Technical Textiles:Creating Value for Spunbond
Nonwovens
Presented at: THE SOUHTERN GUJARAT CHAMBER OF COMMERCE & INDUSTRY, SURAT, INDIA
MARCH 24, 2014
Uday Turaga, Vinitkumar Singh, and Seshadri Ramkumar
Nonwovens and Advanced Materials Laboratory, Texas Tech University, USA
Email: [email protected]
Technical Textiles?
Where is money in technical textiles?
How to grow the industry and make money?
Answers
The answer lies in the THREE major product categories:
1. Consumer tech products
2. Institutional tech products
(infrastructure, hospital or major bulk procurement items)
3. Government procurement products
Source: New classification pertinent to developing countries developed by Seshadri Ramkumar, Texas Tech University, USA.
� ”Textile materials and products manufactured primarily for their technical performance and functional properties rather than their aesthetic or decorative characteristics.”
Textile terms and definitions
The Textile Institute
Technical Textiles-Industry Definition
� Technical Textiles are value-added textile products that provide added functionality and applications other than regular fiber-to-fashion supply chain products
� These technical textiles encompass high performance fibers, yarns, woven, knitted, nonwoven, braided and composite structures
What are Technical Textiles ?
Thrust
Thrust will be to grow the sector that produces products that are close to end-users or where the
value is!!
Are Nonwovens Technical Textiles?� Most of the nonwovens are technical textiles as they have not yet penetrated into the apparel sector
� Nonwovens are predominantly disposable and semi durable goods
� All nonwovens are technical textiles but all technical
textiles are not nonwovens
� Technical textiles can be any fibrous material and their combination with other items which have NON-APPAREL applications, excluding paper
Technical Textiles –Simple Understanding
� Raw cotton with bark, seed coats and trash is a TECHNICAL TEXTILE!
� Situations create new technical textile products
� Generally, margins are high
Amazing Reality
Oil Absorption by FiberTect
Current Status of Indian Textile Industry
� India’s current textile and apparel market size is estimated to be USD 90 billion
� It is projected to reach USD 220 billion by 2020
� Adequate focus on value-addition and value-enhancement will enable India to be a textile power house
Source: Seshadri Ramkumar, TexSnips, January 7, 2014
Global Nonwoven Market Scenario
Global nonwovens consumption was
estimated to be 161.3 billion (square
meters) in 2010 and is projected to be
250.4 billion (square meters) by 2015,
with a CAGR of 9.2%
Global Market for Nonwovens
Source: The Future of Nonwov ens to 2015: Global Market Forecasts, New PIRA International Market Report,http://www.smitherspira.com/core/downloaddoc.aspx?documentid=4971
Global Market for Medical Nonwovens
Majority of the market
will be driven by
increased demand
for wound care, adult
incontinence and
health care wipes
�
Source: The Future of Medical Nonwov ens to 2018, New PIRA International Market Report, https://www.smithersapex.com/market-reports/nonwovens/medical-nonwovens-industry-forecasts.aspx
Worldwide: Demand for Technical Textiles
Source: IFAI Specialty Fabrics Review, February 2012 and Transparency Market Research, USA, July 5, 2013
“Asia Pacific Region
Real Power Engine for Global
Technical Textiles Market ”
Asia’s Influence on the Global Technical Textiles Market
Source: IFAI
Key Markets
China
India
South Korea
Taiwan
Key Sectors
Automotive
Infrastructure
Agriculture
Protective textiles
Medical & Health Care
Asian Technical
Textiles Market Share
in Global Technical
Textiles Market
In 2011, 45%
In 2018, 61%
(expected)
Outlook for Worldwide Nonwovens Production (millions of tonnes)
Source: INDA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)
2006 2011 2016Growth Rate
2006-2011 (%/Year)
Growth
Rate2011-2016 (%/Year)
NAFTA 1.61 1.87 2.2 3.00% 3.30%
Europe 1.56 1.95 2.6 4.60% 5.90%
China 0.97 1.65 2.82 10.50% 12.00%
Other Asia
Pacific 0.51 0.59 0.78 3.00% 5.70%
Japan 0.33 0.33 0.35 0.00% 1.20%
Middle East 0.26 0.32 0.45 3.60% 7.70%
Rest of
World 0.44 0.9 1.88 16.60% 14.60%
TOTAL 5.68 7.61 11.08 6.00% 7.80%
Outlook for Worldwide Nonwovens Production
Source: INDA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)
1997 2002 2011 2016
Growth Rate
1997-2010
(%/Year)
Growth Rate
2011-2016
(%/Year)
Dollars
(billions)$11 $15 $26 $37 6.2% 7.8%
Sq Meters
(billions)61 93 205 305 8.7% 9.0%
Tonnes
(millions)2.7 4.0 7.6 11.1 7.7% 7.8%
Growth Prediction of Technical
Textiles in India
Technical Textiles Growth in IndiaGeneral Idea
Cover Story in Modern Textiles, April/May 2008
Nonwoven and Technical Textiles, January/March 2008
13.3 % CAGR for India
Diversification into Non-commodity Textiles
� Indian textile industry should go on a higher gear in diversifying into unconventional textiles
� Even after 30 years of organized sector status, the nonwoven and technical textile industry is growing at a rate of 6 % in USA and Europe
� This sector is at infancy in India and offers tremendous growth and opportunities until 2050
2011 Asian Nonwovens Market 2.6 million tonnes
Source: INDA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)
Technical Textile Scenario in India
� Technical textiles consumption in India is one-fifth of total Asian consumption
� Employs about 800,000 people and 55% of employment needs technically skilled manpower
� Employment is expected to grow at an annual rate of 13% to reach
2.6 million by 2016-17
Source: Seshadri Ramkumar, TexSnips, July 3, 2013
Technical Textile Scenario in India
� Indian nonwoven textile production is just 3% of Asian production
� Technical Textiles Sector in India to Reach $ 26 Billion
� Expected annual growth rate- 20%
Source: Seshadri Ramkumar, TexSnips, July 3, 2013
Consumption Of Nonwovens/TT in India Vs. GDP Per Capita
(Assuming An Increase Of 13.27% In Per Capita Every Year)
GDP per capita source: World Bank
YEAR GDP PER CAPITA (US$) CONSUMPTION OF NONWOVENS/TT (kg)
2005 733 0.08
2010 1374 0.15
2015 2563 0.27
2020 4780 0.51
2025 8912 0.95
2030 16618 1.77
2035 30985 3.31
2040 57773 6.16
2045 107720 11.49
2050 200850 21.43
Consumption Of Nonwovens/TT in USA vs. GDP Per Capita
(Assuming An Increase Of 4.6% In Per Capita Every Year)
YEAR GDP PER CAPITA (US$) CONSUMPTION OF NONWOVENS/TT (kg)
2005 42499 3.5
2010 52435 4.32
2015 65656 5.41
2020 82213 6.77
2025 102943 8.48
2030 128901 10.62
2035 161404 13.29
2040 202103 16.64
2045 264705 20.84
2050 331452 26.10
GDP per capita source: World Bank
India vs. USA Per Capita Nonwoven/TT Consumption (2005-2050)
GDP per capita source: World Bank
India’’’’s Per Capita Consumption vs. Income Levels (2005-2050)
GDP per capita source: World Bank
India: Technical Textile Scenario 2007-2017
Source: Seshadri Ramkumar, TexSnips, July 3, 2013
Why Then the Indian Technical Textiles Industry has not Grown Yet?
Requirements for the growth of technical textiles sector in India
1) Lack of awareness on how to make finished or converted technical
textile products
2) Marketing know-how to sell and trade technical textile products
3) 1-0-1 basic marketing class on technical textiles
4) Technical textiles sector in India should know where and how
technical textiles are used on a daily basis
Global Perspective of Technical Textiles in
India
� India’s specialty fabric and nonwoven industry is fragmented and still in its infancy, with no state-of-the-art technology in place compared to global players
� Textile industry is also undergoing a major reorientation from apparel to specialty fabric applications
� Specialty fabrics now accounts for more than half of the total textile production in India
� The focus of the government is on upgrading infrastructure (geosynthetics) and increasing the use of automotive textiles (nonwovens)
� Other niche areas: Safety and protective (defense), medical textiles, agriculture (nets, shading, mulch) and filtration fabrics
Source: IFAI
Conclusions(with specific reference to India)
� It is extremely important for the Indian textile industry to diversify into durable technical textiles and disposable nonwovens
� Technical textiles should at least contribute 15 -20 % of the total textile sector by 2015-2020
� Our growth prediction is that the industry should grow in double digits around 13 %
Spunbond Nonwovens
Global Market for PP Spunmelt Nonwovens
� Estimated to be 2 million tonnes in 2011 and is projected to reach 2.4 million tonnes by 2015
� Chief drive of this market is the hygiene sector
� In the hygiene sector, global demand for spunmelt nonwovens was estimated to be 65 billion square meters in 2011 and is projected to reach 80 billion square meters by 2015
�
Source:Spunbond Polypropylene Available from: http://www.nonwovens-industry.com/issues/2012-02/view_features/spunmelt-polypropylene/
Leading Global Nonwoven Producers
Company name Revenue (USD)
Freudenberg 1.45 billion
DuPont 1.40 billion
Kimberly-Clark 1.30 billion
Ahlstrom 1.30 billion
Fiberweb 947 million
Johns Mansville 670 million
Fibertex 295 million
AVGOL 254 million
First Quality Nonwoven 250 million
Source:www.nonwovens-industry.com; Available from: Edison Investment Research estimates, Nonwovens Sector Report, January 2010
Nonwovens vs Polypropylene Nonwovens
Source:Edison Investment Research estimates, Nonwovens Sector Report, January 2010
Market Share of Raw Materials for Nonwovens in 2010
�
Source:PIRA International Ltd. Available from: https://www.smitherspira.com/market-reports/double-digit-asian-growth-to-drive-global-nonwovens-market-to-2015.aspx
Spunbonding Process Flowchart
Source:Malkan SR and Wadsworth LC: A Review on Spunbond Technology, Part I, INB, Nonwovens, Volume 3, 4-14, 1992.
Properties of Spunbond Nonwovens
� High tensile strength
� Excellent barrier properties
� Breathability at lower grammages
� Can be made absorbent
�Source: How to start sell ing PP Spunbond fabric in India. �Available from: http://nonwovenindustryupdate.wordpress.com/2012/04/22/how-to-start-sell ing-pp-spunbond-nonwoven-fabrics-in-india/
�
Spunbond Polypropylene Nonwovens
� Isotactic PP is the most widely used polymer for the production of spunbond nonwovens
� Provides the highest yield (fiber per kilogram) at the lowest cost because of its low density
� Necessitate the use of stabilizers as unstabilized polypropylene is rapidly degraded by UV light
� Fibers of inferior quality can be repelletized and blended with fresh polymer to reduce costs
Source:Spunbond Technology Available from: http://www.engr.utk.edu/mse/Textiles/Spunbond%20Technology.htm
Spunbond Polyester Nonwovens
� Superior tensile strength, modulus and heat resistance properties compared to spunbond PP nonwovens
� Amenable to dyeing and printing with conventional equipment
� Expensive compared to spunbond PP
Source:Spunbond Technology Available from: http://www.engr.utk.edu/mse/Textiles/Spunbond%20Technology.htm
Various Types of Spunbond Nonwovens
Hydrophilic Spunbond PP Nonwovens
� Baby diapers
� Training pants
� Feminine care
� Adult incontinence
Source: General Nonwovens and CompositesAvailable from: http://www.generalnonwovens.com/default.asp?id=21
�
Agricultural Applications of Spunbond Nonwovens
� Crop covers
� Seed blankets
� Weed control fabrics
� Green house shadings
� Root bags
�
Source: How to start sell ing PP Spunbond fabric in India. Available from:http://nonwovenindustryupdate.wordpress.com/2012/04/22/how-to-start-sell ing-pp-spunbond-nonwoven-fabrics-in-india/Figure available from: http://www.generalnonwovens.com/default.asp?id=26
Geotextile Applications of Spunbond Nonwovens
� Asphalt overlay
� Sedimentation and soil erosion
� Impregnation bases
� Drainage channel liners
� Separation reinforcement
� Roadside and drainage
� River and canal banks
Source: How to start sell ing PP Spunbond fabric in India. Available from: http://nonwovenindustryupdate.wordpress.com/2012/04/22/how-to-start-sell ing-pp-spunbond-nonwoven-fabrics-in-india/
�
Applications of Fire Retardant Treated Spunbond Nonwovens
� Fireproof clothing
� Used in seats of air planes, trains and buses when sandwiched between upholstery and outer fabric
� Hotels, restaurants, hospitals and libraries
�Source:AVOCA Technical. Available from: http://www.avoca-group.co.uk/technical/spunbond/fire%20retardant%20treated%20spunbond/
Properties of Fire Retardant Treated Spunbond Nonwovens
� Durability even after multiple washings
� No toxicity
� Should stop burning when off the fire
� No emission of thick smoke, meltdown or droppings
�Source:AVOCA Technical. Available from: http://www.avoca-group.co.uk/technical/spunbond/fire%20retardant%20treated%20spunbond/
Nonwovens in Disposable Absorbent Hygiene Products
Where are Nonwovens Used in Disposable
Absorbent Hygiene Products (AHPs)
� Topsheet or coverstock
� Leg cuff
� Core wrap
� Fastening systems
� Back sheet
� Stretch ears
� Landing zone
� Dusting layer
� Acquisition/distribution layer
�
�Source: http://www.edana.org/discover-nonwovens/products-applications/absorbent-hygiene-products
Advantages of Using Nonwovens in Disposable Absorbent Hygiene Products
(AHPs)
� Excellent absorption
� Softness and smoothness
� Stretchability, comfort and fit
� Double fluid barrier effect allowing moisture to be absorbed and retained
� Strength, elasticity
� Stability and tear resistance
� Breathability
�
�
Source: http://www.edana.org/discover-nonwovens/products-applications/absorbent-hygiene-products
PP Spunbond in Diapers
Source: http://www.sustainablenonwovens.net/index.php?option=com_content&view=article&id=11819:webtor&catid=112:consumer-products-premium
� Huge Demand for disposable baby diapers throughout Asia
� Major Market led by China, India and the ASEAN countries
� Expected to grow from 29 billion pieces in 2012 to 65 billion
pieces in 2020
� Demand for PP spunbond in Asia is projected to increase
from 290,000 tons in 2012 to 750,000 tons in 2020
Diaper Market Overview-Asia Pacific
�
�
2007 - 20 billion units 2015 - 45 billion units
Source:Soft Nonwovens for Diaper Market: Publicly available information and ExxonMobil Chemical estimates
Schematic of a Disposable Diaper
�
�
Source: http://www.edana.org/discover-nonwovens/products-applications/absorbent-hygiene-products
Schematic of an Ultrathin Sanitary Pad
�
�
Source: http://www.edana.org/discover-nonwovens/products-applications/absorbent-hygiene-products
Schematic of a Belted Incontinence Product
�
�
Source: http://www.edana.org/discover-nonwovens/products-applications/absorbent-hygiene-products
Value Addition to Spunbond Nonwovens
Plasma Processing of Nonwovens
� Plasma finish is a surface treatment to textile materials for imparting multiple finishes without water and the use of lot of chemicals and energy.
� Integration of Atmospheric Pressure Plasma Technology (APT) to nonwovens/conventional textile processing is economical and is eco-friendly.
Source:Enercon Industries, Menomonee Falls, WI, USA
Market Value of Plasma Technology
� A typical Atmospheric Pressure Plasma Technology lane for theapplication in textiles with a width of 1524 mm and an operatingspeed of 100 mpm will have a capital cost of approximately $100K.
� This is a capital based process/technology and has negligible costof production compared to its capital cost.
� The hourly gas consumption cost in the latest technology is about$10.
� PLASMA 4, a new technological development by EnerconIndustries Corporation is economical and more profitable.
Source:Enercon Industries, Menomonee Falls, WI, USA
Breathable Spunbond Nonwovens
through APT
Published Research:
Jinka, S., Behrens, R., Korzeniewski, C., Singh, V., Arunachalam, A., Parameswaran, S., Coimbatore G.,
Kendall R. J., Wolf R. and Ramkumar, S., Atmospheric Pressure Plasma Treatment and Breathability of
Polypropylene Nonwoven Fabric. Journal of Industrial Textiles, 2013. 42(4): p. 501-514.
POLYPROPYLENEPOLYPROPYLENE
Initiate Collaboration with Government of India Facility
Drawbacks of Polypropylene
• Restrained in next-to-skin
apparel applications due to lack of comfort characteristics (Breathability issues)
• Not much information available in public domain
Tsai , P. P., Wadsworth, L. C., Surface Modification of Fabric Using a One-Atmosphere Glow Discharge Plasma to Improve
FabricWettabil ity,Textile Research Journal, 67(5), 359-369 (1997)
Source: RoryWolf, Vice President –BusinessDevelopment,Enercon IndustriesCorporation
Atul Dahiya, M. G. Kamath, Raghavendra R. Hegde “Spunbond Technology”,
http://www.engr.utk.edu/mse/pages/Textiles/spunbond technology.htm – accessed on August 24, 2008
� First commercialized in
1960s
� Highly consumed fiber
� Highest yield rate
� Low cost fiber
� Versatile applications
What are Polypropylene Nonwovens
Materials and Methods
• Polypropylene spunbond nonwovens
• Treatment with Nitrogen gas in the presence of Oxygen Atmosphere
• Breathability: BS 7209 1990
• Porosity: PMI Capillary Flow porometer
• Breaking Strength: ASTM D-5034
• FTIR-ATR Analysis: Bruker Vertex 70 Spectophotometer
• SEM: Hitachi S-4800
Atmosphere
Micro- climate
Body
Clothing
Based on Weiner. L.I, Textile Chemist and Colorist, vol.2, 1970.
Cloth-Body System
Breathability
� Measured as Moisture Vapor Transmission Rate (MVTR)
� MVTR: Rate at which moisture vapor moves through a fabric
� Faster a fabric breaths, better the comfort
� Higher the porosity, higher the breathability
Experimental Setup for Breathability Evaluation
MVTR = 24 M g/sq.m/dayAt
M = mass of water lost (g)
t = time period (5 hours)
A = Area of exposure (0.005413 sq.m)
Porosity
� Measured using capillary flow porometer
� Represented in terms of mean flow pore diameter and pore size
distribution (PSD)
� Higher the mean flow pore diameter, higher the porosity
� Larger the PSD, larger the porosity
Fourier Transform Infrared Spectroscopy (FTIR)
� FTIR-ATR is an ideal technique for the detection of chemical surface modifications
� Examines only a limited penetration depth of the outermost few microns of a sample
� Allows to investigate the changes in functional groups between the samples
MVTR results of a 20 GSM spunbond fabric
Breathability Evaluation
0
200
400
600
800
1000
1200
1400
1600
20 GSM 50 GSM 75 GSM
MVTR (gms/day/sq.m)
Weight of the Fabric
Untreated Plasma treated
MVTR results of different spunbonds
� There is a 95% increment in MVTR in low weight fabrics
� Heavier weight of the fabrics need stronger treatment conditions
Porosity Results and DiscussionsSample Weight
Mean Flow Pore Diameter (Microns)
Difference in Mean
Flow Pore Diameter
(%) Untreated Plasma Treated
20 GSM 59.95 (7.31) 72.53 (5.48) 20.98
Increment in number of poresIncrement in size of the pores
Chemical Modification Analysis by FTIR
FTIR spectra of untreated and plasma treated polypropylene fabrics
Wave number
(Cm-1)
Group
2800-3000
1350-1500
Basic groups
on PP
1800-1500 Treated PP
1733 C=O
Ketone,
Carboxylic
1606,1597 Amide,
Amine
1508 -CNH stretch
SEM Observations
SEM image of untreated 20 GSM spunbond PP
nonwoven
� Fibers are intact
� Less breathable
� Fibers get loosened
� Increased pore size between fibers
� Results in enhanced breathability
SEM image of plasma treated 20 GSM spunbond
PP nonwoven
Identifies the changes in surface morphology
Tensile Strength Results
There is no significant statistical difference in the UT and PT values of 20 GSM
� Tensile Strength indicates the bulk strength of the material
� It is measured in two directions (Machine and Cross Directions)
Tensile Strength Results of 20 GSM Sample
n.s
n.s Crossbars represent standard deviation, n=5. n.s. not significant(paired t test, comparison of means)
Summary• Atmospheric Pressure Plasma treatment enhances the breathability of
PP spunbond nonwovens by 95%
• APT enhances the porosity of the PP samples which led to increase in
breathability
• APT loosens the structure of the specimen
• Breaking strength evaluation shows no significant variation
Summary
• Breathability enhancement will enable spunbond PP nonwovens to
penetrate into next-to-skin apparel applications
Examples of Nonwoven End Products
Nonwovens in Automobiles: A Glimpse
of Value-Added Application
Source:Cos Camelio, Association of Nonwoven Fabric Industry, USA
Spunbond Grocery Bag
Spunbond Pillow Cover
Diaper
Cover Stock is Spunbond ~ 10GSM
Diaper
Cover Stock is Spunbond ~ 10GSM
Spunlace Wet Wipes
Moistened Hand Wipes
Majority of Moistened Wipes are Spunlace.
Face Masks
(Spunbond-Meltblown-Spunbond)
Insulation High Lofts
Typical Surgical Gown
(Spunbond-Meltblown-Spunbond)
New Developments in Nonwovens
Reducing Costs of Nonwovens• FiberLink™ is a mineral additive from Imerys, a French based
multinational company
• Engineered for use as an additive for fibers and nonwovens to
significantly reduce the amount of resins while maintaining adequate
production efficiencies and product performance
• Brings down production costs
• Manufactured from a naturally occurring mineral deposit and so
eventually reduces overall carbon footprint of final product making it
ecofriendly
Source:FiberLink™: A Better Way to Produce Nonwovens
Available from: http://www.imerys-perfmins.com/pdf/PFME-F403_FiberLink_Changing_the_way_to_produce_nonwovens.pdf
http://www.imerys-carbonates.com/applications/nonwovens-fiber/
Advantage of using FiberLink™ in Nonwovens
• Improved opacity for better cosmetic appearance
• Increased filtration efficiencies
• Increased air permeability, specially in PP spunbond nonwovens
• Reduced process temperature due to high thermal conductivity of
FiberLink™
85
Source:FiberLink™: A Better Way to Produce Nonwovens
Available from: http://www.imerys-perfmins.com/pdf/PFME-F403_FiberLink_Changing_the_way_to_produce_nonwovens.pdf
http://www.imerys-carbonates.com/applications/nonwovens-fiber/
3D Printing Technology
� Involves depositing layers of material to build up the final fabric or product1
� One variation of this technology uses ultraviolet beams to fuse layers of powdered recyclable thermoplastic into a given shape2
Source: 1. 3D Printing: A Real Alternative to Knitted Textiles Available from: http://www.knittingindustry.com/3d-printing-a-real-alternative-to-knitted-textiles/2. http://www.ecouterre.com/are-3d-printed-fabrics-the-future-of-sustainable-textiles/3d-printer-fabric-7/
Cosyflex™
� Innovative technology for 3D printing of fabrics from TamiCare, a UK based company
� Enables the creation of all direction-stretchable nonwoven fabrics based on integration of elastomers (viscoelastic polymers) and textile fibers
� Excellent elongation, recovery and drape characteristics that allows for enormous flexibility and variety
� Liquid polymers such as natural latex, silicon, polyurethane and teflon and textile fibers such as cotton, viscose and polyamide
Source:TamiCare: http://www.tamicare.com/#!cosyflex/c1gza
Properties of Cosyflex™
� All-direction elasticity
� Leak proof and breathable
� Soft and comfortable
� Dyeable
� Can be made into any pattern
Source: 3D Printing: A Real Alternative to Knitted textiles?Available from: http://www.knittingindustry.com/3d-printing-a-real-alternative-to-knitted-textiles/
Texas Tech University publishes timely news related
to Nonwovens and Technical Textiles called
TexSnips. It is distributed free of charge to interested
parties. If you are interested, please contact Dr. Ramkumar at: [email protected]
Thank You!