5. voltas innovations
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Transcript of 5. voltas innovations
Textile Machinery Division
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 & PolyethyleneProtective 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, GlassSurgical Masks
Polyester & Polyethylene Surgical Drapes , Cloths
Textile Machinery Division
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, NCUSA
Dilo RepresentationOffice ShanghaiPR China
Dilo RepresentationOffice MoscowRussia
sales representatives in over 80 countriesworldwide
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
Fibre – Opening & Blending
Nonwoven Carding
Cross-Lapping
Pre-Needle Loom
Finish Needle Loom
Winding & Cutting
NEEDLE PUNCHING FLOWCHART
Textile Machinery Division
FIBRE OPENING & BLENDING
Textile Machinery Division
NON-WOVEN CARDING
Textile Machinery Division
Textile Machinery Division
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
NEEDLE FELT TECHNOLGY
Textile Machinery Division
NONWOVEN CARD
CROSS LAPPER
NEEDLE LOOM
LAYOUT FIBRE OPENING &BLENDING
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
Card Feed – Vento Feed
DELTA CARD
HYPER LAYER
Minimum GSM – 80
Card Feed – Chute Feed
Servo or Super Servo Card
Horizontal Cross Lapper
Textile Machinery Division
DELTA CARD
Textile Machinery Division
Economic Considerations
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 widthat 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 Width20 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 widthNeedle life: approx. 300 Mill. Stroke
Jet StripsCa. 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
Working Width : 2.5 Mtr, Production Speed : 100 Mtr / MinFinal Product Weight : 50 GSM, Final Product Output : 750 Kg / Hr
Textile Machinery Division
Cyclopunch – Application AreasMedical 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
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
U.S.MARKET POTENTIAL
Textile Machinery Division
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 2003 2004 2005 2006 2007
$437.80 $547.00 $631.80 $712.70 $703.00 $809.00
U.S.MARKET POTENTIAL
Textile Machinery Division
US TRADE of NONWOVENS.xls
Textile Machinery Division
S.NOMEDICAL TEXTILE
PRODUCT
MARKET POTENTIAL
( Rs Mn)
2005 2010
1 Sanitary Napkins 4819 8519
2 Incontinence Diapers 605 1070
3 Surgical Dressing 5828 10302
4 Health Care Textiles 1491 2635
5 Sutures 3160 5587
6 Medical Devices & Implants 1190 2104
Consumption on Different Categories of Medical Textiles
Textile Machinery Division
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