Emerging Trends in Technical Textiles & Nonwovens

PFY
PSF

PTA MEG

PET

Arun Aneja & Chandan Gokhale

Reliance Industries Ltd

NW
1
Agenda

• Points to Consider Globally

• New Challenges

• Product Innovation

• Process Innovation

• Conclusion

2
Points to Consider - The Global Context

3
 What is a Global Macro Trend?

• Must be almost “irreversible”

• Can / does change (or make) the rules

• Can impact business / market / industry

significantly & in positive or negative ways

• Influences the way in which people make

decisions

4
 Global Macro Trends

• Serious financial imbalances

• First signs of “new economy”

• Recession Looming in US and Europe

• An Urban World

• A Mobile Society

• China’s Infrastructure Boom

• More Single Women

• Skewed Wealth Distribution

• Aging Population

• Increasing influence of environmental awareness

5
Capital and Labour

• Capital squeeze on SME’s (Basel2 effect)

• Equity and Venture Capital Shortage

• Skilled labour shortage

• Unskilled labour reserve still ample

6
Looking Ahead: Material Economy

• Volatile oil prices USD 50 - 150/ bbl

– Upward impact on synthetic fibres

• Coal back in vogue

– Moving beyond thermal power generation
– Coal to alcohol to olefins
– Carbon capture & sequestration

• Energy & water price on the rise

• Biotech: Emerging alternative for non-
renewable resources
• Material science at the confluence of IT,
Biotech & Nanotechnology

Bottom of pyramid worst affected 7

Current State

• Fibre base moved to Asia (80% of capacity)

• EU &USA only in specialities( UHMWPE)
• Overall de-industrialisation in USA
• EU focus on cultural capital, eco-products,
mass-customization
• Global Cost Pressure
• Reduced R&D Spending
• Higher Consumer Expectation
• Diverse Customer Base
• Rapid Changes in High Tech Industries
• Regional Trading Blocks, China in WTO

8
Innovative Fibres / Textiles: Patent Position

1994 2004

Europe: 2571 2437 (68%)

USA: 327 625 (18%)

Japan: 145 141 (4%)

China: 75 292 (9%)

S.Korea: 27 60 (2%)

9
Global Market Size: Technical Textiles

Technical Textiles Unit 2005 2010

Output MMT 19.7 23.8

Value US$ bn 107 127
Avg value/MT US$/MT 5431 5336
Avg value/MT INR/MT 2,17,000 2,14,400
Source: DRA

• India & China are expected to be the main growth drivers

• Technical textiles to grow at CAGR of 6.45% in volume terms to reach 24 MMT

• Numbers shows that value of technical textiles is atleast 3-4 times the non-
technical textiles

Higher margins over conventional textiles 10

Technical Textile: Fibre Consumption

Year
Fibre (KT) CAGR (%)
2000 2005 2010
Natural 3462 3839 4447 2.54
Man-made/Inorganic(glass) 13252 15843 19327 3.85
Total 16714 19682 23774 3.59
Source: DRA

• MMF has a dominant share of 80% in technical textiles

• Polyester & polyolefin's share is 50%, natural fibres have a share of 20%
while other man-made fibres have a share of 30%

Versatility in properties makes MMF the preferred fibre 11

Technical Textile: Consumption Pattern

Product type Share (% )

Filling material 24

Yarn 9

Fabrics
-Woven
67
-Knitted
-Non-woven

• Major consumption is in form of fabrics (67%)

Huge opportunities ahead 12

Agenda

• Points to Consider Globally

• New Challenges

• Product Innovation

• Process Innovation

• Conclusion

13
 Milestones

• Mechanical clock
• Printing press LLDPE
Spandex PEN

• Light bulb Polypropylene

• Steam engine Nylon

Polyester
• Immunization & antibiotics
Polyethylene
• Telephone Polystyrene
• Nuclear fission PVC

• Space Shuttle Nitrocellulose paint

• Internet
• Mobile communication Silicon

Viscose

1868-1900 1900-1925 1925-1950 1950-1975 1975 +

Source: usenvy.com, encarta.msn.com

Material science based innovation nearing maturity ? 14

Saturation in process technology !

Product Yield Economy of scale (KTA)

Laggard Leader Variation 1990 2008 Increase
Ethylene 30.4% 30.6% 0.2% 500 1300 3 times
Ethylene Glycol 66.4% 69.8% 3.4% 100 600 6 times
PTA 94.6% 95.3% 0.7% 250 800 3 times
LDPE 96.1% 98.5% 2.4% 80 400 5 times
LLDPE 98.9% 99.5% 0.6% 120 550 5 times
Polypropylene 97.0% 98.8% 1.8% 120 550 5 times
PET 98.9% 99.8% 0.9% 70 450 6 times
S o urc e : Ne xa nt, Inc ./Che m S ys te m s
*C he m ic a l Gra de - 93%, # R e fine ry Gra de , @7% bute ne c o m o no m e r

Key differentiator: Past – Scale with maturing technology

Future - Ownership of new technology key to growth 15
Agenda

• Points to Consider Globally

• New Challenges

• Product Innovation

• Process Innovation

• Conclusion

17
Technical Textiles: Fusion of products
(Marriage of Properties)

Plastics and
Material
Tradi.
Paper
Textile

Construction Technical Textile Rubber and

Elastomers

Healthcare Construction

Electronics

Covers a vast range of products & applications

18
Technical Textiles Products

19
Technical Textiles Products (Cont.)

20
Technical Textiles Products (Cont.)

21
Technical Textiles Products (Cont.)

22
Focus on specialties Super specialties

Idea
Intelligence Opportunities Projects Roll outs
fragments

Market study
Automotive
Consumers
products
Customers Product
development Industrial
Suppliers specialties

Technologies Market
development
Non Wovens
Partners
Nano enabled
Commercial products
launch

0
360 focus on product selection 23
Driving forces: Technical Textile & Non Wovens

 Technology push
 Polymer science and technology
 Fibre production
 Yarn and fabric forming techniques
 Inter disciplinary developments
 Market pull
 Consumer demands
 New avenues for existing products
 Environmental
 Stricter regulations (REACH)
 Increased awareness
Ref : R.Shishoo, Techtextil India, 2007

24
Functionality Directions

• High strength
• High modulus
• High thermal stability
• High flame and heat resistance
• High chemical resistance
• Special functionality
• Conducting, Barrier, Impact, Cut
• Adaptable/smart
• High performance - Nano fibres
• Combination of functionality - Polymer blends
• Eco friendly - Renewable resources, recycled 25
Advanced Fibres
•HT-PES,
•UHMPE,
•Aramid (Kevlar, Nomex)
•Carbon
•PEEK
•Melamine (Basofil)
•Ceramic (Silicon Carbide)
•Electro spun nano fibres
•Conducting Polyanilines, Polypryrroles
•Eco friendly - PLA, PTT, recycled PET

26
New Technologies

• Micro-fibre spinning

• Bicomponent spinning

• Conjugate spinning allowing incorporation of

microcapsules and inorganic substances

• Electro spinning for Nano fibres

• Auxetic Textiles

• Aerogels

27
28
Ultrafine Bicomponent

BEFORE SPLITTING

29
AFTER SPLITTING
Electro Spinning

Electrospun polyester X 1000

Nanofibres from Toray- conventional

30
Nano-Materials

Nanotubes Nanotissue Nano-muscles

31
Nano Surfaces (Lotus Effect)

32
Self Cleaning Fabrics

•Biomemetic led to developing the fabric based on lotus leaf effect

•Alternative technology based on photocatalysis of Ti02 nano particles

33
New Functionalities

34
Nanofibres / Finishes

35
 Nano Fibre Structures

•Gradient
•Porous
•Oriented
•Composite

•Prepared by dual electro spinning to enhance

•Filtration efficiency
•Tissue engineering

Ref : Technical textile international Jun 2008.

36
 Nano Clay Composite

•NanoXcel a new generation sheet moulding

compound used to produce WaveRunner by Yamaha
motors and Interplastic Corp.

Ref : Technical textile international Jul/Aug 2008.

37
Nanocircuits and Sensors

38
Locus of Nanotechnologies

• Structuring of fibre (e.g. electrospinning)

• Bi/Multi-component fibres

• Avivages and nano-texturising

• Surface modifications or encapsulation

• Single and double step functionalisation

39
 Nanotechnologies: A Business Case

• Search for the launching customer

• (military, paramedical, sports, industrial)

• Many Unknowns (medical guarantees)

• High Upfront investments

• New business models (product service

systems)

40
Understanding of the Fundamentals of Nano’s

• Much nano in no-nano

• Textile properties often badly described

• Most are at proof of concept stage

• Processes still small scale

• Functionalities are not stable / predictable

• Life-time behaviour is not known

41
Nanotechnologies: R&D

USA € 3,250 Mn

Japan € 1,750 Mn

Germany € 500 Mn

E.U. (6FPRD) € 525 Mn

U.K. € 270 Mn

Netherlands € 220 Mn

42
Nanotechnologies: Publications

Europe 32%

USA 24%

Japan 12%

Rest of world 32%

Of which - China

- Russia

- India

- S Korea
43
Micro Encapsulation
• PCM encapsulation results in a thermo-regulating
effect, which keeps the microclimate temperature,
close to the body surface, nearly constant
• Controlled release of micro encapsulated fragrance,
vitamins, etc exploited in new brands of clothing

©Shishoo Consulting AB Ref : R.Shishoo, Techtextil India, 2007 44

Building Insulation with PCM Coated Fabrics

45
Water Proof Breathable Textiles

•Ticona’s Riteflex PET elastomer

is barrier to water but permeable
to water vapour, at the same time
recyclable

Ref : Technical textile international Mar/Apr 2008.

46
 Products Used in Beijing 2008 Olympics

•High shock absorption running shoes

•LZR Racer swim suit from speedo minimizes drag.

Ref : Technical textile international Jul/Aug 2008.

47
 Wearable Electronics

•Vitaljacket T-shirt with built in heart wave monitor from

Biodevices

Ref : Technical textile international Jun 2008.

48
 Few More Examples

• Elk polyester nonwoven from Teijin replaces

foam in Japanese Shinkansen
• Ecobond headliner from Johnson with 50%
biomass materials
• Latex free carpet from Reiter automotive
• SolarNext’s flexible, organic photo voltaic cells
• Pacific Northwest National Laboratory are
showing lightweight and man-portable cooling
technology, leading to truly wearable air conditioners
Ref : Technical textile international Jul/Aug 2008.

49
 Green Polyester

• Business to fulfill societal Bottles

obligation along with earning
Flakes
adequate returns for Cleaning
shareholders

Collection
– Waste bottles collected by
unskilled uneducated manpower -
reduces land fill & provides earning
opportunity for downtrodden
– Pillows Processing
Processed to produce fibers
– Fibers used to make pillows Filling
– Business earning above cost of
capital – Waste to wealth
Fibers
– Self sustaining business

Livelihood to 2 lakh people at the bottom of the pyramid 50

Agenda

• Points to Consider Globally

• New Challenges

• Product Innovation

• Process Innovation

• Conclusion

51
The Locus of Functionalisation
Where does added value make a difference?

52
Innovation Supply Chain

Fibre Fabric Product Maintenance

Impact of value addition

Impact of efforts

53
Technologies

• Functionalisation
• Customization

- Scale versus Scope

- Labour versus Capital Intensive

54
Emerging Process Technologies

Yarn/ fabric/ process

technologies Nonwoven technologies
•DREF spinning • Hyperlace needling
• Spunlacing
•3D weaving
• Tubular
•Spacer knitting • Melt blowing
• Multifunctional • Composites
coating/Laminating • SMS, SMMS, etc
•Nanotechnology • Integrated technologies
• Bico spinning
•Micro encapsulated finishing
+Spunbonding
technology
+Spunlacing
•Extrusion/Hot melt coating
•Plasma technology 55
DREF spinning

Sheath core yarns, difficult to spin fibers including metals

56
 3 D weaving

Tailor made shaped products from Radoms to shells to cartileges

for difficult to make shapes

57
Hot Melt / Extrusion Coating

Products from polymeric coatings on difficult to coat substrates

•Johnson’s Baby extra care wipe has a lipid phase of

emulsion, a green strip on the wipe, applied by hot-melt
technique, which reduces skin irritation

58
Spacer Knitting

Products to replace foam in automotives and furnitures

59
 Composites- Shape Memory Polymers (SMP)
Shape memory polymeric materials are 2-component flexible laminated sheets
which can, for example, deform from a straight shape to a curved shape due to
change in environmental temperature

Clothing Shape memory Thermoplastic

layers polymer polyurethane Morph a joint
technology
between Nokia
Section > 25oC and university of
Cambridge is
aiming to design
Air gap flexible,
increased by
Section < 25oC change in stretchable mobile
shape of devices
laminated film

Ref : R.Shishoo, Techtextil India, 2007 60

©Shishoo Consulting AB
 Plasma Technology

Surface of ultra high

modulus polyethylene fiber
treated 2 minutes with
He/O2 plasma.

Green technology for coating difficult to coat substances and

multiple functionalities without using water
61
 Textile Formation at Nanoscale

CSIRO Textile and Fibre Technology (CTFT) and

NanoTech Institute at the University of Texas at Dallas,
have adapted textile technologies to produce yarns made
solely from carbon nanotubes (CNTs)
62
 Nonwoven – Spunlacing

• Fine high pressure jets used to interlock fibres

• Soft, High isotropic structures possible
• Tubular products is made possible in latest development
Softer/ drapable structures obtained at high speeds, eco friendly

Ref : INDA 63
 Nonwovens – Spun bonding

• Different spinning/web bonding

technologies leading to
differentiated products
• Spunjet from Reiter combines
Spun bonding with Spunlacing
• Evolon from Freudenberg made
on a Bicomponent + spunbonding
+ spunlacing line

Evolon

One step process for making fabrics from chips

Very economical and high speed process
Ref : INDA 64
Nonwovens- Melt Blowing

Similar to fibre extrusion

• Melt polymer
• Polymer extrusion
• Stretch/draw filaments by air jets
• Deposit on conveyor followed by
bonding

Highly porous/filtration efficiency but poor web strength

Ref : INDA 65
Nowovens - Composite SMS

Combines high filterability of melt blowing with strengths of

spun bond

66
Agenda

• Points to Consider Globally

• New Challenges

• Product Innovation

• Process Innovation

• Conclusion

67
 Future Directions

• “Intelligent” adaptive textiles

– controlled comfort , antimicrobial activity, self cleaning potential

• “Intelligent” knowledge based technical textiles

– locally compressive behavior and complex actions e.g. comfort type mattresses for

disabled persons, intelligent car seats

• Hybrid multifunctional textiles for protective clothing

– improved protection (a barrier against the selected types of radiation and particles)

with improved comfort

68
Emerging Business Model

New products
Admiration &
rise in Market
bottomline superiority

Rise in topline

Ideas New markets

Reduce risk

Rise in margins Cost

competitiveness

Novel Solutions

Leadership through business model innovation 69

 Strategic Drivers & Challenges

Emerging chemical leaders Global

from ME and Asia
Increasingly global supply
chain in specialties
Global Growth Global “Green”

Strategic
Challenges

drivers

Favouring Asia and ME Growth Green Alternate feedstock

Commoditization of Carbon risk
specialties “Green” Growth Advancing “green wave”
Emergence of importance for
innovation Regional disparities

Innovation to overcome challenges 70

 Conclusion

• Global trends lead to new paradigm

• Abundance of low cost labour leads to industrial regression

• Lack of technology leadership (end of fibre dominance)

• Product Innovation: Low cost solution is the prime driver

• Process Innovation: Competitiveness through cost leadership

• Business innovation: Competitive edge in emerging paradigm

• Innovation distinguishes leaders from followers

71
Thank You

72
 “Being innovative is not the end of the journey
It is just the beginning”

1 Polyester 4 Purified
(Fibre & Yarn) Terephthalic
Acid

3 Refining 6 MEG

4 7 Polypropylene
Paraxylene
179th most 19th most
profitable innovative
company Global capacity ranking company

Innovation distinguishes leaders from laggards 74

Emerging Themes in Consumer Trends

• Easy Care

• Comfort & Stretch

• Fashion & Modernity

• Durability & Versatility

• Importance of Brands

• Health & Well Being

• Environmental Awareness

88
Trends in Lifestyle Changes

• Increasing pressure at work

• Business formal wear becomes more casual

• Comfort over fashion

• Less direct human contacts with clients

and suppliers

• Formality replaced by individuality

• Emphasis on time over money

89