111 ARUN Pal Emerging Trends in Technical Trends & Nonwovens

8/7/2019 111 ARUN Pal Emerging Trends in Technical Trends & Nonwovens

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Arun Aneja & Chandan Gokhale

Reliance Industries Ltd

PTA MEG

PFY

PSF

PET

NW

Emerging Trends in Technical Textiles & Nonwovens


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Agenda

Points to Consider Globally

New Challenges

Product Innovation

Process Innovation

Conclusion


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Points to Consider - The Global Context


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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


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Global Macro Trends

Serious financial imbalances

First signs of new economy

Recession Looming in US and Europe

An Urban World

A Mobile Society

Chinas Infrastructure Boom

More Single Women

SkewedWealth Distribution

Aging Population

Increasing influence of environmental awareness


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Capital and Labour

Capital squeeze on SMEs (Basel2 effect)

Equity and Venture Capital Shortage

Skilled labour shortage

Unskilled labour reserve still ample


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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


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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


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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%)


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Global Market Size: Technical Textiles

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

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

Higher margins over conventional textiles


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Technical Textile: Fibre Consumption

2000 2005 2010

Natural 3462 3839 4447 2.54

Man-made/Inorganic(glass) 13252 15843 19327 3.85

Total 16714 19682 23774 3.59

YearFibre (KT) CAGR (%)

Versatility in properties makes MMF the preferred fibre

MMF has a dominant share of % in technical textiles

Polyester & polyolefin's share is 5 % natural fibres have a share of 2 %

while other man-made fibres have a share of 3 %

Source: DRA


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Technical Textile: Consumption Pattern

Product type hare (%)

Filling material 24

Yarn 9

Fabrics

-Woven

-Knitted

-Non-woven

67

Major consumption is in form offabrics (6 %)

Huge opportunities ahead


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Agenda


New Challenges

Product Innovation

Process Innovation

Conclusion


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Mechanical clock

Printing press

Light bulb

Steam engine

Immunization & antibiotics Telephone

Nuclear fission

Space Shuttle

Internet

Mobile communication

Source: usenvy.com encarta.msn.com

Material science based innovation nearing maturity ?

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

Viscose

Silicon

Nitrocellulose paint

PVC

NylonPolyester

Polyethylene

Polypropylene

PENLLDPE

Polystyrene

Milestones

Spandex


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Product

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

times

PTA 94.6% 95.3% 0.% 250 800 3 times

LDPE 96.1% 98.5% 2.4% 80 400 5 times

LLDPE 98.9% 99.5% 0.

% 120 550 5 times

Polypropylene 97.0% 98.8% 1. % 120 550 5 times

PET 98.9% 99.8% 0. % 70 450

times

Source: Nexant, Inc./Chem Systems

*Chemical Grade - 93%, #Refinery Grade, @7% butene como nomer

Yield Economy of scale (KTA)

Saturation in process technology !

Key differentiator: Past Scale with maturing technology

Future - Ownership of new technology key to growth


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Opex

Efficiency

Capex

Efficiency

Supply chain

optimization

Market

Leadership

Process

Innovation

Disruptive Innovation

Product

Innovation

HumanIntellect

Innovation = (Creativity + Risk) x Execution

It is not the strongest of the species that survives, nor the most

intelligent, but the one most responsive to change Charles Darwin


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Agenda


New Challenges

Product Innovation

Process Innovation

Conclusion


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Technical Textiles: Fusion of products

(Marriage ofProperties)

Technical Textile

Plastics an

MaterialTra i.

TextilePaper

Construction Rubber an

Elastomers

Covers a vast range of products & applications

Healthcare Construction

Electronics


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Technical Textiles Products


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Technical Textiles Products (Cont.)


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Market study

Productdevelopment

Marketdevelopment

Commerciallaunch

OpportunitiesIdea

fragmentsProjects Roll outs

Consumers

Intelligence

Customers

Suppliers

Technologies

Partners

Automotiveproducts

Industrialspecialties

Non Wovens

Nano enabled

products

Focus on specialties Super specialties

3600

focus on product selection


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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


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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


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Advanced Fibres

HT-PES,UHMPE,

Aramid (Kevlar, Nomex)

Carbon

PEEK

Melamine (Basofil)

Ceramic (Silicon Carbide)

Electro spun nano fibresConducting Polyanilines, Polypryrroles

Eco friendly - PLA, PTT, recycled PET


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New Technologies

Micro-fibre spinning

Bicomponent spinning

Conjugate spinning allowing incorporation of

microcapsules and inorganic substances

Electro spinning for Nano fibres

Auxetic Textiles

Aerogels


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Ultrafine Bicomponent

BEFORE SPLITTINGBEFORE SPLITTING

AFTER SPLITTINGAFTER SPLITTING


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Electro Spinning

Electrospun polyester X

Nanofibres from Toray- conventional


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Nano-Materials

NanoNano--musclesmusclesNanotubesNanotubes NanotissueNanotissue


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Nano Surfaces (Lotus Effect)


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Self Cleaning Fabrics

Biomemetic led to developing the fabric based on lotus leaf effect

Alternative technology based on photocatalysis of Ti 2 nano particles


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New Functionalities


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Nanofibres / Finishes


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Nano Fibre Structures

Prepared by dual electro spinning to enhance

Filtration efficiencyTissue engineering

Gra ient

Porous

Oriente

Composite

Ref : Technical textile international Jun 2008.


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Nano Clay Composite

NanoXcel a new generation sheet moulding

compound used to produce WaveRunner by Yamahamotors and Interplastic Corp.

Ref : Technical textile international Jul/Aug 2008.


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Nanocircuits and Sensors


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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


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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)


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Understanding of the Fundamentals of Nanos

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


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Nanotechnologies: R&D

USA 3,250Mn

Japan 1,750Mn

Germany 500Mn

E.U. (6FPRD) 525Mn

U.K. 270Mn

Netherlands 220Mn


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Nanotechnologies: Publications

Europe 32%

USA 24%

Japan 12%

Rest of world 32%

Of which - China

- Russia

- India

- S Korea


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Micro Encapsulation

PCM encapsulation results in a thermo-regulatingeffect, 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



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Building Insulation with PCM Coated Fabrics


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Water Proof Breathable Textiles

Ticonas Riteflex PET elastomeris barrier to water but permeableto water vapour at the same timerecyclable

Ref : Technical textile international Mar/Apr 2008.


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Products Used in Beijing 2008 Olympics

High shock absorption running shoes

LZR Racer swim suit from speedo minimizes drag.



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Wearable Electronics

italjacket T-shirt with built in heart wave monitor fromBiodevices

Ref : Technical textile international Jun 2008.


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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 SolarNexts flexible, organic photo voltaic cells

Pacific Northwest National Laboratory are

showing lightweight and man-portable cooling

technology, leading to truly wearable air conditioners



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Bottles

Filling

Processing

Cleaning

Pillows

Fibers

Flakes

Collection

Green Polyester

Livelihood to 2 lakh people at the bottom of the pyramid

Business to fulfill societal

obligation along with earningadequate returns for

shareholders

Waste bottles collected by

unskilled uneducated manpower -

reduces land fill & provides earning

opportunity for downtrodden

Processed to produce fibers

Fibers used to make pillows

Business earning above cost ofcapital Waste to wealth

Self sustaining business


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Agenda


New Challenges

Product Innovation

Process Innovation

Conclusion


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The Locus of FunctionalisationWhere does added value make a difference?


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FibreFibre FabricFabric ProductProduct MaintenanceMaintenance

Innovation Supply Chain

Impact of value additionImpact of value addition

Impact of effortsImpact of efforts


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Technologies

Functionalisation

Customization

- Scale versus Scope

- Labour versus Capital Intensive


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Nonwoven technologies Hyperlace needling

Spunlacing

Tubular

Melt blowing Composites

SMS SMMS etc

Integrated technologies

Bico spinning+Spunbonding+Spunlacing

Yarn/ fabric/ process

technologies

DREF spinning

3D weaving

Spacer knitting Multifunctionalcoating Laminating

Nanotechnology

Micro encapsulated finishingtechnology

Extrusion Hot melt coating

Plasma technology

Emerging Process Technologies


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DREF spinning

Sheath core yarns, difficult to spin fibers including metals


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3 D weaving

Tailor made shaped products from Radoms to shells tocartileges for difficult to make shapes


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Hot Melt / Extrusion Coating

Products from polymeric coatings on difficult to coat substrates

Johnsons Baby extra care wipe has a lipid phase ofemulsion a green strip on the wipe applied by hot-melttechnique which reduces skin irritation


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Spacer Knitting

Products to replace foam in automotives and furnitures


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Shishoo Consulting AB

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 tochange in environmental temperature

Section > 25oC

Section < 25oC

Clothinglayers

Shape memorypolymer

Thermoplasticpolyurethane

Air gap

increased bychange inshape oflaminated film

Morph a jointtechnology

between Nokiaand university ofCambridge isaiming to designflexiblestretchable mobiledevices



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Plasma Technology

Surface of ultra highmodulus polyethylene fiber

treated 2 minutes withHe 2 plasma.

Green technology for coating difficult to coat substances andmultiple functionalities without using water


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Textile Formation at Nanoscale

CSIROTextile and Fibre Technology (CTFT) andNanoTech Institute at the University ofTexas at Dallas,have adapted textile technologies to produce yarns madesolely from carbon nanotubes (CNTs)

l


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Nonwoven Spunlacing

Fine high pressure jets used to interlock fibres

Soft High isotropic structures possible

Tubular products is made possible in latest developmentSofter/ drapable structures obtained at high speeds, eco friendly

Ref : INDA

N S b di


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Nonwovens Spun bonding

Different spinning web bonding

technologies leading todifferentiated products

Spunjet from Reiter combinesSpun bonding with Spunlacing

Evolon from Freudenberg madeon a Bicomponent + spunbonding+ spunlacing line

One step process for making fabrics from chips

Very economical and high speed processRef : INDA

Evolon

N M l Bl i


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Nonwovens- Melt Blowing

Similar to fibre extrusion

Melt polymer Polymer extrusion

Stretch draw filaments by airjets

Deposit on conveyor followed bybonding

Highly porous/filtration efficiency but poor web strength

Ref : INDA

N C it SMS


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Nowovens - Composite SMS

Combines high filterability of melt blowing with strengths ofspun bond

A d


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Agenda


New Challenges

Product Innovation

Process Innovation

Conclusion

F t Di ti


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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

E i B i M d l


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New products

Ideas New markets

Novel Solutions

Cost

competitiveness

Market

superiority

Reduce risk

Admiration &

rise in

bottomline

Rise in topline

Rise in margins

Emerging Business Model

Leadership through business model innovation

St t gi D i & Ch ll g


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Global

Green

Strategic

drivers

Growth

Emerging chemical leaders

from ME and AsiaIncreasingly global supplychain in specialties

Favouring Asia and ME

Commoditization of

specialties

Emergence of importance forinnovation

Alternate feedstock

Carbon risk

Advancing green wave

Regional disparities

Global GreenGlobal Growth

Green Growth

Challenges

Strategic Drivers & Challenges

Innovation to overcome challenges

Concl sion


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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


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Thank You

Product Life Cycle


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Product Life Cycle

Being innovative is not the end of the journey


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g j y

It is just the beginning

1

3

4

4Polyester(Fibre & Yarn)

Refining

Paraxylene

Purified

Terephthalic

Acid

7

MEG6

Polypropylene

19th most

innovative

company

179th most

profitablecompany Global capacity ranking

Innovation distinguishes leaders from laggards

10 Macro Trends


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10 Macro Trends

1.) 2007 - For the first time in human history,

more people will live in urban areas than ruralareas. Every day in the world, 200,000 people

migrate to cities

NOTE: 70% of India Population is still in rural areas

Ken Livingstone Guardian nlimited January 26 2

10 Macro Trends


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10 Macro Trends

2.) Half the new buildings in the world in the next 10 years will be built in

China


10 Macro Trends


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10 Macro Trends

3.) In 1950, 50 million people a year crossed national borders - last year it

was 840 million


10 Macro Trends


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10 Macro Trends

4.) New Product Launches

105,000 new food and drink productswere launched in 2006 300 per day

77,000 new non-food products were

launched in 2006 211 per day

2 Study by Mintel International

10 Macro Trends


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10 Macro Trends

5.) Average life expectancy is

increasing 2.5 years every decade

Ken Dykwald

Life Expectancy


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Life Expectancy

By the year 2025, 26 countries will have a life

expectancy at birth of above 80 years. It willbe highest in Iceland, Italy, Japan and Sweden

(82 years) followed by Australia, Canada,

France, Greece, Netherlands, Singapore, Spain

and Switzerland (81 years).

NOTE: India will be 71 years

World Health rganization

10 Macro Trends


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10 Macro Trends

6.) 2005 was the first year when over 50% of US women reported being

single

Living Single


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Living Single

Over 50% increase in the number

of people living alone in the last20 years

10 M T d


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10 Macro Trends

7.) Percent of population that is foreign-born US, 12.1%

Sweden, 12.4%

United Kingdom, 9.1%

Greece, 8.8%

Spain, 11.1%

Austria, 15.1%

France, 10.7%

Germany, 12.3%

Netherlands, 10.1%

Switzerland, 22.9%

10 Macro Trends


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10 Macro Trends

8.) Global Wealth 2000

Richest 1% of adults own 40% of global

assets

Richest 2% owned 51%

Richest 5% owned 71% Richest 10% owned 85%

Bottom half owned barely 1%

10 Macro Trends


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10 Macro Trends

9.) By 2050 India, Brazil, Russia, China, Indonesia, Mexico and

Turkey will overtake the economy of G7 countries - Britain,Canada, France, Germany, Italy, Japan, US - in terms of GDP

Ernst and Young European Attractiveness Survey 2


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Retailers and Brands


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Retailers and Brands

Weakened balanced sheets (high gearing)

Structural inability to speed up turnover of capital

Still high end of season sales and left-overs in summer 2008

Emerging Themes in Consumer Trends


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Emerging Themes in Consumer Trends

Easy Care

Comfort & Stretch

Fashion & Modernity

Durability & Versatility

Importance of Brands

Health & Well Being

Environmental Awareness

Trends in Lifestyle Changes


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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

Global Sourcing Textiles/Clothing


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Global Sourcing Textiles/Clothing

ProductionProduction ImportsImportsEU15EU15 NearbyNearby FarFar ExoticExotic

19961996 96 Bln96 Bln 12 Bln12 Bln 19 Bln19 Bln 2 Bln2 Bln(37%)(37%) (58%)(58%) (5%)(5%)

20032003 70 Bln70 Bln 27 Bln27 Bln 31 Bln31 Bln 2 Bln2 Bln(45%)(45%) (52%)(52%) (3%)(3%)

20072007 78 Bln78 Bln 9 Bln9 Bln 45Bln45Bln 2 Bln2 Blnest.est. (21%)(21%) (76%)(76%) (3%)(3%)

Fibre Prices 2007-2008 USD


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b e ces 00 008 US

PES Filament

PES Staple

PA 20D/1

Cotton Grade A

1.30 to 1.65 (25%)

1.36 to 1.60 (+20%)

3.10 to 3.30 (+7%)

1,57 to 1,74 (+10%)

Average Textile Prices / Kg (Ch.62)


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g g ( )

2000 2004 2005 2006

Bangladesh 12,4 9,0 9,0 9,2

China 18,9 10,3 10,8 11,7

India 19,7 18,3 20,8 22,2

Sri Lanka 22,0 14,7 16,5 17,4

World 19,3 13,8 13,8 14,3


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Ref : India Rising- Opportunities in nonwovens & technical textiles, S.Ramkumar andA.Arunachalam, ITJ, Apr 2008.

111 ARUN Pal Emerging Trends in Technical Trends & Nonwovens

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Transcript of 111 ARUN Pal Emerging Trends in Technical Trends & Nonwovens