5. voltas innovations

Textile Machinery Division

INNOVATIONS IN NEEDLE PUNCHING – MEDICAL

TEXTILES

Textile Machinery Division

MEDICAL TEXTILES

Textiles used for hygiene & health care operations.

Textile Machinery Division

Constituent Element of Medical Textile Product

Polymers

Fibres

Yarns

Woven Knitted Braided Non-woven

Fabrics

Textile Medical Products

Textile Machinery Division

CLASSIFICATION - Application

Healthcare & Hygiene Products

Extracorporeal Devices

Implantable Materials

Non- implantable Materials

Textile Machinery Division

HEALTHCARE & HYGIENE NONWOVEN PRODUCTS

Fibres Applications

Polyester & PolyethyleneProtective Clothing, incontinence,

diaper/sheet, Cover Stock

Superabsorbent fibres,wood fluff

Absorbent Layer

Polyethylene Outer Layer

Viscose/Lyocell Clothes/Wipes

Textile Machinery Division

HEALTHCARE & HYGIENE NONWOVEN PRODUCTS

Fibres Applications

Cotton, Polyester & Polypropylene

Surgical Gowns

Viscose Surgical Caps

Viscose, Polyester, GlassSurgical Masks

Polyester & Polyethylene Surgical Drapes , Cloths

Textile Machinery Division

Non-Implantable Material – Nonwoven Products

Fibres Applications

Cotton, Viscose & Lyocell Absorbent Pads

Viscose, Cotton Lint, Wood Pulp Wadding

Poly-lactide, Poly-glycolide, Carbon Scaffold

Textile Machinery Division

Non-Woven Property – Medical Applications

Porosity

Weight of fabric

Thickness

Nonwovens are easy to sterilize

Various Manufacturing technique options according to applications

Economical Manufacturing Process

Textile Machinery Division

Non-Woven

Nonwovens are webs made of fibres / Polymers – Web Forming

For End-use application – Web Bonding

Web Bonding Methods can be Mechanical

Needle Punching Spunlace

Thermal Chemical

Textile Machinery Division

Dilo, Inc.Charlotte, NCUSA

Dilo RepresentationOffice ShanghaiPR China

Dilo RepresentationOffice MoscowRussia

sales representatives in over 80 countriesworldwide

History

Dilo founded in 1902

Spinnbau founded in 1948

Temafa founded in 1874

DiloSpinnbau since 1996

DiloTemafa since 2005

Textile Machinery Division

NEEDLE PUNCHING TECHNOLOGY

Textile Machinery Division

Fibre – Opening & Blending

Nonwoven Carding

Cross-Lapping

Pre-Needle Loom

Finish Needle Loom

Winding & Cutting

NEEDLE PUNCHING FLOWCHART

Textile Machinery Division

FIBRE OPENING & BLENDING

Textile Machinery Division

NON-WOVEN CARDING

Textile Machinery Division

Textile Machinery Division

Felting needles penetrate through crosslapped fibre batt

Barbs of felting needles catch and transport fibres

By means of this fibres entangle, fibre batt consolidates and needle felt with strength properties is created

NEEDLE FELT TECHNOLGY

Textile Machinery Division

NONWOVEN CARD

CROSS LAPPER

NEEDLE LOOM

LAYOUT FIBRE OPENING &BLENDING

Textile Machinery Division

WHY NEEDLE PUNCHED FABRICS !

3 – D Structure

Composites.

Extremely High Densities

High Strength - Geo-Textile Fabrics

Superior Filtration Properties - World’s Filtration Media

Textile Machinery Division

Major Applications – So Far

Automotives

Geo-Textiles

Filtration materials

Wipes

Synthetic Leather

Textile Machinery Division

Major Applications –So Far Floor coverings & Wall coverings

Roofing felts

Blankets

Decoration felts

Paper machine felts

Textile Machinery Division

INNOVATIONS

Hyper Lacing with Cyclopunching

Textile Machinery Division

CYCLOPUNCHING

Translatory & Circular Moving path – New Kinematical Concept

High Density Needling - Individual Fibre transport

Small Dimensional Changes & distortion in the fabric plane.

Textile Machinery Division

Textile Machinery Division

HYPER LACING Vs Std Web Formation

Minimum GSM – 25

Card Feed – Vento Feed

DELTA CARD

HYPER LAYER

Minimum GSM – 80

Card Feed – Chute Feed

Servo or Super Servo Card

Horizontal Cross Lapper

Textile Machinery Division

DELTA CARD

Textile Machinery Division

Economic Considerations

Criteria Cyclopunching without preparation and web forming

Spunlace line incl.drying without preparation and web forming

Space Requirement approx.200 Sq.Mtr approx.700 Sq.Mtr

Investment approx. 4 Mill. Eur approx. 6 Mill. Eur

Power approx.150 KW / Mtr working widthat 0.10 Eur / Kwh

approx. 1000 KW / Mtr Working Width at 0.10 Eur / Kwh

Water Consumption  NIL approx. 1.1 KL / Hr / Mtr Working Width20 Ltr / Min / Mtr Working Width

Waste Water anti-pollution requirements

NIL  approx.1.1 KL / H / Mtr working width at 5.0 Eur / Sq. Mtr

Fibre Loss NIL  approx. 5% Kg Product at 1.50 Eur / Kg

Consumables Needles and needle boards ca.0.133 Eur / Kg / Mtr working widthNeedle life: approx. 300 Mill. Stroke

Jet StripsCa. 0.004 Eur / Kg / Mtr Working Width;Strip Life: approx. 1 Year at 50 bar

Operating Costs of Energy, Water, Fibre loss, needles and boards, jet strips ( Without depriciation, interest, personnel, fibre material, chemicals for water treatment ) at 7,000 Working hours / year

approx.0.995 Eur per min and m working width

approx. 2.061 Eur per min and m working width

Working Width : 2.5 Mtr, Production Speed : 100 Mtr / MinFinal Product Weight : 50 GSM, Final Product Output : 750 Kg / Hr

Textile Machinery Division

Cyclopunch – Application AreasMedical Products : Gowns, Drapes, Cover sheets, Towels, Wound Dressings, Wet Tissue, Pads

Sanitary Products : Baby Wipes

Household and Industrial Wipes, Car Wipes

Home Furnishings : Table Cloths, Napkins, Interlings, Coating Substrates, Synthetic Leather

Automotive Applications : Headliner, Interior Trim

Filtration Material

Textile Machinery Division

Hyperlacing

Textile Machinery Division

Market scenario – US Market U.S.Trade of Nonwoven Roll Goods (HTS code 5603, aggregated )

  2002 2003 2004 2005 2006 2007% Change (2006 - 07

Imports ( Mn. Kg ) 116 138 167.3 169.8 161.9 185.9 14.8

Exports ( Mn.Kg ) 180 195 227.3 263.3 270.9 258.6 4.5

U.S.MARKET POTENTIAL

Textile Machinery Division

Estimated Value of Exports & Imports, Nonwoven Roll Goods 2002 - 2007

FAS Value : U.S.Exports ( Mn. $ )

2002 2003 2004 2005 2006 2007

$744.40 $914.10 $1,027.30 $1,239.60 $1,391.60 $1,302.60

General Customs Value : U.S.Imports ( Mn. $)

2002 2003 2004 2005 2006 2007

$437.80 $547.00 $631.80 $712.70 $703.00 $809.00

U.S.MARKET POTENTIAL

Textile Machinery Division

US TRADE of NONWOVENS.xls

Textile Machinery Division

S.NOMEDICAL TEXTILE

PRODUCT

MARKET POTENTIAL

( Rs Mn)

    2005 2010

1 Sanitary Napkins 4819 8519

2 Incontinence Diapers 605 1070

3 Surgical Dressing 5828 10302

4 Health Care Textiles 1491 2635

5 Sutures 3160 5587

6 Medical Devices & Implants 1190 2104

Consumption on Different Categories of Medical Textiles

Textile Machinery Division

ROAD AHEAD

Enough Awareness on Technology & Potential

Time to TPI

Product – Market – Flexibility

Our Role – Right Technology – Cont. Technical Support – Project Implementation

Textile Machinery Division

Traditional to Technical

Diversify - Flourish

Thank you