Innovation and Nonwovens

Welspun Group I Textiles

Innovations & Nonwoven Industry

Welspun Group | Textiles


Innovation

• An Innovation is a new idea, device or process.

• An innovation must be replicable at an economical cost and must satisfy a specific need.

• An Innovation can be viewed as the application of better solutions that meet new requirements, inarticulated needs, or existing market needs. This is accomplished through more effective products, processes, services, technologies, or ideas that are readily available to markets, governments and society.

• The term innovation can be defined as something original and, as a consequence, new, that "breaks into" the market or society.


Role of Innovation

• Helps to survive with adverse changes in operating circumstances

• Builds brand equity

• Makes life easier for their customers

• Gains competitive advantage

• Helps to protect market share

• Repositions organization and raises its market profile

• Reinforces a reputation as market leader

• Opens new horizons so as to get out of a rut or avenues with limited potential


Drivers of Innovation

Secure, Clean and affordable energy supply

and usage

ENERGY

Focused on Transport,

Construction and ‘Reduce,

Reuse and Recycle’ Agenda

Sustainability

Technologies for

Healthcare, Creative

industries, Defense &

Security

High Value

Markets

Drivers of Innovation


Disruptive Technology

• A disruptive technology is one that displaces an established technology and shakes up the industry or a ground-breaking product that creates a completely new industry.

• The automobile was a revolutionary technological innovation, but it was not a disruptive innovation, because early automobiles were expensive luxury items that did not disrupt the market for horse-drawn vehicles. The market for transportation essentially remained intact until the debut of the lower priced Ford Model T in 1908.

• The mass-produced automobile was a disruptive innovation, because it changed the transportation market.


Disruptive Technologies

Few examples of disruptive technologies:

• The personal computer (PC) displaced the typewriter and forever changed the way we work and communicate.

• Email transformed the way we communicating, largely displacing letter-writing and disrupting the postal and greeting card industries.

• Cell phones made it possible for people to call us anywhere and disrupted the telecom industry.

• The laptop computer and mobile computing made a mobile workforce possible and made it possible for people to connect to corporate networks and collaborate from anywhere. In many organizations, laptops replaced desktops.

• Smartphones largely replaced cell phones and PDAs and, because of the available apps, also disrupted: pocket cameras, MP3 players, calculators and GPS devices, among many other possibilities.

• Social networking has had a major impact on the way we communicate and -- especially for personal use -- disrupting telephone, email, instant messaging and event planning.


Innovation leading to Disruptive Technologies

• Mckinsey instituted a study to identify technologies that create high impact on human life by 2025

• The study assesses the potential reach & scope along with potential economic impact and disruption of major advancing technology & innovation areas.

• Out of extensive research Mckinsey concluded 12 important areas where innovation is creating ‘Disruptive Technologies’



Mobile Internet Inexpensive and capable Mobile internet

connectivity

Automation of Knowledge Intelligent Software that can perform

knowledge work with unstructured commands

Internet of Things Networks of low cost sensors for data collection and process optimization

Cloud Technology Use of Computer hardware & software

resources delivered over internet

Advanced Robotics Capable robots with enhanced intelligence

used to automate tasks

Autonomous Vehicles Vehicles that can navigate with reduced human

intervention



Next generation Genomics Fast, low-cost gene sequencing, advanced bug

data analytics & synthetic biology

Energy Storage Devices or systems that store energy for later

use, including batteries

3D Printing Additive manufacturing techniques to create objects by printing based on digital models

Advanced Materials Materials designed to deliver superior

characteristics

Advanced Oil & Gas Exploration & Recovery

Exploration and recovery techniques that make extraction of unconventional items economical

Renewable Energy Electricity generation from renewable sources

with reduced harmful climate impact


Advanced Materials : A Disruptive Technology

• A new revolution is taking place in research laboratories of materials.

• Abundant discoveries in ways to produce materials with unique attributes

– Smart Textiles

– Nanomaterial

– Memory Metals

• They have high impact applications and potential to drive the disruptive growth.

• Huge scope for Developing countries in terms of commercialization of materials

– Advanced Composites

– Piezoelectric Materials

– Green Materials


Technical Textiles’ contribution to Advanced Materials

Advanced Materials

Structural

Biomaterials

Functional

Multifunctional

Textiles Reinforcements

Technical Textiles

Smart Textiles

Products Types


Overview

Industry Mapping

Sector Personal Home Environment Health & Hygeine

Environment/Home

Industrial Transport Energy Defence / Advanced Healthcare

Aerospace

Products Fibers

Apparel Bed & Bath

Soft Furnishing, Upholstery

Nets, Marine Ropes,

Tyre Cord

Medical /Surgical

Geo Textiles, Agriculture,

Infrastructure Building

Filtration &

Separation

Automobile Railways

Wind Blades, Solar Panels,

Batteries

Bullet Proof Jacket

High Altitude Clothing

Space-Crafts Air Craft Satellite

Components

Bio Active, Multi

Functional Material

Electronic & Optical

Functional Material

High Performance Zone

Carbon Glass

Aramid

Nylon PP Poly Cotton blends

Construction Woven Woven Warp Knitted Warp Knotted

Knotted, Braided, Twisted

NW, Woven, Warp Knitted,

Knotted

NW, Woven, Warp Knitted,

Knotted

NW, Woven

NW, Woven, Uni & Multi-directional

NW

Woven Uni & Multi-directional

NW


NW


NW

Bio - Active Advanced Materials

Functional Advanced Materials

Advanced Textiles

Technical Textiles

Conventional Textiles

Structural Advanced Materials


Technical Textiles

TECHNICAL TEXTILES

Knitted Nonwoven Composites Woven


Nonwoven Manufacturing Processes

Raw Materials Web Formation Web Bonding

Sp

un

Melt

Chips

(PP / PET) Melt Blown

Spun Melt

SMS

Chemical

Bonding

Thermo

Calendared

Needling

F

A

B

R

I

C

Card

ing

Staple Fiber Carding

Needling

Thermobond

Chemical

Spunlace

Value Addition Conversion

Calendar

Lamination

Coating

Cutting &

Sewing

HF Welding

Ultrasonic

Bonding

R

O

L

L

G

O

O

D

S

E

N

D

P

R

O

D

U

C

T

Lo

w V

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Hig

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About Nonwovens

• World Nonwovens consumption in 2013 stood more than 7 Mn MT valued at US $ 33 Bn

• It is projected to reach 11 Mn MT by 2018 valued at US $ 47.5 Bn (CAGR 7.5%)

Source: Future of Global Nonwoven Market, Smithers Apex 2014

CAGR of 6.4% Projected CAGR of 7.5%

5818 6001 6370 6854

7375 7936

8553 9188

9883 10637

11445

2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018

World Nonwoven Consumption

Consumption '000 MT


Global Consumption Trend

1556 1592 1640 1705 1795 1912

270 281 293 307 325 347 1722 1739 1776 1834 1913 2000

1951 2059 2316 2641

2947 3241 320 330

346 366

395 436

2008 2009 2010 2011 2012 2013

Geographic Nonwovens Consumption 2008-13

North America South America Europe Asia RoW

27%

5%

30%

33%

5%

Global NW Consumption Trend

North America South America Europe Asia RoW

24%

4%

25%

41%

6%

Asian Consumption Increased by 8% over 5 years

FY 2008 5.8 Mn MT

FY 2013 7.9 Mn MT

• Asia registered highest CAGR growth of 10.7% in consumption of NW.

• Asian NW consumption moved from US $ 7.5 Bn to US $ 12.3 Bn.



Nonwoven Market Mapping

Nonwoven World Market: US $ 33.1 Bn, 7.9 Mn MT

Disposables Durables

• US $12.5 Bn • 3.5 Mn MT

• US $20.6 Bn • 4.5 Mn MT

57%

3%

15%

7%

8%

10% Hygiene

IndustrialWipes

Personal Wipes

Home Wipes

Medical

Other

20%

1%

10%

13%

10% 10%

2%

7%

3%

6%

3%

12% 3%

Upholstry

Garments

Floor Coverings

Building

Geotextiles

Automotive

Agriculture

Coating Substrates

Air Filters

Liquid Filters

Interlinings

Other

Leather

Break-up FY 2013 in Value Terms



Market Drivers

Durables Disposables

Consumerism

• Rising Income

• Demographics

• Rising spending power

• Awareness

Technology

• Industry Growth

• Industrial Applications

• Technological Innovations

• R & D


Innovative Non-woven Applications

Segment Product

Automotive Floor, Pillars, Roof liners, Filters, Seat Covers

Medical Surgical Gowns, Mask, Wound care, Disposable bed sheets, Anti-skid hospital Mats, Top sheet for diapers

Protective Flame retardant, Arc flash fabrics

Filtration Air Filtration


High Value Non-woven Applications

Segment Product

Home Textiles

Black out Curtains, Blinds, Disposable bed sheets, Wall paper, Heat reflecting curtains , Rugs, Carpet backings, Insulation Materials

Interlinings For apparels & Leather articles

Geo-Textiles Rail & Road, Soil Erosion Prevention

Construction & Roofing

Roof-Liner, Housewrap


• Company : DuPont, USA

Product Name : Nano fiber Polymeric Technology

Use : Increases battery life by 20% by providing stability at

higher temperature

Application : Hybrid Electric Vehicles, Laptop, Cellphones

• Product : Electo – Adsorptive Filter Media

Innovations


• Company : Ahlstrom, US

• Product Name : Disruptor

• Technology : Wetlaid

• Use : Filters with high flow rate

• Application : Water Filtration

• Product : Electo – Adsorptive Filter Media

Innovations


• Company : Fiberweb, UK

• Product Name : Typar Geo Cells

• Technology : Durable Honeycomb Configuration

• Innovation : Water Confinement System

• Application : Geo Textiles fabric for flood control

• Product : Heavy Duty 3 D Honeycomb Geotextiles

Innovations


Company : Johns Manville, USA

•Product Name : Stabilstrand

Innovation : Sustains Higher Impact, Stabilizes Edges, Protects against

Mechanical damages

Application : Office work-tops, Kitchen counter-tops, laboratory work-tops

•Product : Glass Fiber Nonwoven Impregnated with Semi-cured resins

Innovations


• Company : Hollingsworth & Vose, USA

• Brand Name : Viamat

• Innovation : Nonwoven Aramid Paper used as a core substrate, Ultra-

smooth surface, Enhanced drill ability, Process Capabilities

• Application : Printed circuit boards for Avionics, Medical devices, High

Capacity Servers

• Product : Heavy Duty 3 D Honeycomb Geotextiles

Innovations


• Company : Kimberly – Clark, USA

• Brand Name : Cnon Wovens

• Innovation : Carbon fibers in Paper Making

• Application : Sent release wipes, Heated wipes

• Product : Nonwoven Roll goods

Innovations


• Company : Propex Holdings

• Brand Name : Opus Roof Blanket

• Innovation : Anti skid, Light weight

• Technology : Needle Punch Manufacturing

• Application : Roof Blanket

• Product : Light Weight Blanket

Innovations


• Company : Texel, Canada

• Brand Name : Insulation

• Innovation : Enhanced Acoustical Properties

• Technology : Thermofit Technology

• Application : Replacement of Glass/ PP Composites in Automobiles

and replacement of foam in sitting systems

• Product : Thermal Acoustic Insulator

Innovations


• Company : Vita Nonwovens, USA

• Brand Name : EnGuard

• Innovation : No formaldehyde, Uses PET bottles





Innovations


• Company : First Line Technology, USA

• Brand Name : Fiber Tect

• Innovation : Cotton Carbon decontamination wipes, 3 layer inert

flexible nonwoven composite substrate for absorbing toxic

chemicals

• Technology : Needle Punch with Carbon Imprignation

• Application : Chemical Warfare Protection


Innovations


• Company : Vita Nonwovens, USA

• Brand Name : EnGuard

• Innovation : No formaldehyde, Uses PET bottles





Innovations


• Company : NanoSynTex, USA

• Innovation : 3 D Multilayer Composite Fabric against woven

• Technology : Combination of Spunlace & Needle Punch

• Application : Military Garments, Combat Clothing

• Product : Multiple Properties on different parts

Innovations


Freudenberg $1.65 bn Automotive, Apparel, Energy, Filtration, Home, Industry, Medical

DuPont

$1.40 bn

Construction, Healthcare, Filtration, Absorbents, Home, Geo-textiles, Graphics, Packaging, Auto

Ahlstrom

$1.35 bn

Filtration, Wall Covering, Building, Auto, Labels, Food Packaging, Beverages, Medical

Kimberly Clark $1.30 bn Filtration, Acoustics, Industry, Medical, Protective, Sorbents, Wipes

PGI $1.20 bn -----

Top 5 Companies

Company Revenue FY 13

Segments


3 M

• 46 Technology platforms

• Businesses combine multiple platforms to build unique product solution

• 85 laboratories globally, 30 Technology Centers around the world

• 2500 patents issued in 2010, 43,000+ patents pending for issuance

• Able to commercialize the innovation very fast.

• 3M Innovation Philosophy

‘Research is transformation of money into knowledge’

‘Innovation is the transformation of knowledge into Money’


Freudenberg

• Major focus on Innovation. Increase

sales through new product

development

• 165 years old company with robust

R & D facilities.

• R & D investments FY13 were 3.7%

of sales of Euro 6.7 Bn

• Philosophy

‘Achieve significant sales growth through new products’


Importance of Innovation

• Nonwovens is highly research driven industry.

• Authenticated by R & D expenses by top nonwoven companies .

Company 2012

% of total expenses

2012 % of

revenue Remark

Freudenberg 12.6% 3.5% 5% increase in R & D strength. 13% of total workforce is in R & D

DuPont 6.2% 5.15% 2 bn dollar investment in 2011 in RnD .

Ahlstrom 10.8% 1.11% 14% revenue generated by new products which were developed through R & D. Launches new product every year.

Souminen 10.8% 0.86% R & D expenses decreased in the wake of weak financial results

Fiberweb 15.6% 2.83% In 2012, launched a new 35,000 sq ft R&D facility.


Multiple Technologies: Good Platform for Innovation

Name HQ Processes Plant

Locations Products Remark

2013 Revenue for NW

Ahlstrom Finland

Needle punch, resin bond, spunlace, nanofiber, spunmelt/spunbond, Wet laid, Wetlaid/Hydraspun, Wetlaid/spunlace composite, Wetlaid, composite nonwovens, SPC, crepe, caustic entangled Webril,

20

Filtration, medical, food and beverage, automotive, building, wall cover and hygiene.

• Present focus on India and China • Sold wipes business to Souminan. • Increasing presence in automotive sector

$1.35 Bn

DuPont USA

Flash spun (Tyvek), spun bond (Typar), spunlace, Advanced Composite Technology, Hybrid Membrane Technology

8

Biotech, medical, food and beverage, Furniture automotive, marine, energy, and hygiene

• Controls surgical gowns and protective apparel business • Controls 70-75% of both businesses

$ 1.40 Bn

Souminen USA Hydro-entangled, Thermal bonded

10 Wipes, Nonwovens, Film Packaging

• World leader in wipes. • Acquired wipes line from Ahlstrom.

$ 0.515Bn


Continued….

Name HQ Processes Plant

Location Products Remark

Revenue for NW

Sandler Germany

Drylaid thermally bonded, Mechanically bonded, Meltblown, Needle punched, air through bonded, Spunlace, Flexoprinting, embossing, aperturing

4

Furniture, Hygiene, Industrial, medical, Automotive, Filtration, Wipes

•Increasing focus on BRICIT •Aiming to be a dominant player in wipes

$0.367 bn

PGI USA

Spunbond, meltblown, SMS, composites, through air bonded, Adhesive bonded, Resin bonded, Thermal bonded, Spunlace, airlaid, Apertured, thermal laminated, Hydro-entanglement, and binding systems

11 Healthcare, Wipes, Hygiene, Medical

•Leading player in nonwovens with strong presence on hygiene.

$ 1.2 bn

All major players have multiple technologies, enabling diversified product mix.


Contract R & D

• Globalisation coupled with cost arbitrage have provided platform to outsource R & D and product development activities within & across the countries.

• These R & D centers provide High Value Innovations & Product Transformation services.

• Universities in US & Germany are the leaders in providing such services.


Innovation Tracking

Pay particular attention to Industrial needs &

applications

High level planning & coordination with focus on

Value Capture

Effective use of Academicians & non-

governmental organizations

Paying attention to supporting technologies

Not neglecting ‘conventional’ materials and

technologies

Needs assessment from Public Research

organization.

Particular focus on Nanotechnology & Infra-

technology

Framework on Materials, Manufacturing &

Nanoscience

Attention to Critical materials, raw material

policy and execution

Complete view of Materials, Manufacturing, Nano &

Infra Technology

Specific focus on Critical Materials in terms of

Research & Usage

Effective Coordinating activity

Large scale roadmaps for materials involving all

stakeholders.

Focus on supporting technologies developmental

activities

Programs, Workshops, Promotional Events

GERMANY JAPAN EU


Innovation Tracking System

• Germany, Japan & US have well defined ‘Materials Policy’ .

• They have established system of identifying critical materials and processes for the country.

• Innovations in these areas are encouraged through Private-Public Partnership Model

• Innovations are tracked regularly and progress is monitored


Industry – Academics Interactions

• Universities in Developed countries regular interact with Industry for requirements, Innovations and Newer Product Applications

• These universities, partly funded by industry, conduct Research Task specified by industry and the outcome is tested for commercial applications.

• The culture of cross functional environments exists where an Industry expert can function as University Professor / R & D resource.

• Such healthy interaction of Industry – Academia act as catalyst in Innovation and R & D efforts to create new products.


Patents Filing: World Scenario

• No. of Patents granted by U.S. PATENT AND TRADEMARK OFFICE, Patent Technology Monitoring Team (PTMT) in December 2013 for US is 1,47,666 and that is of India 2,474.

• It shows tremendous scope for India.

147666

54170

16605 15745 12118 7272 6597 6555 6551 3152 2930 2572 2474

Patents by Countries -All Patent Types (December 2013)

No. of Patents

Source: http://www.uspto.gov/web/offices/ac/ido/oeip/taf/cst_all.htm


Govt Support in R & D

• The proposed Textile Policy draft mentions

– The expenses on R & D will be Tax exempt

– Payment to R & D Centers will be exempted from Service Tax

Recommendation

• R & D done by overseas universities for individual domestic companies should be entitled for above benefits.


LATEST INNOVATIONS


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Innovation and Nonwovens

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