opportunities in nonwovens and technical textiles
TRANSCRIPT
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Nonwoven TechnicalTextiles: Opportunities
Utkarsh Sata, M. Mallyah*
and Seshadri Ramkumar
Nonwovens and Advanced Materials LaboratoryThe Institute of Environmental and Human Health
Texas Tech UniversityLubbock, TX 79409-1163, USA
E-mail: [email protected]
*Tecnitex Nonwovens, Ltd., Bangalore, India
Presentation given at the FICCI Agrotextiles conference held on 1stOct 2008
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Global Economic Situation:Public Humiliation
World Economyis at Crossroads
Source: Public Humiliation by James Surowiecki, The New Yorker,September 24, 2008
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American Economy Meltdown
US is the largest consumer of commodity goods.
Latest mortgage crisis and credit crunch is hitting the
pocket books of American consumer society.
Monies to spend on consumer good such as clothing
will decrease.
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Implications ofGlobal Economy andIndian Textile Industry
Import of commodity textiles in developed economies
hit by credit crisis will slow down.
Increase in the price of raw materials due to globaleconomic situation.
Indian textile industry should diversify.
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Diversification into Non-commodityTextiles
Indian textile industry should go on a higher gear in
diversifying into unconventional textiles.
Even after 30 years of organized sector status, thenonwoven and technical textile industry is growing
at a rate of 8 % in USA and Europe.
This sector is at infancy in India and offers tremendous
growth and opportunities until 2050.
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Technical
Textiles&
Nonwovens
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Technical Textiles are value-added textile products thatprovide added functionality and applications other thanregularfiber-to-fashion supply chain products.
These technical textiles encompass high performancefibers, yarns, woven, knitted, nonwoven, braided andcomposite structures.
What are Technical Textiles ?
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Are Nonwovens Technical Textiles?
Most of the nonwovens are technical textiles as they havenot yet penetrated into the apparel sector.
Nonwovens are predominantly disposable and semidurable goods.
All nonwovens are technical textiles but all
technical textiles are not nonwovens
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What are Nonwovens?
As the name indicates nonwovens are not woven fabrics.
Cost effective process as it skips intermediary processes suchas spinning, weave preparation and weaving.
Fiber Fabric
without weaving
High speed and productivity compared to conventional/wovenprocesses.
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GeneralDefinition of Nonwoven Fabrics
Nonwoven fabrics are flat structuresmainly defined as sheets or webs made by
bonding and entangling fibers or
filaments by mechanical, thermal orchemical means.
-- Mahmud and Ramkumar, ManMahmud and Ramkumar, Man--Made Textiles in India, September 2001Made Textiles in India, September 2001
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Major Nonwoven Technologies
Needlepunching
Thermalbonding
Airlaid
Spunbonding
Meltblowing
Spunlacing/hydroentanglement
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Nonwoven Technologies
Spunbond Synthetic
Meltblown Synthetic
Needlepunching Versatile (natural and synthetic)Hydroentangling Versatile (natural and synthetic)
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Typical Applications of Nonwovens
Technical applications
Hospital fabrics
Surgical gowns
Face masks
Geo textiles
Consumer and industrial wipes
Upholstery paddings
Military decontamination wipes
Inner liners of protective fabrics
Automotive headliners
Automotive trunkliners
Acoustic and thermal insulation
materials
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Technology and End-use Applications
Spunbonding surgical gowns, diaper coverstocks
Meltbowning barriers, filters and face
masks Needlepunching Geotextiles, automotivefabrics
Thermalbonding upholstering, cussionpads
Hydroentangling wipes
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Needlepunching Technology
Nonwoven Laboratory at Texas Tech University
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Contoured Needleboard TechnologyContoured Needleboard Technology
Width: 1.2 mts.
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Contoured Needle Zone
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Nonwoven Line
Hopper Feeder
Double CylinderCard
Cross Lapper
H1 Needle Loom
Opening fine beating and tuft reduction
Web forming removal of tufts; parallelorientation
Web formation - high loft, layered webs
Web consolidation Interlocking of fibers
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Meltblown Process
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Spunbonding Process
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Major Machinery Makers
Spunbond/Meltblow Reifenhauser, Germany
Hydroentangling Fleissner, Germany.
Reiter Perfoject, Switzerland
Needlepunching Dilo, Germany
Saurer, Switzerland.Fehrer nonwoven operations have been acquired recently by Saurer group
NSC (Asselin + Thibeu), France
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Global
NonwovensOutlook
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Worldwide Production By Region(millions of tonnes)
2.69
5.75
8.41R. Of World
Mid. East
South America
Asia Pacific
Europe - 27
NAFTA
0.9
0.8
0.80.1
1.2
1.3
1.2
0.2
1.5
1.7
2.0
0.3
1.8
2.3
3.2
0.4
0
1
23
4
5
6
7
8
9
10
1997 2002 2007 2012
Source: INDA Estimates, Ian Butler, INTC-2008
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NonwovenGrowth By Region(%, based upon tonnes)
0 5 10 15 20
he a a
d a
Japan
u ope (27)
N F
Ch na
o d
2007 2012
1997 2007
Source: INDA Estimates, Ian Butler, INTC-2008
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2007 Nonwoven Production(000, tonnes)
Regions
Europe (27) 1,659
Asia-Pacific * 2,047
NAFTA 1,491
South America** 254 Mid. East 174
R. of World 126
* Australia, China, Indonesia,
Japan,Korea,Taiwan,Thailand
** Top 6: Argentina, Brazil,Chile, Colombia, Mexico,Venezuela
Selected Countries Mexico 126
Brazil 135
Mexico 130
Taiwan 160
Korea 213
Turkey 93
Japan 338
S. Africa 26
Saudi Arabia 52
Australia 62
Source: INDA Estimates, Ian Butler, INTC-2008
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Nonwoven Consumption Per Capita(kilograms)
0 1 2 3 4 5 6 7
Taiwan
Korea
NAFTA
Europe -27
Australia
Japan
Malaysia
Saudi Arabia
Turkey
MexicoChina
South America
Brazil
S. Africa
Russia
India
Developed Markets
Early Development Markets
Emerging Markets
High export volumes
Source: INDA Estimates, Ian Butler, INTC-2008
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Nonwoven Consumption Rises asGDP Per Capita Increases *
Source: INDA Estimates, Ian Butler, INTC-2008 * PPP in US$
equivalents
Kg/Capita
0
0.51
1.5
2
2.5
3
3.5
4
4.5
$0 $10,000 $20,000 $30,000 $40,000 $50,000
Czech Rep.
Korea
Brazil
Turkey
Europe
apan
NAFTA
Taiwan
India now
China now
India,2012
Trend line
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Worldwide Consumption ofTechnical Textiles (000 tonnes)
Region Years CAGR%
1995 2000 2005 2010 95-00 00-05 05-10
Americas 4,288 5,031 5,777 6,821 3.2% 2.8% 3.4%
Europe 3,494 4,162 4,773 5,577 3.6% 2.8% 3.2%
Asia 5,716 6,963 8,504 10,645 4.0% 4.1% 4.6%
ROW 473 558 628 730 3.3% 2.4% 3.1%
Totals 13,971 16,714 19,683 23,774 3.7% 3.3% 3.8%
Source: David Rigby Associates
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Worldwide Consumption ofTechnical Textiles (000 tonnes)
Application Area Years CAGR%
1995 2000 2005 2010 95-00 00-05 05-10
Agrotech 1,173 1,381 1,615 1,958 3.3% 3.2% 3.9%
Geotech 196 255 319 413 5.4% 4.6% 5.3%
Medtech 1,228 1,543 1,928 2,380 4.7% 4.6% 4.3%
Protech 184 238 279 340 5.3% 3.3% 4.0%
Totals 2,781 3,417 4,141 5,091 4.68% 3.93% 4.38%
Source: David Rigby Associates
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Growth
Prediction ofTechnical
Textiles inIndia
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Consumption Of Nonwovens/TTin India Vs. GDP Per Capita
(Assuming An Increase Of 13.27% In Per Capita Every Year)
GDP per capita source: World Bank
YEAR GDP PER CAPITA
(US$)
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
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Consumption Of Nonwovens/TTin 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 4.322015 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
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India vs. USA Per Capita Nonwoven/TTConsumption (2005-2050)
GDP per capita source: World Bank
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Indias Per Capita Consumptionvs. Income Levels (2005-2050)
GDP per capita source: World Bank
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Agrotextiles(Few Examples)
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What are Agrotextiles ?
Agricultural Textiles are used for Increasing yield, quality andsafeguarding agricultural products.
Agrotextiles are basically technical textiles that have specialtyapplications in agriculture, horticulture, aquaculture, animal
husbandry & forestry.
Agricultural Textiles find applications right from sowing toharvesting.
They offer new insight on solving the problems faced by agricultural
industry.
Various technical textiles such as woven, nonwoven, knitted, netsand coated textiles are used as agrotextiles.
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Applications of Agrotextiles
Sunscreening (shade cloth) Frost Covering Harvesting Wind protection Landscape covering Bird protection Insect protection Turf protection Irrigation Drainage
Aquaculture Insulation Horticulture Animal Husbandary
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Agro Shade Cloths
Shade cloth/Shade Netting
These are sunscreens and providenecessary protection to the plantsagainst:
Excessive heat, Burning of the crops due to direct
sunshine and UV damage. Source: www.karatzis.gr/products/agricultural/04s.jpg
Examples:
Knitted or woven polyethylene fabrics.
Should not rot or become brittle & should avoid mildew formation
Range of shade percentages are:25%, 35%, 50%, 75% and 90%
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Frost Covering
Adverse Effects of Frost
Frost can kill the seeds and adversely affect theariel portion of the plant.Frost makes the plant loose its moisture anddry out.
Frost Covering
Minimizes moisture and heat loss.
Keeps the plant warm and healthy.
Nonwoven fabrics are preferred for Frost Covers:
Lightweight, breathable and those which dryquickly are used. These fabrics should provideopen spaces for crop treatments.
Source: http://www.anti-frost.com/
Source: http://www.anti-frost.com/
Examples:Nonwoven spunbonded mesh fabric andnonwoven UV resistant polypropylene fleece.
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Harvesting Aides
Harvesting nets are used tocollect the fruits falling froma tree.
This helps to keep the cost ofcultivation low byeliminating additional laborassociated with harvesting.
Harvesting nets are
predominantly gripstructures which can bedeveloped using warpknitting technology.
Source: http://farm4.static.flickr.com/3169/2638810726_a4ceefdcc6.jpg?v=0
Source: http://lh3.ggpht.com
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Windshields
Windshields are used to protect thecrops from high velocity wind damage.
These can also be used to control thetemperature by hindering cooling due to thewind.
These are installed perpendicular to thedirection of the wind to reduce the windspeed.
These Prevent:
Breaking of branches,Early falling of the fruits andDamage to the leaves and flowers.
Source: http://www.karatzis.gr
Source: http://www.arrigoni.it
Examples:Woven and knitted UV stabilized windshields using
high density polyethylene monofilaments.
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Landscape Covers
These are used for weed control andprevent penetration of thin roots of weeds.
In addition they also maintain optimal soil
temperatures for rapid plant growth.
Source: http://www.terramdirect.com
Examples:Biodegradable needlepunched nonwovens and coated fabrics
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Spunbonds with Phase Change Materials
Spunbond PP Row Cover Fabric Agrotextiles in Experimental
Strawberry Rows
Source: Wadsworth L. C. et al. Nonwoven & Technical Textiles, Oct-Dec 2007
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Pesticide
ProtectiveClothing
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Pesticide Protective Materials
Three layered Chemical Protective
Fabric: Patent Pending
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Conclusions
It is extremely important for the Indian textile industry to diversifyinto 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 doubledigits around 13 %.