Innovation in Nonwoven Technical Textiles

Mind to Market

Seshadri S. Ramkumar

Innovation in Nonwoven Technical Textiles

Mind to Market

Seshadri S. Ramkumar

Nonwovens & Advanced Materials LaboratoryTexas Tech University

Lubbock TX, USA.E-mail: 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

India’s 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 Nonwovens 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 Nonwovens 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 RegionReal Power Engine for Global

Technical Textiles Market ”

Asia’s 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.

2016 Nonwoven Projection in Asia

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

4.3 million tonnes

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

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

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

Consumption Of Nonwovens/TT in USA vs.

GDP Per CapitaYEAR 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

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

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

GDP per capita source: World Bank

India’s 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

India’s 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

Summary(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 %.

Nonwoven and Advanced Materials Lab

Research and education activities focus on basic and applied R&D activities on value-added fibrous materials for enhancing human life and protecting the environment.

These materials find applications in defense, homeland security and industrial markets.

Source: www.indiamart.com

Outcomes & Impact Next Generation Low Cost Personnel

Decontamination System.

TTU wipe technology proved to be the best available technology by Lawrence Livermore National Laboratory.

US Patent published.

Process for making protective chemical wipe and such wipes, US 7,516,525 , April 14th, 2009.

Four international scientific conferences organized .

DecontaminationNeed and National Priority

Development of: Non-particulate, Non-corrosive and Environmentally Safe Decontaminating System for military personnel & equipment is an international priority research endeavor.

R&D in Sorbents, Catalysis, Membranes etc. is part of the Modernization Strategy of the CBD Program of US Department of Defense.*

* (Annual Reports from the US Department of Defense to the US Congress ’04 ’05 ’06 ‘07).

Wiping a surface using the M291 Kit.

Fibrous Materials to Protect Human Life and Environment

Nonwoven Fabric Structures

a) Personal decontamination wipe for removing Chemical warfare agents and toxic chemicals.

b) Breathable protective inner liners for chemical protective suit.

Objectives1) DEVELOPMENT:

To develop cotton-based Nonparticulate, Non- corrosive & Nontoxic chemical protective substrates for individual protection that could find following applications such as:

Personal Decontamination Wipes Breathable Protective Inner Liners.

2) EVALUATION:

To Quantify and compare the adsorption capabilities of the nonwoven composite sorbent fabric.

L1

L3

L2

Three Layered Decontamination Wipe L1 Pre-filter layer L2 Middle adsorbent layer L3 Next-to-skin layer

Needlepunching the composite

• L1 and L3 layers are cotton-based substrates which are hydrophilic in nature, and help with absorption of CW agents & simulants in liquid form.

• Many CW agents and their simulants can be volatile. It is important to adsorb the agents in vapor phase.

• The core adsorbent layer is entirely microporous & helps with vapor adsorption.

Top Needlepunched Fabric

Activated Carbon Nonwoven Fabric

Bottom Needlepunched Fabric

Interlocking is only at the Interface

(Interlocking takes place only at the interface)

Cross-section of Absorbent-Adsorbent Nonwoven Composite Wipe

Ramkumar et al. 2008, Next Generation Non-particulate Dry Nonwoven Wipe for Chemical Warfare Agent Decontamination, Ind. Eng. Chem. Res., 47, (24) pp. 6885-6895.

SEM Images of the Interlocking atthe Interface

SEM Images of the Interlocking atthe Interface

Next-to-Skin Friendly Decontamination WipeNext-to-Skin Friendly

Decontamination Wipe

Three Layered Nonwoven Wipe

Patent - S. S. Ramkumar, “Process for Making Chemical Protective Wipes and Such Wipes,” US Patent 7,516, 525, April 14, 2009

Next-to-Skin Friendly Decontamination WipeNext-to-Skin Friendly

Decontamination Wipe

(Featured as the Quality Fabric of the Month in the Textile World Magazine)

Highly Efficient & Flexible Decontamination Wipe

Decon Wipe Drapes Around the Arm Decon Wipe Cleans the Elbow

Decon Wipe Cleans the Intricate Part of an Automobile

Decon Wipe Drapes Around the Corner of a Table

Novel Features & Superior Characteristics of Nonwoven Decon Wipes

The three-layered decontamination wipe is flexible, drapable and soft.

The decontamination wipe will be “next-to-skin” friendly, which is extremely important for personnel/human body decontamination.

The decontamination wipe due to its flexibility will be able to follow the shapes and contours of intricate parts of the human body and equipment.

The top and bottom layers of the decontamination wipe provides the necessary structural coherence and enhanced strength.

Novel Features & Superior Characteristics of Nonwoven Decon Wipes

The important difference between the currently available rigid wipes and the nonwoven wipe is that the polymer films in rigid wipes mask the active adsorption sites of the middle activated carbon. This is NOT the case in flexible nonwoven wipe.

The three-layered structure allows to add functionality to the wipe such as topical antibacterial treatment, etc.

M 291 Skin Decon Kit

Currently fielded skin decontamination kit.

M 291 consists of a decontamination powder (Ambergard XE-555 resin) in an applicator pad.

The dry powder is a carbonaceous adsorbent, a polystyrene polymer and an ion-exchange resin.

Leaves a black powder on skin-this is a NEGATIVE aspect for DoD personnel use.Forms a dust cloud (particles in eye/inhaled).

**

*

Retention of Sulfur Mustard (HD) Adsorbed by Nonwoven

Decontamination WipeRamkumar et. al. 2008. Next Generation Non-particulate Dry Nonwoven Wipe for Chemical Warfare Agent Decontamination Ind. & Eng. Chem, Res. 47 , No 24 pp. 9889-9895

**

*

Retention of Sulfur Mustard (HD) Adsorbed by Nonwoven Decontamination Wipe

Figure & Table: Ramkumar et. al. 2008. Ind. & Eng. Chem, Res. 47 , No 24 pp. 9889-9895

Details of Materials Used

Physical Properties Type

Viscose Nonwoven

Fabric Polyester Nonwoven

Fabric Nonwoven Activated

Carbon

Weight (g/m2) 100 80 140

Fiber Denier 3 6 - Fiber Staple Length (mm) 50.8 50.8 -

BET Surface Area (m2/g) - - 1071* *Surface area data for nonwoven activated carbon were obtained from Professional Analytical and Consulting Services.22 Viscose and polyester fiber details were provided by each manufacturer.

Memorable Date: April, 20th

Deepwater Horizon, Gulf of Mexico Oil Spill

Cotton And Oil Sorption

Source: Singh, V.; Kendall, R. J.; Hake, K.; Ramkumar, S., Crude Oil Sorption by Raw Cotton. Industrial & Engineering Chemistry Research 2013, 52 (18), 6277-6281

Cotton And Oil Sorption

Crude oil sorption by raw cotton in oil-water system

Need of the Awareness on the Technical

Textiles Converted Sector

Converted Products are Necessary

Texas Tech University publishes timely news related to Nonwovens and Technical Textiles called

TexSnips. It is distributed free of charge to interested parties. If you are interested, please contact Dr.

Ramkumar at: s.ramkumar@ttu.edu

Research Output Technology Transfer

A novel non-particulate dry sorbent nonwoven wipe has been developed for decontamination of personnel and sensitive equipment.

This technology has been commercialized.

TTU’s wipe technology has been recommended for the next generation low cost personnel decontamination system.