Raw Materials for Technical Textiles

Exhibition- cum- Conference on Technical Textiles25th Aug’11

Manohar Samuel

Birla Cellulose

• Fibres and Functional value in technical textiles

• Business Growth recommendation for technical textiles

Presentation Covers…….

Mn T – In Million Tons

Global Fiber Production Scenario

Based on Average Production as on 2010

Natural26 Mn T

Manmade54 Mn T

Linen0.52 Mn T

Silk0.15 Mn T

Wool1 Mn T

Cotton24 Mn T

Synthetics50 Mn T

Cellulosic #4.28Mn T

Polyester37 Mn T

Nylon4 Mn T

Acrylic1.98 Mn T

Others1 Mn T

Staple (Viscose)3.2 Mn T

Tow (Acetate/ Viscose)0.7 Mn T

Filament (Acetate, Viscose, Cupro)

0.38 Mn T

All Fibres80 Million T

Technical Textiles: Million TApparel/Textiles: Million T

Source : Fibre Organon

Olefin6 Mn T

Jute –extra

Source:- Fibre Organon Jun-11

• Dominance of Synthetic filament yarns• Cotton is flat but highly sought after due to its properties• Consistent growth in VSF with highest CAGR%

Share Share Capacity 2012K tons

Share

% % K tons (Projected) % Synthetics Staple

15456 23% 17159 21.4% 2%22322

17858 21.1%

Synthetics Filament

24574 36% 33036 41.3% 6%43948

35158 41.5%

Cotton 24487 36% 24460 30.5% 0% 27400 26000 30.7%

VSF 2076 3% 3246 4.1% 9.4% 4193 3759 4.4%

Others 1838 3% 2182 2.7% 3% 553 2000 2.4%

Total 68431 100% 80083 100.0% 3.2% 98416 84775 100%

Fibre 2005

(KTons)2010

(KTons)CAGR

World Fibre Basket in last five years

What is Technical Textile?Textile products manufactured primarily for their technical and performance properties

Technical Textiles – Importance of Fibre

How do we get the Functional Performance for the End User?Differentiation at Fibre stage Yarn StageFabric StageWet Processing StageTechnology at Fibre, yarn, Fabric and End Conversion stage

Raw Materials for Technical Textiles

1. Regular/Generic fibers

• Natural fibers: Cotton, silk, wool, jute, hamp, ramie, flax• Regenerated fibers: Viscose, Lyocell.• Synthetic fibers: Nylon, PET, PP, Acrylic.

2. Specialty variants of regular/generic fibers

• Flame retardant• Super absorbent • Antimicro bacterial • Ultra fine fibers. etc.

3. High tech/high performance fibers:

• High chemical- and combustion-resistant organic fibres: Nomex, Kevlar

• High performance inorganic fibres: Glass, Asbestos, Carbon

Worldwide Fiber composition in Technical Textiles

• World over, PSF/PFY and PP based products have maximum application in Technical textile, comprising over 50% of the share, the applications are across product categories and usage

• Viscose and other cellulosic fibres has 6% share

Fiber composition in Technical Textiles in India

• In India the fibre composition in Technical Textile is quite contrasting to the world as natural fibres have 50% share.

• Viscose, Cellulosic and Regenerated fibre comprise of 6.6% share which is comparable to the share of these fibres in technical textiles across the world

• Glass fibre for Technical textile in India is just 2.1% where as worldwide it has a 15% share

World Technical Textiles Consumption, 2010

Value wise

$ 127 bn. 23,774,000 tons

Volume wise

Sportech although is 6% of the Volume, in Value terms it contributes 15%,Mobiltech is 14% in volume but 24% in value terms in 2010Packtech is 15% in Volume but contributes 5% in Value terms, similarly hometech is 12% in volume terms but contributes 7% in volume terms

Specialty Variants of Viscose, Polyester and other fibres Viscose Polyester Other fibres

Basic Characteristics Specialty Variant Basic Characteristic Specialty

Variant Fibre Additional Characteristic

Very good softness

Viscose for nonwovens

High melting point, high heat and chemical resistance

High Tenacity PET

Super-absorbent fibre (acrylic)

High absorbency

Excellent absorbency

Viscose with tri-lobal cross-section

Very low moisture absorbency

trilobal cross-section

High Density Polyethylene (HDPE)

High tensile strength

Added strength and moderate abrasion resistance

Temperature regulating Viscose (Outlast )

High strength, Good abrasion resistance,, Good resiliency

Hollow fiber High Modulus PE (HMPE)

Higher modulus

Relatively poor strength wet

Short cut PET/Viscose

Inert, biocompatible & flexible

Flame retardant

High Tenacity Nylon

High tenacity and low shrinkage

Low resiliency Anti-microbial, Anti-bacterial viscose fibers.

Anti-microbial, Anti-fungal, Anti-bacterial PET fibers.

High Tenacity PP

High strength and stability

Natural and pure Fire Retardant (FR) Viscose/PET

Cationic dyeable

Anti bacterial Acrylic

Prevents & limits the growth of bacteria, fungi and microbes.

Fiber Characteristics Applications Key players

Meta Aramid (Nomex)

Heat Resistance, high strength and high impact absorbing capacity

Fire retardant apparel, bullet proof jackets, helmets, gloves etc.

Dupont (USA), Teijin Twaron (Japan), SRO Group (China), Yantai Spandex (China), Kermel (France)

Para Aramid (Kevlar)

High strength to weight ratio, Excellent thermal & chemical stability

Fire retardant apparel, bullet proof jackets, helmets, gloves etc.

Dupont (USA), Teijin Twaron (Japan), Yantai Spandex (China)

Carbon Low weight and high strength

Air craft body, wind mill wings, racing cars.

Toray Industries (Japan), Toho Tenax (Japan), Mitsubishi Rayon (Japan), Zoltek (USA), Hexcelcorp (USA), SGL Carbon AG (Germany) , Kemrock (India)

Polyphenylene sulfide Fibres (PPS)

Highly resistance to heat, acid and alkaline

Electrical products, liquid filters, dryer canvas.

Armoco Fabrics & Fibres Co (USA), Toyobo (Japan), Toray Industries (Japan), etc

Glass fiber Thermal insulation properties with high strength and low elongation.

Automotive bodies, hockey sticks, boats, surfboard etc.

Owens-Corning Fibreglas, Nicofiber (USA), Fibreglass (Canada), Asahi Fibre Glass Co (Japan), Chemitex-Anilana (Poland), Owens Corning , Goa glass, Twiga (india)

High-tech fibre

Fiber Characteristics Applications Key players

Polytetrafluoroethylene (PTFE)

Excellent dielectric properties, high melting point.

Nonstick coating of pans, laboratory containers, magnetic stirrer.

DuPont (USA), Newton Filaments, Inc (USA), Albany Internation Inc. (USA), Toyobo (Japan)

Phenolic fiber High strength Automotive and electrical components.

Phenco (USA), The Vermont Organic Fiber Company (USA)

Conductive fiber

Electric conductive Military garments, intelligent garments.

Shakespeare Conductive Fibres LLC and Bekaert , Bakaert India (India)

PBI (Polybenzimidazole)

High strength and does not burn or melt.

Automotive parts, aircraft parts, insulation shield etc.

Celanese Acetate

Alginate fiber Highly absorbent Wound dressing, textile printing etc.

Speciality Fibres and Materials Ltd (UK), FMC Biopolymer (USA), Degussa Texturant Systems (Germany), Danisco Cultor (Denmark), Kimica Corporation (Japan), China Seaweed Industrial Association (China)

PBO fiber- Zylon

Highest strength among fibers.

Protective clothing and equipments. Toyobo Co. Ltd. (Japan)

High-tech fibre

Cotton Jute Viscose PET Nylon PP HDPE

LDPE/LLDPE

Aramid Glass Carbon

Agrotech

Meditech

Mobiltech

Packtech

Sporttech

Buildtech

Clothtech

Hometech

Protech

Geotech

Oekotech

Inditech

Segment wise consumption of different fibres

Tech Textile – Growth

Role of Fibre Manufacturers

India as Global Manufacturing HubIndia as Consuming Hub owing to the large population

The Key Challenge has been always whether Market comes first or the product

The Answer is both come together……

Technical Textiles – Indian Business Growth Focus

Fibre Innovation first time in the world

Fibr

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nova

tion

first

tim

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r Ind

ia

Application Development for new Product

Application Development Specific to Particular

markets

Business Development – Components & Focus

Role of Centre of Excellence in Tech Textiles

Review and Recommendations for Growth of Tech Textile Sector

• A global understanding o f the Tech Textile sector in size •Ministry of Textiles can extend the base line survey to Global

context •Market potential from current to the next ten years mapped

for need gap analysis

a.Technology and equipment gap – bring in partnersb.Specialty fibre gap – Aramid, Glass fibre etc. R&D and

collaborationsc.Capital equipment Gap - collaboration from abroad.

Recommendations : Market Mapping #1

• To Buy out relevant International samples and decode

• Create facility for Prototype development exactly matching

• Build a studio for their specialization with International samples

• Commercials made for each potential product with Industry

• Tabulate different comparative standards

• Formulate Indian standards for application based

Recommendations : Product Understanding- Role of COE’s #2

• ITTA should support standard formulation ta.Buyer’s standards not mentioned in Global standardsb.Support COE’s for fixing Indian standards with BIS

• ITTA should support technical projects with COE’sa.Practical projects which help to understand Indian conditionsb.Commercial information on worthwhile projects

• ITTA should make a lifetime benefit for large applications - shared with respective user industry ministry along with Textile Commissioner’s Office

Recommendations : Product Understanding- Role of IITA #3

• Gov. of India’s legislation for the safety, cost and welfare of the common man in the following areas wud help.

a.Only BIS and pharmacopeia consistent meditech productsb.Flame retardant fabrics in public places and railways, buses c.Geo tech in all express ways, highways, dams and rail tracksd.Protech for firemen, mining, defense sectors

• Textile Ministry support with the other Ministry’s a.Health Ministry for meditech products and DGCAb.Railways Ministry for Geotechc.Education Ministry for including Tech Tex in syllabus of

*Meditech for MBBS*Geotech for Civil Engineers*Agritech for agricultural engineering*ITI courses for operations of tech textiles

Recommendations : Role of Gov. for Legislation #4

• Excise duty to be at least in line with regular textiles for non-woven tech textiles.

• Duty drawback and DEPB for nonwoven and converted products do not find a mention and needs to be notified

• Specific HS codes is proposed for specialty fibres

• All standards for Non-implantables should have Woven & Nonwoven both as product option; and should thus find a place in govt. tenders

Recommendations : Role of Gov. for Fiscal & Non Fiscal Correction #5

• Leaders in Industry to work with Gov to set up specific Tech Textile parks similar to Apparel parks.

• Technical Textiles should be promoted by all stakeholdersa.Conferences with actual cost benefit and user industry

participation for each sectorb.International Technical Textile Exhibitionsc.Specific websites for technical textiles in Gov. and Industry

Association forums

Recommendations : Role of Indian Textile Industry for Technical Textiles #7

Thank You for your attention