SPUNBOND NONWOVENS - NEW IDEAS

5,538 views

Published on

  • Be the first to comment

SPUNBOND NONWOVENS - NEW IDEAS

  1. 1. Indian Nonwoven Industry-Present Scenario & Future Prospects D.K.T.E. Society’s Textile & Engineering Institute, Ichalkaranji, Dist: Kolhapur, Maharashtra State 1
  2. 2. DKTE CENTRE OF EXCELLENCE IN NONWOVENS 2 (PROMOTED BY OFFICE OF THE TEXTILE COMMISSIONER, MINISTRY OF TEXTILE, GOVERNMENT OF INDIA)
  3. 3. Technical Textiles
  4. 4. 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
  5. 5. 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
  6. 6. 6  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
  7. 7. 7 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
  8. 8. 8 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 mTons PP PET Vis Bico Wood pulp Other Source: Pira estimation Nonwoven Market
  9. 9. Nonwoven Market End-uses of Nonwovens 9 Source: EDANA , INDA estimation
  10. 10. Nonwoven Market Nonwovens Consumption per Capita (kg) 10 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
  11. 11. 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 11
  12. 12. Nonwoven Processes 12 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
  13. 13. 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 13
  14. 14. 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 14 NONWOVENS MANUFACTURING
  15. 15. NONWOVENS MANUFACTURING 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 15
  16. 16. 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 16 NONWOVENS MANUFACTURING
  17. 17. 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 17 NONWOVENS MANUFACTURING
  18. 18. 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 18 NONWOVENS MANUFACTURING
  19. 19. 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 19 NONWOVENS MANUFACTURING
  20. 20. 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 20 NONWOVENS MANUFACTURING
  21. 21. 21 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
  22. 22. Finishing of Nonwovens • Hydrophilic • Hydrophobic • Repellent • Flame Retardant • Coating • Anitmicrobial • Dye • Finishing • Print • Corrugate • Emboss • Compact • Crepe • Flock • Plasma • Encapsulate 22
  23. 23. APPLICATIONS OF NONWOVENS DISPOSABLE APPLICATIONS Medical • Drapes • Surgical / Isolation gowns • CSR Wraps • Caps ,Facemasks ,shoe covers Hygiene • Baby Diapers, Training pants • Feminine Hygiene products • Adult Incontinence products Wipes • Baby • Household • Industrial 23 DURABLE APPLICATIONS Geotextiles • Soil Stabilization, Drainage • Road and Rail construction Filtration • Air, gas, liquid Agriculture • Crop covers, Greenhouse shades • Mulches Home Furnishing • Carpet backing • Furniture Construction Building and Construction • Insulation, Roofing Automotives • Carpets & Headliner. • Door panel insulation, Carpet backing.
  24. 24. NONWOVEN APPLICATIONS 24
  25. 25. APPLICATIONS OF NONWOVENS AGROTECH BUILDTECH
  26. 26. NonWoven Geotextiles Applications - – Sub-surface drainage – Separation – Stabilization – Erosion Control – Geomembrane Protection
  27. 27. 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
  28. 28. Typical French Drain Application
  29. 29. 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)
  30. 30. Environmental Cracking
  31. 31. Geotextile for Sealing New Overlay Reflective Crack without Paving Fabric Old Pavement Base Course PavementCrack withPavingFabric
  32. 32. Geosynthetic Clay Liner Bentonite/textile composite for Water Reservoir application
  33. 33. Endurance Properties • Abrasion Resistance • UV Stability • Chemical Resistance • Biological Resistance • Wet/Dry Stability • Temperature Stability
  34. 34. CLOTHTECH AND GEOTECH APPLICATIONS OF NONWOVENS
  35. 35. HOMETECH and INDUTECH APPLICATIONS OF NONWOVENS
  36. 36. MEDITECH APPLICATIONS OF NONWOVENS
  37. 37. MOBILTECH APPLICATIONS OF NONWOVENS
  38. 38. PACKTECH AND PROTECH APPLICATIONS OF NONWOVENS
  39. 39. 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)
  40. 40. DKTE CENTRE OF EXCELLENCE IN NONWOVENS 42 (PROMOTED BY OFFICE OF THE TEXTILE COMMISSIONER, MINISTRY OF TEXTILE, GOVERNMENT OF INDIA)
  41. 41. 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. 43
  42. 42. 44 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
  43. 43. COEs under Technology Mission on Technical Textiles (TMTT)
  44. 44. SITE OF DKTE CoE 46
  45. 45. 47 SITE OF DKTE CoE
  46. 46. 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
  47. 47. ACTIVITIES OF DKTE COE IN NONWOVENS 49
  48. 48. Testing Facilities 50 • 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
  49. 49. 51 Physical Testing Laboratory
  50. 50. 52 Physical Testing Laboratory
  51. 51. 53 Physical Testing Laboratory
  52. 52. 54 Physical Testing Laboratory
  53. 53. Hydrodynamic Testing Laboratory 55
  54. 54. Hydrodynamic Testing Laboratory 56
  55. 55. PROTOTYPING FACILITY AT INCUBATION CENTRE 57
  56. 56. 58 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”
  57. 57. 59 SEMINARS AND WORKSHOPS
  58. 58. 60 SEMINARS AND WORKSHOPS
  59. 59. 61 • 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
  60. 60. • 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
  61. 61. • 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 . 63 Conclusion
  62. 62. CONTACT 64 DKTE CoE in Nonwovens, DKTE Textile and Engineering Institute, ‘Rajwada’, P B No 130, ICHALKARANJI. Dt. Kolhapur – 416115 (MS) India Phone: +91 230 2421300 Fax: +91 230 2432329 Email : dktestextile@gmail.com www.dktes.com ANIKET BHUTE Scientist, DKTE COE in Nonwovens Mobile: 9975437345 Email : abhute@gmail.com VARUN GOUD Scientist, DKTE COE in Nonwovens Mobile: 8652752540 Email : varun.s.goud@gmail.com
  63. 63. 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) India Tel: +91 230 2366354 Email: dktecoe@gmail.com, Web: www.dktecoenonwovens.in ‘Rajwada', P Box No. 130, Ichalkaranji Tal: Hatkanangle, Dt. Kolhapur – 416 115 (MS) India Tel: +91 230 2421300, 2437316, 2437317 Email: dktestextile@gmail.com ; Web: www.dktes.com

×