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Welspun Group I Textiles
Innovations & Nonwoven Industry
Welspun Group | Textiles
Welspun Group I 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.
Welspun Group I Textiles
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
Welspun Group I Textiles
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
Welspun Group I Textiles
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.
Welspun Group I Textiles
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.
Welspun Group I Textiles
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’
Welspun Group I Textiles
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
Welspun Group I Textiles
Disruptive Technologies
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
Welspun Group I Textiles
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
Welspun Group I Textiles
Technical Textiles’ contribution to Advanced Materials
Advanced Materials
Structural
Biomaterials
Functional
Multifunctional
Textiles Reinforcements
Technical Textiles
Smart Textiles
Products Types
Welspun Group I Textiles
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
Woven Uni & Multi-directional
NW
Woven Uni & Multi-directional
NW
Bio - Active Advanced Materials
Functional Advanced Materials
Advanced Textiles
Technical Textiles
Conventional Textiles
Structural Advanced Materials
Welspun Group I Textiles
Technical Textiles
TECHNICAL TEXTILES
Knitted Nonwoven Composites Woven
Welspun Group I Textiles
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
alu
e
Hig
h V
alu
e
Welspun Group I Textiles
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
Welspun Group I Textiles
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.
Source: Future of Global Nonwoven Market, Smithers Apex 2014
Welspun Group I Textiles
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
Source: Future of Global Nonwoven Market, Smithers Apex 2014
Welspun Group I Textiles
Market Drivers
Durables Disposables
Consumerism
• Rising Income
• Demographics
• Rising spending power
• Awareness
Technology
• Industry Growth
• Industrial Applications
• Technological Innovations
• R & D
Welspun Group I Textiles
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
Welspun Group I Textiles
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
Welspun Group I Textiles
• 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
Welspun Group I Textiles
• Company : Ahlstrom, US
• Product Name : Disruptor
• Technology : Wetlaid
• Use : Filters with high flow rate
• Application : Water Filtration
• Product : Electo – Adsorptive Filter Media
Innovations
Welspun Group I Textiles
• 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
Welspun Group I Textiles
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
Welspun Group I Textiles
• 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
Welspun Group I Textiles
• 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
Welspun Group I Textiles
• 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
Welspun Group I Textiles
• 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
Welspun Group I Textiles
• Company : Vita Nonwovens, USA
• Brand Name : EnGuard
• Innovation : No formaldehyde, Uses PET bottles
• Technology : Thermofit Technology
• Application : Replacement of Glass/ PP Composites in Automobiles
and replacement of foam in sitting systems
• Product : Thermal Acoustic Insulator
Innovations
Welspun Group I Textiles
• 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
• Product : Thermal Acoustic Insulator
Innovations
Welspun Group I Textiles
• Company : Vita Nonwovens, USA
• Brand Name : EnGuard
• Innovation : No formaldehyde, Uses PET bottles
• Technology : Thermofit Technology
• Application : Replacement of Glass/ PP Composites in Automobiles
and replacement of foam in sitting systems
• Product : Thermal Acoustic Insulator
Innovations
Welspun Group I Textiles
• 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
Welspun Group I Textiles
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
Welspun Group I Textiles
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’
Welspun Group I Textiles
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’
Welspun Group I Textiles
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.
Welspun Group I Textiles
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
Welspun Group I Textiles
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.
Welspun Group I Textiles
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.
Welspun Group I Textiles
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
Welspun Group I Textiles
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
Welspun Group I Textiles
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.
Welspun Group I Textiles
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
Welspun Group I Textiles
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.
Welspun Group I Textiles
LATEST INNOVATIONS
Welspun Group I Textiles
THANK YOU