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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
Points to Consider Globally
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
Points to Consider Globally
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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1
Technical Textiles Products (Cont.)
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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
Ref : R.Shishoo, Techtextil India, 2007
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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.
Ref : Technical textile international Jul/Aug 2008.
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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
Ref : Technical textile international Jul/Aug 2008.
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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
Points to Consider Globally
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
Ref : R.Shishoo, Techtextil India, 2007
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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
Points to Consider Globally
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
Ken Livingstone Guardian nlimited January 26 2
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
Ken Livingstone Guardian nlimited January 26 2
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
8/7/2019 111 ARUN Pal Emerging Trends in Technical Trends & Nonwovens
91/93
91
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)
8/7/2019 111 ARUN Pal Emerging Trends in Technical Trends & Nonwovens
92/93
92
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
8/7/2019 111 ARUN Pal Emerging Trends in Technical Trends & Nonwovens
93/93
Ref : India Rising- Opportunities in nonwovens & technical textiles, S.Ramkumar andA.Arunachalam, ITJ, Apr 2008.