Transcript MEDICAL TEXTILES

INNOVATIONS IN NEEDLE
PUNCHING – MEDICAL
TEXTILES
Textile Machinery Division
MEDICAL TEXTILES
Textiles used for hygiene & health care
operations.
Textile Machinery Division
Constituent Element of Medical Textile
Product
Polymers
Fibres
Yarns
Woven Knitted Braided Non-woven
Fabrics
Textile Medical Products
Textile Machinery Division
CLASSIFICATION - Application
 Healthcare & Hygiene Products
 Extracorporeal Devices
 Implantable Materials
 Non- implantable Materials
Textile Machinery Division
HEALTHCARE & HYGIENE
NONWOVEN PRODUCTS
Fibres
Applications
Polyester & Polyethylene
Protective Clothing, incontinence,
diaper/sheet, Cover Stock
Superabsorbent
fibres,wood fluff
Absorbent Layer
Polyethylene
Outer Layer
Viscose/Lyocell
Clothes/Wipes
Textile Machinery Division
HEALTHCARE & HYGIENE
NONWOVEN PRODUCTS
Fibres
Applications
Cotton, Polyester &
Polypropylene
Surgical Gowns
Viscose
Surgical Caps
Viscose, Polyester, Glass
Polyester & Polyethylene
Textile Machinery Division
Surgical Masks
Surgical Drapes , Cloths
Non-Implantable Material – Nonwoven Products
Fibres
Applications
Cotton, Viscose & Lyocell
Absorbent Pads
Viscose, Cotton Lint, Wood Pulp
Wadding
Poly-lactide, Poly-glycolide, Carbon
Scaffold
Textile Machinery Division
Non-Woven Property –
Medical Applications
 Porosity
 Weight of fabric
 Thickness
 Nonwovens are easy to sterilize
 Various Manufacturing technique options
according to applications
 Economical Manufacturing Process
Textile Machinery Division
Non-Woven
 Nonwovens are webs made of fibres / Polymers –
Web Forming
 For End-use application – Web Bonding
 Web Bonding Methods can be
 Mechanical
 Needle Punching
 Spunlace
 Thermal
 Chemical
Textile Machinery Division
Dilo, Inc.
Charlotte, NC
USA
Dilo Representation
Office Shanghai
PR China
Dilo Representation
Office Moscow
Russia
sales representatives
in over 80 countries
worldwide
History
Dilo
founded in 1902
Spinnbau
founded in 1948
Temafa
founded in 1874
DiloSpinnbau
since 1996
DiloTemafa
since 2005
Textile Machinery Division
NEEDLE PUNCHING
TECHNOLOGY
Textile Machinery Division
NEEDLE PUNCHING FLOWCHART
Fibre – Opening & Blending
Nonwoven Carding
Cross-Lapping
Pre-Needle Loom
Finish Needle Loom
Winding & Cutting
Textile Machinery Division
FIBRE OPENING & BLENDING
Textile Machinery Division
NON-WOVEN CARDING
Textile Machinery Division
Textile Machinery Division
NEEDLE FELT TECHNOLGY
 Felting needles penetrate
through crosslapped fibre
batt
 Barbs of felting needles
catch and transport fibres
 By means of this fibres
entangle, fibre batt
consolidates and needle felt
with strength properties is
created
Textile Machinery Division
LAYOUT
FIBRE OPENING &
BLENDING
NONWOVEN CARD
CROSS LAPPER
NEEDLE LOOM
Textile Machinery Division
WHY NEEDLE PUNCHED FABRICS !
 3 – D Structure
 Composites.
 Extremely High Densities
 High Strength - Geo-Textile Fabrics
 Superior Filtration Properties - World’s Filtration Media
Textile Machinery Division
Major Applications – So Far
 Automotives
 Geo-Textiles
 Filtration materials
 Wipes
 Synthetic Leather
Textile Machinery Division
Major Applications –So Far
 Floor coverings & Wall coverings
 Roofing felts
 Blankets
 Decoration felts
 Paper machine felts
Textile Machinery Division
INNOVATIONS
Hyper Lacing with Cyclopunching
Textile Machinery Division
CYCLOPUNCHING
 Translatory & Circular Moving path – New
Kinematical Concept
 High Density Needling - Individual Fibre transport
 Small Dimensional Changes & distortion in the fabric
plane.
Textile Machinery Division
Textile Machinery Division
HYPER LACING Vs Std Web Formation
 Minimum GSM – 25
 Minimum GSM – 80
 Card Feed – Vento Feed
 Card Feed – Chute Feed
 DELTA CARD
 Servo or Super Servo
Card
 HYPER LAYER
 Horizontal Cross Lapper
Textile Machinery Division
DELTA CARD
Textile Machinery Division
Economic Considerations
Working Width : 2.5 Mtr, Production Speed : 100 Mtr / Min
Final Product Weight : 50 GSM, Final Product Output : 750 Kg / Hr
Criteria
Cyclopunching without preparation
and web forming
Spunlace line incl.drying without
preparation and web forming
Space Requirement
approx.200 Sq.Mtr
approx.700 Sq.Mtr
Investment
approx. 4 Mill. Eur
approx. 6 Mill. Eur
Power
approx.150 KW / Mtr working width
at 0.10 Eur / Kwh
approx. 1000 KW / Mtr
Working Width at 0.10 Eur / Kwh
Water Consumption
NIL
approx. 1.1 KL / Hr / Mtr Working Width
20 Ltr / Min / Mtr Working Width
Waste Water anti-pollution
requirements
NIL
approx.1.1 KL / H / Mtr working width
at 5.0 Eur / Sq. Mtr
Fibre Loss
NIL
approx. 5% Kg Product
at 1.50 Eur / Kg
Consumables
Needles and needle boards ca.0.133 Eur /
Kg / Mtr working width
Needle life: approx. 300 Mill. Stroke
Jet Strips
Ca. 0.004 Eur / Kg / Mtr Working Width;
Strip Life: approx. 1 Year at 50 bar
Operating Costs of Energy, Water,
Fibre loss, needles and boards, jet
strips ( Without depriciation, interest,
personnel, fibre material, chemicals
for water treatment ) at 7,000 Working
hours / year
approx.0.995 Eur per min and m working
width
approx. 2.061 Eur per min and m working
width
Textile Machinery Division
Cyclopunch – Application Areas
Medical Products : Gowns, Drapes, Cover sheets, Towels,
Wound Dressings, Wet Tissue, Pads
Sanitary Products : Baby Wipes
Household and Industrial Wipes, Car Wipes
Home Furnishings : Table Cloths, Napkins, Interlings,
Coating Substrates, Synthetic Leather
Automotive Applications : Headliner, Interior Trim
Filtration Material
Textile Machinery Division
Hyperlacing
Textile Machinery Division
U.S.MARKET POTENTIAL
Market scenario – US Market U.S.Trade of Nonwoven Roll Goods (HTS code
5603, aggregated )
2002
2003
2004
2005
2006
2007
% Change
(2006 - 07
Imports
( Mn. Kg )
116
138
167.3
169.8
161.9
185.9
14.8
Exports
( Mn.Kg )
180
195
227.3
263.3
270.9
258.6
4.5
Textile Machinery Division
U.S.MARKET POTENTIAL
Estimated Value of Exports & Imports, Nonwoven Roll Goods 2002 - 2007
FAS Value : U.S.Exports ( Mn. $ )
2002
2003
2004
2005
2006
2007
$744.40
$914.10
$1,027.30
$1,239.60
$1,391.60
$1,302.60
General Customs Value : U.S.Imports ( Mn. $)
2002
$437.80
2003
$547.00
2004
2005
$631.80
Textile Machinery Division
$712.70
2006
$703.00
2007
$809.00
US TRADE of NONWOVENS.xls
Textile Machinery Division
Consumption on Different Categories of
Medical Textiles
S.NO
MEDICAL TEXTILE
PRODUCT
1
2
3
Sanitary Napkins
Incontinence Diapers
Surgical Dressing
4
5
6
Health Care Textiles
Sutures
Medical Devices & Implants
Textile Machinery Division
MARKET
POTENTIAL
( Rs Mn)
2005
2010
4819
8519
605
1070
5828
10302
1491
2635
3160
5587
1190
2104
ROAD AHEAD
 Enough Awareness on Technology & Potential
Time to TPI
 Product – Market – Flexibility
 Our Role – Right Technology – Cont. Technical Support –
Project Implementation
Textile Machinery Division
Traditional to Technical
Diversify - Flourish
Thank you
Textile Machinery Division