ram-kumar_non woven fabric ppt
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A presentation on non woven fabricTRANSCRIPT
Technical Textiles & Nonwovens: Product Applications Trends
World and IndiaWorld and India
Seshadri RamkumarNonwovens and Advanced Materials Laboratory
Texas Tech UniversityLubbock, TX, USA
Technotex, January 17-19, 2013, New Delhi, India
Overview
• Growth Statistics
• Nonwoven Processes
• Examples of Nonwoven Products
Nonwovens Growth Prospects
• Grew by 5.7% in 2011 in volume terms.
• Spunmelt recorded growth of over 9% in 2010 and • Spunmelt recorded growth of over 9% in 2010 and 2011.
• Spunlace is the important drylaid technology.
Source: EDANA, July, 12, 2012
Nonwovens Growth Prospects
Markets that recorded growth include baby diaper, medical, personal care wipes, civil engineering, automobiles and agriculture engineering, automobiles and agriculture applications.
Growth in 2010: 10.9%
Growth in 2011: 5.7%
Source: EDANA, July, 12, 2012
Outlook for Worldwide Nonwovens Production (millions of tonnes)
2006 2011 2016Growth Rate
2006-2011 (%/Year)
Growth Rate2011-2016
(%/Year)
NAFTA 1.61 1.87 2.2 3.00% 3.30%
Source: INDA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)
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
1997 2002 2011 2016
Growth Rate
1997-2010
(%/Year)
Growth Rate
2011-2016
(%/Year)
Source: INDA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)
Dollars
(billions)$11 $15 $26 $37 6.2% 7.8%
Sq Meters
(billions)61 93 205 305 8.7% 9.0%
Tonnes
(millions)2.7 4.0 7.6 11.1 7.7% 7.8%
Summary of 2011 NA Disposable Market 1,091,000
(tonnes)
Source: INDA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)
Summary of 2011 European Disposable Market
1,096,200 (tonnes)
Source: INDA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)
2011 Asian Nonwovens Market 2.6 million tonnes
Source: ANFA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)
Nonwoven Consumption Per Capita
(kilograms)
Mexico
China
South America
Brazil
S. Africa
Russia
India
Early Development Markets
Emerging Markets
0 1 2 3 4 5 6 7
Taiwan
Korea
NAFTA
Europe -27
Australia
Japan
Malaysia
Saudi Arabia
Turkey
Developed Markets
High export volumes
Source: INDA Estimates, Ian Butler, INTC-2008
Nonwoven Consumption Rises as GDP Per Capita Increases *
Kg/Capita
3
3.5
4
4.5
Europe NAFTA
Taiwan
Trend line
Source: INDA Estimates, Ian Butler, INTC-2008
* PPP in US$ equivalents
0
0.5
1
1.5
2
2.5
$0 $10,000 $20,000 $30,000 $40,000 $50,000
Czech Rep.
Korea
Brazil
Turkey
Japan
India now
China now
India, 2012
Consumption Of Nonwovens/TT in India Vs. GDP Per Capita
(Assuming An Increase Of 13.27% In Per Capita Every Year)
YEAR GDP PER CAPITA (US$) CONSUMPTION OF NONWOVENS/TT (kg)
2005 733 0.08
2010 1374 0.15
GDP per capita source: World Bank
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 4.322010 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
General Definition of Nonwoven Fabrics
Nonwoven fabrics are flat structures mainly defined as sheets or webs made by bonding and entangling fibers or filaments by mechanical, thermal or chemical means.chemical means.
- Mahmud and Ramkumar, Man-Made Textiles in India, September 2001
Nonwoven Process
Nonwoven process consists of three major steps:
1) Fiber feeding1) Fiber feeding
2) Web/matt formation
3) Web consolidation/interlocking
Nonwoven Processes
Source: TAPPI & Gajanan Bhat, University of Tennessee
Major Nonwoven Technologies
• Needlepunching
• Thermalbonding
• Airlaid
• Spunbonding
• Meltblowing
• Spunlacing/Hydroentanglement
Nonwoven Technologies(Based on Fiber Type)
Spunbond – Synthetic
Meltblown – Synthetic
Needlepunching – Versatile (natural and synthetic)
Hydroentangling – Versatile (natural and synthetic)
Typical Applications of Nonwovens
• Technical applications• Hospital fabrics• Surgical gowns• Face masks• Geo textiles• Geo textiles• Consumer and industrial wipes• Upholstery paddings• Military decontamination wipes• Inner liners of protective fabrics• Automotive headliners• Automotive trunkliners• Acoustic and thermal insulation materials
Technology and End-use Applications
• Spunbonding – surgical gowns, diaper cover stocks
• Meltbowning – barriers, filters and face masks
• Needlepunching – geotextiles, automotive fabrics• Needlepunching – geotextiles, automotive fabrics
• Thermalbonding – upholstering, cussion pads
• Hydroentangling – wipes
Melt Blowing Process
• Uses a high-velocity stream of air to force the filaments away from the
spinneret face.
• Fibers are attenuated by air-stream to a degree of fineness much
Source: Gajanan Bhat, University of Tennessee
smaller than typical extruded textile fibers.
• Fibers (typically 1-5 microns) are deposited onto a condenser/conveyer
belt and bonded before take-up.
• Makes a web with very fine pore-structure and large surface area.
• Suitable for absorption and filtration applications.
Melt Blown Webs
• Fiber Diameter (2-5 µm)
• Uniformity
• Air permeability/Hydrohead
Source: Gajanan Bhat, University of Tennessee
• Air permeability/Hydrohead
• Filtration efficiency
• Porosity, pore size & Distribution
• Mechanical Properties
• Composite structures
Spunbond NonwovensSpunbond Nonwovens
Spunbonding Process
• Integrated process.
• Production rate: 30 to 300 m2 /min.
• Filament production speed: 1000-6000 m/min being • Filament production speed: 1000-6000 m/min being
operated.
• Isotactic polypropylene has been used predominantly in
commercial production.
• Other Polymers Used: Polyesters, Nylons, PE and
Bicomponents.
Source: Gajanan Bhat, University of Tennessee
Spunbonded Fabrics• Random fibrous structure.
• Basis weights range between 5 and 800 g/m2, typically 10-100
g/ m2.
• Web thickness range between 0.1 and 4.0mm, typically 0.2-• Web thickness range between 0.1 and 4.0mm, typically 0.2-
1.5mm.
• Fiber diameters range between 1 and 50µm, but the preferred
range is between 15 and 30µm.
• High strength-to-weight ratios compared to other nonwoven
and knitted structures.
• High tear strength. Source: Gajanan Bhat, University of Tennessee
Spunbonding Process Variables
• Spinning• Melt Temperature
• Throughput
• Quench Air Temp
• Bonding• Type
• Bond Area
• Temperature
Source: Gajanan Bhat, University of Tennessee
• Quench Air Temp
• Draw Down Speed
• Laydown• Spinning Speed/Belt
Speed
• Temperature
• Time (Speed)
• Pressure
Spunlace NonwovensSpunlace Nonwovens
Spunlace Nonwovens
• Spunlace is an industrial terminology for nonwoven fabrics made by interlocking using high pressure jets of water.
• Pre-wetting pressure – 20 to100 bars.
Maximum operating pressure – 250 bars.
• Spunlace are predominantly used as wipes.
Examples of Nonwoven End ProductsExamples of Nonwoven End Products
Nonwovens in Automobiles: A Glimpse
of Value-Added Application
Source: Cos Camelio, Association of Nonwoven Fabric Industry, USA
Diaper
Cover Stock is Spunbond ~ 10GSM
Spunlace Wet Wipes
Moistened Hand Wipes
Majority of moistened wipes are Spunlace
Insulation High Lofts
Awareness on the Technical Textiles Technical Textiles Converted Sector
Converted Products are Necessary