mr. b. s. pancholi | key issues and strategies for indian nonwoven industry

B. S. Pancholi & Dr S. K. Basu

Man Made Textiles Research Association, MANTRA Surat

Key Issues and strategies for Indian Nonwoven industry

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What is being discussed

Index1. Nonwovens -Current Indian Scenario

2. Key Issues with Indian Nonwoven

3. Major Hurdles for nonwoven industry

4. Strategic actions for sustainable growth of Nonwovens

5. MANTRA-COE: One stop solution provider for Nonwoven sector

6. MANTRA-COE: Infrastructure and facilities .

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Only 2% of the 3000 NW units have some international recognition.

Indian NW shares is only 4% of the entire World market share against its potential to have a world

market share greater than 10%.

WEB site on 2018 Nonwoven world business from Transparency Market Research Source

http://www.prweb.com/releases/2013/7/prweb10901676.htm

Percapita consumption of NW Nonwoven in India is 200 gm against the percapita consumption of the

world being 3.3 Kg

Majority of cash rich business men shy away to invest big in Nonwoven sector despite attending

Nonwoven seminars, workshops, exhibitions, promotional meetings

1. Nonwovens: Current Scenario

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CURRENT INDIAN NONWOVEN TECHNICAL TEXTILE SCENARIO:

2/3 of NW produced are commodity products (Packtech,Clothtech,Hometech and Sprotech) . Packaging,filtration,carpets,auomtive and Geotextile applications

1/3 of NW produced is niche or High end products.

Niche or high end products require R&D and Technology to be competitive in the world market

Majority of Commodity products are for durable applications and only very few are producing disposable and hygiene products.

Disposables have huge untapped market in India

Disposable products require high quality to be matched with international norms to substitute imports

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CURRENT INDIAN NON WOVEN TECHNICAL TEXTILE SCENARIO:

90% of the Technical Textile producers are SMEs

A majority of them produce only the nonwoven or Needle punched fabrics.

Converters purchase this product from them to convert and sell to make a larger profit than the Nonwoven fabric producers.

This is presumably because of lack of marketing capability with Nonwoven Fabric producers.

There is no effort to make differential products and hence most of them produce identical and undifferentiated products.

With out own marketing teams and undifferentiated products in commodity applications lead to low and marginal profits.Some of them have faced losses and under closure

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2. Key issues with Indian Nonwoven industry

It is a proven philosophy that every EFFECT has a CUASE

There are few but highly successful NW investors who are growing by leaps and bounds in the same industry.

Hence the problem for not making enough profits from Nonwoven investment is not due to lack of demand or potential.

Industry experts feel that the most critical reasons for failure to grow are :•HERD mentality•Production Focus•Lack of expert advise and Guidance

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2.Key issues with Indian Nonwoven Industry

1. HERD mentality: Blind following others unthinkingly.Most jumped into the bandwagon of Nonwovens for shopping bag applications assuming that they are ultimate substitute for plastics but do not realize that nonwovens are equally not bio-degradable.

2. Production Focus: Let me produce and people will automatically come to buy.Marketing and distribution as well as profit is sacrificed to convertersCommodity products especially require great marketing and distribution efforts and differentiation by value addition and quality.

3. Lack of expert advise : No expert consultant approached or allowed themselves to be conned by half-baked consultants giving misleading information and having their own profit making goals.

4. Poor technology selection : Purchased obsolete or poorly designed technology which have limitations on productivity, profitability and quality

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No Clear guidance on product identification to product launch

Market development through promotional effects may add more cost to the project.

No regulatory or mandatory requirements imposed on use of Technical

textiles by Indian government unlike developed countries.

Therefore Longer payback period for realizing the profits from the investment.

3. Major Hurdles for new entrants in the Nonwoven sector

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3. Major Hurdles for Existing Nonwoven manufacturers

Improper selection of machinery and raw materials due to lack of expert technical

advice...

Lack of required skilled manpower to give better cost effective production processes and

better quality products

No Product innovation efforts as they require R&D Trials which are found unaffordable by

them.

No efforts to match international quality parameters due to lack of expertise and least

efforts to put quality on forefront for competing with the global NW producers.

Very little marketing efforts to create demand through consumer awareness and

education programs

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4. Strategic Actions for sustainable growth of nonwovens

Investors need clear guidance for product identification to product launch.

Provide active assistance in the selection of raw materials, equipments and machineries.

Provide them with comprehensive project reports

Provide them comprehensive consultancy in market forecasting, market development and consumer awareness

programs.

Provide them technical knowhow on product innovation through pilot plant R&D studies at a very nominal cost.

Provide them quality assurance support through setting up quality specifications and standards, product testing

and process parameter optimization for getting right first time quality of the products.

YOU CAN GET SUPPORT FROM MANTRA TO PROVIDE ACTIVE ASSISTANCE FOR MOST OF THE ABOVE

REQUIREMENTS AS YOU CAN SEE FROM NEXT FEW SLIDES OF THIS PRESENTATION

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5. MANTRA-COE : One stop solution provider

MANTRA has 32 years R & D Experience.

Partner for COE in AGROTECH by MOT.

COE in Nonwoven by Govt. Of Gujarat.

Strong R&D data base and testing services capability well suited for Non-woven

technical textiles whose raw materials are derived from synthetic and manmade

fibres.

Well qualified and well experienced staff who have extensive experience to handle

all types of manmade textile based products and processes.

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5. MANTRA-One Stop Solution for Nonwoven sector

MANTRA can provide the following solutions to the Nonwoven industry

A.Product innovation

Development of prototype for new product.Techno-economic feasibility studies.Re-engineering of existing products

B.Process development and optimization.

Pilot studies for Development of process optimization standards.Pilot studies for Process modification and development for quality improvement to match international standards.Pilot studies for Development of technical know-how for new products and processes

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C. People Skill development and knowledge up gradation.

Provide intensive training for imparting and enhancing technical skills in manufacturing and process management for personnel sponsored by MSMEs.Providing practical awareness and training programs for new and existing MSME entrepreneurs on the latest developments in technical textile products and processes and marketing.

D.Market research and development.

Pilot production and testing of new and modified products and studying the market potential for them.Market feasibility studies for existing and new products through reworking on cost and technical specifications by pilot studies.

MANTRA-One Stop Solution for Nonwoven sector

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NONWOVEN PLANTS:

MANTRA has commissioned a NONWOVEN 500mm pilot plant machines under the

partial grant-in-aid by the Govt of Gujarat. which can produce most of the

Nonwoven products.

Nonwoven pilot plant

Spunlace technology

Needlepunch technology

Chemical bonding

Thermal bonding

Centre of Excellence in Technical Textiles (sponsored by Govt. of Gujarat)

6. MANTRA-COE: Infrastructure and facilties

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Melt spinning Pilot plant Unit: Polymer to Filament yarn conversion.

Pilot Plant Facilities at MANTRA


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Fully functional Weaving Services Centers at Sachin and Pandesara for

Woven Nonwoven pilot plant studies.

Powerloom – PSC Pandesara Powerloom – PSC Sachin



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Pilot plant facilities: Coating and Lamination

Coating machine

Hot melt laminating machine

Narrow width fabric machine

Testing Lab

To test raw materials and finished product

Product display center


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Has the state of art Pilot plant for Coating and lamination

Matex multilabo coating machine Cavitec hot melt laminating machine


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Product Development


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Plasma machine

This machine is installed at MANTRA under DST project

In collaboration with IPR, Gandhinagar


Plasma technology is widely applicable for the surface modification of textiles & can improve functionality of textile materials, such as 1. improves coating adhesion 2. Pre-treatment process 3. Dyeing & Printing 4. Finishing.

Thus reduces the consumption of

dye & chemicals

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Narrow Width Fabric Section



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WEB forming Line- It is a single web forming system which is unique across the world for Nonwoven


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Pilot plant Facilities COE in Agrotech under MOT MANTRA has purchased industrial scale Raschael machine for the products to be

used in Agriculture, mainly in shading purpose.


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Agrotech Products manufactured on Rachel machine


Insect net Shade net

Bird net

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Fully equipped Testing laboratory for quality evaluation of all types of Nonwoven

products

Technical Textile Lab


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Centre of Excellence in Technical Textiles (Phase – I) TESTING

FACILITY


Measures thermal resistance (Tog value).

Measures re-wetting properties of non-woven cover stock.

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A time taken for known volume of test liquid to penetrate in hygiene products like SN, Diaper,

underpad is measured

To determine air permeability at upto 2500 pascal pressure.


FACILITY

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Measures vertical flammability of substrates.

Measures resistance of textiles to water

absorption and penetration.


FACILITY

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Determines the resistance of fabric to surface wetting by

water.

Measures amount of liquid that specimen can hold after period of immersion and drainage.


FACILITY

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Sample is immersed in water. Measures time required for

complete wetting


FACILITY

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MANTRA has well-organized sample studio to show case the

technical textile samples, both developed as well as having a

good potential to develop in future.


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Implementing Agency

MAN MADE TEXTILES RESEARCH MAN MADE TEXTILES RESEARCH ASSOCIATIONASSOCIATION

Integrated Skill Development Scheme in Technical Textiles

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Courses

conducted

I. Training course for Textile coating and laminating machine operator

II. Training course for Technical textiles entrepreneur ( coating, laminating and value addition)

III. Training course for technical textiles entrepreneur ( Nonwoven technology )

IV. Refreshers training course in weaving

V. Entrepreneurs training course in weaving for technical textiles

VI. Workers training course in weaving on modern machine

VII. Jobber Fitter training course for power loom

MANTRA is fully equipped Technical Training centre conducts many customized training courses for members including MOT sponsored 7 different ISDS training

courses catering to the skill development needs of technical textile industry.


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MANTRA ISDS in Technical Textiles performance

till now All Courses are operationalised.

Last year we trained 574 trainees comprising of workers and entrepreneurs

%age target achieved ~ 120%

We also conducted One unique training workshop on Nonwoven technical

textiles at MANTRA for delegates for all deputy directors from

Karnataka state Handloom and Textiles and was well appreciated

by all Participants.


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ISDS Training Session in

progress


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Spunbond

Machine Technical Training Center for ISDS activities at Pandesara.

Pilot Scale 500 mm width Spunbond machine has been installed at ISDS building of

MANTRA


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7. SUMMARY

Indian nonwoven industry has key identifiable issues to be resolved for accelerating its growth to its forecast potential.

All these issues are solvable with active assistance with expert guidance

MANTRA is recognized and funded by Central and state government of Gujarat to become a COE for helping Nonwoven Nonwoven industry development.

MANTRA is well equipped with pilot plants and expertise and can assist in product innovation and value added process development

MANTRA is ONE STOP SOLUTION for all the issues faced by the Nonwoven Nonwoven industry through its 3 P strategy.

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THEME / MESSAGE

True Guidance can be like a small lamp in a Tunnel. It may not

show us everything at once, but it will give us enough light to

take our next step safely.

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mr. b. s. pancholi | key issues and strategies for indian nonwoven industry

Small Business & Entrepreneurship

indian nonwoven industry

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nonwoven world business

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undifferentiated products

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