SPUNBOND NONWOVENS - NEW IDEAS

Indian Nonwoven Industry-Present Scenario & Future Prospects

D.K.T.E. Society’s Textile & Engineering Institute, Ichalkaranji,

Dist: Kolhapur, Maharashtra State

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DKTE CENTRE OF EXCELLENCE IN NONWOVENS

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(PROMOTED BY OFFICE OF THE TEXTILE COMMISSIONER, MINISTRY OF TEXTILE, GOVERNMENT OF INDIA)

Technical Textiles

Global Technical Textile Industry outlook

Value-wise share of each segment in global technical textile market

Sources: Report of the Expert Committee on Technical Textiles (ECTT) Volume – I, ‘World Market Forecasts for 2010 of technical textiles and industrial nonwovens’ by David Rigby Associates

Source: Baseline survey of the Technical Textile industry in India, IMaCS Analysis

Value-wise CAGR for various technical textile segments from 2009-10 to 2012-13

Value-wise share of each segment in Indian technical textile market in US$ million

Indian Technical Textile industry

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In the Indian market, needlepunch has the maximum share followed

by spunbond technology due to the high demand for nonwovens in

automobile, hygiene and geotextile sectors.

However spunlace technology has the highest growth rate for future

with a CAGR of 27%.

Organised Retail is expected to grow at 50% for the next five years,

which will be a big boost for products like wipes that make up for

more than 60% of spunlace consumption in the world.

Indian Healthcare Industry is growing at 15%. Privatisation and

increasing medical tourism has resulted in growing demand of

disposable nonwoven products like gowns, caps, masks etc. Spunlace

based products provide high barrier against harmful microbes as well

as provide comfortable wear.

Market Share of Nonwoven Technologies

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Worldwide nonwovens production

Nonwoven Market

Growth rates between 2005 and 2015: 7.3% - Tonnage 8.4% - m²

0

2

4

6

8

10

12

2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

0

50 000

100 000

150 000

200 000

250 000

300 000

Tonnes (millions)

m² (millions)

Source: Pira estimation

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Consumption of fibers for nonwovens

PP and PET are the main fibres used in drylaid web forming.

Between 2010 and 2015, the consumption of Wood pulp will increase of 45%

0

0,2

0,4

0,6

0,8

1

1,2

1,4

1,6

1,8

2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

m T

on

s

PP

PET

Vis

Bico

Wood pulp

Other

Source: Pira estimation

Nonwoven Market

Nonwoven MarketEnd-uses of Nonwovens

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Source: EDANA , INDA estimation

Nonwoven MarketNonwovens Consumption per Capita (kg)

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Source: INDA Estimates, Ian Butler, INTC-2008

0 1 2 3 4 5 6 7

Taiwan

Korea

NAFTA

Europe -27

Australia

Japan

Malaysia

Saudi Arabia

Turkey

Mexico

China

South America

Brazil

S. Africa

Russia

India

kg

Developed Markets

Early Development Markets

Emerging Markets

High export volumes

ENCOURAGING FACTORS IN INDIA

• Population factor (90 million young people, 21 million educated people).

• Income, Willingness and Availability of plastic money to spend. People are

ready to spend more if they see value & brands.

• Consumer changes to look for life style changing products like wipes,

diapers etc.

• Growth of retail market or mall culture.

• Competition will push the price down thereby increase the demand.

• Increasing exposure to international lifestyle.

• Large Raw material base in cotton, polyester, viscose etc.

• Promotion of special economic zones (SEZ), textile parks and TUFS

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Nonwoven Processes

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Web-Forming Meltspun Drylaid Airlaid Wetlaid

Meltblown Carded Airlaid Wetlaid

Spunlaid

Web-Treatment Dewatering Drying Dyeing Chemical

Vacuum TAD Padder Padder

Squeezer Low add-on

Web-Bonding Thermal Chemical Hydro-

entanglement Calender Padder

Needlepunch Oven

Mechanical

Web-Handling Winding Slitting Packaging Control

Winder Slitter Packaging Line control

Quality control

NONWOVENS MANUFACTURING


CARDING

• A loose web of fibers

• Separates fibers through combing action

• Can be use to blend two or more fibres

• Basic structure of fiber to fabric, require bonding

APPLICATIONS

• Wipes, Hygiene

• Automotive, insulation,

• Interlining

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AIR LAID

• Can be fibers, blends of fibers or wood pulp

• Fibers are introduced into an air stream and form web on a belt

or drum which requires bonding

• Air laid fibers have random distribution

APPLICATIONS

• Wipes, Hygiene

• Automotive, insulation,

• Interlining

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WET LAID

• Fibers / Blended fibers or Wood pulp in water with very low

concentration

• Water / fiber mixture released onto a forming belt

• Excess water is removed and then bonded for stability

APPLICATIONS

• Tea bags,

• Vacuum cleaner, Filtration

• Meditech applications

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NEEDLE PUNCHING

• Oscillating needles penetrate the web in vertical direction

• Causing entanglement of fibers to create stable web

• High strength and durability

APPLICATIONS

• Geotextile

• Synthetic leather, Blankets

• Carpet and liners

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SPUNBOND

• Melting polymers pallets through an extruder and spinnerette to form

filaments

• Stretch and cool Filaments, deposit on moving conveyer to form web

which is bonded thermally.

• Economical process,

• Uniform and strong fabric

APPLICATIONS

• Home furnishing, Bedding

• Roofing Substrate, House wrap

• Diaper covers

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CHEMICAL BONDING

• On dry laid web chemical binder is applied using either

Gravure printer, Padder, foam applicator or spray

• Binder may be applied in pattern or overall

• After drying binder-fiber form strong bond

APPLICATIONS

• Roofing, Shoe components

• Apparel interlining

• Wipes

• Automotive substrate

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THERMAL BONDING

• Fibers are formed in to a web

• Bonded by hot air or heat and pressure

• Thermoplastic fibers are selected

• Can be converted to soft to stiff fabric

APPLICATIONS

• Diaper components, window blinds

• Apparel interlining, filtration media

• Geotextile applications

• Automotive trims

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SPUNLACE

Dry laid web is directed under series of fine, high pressure water jets

• Suction under belt removes water leaving behind entangled fibers

which further dried

APPLICATIONS

• Wipes, Single use medical applications

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Nano Spunlaid & Meltblown Nonwoven Fabrics

– High surface area

– Lighter weights (8-10 gsm)

– Improved web uniformity

– Target market: absorbent hygiene, filtration

Bi component Fibres

Recent Developments

Finishing of Nonwovens

• Hydrophilic• Hydrophobic• Repellent• Flame Retardant• Coating• Anitmicrobial• Dye• Finishing

• Print• Corrugate• Emboss• Compact• Crepe• Flock• Plasma• Encapsulate

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APPLICATIONS OF NONWOVENS

DISPOSABLE APPLICATIONSMedical• Drapes• Surgical / Isolation gowns• CSR Wraps• Caps ,Facemasks ,shoe coversHygiene• Baby Diapers, Training pants• Feminine Hygiene products• Adult Incontinence productsWipes• Baby• Household• Industrial

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DURABLE APPLICATIONSGeotextiles• Soil Stabilization, Drainage• Road and Rail constructionFiltration• Air, gas, liquidAgriculture• Crop covers, Greenhouse shades• MulchesHome Furnishing• Carpet backing• Furniture ConstructionBuilding and Construction• Insulation, RoofingAutomotives• Carpets & Headliner.• Door panel insulation, Carpet

backing.

NONWOVEN APPLICATIONS

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AGROTECHBUILDTECH

NonWoven Geotextiles

Applications -– Sub-surface drainage– Separation– Stabilization– Erosion Control– Geomembrane Protection

Uses of Non-Woven Geotextiles

• Non-wovens– Drainage application

• French drains, pipe sock• MSE walls

– Separation application• Remediation projects, waste containment• Road building • Parking lots • Weed barrier

Typical French Drain Application

These are geocomposites formed of a hollow cored, geotextile wrapped drainage element (geonet) inserted vertically into soft ground to speed up the consolidation process.

Prefabricated Vertical Drain Installation of PVD

Geocomposites: Prefabricated Vertical Drains (PVD)

Environmental Cracking

Geotextile for Sealing

New Overlay

Reflective Crack without Paving Fabric

Old Pavement

Base Course

Pav

emen

t C

rack

w

ith

Pav

ing

Fab

ric

Geosynthetic Clay Liner

Bentonite/textile composite for Water Reservoir application

Endurance Properties

• Abrasion Resistance• UV Stability• Chemical Resistance• Biological Resistance• Wet/Dry Stability• Temperature Stability

CLOTHTECH AND GEOTECH


HOMETECH and INDUTECH


http://news.thomasnet.com/images/large/023/23795.jpg

MEDITECH


MOBILTECH


PACKTECH AND PROTECH


Government’s Schemes Technology Mission on Technical Textiles (Launched in December 2010) encourages

domestic & export market development of technical textiles .

Business start-up assistance Handholding support to new entrepreneurs through empanelled consultants Empanelled consultant will help MSME in product selection, market selection,

technology selection & sourcing and preparation of project report Financial Assistance – 2% - 3% of the project cost with an upper ceiling at Rs. 5 lakhs –

Rs. 6 lakhs

Contract research assistance Encourages contract research in development of product, process and technology in

technical textiles. Financial Assistance – 60% of the research cost upto Rs. 20 lakhs

Market development assistance for export sales Encourages participation in exhibition, trade fairs, etc. in foreign countries Financial assistance – 50% of the cost upto Rs. 5 lakh per visit. (Details available on

http://technotex.gov.in/tmttsub.htm)

DKTE CENTRE OF EXCELLENCE IN NONWOVENS

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(PROMOTED BY OFFICE OF THE TEXTILE COMMISSIONER, MINISTRY OF TEXTILE, GOVERNMENT OF INDIA)

Centre of Excellence

The Centre of Excellence offers its facilities, knowledge,

research support, HRD, Technical consultancy, etc to

serious entrepreneurs.

Provides facilities like

– Testing facilities,

– Product, process & prototype development facilities,

– Sample Bank, competent manpower,

– Training facilities and incubation centre.

Provides facilities to the entrepreneurs in one hand and

suitable products to the users on the other.

Incubation of new ideas into practical tradable products

and

Dissemination of information through workshop &

seminar.

The CoE provides infrastructure at one place for the

convenience of the manufacturers of technical textiles

in India.

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Area Organisation

Product-focused Centres of Excellence

Agrotech Synthetic & Art Silk Mills Research Association (SASMIRA), Mumbai

Geotech Bombay Textile Research Association (BTRA) , Mumbai

Meditech South India Textile Research Association (SITRA), Coimbatore

Protech Northern India Textile Research Association (NITRA), Ghaziabad

Indutech PSG College of Technology, Coimbatore

Sportech WRA, Mumbai in association with VJTI & Kusumgar Corporates

Process-oriented Centres of Excellence

Composites Ahmedabad Textile Industry's Research Association (ATIRA), Ahmedabad

Nonwovens D.K.T.E. Society's Textile & Engineering Institute, Ichalkaranji

COEs IN INDIA FOR TECHNICAL TEXTILES

COEs under Technology Mission on Technical Textiles (TMTT)

SITE OF DKTE CoE

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SITE OF DKTE CoE

OBJECTIVE: CENTRE OF EXCELLENCE

1. Facilities for testing and evaluation of products in Nonwovens

2. Resource centre with IT infrastructure that provides knowledge and information on

Nonwovens & technical textiles.

3. Facilities for indigenous development of prototypes.

4. Pilot plant facilities are being created for development of prototypes / technology

which shall be transferred to the industry after standardization and optimization of

the production process.

4. Facilities for training of personnel

5. Knowledge sharing with stakeholders by arranging seminars and awareness

programmes

6. Incubation centers where each of the COEs will provide necessary facilities to

entrepreneurs for testing new ideas and technologies.

7. Setting up standards that are at par with global level. 48

ACTIVITIES OF DKTE COE IN NONWOVENS

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Testing Facilities

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• GSM Tester

• Digital Bursting Strength Tester

• Digital Thickness Tester

• Water Repellency Tester

• Microscope With Microtome

• LOI Tester

• Pore Size Analyser

• UV Accelerated Weathering Tester

• Linear Density & Fibre Crimp

• Air Permeability Tester

• Water Vapour Transmitivity Tester

• Non Woven Orientation

• Liquid Strike Through & Wet Back

• Thermal Conductivity Tester

• Digital Tearing Strength Tester

• Hydrostatic Water Head Tester

• Gradient Ratio Test Apparatus

• Water Transmittivity Tester

• Tensile Testing Instrument

• Direct Shear Box

• Digital pH Meter

• Viscometer

• Shaking Water Bath

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Physical Testing Laboratory

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Hydrodynamic Testing Laboratory

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Hydrodynamic Testing Laboratory

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PROTOTYPING FACILITY AT INCUBATION CENTRE

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Training Activities

• Training programme and workshop on “Applications of textiles in agriculture”

• Training programme on Solution Spinning technology and its applications

• Training Cum Workshop on Applications of Geo Synthetics & Geo-textiles in Civil Engineering

• Training programme on Nonwoven technology: Manufacturing, Hands-on Testing of Nonwovens and Nonwoven Sector Market Overview

• Workshop on Role of Technical Textiles & Nonwovens in Civil Engineering

• Training Programme on Applications of Geo-synthetics in Civil Engineering and Road Construction

• Training programme on “Nonwovens in Indutech and Buildtech Sectors”

• Training programme on “Technical Textiles in Mobiltech and Buildtech Sectors”

• Training programme on “Nonwovens in Oekotech applications”

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SEMINARS AND WORKSHOPS

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SEMINARS AND WORKSHOPS

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• Super absorbent polymers based nonwovens

• Chicken Feather BASED Nonwoven composite acoustic material

• Development of fiber Reinforced Concrete

• Antimicrobial cum antistatic surgical gown

• PU coated artificial leather from nonwovens

• Nonwoven fabrics for reinforcing unpaved roads

• Reflective crack resistant nonwoven for paved roads

• Static dissipating nonwovens (automobiles, home furnishing carpets etc.)

R&D Activities

• Nonwovens are widely used in different areas of Technical Textiles and are

rapidly replacing and/or providing cost-effective alternative to the traditional

woven and knitted fabrics.

• Composites of nonwovens with woven/knitted fabrics provides another

avenue to the technical textiles industry in India to explore new market

segments.

• India with an excellent background of textile manufacturing industry, is rapidly

emerging as a major player in the world nonwoven and technical textile

industry. 62

Conclusion

• Needle punching and Spunbonding technologies are being used for the

production of nonwovens in India.

• However, the industry has to upgrade itself with latest technologies like

Meltblown technology, bicomponent spinning as well as latest coating and

finishing technologies to be at par with the global entities.

• DKTE Centre of Excellence in Nonwovens is actively engaged promoting

nonwoven industry and closely working with the nonwovens and technical

industry .

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Conclusion

CONTACT

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DKTE CoE in Nonwovens,DKTE Textile and Engineering Institute, ‘Rajwada’, P B No 130, ICHALKARANJI. Dt. Kolhapur – 416115 (MS) IndiaPhone: +91 230 2421300Fax: +91 230 2432329Email : [email protected] www.dktes.com

ANIKET BHUTE

Scientist,

DKTE COE in Nonwovens

Mobile: 9975437345

Email : [email protected]

VARUN GOUD

Scientist,

DKTE COE in Nonwovens

Mobile: 8652752540

Email : [email protected]

mailto:[email protected]


Thank You

D.K.T.E. Society’s

Textile & Engineering Institute, Ichalkaranji

DKTE Center of Excellence in Nonwovens

Promoted by Ministry of Textiles, Govt. of India

Plot No. 1, 2 and 3, Shri. Lakshmi Co-Operative Industrial Estate, Hatkanangle – Ichalkaranji

Dt. Kolhapur – 416109 (MS) IndiaTel: +91 230 2366354 Email:

[email protected], Web: www.dktecoenonwovens.in

‘Rajwada', P Box No. 130, Ichalkaranji Tal: Hatkanangle, Dt. Kolhapur – 416

115 (MS) IndiaTel: +91 230 2421300, 2437316,

2437317 Email: [email protected] ; Web:

www.dktes.com


http://www.dktecoenonwovens.in/


http://www.dktes.com/

SPUNBOND NONWOVENS - NEW IDEAS

Presentations & Public Speaking

Transcript of SPUNBOND NONWOVENS - NEW IDEAS