B. S. Pancholi & Dr S. K. Basu
Man Made Textiles Research Association, MANTRA Surat
Key Issues and strategies for Indian Nonwoven industry
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What is being discussed
Index1. Nonwovens -Current Indian Scenario
2. Key Issues with Indian Nonwoven
3. Major Hurdles for nonwoven industry
4. Strategic actions for sustainable growth of Nonwovens
5. MANTRA-COE: One stop solution provider for Nonwoven sector
6. MANTRA-COE: Infrastructure and facilities .
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Only 2% of the 3000 NW units have some international recognition.
Indian NW shares is only 4% of the entire World market share against its potential to have a world
market share greater than 10%.
WEB site on 2018 Nonwoven world business from Transparency Market Research Source
http://www.prweb.com/releases/2013/7/prweb10901676.htm
Percapita consumption of NW Nonwoven in India is 200 gm against the percapita consumption of the
world being 3.3 Kg
Majority of cash rich business men shy away to invest big in Nonwoven sector despite attending
Nonwoven seminars, workshops, exhibitions, promotional meetings
1. Nonwovens: Current Scenario
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1. Nonwovens: Current Scenario
CURRENT INDIAN NONWOVEN TECHNICAL TEXTILE SCENARIO:
2/3 of NW produced are commodity products (Packtech,Clothtech,Hometech and Sprotech) . Packaging,filtration,carpets,auomtive and Geotextile applications
1/3 of NW produced is niche or High end products.
Niche or high end products require R&D and Technology to be competitive in the world market
Majority of Commodity products are for durable applications and only very few are producing disposable and hygiene products.
Disposables have huge untapped market in India
Disposable products require high quality to be matched with international norms to substitute imports
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1. Nonwovens: Current Scenario
CURRENT INDIAN NON WOVEN TECHNICAL TEXTILE SCENARIO:
90% of the Technical Textile producers are SMEs
A majority of them produce only the nonwoven or Needle punched fabrics.
Converters purchase this product from them to convert and sell to make a larger profit than the Nonwoven fabric producers.
This is presumably because of lack of marketing capability with Nonwoven Fabric producers.
There is no effort to make differential products and hence most of them produce identical and undifferentiated products.
With out own marketing teams and undifferentiated products in commodity applications lead to low and marginal profits.Some of them have faced losses and under closure
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2. Key issues with Indian Nonwoven industry
It is a proven philosophy that every EFFECT has a CUASE
There are few but highly successful NW investors who are growing by leaps and bounds in the same industry.
Hence the problem for not making enough profits from Nonwoven investment is not due to lack of demand or potential.
Industry experts feel that the most critical reasons for failure to grow are :•HERD mentality•Production Focus•Lack of expert advise and Guidance
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2.Key issues with Indian Nonwoven Industry
1. HERD mentality: Blind following others unthinkingly.Most jumped into the bandwagon of Nonwovens for shopping bag applications assuming that they are ultimate substitute for plastics but do not realize that nonwovens are equally not bio-degradable.
2. Production Focus: Let me produce and people will automatically come to buy.Marketing and distribution as well as profit is sacrificed to convertersCommodity products especially require great marketing and distribution efforts and differentiation by value addition and quality.
3. Lack of expert advise : No expert consultant approached or allowed themselves to be conned by half-baked consultants giving misleading information and having their own profit making goals.
4. Poor technology selection : Purchased obsolete or poorly designed technology which have limitations on productivity, profitability and quality
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No Clear guidance on product identification to product launch
Market development through promotional effects may add more cost to the project.
No regulatory or mandatory requirements imposed on use of Technical
textiles by Indian government unlike developed countries.
Therefore Longer payback period for realizing the profits from the investment.
3. Major Hurdles for new entrants in the Nonwoven sector
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3. Major Hurdles for Existing Nonwoven manufacturers
Improper selection of machinery and raw materials due to lack of expert technical
advice...
Lack of required skilled manpower to give better cost effective production processes and
better quality products
No Product innovation efforts as they require R&D Trials which are found unaffordable by
them.
No efforts to match international quality parameters due to lack of expertise and least
efforts to put quality on forefront for competing with the global NW producers.
Very little marketing efforts to create demand through consumer awareness and
education programs
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4. Strategic Actions for sustainable growth of nonwovens
Investors need clear guidance for product identification to product launch.
Provide active assistance in the selection of raw materials, equipments and machineries.
Provide them with comprehensive project reports
Provide them comprehensive consultancy in market forecasting, market development and consumer awareness
programs.
Provide them technical knowhow on product innovation through pilot plant R&D studies at a very nominal cost.
Provide them quality assurance support through setting up quality specifications and standards, product testing
and process parameter optimization for getting right first time quality of the products.
YOU CAN GET SUPPORT FROM MANTRA TO PROVIDE ACTIVE ASSISTANCE FOR MOST OF THE ABOVE
REQUIREMENTS AS YOU CAN SEE FROM NEXT FEW SLIDES OF THIS PRESENTATION
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5. MANTRA-COE : One stop solution provider
MANTRA has 32 years R & D Experience.
Partner for COE in AGROTECH by MOT.
COE in Nonwoven by Govt. Of Gujarat.
Strong R&D data base and testing services capability well suited for Non-woven
technical textiles whose raw materials are derived from synthetic and manmade
fibres.
Well qualified and well experienced staff who have extensive experience to handle
all types of manmade textile based products and processes.
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5. MANTRA-One Stop Solution for Nonwoven sector
MANTRA can provide the following solutions to the Nonwoven industry
A.Product innovation
Development of prototype for new product.Techno-economic feasibility studies.Re-engineering of existing products
B.Process development and optimization.
Pilot studies for Development of process optimization standards.Pilot studies for Process modification and development for quality improvement to match international standards.Pilot studies for Development of technical know-how for new products and processes
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C. People Skill development and knowledge up gradation.
Provide intensive training for imparting and enhancing technical skills in manufacturing and process management for personnel sponsored by MSMEs.Providing practical awareness and training programs for new and existing MSME entrepreneurs on the latest developments in technical textile products and processes and marketing.
D.Market research and development.
Pilot production and testing of new and modified products and studying the market potential for them.Market feasibility studies for existing and new products through reworking on cost and technical specifications by pilot studies.
MANTRA-One Stop Solution for Nonwoven sector
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NONWOVEN PLANTS:
MANTRA has commissioned a NONWOVEN 500mm pilot plant machines under the
partial grant-in-aid by the Govt of Gujarat. which can produce most of the
Nonwoven products.
Nonwoven pilot plant
Spunlace technology
Needlepunch technology
Chemical bonding
Thermal bonding
Centre of Excellence in Technical Textiles (sponsored by Govt. of Gujarat)
6. MANTRA-COE: Infrastructure and facilties
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Melt spinning Pilot plant Unit: Polymer to Filament yarn conversion.
Pilot Plant Facilities at MANTRA
6. MANTRA-COE: Infrastructure and facilties
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Fully functional Weaving Services Centers at Sachin and Pandesara for
Woven Nonwoven pilot plant studies.
Powerloom – PSC Pandesara Powerloom – PSC Sachin
6. MANTRA-COE: Infrastructure and facilties
Pilot Plant Facilities at MANTRA
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Pilot plant facilities: Coating and Lamination
Coating machine
Hot melt laminating machine
Narrow width fabric machine
Testing Lab
To test raw materials and finished product
Product display center
6. MANTRA-COE: Infrastructure and facilties
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Has the state of art Pilot plant for Coating and lamination
Matex multilabo coating machine Cavitec hot melt laminating machine
6. MANTRA-COE: Infrastructure and facilties
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Plasma machine
This machine is installed at MANTRA under DST project
In collaboration with IPR, Gandhinagar
6. MANTRA-COE: Infrastructure and facilties
Plasma technology is widely applicable for the surface modification of textiles & can improve functionality of textile materials, such as 1. improves coating adhesion 2. Pre-treatment process 3. Dyeing & Printing 4. Finishing.
Thus reduces the consumption of
dye & chemicals
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Narrow Width Fabric Section
6. MANTRA-COE: Infrastructure and facilties
Pilot Plant Facilities at MANTRA
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WEB forming Line- It is a single web forming system which is unique across the world for Nonwoven
6. MANTRA-COE: Infrastructure and facilties
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Pilot plant Facilities COE in Agrotech under MOT MANTRA has purchased industrial scale Raschael machine for the products to be
used in Agriculture, mainly in shading purpose.
6. MANTRA-COE: Infrastructure and facilties
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Agrotech Products manufactured on Rachel machine
6. MANTRA-COE: Infrastructure and facilties
Insect net Shade net
Bird net
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Fully equipped Testing laboratory for quality evaluation of all types of Nonwoven
products
Technical Textile Lab
6. MANTRA-COE: Infrastructure and facilties
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Centre of Excellence in Technical Textiles (Phase – I) TESTING
FACILITY
6. MANTRA-COE: Infrastructure and facilties
Measures thermal resistance (Tog value).
Measures re-wetting properties of non-woven cover stock.
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6. MANTRA-COE: Infrastructure and facilties
A time taken for known volume of test liquid to penetrate in hygiene products like SN, Diaper,
underpad is measured
To determine air permeability at upto 2500 pascal pressure.
Centre of Excellence in Technical Textiles (Phase – I) TESTING
FACILITY
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6. MANTRA-COE: Infrastructure and facilties
Measures vertical flammability of substrates.
Measures resistance of textiles to water
absorption and penetration.
Centre of Excellence in Technical Textiles (Phase – I) TESTING
FACILITY
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6. MANTRA-COE: Infrastructure and facilties
Determines the resistance of fabric to surface wetting by
water.
Measures amount of liquid that specimen can hold after period of immersion and drainage.
Centre of Excellence in Technical Textiles (Phase – I) TESTING
FACILITY
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6. MANTRA-COE: Infrastructure and facilties
Sample is immersed in water. Measures time required for
complete wetting
Centre of Excellence in Technical Textiles (Phase – I) TESTING
FACILITY
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MANTRA has well-organized sample studio to show case the
technical textile samples, both developed as well as having a
good potential to develop in future.
6. MANTRA-COE: Infrastructure and facilties
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Implementing Agency
MAN MADE TEXTILES RESEARCH MAN MADE TEXTILES RESEARCH ASSOCIATIONASSOCIATION
Integrated Skill Development Scheme in Technical Textiles
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Courses
conducted
I. Training course for Textile coating and laminating machine operator
II. Training course for Technical textiles entrepreneur ( coating, laminating and value addition)
III. Training course for technical textiles entrepreneur ( Nonwoven technology )
IV. Refreshers training course in weaving
V. Entrepreneurs training course in weaving for technical textiles
VI. Workers training course in weaving on modern machine
VII. Jobber Fitter training course for power loom
MANTRA is fully equipped Technical Training centre conducts many customized training courses for members including MOT sponsored 7 different ISDS training
courses catering to the skill development needs of technical textile industry.
6. MANTRA-COE: Infrastructure and facilties
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MANTRA ISDS in Technical Textiles performance
till now All Courses are operationalised.
Last year we trained 574 trainees comprising of workers and entrepreneurs
%age target achieved ~ 120%
We also conducted One unique training workshop on Nonwoven technical
textiles at MANTRA for delegates for all deputy directors from
Karnataka state Handloom and Textiles and was well appreciated
by all Participants.
6. MANTRA-COE: Infrastructure and facilties
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Spunbond
Machine Technical Training Center for ISDS activities at Pandesara.
Pilot Scale 500 mm width Spunbond machine has been installed at ISDS building of
MANTRA
6. MANTRA-COE: Infrastructure and facilties
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7. SUMMARY
Indian nonwoven industry has key identifiable issues to be resolved for accelerating its growth to its forecast potential.
All these issues are solvable with active assistance with expert guidance
MANTRA is recognized and funded by Central and state government of Gujarat to become a COE for helping Nonwoven Nonwoven industry development.
MANTRA is well equipped with pilot plants and expertise and can assist in product innovation and value added process development
MANTRA is ONE STOP SOLUTION for all the issues faced by the Nonwoven Nonwoven industry through its 3 P strategy.
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THEME / MESSAGE
True Guidance can be like a small lamp in a Tunnel. It may not
show us everything at once, but it will give us enough light to
take our next step safely.
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