1. Indian Nonwoven Industry-Present Scenario &
Future Prospects
D.K.T.E. Society’s
Textile & Engineering Institute, Ichalkaranji,
Dist: Kolhapur, Maharashtra State
1

2. DKTE CENTRE OF EXCELLENCE IN NONWOVENS
2
(PROMOTED BY OFFICE OF THE TEXTILE COMMISSIONER,
MINISTRY OF TEXTILE, GOVERNMENT OF INDIA)

3. Technical Textiles

4. Global Technical Textile Industry outlook
Value-wise share of each segment in global technical textile market
Sources: Report of the Expert Committee on Technical Textiles (ECTT) Volume – I,
‘World Market Forecasts for 2010 of technical textiles and industrial nonwovens’ by David Rigby Associates

5. Source: Baseline survey of the Technical Textile industry in India, IMaCS Analysis
Value-wise CAGR for various technical textile
segments from 2009-10 to 2012-13
Value-wise share of each segment in
Indian technical textile market in US$
million
Indian Technical Textile industry

6. 6
 In the Indian market, needlepunch has the maximum share followed by spunbond
technology due to the high demand for nonwovens in automobile, hygiene and geotextile
sectors.
 However spunlace technology has the highest growth rate for future with a CAGR of 27%.
 Organised Retail is expected to grow at 50% for the next five years, which will be a big boost
for products like wipes that make up for more than 60% of spunlace consumption in the
world.
 Indian Healthcare Industry is growing at 15%. Privatisation and increasing medical tourism
has resulted in growing demand of disposable nonwoven products like gowns, caps, masks
etc. Spunlace based products provide high barrier against harmful microbes as well as provide
comfortable wear.
Market Share of Nonwoven Technologies

7. 7
Worldwide nonwovens production
Nonwoven Market
Growth rates between 2005 and 2015:
 7.3% - Tonnage
 8.4% - m²
0
2
4
6
8
10
12
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
0
50 000
100 000
150 000
200 000
250 000
300 000
Tonnes (millions)
m² (millions)
Source: Pira estimation

8. 8
Consumption of fibers for nonwovens
PP and PET are the main fibres used in drylaid web forming.
Between 2010 and 2015, the consumption of Wood pulp will increase of 45%
0
0,2
0,4
0,6
0,8
1
1,2
1,4
1,6
1,8
2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015
mTons
PP
PET
Vis
Bico
Wood pulp
Other
Source: Pira estimation
Nonwoven Market

9. Nonwoven Market
End-uses of Nonwovens
9
Source: EDANA , INDA estimation

10. Nonwoven Market
Nonwovens Consumption per Capita (kg)
10
Source: INDA Estimates, Ian Butler, INTC-2008
0 1 2 3 4 5 6 7
Taiwan
Korea
NAFTA
Europe -27
Australia
Japan
Malaysia
Saudi Arabia
Turkey
Mexico
China
South America
Brazil
S. Africa
Russia
India
kg
Developed Markets
Early Development Markets
Emerging Markets
High export volumes

11. ENCOURAGING FACTORS IN INDIA
• Population factor (90 million young people, 21 million educated people).
• Income, Willingness and Availability of plastic money to spend. People are
ready to spend more if they see value & brands.
• Consumer changes to look for life style changing products like wipes,
diapers etc.
• Growth of retail market or mall culture.
• Competition will push the price down thereby increase the demand.
• Increasing exposure to international lifestyle.
• Large Raw material base in cotton, polyester, viscose etc.
• Promotion of special economic zones (SEZ), textile parks and TUFS
11

12. Nonwoven Processes
12
Web-Forming Meltspun Drylaid Airlaid Wetlaid
 Meltblown  Carded  Airlaid  Wetlaid
 Spunlaid
Web-Treatment Dewatering Drying Dyeing Chemical
 Vacuum  TAD  Padder  Padder
 Squeezer  Low add-on
Web-Bonding Thermal Chemical
 Hydro-
entanglement
 Calender  Padder
 Needlepunch
 Oven
Mechanical
Web-Handling Winding Slitting Packaging Control
 Winder  Slitter  Packaging  Line control
 Quality control
NONWOVENS MANUFACTURING

13. NONWOVENS MANUFACTURING
CARDING
• A loose web of fibers
• Separates fibers through combing action
• Can be use to blend two or more fibres
• Basic structure of fiber to fabric, require bonding
APPLICATIONS
• Wipes, Hygiene
• Automotive, insulation,
• Interlining
13

14. AIR LAID
• Can be fibers, blends of fibers or wood pulp
• Fibers are introduced into an air stream and form web on a belt
or drum which requires bonding
• Air laid fibers have random distribution
APPLICATIONS
• Wipes, Hygiene
• Automotive, insulation,
• Interlining
14
NONWOVENS MANUFACTURING

15. NONWOVENS MANUFACTURING
WET LAID
• Fibers / Blended fibers or Wood pulp in water with very low
concentration
• Water / fiber mixture released onto a forming belt
• Excess water is removed and then bonded for stability
APPLICATIONS
• Tea bags,
• Vacuum cleaner, Filtration
• Meditech applications
15

16. NEEDLE PUNCHING
• Oscillating needles penetrate the web in vertical direction
• Causing entanglement of fibers to create stable web
• High strength and durability
APPLICATIONS
• Geotextile
• Synthetic leather, Blankets
• Carpet and liners
16
NONWOVENS MANUFACTURING

17. SPUNBOND
• Melting polymers pallets through an extruder and spinnerette to form
filaments
• Stretch and cool Filaments, deposit on moving conveyer to form web
which is bonded thermally.
• Economical process,
• Uniform and strong fabric
APPLICATIONS
• Home furnishing, Bedding
• Roofing Substrate, House wrap
• Diaper covers
17
NONWOVENS MANUFACTURING

18. CHEMICAL BONDING
• On dry laid web chemical binder is applied using either
Gravure printer, Padder, foam applicator or spray
• Binder may be applied in pattern or overall
• After drying binder-fiber form strong bond
APPLICATIONS
• Roofing, Shoe components
• Apparel interlining
• Wipes
• Automotive substrate
18
NONWOVENS MANUFACTURING

19. THERMAL BONDING
• Fibers are formed in to a web
• Bonded by hot air or heat and pressure
• Thermoplastic fibers are selected
• Can be converted to soft to stiff fabric
APPLICATIONS
• Diaper components, window blinds
• Apparel interlining, filtration media
• Geotextile applications
• Automotive trims
19
NONWOVENS MANUFACTURING

20. SPUNLACE
Dry laid web is directed under series of fine, high pressure water jets
• Suction under belt removes water leaving behind entangled fibers
which further dried
APPLICATIONS
• Wipes, Single use medical applications
20
NONWOVENS MANUFACTURING

21. 21
Nano Spunlaid & Meltblown Nonwoven Fabrics
– High surface area
– Lighter weights (8-10 gsm)
– Improved web uniformity
– Target market: absorbent hygiene, filtration
Bi component Fibres
Recent Developments

22. Finishing of Nonwovens
• Hydrophilic
• Hydrophobic
• Repellent
• Flame Retardant
• Coating
• Anitmicrobial
• Dye
• Finishing
• Print
• Corrugate
• Emboss
• Compact
• Crepe
• Flock
• Plasma
• Encapsulate
22

23. APPLICATIONS OF NONWOVENS
DISPOSABLE APPLICATIONS
Medical
• Drapes
• Surgical / Isolation gowns
• CSR Wraps
• Caps ,Facemasks ,shoe covers
Hygiene
• Baby Diapers, Training pants
• Feminine Hygiene products
• Adult Incontinence products
Wipes
• Baby
• Household
• Industrial
23
DURABLE APPLICATIONS
Geotextiles
• Soil Stabilization, Drainage
• Road and Rail construction
Filtration
• Air, gas, liquid
Agriculture
• Crop covers, Greenhouse shades
• Mulches
Home Furnishing
• Carpet backing
• Furniture Construction
Building and Construction
• Insulation, Roofing
Automotives
• Carpets & Headliner.
• Door panel insulation, Carpet
backing.

24. NONWOVEN APPLICATIONS
24

25. APPLICATIONS OF NONWOVENS
AGROTECH
BUILDTECH

26. NonWoven Geotextiles
Applications -
– Sub-surface drainage
– Separation
– Stabilization
– Erosion Control
– Geomembrane Protection

27. Uses of Non-Woven Geotextiles
• Non-wovens
– Drainage application
• French drains, pipe sock
• MSE walls
– Separation application
• Remediation projects, waste containment
• Road building
• Parking lots
• Weed barrier

29. Typical French Drain Application

30. These are geocomposites formed of a hollow cored,
geotextile wrapped drainage element (geonet) inserted
vertically into soft ground to speed up the
consolidation process.
Prefabricated Vertical Drain Installation of PVD
Geocomposites: Prefabricated Vertical Drains
(PVD)

32. Environmental Cracking

33. Geotextile for Sealing
New Overlay
Reflective Crack
without Paving Fabric
Old Pavement
Base Course
PavementCrack
withPavingFabric

34. Geosynthetic Clay Liner
Bentonite/textile composite for Water Reservoir application

35. Endurance Properties
• Abrasion Resistance
• UV Stability
• Chemical Resistance
• Biological Resistance
• Wet/Dry Stability
• Temperature Stability

36. CLOTHTECH
AND
GEOTECH
APPLICATIONS OF NONWOVENS

37. HOMETECH and INDUTECH
APPLICATIONS OF NONWOVENS

38. MEDITECH
APPLICATIONS OF NONWOVENS

39. MOBILTECH
APPLICATIONS OF NONWOVENS

40. PACKTECH AND PROTECH
APPLICATIONS OF NONWOVENS

41. Government’s Schemes
 Technology Mission on Technical Textiles (Launched in December 2010) encourages
domestic & export market development of technical textiles .
 Business start-up assistance
 Handholding support to new entrepreneurs through empanelled consultants
 Empanelled consultant will help MSME in product selection, market selection,
technology selection & sourcing and preparation of project report
 Financial Assistance – 2% - 3% of the project cost with an upper ceiling at Rs. 5 lakhs –
Rs. 6 lakhs
 Contract research assistance
 Encourages contract research in development of product, process and technology in
technical textiles.
 Financial Assistance – 60% of the research cost upto Rs. 20 lakhs
 Market development assistance for export sales
 Encourages participation in exhibition, trade fairs, etc. in foreign countries
 Financial assistance – 50% of the cost upto Rs. 5 lakh per visit. (Details available on
http://technotex.gov.in/tmttsub.htm)

42. DKTE CENTRE OF EXCELLENCE IN NONWOVENS
42
(PROMOTED BY OFFICE OF THE TEXTILE COMMISSIONER,
MINISTRY OF TEXTILE, GOVERNMENT OF INDIA)

43. Centre of Excellence
 The Centre of Excellence offers its facilities, knowledge, research support,
HRD, Technical consultancy, etc to serious entrepreneurs.
 Provides facilities like
– Testing facilities,
– Product, process & prototype development facilities,
– Sample Bank, competent manpower,
– Training facilities and incubation centre.
 Provides facilities to the entrepreneurs in one hand and suitable products
to the users on the other.
 Incubation of new ideas into practical tradable products and
 Dissemination of information through workshop & seminar.
 The CoE provides infrastructure at one place for the convenience of the
manufacturers of technical textiles in India. 43

44. 44
Area Organisation
Product-
focused
Centres of
Excellence
Agrotech Synthetic & Art Silk Mills Research Association (SASMIRA), Mumbai
Geotech Bombay Textile Research Association (BTRA) , Mumbai
Meditech South India Textile Research Association (SITRA), Coimbatore
Protech Northern India Textile Research Association (NITRA), Ghaziabad
Indutech PSG College of Technology, Coimbatore
Sportech WRA, Mumbai in association with VJTI & Kusumgar Corporates
Process-
oriented
Centres of
Excellence
Composites Ahmedabad Textile Industry's Research Association (ATIRA),
Ahmedabad
Nonwovens D.K.T.E. Society's Textile & Engineering Institute,
Ichalkaranji
COEs IN INDIA FOR TECHNICAL TEXTILES

45. COEs under Technology Mission on Technical Textiles (TMTT)

46. SITE OF DKTE CoE
46

47. 47
SITE OF DKTE CoE

48. OBJECTIVE: CENTRE OF EXCELLENCE
1. Facilities for testing and evaluation of products in Nonwovens
2. Resource centre with IT infrastructure that provides knowledge and information on
Nonwovens & technical textiles.
3. Facilities for indigenous development of prototypes.
4. Pilot plant facilities are being created for development of prototypes / technology
which shall be transferred to the industry after standardization and optimization of
the production process.
4. Facilities for training of personnel
5. Knowledge sharing with stakeholders by arranging seminars and awareness
programmes
6. Incubation centers where each of the COEs will provide necessary facilities to
entrepreneurs for testing new ideas and technologies.
7. Setting up standards that are at par with global level.
48

49. ACTIVITIES OF DKTE COE IN NONWOVENS
49

50. Testing Facilities
50
• GSM Tester
• Digital Bursting Strength Tester
• Digital Thickness Tester
• Water Repellency Tester
• Microscope With Microtome
• LOI Tester
• Pore Size Analyser
• UV Accelerated Weathering Tester
• Linear Density & Fibre Crimp
• Air Permeability Tester
• Water Vapour Transmitivity Tester
• Non Woven Orientation
• Liquid Strike Through & Wet Back
• Thermal Conductivity Tester
• Digital Tearing Strength Tester
• Hydrostatic Water Head Tester
• Gradient Ratio Test Apparatus
• Water Transmittivity Tester
• Tensile Testing Instrument
• Direct Shear Box
• Digital pH Meter
• Viscometer
• Shaking Water Bath

51. 51
Physical Testing Laboratory

52. 52
Physical Testing Laboratory

53. 53
Physical Testing Laboratory

54. 54
Physical Testing Laboratory

55. Hydrodynamic Testing Laboratory
55

56. Hydrodynamic Testing Laboratory
56

57. PROTOTYPING FACILITY AT INCUBATION CENTRE
57

58. 58
Training Activities
• Training programme and workshop on “Applications of textiles in agriculture”
• Training programme on Solution Spinning technology and its applications
• Training Cum Workshop on Applications of Geo Synthetics & Geo-textiles in Civil
Engineering
• Training programme on Nonwoven technology: Manufacturing, Hands-on Testing of
Nonwovens and Nonwoven Sector Market Overview
• Workshop on Role of Technical Textiles & Nonwovens in Civil Engineering
• Training Programme on Applications of Geo-synthetics in Civil Engineering and Road
Construction
• Training programme on “Nonwovens in Indutech and Buildtech Sectors”
• Training programme on “Technical Textiles in Mobiltech and Buildtech Sectors”
• Training programme on “Nonwovens in Oekotech applications”

59. 59
SEMINARS AND WORKSHOPS

60. 60
SEMINARS AND WORKSHOPS

61. 61
• Super absorbent polymers based nonwovens
• Chicken Feather BASED Nonwoven composite acoustic material
• Development of fiber Reinforced Concrete
• Antimicrobial cum antistatic surgical gown
• PU coated artificial leather from nonwovens
• Nonwoven fabrics for reinforcing unpaved roads
• Reflective crack resistant nonwoven for paved roads
• Static dissipating nonwovens (automobiles, home furnishing carpets etc.)
R&D Activities

62. • Nonwovens are widely used in different areas of Technical Textiles and are
rapidly replacing and/or providing cost-effective alternative to the traditional
woven and knitted fabrics.
• Composites of nonwovens with woven/knitted fabrics provides another
avenue to the technical textiles industry in India to explore new market
segments.
• India with an excellent background of textile manufacturing industry, is rapidly
emerging as a major player in the world nonwoven and technical textile
industry. 62
Conclusion

63. • Needle punching and Spunbonding technologies are being used for the
production of nonwovens in India.
• However, the industry has to upgrade itself with latest technologies like
Meltblown technology, bicomponent spinning as well as latest coating and
finishing technologies to be at par with the global entities.
• DKTE Centre of Excellence in Nonwovens is actively engaged promoting
nonwoven industry and closely working with the nonwovens and technical
industry .
63
Conclusion

64. CONTACT
64
DKTE CoE in Nonwovens,
DKTE Textile and Engineering Institute, ‘Rajwada’, P B No 130,
ICHALKARANJI. Dt. Kolhapur – 416115 (MS) India
Phone: +91 230 2421300
Fax: +91 230 2432329
Email : dktestextile@gmail.com
www.dktes.com
ANIKET BHUTE
Scientist,
DKTE COE in Nonwovens
Mobile: 9975437345
Email : abhute@gmail.com
VARUN GOUD
Scientist,
DKTE COE in Nonwovens
Mobile: 8652752540
Email : varun.s.goud@gmail.com

65. Thank You
D.K.T.E. Society’s
Textile & Engineering Institute, Ichalkaranji
DKTE Center of Excellence in Nonwovens
Promoted by Ministry of Textiles, Govt. of India
Plot No. 1, 2 and 3, Shri. Lakshmi Co-Operative
Industrial Estate, Hatkanangle – Ichalkaranji
Dt. Kolhapur – 416109 (MS) India
Tel: +91 230 2366354 Email: dktecoe@gmail.com,
Web: www.dktecoenonwovens.in
‘Rajwada', P Box No. 130, Ichalkaranji
Tal: Hatkanangle, Dt. Kolhapur – 416 115 (MS) India
Tel: +91 230 2421300, 2437316, 2437317
Email: dktestextile@gmail.com ; Web: www.dktes.com