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The surge in demand for medical products and other personal protective equipment has led to a strong development of global spunmelt nonwovens investment starting in 2020. The new production lines announced in 2020-2021 revolve around Reicofil 5 technology with high productivity, greater capacity and greater flexibility. These lines are not only responding to the growing demand for spunmelt nonwovens, but in some cases are replacing old capacity.

Image copyright of the Reicofil of Levenhauer

As these new production lines have been put into production and commercialized, the number of new production lines announced for investment has gradually decreased worldwide. Spun-melt nonwovens manufacturers are focusing on innovation to provide more differentiated products.

Avgol

Last month, spun-melt nonwovens manufacturer Avgol announced a partnership with YanJan USA LLC (Yanjiang, USA), a specialist material supplier for the disposable hygiene market, to provide exclusive products for the North American market. The partners will each develop and manufacture products that are tailored to each company's skill set and meet customer needs. "This partnership allows us to diversify our product range and effectively drive new market opportunities," said Jian Weng, president and general manager of Yanjiang, USA.

Ronnie Batchler, vice president of Avgol USA, said: "This is an exciting partnership for our company. Our materials will be specifically designed to meet customer specifications and provide the best performance. Punched spunbond nonwovens will give nonwovens additional unique attributes, such as improved physical properties and aesthetics."

"Avgol will also use its sales team in North America to more actively promote new products and provide Yanjiang's complete products to a wider range of industries." He added. Avgol has a spunmelt production facility in North Carolina, USA, as well as facilities in China, Israel, India and Russia.

In Russia, Avgol announced new investments last year to strengthen its position in existing markets and expand into new areas. Avgol CEO Tommi Bjornman said that the most important part of the investment is the addition of a high-speed Reicofil 5 production line, which will provide greater capacity for the growing regional market and support the launch of new Avgol technology. "This investment will serve the growing market for baby diapers, adult incontinence and feminine hygiene products, while meeting the continued demand for meltblown filtration and medical materials, which allows us to provide a higher level of service throughout the region while consolidating and strengthening our existing position." He said.

Avgol offers a full range of ultra-light spun-melt nonwovens for the global hygiene products market. The latest investment is Avgol's third production line in Russia, which will include biomaterials and high loft to meet the demand for hygienic surface materials. In addition to the R5 production line, Avgol will also add a meltblown production line at the Russian plant and a new production line that provides advanced laminates.

In India, Avgol recently moved an asset from Israel to India as part of a direct strategic investment in the region. Chief executive Shachar Rachim said the move was part of the company's commitment to continue enhancing its presence and services in India and South Asia. The demand for hygiene products in India and across Southeast Asia is huge, but high tariffs are imposed on imported materials. Demand for local supply capacity has reached 165 per cent. We expect that demand will only increase further, given the regional organic growth, the promotion of women's health and the increased health awareness due to the new crown pandemic.

Avgol entered the Indian market by investing in its first spunmelt production line locally in 2018. At the time, the company said the investment was intended to help support existing customers to enter the Indian market.

Berry Global

The latest news from Berry Global, the world's largest nonwovens producer, includes the development of three-dimensional embossed nonwoven Suavis 3D to meet the growing high-end market demand for high softness and comfort. Suavis 3D technology can enhance the softness and cushioning of the company's non-woven fabrics for sanitary products applications, and provide more attractive embossed patterns in appearance, thus having the opportunity to provide end consumers with a better experience.

With the addition of a 3D embossing line at its factory in Bisheim, France, Berry was able to produce these innovative materials. This investment meets the growing demand for products with high softness and comfort.

The combination of 3D technology and Berry's high-quality soft nonwoven solutions can provide better liquid management and skin comfort, and enhance cushioning performance and fluffiness. This new embossed material will be used in the manufacture of diapers, adult incontinence and feminine care products.

"From the installation of our 3D production line in Bisheim, France to the launch of Suavis 3D material, this is a wonderful journey. I am proud that this new high-quality nonwoven platform meets the demand for softness and cushioning." Vincenzo D'Acchioli, director of marketing at Berry Global.

At the same time, Berry has invested in the Reicofil of 5 SMS production lines in China to serve the fast-growing medical nonwovens market in the region and globally. In addition, Berry recently invested $8 million million in new equipment and improvements to its production line in North Carolina to further optimize its capacity for spunmelt nonwovens used in the manufacture of surgical gowns, masks and other personal protective equipment.

"In addition to organic growth in healthcare, health and some professional segments, we are seeing unprecedented demand from the new crown epidemic in every region of the world." David Parks, Berry's executive vice president of global marketing, strategy and business development, said, "The new crown epidemic has increased demand for medical products and has driven use in underpenetrated markets and regions. The expanded demand for healthcare has led to a shift in capacity utilization from health to medical, thus tightening the balance between supply and demand for sanitary materials."

In addition to significantly expanding capacity to support growing market demand, these investments, combined with Berry's leading proprietary technologies and materials, will expand the company's portfolio of products with the highest quality and performance in the market.

"We continue to drive the development of spunmelt technology to meet the needs of our customers and their end products for feel, appearance and barrier properties. Berry works with key customers to improve their products and bring more innovations to market." Robert Weilminster, executive vice president and general manager of the company's sanitary products business in the United States and Canada, said.

Fibertex Personal Care

Fibertex Personal Care has invested about $40 million to add new production lines at its factories in Malaysia and the United States. The Malaysia plant will be expanded by adding a specialty nonwovens production line, while a printing line will be added in North Carolina. Both production lines began operating at the end of last year.

"Demand for specialty products and services is growing across our business segments," said Axelsen Mikael Staal, Chief Executive Officer. "Our strong product portfolio gives us a strong position in these markets. This, coupled with steady growth in Asia, growing demand in the U.S. and Covid-19-induced market dynamics, makes the expansion well timed."

In addition to the recent investment, Fibertex Personal Care operates five production lines with an annual capacity of about 90,000 tons of spunmelt nonwovens at its two factories in Malaysia, with its latest production line coming into operation in mid -2017. Martin Holten, the company's commercial director in Malaysia, said the new production line is based on the latest technology, including advances in energy efficiency, which will help the company achieve its sustainability goals.

Fibertex Personal Care has partnered with SABIC to launch a range of high-purity non-woven products for the hygiene products market using recycled PP polymers certified by ISCC PLUS. The recycled raw materials used in it are from post-consumer plastic waste, and the resulting certified recycled non-woven fabric will be the first non-woven product based on recycled plastic in the global hygiene products industry, and can be used in existing downstream processes without affecting conversion rates, material properties or final product performance.

Fitesa Nonwovens

Fitesa will invest in a new Reicofil 5 production line in Europe, with production scheduled for the second quarter of 2023. The new production line will be installed in an established factory in Fitesa Europe to produce high loft and standard spunmelt nonwovens using sustainable raw materials such as bio-based PE and PLA materials.

Michael Baumgartner, Fitesa's senior vice president for Europe and China, said: "This advanced production line will be able to meet the growing demand for sustainable spunmelt nonwovens. This will significantly improve our ability to supply softer products to the market and increase the recycling and green content of local production in Europe."

"This investment is part of our strategic direction and will help change the sustainability profile of the spunmelt industry. It should be seen as one of the three pillars that can have a significant impact: innovative technology products, environmentally friendly raw materials and reducing greenhouse gas emissions in operations," said Fernanda Gastal, vice president of purchasing and marketing at Fitesa and head of the company's ESG committee."

Fitesa has been using bio-based polymers to produce nonwovens since the early 2010 s, and its 100 percent bio-based spunbond material has also been recognized. Fitesa Sweden recently received ISCC Plus certification, which is recognition of the company's ability to commercialize bio-based and renewable materials under the concept of material balance.

Fitesa is also adding a Reicofil 5 production line in the US state of South Carolina, which was announced in early 2021 and should be completed by the end of this year. In November 2020, Fitesa announced a global capacity expansion plan of 55000 tons, including investment in spunbonded nonwovens capacity in Brazil and investment in meltblown nonwovens capacity in Brazil, Germany and Italy.

PFNonwovens

In June 2021, PFNonwovens announced that it would invest $40 million to expand its operations in Cape Town, South Africa. The investment will include a new Reicofil 5 spinning and melting line to meet the demand for high-value and specialty products with higher levels of softness, comfort and sustainability.

"We are the first company to invest in the latest Reicofil 5 production line in South Africa. This exciting expansion will not only localize manufacturing, but also enable more sustainable and flexible production to meet our growing global demand." PFN South Africa director Wilhelm Cronje said. The new capacity is scheduled to be built by the end of 2022.

PFN invested $90 million to build the South African plant in 2017. With this latest investment, the company's leading position as the largest spunmelt producer in the South African sanitary products market will be further strengthened.

PFNonwovens also recently celebrated the completion of a new production line at its North American Center of Excellence in Pennsylvania, which will soon add another new production line and has a semi-commercial R5 in the Czech Republic. The first North American production line is centered on the Reicofil 5 spunmelt production line, which will be up and running in the second half of this year.

"It makes sense to invest in Reicofil 5 technology in our global factories, because the high-end diapers and the demand for more sustainable products make this technology very powerful." "Innovation takes a lot of our time, and the Reicofil 5 production line is a great tool to do that," says Tonny De Beer, CTO. "It produces products that are unmatched in the market today, and we have more potential to improve softness, volume and the ability to use sustainable materials."

This article is from Nonwovens Industry Journal
作者：Karen McIntyre

Source: Jung-International Nonwoven Industry Business