT Consumption (2005-2050)

    GDP per capita source: World Bank

  • Indias Per Capita Consumption vs. Income Levels (2005-2050)

    GDP per capita source: World Bank

  • India: Technical Textile Scenario 2007-2017

    Source: Seshadri Ramkumar, TexSnips, July 3, 2013

  • Why Then the Indian Technical Textiles Industry has not Grown Yet?

    Requirements for the growth of technical textiles sector in India

    1) Lack of awareness on how to make finished or converted technical

    textile products

    2) Marketing know-how to sell and trade technical textile products

    3) 1-0-1 basic marketing class on technical textiles

    4) Technical textiles sector in India should know where and how

    technical textiles are used on a daily basis

  • Global Perspective of Technical Textiles in

    India

    Indias specialty fabric and nonwoven industry is fragmented and still in its infancy, with no state-of-the-art technology in place compared to global players

    Textile industry is also undergoing a major reorientation from apparel to specialty fabric applications

    Specialty fabrics now accounts for more than half of the total textile production in India

    The focus of the government is on upgrading infrastructure (geosynthetics) and increasing the use of automotive textiles (nonwovens)

    Other niche areas: Safety and protective (defense), medical textiles, agriculture (nets, shading, mulch) and filtration fabrics

    Source: IFAI

  • Conclusions(with specific reference to India)

    It is extremely important for the Indian textile industry to diversify into durable technical textiles and disposable nonwovens

    Technical textiles should at least contribute 15 -20 % of the total textile sector by 2015-2020

    Our growth prediction is that the industry should grow in double digits around 13 %

  • Spunbond Nonwovens

  • Global Market for PP Spunmelt Nonwovens

    Estimated to be 2 million tonnes in 2011 and is projected to reach 2.4 million tonnes by 2015

    Chief drive of this market is the hygiene sector

    In the hygiene sector, global demand for spunmelt nonwovens was estimated to be 65 billion square meters in 2011 and is projected to reach 80 billion square meters by 2015

    Source:Spunbond Polypropylene Available from: http://www.nonwovens-industry.com/issues/2012-02/view_features/spunmelt-polypropylene/

  • Leading Global Nonwoven Producers

    Company name Revenue (USD)

    Freudenberg 1.45 billion

    DuPont 1.40 billion

    Kimberly-Clark 1.30 billion

    Ahlstrom 1.30 billion

    Fiberweb 947 million

    Johns Mansville 670 million

    Fibertex 295 million

    AVGOL 254 million

    First Quality Nonwoven 250 million

    Source:www.nonwovens-industry.com; Available from: Edison Investment Research estimates, Nonwovens Sector Report, January 2010

  • Nonwovens vs Polypropylene Nonwovens

    Source:Edison Investment Research estimates, Nonwovens Sector Report, January 2010

  • Market Share of Raw Materials for Nonwovens in 2010

    Source:PIRA International Ltd. Available from: https://www.smitherspira.com/market-reports/double-digit-asian-growth-to-drive-global-nonwovens-market-to-2015.aspx

  • Spunbonding Process Flowchart

    Source:Malkan SR and Wadsworth LC: A Review on Spunbond Technology, Part I, INB, Nonwovens, Volume 3, 4-14, 1992.

  • Properties of Spunbond Nonwovens

    High tensile strength

    Excellent barrier properties

    Breathability at lower grammages

    Can be made absorbent

    Source: How to start sell ing PP Spunbond fabric in India. Available from: http://nonwovenindustryupdate.wordpress.com/2012/04/22/how-to-start-sell ing-pp-spunbond-nonwoven-fabrics-in-india/

  • Spunbond Polypropylene Nonwovens

    Isotactic PP is the most widely used polymer for the production of spunbond nonwovens

    Provides the highest yield (fiber per kilogram) at the lowest cost because of its low density

    Necessitate the use of stabilizers as unstabilized polypropylene is rapidly degraded by UV light

    Fibers of inferior quality can be repelletized and blended with fresh polymer to reduce costs

    Source:Spunbond Technology Available from: http://www.engr.utk.edu/mse/Textiles/Spunbond%20Technology.htm

  • Spunbond Polyester Nonwovens

    Superior tensile strength, modulus and heat resistance properties compared to spunbond PP nonwovens

    Amenable to dyeing and printing with conventional equipment

    Expensive compared to spunbond PP

    Source:Spunbond Technology Available from: http://www.engr.utk.edu/mse/Textiles/Spunbond%20Technology.htm

  • Various Types of Spunbond Nonwovens

  • Hydrophilic Spunbond PP Nonwovens

    Baby diapers

    Training pants

    Feminine care

    Adult incontinence

    Source: General Nonwovens and CompositesAvailable from: http://www.generalnonwovens.com/default.asp?id=21

  • Agricultural Applications of Spunbond Nonwovens

    Crop covers

    Seed blankets

    Weed control fabrics

    Green house shadings

    Root bags

    Source: How to start sell ing PP Spunbond fabric in India. Available from:http://nonwovenindustryupdate.wordpress.com/2012/04/22/how-to-start-sell ing-pp-spunbond-nonwoven-fabrics-in-india/Figure available from: http://www.generalnonwovens.com/default.asp?id=26

  • Geotextile Applications of Spunbond Nonwovens

    Asphalt overlay

    Sedimentation and soil erosion

    Impregnation bases

    Drainage channel liners

    Separation reinforcement

    Roadside and drainage

    River and canal banks

    Source: How to start sell ing PP Spunbond fabric in India. Available from: http://nonwovenindustryupdate.wordpress.com/2012/04/22/how-to-start-sell ing-pp-spunbond-nonwoven-fabrics-in-india/

  • Applications of Fire Retardant Treated Spunbond Nonwovens

    Fireproof clothing

    Used in seats of air planes, trains and buses when sandwiched between upholstery and outer fabric

    Hotels, restaurants, hospitals and libraries

    Source:AVOCA Technical. Available from: http://www.avoca-group.co.uk/technical/spunbond/fire%20retardant%20treated%20spunbond/

  • Properties of Fire Retardant Treated Spunbond Nonwovens

    Durability even after multiple washings

    No toxicity

    Should stop burning when off the fire

    No emission of thick smoke, meltdown or droppings

    Source:AVOCA Technical. Available from: http://www.avoca-group.co.uk/technical/spunbond/fire%20retardant%20treated%20spunbond/

  • Nonwovens in Disposable Absorbent Hygiene Products

  • Where are Nonwovens Used in Disposable

    Absorbent Hygiene Products (AHPs)

    Topsheet or coverstock

    Leg cuff

    Core wrap

    Fastening systems

    Back sheet

    Stretch ears

    Landing zone

    Dusting layer

    Acquisition/distribution layer

    Source: http://www.edana.org/discover-nonwovens/products-applications/absorbent-hygiene-products

  • Advantages of Using Nonwovens in Disposable Absorbent Hygiene Products

    (AHPs)

    Excellent absorption

    Softness and smoothness

    Stretchability, comfort and fit

    Double fluid barrier effect allowing moisture to be absorbed and retained

    Strength, elasticity

    Stability and tear resistance

    Breathability

    Source: http://www.edana.org/discover-nonwovens/products-applications/absorbent-hygiene-products

  • PP Spunbond in Diapers

    Source: http://www.sustainablenonwovens.net/index.php?option=com_content&view=article&id=11819:webtor&catid=112:consumer-products-premium

    Huge Demand for disposable baby diapers throughout Asia

    Major Market led by China, India and the ASEAN countries

    Expected to grow from 29 billion pieces in 2012 to 65 billion

    pieces in 2020

    Demand for PP spunbond in Asia is projected to increase

    from 290,000 tons in 2012 to 750,000 tons in 2020

  • Diaper Market Overview-Asia Pacific

    2007 - 20 billion units 2015 - 45 billion units

    Source:Soft Nonwovens for Diaper Market: Publicly available information and ExxonMobil Chemical estimates

  • Schematic of a Disposable Diaper

    Source: http://www.edana.org/discover-nonwovens/products-applications/absorbent-hygiene-products

  • Schematic of an Ultrathin Sanitary Pad

    Source: http://www.edana.org/discover-nonwovens/products-applications/absorbent-hygiene-products

  • Schematic of a Belted Incontinence Product

    Source: http://www.edana.org/discover-nonwovens/products-applications/absorbent-hygiene-products

  • Value Addition to Spunbond Nonwovens

  • Plasma Processing of Nonwovens

    Plasma finish is a surface treatment to textile materials for imparting multiple finishes without water and the use of lot of chemicals and energy.

    Integration of Atmospheric Pressure Plasma Technology (APT) to nonwovens/conventional textile processing is economical and is eco-friendly.

    Source:Enercon Industries, Menomonee Falls, WI, USA

  • Market Value of Plasma Technology

    A typical Atmospheric Pressure Pl...

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