Nonwovens in medical industry - Ahlstrom-Munksjö...• Nonwovens are used in many medical and...

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1 © Ahlstrom Nonwovens in medical industry Ahlstrom Corporation Paul Marold, Senior Vice President, Advanced Nonwovens Rami Raulas, Senior Vice President, Sales & Marketing June 15, 2009

Transcript of Nonwovens in medical industry - Ahlstrom-Munksjö...• Nonwovens are used in many medical and...

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Nonwovens in medical industry

Ahlstrom CorporationPaul Marold, Senior Vice President, Advanced NonwovensRami Raulas, Senior Vice President, Sales & MarketingJune 15, 2009

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Agenda

1. Ahlstrom today

2. Medical nonwovens market

3. Ahlstrom solutions in medical nonwovens

4. Single-use vs. reusable medical fabrics

5. Nonwovens in the prevention of pandemics

6. Summary

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1. Ahlstrom today

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Ahlstrom today

• Leading supplier of fiber-based materials

• 6,100 employees in over 20 countries on six continents

• Business segments• Fiber Composites • Specialty Papers

• Listed on the NASDAQ OMX Helsinki since 2006

• IPO proceeds used for growth mainly in BRIC-countries (Brazil, Russia, India, China)

• Net sales EUR 1.8 billion in 2008

• Founded in 1851

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Ahlstrom locationsSales officesPlants

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Roll goods producer

Pulp producers

Synthetic fiber producers(PET, PP, glass)

Chemicalsuppliers

Printers (label, decor, poster, wallcover...)

Label metalizers

Siliconizers

Automotive industry suppliers (filter, gasket)

Compositeindustry

World class consumer or industrial brands

Raw material supplier

Primaryproduction

Converter Marketer/seller

Consumers

Industrial customersNatural

fibers (wood,cotton, hemp)

Oil/petro-chemicals

Ahlstrom in the value chain

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romNet sales by business area (Q1/2009) & end useapplication examples

Glass & IndustrialNonwovens

Release & LabelPapers

Technical Papers

Home & PersonalNonwovens

Filtration

AdvancedNonwovens

Building

GraphicsTransportation

Healthcareand hygiene

Food and industrialpackaging

Utilities

17%

15%

12%

28%

17%

12%

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Specialty papers market position (1)

Leading supplier of fiber-based materials

Nonwovens market position (2)

1) Source: Pöyry 2008 2) Source: Nonwovens Industry, September 2008

First Quality

Buckeye

Fibertex

Johns Manville

PGI

Ahlstrom

Kimberly-Clark

Freudenberg

DuPont

0 500 1000 1500$'m

Koehler

International Paper

Wausau Paper

Stora Enso

NewPage

UPM

Arjowiggins

Felix Schoeller

Ahlstrom

MeadWest-vaco

1000Tons'000

0500

Fiberweb

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Leading position in most product lines

Ahlstrom is the market leader ornumber two in:• Transportation filtration• Glass fiber tissue• Pre-impregnated decor paper• Nonwoven wipes• Wallpaper and poster paper• Crepe paper• Food nonwovens food casings &

infusion• Genuine vegetable parchment• Release base paper• Medical nonwovens• Abrasive paper• Glass fiber specialty reinforcements• Metalized label papers• Post-it papers

Key competitors

• Filtration: Andrew Industrial, H&V, Neenah

• Glass Nonwovens: Johns Manville, OCV, Saertex

• Technical Papers: ArjoWiggins, M-real, Neenah, Nordic Paper, SAPPI

• Release & Label Papers: ChamPaper Group, Delfort, New Page, UPM

• Advanced Nonwovens: PGI, Dupont, Kimberly-Clark

• Home & Personal Nonwovens: Jacob Holm, Kimberly-Clark, PGI

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2. Medical nonwovens market

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What are medical nonwovens?

• Nonwovens are used in many medical and surgical applications:• Surgical drapes• Surgical garments such as gowns, caps, scrubs, aprons, and

shoe covers • Sponges, swabs• Dressings and wound-contact pads of any kind• Face masks

• Nonwovens can be used outside the operating room as well in applications like home healthcare, temperature management and personnel protective equipment (PPE)

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Medical applications

Surgical Gowns

Surgical Drapes

Facemask components

Sterile Barrier Systems

Facemask

GownsPPE

TEMPERATURE MANAGEMENTHOME

HEALTHCARE

Warming Blankets

OPERATING ROOM

Warming Blankets

BVBHOSPITAL

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romThe Medical Nonwovens market exceeds EUR 1.4 billion

Rest Of the World24 %

North America42 %

Europe34 %

Medical nonwovens market size by geographical area 2008

Source : Internal Ahlstrom Intelligence, INDA Report, 2008

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Global Disposable Market split by product segment

Facemasks8 %

Drapes42 %

SterileBarrier

Systems21 %

Gowns29 %

Product segments by volume (tons)

Source : Internal Ahlstrom Intelligence, INDA Report, 2008

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Global growth potential per region 2007-2012

0102030405060708090

100

NorthAmerica

Europe AsiaPacific

ROW

Global market demand (single-use medical fabrics)

% in

tons Growth estimate for

2007-2012Volume in 2006

Source: D. Rigby – Nonwovens End-Use produtcs; INDA; World Demand and Supply Outlook for Spunbonded Polypropylene and Spunbonded/Melt Blown Composites, John R. Star, Inc. – June 2002; internal discussions; Freedonia 2006

3 %

5.6% 7.2%

6.7%

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romGlobal growth potential per product segment2007-2012

0102030405060708090

100

Drape Gown SterilizatonWrap

Facemasks

Global market demand

% in

tons Growth estimate for

2007-2012Volume in 2006

5.1%

5.1% 4.1%

11.1%

Source: D. Rigby – Nonwovens End-Use produtcs; INDA; World Demand and Supply Outlook for Spunbonded Polypropylene and Spunbonded/Melt BlownComposites, John R. Star, Inc. – June 2002; internal discussions; Freedonia 2006

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Key growth drivers

• Rising standard of living in Asia Pacific

• Aging population worldwide • (APPENDIX: population pyramids in India, China, USA & Finland)

• Ongoing awareness of and concern over hospital acquired infections (HAI)

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Growth drivers by market area• USA

• Medical market is mature – growth is slowing due to saturated market• US Market is highly penetrated – thus little opportunity for growth

Surgical drapes: 90-95% of all major surgical proceduresSurgical gowns: 80% of all major surgical procedures

• Europe• Projected to experience high growth in medical nonwovens sector in the

coming years • Local national standards being harmonized into European Standards (EN) –

e.g. medical devices, protective equipment• APAC

• Rising standard of living, particularly in China, facilitates higher healthcare expenditures

• India• Traditional major disposable markets of absorbent hygiene, surgical apparel

and patient drapes are underdeveloped, yet large potential markets • Indian market still very oriented to cotton (reusable textiles)• Healthcare industry growing at a rate of over 20%

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Medical nonwovens value chain

Raw Materials Roll GoodsManufacturing

Converter Customer

Input: Fibers Input: Roll goods

Resin

Bale Fiber

Web Formation

Bonding

Finishing Cutting/Slitting

Sewing

Folding

Packaging

Sterilization

Distributor

Wholesaler

Hospital

Clinics

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3. Ahlstrom solutions for medical nonwovens

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Advanced Nonwovens business area

Medical Fabrics

Food Nonwovens

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Medical fabrics

• Manufacturing in the USA, Europe and (starting in early 2010) India

• Material attributes provide infection control,sterility and guarantee patient, doctor and staff safety

• Ahlstrom provides single-use medical fabrics for operating rooms and other protective applications worldwide

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Market positioning

• Medical Sales

• 5 Technology Platforms : SpunlaceFilm based composites (BVB)Spunmelt (SMS)Spunlace CompositeWetlaid

• Ahlstrom is 2nd largest supplier in medical nonwovens

• Leader in technology and innovation: 36 % of revenue comes from new products

• Major wet-laid supplier for medical applications

• Leader in facemask coverstock

Europe14 %

North America

76 %

Asia10 %

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Ahlstrom products for medical nonwovens

• Surgical drape• Back Table Cover• Drape sheet

• Surgical gown• Procedure/ Isolation gown• Scrub suit

• Facemask materials• Operating room• Dentist office

• Sterile barrier systems• Sterilization wrap• Tray liner

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Our manufacturing platform

PlantsSales offices

Windsor Locks, CT, USA

Chirnside, UK

Mundra, IndiaStart up in early 2010

Ställdalen, Sweden

Pont-Audemer, France

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Pioneering into the medical market

• Ahlstrom entered the market through the DexterNonwovens acquisition in 2000 (EUR 275 million)

• Sterilization wrap• Surgical drape and accessories• Facemask materials

• Ahlstrom then invested in new technologies• Nonwoven composites combined with specialty films - 2001• Impacting the market in North America for surgical drapes and the globe

for gowns (BVB - Breathable Viral Barrier) - 2002

• Ahlstrom continues to invest• New plant starting up in India - 2010

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Customer references

• Ahlstrom works with the major marketers in established markets:• Europe #1, #2 & #4• North America #1, #2 & #3• Japan #1 & #2

• Customer relationships are based on joint development and supplychain optimization

• Customers include e.g.• OneMed• Mölnlycke Health Care

• Ahlstrom is recognized for product innovation, quality, and after-saleservice

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New medical fabrics plant in India

• After an investment of EUR 38 million, Ahlstrom will start a new spunmelt nonwoven plant in Mundra, in the western Indian state of Gujarat

• Mainly targeting the medical market, it will manufacture a full range of multi-layer spunmelt fabrics for applications in gowns, drapes and facemasks

• Strategically located close to suppliers and customers

• Consolidates Ahlstrom’s position as one of the top-three global nonwoven suppliers

• Commercial production will start in early 2010

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4. Single-use vs. reusable medical fabrics

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Background

• In Europe up to 1970 - 1975 all hospital garments were reusable made with conventional textiles (cotton & cotton polyester)

• Conventional reusables have been linked to the increase of Hospital Acquired Infections (HAI) hospital infection

• In the early 1970’s wetlaid single-use surgical drapes & gowns started to replace cotton & cotton polyester in the USA and later in Europe

• In the late 1980’s the textile industry responded with introduction of new textiles (Goretex and Micro –fibres)

• Single-use fabrics have evolved over the last few years from paper to cloth-like (Spunlace, SMS, Triplex, Bicomponent)

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Background

• Developed countries have high single-use penetration, with growth expected in emerging countries (BRIC)

Estimated single-use penetration in % vs. conventional textiles

4 5 10 15

40

55 60

95

0

10

20

30

40

50

60

70

80

90

100

%

Africa Russia South America Asia Arabic countries Europe Australia USA

Source: management estimate

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Trends

• Many hospitals are still treating wound infections rather than pro-actively avoiding infections

• Abuse of antibiotics has created resistance to treatment in hospitals

• Throughout the world new Viruses and Multi Resistant Bacteria (MRSA) are becoming a factor in HAI’s (Hospital Acquired infection)

• Worst-case scenario: a Pandemic (Mutated H5N1 Avian Flu ~ H1N1 Swine Flu)• WHO just announced that Swine flu is a pandemic (June 11, 2009)

• Governments are reducing healthcare budgets

• Private insurance costs are increasing

• Need to reduce/eliminate hospital infections and mortality rates

• The aged population is increasing

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RegulationsSINGLE - USE REUSABLE

COMPLIANCE WITH GLOBAL STANDARDSCOMPLIANCE WITH GLOBAL STANDARDS

BARRIER PROTECTION BARRIER PROTECTION

FLEXIBILITY IN USE FLEXIBILITY IN USE

CONSISTENCY IN USECONSISTENCY IN USE

YES

Completely fulfill global standards

YES

From blood-borne pathogens and cross contamination

YES

When incision needs to be enlarged/modified

YES

Always new and clean, consistent in performance

NO

Conventional textiles do not

NO

Do not give any protection

NO

Reduced flexibility

NO

Textile can be compromised during laundering process (dirt, virus parts, blood…)

VS.

VS.

VS.

VS.

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Environmental impactSINGLE-USE REUSABLE

ENVIROMENTALLY “GREEN”ENVIROMENTALLY “GREEN”

WAREHOUSE STORAGEWAREHOUSE STORAGE

YES

Single use products are incinerated generating energy (2000T per day creating 200 million KWh yearly)

Single use drapes and gowns represent only 2% of hospital waste (hospital waste only 2% of municipal waste)

Synthetic fibers need 0 hectare agricultural area

Less than 1% of crude oil globally is actually consumed in production of man-made fibers

NO

Stock continually replenished

NO

High amount of detergent needed to launder and possible fluoro-carbonates (textiles need repeated impregnation)

Hospital or external laudries drain “contaminated wash water”

Cotton needs 1.3 hectare agricultural area/ton fiber

Cotton fields need lots of water (25000m3/ton) fertilizer pesticides, herbicides which destroy land by chemical pollution

YES

Substantially more storage space – stock, prepared and used must be stored

VS.

VS.

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Cost comparison

SINGLE - USE REUSABLELOWER FIXED COSTSLOWER FIXED COSTS

HIGHER VARIABLE COSTSHIGHER VARIABLE COSTS

YES

Fixed costs to hospitals

NO

NO

Unexpected repair/replacement costs

YES

Sorting, segregation, sharp instruments damage, laundering, inspection, folding,

packing

LOWER OTHER COSTSLOWER OTHER COSTS

YES

Reduced costs to hospitals due to reduced HAINO

VS.

VS.

VS.

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5. Nonwovens in the prevention of pandemics

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The facts of influenza

• Influenza, also known as the flu, is caused by a virus

• Antibiotics will not cure influenza

• In the last century: three pandemics

• Spanish Flu (1918-19), 40 million people died

• Asian Flu (1957-58), estimate 1 million people died

• Hong Kong Flu (1968-69), estimate 1 million people died

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Pandemic influenza

1. Influenza pandemics are recurring events

2. All countries must be prepared

3. Existing medical supplies are not inadequate

4. Causes large number of deaths

5. Causes economic and social disruption

6. WHO will alert the world when a pandemic threat increases

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PREVENTION

• Education/awareness

• Animal extermination

• Travel restrictions, closure of borders

• Quarantine

• Vaccine inventory

PROTECTION

• Proper hygiene techniques

• Source protection• Poultry workers• Healthcare providers

• Protective Apparel• Eye, face, glove, garment

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Ahlstrom BVB applications

• BVB = Breathable ViralBarrier

• Surgical gowns • Reduce cross-

contamination between medical staff and patient’s body fluids

• PPE (Personal Protective Equipment) apparel :

• Protection for pandemic Influenza

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BVB technology

• Construction• Outer layer: additional fluid

repellency & strength • Middle layer: responsive,

monolithic membrane for impervious barrier

• Comfort layer: soft touch to the wearer’s skin

• Protection against bacteria and viruses, as small as 0.027 micron (Avian flu/Swine flu: 3x larger=0.08-0.12 microns)

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BVB: Product benefits

• Barrier against viruses such as:• Hepatitis, HIV, AIDS, CJD

• MRSA (bacteria)

• SARS, Avian influenza, Swine influenza

• Liquid barrier• Reduces cross-contamination between medical

staff and patient’s body fluids

• In compliance with international standards

• Comfortable to use: light weight, breathable, cool

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Global standards compliance (2009)

Europe

EN 13975parts 1,2,3

MDD 93/42/EEC

PPE 89/686/EEC

Endorsed by AFPP/NATN

Global

Recognized by Center for Disease Control

Certified by China CDC

North America

AAMI PB-70Level 4

ASTM F1670/1671OSHA Guidelines

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Where is Ahlstrom BVB used?

Under evaluation

In use

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6. Summary

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Ahlstrom medical fabrics – summary

• More than 25 years of expertise in the medical market

• Growth through innovation

• Customized solutions based on a broad technology base

• Globally expanding manufacturing and service network

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The future of medical nonwovens

• Continued focus on infection prevention

• Driven by innovation and cost-effectiveness

• The effect on demand of emerging markets and an aging population

• Leveraging Ahlstrom’s global reach

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APPENDIX

Population pyramids in the years 2000 and 2025

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India in 2000

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India in 2025

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China in 2000

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China in 2025

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Finland in 2000

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Finland in 2025

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USA in 2000

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USA in 2025