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Nonwoven Technical Textiles: Opportunities

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Indian textile industry should go on a higher gear in diversifying into unconventional textiles. Even after 30 years of organized sector status, the ... – PowerPoint PPT presentation

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Title: Nonwoven Technical Textiles: Opportunities


1
Nonwoven Technical Textiles Opportunities
  • Utkarsh Sata, M. Mallyah and Seshadri Ramkumar
  • Nonwovens and Advanced Materials Laboratory
  • The Institute of Environmental and Human Health
  • Texas Tech University
  • Lubbock, TX 79409-1163, USA
  • E-mail s.ramkumar_at_ttu.edu
  • Tecnitex Nonwovens, Ltd., Bangalore, India
  • Presentation given at the FICCI Agrotextiles
    conference held on 1st Oct 2008

2
Global Economic Situation Public Humiliation
  • World Economy is at Crossroads

Source Public Humiliation by James Surowiecki,
The New Yorker, September 24, 2008
3
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.

4
Implications of Global Economy and Indian 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
    global
  • economic situation.
  • Indian textile industry should diversify.

5
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 8 in USA and Europe.
  • This sector is at infancy in India and offers
    tremendous
  • growth and opportunities until 2050.

6
Technical Textiles Nonwovens
7

What are Technical Textiles ?
  • 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.

8
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

9
What are Nonwovens?
  • As the name indicates nonwovens are not woven
    fabrics.
  • Cost effective process as it skips intermediary
    processes such as spinning, weave preparation and
    weaving.

Fiber
Fabric
without weaving
  • High speed and productivity compared to
    conventional/woven processes.

10
General Definition of Nonwoven Fabrics
  • Nonwoven fabrics are flat structures mainly
    defined as sheets or webs made by bonding and
    entangling fibers or filaments by mechanical,
    thermal or chemical means.

- Mahmud and Ramkumar, Man-Made Textiles in
India, September 2001
11
Major Nonwoven Technologies
  • Needlepunching
  • Thermalbonding
  • Airlaid
  • Spunbonding
  • Meltblowing
  • Spunlacing/hydroentanglement

12
Nonwoven Technologies
  • Spunbond Synthetic
  • Meltblown Synthetic
  • Needlepunching Versatile (natural and
    synthetic)
  • Hydroentangling Versatile (natural and
    synthetic)

13
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

14
Technology and End-use Applications
  • Spunbonding surgical gowns, diaper cover stocks
  • Meltbowning barriers, filters and face masks
  • Needlepunching Geotextiles, automotive fabrics
  • Thermalbonding upholstering, cussion pads
  • Hydroentangling wipes

15
Needlepunching Technology
Nonwoven Laboratory at Texas Tech University
16
Contoured Needleboard Technology
Width 1.2 mts.
17
Contoured Needle Zone
18
Nonwoven Line
Hopper Feeder
Opening fine beating and tuft reduction
Double Cylinder Card
Web forming removal of tufts parallel
orientation
Cross Lapper
Web formation - high loft, layered webs
H1 Needle Loom
Web consolidation Interlocking of fibers
19
Meltblown Process
20
Spunbonding Process
21
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

22
Global Nonwovens Outlook
23
Worldwide Production By Region (millions of
tonnes)
Source INDA Estimates, Ian Butler, INTC-2008
24
Nonwoven Growth By Region(, based upon tonnes)
Source INDA Estimates, Ian Butler, INTC-2008
25
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
26
Nonwoven Consumption Per Capita(kilograms)
Source INDA Estimates, Ian Butler, INTC-2008
27
Nonwoven Consumption Rises as GDP Per Capita
Increases
Kg/Capita
Trend line
PPP in US equivalents
Source INDA Estimates, Ian Butler, INTC-2008
28
Worldwide Consumption of Technical Textiles (000
tonnes)
Region Years Years Years Years CAGR CAGR CAGR
Region 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
29
Worldwide Consumption of Technical Textiles (000
tonnes)
Application Area Years Years Years Years CAGR CAGR CAGR
Application Area 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
30
Growth Prediction of Technical Textiles in India
31
Consumption Of Nonwovens/TT in India Vs. GDP Per
Capita (Assuming An Increase Of 13.27 In Per
Capita Every Year)
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
GDP per capita source World Bank
32
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
33
India vs. USA Per Capita Nonwoven/TT Consumption
(2005-2050)
GDP per capita source World Bank
34
Indias Per Capita Consumption vs. Income Levels
(2005-2050)
GDP per capita source World Bank
35
Agrotextiles(Few Examples)
36
What are Agrotextiles ?
  • Agricultural Textiles are used for Increasing
    yield, quality and safeguarding agricultural
    products.
  • Agrotextiles are basically technical textiles
    that have specialty applications in agriculture,
    horticulture, aquaculture, animal husbandry
    forestry.
  • Agricultural Textiles find applications right
    from sowing to harvesting.
  • They offer new insight on solving the problems
    faced by agricultural industry.
  • Various technical textiles such as woven,
    nonwoven, knitted, nets and coated textiles are
    used as agrotextiles.

37
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

38
Agro Shade Cloths
  • Shade cloth/Shade Netting
  • These are sunscreens and provide necessary
    protection to the plants against
  • Excessive heat,
  • Burning of the crops due to direct sunshine and
  • UV damage.

Source www.karatzis.gr/products/agricultural/04s.
jpg
Range of shade percentages are 25, 35, 50,
75 and 90
Examples Knitted or woven polyethylene
fabrics. Should not rot or become brittle
should avoid mildew formation
39
Frost Covering
  • Adverse Effects of Frost
  • Frost can kill the seeds and adversely affect
    the ariel portion of the plant.
  • Frost makes the plant loose its moisture and dry
    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 dry
    quickly are used. These fabrics should provide
    open spaces for crop treatments.

Source http//www.anti-frost.com/
Examples Nonwoven spunbonded mesh fabric and
nonwoven UV resistant polypropylene fleece.
Source http//www.anti-frost.com/
40
Harvesting Aides
  • Harvesting nets are used to collect the fruits
    falling from a tree.
  • This helps to keep the cost of cultivation low by
    eliminating additional labor associated with
    harvesting.
  • Harvesting nets are predominantly grip structures
    which can be developed using warp knitting
    technology.

Source http//farm4.static.flickr.com/3169/263881
0726_a4ceefdcc6.jpg?v0
Source http//lh3.ggpht.com
41
Windshields
  • Windshields are used to protect the
  • crops from high velocity wind damage.
  • These can also be used to control the temperature
    by hindering cooling due to the wind.
  • These are installed perpendicular to the
    direction of the wind to reduce the wind speed.
  • These Prevent
  • Breaking of branches,
  • Early falling of the fruits and
  • Damage to the leaves and flowers.

Source http//www.arrigoni.it
Examples Woven and knitted UV stabilized
windshields using high density polyethylene
monofilaments.
Source http//www.karatzis.gr
42
Landscape Covers
  • These are used for weed control and prevent
    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
43
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
44
Pesticide Protective Clothing
45
Pesticide Protective Materials
Three layered Chemical Protective Fabric Patent
Pending
46
Conclusions
  • 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 .
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