This document discusses innovations in needle punching technology for medical textiles. It begins by describing how medical textiles are used for hygiene and healthcare. It then discusses the classification and constituent elements of medical textiles, including polymers, fibers, yarns, fabrics, and final textile medical products. The document focuses on the needle punching process, including fiber opening and blending, nonwoven carding, cross-lapping, needle looming, winding, and cutting. It describes innovations like cyclopunching that allow for higher density needling. The document concludes by discussing the potential of these technologies in markets like the US and opportunities in medical textile products.

1. INNOVATIONS IN NEEDLE
PUNCHING – MEDICAL
TEXTILES
Textile Machinery Division

2. MEDICAL TEXTILES
 Textiles used for hygiene & health care
operations.
Textile Machinery Division

3. Constituent Element of Medical Textile
Product
Polymers
Fibres
Yarns
Woven Knitted Braided Non-woven
Fabrics
Textile Medical Products
Textile Machinery Division

4. CLASSIFICATION - Application
 Healthcare & Hygiene Products
 Extracorporeal Devices
 Implantable Materials
 Non- implantable Materials
Textile Machinery Division

5. HEALTHCARE & HYGIENE
NONWOVEN PRODUCTS
Fibres Applications
Protective Clothing, incontinence,
Polyester & Polyethylene
diaper/sheet, Cover Stock
Superabsorbent
Absorbent Layer
fibres,wood fluff
Polyethylene Outer Layer
Viscose/Lyocell Clothes/Wipes
Textile Machinery Division

6. HEALTHCARE & HYGIENE
NONWOVEN PRODUCTS
Fibres Applications
Cotton, Polyester & Surgical Gowns
Polypropylene
Viscose Surgical Caps
Surgical Masks
Viscose, Polyester, Glass
Polyester & Polyethylene Surgical Drapes , Cloths
Textile Machinery Division

7. Non-Implantable Material – Nonwoven Products
Fibres Applications
Cotton, Viscose & Lyocell Absorbent Pads
Viscose, Cotton Lint, Wood Pulp Wadding
Poly-lactide, Poly-glycolide, Carbon Scaffold
Textile Machinery Division

8. Non-Woven Property –
Medical Applications
 Porosity
 Weight of fabric
 Thickness
 Nonwovens are easy to sterilize
 Various Manufacturing technique options
according to applications
 Economical Manufacturing Process
Textile Machinery Division

9. Non-Woven
 Nonwovens are webs made of fibres / Polymers –
Web Forming
 For End-use application – Web Bonding
 Web Bonding Methods can be
 Mechanical
 Needle Punching
 Spunlace
 Thermal
 Chemical
Textile Machinery Division

10. Dilo, Inc.
Charlotte, NC
USA
History
Dilo Representation
Office Shanghai Dilo founded in 1902
PR China
Spinnbau founded in 1948
Dilo Representation
Office Moscow Temafa founded in 1874
Russia
DiloSpinnbau since 1996
sales representatives
in over 80 countries DiloTemafa since 2005
worldwide
Textile Machinery Division

11. NEEDLE PUNCHING
TECHNOLOGY
Textile Machinery Division

12. NEEDLE PUNCHING FLOWCHART
Fibre – Opening & Blending
Nonwoven Carding
Cross-Lapping
Pre-Needle Loom
Finish Needle Loom
Winding & Cutting
Textile Machinery Division

13. FIBRE OPENING & BLENDING
Textile Machinery Division

14. NON-WOVEN CARDING
Textile Machinery Division

15. Textile Machinery Division

16. NEEDLE FELT TECHNOLGY
 Felting needles penetrate
through crosslapped fibre
batt
 Barbs of felting needles
catch and transport fibres
 By means of this fibres
entangle, fibre batt
consolidates and needle felt
with strength properties is
created
Textile Machinery Division

17. LAYOUT
FIBRE OPENING & NONWOVEN CARD
BLENDING
CROSS LAPPER
NEEDLE LOOM
Textile Machinery Division

18. WHY NEEDLE PUNCHED FABRICS !
 3 – D Structure
 Composites.
 Extremely High Densities
 High Strength - Geo-Textile Fabrics
 Superior Filtration Properties - World’s Filtration Media
Textile Machinery Division

19. Major Applications – So Far
 Automotives
 Geo-Textiles
 Filtration materials
 Wipes
 Synthetic Leather
Textile Machinery Division

20. Major Applications –So Far
 Floor coverings & Wall coverings
 Roofing felts
 Blankets
 Decoration felts
 Paper machine felts
Textile Machinery Division

21. INNOVATIONS
Hyper Lacing with Cyclopunching
Textile Machinery Division

22. CYCLOPUNCHING
 Translatory & Circular Moving path – New
Kinematical Concept
 High Density Needling - Individual Fibre transport
 Small Dimensional Changes & distortion in the fabric
plane.
Textile Machinery Division

23. Textile Machinery Division

24. HYPER LACING Vs Std Web Formation
 Minimum GSM – 25  Minimum GSM – 80
 Card Feed – Vento Feed  Card Feed – Chute Feed
 DELTA CARD  Servo or Super Servo
Card
 HYPER LAYER  Horizontal Cross Lapper
Textile Machinery Division

25. DELTA CARD
Textile Machinery Division

26. Economic Considerations
Working Width : 2.5 Mtr, Production Speed : 100 Mtr / Min
Final Product Weight : 50 GSM, Final Product Output : 750 Kg / Hr
Criteria Cyclopunching without preparation Spunlace line incl.drying without
and web forming preparation and web forming
Space Requirement approx.200 Sq.Mtr approx.700 Sq.Mtr
Investment approx. 4 Mill. Eur approx. 6 Mill. Eur
Power approx.150 KW / Mtr working width approx. 1000 KW / Mtr
at 0.10 Eur / Kwh Working Width at 0.10 Eur / Kwh
Water Consumption NIL approx. 1.1 KL / Hr / Mtr Working Width
20 Ltr / Min / Mtr Working Width
Waste Water anti-pollution NIL approx.1.1 KL / H / Mtr working width
requirements at 5.0 Eur / Sq. Mtr
Fibre Loss NIL approx. 5% Kg Product
at 1.50 Eur / Kg
Consumables Needles and needle boards ca.0.133 Eur / Jet Strips
Kg / Mtr working width Ca. 0.004 Eur / Kg / Mtr Working Width;
Needle life: approx. 300 Mill. Stroke Strip Life: approx. 1 Year at 50 bar
Operating Costs of Energy, Water, approx.0.995 Eur per min and m working approx. 2.061 Eur per min and m working
Fibre loss, needles and boards, jet width width
strips ( Without depriciation, interest,
personnel, fibre material, chemicals
for water treatment ) at 7,000 Working
hours / year
Textile Machinery Division

27. Cyclopunch – Application Areas
Medical Products : Gowns, Drapes, Cover sheets, Towels,
Wound Dressings, Wet Tissue, Pads
Sanitary Products : Baby Wipes
Household and Industrial Wipes, Car Wipes
Home Furnishings : Table Cloths, Napkins, Interlings,
Coating Substrates, Synthetic Leather
Automotive Applications : Headliner, Interior Trim
Filtration Material
Textile Machinery Division

28. Hyperlacing
Textile Machinery Division

29. U.S.MARKET POTENTIAL
Market scenario – US Market U.S.Trade of Nonwoven Roll Goods (HTS code
5603, aggregated )
% Change
2002 2003 2004 2005 2006 2007 (2006 - 07
Imports
( Mn. Kg ) 116 138 167.3 169.8 161.9 185.9 14.8
Exports
( Mn.Kg ) 180 195 227.3 263.3 270.9 258.6 4.5
Textile Machinery Division

30. U.S.MARKET POTENTIAL
Estimated Value of Exports & Imports, Nonwoven Roll Goods 2002 - 2007
FAS Value : U.S.Exports ( Mn. $ )
2002 2003 2004 2005 2006 2007
$744.40 $914.10 $1,027.30 $1,239.60 $1,391.60 $1,302.60
General Customs Value : U.S.Imports ( Mn. $)
2002 2003 2004 2005 2006 2007
$437.80 $547.00 $631.80 $712.70 $703.00 $809.00
Textile Machinery Division

31. US TRADE of NONWOVENS.xls
Textile Machinery Division

32. Consumption on Different Categories of
Medical Textiles
MARKET
MEDICAL TEXTILE POTENTIAL
S.NO PRODUCT ( Rs Mn)
2005 2010
1 Sanitary Napkins 4819 8519
2 Incontinence Diapers 605 1070
3 Surgical Dressing 5828 10302
4 Health Care Textiles 1491 2635
5 Sutures 3160 5587
6 Medical Devices & Implants 1190 2104
Textile Machinery Division

33. ROAD AHEAD
 Enough Awareness on Technology & Potential
Time to TPI
 Product – Market – Flexibility
 Our Role – Right Technology – Cont. Technical Support
– Project Implementation
Textile Machinery Division

34. Traditional to Technical
Diversify - Flourish
Thank you
Textile Machinery Division