Transcript Novel Fabric Structures for Defense and Value

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: [email protected]
*
Tecnitex Nonwovens, Ltd., Bangalore, India
Presentation given at the FICCI Agrotextiles conference held on 1st Oct 2008
Global Economic Situation:
Public Humiliation
World Economy
is at Crossroads
Source: Public Humiliation by James Surowiecki, The New Yorker,
September 24, 2008
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.
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.
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.
Technical
Textiles
&
Nonwovens
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.
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
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.
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
Major Nonwoven Technologies
• Needlepunching
• Thermalbonding
• Airlaid
• Spunbonding
• Meltblowing
• Spunlacing/hydroentanglement
Nonwoven Technologies
Spunbond – Synthetic
Meltblown – Synthetic
Needlepunching – Versatile (natural and synthetic)
Hydroentangling – Versatile (natural and synthetic)
Typical Applications of Nonwovens
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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
Needlepunching Technology
Nonwoven Laboratory at Texas Tech University
Contoured Needleboard Technology
Width: 1.2 mts.
Contoured Needle Zone
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
Meltblown Process
Spunbonding Process
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
Global
Nonwovens
Outlook
Worldwide Production By Region
(millions of tonnes)
10
8.41
9
8
5.75
7
R. Of World
Mid. East
South America
0.4
Asia Pacific
6
3.2
0.3
5
2.69
4
2.0
0.2
1.2
3
0.1
2
1
0.8
2.3
Europe - 27
1.7
1.3
0.8
0.9
1.2
1.5
1.8
1997
2002
2007
2012
0
Source: INDA Estimates, Ian Butler, INTC-2008
NAFTA
Nonwoven Growth By Region
(%, based upon tonnes)
World
China
NAFTA
Europe (27)
Japan
2007-2012
1997-2007
Mid East
Other Asia Pacific
0
5
Source: INDA Estimates, Ian Butler, INTC-2008
10
15
20
2007 Nonwoven Production
(000, tonnes)
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Regions
Europe (27) 1,659
Asia-Pacific *
NAFTA
South America**
Mid. East
R. of World 126
Selected Countries
2,047
1,491
254
174
* Australia, China, Indonesia,
Japan,
Korea,Taiwan,Thailand
** Top 6: Argentina, Brazil,
Chile, Colombia, Mexico,
Venezuela
Source: INDA Estimates, Ian Butler, INTC-2008
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Mexico
Brazil
Mexico
Taiwan
Korea
Turkey
Japan
S. Africa
Saudi Arabia 52
Australia
126
135
130
160
213
93
338
26
62
Nonwoven Consumption Per Capita
(kilograms)
India
Emerging Markets
Russia
S. Africa
Brazil
South America
Early Development Markets
China
Mexico
Turkey
Saudi Arabia
Malaysia
Japan
Developed Markets
Australia
Europe -27
High export volumes
NAFTA
Korea
Taiwan
0
1
2
Source: INDA Estimates, Ian Butler, INTC-2008
3
4
5
6
7
Nonwoven Consumption Rises as
GDP Per Capita Increases *
Kg/Capita
Trend line
4.5
4
Taiwan
3.5
Europe
NAFTA
3
Japan
2.5
2
China now
Turkey
Czech Rep.
1.5
1
Brazil
0.5
India now
Korea
India, 2012
0
$0
$10,000
$20,000
Source: INDA Estimates, Ian Butler, INTC-2008
$30,000
$40,000
$50,000
* PPP in US$ equivalents
Worldwide Consumption of
Technical 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
Worldwide Consumption of
Technical 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
Growth
Prediction of
Technical
Textiles in India
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$)
CONSUMPTION OF
NONWOVENS/TT (kg)
2005
733
0.08
2010
1374
0.15
2015
2563
0.27
2020
4780
0.51
2025
8912
0.95
2030
16618
1.77
2035
30985
3.31
2040
57773
6.16
2045
107720
11.49
2050
200850
21.43
GDP per capita source: World Bank
Consumption Of Nonwovens/TT
in USA vs. GDP Per Capita
(Assuming An Increase Of 4.6% In Per Capita Every Year)
YEAR
GDP PER CAPITA
(US$)
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
India vs. USA Per Capita Nonwoven/TT
Consumption (2005-2050)
GDP per capita source: World Bank
India’s Per Capita Consumption
vs. Income Levels (2005-2050)
GDP per capita source: World Bank
Agrotextiles
(Few Examples)
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.
Applications of Agrotextiles
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Sunscreening (shade cloth)
Frost Covering
Harvesting
Wind protection
Landscape covering
Bird protection
Insect protection
Turf protection
Irrigation
Drainage
Aquaculture
Insulation
Horticulture
Animal Husbandary
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
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
Source: http://www.anti-frost.com/
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.
Examples:
Nonwoven spunbonded mesh fabric and
nonwoven UV resistant polypropylene fleece.
Source: http://www.anti-frost.com/
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.
Source: http://farm4.static.flickr.com/3169/2638810726_a4ceefdcc6.jpg?v=0
• Harvesting nets are
predominantly grip
structures which can be
developed using warp
knitting technology.
Source: http://lh3.ggpht.com
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.
Source: http://www.arrigoni.it
These Prevent:
Breaking of branches,
Early falling of the fruits and
Damage to the leaves and flowers.
Examples:
Woven and knitted UV stabilized windshields using
high density polyethylene monofilaments.
Source: http://www.karatzis.gr
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
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
Pesticide
Protective
Clothing
Pesticide Protective Materials
Three layered Chemical Protective
Fabric: Patent Pending
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 %.