what is a nonwoven fabric?...• market size: $7.9b –6.1% growth rate since 2011, slowing to 5.1%...

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Copyright - NWI, NC State University - 1991-2019

Important Trends Impacting Nonwoven Technology in Industrial Fabrics

Dave NelsonDirector, Industry Engagement

The Nonwovens InstituteNC State University


What is a Nonwoven Fabric?


What Is a “Nonwoven Fabric”?

“A fabric made from a web of fiber”

Assembly of loose fibers Fiber held together by

bonding/interlocking

Spunbond /Thermal bonded Nonwoven

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What Is a “Nonwoven Fabric”?

ISO 9092 (2011) “A nonwoven is a structure of fibers, continuous filaments, or

chopped yarns of any nature of origin that have been formed into a web by any means, and bonded together by any means with the exception of weaving or knitting, and wet milling.”

ISO 9092 (2019) “ An engineered fibrous assembly, primarily planar, which has been

given a designed level of structural integrity by physical and/or chemical means, excluding weaving, knitting or papermaking”

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What Is Not a “Nonwoven Fabric”?

Knit

Woven

Paper

Film

(www.cogentemr.com) (Erksen et al 2005) 5


Unique Nonwoven Aspects

Nonwovens Variable fiber orientation

Structure non-uniformity

Diverse web bonding methods: mechanical, thermal, chemical

Woven Clearly Defined Geometry,

x, y orientation Strong x, y direction, weak bias direction

Bonding: Friction, interweaving, weave crimp

Wetlay Thermal bond

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Nonwoven Product & Applications

Nonwoven applications Nonwovens are the fabrics that you don’t see,

but are there where you need them;

They are the fabrics that you don’t recognize,

but are performing in ways that others can’t

Wide ranges of nonwoven products in wide ranges of applications

Possibility to produced highly engineered and customized product

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Today’s Message

The nonwovens market is

a successful, growing,

continuously evolving, dynamic

and diverse industry!

A $15.5B Industry in North America2018 Nonwoven Material/Rolled Goods at the Producer Level


Nonwoven Market Segments by Applications (243 product categories)

Short-life (Disposable) Absorbent Hygiene

Wipes

Filtration

Medical/Surgical

Other Disposable Applications

Long-life (Durable) Building Construction

Home and Office Furnishings

Vehicle Construction

Geosynthetics

Apparel

Other Durable Applications

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115 distinct product

categories

128 distinct product

categories

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0%

2%

4%

6%

8%

0% 2% 4% 6% 8%

Robust Global ProductionProduction Growth in Tonnes, Historical and Forecast Average Annual Growth Rates

Source: Worldwide Nonwovens Industry Outlook, INDA/EDANA, 2015

HistoricalGrowth

ForecastGrowth

Historical Growth5.7% 2008-2018

903k per Year

Forecast Growth4.8% 2019-2023

776k per Year


0%

2%

4%

6%

8%

0% 2% 4% 6% 8%

Strong and Steady Growth in North AmericaProduction Growth in Tonnes, Historical and Forecast Average Annual Growth Rates

Source: INDA, April 2019

Historical2013-2018CAGR

Forecast2019-2023

CAGR

Historical Growth5.1% 2013-2018

185k per YearForecast Growth4.3% 2019-2023

198k per Year


North American Nonwoven Market

Durable35%

Disposable65%

North American Nonwoven MarketTonnage Consumption, 2013

$12.1 Billion Sales of materials at producer level

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Distribution of North American ProductionNorth America Production by End Use in Tonnes, 2018

Source: INDA North American Nonwovens Supply Report 2018, April 2019

Green Shades RepresentDurable End-Use Markets

52%

Blue Shades RepresentDisposable End-Use Markets

48%


North America Investments Exceed GDP North America Capacity by Process, 1990 to 2018, in Thousands of Tonnes

28 yearsNonwovens 4.6%U.S. GDP 2.4%

Investments Have Been

and Will Continue To Be

Made in North America

Source: INDA North American Nonwovens Supply Report 2018, April 2019


Diversity of Processes…North America Capacity Additions by Web-Forming Process

Number of Lines and Thousand of Tonnes, 2016–2018 (69 new lines, 613,450 tonnes)

Source: INDA, June 2019

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North American Nonwovens Market

Growth Drivers:• Demographics• Strength of global

economy• Innovation• Material substitution• Regulation


North American Nonwovens Market

Durables Growing > 2X Disposables


Nonwovens In Filtration

Air Filtration Industrial/Manufacturing

Transportation

Commercial Air Systems

Residential Locations

Personal Protection

Vacuum Cleaner

Liquid Filtration Transportation

(oil/hydraulic/lubrication/fuel)

Industrial/Manufacturing

Water

Food and Beverage Processing

Largest NW Market behind Hygiene and Wipes includes30 Major Market Segments

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Market Outlook for Filtration

>$32B End Use Sales


Market Outlook for Filtration

• Primary Growth Drivers: The economy …. 2.2% annually since

2011 Consumer awareness and sensitivity Government legislation and regulation Passenger car and light truck production

(+6% since 2011) New residential starts (+14% since 2011) Residential repair and remodel Private non-residential construction Public non-residential construction

• Secondary Drivers: Filter efficiency improvements Increasing share of nonwovens in filter

media Nanofibers (?) Sustainability

Why Nonwovens?

• Can be specifically engineered for the exact filtration performance desired

• Can be specifically engineered for the physical and chemical properties desired


Industrial/Manufacturing

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Dust collections systems (bag filters) and air intake systems (cartridge filters)

Growth Drivers:• Energy Usage• Emissions Reduction• Technology Advances• Cost Reduction

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Copyright - NWI, NC State University - 1991-2019 22

Engine Filtration

• Air induction, engine oil and inline fuel filtration • Market size: $7.9B – 6.1% growth rate since 2011, slowing to

5.1% thru 2021• Materials:

Lighter weight polymeric materials taking the place of cellulosic wetlaid Smaller, more efficient filters

• Requirements: Higher efficiency, longer life, reduced pressure differential, etc., without,

providing a ˝larger˝ filter:

Tighter tolerances and on-board engine control to protect instruments such as mass-air-flow sensors (MAF):

• Filters must contribute to decreasing engine wear

To remove smaller and smaller particles:

• Multi-stage filter systems - the rule and not the exception.

The diversity of microfiber/meltblown/spunbonding technology will contribute.


Cabin Air Filtration

• Air Contaminants in the automobile include Exhaust fumes

Dust

Odors

Volatiles from interior components (carpeting, moldings)

• Filters are included as part of the HVAC system


Cabin Air Filtration

• More than 1/3rd of North American cars had cabin filters in 2014, now almost 100% -fastest growing segment for transportation

• Filters are designed to be replaced during routine maintenance• Meltblown or composite nonwovens are used as the filtration media with electrostatic

charge added to improve their capture efficiency• Required properties:

Accommodate space restraints (as small as 0.5 m2) Sustain a low pressure drop High collection efficiencies of fine particles (<3 m) Blockage-proof Perform in high humidity Rigid design Non-toxic binders Ideally, remove odor and be 100% recyclable

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Commercial HVAC

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Low, Medium and High Efficiency Segments – High Efficiency (HEPA and ULPA growing the fastest -8.6%)

Growth Drivers:• Energy Usage• Sick Building Syndrome/Health• Technology Advances


Residential Air Filtration

Residential HVAC

Copyright, NWI, NC State, 1991-to date

Grow Drivers:• Concern over indoor air quality –

demanding “real” filtration vs. protecting the furnace

• Portable room air purifiers• Consumer IQ• Technology – media and product design

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Personal Protection

Includes: Face Masks (not regulated) and Respirators (regulated)

Grow Drivers:• Threat of infections and pandemics• Worker and consumer safety demand

and regulation• “Fashion”• Technology – fit, comfort, specific

uses, etc.


Vacuum Cleaner Filters

Bag vs. Bagless


Liquid Filtration

Major Segments: Transportation (fuel, oil, lubrication, hydraulic)

Industrial/Manufacturing (high tech, hydraulics, hydrocarbon processing, industrial processes

Water (industrial processes, swimming pools/spa, water treatment)

Food and Beverage Processing

Healthcare (biotech/pharma, blood)

Growth Drivers: The economy

Consumer awareness and sensitivity

Legislation and regulation

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Liquid Filtration

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Technology Drivers:• Filter Efficiency Demands• Innovative Nonwoven Materials• Selective Separation• Sustainability• Composites• Testing• Product Design


Nanofiber and Composite Media Technology

Product InnovationMaterial / Technology Development

Images Courtesy of Berry Global and M. Faccini, C. Vaquero, and D. Amantia

Spunbond

Nanofiber

Meltblown


Nanofiber and Composite Media Technology


Images Courtesy of Cummins Filtration

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Nonwovens In Transportation

Automotive Passenger Vehicles

Light Trucks/SUV’s/Vans

Other Transportation Modes Heavy Trucks/Commercial Freight/Buses/RV’s

Air

Rail

Water


Market Outlook for Transportation

• INDA has expanded “automotive” to “transportation”

• Strong recovery of automotive industry, plus higher growth rates for “other transportation” – now slowing

• Excellent opportunities for nonwovens replacing conventional materials – textiles, glass, paper, leather, etc.

• Primary Growth Drivers: The economy ….

Passenger car and light truck production

Corporate Average Fuel Economy (CAFE) regulation

• Secondary Drivers: Pent-up demand

Fuel efficient vehicles (light weight material substitution)

Increased vehicle size

Parts consolidation (composites)

Aging population/Driverless cars/Shared Rides/ownership?

Strong RV and leisure market

Changing filtration needs for vehicle of the future


Automotive Nonwovens

Interior• Headliner

− Acoustic Control− Face Fabric− Insulation

• Dashboard Insulation− Acoustic Control− Insulation

• Carpet and Flooring• Seats• Interior Trim• Cabin Air Filtration• Air Bags

Engine/Exterior• Wheel Housing• Fire Retardancy• Hood insulation• Fluid Filtration• Engine Air Filtration• Heat Shields• Molded Bonnet Liners

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Nonwovens in Transportation



Images Courtesy of Freudenberg



Images Courtesy of Autoneum

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Acoustic Insulation


Filtration


Aerospace, Rail, Ship Building

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Nonwovens In Construction

End Uses: Roofing (Residential and Non-

residential)

Underlayment (Housewrap, Roof Underlayment, Other)

Other Building Construction (Product Facing Materials, Insulation Panels/Boards, Other)


Market Outlook for Construction

Growth Drivers: New residential starts

Existing home sales

Repair and remodel

Private and public non-residential

Secondary Drivers: Pent-Up Demand

Energy Codes and Other Regulations

Nonwoven Material Share

Product Innovation


Nonwovens In Home and Office Furnishings

End Uses: Flooring (carpet, underlayment, entrance

and walk-off mats) Upholstering Bedding (mattress, bed coverings and

linens) Other (window treatment, wall coverings,

acoustic, other padding)

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Market Outlook for Home and Office Furnishings

Growth Drivers: New residential starts

Existing home sales

Repair and remodel

Business spending

Secondary Drivers: Regulation – i.e. flammability

Style/Design - aesthetics

Capturing share from other materials

Product Innovation –functionality, weight, cost


Nonwovens In Geosynthetics

End Uses: Civil Engineering (road, drainage,

containment, cure-in place pipe) Agriculture (crop covers, shading,

landscape fabrics, root and product bags


Market Outlook for Geosynthetics

Growth Drivers: Public infrastructure

Private infrastructure

Regulatory

Secondary Drivers: Government spending

Nonwoven Material Share

Product Innovation

Sustainability – “organic” “green”

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Nonwovens in Apparel

End Uses: Thermal Insulation Artificial Leather Interlinings/Interfacings PPE (military, 1st responders,

police, safety) Shoe Materials Recreational Wear


Market Outlook for Apparel

Growth Drivers: The economy

Demographics

Material substitution

Secondary Drivers: Apparel design

Regulatory

Manufacturing in NA

Product Innovation –aesthetics, cost, functionality


Markets and Products for Safety Applications

• Filtration – Personal Protection Face Masks (non-regulated)

• 5.8% sales growth forecasted (2013-2018)

Respirators• 7.5% sales growth forecasted (2013-2018)

No recent “pandemics” i.e. Avian Flu, etc.

• Personal Protective Equipment – PPE (sales growth forecast – 7.2%)

Emergency Response, Chemical Biological Hazard Apparel

Agriculture, Paint, Food Processing Apparel

Cleanroom/Laboratory Apparel

Market Drivers: the economy, legislation and regulatory control

• Medical (sales growth forecast – 4-5% range)

Surgical Packs and Gowns

Other Apparel – masks, headcovers, shoe covers, bedding

Market Drivers: aging population, in home healthcare, infection prevention awareness

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Protective Apparel - PPE


Medical Fabrics and Apparel


Other Applications

End Use Comprises: Durable Graphics (art, maps, book covers)

Electronics • Battery separators

• Cable insulators

• Conductive/smart fabrics

Fabric Graphics

Fabric Structures

Industrials Felts (gaskets, seals, sound/vibration dampening)

Advanced Composites• Pre-preg

• Membranes

• Military

Main Drivers: The economy

New markets

New products

Secondary Drivers: Product innovation

Product substitution

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Why We Need Fine Fibers For Mechanical Filtration

B Maze, HV Tafreshi, Q Wang, & B Pourdeyhimi, J. Aerosol Sci., 38, 550 (2007)

SVF=1.7%; 10 nm< dp<150 nm


Electrospinning

A New Old Technology Electrospinning

Co-axial Electrospinning

Emulsion Spinning

Melt Electrospinning

Sometimes it takes a LONG time to find the value of a new technology…

This technology was re-discovered only recently


Electrospinning

Nozzle based Nozzle-less

Free liquid surface electrospinning of Polyvinyalcohol(Courtesy of David Lukas, Technical University of Liberec)

Rotating drum is dipped into a bath of liquid polymer. Thin layer of polymer is carried on the drum surface and exposed to a high voltage electric field.When the voltage exceeds the critical value Ec, a number of electrospinning jets are generated.

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2020

Fiber Diameter, nm

0 300 600 900 1200 1500 1800 2100 2400 2700 3000

Fre

qu

enc

y

0

5

10

15

20

25

Mean 1482 nmSD 872 nmMin 495 nm

0.2-C-20

Fiber Diameter, nm

0 300 600 900 1200 1500 1800 2100 2400 2700 3000

Fre

qu

en

cy

0

10

20

30

40

50


0.012-A-2.5

Fiber Diameter, nm

0 300 600 900 1200 1500 1800 2100 2400 2700 3000

Fre

qu

en

cy

0

2

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0.002-B-0.5

Meltblowing:Hills High Density Dies


The NWI ProcessFibrillating Bicomponent Fibers

• The islands in the sea or multilobal fibers are sheared and subjected to high pressure water jets to simultaneously fibrillate and entangle and consolidate the microfilaments.

50/50 Sea-Island Ratio

Number of Islands

7 37 240

600

1200

Dia

mte

r (

m)

7.00

2.00

0.87

0.340.220.15

US Patent 7,883,772US Patent 7,981,336 US Patent 7,981,226US Patent 7,438,777

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Denier Per Filament0.0001 0.001 0.01 0.1 1 10 100 1000

Sp

ecif

ic S

urf

ace,

m2 /g

0.01

0.1

1

10

100

Round

4DG

Winged

Diameter (Microns)0.1 1 10 100 1000

The NWI ProcessSuper Surface Area Fibers…

Photos courtesy of Allasso Industries. Inc.

US Patent 8,129,019 B2, March 6, 2012US Patent 8,410,006 B2, April 2, 2013

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And, Fibers Below 50 nm ??UIC & NWI – Disruptive Tech.

Supersonic electrically-assisted blowing and resulting nanofibers. (a) Schematic of the electrically-assisted solution blowing setup. (b) Two-stage stretching of polymer jet and crystal sheet alignment and packing.

Patent Pending


Nonwovens Will Continue to Grow

• Trends that drive the growth Population growth, urbanization, increase in prosperity, scarcity of natural resources, health

awareness and sustainability

• China and developing nations are the fastest growing markets for nonwovens and especially filtration

• New fibers, new process technologies, new products are needed to meet market needs Industrial fabrics of the future requires new materials, processes and integration systems that have

not been developed yet…


Nonwovens Will Dominate Many Markets

• The Nonwovens Industry is High volume Highly innovative Growing Mostly focused on melt spinning Highly automated

• The main opportunities are in New resins

• Polyamides• PBT• PLA• Others – water soluble?

New additives• Nucleating agents, etc., electret• Surface energy• Alcohol repellency

New chemistries Composites

• The segments to penetrate Filtration Transportation Durables/Apparel Geosynthetics Medical/Hygiene

• Drivers Multi-functionality Sustainability Lower weight Lower energy Higher differentiation Low labor component

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The Nonwovens InstituteEstablished 1991 as a NSF State I/UCRC

The Nonwovens Institute is a university-wide unit that works with the faculty in the participating colleges and partner universities and member companies to support the various industrial sectors that it represents… and train future leaders for the industry…

Nonwovens Institute

Fiber & Polymer Science

Fiber & Polymer ScienceChemical Engineering

Paper Science & Engineering


Industrial Needs & Challenges

• Balancing long-term & short term research objectives is the major issue faced by the industry. We have to do both…

• Problem driven industrial needs are often short term and applied… looking for a product in a structured manner involving a stage-gate process. NWI carries out this on a one-to-one basis.

• Longer term basic and fundamental research is also critical for creating an innovation pipeline. NWI has a shared research platform for its members

Create KnowledgeCreate Knowledge Add ValueAdd Value Transfer KnowledgeTransfer Knowledge


What Does NWI Actually Do?Vertical Integration is Key – TRL 1-8

Knowledge Creation

Funded by NWI membership dues

PhD Research

Graduate Certificate

Short Courses

In-plant Training

50+ PhD Students

Faculty

Meet twice/year

Project monitoring

Typically no IP, but Bylaws define IP rights

Funded by NWI membership dues

PhD Research

Graduate Certificate

Short Courses

In-plant Training

50+ PhD Students

Faculty

Meet twice/year

Project monitoring

Typically no IP, but Bylaws define IP rights

Knowledge Transfer

Nonwoven Products and Processes

Manufacturing Process Fundamentals

Spunbonding & Meltblowing

Fundamentals

Bonding Fundamentals

Characterization Methods

Product Development

Nonwoven Products and Processes

Manufacturing Process Fundamentals

Spunbonding & Meltblowing

Fundamentals

Bonding Fundamentals

Characterization Methods

Product Development

Testing & Fabrication

Funded by Sponsor

No student/faculty involvement

Research Staff only

Confidential

Sponsor present at trial

Sponsor defines protocol

Simple Agreement with no IP terms

Enabler for innovation

Funded by Sponsor

No student/faculty involvement

Research Staff only

Confidential

Sponsor present at trial

Sponsor defines protocol

Simple Agreement with no IP terms

Enabler for innovation

New Product Development

Funded by Sponsor

No student involvement

Research scientists

Meet monthly

Reporting requirement

Project monitoring

Option to License IP generated

Assistance with commercialization

Funded by Sponsor

No student involvement

Research scientists

Meet monthly

Reporting requirement

Project monitoring

Option to License IP generated

Assistance with commercialization

Incubation

LINC, LLC

Affiliated entity of NC State

Help commercialize technologies

developed at NWI

Manufacture on a limited basis products

Identify companies who can produce the

products

Help build new facilities

Transfer technology to client

Affiliated entity of NC State

Help commercialize technologies

developed at NWI

Manufacture on a limited basis products

Identify companies who can produce the

products

Help build new facilities

Transfer technology to client

TRL 1-8TRL 1-8

LINC is a non-profit affiliated entity of NC State…

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NWI’s Mission

Knowledge creation and diffusion by conducting and sharing relevant basic research with stakeholders and policy makers and Creating a shared scientific basis for joint resolution of complex materials and manufacturing issues,

Training the next generation of engineers/scientists as future leaders for the industries we represent,

Technical and expert assistance in new product development to bring about new opportunities for the industry,

Technology transfer and assistance with commercialization through incubation of new products,

Be the “go-to” information resource for communications and research, development and education tools, and Coordinating professional development opportunities.

Forecasting technology and market needs through market intelligence to foster new opportunities for stakeholders.

Diagnostic and testing and pilot production services by creating testbeds and make these available at reasonable fees,

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Thank You !!

Any Questions?

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what is a nonwoven fabric?...• market size: $7.9b –6.1% growth rate since 2011, slowing to 5.1%...

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