Mitsui Chemical


Location: Tokyo, Japan

Sales: $101 Million

Description: Key Personnel
Kenji Suzuki, director

Plants
Yokkaichi and Iakuni

Processes
Spunbonded, needlepunched, melt blown, thermal bonded

Brand Names
Tafnel, Syntex

Major Markets
Coverstock, geotextiles, oil absorbing materials, air filtration, wipes, agricultural materials, household materials..


In expansion mode is roll goods producer Mitsui Chemicals, Tokyo, Japan, which specializes in polypropylene spunbonded nonwovens as well as SMS materials. The company is currently constructing a 14,000-ton-per-year SMS facility, based on Reifenhauser technology, in Thailand through its wholly-owned Taiwanese subsidiary MHM. The new line brings the company’s total SMS capacity to 23,000 tons. The company also produces 25,000 tons of polypropylene spunbonded nonwovens.
 
The demand for spunbond and SMS in Southeast Asia and China is growing in tandem with increasing demand for baby diapers and subsequently coverstock materials. The Thailand site will help to satisfy this demand, allowing Mitsui to produce materials locally rather than exporting them from Japan. The new facility will target Thailand, China and the Philippines. Mitsui intends to ramp up production at the new site until 2005 when it will be fully operational. Then, if things go well, additional capacity will be added in 2006.
 
In addition to targeting the growing Southeast Asian market, the new capacity could eventually be imported into Japan where nonwovens production is reportedly costly and results don’t stand up to price competition.
 
Besides coverstock material, Mitsui Chemicals is developing various new uses for nonwovens. Among these new uses, the diaper plays a prominent role with about 80% of the new applications involving diapers in one way or another. It is in this way that Mitsui Chemicals, the largest producer of spunbond nonwovens in Japan, hopes to open up the domestic market.
 
The largest Japanese manufacturer of spunbond nonwovens for diaper applications, Mitsui holds a 50% share of the domestic market. The company first entered the SMS market in 2000 with the construction of a new line. SMS materials created by Mitsui compete with products from Asahi Kasei, Osaka, Japan, the second largest producer of spunbond nonwovens in Japan.
Location: Tokyo, Japan

Sales: $96 Million

Description: Key Personnel
Toshimi Hachimori, director

Plants
Yokkaichi, Iwakuni, Bangkok

Processes
Spunbonded, needlepunched, meltblown, thermal bonded

Brand Names
Tafnel, Syntex

Major Markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials

The big news from Mitsui Chemicals, Osaka, Japan, is the opening of a new facility in Bangkok, Thailand. Created through Mitsui’s wholly-owned subsidiary, Mitsui Hygiene Materials (MHM), this facility can make 14,000 tons of polypropylene-based spunbonded nonwovens per year. It was completed in September 2002 and began operating in February 2003. Representing a $13 million investment for Mitsui, MHM sells 40% of its spunbond output to diaper producers Uni-Charm, Tokyo, Japan and Procter & Gamble, Cincinnati, OH, which use it for coverstock in hygiene applications. The remaining output is sold to consumers in the Philippines, China and Japan. It is estimated that the plant will be operating at full capacity by the end of this year, buoyed by increased diaper consumption in southeast Asia and China.
 
Meanwhile in Japan, Mitsui Chemicals can produce more than 30,000 tons of nonwovens per year at its plants in Yokkaichi and Iwakuni. Included in this capacity is 25,000 tons of polypropylene spunbonded nonwovens and 9000 tons of SMS. Mitsui intends to shift the production of more commodity-type products to Thailand in an effort to cut costs. This decision comes amidst severe pricing pressures in the Japanese nonwovens industry, particularly for hygiene items. Meanwhile, Mitsui has been striving to differentiate its domestic products in an effort to add value to its nonwovens and strengthen its competitive power.
Location: Tokyo, Japan

Sales: $115 Million

Description: Key Personnel
Toshimi Hachimori, general manager, functional fabricated products division

Plants
Yakkaichi and Iwakuni

Processes
Spunbonded, needlepunched, meltblown, thermal bonded

Brand Names
Tafnel, Syntex

Major markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials.

Mitsui Chemicals’ total production capacity is 48,000 tons per year. This includes 25,000 of polypropylene-based spunbonded materials and 9000 tons of SMS, all made in Japan, and 14,000 tons of SMMS made in Thailand through the company’s MHM division. MHM, a wholly owned subsidiary of Mitsui Chemicals, has been producing SMMS in Thailand since 2003 to meet increasing demands for diaper material, and expansion plans are reportedly already underway.
 
According to Nonwovens Industry Far East correspondent, Kin Ohmura, Mitsui examined several locations for the new capacity but ultimately decided to expand the existing MHM site because its infrastructure was already in place. While the capacity for the new site, 20,000 tons, has been announced, it is not yet clear what type of technology will dominate. Industry are predicting it will feature the same four-beam spunmelt technology found on the first line. The new line is set to come onstream in 2006 and will likely be followed with another new line, probably in Southeast Asia or China, in 2007.
 
Much of Mitsui Chemicals’ future expansion strategy will reportedly target southeast Asia and China where greater growth prospects are being seen. This will require honing products to meet the needs of customers in Thailand and other southeast Asia countries. These consumers are looking for more general-purpose products than the specialized nonwovens made by Mitsui in Japan.
Location: Tokyo, Japan

Sales: $127 Million

Description: Key Personnel
Toshimi Hachimori, general manager, functional fabricated products division

Plants
Yokkaichi and Iwakuni

Processes
Spunbonded, needlepunched, meltblown, thermal bonded

Brand Names
Tafnel, Syntex

Major markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials

Mitsui Chemicals’ total production capacity is 48,000 tons per year. This includes 25,000 tons of polypropylene-based spunbonded materials and 9000 tons of SMS nonwovens, all made in Japan, and 14,000 tons of SMMS material made in Thailand through the company’s MHM division. MHM, a wholly-owned subsidiary of Mitsui Chemicals, has been producing SMMS in Thailand since 2003 to meet increasing demands for diaper material. As part of a recent ¥5 billion investment, Mitsui will add 20,000 tons per year of capacity to its MHM venture, with start-up expected in the beginning of 2007.

Meanwhile, at its 7500-ton-per-year Japanese plant, Mitsui Chemicals produces breathable films used for diaper backsheets. The laminated backsheets are comprised of breathable films and nonwovens and Mitsui is reportedly the only manufacturer in Japan producing both films and nonwovens for such products.
 
Films will also be produced at Mitsui’s MHM plant. The company plans to build two lines, each of which will have a capacity of 3000 tons annually. Upon completion of these films lines—slated for January 2006—Mitsui will have the capability to produce breathable films and nonwovens for backsheets in Thailand as well as Japan.
 
By 2007, the company expects to produce 34,000 tons per year of nonwovens at its MHM subsidiary in addition to 6000 tons per year of breathable films. According to Mitsui, it will not only benefit from its position as a key supplier in the Thai market but also become the largest producer of diaper materials in Southeast Asia.
Location: Tokyo, Japan

Sales: $132 Million

Description: Key Personnel
Yasushi Nawa, general manager, functional fabricated products division

Plants
Yokkaichi and Iwakuni

Processes
Spunbonded, needlepunched, meltblown, thermal bonded

Brand Names
Tafnel, Syntex

Major Markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agricultural materials, household materials

With headquarters in tokyo, Japan, Mitsui Chemicals produces a total of 48,000 tons per year of spunbonded, needlepunched, meltblown and thermal bonded nonwovens. This includes 25,000 tons of polypropylene-based spunbonded materials; 9000 tons of SMS, all made in Japan; and 14,000 tons of SMMS made in Thailand through the company’s MHM division. MHM, a wholly owned subsidiary of Mitsui Chemicals, has been producing SMMS in Thailand since 2003 to meet increasing demand for diaper material.
 
MHM is fully operational with 16,000 tons of planned annual capacity expected to come onstream in January 2008. The expansion will bring Mitsui’s total production capacity in Thailand to 30,000 tons per year while its capacity in Japan will reach 64,000 tons annually. To support this additional capacity, the company plans to introduce new production equipment for its MHM business in 2009-2010.
 
The nonwovens produced in Thailand will be general-purpose materials for diapers and other end uses while the fabrics manufactured in Japan will consist of value-added substrates for higher-end applications. Up until now, Mitsui has produced polypropylene spunbonded nonwovens for diapers on a third machine with a production capacity of 12,600 tons per year as well as on a fourth, 8000-ton-per-year line.
 
Reflecting an overall trend in the diaper market toward composites such as SMS and SMMS, Mitsui reports that demand for single-layer polypropylene spunbond is on the decline. In response, the company plans to remodel its existing third and fourth lines so that they can produce added-value nonwovens for uses other than diapers. Meanwhile, the company expects to be able to meet demand from the Japanese diaper market by importing materials from its facility in Thailand.
Location: Tokyo, Japan

Sales: $130 Million

Description: Key Personnel
Motoyuki Ezaki, general manager, life and energy materials division

Plants
Yokkaichi and Iwakuni

Processes
Spunbonded, needlepunched, meltblown, thermal bonded

Brand Names
Tafnel, Syntex

Major Markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agricultural materials, household materials

Mitsui Chemicals can produce 25,000 tons of polypropylene spunbonded nonwovens on four production lines. Among these, one can make 3000 tons; one can make 3500 tons, one can make 12,500 tons and one can make 6000 tons per year of spunbond materials. Additionally, a fifth line can make 9000 tons of SMS materials.  Of this capacity, 18,500 tons of spunbond and all 9000 tons of SMS material are targeting the diaper market.
 
Additionally, MHM, Mitsui Chemicals’ wholly-owned subsidiary in Thailand, has been making 14,000 tons of SMMS per year since 2003 and a second line, capable of producing 16,000 tons of SMMS, is scheduled to start operation in January 2008. Most of this capacity is exported to Japan, but diaper manufacturers in Southeast Asia and China are also customers.
 
Mitsui Chemicals is the top maker of polypropylene spunbond and spunmelt nonwovens for the Japanese diaper market with a reported marketshare of 41%. The sales of imported SMMS from MHM has increased considerably due to the low cost of this material compared to products made in Japan. Contrary to original expectations of production expansion into China, the company said it will not build a site there but will instead focus expansion initiatives on its MHM site to serve the Asian market.
Location: Tokyo, Japan

Sales: $136 Million

Description: Key Personnel
Motoyuki Ezaki, general manager, life and energy materials division

Plants
Yokkaichi and Iwakuni

Processes
Spunbonded, needlepunched, meltblown, thermal bonded

Mitsui Chemicals produces 25,000 tons of polypropylene-based spunbonded nonwovens per year. These are made on four lines with capacities ranging from 3000 to 12,500 tons. Additionally, Mitsui operates an SMS line that can make 9000 tons of nonwovens per year.
 
In Thailand, Mitsui operates MHM, a wholly-owned subsidiary, which has been making 14,000 tons of SMMS nonwovens since 2003 with another 16,000-ton line coming onstream currently. MHM ships its nonwovens to southeast Asia and Japan where they are used in diapers.
 
In fact, more than half of Mitsui’s output targets the diaper market, something that company has been trying to change in recent years as margins in this market have become more challenging. One result of these efforts is a new type of meltblown nonwovens—sold under the Syntex brand name—which has an extremely low diameter fiber. This product is being sold as a raw material for filters.
 
Although ordinary meltblown nonwovens are used in filters, Syntex nano has two types of nonwovens—the 10 type and the 6 type. As for the characteristic of the 10 type, it weighs 18 gsm and is 0.27mm thick. The porosity is about that same as ordinary meltblown nonwovens but the average pore size is significantly smaller, The result is high dust collection efficiency leading to a high performance filter. Mitsui Chemicals is developing a new market for raw materials such as air filters, liquid filters and battery separators in North America.
Location: TOKYO, JAPAN


Sales: $155 Million


Description: Key Personnel
Haruhiro Uesugi, general manager, life and energy materials division

Plants
Japan, Thailand

Processes
Spunbonded, needlepunched, meltblown, thermal bonded

Brand Names
Tafnel, Syntex

Major Markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials.

Mitsui Chemicals’ annual production capacity of nonwovens is 64,000 tons per year at its sites in Japan and Thailand. Among its output is polypropylene spunbonded nonwovens, SMS and SMMS.

In 2008, the company’s nonwovens sales increased, partly because of its role in the diaper market. In particular, demand in Thailand and China is driving growth. Mitsui is partially serving this demand with a new 16,000-ton spunmelt line at its MHM facility in Thailand, which began operating in January 2008. MHM also makes microporous films for the diaper market with an annual capacity of 6000 tons per year and can supply a backsheet film for diapers, which is laminated nonwovens with microporous films. About 80% of MHM’s output is exported.

MHM has been making nonwovens since March 2003 and since then has grown to comprise a significant share of Mitsui’s nonwovens operation. Currently, this operation makes nearly the same amount of nonwovens as the Japanese business and the cost competitiveness is much stronger than it is in Japan. Additionally, growth prospects within Asia and China are much stronger than in Japan.
Location: Tokyo, Japan

Sales: $164 million

Description: Key Personnel
Haruhiro Uesugi, general manager, spunbond fabrics division

Plants
Yokkaichi, Iwakuni, Japan

Processes
Spunbond, needlepunch, meltblown, thermal bonded

Brand Names
Tafnel, Syntec

Major Markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials.

Annual production capacity for Tokyo’s Mitsui Chemicals is 65,000 tons. By production type, the company’s capacity is 26,000 tons of polypropylene spunbond nonwovens (made on four lines) and 9000 tons of SMS nonwovens on one line as well as 30,000 tons of SMMS nonwovens made in Thailand at a wholly-owned subsidiary.
Although Mitsui Chemicals is the largest maker of polypropylene spunbonded nonwovens in Japan, nonwovens sales fell in 2009 because of decreased demand and lower selling prices. Additionally, nonwovens made and sold in Thailand, where the company has operated since 2008, fetch significantly lower prices than those made in Japan.
To help boost sales, Mitsui has developed a number of value-added products. Most recently, a low fiber diameter meltblown nonwovens is being sold under the brand name Syntec nano, which competes significantly with electrospun nonwovens in the air and liquid filtration markets. Mitsui is currently making these nonwovens on two lines.
Within the polypropylene spunbonded nonwovens segment, Mistui has developed hollow fiber materials for oil absorption mats, which absorb spilled oil in natural bodies of water. Buoyancy performance of the fiber increases because the inside of the fiber is hollow, making oil absorption easier and more effective. In fact, oil absorption performance improves around 20% because of the fibers’ larger surface area.

Tokyo, Japan
www.mitsui.com/jp
2011 Nonwovens Sales: $219 million

Key Personnel: Kensaku Takahashi, general manager, spunbond fabrics division

Plants: Yokkaichi and Iwakuni, Japan

Processes: Spunbond, meltblown, needlepunch, thermal bonded

Brands: Tafnel, Syntex

Major Markets: Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials

Annually, Mitsui Chemicals produces 40,000 tons of polypropylene spunbond nonwovens on five lines and 9,000 tons of SMS on one line—all in Japan. Additionally, MHM, the company’s Thai subsidiary, makes 30,000 tons of SMS on two lines.

The company’s latest line, which produces 15,000 tons per year, was added in Japan in April 2012. Additionally, the company has established a Chinese subsidiary in December 2011. The first line in this subsidiary, which also produces 15,000 tons per year, is expected to start operation in December 2013 in Tianjin. Once this line is complete, the company will have manufacturing assets in Japan, China and Thailand, giving it greater access to the entire Asian region. This will allow the company to capitalize on increased demand for diapers in Southeast Asia and China.

The new Chinese line will match the same high quality as Mitsui’s assets in Japan to meet demand for sophisticated diapers whereas the lines in Thailand make more general-purpose nonwovens. According to reports, Mitsui chose to make varying grades of nonwovens in China and Thailand due to free trade agreements between the countries that have reduced import duties. This allows the two sites to supply each other depending on market needs.

A producer of polypropylene polymers, Mitsui is able to make unique nonwovens, superior to competitors that use similar Reifenhauser technology, executives say. This gives the company an advantage in markets like baby diapers, feminine hygiene items, adult incontinence and medical. 
Tokyo, Japan
www.mitsui.co.jp
2012 Nonwovens Sales: $183 million
 
Key Personnel: Kensaku Takahashi, general manager, spunbond fabrics division
 
Plants: Yokkaichi and Iwakuni, Japan
 
Processes: spunbond, meltblown, needlepunch, thermal bonded
 
Brands: Tafnel, Synetx, Syntex Nano
 
With a new line up and running in Japan and one under construction in Tianjin, China, Mitsui Chemicals’ global spunbond capacity is going to surpass 94,000 tons by the end of the year. The company operates six lines in Japan, two in Thailand and will start its first Chinese line, able to make 15,000 tons of material, this month.
 
Currently, about 80% of Mitsui’s output is geared toward hygiene applications while the remaining is sold into industrial markets. Within hygiene, Mitsui has an advantage over other nonwovens producers because it is also a major supplier of polypropylene and Mitsui makes its nonwovens using the highest grades of polypropylene, resulting in a soft and flexible product.
 
In addition to its spunbond business, Mitsui makes meltblown nonwovens with very low diameter, which are sold under the brand name of syntex Nano. Although the other nonwovens manufacturers make the meltblown nonwovens of 600 nm, Mitsui is the first company to make them with a 300 nm. These products have been used liquid filtration media.
Tokyo, Japan
www.mitsuichem.com
2013 Nonwoven Sales: $186 million

Key Personnel
Kensaku Takahashi, general manager, spunbond fabircs division

Plants
Japan, China, Thailand

Processes
Spunbond

Brand names
Syntex

Major markets
Hygiene

While nonwovens counts as just one of many business segments targeted by Mitsui Chemicals, whose interests span from agrochemicals to electronics to construction, this market continues to be an important one to the Japanese corporation. In its mid-year 2011 strategic plan, the company targeted nonwovens as one of its priority businesses and pledged to expand its scope into new markets.

Since then, Mitsui certainly has proven its commitment to nonwovens through investment. Just last month, the company held a ceremony commemorating its new Chinese subsidiary, located in Tianjin. The site’s first line, a 15,000-ton spunbond line, will target the fast-growing hygiene market in China, according to executives. Mitsui announced the new site in November 2011.

Meanwhile, at its Japanese operation in Tokyo, Mitsui’s latest investment, a 15,000-ton line came onstream in April 2012, bringing that site’s capacity to 49,000 tons. Elsewhere in Asia, Mistui operates a two-line site in Thailand capable of making 30,000 tons of materials.

With a leading position in the spunbond markets in Japan as well as in Asia, Mitsui’s Syntex brand of spunbond nonwovens is projected to grow about 11% annually due to growth in the robust disposable diaper market. Currently, about 80% of the company’s nonwovens are sold into the disposable diaper market, and the company expects that investment in China and Thailand will help it grow in areas of Asia with low diaper penetration like China and Southeast Asia.

The nonwovens division is apart of Mistui’s functional chemicals division, which also includes healthcare, agrochemicals and fine and performance chemicals.

According to executives, Mitsui Chemicals’ strengths lie in its ability to engage in comprehensive production extending from the creation of base resins to final processing, its longstanding R&D capabilities, and its advanced quality management. Drawing on these strengths, the company has continued to differentiate itself from competitors through the production and sale of highly functional spunbonded nonwoven fabric.

Moving forward, Mitsui Chemicals says it will accelerate to a pace that allows it to harness its strengths while coordinating closely with customers. In this manner, the company will reinforce its standing as a leading provider of highly functional spunbonded nonwoven fabric in Asia.
Mitsui Chemicals
Tokyo, Japan
www.mitsuichem.com
2014 Nonwovens Sales: $157 million

Key Personnel

Kensaku Takahashi, general manager, nonwoven fabrics division

Plants
Japan, China, Thailand

Processes
Spunbond, meltblown, needlepunch, thermal bonded

Brand Names
Tafnel, Syntex, Syntex Nano

Major markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agricultural materials, household materials

Mitsui Chemicals produces polypropylene spunbond nonwovens in three countries—Japan where it produces 49,000 tons per year on six lines; Thailand with 30,000 tons  on two lines; and China where it makes 15,000 tons a year ion one line. All told Mitsui’s global spunbond capacity is currently 94,000 tons/year.

Mitsui Chemicals’ production capacity of meltblown nonwovens is 1000 tons/year.

Sales were boosted in 2014 by Mitsui’s latest investment, a line making polypropylene spunbond nonwovens, which began operating in December 2013. However, despite the increase in sales, the company has not reached its targeted profit because of the increasing prices of crude materials due to the low yen rate.

About 80% of Mitsui’s nonwoven products are used for diapers, with the high quality polypropylene spunbond nonwovens being used in Japan but Mitsui is starting to see greater demand for high quality polypropylene spunbond in China as there has been demand for high functioning diapers. Because of this, Mitsui Chemicals plans to improve its equipment in China to produce high quality nonwovens. Although it’s planning to start a new line for polypropylene spunbond in 2017, the company has not yet decided which country to set up the industrial plant.

Mitsui’s expansion strategy, outside of diapers, includes medical materials, industrial materials and agricultural materials. In the medical sector, it is going to strengthen its gowns for surgery with spunbond or meltblown nonwovens—and in the industrial materials sector, filters by nanofiber nonwovens will be strengthened. Mitsui Chemicals has also introduced Syntex Nano, meltblown nanofiber nonwovens, for liquid filters.
Tokyo, Japan
www.mitsui-chem.com.jp
2015 Nonwovens Sales: $214 million


Key Personnel
Akihiro Tachibana, general manager, nonwoven fabrics division

Plants
Yokkaichi, Nagoya

Processes
Spunbond, meltblown, needlepunch and thermal bond

Brand Names
Tafnel, Synetx, Syntex Nano

Major Markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials


The latest news from Mitsui Chemicals is the addition of 6000 tons of spunbond nonwovens at its Sunrex facility in Yokkaichi, Japan. The company announced the expansion in June 2016 saying it supports growth in the baby diaper market in Japan and throughout Asia.

The new line, which is expected to be complete by the end of next year, will feature proprietary technology to make premium spunbond nonwovens. The nonwovens made on this new line will offer excellent flexibility and expandability accompanied by superior comfort. These attributes will help Mitsui expand its role in premium diaper markets.

According to executives, Mitsui’s mid-term plan is to position its healthcare business as a targeted business domain and the nonwovens business is a part of that segment. Expansion into the Asian diaper markets is considered a significant part of this plan.

This expansion follows a similar project, announced in mid-2015, to add a 15,000-ton-line in Japan. This new line is currently coming onstream in Mitsui’s Nagoya facility. Like the Sunrex investment, this new line is responding to growth in the Asian baby diaper market.

Together these two investments will bring Mitsui’s Japanese capacity from 49,000 tons to 70,000 tons.

Outside of Japan, Mitsui operates spunbond and spunmelt facilities in Thailand and China.

The Chinese operation, which currently contains one line capable of making 15,000 tons of nonwovens per year, opened up shop in 2014 in Tianjin after originally being announced in 2011. Meanwhile, the Thai operation, which was established in 2002, can make 30,000 tons of nonwovens on two lines.

Mitsui also makes 1000 tons of meltblown nonwovens per year. These nonwovens range from 300-600 nm and are largely used in filter cartridges.
Tokyo, Japan
www.mitsui.co.jp
2016 Nonwovens Sales: $207 million


Key Personnel
Ahikiro Tachibana, general manager, nonwoven fabrics

Plants
Yokkaichi, Nagoya, Japan

Processes
Spunbond, meltblown, needlepunch, thermal bonded

Brands
Tafnel, Syntex, Syntex Nano

Major Markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials

Japanese nonwovens producer Mitsui Chemicals makes 49,000 tons of polypropylene-based spunbond nonwovens in Japan, 30,000 tons in Thailand and 15,000 tons in China for a total of 94,000 tons per year. Additionally, the company makes 1000 tons of meltblown.

In 2016, sales increased slightly for the company to reach ¥22.6 billion. The sales increase in its overseas business somewhat offset declines in Japan, due to sluggish demand for spunbond materials in a stagnant diaper market.

Still, Mitsui is adding 21,000 tons of nonwovens capacity through investment projects at Nagoya, which is being expanded by 15000 tons, and Yokkaichi, where 6000 tons are being added. Both projects are expected to be complete in November 2017 and will start operation in March 2018.

Mitsui has been focused on providing high performance, higher value added nonwovens for diapers as demand for Japanese-made diapers is expanding steadily in China. Wealthy Chinese people are willing to purchase diapers made in Japan because they offer a higher quality than Chinese-made diapers. This trend is encouraging Japanese diaper manufacturers to expand their domestic diaper operations and this will boost demand for Japanese-made nonwovens in the near term while stifling demand for materials made in China and other parts of Asia.

Also in response for the Chinese consumers’ need for sophisticated diapers, Mitsui has developed high performance spunbond nonwovens with excellent stretch, elasticity and softness. These will be made on the new lines currently being added in Nagoya and Yokkaich.
Tokyo, Japan
www.mitsui.com.jp
2017 Nonwovens Sales: $215 million


Key Personnel
Akihiro Tachibana, general manager, nonwoven fabrics division

Plants
Yokkaichi and Nagoya

Processes
Spunbond, meltblown, needlepunch, thermal bonded

Brand Names
Tafnel, Syntex, Nano, Airyfa

Major Markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials


Mitsui Chemicals can make 70,000 tons of polypropylene spunbond nonwovens per year in Japan as well as 30,000 tons of the material in Thailand and 15,000 tons in China, making global production 115,000 tons. In addition, Mitsui can make 1000 tons of meltblown nonwovens per year and sales of this material increased greatly in 2017.

Diaper market growth in Japan is driving demand for nonwovens sales not only in Japan but also in Thailand. In recent months, Mitsui has made two capacity investments, adding a 15,000-ton-per-year line in Nagoya and 6000 tons in Yokkaichi. The Nagoya plant was complete in November 2017 and the Yokkaichi investment was finished in June 2018. The company is reportedly considering making its next investment in India where many of its customers in the disposable diaper market are looking to penetrate.

Both new lines make high performance nonwovens featuring stretchable nonwovens with polyurethane fibers and polyolefin fibers at random. Nonwoven fabrics with crimped fibers like coils of the spring have also been produced at the new facility in Nagoya. This nonwoven fabric is superior in both flexibility and bulkiness.

Mitsui Chemicals has developed some high performance nonwoven fabrics for the premium diaper products and began full-scale production of this technology. Above all, the volumes of polypropylene spunbond nonwoven fabrics with hollow fibers, sold under the brand name Airyfa, have been increasing. Because its fibers are hollow, the material is light-weight but strong. It is mainly used for the gathering part of the diaper. It can be produced by changing the nozzles of existing facilities so the facilities can be changed relatively easily. Airfya is made using existing facilities in Yokkaichi, Japan, and production capacity is thought to be around 10,000 tons. In addition, one of the lines in Thailand was converted to be able to make Airyfa and started making it this summer. Full-scale production is also going to begin in China.

All of these nonwovens technologies are based on spunbonding technology, developed by Mitsui. They are all high value materials and adhere to Mitsui’s strategy of growing its nonwovens business through innovation.
Tokyo, Japan
www.mitsui.com.jp
2018 Nonwovens Sales: $218 million


Key Personnel
Akihiro Tachibana, general manager, nonwoven fabrics division

Plants
Yokkaichi and Nagoya, Japan; Tianjin, China; Rayong, Thailand

Processes
Spunbond, meltblown, needlepunch, thermal bonded nonwovens

Brand Names
Tafnel, Syntex, Syntex Nano, Airyfa

Major Markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials


Mitsui Chemicals’ annual production capacity of polypropylene spunbond nonwovens was 58,000 tons in Japan, 30,000 tons in Thailand, 15,000 tons in China, totaling 103,000 tons. The production capacity of its meltblown nonwovens was 1000 tons/year.

In terms of the nonwoven business in Japan in 2018, the quantities of production greatly decreased in the baby diaper category. Therefore, the demand for polypropylene spunbond nonwovens had declined, which led to a decrease in sales in the nonwovens business. New capacity of 15,000 tons/year was added in Mitsui’s Nagoya factory, while 6000 tons/year was added in the Yokkaichi factory in October 2018, bringing production capacity in Japan increased to 58,000 tons.

Although MHM, a subsidiary of the company, had produced polypropylene spunbond nonwovens with the capacity of 30,000 tons/year in Thailand, they added 6000 tons with equipment that was purchased from a Chinese enterprise. This new capacity is and included in production capacity of the commercial production because they are used in the trial manufacture of the development of products. Thus, the facilities line of MHM became three lines—14,000 tons/year (operated since 2003), 16,000 tons/year (operated since 2007) and 6000 tons/year (operated since 2018).

The diaper business holds the highest proportion of nonwovens for Mitsui Chemicals, therefore, the business results of nonwovens greatly depends on the production trends of diapers. Although the diapers produced in Japan were exported to China in large quantities, many of them were resale objects for Chinese brokers. However, these brokers are not as active as they once were causing a decline in Japanese diaper sales. This decline, however, does not necessarily reflect a decline in public demand for diapers and is expected to be a temporary decrease.

Special nonwoven fabric has been developed for diapers, such as spunbond nonwovens with hollow fibers (trade name: Airyfa). They could also be developed for purposes other than diapers. Mitsui Chemicals has produced meltblown nonwoven fabrics using nanofibers, and they are pushing forward to open new markets for meltblown nonwovens.
Tokyo, Japan
www.mitsui.com.jp
2019 Nonwovens Sales: $218 million


Key Personnel
Akihiro Tachibana, general manager, nonwoven fabrics division

Plants
Yokkaichi and Nagoya, Japan; Tianjin, China; Rayong, Thailand

Processes
Spunbond, meltblown, needlepunch, thermal bonded nonwovens

Brand Names
Tafnel, Syntex, Syntex Nano, Airyfa

Major Markets
Coverstock, geotextiles, oil absorbing materials

In March 2020, Mitsui Chemicals announced it had expanded its production facilities for meltblown nonwovens at wholly owned subsidiary Sunrex Industry Co., Ltd., starting operations at the new facilities in January. The move comes as an effort to respond to growing demand for industrial-use meltblown nonwovens, and will increase the Mitsui Chemicals Group’s overall production capacity for these materials by 50%.

Mitsui Chemicals continues to position its nonwovens business as a growth sector, making efforts here to supply high-quality nonwovens as industrial materials for a variety of applications. This includes use in car seats (product name: Tafnel), masks (product name: Syntex) and agricultural sheets (product name: Syntex). With particular respect to Syntex MB nano, marketing efforts are going toward use in filters and other such applications that will take advantage of the meltblown nonwovens line’s superfine fibers, which are no more than several hundred nanometers in diameter.

Through this latest facility expansion, Mitsui Chemicals plans to further bolster and grow its business for nonwovens going forward.

Mitsui has pivoted its production output in response to the coronavirus. In April, the company started to supply nonwovens as raw materials for isolation gowns in an effort to support health care providers on the front lines in cutting-edge medical facilities. This effort comes as the increasing spread of the virus has made isolation gowns – for which Japan has been largely reliant on foreign imports – difficult to obtain amid the global pandemic.

To establish this supply, Mitsui Chemicals is making use of wholly owned subsidiary Sunrex Industry Co. Ltd., which serves as a major plant for nonwovens production. Mitsui Chemicals is taking production facilities here that normally produce nonwoven sanitary materials and repurposing these to begin production of nonwovens for isolation gowns.

In other efforts aimed at stopping the novel coronavirus, Mitsui Chemicals is already contributing significantly to domestic mask production by supplying meltblown nonwovens and nose clamps. But to help resolve the current mask shortage, Mitsui Chemicals is also pursuing plans for further production increase.

In March, Mitsui began working on the development of a new, reusable 3D-printed mask with Professor HORI Katsutoshi of the Graduate School of Engineering at Nagoya University and Friend Microbe Inc., a spinoff venture from Nagoya University.

The key feature of the mask design is that is can filter out viral particles but can also be reused. It consists of a reusable body and a disposable filter. Mitsui Chemicals will provide the nonwoven disposable filter, which removes viral particles. Professor HORI has produced the mask body using a 3D printer and is investigating enzyme preparations and various other antiviral agents that could be applied. Plans are to produce a mask with consideration of design and comfort while also ensuring that it provides outstanding protection against viruses.
Tokyo, Japan
www.mitsui.co.jp
2021 Nonwovens Sales: $167 million


Key Personnel
Kazuya Kusana, general manager

Plants
Japan, Thailand

Processes
Spunbond, meltblown, needlepunch, thermal bond

Brand Names
Tafnel, Syntex, Syntex Nano

Major Markets
Hygiene, medical, face masks, filtration, agriculture

The big news at Mitsui Chemicals in 2021 was the divestment of its ownership in Mitsui Chemicals Nonwovens (Tianjin), its Chinese subsidiary to Foshan Nanhai Beautiful Nonwoven (BTF) Co. The site was opened in 2014 and is capable of making 15,000 tons of spunbond nonwovens per year. Prior to the deal, Mitsui and BTF, a manufacturer of medical and sanitary nonwovens with factories in China and the U.S., had a relationship for more than 15 years. The partnership included outsourced manufacturing of high-performance medical nonwovens.

Without the Chinese subsidiary, Mitsui now operates nonwoven production facilities in Japan and Thailand, which together can make 88,000 of commercial grade spunbond nonwovens—the Thai site also has a 6300 ton pilot line for the development and testing of high performance materials. Additionally, the company operates three meltblown lines and is in the process of adding a fourth line, which will be operational in April 2023 to target media for liquid cartridge filters.

Growth in technical markets like filtration is helping to offset declines in the hygiene market, particularly the baby diaper market, which has been challenged two-fold. The birth rate in China continues to decline, meaning fewer diapers are being used. Additionally, volumes of spunbond materials targeting hygiene applications grew significantly during the coronavirus pandemic for materials like face masks and gowns, which are seeing decreases in demand.

For Mitsui Chemicals' 2020 top company profile, click here.
Tokyo, Japan
www.mitsui-chemicals.com
2022 Nonwovens Sales: $157 million


Key Personnel
Kazuya Kusano, general manager, nonwoven fabric division

Plants
Japan, Thailand

Processes
Spunbond, meltblown, needlepunch, thermal

Brands
Tafnel, Synetx, Syntex Nano, Airyfa

Major Markets
Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agricultural materials, household materials

In February 2023, Mitsui Chemicals and fellow leader in the Japanese nonwovens industry Asahi Kasei, announced a plan to form a new integrated company combining their nonwovens businesses with a tentative start date of October 2, 2023. This plan will be carried out through a corporation-type demerger enabling the establishment of the new integrated company pending the approval of authorities in Japan and Thailand, where the two companies have operations.

Under the proposed plan, all of Mitsui Chemicals’ nonwovens businesses with the exception of its SWP fibrillated polyolefin fiber will be integrated with Asahi Kasei’s spunbond and cartridge filter business. The new company will be known as Mitsui Chemicals Asahi Life Materials Co. and it will be based in Tokyo, Japan. Mitsui will own slightly more than 60% of the company while Asahi Kasei will hold the remaining shares. Sales are estimated at ¥48.3 billion or about $370 million annually.

The Japanese sites for the company will include Mitsui’s Sunrex subsidiary in Mie, Japan as well as its Nogoya Works plant in Aichi. Meanwhile, Asahi Kasei’s plant in Moriyama will provide outsourced production. Overseas sites including both companies’ Thailand operations, will continue to carry out production and sales as subsidiaries of the integrated company. Asahi Kasei’s spunbond operation in Moriyama will be merged into the company by way of an absorption-type merger at a later date.

The main reason for the integration has been cited as intensifying competition in Asia, particularly among polypropylene spunbond manufacturers. The larger scale created by the merger of the two companies, which will produce 132,000 tons of polypropylene spunbond nonwovens per year initially, will improve the companies’ position within Asia, particularly in the Chinese diaper market where oversupply has been caused by decreasing birth rates. The Regional Comprehensive Economic Partnership (RCEP), enacted in January 2022, and the elimination of tariffs in East Asia has also contributed to increased competition, and escalating raw material prices have made achieving profitability more difficult.

Mitsui Chemicals currently makes 85,000 tons of spunbond nonwovens at sites in Japan and Thailand. In 2021, the company exited the Chinese market through the sale of its subsidiary there to a Chinese company. The company also makes meltblown nonwovens