PPNonwoven a revolutionaryfabric

DevenMehta
AGM Sales
AGM

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Agenda

PPNonwovenApplication/Markets
Propertiesofthefabric
Advantages
M k
Marketscenario
i
Whatisnonwoven?
M
ManufacturingProcess
f t i P
Atypicalmachinesetup
Rajoo ataglance
Rajoo
at a glance

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Applications

Automotive
Medical
Personalcareandhygiene
Home furnishings
Homefurnishings
Household
Stationery
Stationery
Agriculture
Geotextiles

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Applications

automotive
Floorcovers

Airfilters

Hoodsilencerpads

Sideliners
Side liners

Doortrimpanelcarpets
Door trim panel carpets

Dashinsulators
D hi l t

Frontandbackliners

Doortrimpanelpadding

Wheelhousecovers

Coverslipsheets

Carpettuftingfabricandunder

Seatapplications
Seat applications

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padding
Foamreinforcements

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Applications
medical

Surgical:
9disposablecaps,gowns,
9masksandshoecovers
Drapes wraps and packs
Drapes,wrapsandpacks
Sponges,dressingsandwipes
Bedlinen
Contaminationcontrolgowns
Examinationgowns
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Shrouds
Underpads
Procedurepacks
Heat packs
Heatpacks
Ostomy bagliners
Fixationtapes
Incubatormattress
ProtectiveCloth

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Applications
Personal care&hygieneproducts

Diapers
Di

i
Lenstissues

Sanitarynapkins

Handwarmers

Trainingpants

Vacuumcleanerbags

Incontinenceproducts

Teaandcoffeebags

Dryandwetwipes

Shoecovers

Cosmeticapplicators,removers

Buffpads

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Applications
homefurnishings

Furnitureconstructionsheeting

Beddingconstructionsheeting

Insulators,armsandback
Pillows&pillowcases
Pillows & pillow cases

Carpetbackings,carpets&
pads
p

Dustcovers

Dustcovers

Mattresspadcomponents

Blankets

Acousticalwallcoverings
A
ti l ll
i

Spring wraps
Springwraps
Tabledecoration

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Applications
house hold

Aprons

Placemats,napkins

Scouringpads
Scouring pads

Washcloth
Wash cloth

Fabricsoftenersheets

Tablecloth

Dustcloths,mops

CoatCover

Teaandcoffeebags
Tea and coffee bags

Carrybags
Carry bags

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Applications
stationery

Bookcovers

Promotionalitems

Mailingenvelopes,labels
Mailing envelopes labels

Postersandbanners
Posters and banners

Maps,signs,pennants
CDdiskliners

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Applications
leisure & travel

Sleepingbags
Tarpaulins,tents
Artificialleather,luggage
Airlineheadrests,pillowcases

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Applications
agriculture

CropCovers

Containers

TurfProtectionproducts

Capillarymatting

Nurseryoverwintering

Greenhouseshading

WeedControlfabrics

Seedblanket

Rootbags

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Applications
geotextiles

Asphaltoverlay

Golfandtenniscourts

Roadandrailroadbeds

Artificialturf

Soilstabilization

Sedimentationanderosioncontrol

Drainage

Damandstreamembankments

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DesirableProperties

Abrasionresistant
Absorbent
Antistatic
Breathable
Conductive
Colourfast
Crease resistant
Creaseresistant
Dense
Drapeable
Drycleanable
Durable
Durable
Dustfree
Elastic
Flameresistant
Foldable
ld bl
Heatsealable
Impermeable
Kindtoskin
Light
Longlasting

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Combinationofmanyfeaturespossiblewith
PPnonwovens

Lintfree
Mouldable
Nonconductive
Nonfading
Permeable
Porous
Printable
Printable
Protective
Sewable
Smooth
Soft
Soft
Stable
Sterilisable
Stiff
Strong
Tearresistant
Washable
Waterrepellent
Weatherproof
Weldable

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Advantages of Nonwoven
AdvantagesofNonwoven
Fabricatedmuchfasterwithgreaterflexibility
Fabricated much faster with greater flexibility
Canbeslitinbothdirectionswithoutfraying
y g
Heatsealed/seamed/folded/shapedinavarietyofways
Ultrasonicweldingpossible

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PP Nonwoven Industry GlobalMarketScenario

PPNonwovenIndustry
Global Market Scenario
Worldmarket 7.5% perannumgrowthrate

60%nonwovensusageisin
disposableproducts

China today is producing over

1 million tons of nonwovens.

Currentnonwoven
productionlevelin
Indiaisonlyabout
70,000tonsper
annumwhichwasthe
samelevelinChina,15
yearsago.

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PP Nonwoven Industry MarketScenario

PPNonwovenIndustry
Market Scenario
IsIndiathenextboomingmarketfornonwovens?
WillIndiabereachingthenewhorizonsinnonwovensand
g
technicaltextiles?
Strength:
Indiaisoneofthelargestproducersofnaturalandmanmadefibers
Populationgrowthandincreaseinmiddleclassdisposableincome
Lowcostskilledlabor
Abilitytocatertothevaluechain
Growingdomesticretailmarket

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PP Nonwoven Industry MarketScenario

PPNonwovenIndustry
Market Scenario
IsIndiathenextboomingmarketfornonwovens?
WillIndiabereachingthenewhorizonsinnonwovensand
g
technicaltextiles?
Weakness:
Textileindustrybeingfragmentedlessoforganizedandmoreunorganizedsector
Lowproductivityandcostcompetitiveness
Obsoletetechnology
Lackofproductknowledgeandexpertise

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What is PP Nonwovens?
WhatisPPNonwovens?

Nonwoven fabric is an engineering fabric, manufactured by putting small fibers

together in the form of a sheet and then binding them either through thermal
bonding, mechanically (as in the case of felt), with an adhesive, or by interlocking
them with serrated needles such that the interfiber friction results in a strong fabric

Nonwovens can be single use (disposable) products or durable fabrics depending

upon the need of end use.

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PP Nonwoven Fabric
PPNonwoven
Flat flexible porous sheet structure
Produced by interlocking layers or networks of
fibers, filaments.
Classified as disposable or durable nonwovens
based on usage.
Disposable applications include Baby Diapers,
Adult incontinence products, Feminine Hygiene
products, Wet Wipes.
Durable applications include Filtration Media,
Protective Apparel, Geo textiles, Home
Furnishings, Automotive and Agricultural fabrics.

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PP grades for Nonwoven

PPgradesforNonwoven
MainlyHomopolymerPP
Staplefiberprocess

12to25MFI

Spu
Spunbondedprocess
bo ded p ocess

20to35MFI
0 o 35

Meltblownprocess

450to1200MFI

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Basepolymercost
Basic cost of Filler (upto 50%)
BasiccostofFiller(upto50%)
EffectivecostperKgofRawmaterial

Rs.80/ Kg
Rs. 40 / Kg
Rs.40/
Rs. 60/ Kg

ConversionintoNonwoven
Directcost
=
Rs.9/ Kg
Indirectcost =
Rs.5/ Kg
Packingcost =
Rs.1/ Kg
SalesRealization
NettValueaddition

=
=

Rs.115/ Kg[uptoRs120/ ]
Rs. 35toRs. 45PerKg

GrossProfitat80%capacityutilization=Rs.1200M.Ton xRs.35,000
=Rs.420Lacs /year

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Prospecctsarerequestedtoch
heckthesenumbersindependently.Rajooisresponsibleforcorrrectnessofthisdata.

PP Nonwoven Fabric Costing

PPNonwovenFabric

Manufacturing process
Manufacturingprocess
Nonwoveniscommonlymanufacturedby threeprocesses:

Spunbondedprocessdirectextrusionfollowedbyonlinethermalweb
bonding
Meltblownprocessfollowedbyonlinewebbonding
Staplefiberprocessfollowedbycarding

PP Nonwoven production in India is mainly through Spun bonding

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Manufacturing process Spunbonding

Manufacturingprocess
Spun bonding

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Manufacturing process spunbonding

Manufacturingprocess
spun bonding

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A Typical machinery set up

ATypicalmachinerysetup
Mainmachinery

Auxiliaryequipments

Extruder

Refrigerationforchilledair

RecycleExtruder

OilheatingSystem

Spinning&stretching
Webforming

Blower
Spinneretsultrasoniccleaner
Spinnerets ultrasonic cleaner

Thermalbonding

Coolingtower

Winding
Slitting /Rewinding

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PP Non woven GA Drawing of our FabREx

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PP Non woven : Rajoo offering ..

FabREx PP Non woven Spun Bonded Fabric Extrusion Line

RENW1513/1600 Finishedwidth1600mm
RENW1515/2400 Finishedwidth2400mm
RENW1515/3200 Finishedwidth3200mm

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PP Non woven : Rajoo offering RENW

RENW1513/1600
1513/1600
SALIENT FEATURES OF THE LINE
Screw diameters

mm

150 & 105

Screw length

30 & 15

Spinneret width

mm

1910

Maximum fabric width (trimmed)

mm

1600

Fabric
Fabric weight range

gsm

12 to 150

Average output

kg/hr

225

Line speed range

mts/min

15.0 150.0

Filament denier

denier

1.8 to 3

Total installed load

kW

434.13

Space
S
requirement
i
t (LxWxH)
(L W H)

mm

17000 x 11000 x 12000

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PP Non woven : Rajoo offering RENW

RENW1515/2400
1515/2400
SALIENT FEATURES OF THE LINE
Screw diameters

mm

150 & 105

Screw length

30 & 15

Spinneret width

mm

2710

Maximum fabric width (trimmed)

mm

2400

Fabric
Fabric weight range

gsm

12 to 150

Average output

kg/hr

325

Line speed range

mts/min

15.0 150.0

Filament denier

denier

1.8 to 3

Total installed load

kW

528.37

Space
S
requirement
i
t (LxWxH)
(L W H)

mm

18000 x 12000 x 12000

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PP Non woven : Rajoo offering RENW

RENW1515/3200
1515/3200
SALIENT FEATURES OF THE LINE
Screw diameters

mm

150 & 105

Screw length

30 & 15

Spinneret width

mm

3510

Maximum fabric width (trimmed)

mm

3200

Fabric
Fabric weight range

gsm

12 to 150

Average output

kg/hr

450

Line speed range

mts/min

15.0 150.0

Filament denier

denier

1.8 to 3

Total installed load

kW

562.79

Space
S
requirement
i
t (LxWxH)
(L W H)

mm

19000 x 14000 x 13000

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Raw material feeding

Rawmaterialfeeding
HerePPismixedwithstabilizers,additives,color masterbatch,resin
modifiers,orotheradditivesandfedtotheextruderthroat.

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European Designed Extrusion System

EuropeanDesignedExtrusion
System
Heavydutymainextruderwith130mmor150mmscrewsize.
Spec
Speciallydesignedrecyclingextruderwith105mmscrewsizewithdirect
a y des g ed ecyc g e t ude
t 05
sc e s e t d ect
feedingoffabricsidetrim.

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Melt Filtering & Screening

MeltFiltering&Screening
Divertertypecontinuousscreenchanger.
Meltpressuretransducersareprovidedbeforescreenchangerandonboth
e t p essu e t a sduce s a e p o ded be o e sc ee c a ge a d o bot
portsofmeltpump

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Melt metering pump

Meltmeteringpump
The molten polymer is conveyed to a filter and
foreign particles such as metals, solid polymer
particles and others are separated from the
molten polymer.
The filtering is very important, because the
unfiltered p
polymer
y
mayy cause p
problems such
as blocking the spinneret holes or creating
filament breaks.
Then it is conveyed to a metering pump which
plays an important role in a precise volumetric
flow rate of the molten polymer.
The important thing is that once the polymer
is melted and liquefied uniform temperature
must be maintained to a die block assembly.
The metering pumps is insulated on all sides
and the speed is generally between 10rpm
and 40 rpm
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Spin Beam with two Spinnrets

SpinBeamwithtwoSpinnrets
Thespinneretisasingleblockofmetalhavingthousandsofdrilledorificesor
holesonit,andthedesigningandfabricationofthispartaffectwebuniformity

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Filament spinning
Filamentspinning
The molten polymer is emitted through the spinneret holes. When the
emitted filaments pass through quench chambers, cool air is directed
across the
h filament
fl
b dl to cooll the
bundle
h molten
l
fl
filaments
sufficiently
ff
l to
cause solidification.
quenchingg can be done byy blowingg air with a twosided inflow q
quench
The q
air supply box.

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Filament Drawing, Air quenching and deposition

FilamentDrawing,Airquenchinganddeposition
In the attenuation the filaments are
led into a tapered conduit by high
velocity
l i air,
i causing
i acceleration
l
i and
d
accompanying
attenuation
or
stretching of the individual filaments.
The attenuation leads to a polymer
molecular orientation making up the
continuous
filament
and
a
modification of fiber diameter.
Polypropylene (PP) usually spins at
about 2,000 m/min. When quenching
q
g
using air, other parameters like
temperature and humidity must be
controlled

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Fiber deposition on conveyer

Fiberdepositiononconveyer

Row off spin

i pack
k
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Web formation
Webformation
The filaments are deposited on a moving belt. High pressure air through a
blower is used to move the filaments and a vacuum under the belt helps in
f
forming
i the
th filament
fil
t web
b on the
th forming
f
i belt.
b lt The
Th filaments
fil
t are separated
t d by
b
aerodynamic force before reaching the belt to achieve maximum uniformity
and cover.

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Thermal bonding HotSRolecalendar

Thermalbonding
Hot S Role calendar
Bothtemperatureandpressuretoeffectfiberfusion

Calendarroll meantfor embossing

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Winding & Slitting /Rewinding

Winding&Slitting/Rewinding

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Melt Blown Process

MeltBlownProcess

Singlerowoffilamentsblownintofinefibers(1to10micron) byheatedairjet
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SMS Technology CombinationofSpun

SMSTechnology
Combination of Spun Melt
Melt Spun
Spun
bonded
fiber

Melt
blown
fiber

Spunbond meltblown spunbondcompositenonwovenstructure

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AGlimpseof

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Overview
Vision
Coreteam
Productportfolio
Infrastructure
Culture
Expandingfootprint
Credentials

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Vision

To become one of the most

trusted and passionate solution
providers for the plastic
extrusion machinery world
wide in the best interests of all
the stake holders pursuing
ethical business practices.

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Core team
Coreteam

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Product portfolio
Productportfolio
FabRex PPNonWovenFabricExtrusionLines
Foilex UpwardextrusionmonolayerblownfilmLines
Multifoil UpwardextrusionmultilayerblownfilmLines
Aquaflex Downwardextrusionmono&multilayerblownfilmlines
Lamina Monoandmultilayersheetlines
Fomex PhysicalandchemicallyfoamedPEsheetlines
p y y
Fomex EPS Foamedpolystyrenesheetlines
Dispocon Thermoformerssolid&foamed disposablesline

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Rajoo infrastructure Operations

Rajooinfrastructure
Designcentre
Extrudermanufacture
Die manufacture
Diemanufacture
Surfacetreatment
Aluminiumcastingandfabrication
l
df b
Steelfabrication
Assembly,trialandwettesting
((blownfilmplantsof22mheight)
p
g )
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Design centre
Designcentre

22Qualified
22
Qualified
DesignEngineers

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Surface treatment (including gas nitriding)

Surfacetreatment(includinggasnitriding)

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Shree Yantralaya (dustfree&airconditioned)

ShreeYantralaya
(dust free & air conditioned)

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Shree Yantralaya (dustfree&airconditioned)

ShreeYantralaya
(dust free & air conditioned)
3axis CNC thread millingg machineWMW,,
GermanyABC 3300 mm and SOB 110 mm.
3axis CNC smart turn lathe Pinacho, Spain
ABC 4000 mm and SOB 700 mm.
mm
3axis high speed milling center Huron,
France X1000 mm, Y800 mm, Z500mm
4axis CNC double column
machining center Huron, France
mm, Y2200mm, Z800 mm

vertical
X3200

3axis vertical turning lathe You Ji, Taiwan

SOB 2000 mm, turning height 1200 mm

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Shree Yantralaya (dustfree&airconditioned)

ShreeYantralaya
(dust free & air conditioned)

2axis CNC Water Jet cutting machine

KMT Jet
J t Line,
Li
G
Germany
4000 mm x
2000 mm

3axis CNC turning center Jyoti, India

ABC 1000 mm and SOB 200 mm

3axis CNC turning center Jyoti, India

ABC 1000 mm and SOB 300 mm

3axis CNC vertical machining center

Feeler, Taiwan X1600mm, Y1600
mm ZZ800mm
mm,
800mm
Universal cylindrical grinding machine
Smithson, India ABC 4000 mm and
SOB 600 mm

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Assembly, trial and testing (wettrialsforallmachines)

Assembly,trialandtesting
(wet trials for all machines)

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Assembly, trial and testing (wettrialsforallmachines)

Assembly,trialandtesting
(wet trials for all machines)

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Assembly, trial and testing (wettrialsforallmachines)

Assembly,trialandtesting
(wet trials for all machines)

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CULTURE

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Culture Environment,healthand
Culture
Environment, health and safety

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going green
goingpaperless

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Culture wecare!
Culture
we care!

Blooddonationcamp

RELclub milkdistribution
activity
ti it

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Ruraleducationalprogram

Fl h ti b
Flaghostingbyruralkids
l kid

Trainingprogramfor
educationalInstitutes
d ti
l I tit t

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Expanding footprint
Expandingfootprint

I t ll ti
Installationsin52countries..
i 52
ti
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Expanding footprint 52 countries.

Expandingfootprint
countries.
LatinAmerica

Colombia,Mexico,Ecuador,Argentina

Europe
E

UK,Germany,Spain
UK G
S i

NorthAmerica

USA

Gulf
Gulf

Iran,Kuwait,UAE,Oman,SaudiArabia,
Iran Kuwait UAE Oman Saudi Arabia
Egypt,Syria

EastAfrica

y ,
,
, g
Kenya,Tanzania,Malawi,Uganda

WestAfrica

Nigeria,Ghana

SouthernAfrica

RSA,Zambia,Leshoto,Botswana

AsiaPacific

Malaysia,Vietnam,Thailand,
SriLanka,Nepal,Pakistan,Bangladesh

Australasia
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PapuaNewGuinea
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Credentials
Commenced business as Rajoo
Engineers Pvt. Ltd. at Manavadar, a
small village In Junagadh district to
manufacture mechanical cutting
sealing machines.

1986

1988

Launched the first ever blown film

line to manufacture chemically
foamed PE films.

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Ventured into the manufacture of

blown film lines and delivered first
PPTQ blown film line.

1990

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Credentials

1991
Introduced
the
first
ever
indigenously
designed
and
developed Oscillating Haul off
system for blown film lines and
displayed at Plastindia 1994 over
100 installations now.

1994

1995
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Introduced the first Indian co

extrusion feed block for multilayer
sheet line and today command the
largest market share of sheet
extrusion lines in India.

Introduced the first indigenously

designed wide width blown film line
for a lay flat width of 3000 mm.
mm

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Credentials
G rooved feed extruder with barrier
screw first
fi t time
ti
i Asia
is
A i over 600
extruders operating worldwide

1995

1996

Internal bubble
during Plastindia

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cooling

system

Exported countrys first CE marked

machine to the most demanding
European market and since regularly
exporting to Europe over 500
machines now operating overseas
and in India

1997

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Credentials

2000
5 layer stack die (UCD) with
horizontal first time in India and
4th in the world during Plastindia
2000 over 40 such
h dies
di
i
in
operation.

2000

2001
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Launched the first ever sheet line for

PET at Plastindia 2000.

Introduced worlds highest output

PPTQ downward extrusion blown
film line at Plastivision 2002.
christened Aquaflex.

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Credentials
Introduced Indias first Electrohydro
pneumatic plugassist thermometer
with
inmould
cutting
for
Polypropylene & PS containers.

2002

2003

Asias first 2 layer PPTQ film plant

150 kg/hour.
kg/hour

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Asias highest output 3 layer blown

film line with stack die (UCD)
during Plastindia

2003

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Credentials
a)

2004

Developed Asias first resin sack

three layer blown film line and
exported to Iran.

Developed a CE complaint high output

sheet line for processing PET regrind at
the rate of 700 kg/hr and exported the
same to Germany.
Germany
b) Developed and supplied first sheet line
for physically foamed PE sheets using
carbon dioxide as blowing agent.

2005
a)

2006
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Developed Asias first seven layer blown

film line incorporating conical spiral
stack (INCOSS) die.
b) Developed Asias first three layer wide
width
idth blown
bl
fil line
film
li incorporating
i
ti die
di
dia 1200 mm and 4000 mm LFW. The
maximum output is 1200 kg/hr.

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Credentials

2007

Launched Indias first PS foam

extrusion line and vacuum forming
machine and exported
p
to Ghana.

2009

2010
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Entered into technical collaborations

with Commodore Inc. USA for
manufacture
f
off XPS sheet
h
li and
line
d
thermoformer.

Vacuum forming
V
f
i
machine
hi
with
ith
mould : model RECR 7086 XPS
received and award Machinery for
packaging operations from IPMMI
IMDIR 2009.

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Credentials

2010
Wonderpack merger : A unified approach for
the benefit of the thermoforming industry
Rajoo Engineers JV with Bausano of Italy :
plastic pipe manufacturing industry in India to
gett a fillip
filli
Rajoo Engineers forges ahead; Technical
collaboration with Hosokawa Alpine AG,
Germany

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Credentials

2011

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Supplied Asias first CE

compliance 7 layer fully
automatic blown film line
to Turkey

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Thankyou
ww w .rajoo
j
.com
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