2012 Nonwovens Sales: $147 million
Plants: Istanbul and Tekirdag, Turkey
Processes: Web Forming Technologies: airlaid, carded, spunlaid; Bonding Technologies: needlepunched, thermal bonded, air-through bonded, calender bonded, chemical bonded, resin bonded
Brands: Hygenius for ADL (acquisition distribution layer) from Merkas for baby diapers, sanitary napkins and adult incontinence products; Polybond spunbond
Lines: More than 15 nonwoven web forming lines and more than 50 converting and finishing lines, including several other extrusion, film and lamination lines in the group companies. Additionally, Hassan Group converts nonwoven waddings and interlinings in its own quilting and home textiles divisions. Trade, insurance and construction are other activities of Hassan Group.
Applications: Artificial leather (backing), automotive, carpet (underlay), construction (geotextiles), filtration, footwear, furniture and bedding, household (wipes), hygiene and medical, ready-to-wear, technical textiles, white goods (isolation)
Hassan Group’s nonwovens operations serve European, Middle Eastern, African, South American and Russian markets. The company is divided into five roll goods producing companies (Siteks, Hassan, Telasis, Aksis and Merkas), which together produce nearly 100,000 tons of nonwovens per year, as well as three converter companies (Haspas, Catsis and Pelsan).
Concerning roll goods production, Siteks, founded in 1980, produces 50,000 tons of nonwovens per year, with a range of 200-3000 gsm in cut sheets, rolls and die cuts. Hassan, founded in 1985, produces 20,000 tons per year, with a range of 50-2,500 gsm in cut sheets, rolls and die cuts. Founded in 1995, Telasis currently produces 12,000 tons of nonwovens per year, offering 10-80 gsm in rolls. Aksis (2010) produces 6000 tons of spunlaid nonwovens per year (9-150 gsm in rolls).
Lastly, Merkas, which is one of Hassan Group’s latest investments having begun production in 2011, produces 9000 tons of air-through bonded nonwovens with a range of 25-120 gsm in slitted or spooled rolls. The company uses the through-air bonding process to manufacture high loft nonwovens to be used as acquisition distribution layer (Surge Layer) and top sheets in the production of baby diapers, sanitary napkins and adult incontinence products.
Hassan Group’s history can be traced back to nonwoven cotton wadding production in the 1930s. In 1992 the group entered the hygiene industry when it began manufacturing household use nonwoven cleaning cloths. In 1995, it expanded its production to include carded and thermal-bonded nonwovens; the softness and performance of which are especially important in the production of baby diapers, sanitary napkins and adult incontinence products. In 2007, the group began manufacturing breathable and non-breathable nonwoven laminated films for the hygiene and medical industries. In 2010, Hassan Group invested in spunbond nonwoven technologies, thus establishing Turkey s first integrated spunbond, film and lamination facilities.
In 2011, Hassan Group strengthened and diversified its place in the hygiene industry by introducing the Hygenius brand high loft nonwovens along with its through-air bonded soft top sheet manufacturing capabilities; another first in Turkey.
With state-of-the-art technology and a high level of experience, Hygenius nonwovens provide best-in-class volume and fiber structure to assure optimal fluid management for excellent dryness.
Hygenius products can be delivered in pancake, spool or step winded rolls in various fiber structures, basis weights and colors to fulfill the diverse needs of its customers.
Total sales of the nonwovens related companies were $147 million in 2012.
The two young companies of the group, Merkas Inc. and Aksis are experiencing positive growth while there is also an increase in the use of existing capacity in all companies the group reports.
Asked if his company was satisfied with its results last year, Hakan Sisman, deputy general manager of Merkas, says while yes, the group produced satisfying results, there is room for more growth. “Operating in the current economic and political atmosphere has been challenging,” he says.
Sisman says that the group has increased some more focus on the automotive, hygiene and geotextile sectors. In terms of new investments, he says several lines have been added to existing capacities.
“Hassan started another carding and needlepunching line for the automotive market while Siteks started another airlaid line for automotive and white goods,” says Sisman. “Merkas has extended its slitting and spooling capacity while spunbond producer Aksis added a new SMS line with a capacity over 6000 tons annually and will start production in November 2013.
“In the first quarter of 2014, a new carding line will start up at Merkas for high loft air through bonded nonwovens used in baby diapers, sanitary napkins and adult incontinence products. The company will have an additional capacity of 7000 tons annually in this area.”
There are also other investments besides nonwovens. The breathable fi lm and laminates producer company Pelsan also made a new line investment to meet the increasing demand particularly in hygienic applications.
In terms of regional operation, the group exports about 40% of its production. “We are mainly active in the Middle East, North Africa, Eastern Europe and Russia,” says Sisman. “Moving forward our target is to extend activities in Europe and Russia.”
On the research front, Sisman says Hassan’s main goal is to create more synergy in the group. “This will help to bring out more new materials created by diversified materials made by Hassan Group companies with a combined R&D effort,” he says. “Several projects are up and running.”