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Technical Textiles & Nonwovens: Product Applications Trends World and India

Seshadri Ramkumar Nonwovens and Advanced Materials Laboratory Texas Tech University Lubbock, TX, USA s.ramkumar@ttu.edu Technotex, January 17-19, 2013, New Delhi, India

Overview
Growth Statistics Nonwoven Processes Examples of Nonwoven Products

Nonwovens Growth Prospects


Grew by 5.7% in 2011 in volume terms. Spunmelt recorded growth of over 9% in 2010 and 2011. Spunlace is the important drylaid technology.

Source: EDANA, July, 12, 2012

Nonwovens Growth Prospects


Markets that recorded growth include baby diaper, medical, personal care wipes, civil engineering, automobiles and agriculture applications. Growth in 2010: 10.9% Growth in 2011: 5.7%
Source: EDANA, July, 12, 2012

Outlook for Worldwide Nonwovens Production (millions of tonnes)


Growth Rate 2006-2011 (%/Year) 3.00% 4.60% 10.50% 3.00% 0.00% 3.60% 16.60% 6.00% Growth Rate2011-2016 (%/Year) 3.30% 5.90% 12.00% 5.70% 1.20% 7.70% 14.60% 7.80%

2006 NAFTA Europe China Other Asia Pacific Japan Middle East Rest of World TOTAL 1.61 1.56 0.97 0.51 0.33 0.26 0.44 5.68

2011 1.87 1.95 1.65 0.59 0.33 0.32 0.9 7.61

2016 2.2 2.6 2.82 0.78 0.35 0.45 1.88 11.08

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

Outlook for Worldwide Nonwovens Production


Growth Rate 1997 2002 2011 2016 1997-2010 (%/Year) Dollars $11 (billions) Sq Meters 61 (billions) Tonnes 2.7 (millions) 4.0 7.6 11.1 7.7% 7.8% 93 205 305 8.7% 9.0% $15 $26 $37 6.2% 7.8% Growth Rate 2011-2016 (%/Year)

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

Summary of 2011 NA Disposable Market 1,091,000 (tonnes)

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

Summary of 2011 European Disposable Market 1,096,200 (tonnes)

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

2011 Asian Nonwovens Market 2.6 million tonnes

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

Nonwoven Consumption Per Capita (kilograms)


India Russia S. Africa Brazil South America China Mexico Turkey Saudi Arabia Malaysia Japan Australia Europe -27 NAFTA Korea Taiwan

Emerging Markets

Early Development Markets

Developed Markets High export volumes

Source: INDA Estimates, Ian Butler, INTC-2008

Nonwoven Consumption Rises as GDP Per Capita Increases *


Kg/Capita Trend line

4.5 4 3.5 3 2.5 2


China now Turkey Czech Rep. Japan Korea Taiwan Europe NAFTA

1.5 1 0.5 0 $0
Brazil India, 2012

India now

$10,000

$20,000

$30,000

$40,000

$50,000

* PPP in US$ equivalents


Source: INDA Estimates, Ian Butler, INTC-2008

Consumption Of Nonwovens/TT in India Vs. GDP Per Capita


(Assuming An Increase Of 13.27% In Per Capita Every Year)
YEAR 2005 2010 2015 2020 2025 2030 2035 2040 2045 2050 GDP PER CAPITA (US$) 733 1374 2563 4780 8912 16618 30985 57773 107720 200850 CONSUMPTION OF NONWOVENS/TT (kg) 0.08 0.15 0.27 0.51 0.95 1.77 3.31 6.16 11.49 21.43 GDP per capita source: World Bank

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 2010 2015 2020 2025 2030 2035 2040 2045 2050

42499 52435 65656 82213 102943 128901 161404 202103 264705 331452

3.5 4.32 5.41 6.77 8.48 10.62 13.29 16.64 20.84 26.10 GDP per capita source: World Bank

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

GDP per capita source: World Bank

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

Nonwoven Process
Nonwoven process consists of three major steps: 1) Fiber feeding 2) Web/matt formation 3) Web consolidation/interlocking

Nonwoven Processes

Source: TAPPI & Gajanan Bhat, University of Tennessee

Major Nonwoven Technologies


Needlepunching Thermalbonding Airlaid Spunbonding Meltblowing Spunlacing/Hydroentanglement

Nonwoven Technologies
(Based on Fiber Type) Spunbond Synthetic Meltblown Synthetic Needlepunching Versatile (natural and synthetic) Hydroentangling Versatile (natural and synthetic)

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

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

Melt Blowing Process


Uses a high-velocity stream of air to force the filaments away from the spinneret face. Fibers are attenuated by air-stream to a degree of fineness much smaller than typical extruded textile fibers. Fibers (typically 1-5 microns) are deposited onto a condenser/conveyer belt and bonded before take-up. Makes a web with very fine pore-structure and large surface area. Suitable for absorption and filtration applications.

Source: Gajanan Bhat, University of Tennessee

Melt Blown Webs


Fiber Diameter (2-5 m) Uniformity Air permeability/Hydrohead Filtration efficiency Porosity, pore size & Distribution Mechanical Properties Composite structures
Source: Gajanan Bhat, University of Tennessee

Spunbond Nonwovens

Spunbonding Process
Integrated process. Production rate: 30 to 300 m2 /min. Filament production speed: 1000-6000 m/min being operated. Isotactic polypropylene has been used predominantly in commercial production. Other Polymers Used: Polyesters, Nylons, PE and Bicomponents.
Source: Gajanan Bhat, University of Tennessee

Spunbonded Fabrics
Random fibrous structure. Basis weights range between 5 and 800 g/m2, typically 10-100 g/ m2. Web thickness range between 0.1 and 4.0mm, typically 0.21.5mm. Fiber diameters range between 1 and 50m, but the preferred range is between 15 and 30m. High strength-to-weight ratios compared to other nonwoven and knitted structures. High tear strength.
Source: Gajanan Bhat, University of Tennessee

Spunbonding Process Variables


Spinning
Melt Temperature Throughput Quench Air Temp Draw Down Speed

Bonding
Type Bond Area Temperature Time (Speed) Pressure

Laydown
Spinning Speed/Belt Speed

Source: Gajanan Bhat, University of Tennessee

Spunlace Nonwovens

Spunlace Nonwovens
Spunlace is an industrial terminology for nonwoven fabrics made by interlocking using high pressure jets of water. Pre-wetting pressure 20 to100 bars. Maximum operating pressure 250 bars. Spunlace are predominantly used as wipes.

Examples of Nonwoven End Products

Nonwovens in Automobiles: A Glimpse of Value-Added Application

Source: Cos Camelio, Association of Nonwoven Fabric Industry, USA

Diaper

Cover Stock is Spunbond ~ 10GSM

Spunlace Wet Wipes

Moistened Hand Wipes

Majority of moistened wipes are Spunlace

Insulation High Lofts

Awareness on the Technical Textiles Converted Sector

Converted Products are Necessary

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