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February 2001 - Volume 16 I Number 1 Growth of Nonwovens By Stan Dobson, Consultant, TECNON (UK) Ltd. The nonwoven textile industry has made dramatic technical and commercial progress in recent years. Worldwide consumption of nonwovens in 1998 reached 2.4 million tons (8.1% of textile consumption). As recently as 1970 consumption was 0.4 million tons, but by 2007 is likely to reach 4.0 million tons. Production of nonwovens (as distinct from textiles generally) is still concentrated in the USA (41% of world total) West Europe (30%) and Japan (8%). China produces 3.5% and the rest of the world 17.5%. By 2007 China will produce 7% of the world total to the rest of the world’s 21%.
Manmade Fibers Dominate Manmade fibers dominate nonwovens production at present (99% of total) and the situation is unlikely to change markedly in the period to 2007. World usage of fibers in nonwoven production is 63% polypropylene, 23% polyester, 8% viscose rayon, 2% acrylic, 1.5% polyamide and 3% other specialty fibers. The nonwoven textiles end-uses likely to show the best growths are hygiene absorbent products (notably nappies or diapers), medical textiles, vehicle textiles, shoe components and artificial leather, as well as new miscellaneous niche markets. Major global players account for more than 75% of all roll goods production. US-owned firms, such as DuPont, PGI, Kimberly-Clark, Johns Manville, Dexter, Lydoce, Foss and Synthetic Industries, and the West European-owned Freudenberg, BBA Group, BP Amoco, Fibretex and Acordis, dominate the global market. Production and Consumption Global consumption of nonwovens (at the roll goods stage) was estimated at 800,000 tons in 1983. This rose to 1.1 million tons in 1985, 1.4 million tons in 1988 and 2.4 million tons by 1998. It is forecast that global consumption of nonwovens will reach 3.7 million tons by 2005 and 4.0 million tons by 2007. Comparisons of consumption of manmade fibers in all textiles and in nonwovens are detailed in the accompanying tables and figures. Total consumption of all manmade fibers in all types of textiles was 16.9 million tons in 1983, rising to 20.4 million tons in 1988, 30.4 million tons in 1988 with a forecast rise to 37 million tons by 2005 and 38.3 million tons by 2007. Consumption of manmade fibers in nonwovens versus all textiles rose from 3.7% in 1970 to 8.1% by 1998 and is expected to reach 10% by 2005 and 10.4% by 2007. Part of the reason why the nonwoven industry consumption rate is increasing at a high level is the growth of emerging industries in regions such as China, Southeast Asia, Latin America and the Middle East. The regional distribution of consumption differs from that of production, which implies considerable trade between the West (West Europe and the US) and the rest of the world. This applies to both roll goods and finished nonwoven textiles. Factors Influencing Growth Most major factors influencing the growth of all manmade fiber-derived textiles can be applied, to a greater or lesser extent, specifically to nonwoven textiles. Population growth: This is perhaps of less importance for nonwovens than it is for textiles as a whole in that the bulk of all textiles goes to the formation of apparel, whereas this is not true for nonwoven structures. However, population growth is important in major applications such as baby diapers. Allied demographic considerations would include an aging population with a requirement for nonwovens for adult incontinence products. Growth in GNP per capita and level of disposable income: Such factors are of particular importance in the case of the more industrially developed countries reflected in higher expenditure from disposable income on items such as baby diapers, but also on nonwoven-based household goods and nonwoven vehicle textiles. Competition with and replacement of natural fibers: This is of less importance for nonwovens than textiles as a whole in that it is already established that nonwovens are essentially based on manmade fibers. Commercial development of manmade fibers and variants tailor-made for use in nonwovens: Notable here would be the use of microfibers (via meltblown operations), of bicomponent fibers, of biodegradable fibers, of super-absorbent fibers and of new types of polyester fibers. Increases in trade as the result of formation of trade accords: Here again, such arrangements as the EU, NAFTA, ASEAN etc., have importance for nonwovens but are perhaps not so pertinent as is the case with apparel, woven and knitted textiles. Replacement of other textiles and other commodities: This would include the replacement by nonwovens of woven, knitted or tufted textiles and the replacement of plastic sheeting, polyurethane foam, wood pulp, cardboard, wood paper and leather, on grounds of cost, performance, cost/ performance ratios and the attainment of desirable aesthetics. Introduction of new and more efficient and more economical processing technologies: From polymer to finished web and roll goods, use of new types of composite nonwovens and laminates, new types of nonwoven finishing techniques and the introduction of superior fiber and nonwoven textile additives.
Big Three Fibers It can be seen that for nonwoven textiles the three major fibers are polypropylene (62% of total usage), polyester (24%) and viscose rayon (8%). During the period 1970-1985 there was a considerably higher use of viscose in the production of nonwovens, especially for hygiene absorbent applications, medical textiles and interlinings. However, in the last five years, the ascendancy of polypropylene and polyester fiber in this market has been fully established. In earlier nonwoven textile markets, there was a greater use of nylon and since 1998 there has been a rise in the consumption of acrylic microfibers, especially in the development of artificial leathers. Mr. Dobson’s article is a summary of the report, “Nonwoven Textiles 1997-2007 World Survey,” completed in July 2000. The report was drawn from sources in every part of the nonwovens industry and consolidated by personal visits and interviews with fiber producers, roll goods and finished nonwovens producers, consumers and traders. Copies of the 200-page report may be obtained from TECNON Consulting (UK) Ltd. Tel: 44 20 7924 3955. Fax: 44 20 7978 5307. Email enquiries@tecnon.co.uk The cost is UK£ 3,500.  |
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