Toyobo
Location: Osaka, Japan
Sales: $141 Million
Description: Key Personnel
Yukio Kawasaki, general manager, spunbond division of Toyobo; Hidemichi Mukunashi, managing director of Kureha
Plants
Tsuruga, Iwakuni, Shiga
Processes
Spunbonded, needlepunched, resin bonded, spunlaced, stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, carpeting, hot melt bonding sheets, plaster braces
Operating as three companies, Toyobo, Osaka, Japan, achieved nonwovens sales of $141 million (¥16 billion) last year. Spunbonded nonwovens are produced by Toyobo while its subsidiaries Kureha and Yuho manufacture resin bonded, needlepunched and spunbonded nonwovens and needlepunched spunlaced and stitch bonded materials, respectively. The company discontinued its melt blown operations in September 2001.
In terms of capital expansion, Toyobo is currently constructing a new polyester spunbond facility with an annual capacity of 6000 tons, which is scheduled to be complete in October. The new investment brings Toyobo’s total production of polyester spunbonded materials to 14,000 tons per year. The new site will help relieve undercapacity problems at Toyobo, which reports all of its lines running at full capacity, leaving little room for sales growth. While waiting for the new capacity to come onstream, Toyobo has been importing spunbonded nonwovens made by foreign companies. Last year, Toyobo purchased 1000 tons of the material.
Kureha has been targeting the automotive interiors, automotive engine filters and plaster base markets with its needlepunched nonwovens. The subsidiary also produces special spunbonded nonwovens for hot melt bonding. Nylon and polyester are used as polymers for these thin nonwovens, which are sometimes called cobweb sheets. Melt blown nonwovens are often used for hot melt bonding. Therefore, Kureha has been developing them for spunbonded nonwovens for some time.
In terms of market development, Toyobo is focusing its attention on the automotive engine filter market, a move that is in synergy with the growing automotive market in Southeast Asia. Additionally, the company recently announced plans to enter the battery separator market, an area long dominated by rival Japan Vilene, Tokyo, Japan. The company has already begun sample distribution of nonwoven separators for nickel and hydrogen batteries to producers. Nickel and hydrogen batteries are typically used for hybrid electric vehicles, which are expected to grow their share of the world automotives market.
Sales: $141 Million
Description: Key Personnel
Yukio Kawasaki, general manager, spunbond division of Toyobo; Hidemichi Mukunashi, managing director of Kureha
Plants
Tsuruga, Iwakuni, Shiga
Processes
Spunbonded, needlepunched, resin bonded, spunlaced, stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, carpeting, hot melt bonding sheets, plaster braces
Operating as three companies, Toyobo, Osaka, Japan, achieved nonwovens sales of $141 million (¥16 billion) last year. Spunbonded nonwovens are produced by Toyobo while its subsidiaries Kureha and Yuho manufacture resin bonded, needlepunched and spunbonded nonwovens and needlepunched spunlaced and stitch bonded materials, respectively. The company discontinued its melt blown operations in September 2001.
In terms of capital expansion, Toyobo is currently constructing a new polyester spunbond facility with an annual capacity of 6000 tons, which is scheduled to be complete in October. The new investment brings Toyobo’s total production of polyester spunbonded materials to 14,000 tons per year. The new site will help relieve undercapacity problems at Toyobo, which reports all of its lines running at full capacity, leaving little room for sales growth. While waiting for the new capacity to come onstream, Toyobo has been importing spunbonded nonwovens made by foreign companies. Last year, Toyobo purchased 1000 tons of the material.
Kureha has been targeting the automotive interiors, automotive engine filters and plaster base markets with its needlepunched nonwovens. The subsidiary also produces special spunbonded nonwovens for hot melt bonding. Nylon and polyester are used as polymers for these thin nonwovens, which are sometimes called cobweb sheets. Melt blown nonwovens are often used for hot melt bonding. Therefore, Kureha has been developing them for spunbonded nonwovens for some time.
In terms of market development, Toyobo is focusing its attention on the automotive engine filter market, a move that is in synergy with the growing automotive market in Southeast Asia. Additionally, the company recently announced plans to enter the battery separator market, an area long dominated by rival Japan Vilene, Tokyo, Japan. The company has already begun sample distribution of nonwoven separators for nickel and hydrogen batteries to producers. Nickel and hydrogen batteries are typically used for hybrid electric vehicles, which are expected to grow their share of the world automotives market.
Location: Osaka, Japan
Sales: $125 million
Description: Key Personnel
Yukio Kawasaki, general manager, spunbond division of Toyobo; Hidemichi Mukunashi, managing director of Kureha
Plants
Tsuruga, Iwakuni, Shiga
Processes
Spunbonded, needlepunched, resin bonded, spunlaced, stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunched carpets, hot melt bonding sheets, plaster bases
The Toyobo Group, based in Osaka, Japan, includes Kureha which produces resin bonded, needlepunched and spunbonded nonwovens; Yuho, which produces needlepunched, spunlaced and stitchbonded nonwovens, and Toyobo, which produces polyester spunbonded nonwovens.
The Toyobo division can now produce 14,000 tons of polyester spunbonded nonwovens, thanks to the completion of a new plant, capable of producing 6000 tons per year in October 2002. This expansion was intended to meet pent-up demand as well as open up new applications for the material. Currently, major markets for Toyobo’s spunbonded nonwovens include geotextiles, roofing sheets and carpet backings. As demand in these applications, which once comprised 80% of total sales of the segment, have been sluggish, new applications include sound control devices, car covers and agriculture and industrial products.
Also included in Toyobo’s growth strategy is the development of European and U.S. markets as well as increased exports to China. Kureha has a high marketshare in car interior and filtration and poultice medicines in the domestic market while Toyobo has developed superior nonwovens with excellent modability for car engines to target new areas.
Sales: $125 million
Description: Key Personnel
Yukio Kawasaki, general manager, spunbond division of Toyobo; Hidemichi Mukunashi, managing director of Kureha
Plants
Tsuruga, Iwakuni, Shiga
Processes
Spunbonded, needlepunched, resin bonded, spunlaced, stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunched carpets, hot melt bonding sheets, plaster bases
The Toyobo Group, based in Osaka, Japan, includes Kureha which produces resin bonded, needlepunched and spunbonded nonwovens; Yuho, which produces needlepunched, spunlaced and stitchbonded nonwovens, and Toyobo, which produces polyester spunbonded nonwovens.
The Toyobo division can now produce 14,000 tons of polyester spunbonded nonwovens, thanks to the completion of a new plant, capable of producing 6000 tons per year in October 2002. This expansion was intended to meet pent-up demand as well as open up new applications for the material. Currently, major markets for Toyobo’s spunbonded nonwovens include geotextiles, roofing sheets and carpet backings. As demand in these applications, which once comprised 80% of total sales of the segment, have been sluggish, new applications include sound control devices, car covers and agriculture and industrial products.
Also included in Toyobo’s growth strategy is the development of European and U.S. markets as well as increased exports to China. Kureha has a high marketshare in car interior and filtration and poultice medicines in the domestic market while Toyobo has developed superior nonwovens with excellent modability for car engines to target new areas.
Location: Osaka, Japan
Sales: $133 MILLION
Description: Key Personnel
Yukio Kawasaki, general manager, spunbond division of Toyobo; Hidemichi Mukunashi, managing director of Kureha
Plants: Tsuruga, Iwakuni and Shiga
Processes
Spunbond, needlepunch, resin bonded, spunlaced, stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunched carpets, hot melt bonding sheets, plaster bases
Among the nonwovens producers in the Toyobo Group are Kureha and Yuho. Kureha produces resin bonded, needlepunched and spunbonded nonwovens, while Yuho produces needlepunched, spunlaced and stitch bonded nonwovens. Toyobo also produces needlepunched nonwovens.
Because many of its products contain added-value properties, sales of Toyobo are considerably higher than they would be at a nonwovens producer of a similar size. Despite these added benefits, Toyobo was not able to maintain its higher price points in 2003 and sales were unable to move upward. Polyester spunbonded nonwovens proved immune to these struggles, however. Production capacity is 24,000 tons per year.
Markets showing considerable promise include the automotive interior and engine filtration markets, which are largely targeted by Kureha. Kureha produces nonwovens for air cleaners in Japan, the U.S. and Thailand. Production capacity for this market is believed to be 7.2 million square meters a year in Japan, 4.3 million square meters in the U.S. and 3 million square meters in Thailand.
The demand for Kureha-made materials in automotive filtration systems has been strong in Japan. This product has outpaced the growth of the automotives market in the U.S. and Southeast Asia. As for the interior materials of the car, needlepunched nonwovens have been supplied for the carpet in the cabin and trunk areas.
Meanwhile, at Toyobo’s Yuho division, key products include spunlaced nonwovens, which are mainly custom-made to customer demands, and needlepunched nonwovens made from glass, carbon and other synthetic fibers. This falls in sync with Toyobo’s core growth strategy—producing unique products not offered by other companies.
Sales: $133 MILLION
Description: Key Personnel
Yukio Kawasaki, general manager, spunbond division of Toyobo; Hidemichi Mukunashi, managing director of Kureha
Plants: Tsuruga, Iwakuni and Shiga
Processes
Spunbond, needlepunch, resin bonded, spunlaced, stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunched carpets, hot melt bonding sheets, plaster bases
Among the nonwovens producers in the Toyobo Group are Kureha and Yuho. Kureha produces resin bonded, needlepunched and spunbonded nonwovens, while Yuho produces needlepunched, spunlaced and stitch bonded nonwovens. Toyobo also produces needlepunched nonwovens.
Because many of its products contain added-value properties, sales of Toyobo are considerably higher than they would be at a nonwovens producer of a similar size. Despite these added benefits, Toyobo was not able to maintain its higher price points in 2003 and sales were unable to move upward. Polyester spunbonded nonwovens proved immune to these struggles, however. Production capacity is 24,000 tons per year.
Markets showing considerable promise include the automotive interior and engine filtration markets, which are largely targeted by Kureha. Kureha produces nonwovens for air cleaners in Japan, the U.S. and Thailand. Production capacity for this market is believed to be 7.2 million square meters a year in Japan, 4.3 million square meters in the U.S. and 3 million square meters in Thailand.
The demand for Kureha-made materials in automotive filtration systems has been strong in Japan. This product has outpaced the growth of the automotives market in the U.S. and Southeast Asia. As for the interior materials of the car, needlepunched nonwovens have been supplied for the carpet in the cabin and trunk areas.
Meanwhile, at Toyobo’s Yuho division, key products include spunlaced nonwovens, which are mainly custom-made to customer demands, and needlepunched nonwovens made from glass, carbon and other synthetic fibers. This falls in sync with Toyobo’s core growth strategy—producing unique products not offered by other companies.
Location: Osaka, Japan
Sales: $145 million
Description: Key Personnel
Kazumasa Kayama, general manager, spunbond division of Toyobo; Yukio Kawasaki, president of Kureha
Plants
Tsuruga, Iwakuni and Shiga
Processes
Spunbond, needlepunch, resin bonded, spunlaced, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunched carpets, hot melt bonding sheets, plaster bases
Among the nonwovens producers in the Toyobo Group are Kureha and Yuho. Kureha produces resin bonded, needlepunched and spunbonded nonwovens, while Yuho produces needlepunched, spunlaced and stitchbonded nonwovens. Toyobo itself produces polyester spunbonded nonwovens. In terms of production capacities, Toyobo is in the lead with 14,000 tons of polyester spunbond nonwovens while Kureha manufactures 7000 tons annually and Yuho’s capacity is 3000 tons per year.
A 6000-ton-per-year polyester spunbond line added by Toyobo in 2002 is approximately 50% full at this time. Spunbonded nonwovens based on new polymers are being developed on this line as well as existing spunbonded products that are shifting to the use of new types of materials. New polymers for spunbonded fabrics include PBT and polyester elastomer. PBT-based spunbonded materials feature softness and flexibility, according to Toyobo, and are beginning to find application as automotive ceiling materials. Polyester elastomer-based spunbonded nonwovens reportedly offer high elasticity and are being explored for use in diaper applications.
Kureha’s activity in automotive interiors and engine filtration reportedly is faring well in Japan and internationally. Overseas output of Kureha’s automotive materials has outpaced domestic production as the company has continued to make efforts to globalize its supply system. Meanwhile, within Japan, a good sign for Toyobo is the initial introduction of these nonwovens by domestic automotive makers as part of cost reduction programs.
Because many of its products contain added-value properties, sales of Toyobo are considerably higher than similar-sized nonwovens producers. Despite these added benefits, Toyobo was not able to maintain its higher price points in 2003, and sales were unable to move upward. Polyester spunbonded nonwovens proved immune to these struggles, however. Production capacity is 24,000 tons per year.
Markets showing considerable promise include the automotive interior and engine filtration markets, which are largely targeted by Kureha. Kureha produces nonwovens for air cleaners in Japan, the U.S. and Thailand. Nonwovens usage in this market is believed to be 7.2 million square meters a year in Japan, 4.3 million square meters in the U.S. and 3 million square meters in Thailand.
The demand for Kureha-made materials in automotive filtration systems has been strong in Japan. This product has outpaced the growth of the automotives market in the U.S. and Southeast Asia. As for the interior materials of the car, needlepunched nonwovens have been supplied for the carpet in the cabin and trunk areas.
Meanwhile, at Toyobo’s Yuho division, key products include spunlaced nonwovens, which are mainly custom-made to customer demands, and needlepunched nonwovens made from glass, carbon and other synthetic fibers. This falls in sync with Toyobo’s core growth strategy—producing unique products not offered by other companies.
Sales: $145 million
Description: Key Personnel
Kazumasa Kayama, general manager, spunbond division of Toyobo; Yukio Kawasaki, president of Kureha
Plants
Tsuruga, Iwakuni and Shiga
Processes
Spunbond, needlepunch, resin bonded, spunlaced, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunched carpets, hot melt bonding sheets, plaster bases
Among the nonwovens producers in the Toyobo Group are Kureha and Yuho. Kureha produces resin bonded, needlepunched and spunbonded nonwovens, while Yuho produces needlepunched, spunlaced and stitchbonded nonwovens. Toyobo itself produces polyester spunbonded nonwovens. In terms of production capacities, Toyobo is in the lead with 14,000 tons of polyester spunbond nonwovens while Kureha manufactures 7000 tons annually and Yuho’s capacity is 3000 tons per year.
A 6000-ton-per-year polyester spunbond line added by Toyobo in 2002 is approximately 50% full at this time. Spunbonded nonwovens based on new polymers are being developed on this line as well as existing spunbonded products that are shifting to the use of new types of materials. New polymers for spunbonded fabrics include PBT and polyester elastomer. PBT-based spunbonded materials feature softness and flexibility, according to Toyobo, and are beginning to find application as automotive ceiling materials. Polyester elastomer-based spunbonded nonwovens reportedly offer high elasticity and are being explored for use in diaper applications.
Kureha’s activity in automotive interiors and engine filtration reportedly is faring well in Japan and internationally. Overseas output of Kureha’s automotive materials has outpaced domestic production as the company has continued to make efforts to globalize its supply system. Meanwhile, within Japan, a good sign for Toyobo is the initial introduction of these nonwovens by domestic automotive makers as part of cost reduction programs.
Because many of its products contain added-value properties, sales of Toyobo are considerably higher than similar-sized nonwovens producers. Despite these added benefits, Toyobo was not able to maintain its higher price points in 2003, and sales were unable to move upward. Polyester spunbonded nonwovens proved immune to these struggles, however. Production capacity is 24,000 tons per year.
Markets showing considerable promise include the automotive interior and engine filtration markets, which are largely targeted by Kureha. Kureha produces nonwovens for air cleaners in Japan, the U.S. and Thailand. Nonwovens usage in this market is believed to be 7.2 million square meters a year in Japan, 4.3 million square meters in the U.S. and 3 million square meters in Thailand.
The demand for Kureha-made materials in automotive filtration systems has been strong in Japan. This product has outpaced the growth of the automotives market in the U.S. and Southeast Asia. As for the interior materials of the car, needlepunched nonwovens have been supplied for the carpet in the cabin and trunk areas.
Meanwhile, at Toyobo’s Yuho division, key products include spunlaced nonwovens, which are mainly custom-made to customer demands, and needlepunched nonwovens made from glass, carbon and other synthetic fibers. This falls in sync with Toyobo’s core growth strategy—producing unique products not offered by other companies.
Location: Osaka, Japan
Sales: $145 million
Description: Key Personnel
Kazumasa Kayama, general manager, spunbond division of Toyobo; Yukio Kawasaki, president of Kureha
Plants
Tsuruga, Iwakuni and Shiga
Processes
Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunched carpets, hot melt bonding sheets, plaster bases
Among the nonwovens producers in the Toyobo Group are Kureha and Yuho. Kureha produces resin bonded, needlepunched, thermal bonded and spunbonded nonwovens, while Yuho produces needlepunched, spunlaced and stitchbonded nonwovens. Toyobo itself produces polyester spunbonded nonwovens. In terms of production capacities, Toyobo is in the lead with 14,000 tons of polyester spunbond nonwovens while Kureha manufactures 7000 tons annually and Yuho’s capacity is 3000 tons per year.
While in the past, the three main applications for Toyobo’s polyester spunbonded nonwovens were geotextiles, roofing sheets and carpet backings, steady sales growth has placed automotive materials on this list as well. Spunbonded nonwovens based on new polymers such as PBT and polyester elastomers are being used for novel applications in this field while polyester spunbonds are finding application in automotive headliners because of their softness and flexibility for molding. According to Toyobo, polyester elastomer-based nonwovens offer excellent stretch and are expected to reach full scale sales levels in 2006-2007.
Sales: $145 million
Description: Key Personnel
Kazumasa Kayama, general manager, spunbond division of Toyobo; Yukio Kawasaki, president of Kureha
Plants
Tsuruga, Iwakuni and Shiga
Processes
Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunched carpets, hot melt bonding sheets, plaster bases
Among the nonwovens producers in the Toyobo Group are Kureha and Yuho. Kureha produces resin bonded, needlepunched, thermal bonded and spunbonded nonwovens, while Yuho produces needlepunched, spunlaced and stitchbonded nonwovens. Toyobo itself produces polyester spunbonded nonwovens. In terms of production capacities, Toyobo is in the lead with 14,000 tons of polyester spunbond nonwovens while Kureha manufactures 7000 tons annually and Yuho’s capacity is 3000 tons per year.
While in the past, the three main applications for Toyobo’s polyester spunbonded nonwovens were geotextiles, roofing sheets and carpet backings, steady sales growth has placed automotive materials on this list as well. Spunbonded nonwovens based on new polymers such as PBT and polyester elastomers are being used for novel applications in this field while polyester spunbonds are finding application in automotive headliners because of their softness and flexibility for molding. According to Toyobo, polyester elastomer-based nonwovens offer excellent stretch and are expected to reach full scale sales levels in 2006-2007.
Location: Tokyo, Japan
Sales: $141 million
Description: Key Personnel
Kazumasa Kayama, general manager, spunbond division of Toyobo; Yukio Kawasaki, president of Kureha
Plants
Tsuruga, Iwakuni and Shiga
Processes
Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunched carpets, hot melt bonding sheets, plaster bases
Toyobo produces 14,000 tons of polyester-based spunbonded nonwovens on four lines, two in Iwakuni and two in Tsuruga, Japan. Toyobo is currently streamlining its operation in Iwakuni, which is expected to increase its capacity by 2000 tons by April 2008. The company also produces spunbond nonwovens from polybutylene terephthalate and polyphenylene sulfide. Nonwovens with PBT have moderate stretch properties and the PPS-based materials feature excellent heat resistance.
Kureha, an associated company, makes nonwovens via resin bonding, needlepunching, thermal bonding and spunbonding with a capacity of about 7000 tons per year. There are five thermal and resin bonding lines, eight needlepunch lines and four spunbond lines. The spunbond nonwovens made by Kureha are hotmelt sheets used as adhesives in specialty nonwovens, unlike normal spunbond nonwovens, they are thin and lightweight with low density and are used as an adhesive to laminate nonwovens, textile fabrics and knits. Kureha also operates subsidiaries in Taiwan, Thailand and the U.S., where each company makes and sells nonwovens. The American subsidiary produces air filters for mobile engines by making nonwovens and molding the filters. These filters are supplied to American Toyota. Subsidiaries in Taiwan and Thailand produce and sell nonwovens for automotive interiors.
Yuho, another associated company of Toyobo, makes needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.
Sales: $141 million
Description: Key Personnel
Kazumasa Kayama, general manager, spunbond division of Toyobo; Yukio Kawasaki, president of Kureha
Plants
Tsuruga, Iwakuni and Shiga
Processes
Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunched carpets, hot melt bonding sheets, plaster bases
Toyobo produces 14,000 tons of polyester-based spunbonded nonwovens on four lines, two in Iwakuni and two in Tsuruga, Japan. Toyobo is currently streamlining its operation in Iwakuni, which is expected to increase its capacity by 2000 tons by April 2008. The company also produces spunbond nonwovens from polybutylene terephthalate and polyphenylene sulfide. Nonwovens with PBT have moderate stretch properties and the PPS-based materials feature excellent heat resistance.
Kureha, an associated company, makes nonwovens via resin bonding, needlepunching, thermal bonding and spunbonding with a capacity of about 7000 tons per year. There are five thermal and resin bonding lines, eight needlepunch lines and four spunbond lines. The spunbond nonwovens made by Kureha are hotmelt sheets used as adhesives in specialty nonwovens, unlike normal spunbond nonwovens, they are thin and lightweight with low density and are used as an adhesive to laminate nonwovens, textile fabrics and knits. Kureha also operates subsidiaries in Taiwan, Thailand and the U.S., where each company makes and sells nonwovens. The American subsidiary produces air filters for mobile engines by making nonwovens and molding the filters. These filters are supplied to American Toyota. Subsidiaries in Taiwan and Thailand produce and sell nonwovens for automotive interiors.
Yuho, another associated company of Toyobo, makes needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.
Location: TOKYO, JAPAN
Sales: $143 million
Description: Key Personnel
Yuuji Taneda, general manager, spunbond division of Toyobo; Yukio Kawasaki, president of Kureha
Plants
Tsuruga, Iwakuni, Shiga
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo upgraded equipment in its Iwakuni, Japan plant in 2008 in a move that increased production capacity of its polyester spunbonded nonwovens from 14,000 to 16,000 tons per year. Additionally, the company developed nonwovens with polybutylene terephthalate (PBT) and polyphenylene sulfide (PPS) as the crude materials. Toyobo has been outsourcing production of this materials to a Chinese PET spunbonded maker since spring 2007 and sells this material for the automotives market in China. Since the Japanese auto makers are looking to China for the same quality as Japanese-made products, Toyobo has been providing Chinese spunbond makers with technical guidance and sells the nonwovens of identical quality to Japanese products under the Toyobo brand name.
Kureha, Toyobo’s subsidiary, produces resin bonded, needlepunched, thermal bonded and spunbonded nonwovens with a capacity of about 7000 tons per year, and Yuho, another subsidiary, produces needlepunched, spunlaced and stitchbonded nonwovens with a capacity of about 3000 tons per year.
Kureha is good at automotive filter production and has developed the suction filter of a fuel pump as a new application for nonwovens. Although the mesh textile fabrics of the nylon fibers are used for the suction filter of the fuel pump, Kureha has developed a new filter medium made of spunbonded nonwovens or thermal bonded nonwovens to enable a longer filter life and enhance filtration efficiency. More and more automobiles are using this product.
Yuho also performs the assembling of the honeycomb filter to be equipped to the filter unit for building an air conditioning or solvent recovery device, while producing nonwovens. With a reinforcement of the environmental regulation, the demand for the solvent recovery device has been getting higher and the demand for honeycomb filters has also been increasing.
Sales: $143 million
Description: Key Personnel
Yuuji Taneda, general manager, spunbond division of Toyobo; Yukio Kawasaki, president of Kureha
Plants
Tsuruga, Iwakuni, Shiga
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo upgraded equipment in its Iwakuni, Japan plant in 2008 in a move that increased production capacity of its polyester spunbonded nonwovens from 14,000 to 16,000 tons per year. Additionally, the company developed nonwovens with polybutylene terephthalate (PBT) and polyphenylene sulfide (PPS) as the crude materials. Toyobo has been outsourcing production of this materials to a Chinese PET spunbonded maker since spring 2007 and sells this material for the automotives market in China. Since the Japanese auto makers are looking to China for the same quality as Japanese-made products, Toyobo has been providing Chinese spunbond makers with technical guidance and sells the nonwovens of identical quality to Japanese products under the Toyobo brand name.
Kureha, Toyobo’s subsidiary, produces resin bonded, needlepunched, thermal bonded and spunbonded nonwovens with a capacity of about 7000 tons per year, and Yuho, another subsidiary, produces needlepunched, spunlaced and stitchbonded nonwovens with a capacity of about 3000 tons per year.
Kureha is good at automotive filter production and has developed the suction filter of a fuel pump as a new application for nonwovens. Although the mesh textile fabrics of the nylon fibers are used for the suction filter of the fuel pump, Kureha has developed a new filter medium made of spunbonded nonwovens or thermal bonded nonwovens to enable a longer filter life and enhance filtration efficiency. More and more automobiles are using this product.
Yuho also performs the assembling of the honeycomb filter to be equipped to the filter unit for building an air conditioning or solvent recovery device, while producing nonwovens. With a reinforcement of the environmental regulation, the demand for the solvent recovery device has been getting higher and the demand for honeycomb filters has also been increasing.
Location: TOKYO, JAPAN
Sales: $163 Million
Description: Key Personnel
Yuuji Taneda, general manager, spunbond division of Toyobo; Yukio Kawasaki, president of Kureha
Plants
Tsuruga, Iwakuni, Shiga
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo produces 14,000 tons of PET spunbond nonwovens per year and its OEM production has been entrusted to a Chinese PET spunbonded nonwovens maker since spring 2007 for the manufacture of automotive materials. Additionally, Kureha, Toyobo’s subsidiary, produces resin bonded, needlepunched, thermal bonded and spunbond nonwovens with a capacity of about 7000 tons per year. Its other subsidiary Yuho makes needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.
As for the PET spunbonded nonwovens of Toyobo, about 30-40% of this material targets the automotives business and Kureha’s business is about 60% related to automotives, meaning that Toyobo is quite dependent on this market. As this market has undergone significant decreases so has Toyobo’s income.
That said, Toyobo has defended itself by improving its nonwoven products. The company’s policy is to focus on the development of added-value properties to raise the processing percentage of the raw materials by strengthening the cooperation with the group enterprises. In addition, Toyobo intends to move forward with the development of new applications for spunbonded nonwovens by integrating new polymers into its processes. This has opened up new applications, namely nonwovens with stretch properties which have already been developed and mass production should be underway by the end of 2009. Furthermore, Toyobo’s strategy of enhancing manufacturing efficiency and quality, has been achieved by upgrading older equipment and facilities. Meanwhile, the crude oil prices and business fluctuations have been intensive in the market.
Sales: $163 Million
Description: Key Personnel
Yuuji Taneda, general manager, spunbond division of Toyobo; Yukio Kawasaki, president of Kureha
Plants
Tsuruga, Iwakuni, Shiga
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo produces 14,000 tons of PET spunbond nonwovens per year and its OEM production has been entrusted to a Chinese PET spunbonded nonwovens maker since spring 2007 for the manufacture of automotive materials. Additionally, Kureha, Toyobo’s subsidiary, produces resin bonded, needlepunched, thermal bonded and spunbond nonwovens with a capacity of about 7000 tons per year. Its other subsidiary Yuho makes needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.
As for the PET spunbonded nonwovens of Toyobo, about 30-40% of this material targets the automotives business and Kureha’s business is about 60% related to automotives, meaning that Toyobo is quite dependent on this market. As this market has undergone significant decreases so has Toyobo’s income.
That said, Toyobo has defended itself by improving its nonwoven products. The company’s policy is to focus on the development of added-value properties to raise the processing percentage of the raw materials by strengthening the cooperation with the group enterprises. In addition, Toyobo intends to move forward with the development of new applications for spunbonded nonwovens by integrating new polymers into its processes. This has opened up new applications, namely nonwovens with stretch properties which have already been developed and mass production should be underway by the end of 2009. Furthermore, Toyobo’s strategy of enhancing manufacturing efficiency and quality, has been achieved by upgrading older equipment and facilities. Meanwhile, the crude oil prices and business fluctuations have been intensive in the market.
Location: Tokyo, Japan
Sales: $144 million
Description: Personnel
Yukio Kawasaki, general manager, spunbond division of Toyobo; Akio Oda, president of Kureha
Plants
Tsuruga, Iwakuni, Shiga, Japan
Processes
Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded, stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo’s annual production of polyester spunbond nonwovens is 12,000 tons while its subsidiary Kureha makes resin bonded, needlepunched, thermal bonded and spunbonded nonwovens with a capacity of about 7000 tons. Its Yuho subsidiary makes needlepunch, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.
Toyobo added a new spunbond line in 2008 but this line had not become operational until recently because of the rapid decline in production. Production on the new line replaces capacity made on an older line which was shut down in October 2009. The result of these efforts was a drop in spunbond nonwovens production from 14,000 to 12,000 tons.
In 2009, sales volumes decreased as many of the company’s core markets—automotives, construction, geotextiles and civil engineering—suffered. The main uses of Toyobo’s spunbond nonwovens are automotives, construction and civil engineering which together account for 80-85% of the total. Therefore, it is necessary for activity in these markets to recover for the company to return to success.
To help speed this along, Toyobo is developing new products for new applications. These include filters, insulation materials, sound absorption materials and hygienic goods. Yet, the spunbonded nonwovens made from polymers other than polyester are also necessary and the new products of other polymers have been pushed forward to development.
Overseas, Kureha has been making automotive filters in Thailand and the U.S. Meanwhile, in China the company has been expanding outside the automotives market in China as the use of nonwovens has been increasing in usage.
Sales: $144 million
Description: Personnel
Yukio Kawasaki, general manager, spunbond division of Toyobo; Akio Oda, president of Kureha
Plants
Tsuruga, Iwakuni, Shiga, Japan
Processes
Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded, stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Kurehalock, Dynac
Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo’s annual production of polyester spunbond nonwovens is 12,000 tons while its subsidiary Kureha makes resin bonded, needlepunched, thermal bonded and spunbonded nonwovens with a capacity of about 7000 tons. Its Yuho subsidiary makes needlepunch, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.
Toyobo added a new spunbond line in 2008 but this line had not become operational until recently because of the rapid decline in production. Production on the new line replaces capacity made on an older line which was shut down in October 2009. The result of these efforts was a drop in spunbond nonwovens production from 14,000 to 12,000 tons.
In 2009, sales volumes decreased as many of the company’s core markets—automotives, construction, geotextiles and civil engineering—suffered. The main uses of Toyobo’s spunbond nonwovens are automotives, construction and civil engineering which together account for 80-85% of the total. Therefore, it is necessary for activity in these markets to recover for the company to return to success.
To help speed this along, Toyobo is developing new products for new applications. These include filters, insulation materials, sound absorption materials and hygienic goods. Yet, the spunbonded nonwovens made from polymers other than polyester are also necessary and the new products of other polymers have been pushed forward to development.
Overseas, Kureha has been making automotive filters in Thailand and the U.S. Meanwhile, in China the company has been expanding outside the automotives market in China as the use of nonwovens has been increasing in usage.
Osaka, Japan
www.toyobo.co.jp
2011 Nonwovens Sales: $164 million
Key Personnel: Shigeki Tanaka, general manager of spunbond division; Akio Oda, president
Plants: Tsuruga, Iwakuni and Shiga, Japan
Processes: Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded, stitch bonded
Brands: Volans, Ecule, Bonden, Kurelock, Dynac
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Production capacity of polyester spunbond nonwovens at Toyobo is 12,000 tons per year. Kureha, a subsidiary of Toyobo, produces resin bonded, needlepunch, thermal bonded and spunbond nonwovens with a capacity of 7,000 tons per year. Yuho, also a subsidiary of Toyobo, has made needlepunched, spunlaced and stitch bonded nonwovens with a capacity of about 3,000 tons per year.
Polyester spunbond nonwovens made by Toyobo are largely sold for automotive applications. Sales have been mostly flat during the last year despite the recovery seen during the second half.
Kureha also sells a large amount of nonwovens for automotives and has been affected by a reduction in domestic demand caused by an increase in overseas production. This has led Kureha to focus on new product development.
One area of success has been in automotive filters, a product Kureha makes in both Japan and Thailand, which aids in supply to China. Additionally, the company plans to begin manufacturing of automotive filter material in Taiwan by the end of 2012, which will also supply the Chinese market.
www.toyobo.co.jp
2011 Nonwovens Sales: $164 million
Key Personnel: Shigeki Tanaka, general manager of spunbond division; Akio Oda, president
Plants: Tsuruga, Iwakuni and Shiga, Japan
Processes: Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded, stitch bonded
Brands: Volans, Ecule, Bonden, Kurelock, Dynac
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Production capacity of polyester spunbond nonwovens at Toyobo is 12,000 tons per year. Kureha, a subsidiary of Toyobo, produces resin bonded, needlepunch, thermal bonded and spunbond nonwovens with a capacity of 7,000 tons per year. Yuho, also a subsidiary of Toyobo, has made needlepunched, spunlaced and stitch bonded nonwovens with a capacity of about 3,000 tons per year.
Polyester spunbond nonwovens made by Toyobo are largely sold for automotive applications. Sales have been mostly flat during the last year despite the recovery seen during the second half.
Kureha also sells a large amount of nonwovens for automotives and has been affected by a reduction in domestic demand caused by an increase in overseas production. This has led Kureha to focus on new product development.
One area of success has been in automotive filters, a product Kureha makes in both Japan and Thailand, which aids in supply to China. Additionally, the company plans to begin manufacturing of automotive filter material in Taiwan by the end of 2012, which will also supply the Chinese market.
Osaka, Japan
www.toyobo.co.jp
2012 Nonwovens Sales: $129 million
Key Personnel: Shigeki Tanak, general manager, spunbond division; Akio Oda, president of Kureha
Plants: Tsuruga, Iwakini, Shiga
Processes: Spunbond, needlepunch, resin bonded, thermal bonded, spunlaced, stitch bonded
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Production capacity of Toyobo is 12,000 tons per years. Kureha is a subsidiary of Toyobo and has a capacity of about 7000 tons per year within resin bonded, needlepunch, thermal bonded and spunbond technologies. Another subsidiary, Yuho, makes needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.
Although the polyester spunbond nonwovens made by Toyobo failed to raise sales in 2012, sales in this segment are increasing in 2013 due to the fallout from the great earthquake in east Japan. This has increased demand for materials used in the reconstruction of the disaster area, namely geotextile materials which are produced by Toyobo.
Meanwhile, Kureha is a large producer of air filter material for mobile engines and is producing the filters in Japan and Thailand. To meet Chinese demand, the company exports products from Kureha Thailand, which is also meeting increasing demand for products domestically.
To help Kureha meet demand, both within Thailand and abroad, the company updated its facilities in June 2013. Other growth areas include Indonesia.
In new product news, Toyobo has developed a cushion material out of polyester nonwovens, which are being sold under the trade name Breathair as seat cushioning in trains and mattresses. Breathair is both breathable and durable and can be recycled without releasing harmful gases. Toyobo will next expand production of these materials to Europe where demand for environmentally sound and recyclable products is strong. A new facility able to make 1000 tons of the material per year is currently beginning operation.
www.toyobo.co.jp
2012 Nonwovens Sales: $129 million
Key Personnel: Shigeki Tanak, general manager, spunbond division; Akio Oda, president of Kureha
Plants: Tsuruga, Iwakini, Shiga
Processes: Spunbond, needlepunch, resin bonded, thermal bonded, spunlaced, stitch bonded
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Production capacity of Toyobo is 12,000 tons per years. Kureha is a subsidiary of Toyobo and has a capacity of about 7000 tons per year within resin bonded, needlepunch, thermal bonded and spunbond technologies. Another subsidiary, Yuho, makes needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.
Although the polyester spunbond nonwovens made by Toyobo failed to raise sales in 2012, sales in this segment are increasing in 2013 due to the fallout from the great earthquake in east Japan. This has increased demand for materials used in the reconstruction of the disaster area, namely geotextile materials which are produced by Toyobo.
Meanwhile, Kureha is a large producer of air filter material for mobile engines and is producing the filters in Japan and Thailand. To meet Chinese demand, the company exports products from Kureha Thailand, which is also meeting increasing demand for products domestically.
To help Kureha meet demand, both within Thailand and abroad, the company updated its facilities in June 2013. Other growth areas include Indonesia.
In new product news, Toyobo has developed a cushion material out of polyester nonwovens, which are being sold under the trade name Breathair as seat cushioning in trains and mattresses. Breathair is both breathable and durable and can be recycled without releasing harmful gases. Toyobo will next expand production of these materials to Europe where demand for environmentally sound and recyclable products is strong. A new facility able to make 1000 tons of the material per year is currently beginning operation.
Osaka, Japan
www.toyobo.co.jp
2013 Nonwovens Sales: $129 million
Key personnel
Shigeki Tanaka, general manager, spunbond division; Akio Oda, president of Kureha
Plants
Tsuruga, Iwakuni, Shiga
Processes
Spunbond, needlepunch, resin bonded, spunlace, thermal bonded, stitch bonded
Brand names
Volans, Ecule, Bonden, Kurelock, Dynac
Major markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Installation of a new pilot line, capable of making 1,500 tons of spunbond polyester material per year is currently underway. When complete the new line will enable Toyobo, which already operates a 12,000-ton PET spunbond line, to improve its focus on new product development. In 2013, the company reported increased sales of this technology, owing to favorable conditions in engineering, construction and automotive markets.
Within automotives, Toyobo, sources spunbond polyester from two Chinese companies, which it then sells in the Chinese market. The company is reportedly hoping to enter the North American market soon either with a similar outsourcing setup or through its own manufacturing assets.
According to the company, demand for civil engineering products have grown in Japan following the great earthquake in 2011. As repairs continue the company has seen increased need for geotextile products.
Meanwhile, Kureha, Toyobo’s subsidiary, can make resin bonded, neeldepunched, thermal bonded and spunbondned materials, all with a capacity of 7000 tons per year, as well as needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3,000 tons per year.
Kureha is a large producer of air filters for mobile engines and has made filters in Japan, Thailand and Taiwan and may soon establish a production base in India possibly with its current Indian partner, Arvind. Kureha already operates a joint venture with Arvind in India making needlepunch nonwovens for bag filters. Established in June 2014 and capable of making 1,500 tons of material, the joint venture relies on Kureha’s technical guidance and Arvind’s manufacturing assets.
www.toyobo.co.jp
2013 Nonwovens Sales: $129 million
Key personnel
Shigeki Tanaka, general manager, spunbond division; Akio Oda, president of Kureha
Plants
Tsuruga, Iwakuni, Shiga
Processes
Spunbond, needlepunch, resin bonded, spunlace, thermal bonded, stitch bonded
Brand names
Volans, Ecule, Bonden, Kurelock, Dynac
Major markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Installation of a new pilot line, capable of making 1,500 tons of spunbond polyester material per year is currently underway. When complete the new line will enable Toyobo, which already operates a 12,000-ton PET spunbond line, to improve its focus on new product development. In 2013, the company reported increased sales of this technology, owing to favorable conditions in engineering, construction and automotive markets.
Within automotives, Toyobo, sources spunbond polyester from two Chinese companies, which it then sells in the Chinese market. The company is reportedly hoping to enter the North American market soon either with a similar outsourcing setup or through its own manufacturing assets.
According to the company, demand for civil engineering products have grown in Japan following the great earthquake in 2011. As repairs continue the company has seen increased need for geotextile products.
Meanwhile, Kureha, Toyobo’s subsidiary, can make resin bonded, neeldepunched, thermal bonded and spunbondned materials, all with a capacity of 7000 tons per year, as well as needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3,000 tons per year.
Kureha is a large producer of air filters for mobile engines and has made filters in Japan, Thailand and Taiwan and may soon establish a production base in India possibly with its current Indian partner, Arvind. Kureha already operates a joint venture with Arvind in India making needlepunch nonwovens for bag filters. Established in June 2014 and capable of making 1,500 tons of material, the joint venture relies on Kureha’s technical guidance and Arvind’s manufacturing assets.
Toyobo
Osaka, Japan
www.toyobo-global.com
2014 Nonwovens Sales: $109 million
Key Personnel
Shigeki Tanaka, general manager, spunbonded division of Toyobo; Masakazu Saito, president of Kureha
Plants
Tsuruga, Japan; Iwakuni, Japan; Shiga, Japan
Processes
Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded, stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
The production capacity of Toyobo’s PET spunbond nonwovens is 12,000 tons/year, but a pilot plant producing 1500 tons/year was introduced last year. Toyobo’s subsidiary Kureha has produced resin bonded, needlepunched, thermal bonded and spunbond nonwovens, each with the capacity of about 7000 tons/year. Kureha is a major producer of air filters for mobile engines, and has produced filters in Japan, Thailand, Taiwan and the U.S. Another leading product for Kureha is its plaster based cloth, but due to the decrease in domestic demand for the material, part of the production facility making it was altered to produce materials for automotives.
Yuho, another subsidiary of the company, has also produced needlepunched, spunlaced and stitch bonded nonwovens each with the capacity of about 3000 tons/year.
According to the company, among its products for consumer and industrial uses, sales of Breathair, a functional cushion material, held firm, and sales of its spunbond nonwovens—mainly supplied to the civil engineering and construction industries—expanded.
Breathair is a polyester nonwoven of a thermoplasticity elastomer. Toyoba’s Tsuruga facility has a capacity of 2200 tons/year on two lines and its Orbenburg facility in Germany has a capacity of 1100 tons/year on one line. Because of the characteristics of Breathair, a breathable material that’s lightweight, is superior in durability and workability, and maintains a bulking power even when it’s used long term, demands for the finished goods are increasing for seat cushioning in the railway vehicles, bed mats, couches, mats for care, mats for leisure, etc.
Due to the increasing demand, the company may add 1100 tons/year in 2017, and add another 1100 tons/year by 2020.’’
Osaka, Japan
www.toyobo-global.com
2014 Nonwovens Sales: $109 million
Key Personnel
Shigeki Tanaka, general manager, spunbonded division of Toyobo; Masakazu Saito, president of Kureha
Plants
Tsuruga, Japan; Iwakuni, Japan; Shiga, Japan
Processes
Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded, stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
The production capacity of Toyobo’s PET spunbond nonwovens is 12,000 tons/year, but a pilot plant producing 1500 tons/year was introduced last year. Toyobo’s subsidiary Kureha has produced resin bonded, needlepunched, thermal bonded and spunbond nonwovens, each with the capacity of about 7000 tons/year. Kureha is a major producer of air filters for mobile engines, and has produced filters in Japan, Thailand, Taiwan and the U.S. Another leading product for Kureha is its plaster based cloth, but due to the decrease in domestic demand for the material, part of the production facility making it was altered to produce materials for automotives.
Yuho, another subsidiary of the company, has also produced needlepunched, spunlaced and stitch bonded nonwovens each with the capacity of about 3000 tons/year.
According to the company, among its products for consumer and industrial uses, sales of Breathair, a functional cushion material, held firm, and sales of its spunbond nonwovens—mainly supplied to the civil engineering and construction industries—expanded.
Breathair is a polyester nonwoven of a thermoplasticity elastomer. Toyoba’s Tsuruga facility has a capacity of 2200 tons/year on two lines and its Orbenburg facility in Germany has a capacity of 1100 tons/year on one line. Because of the characteristics of Breathair, a breathable material that’s lightweight, is superior in durability and workability, and maintains a bulking power even when it’s used long term, demands for the finished goods are increasing for seat cushioning in the railway vehicles, bed mats, couches, mats for care, mats for leisure, etc.
Due to the increasing demand, the company may add 1100 tons/year in 2017, and add another 1100 tons/year by 2020.’’
Osaka, Japan
www.toyobo.co.jp
2015 Nonwoven Sales: $137 million
Key Personnel
Shigeki Tanaka, general manager, spunbond division of Toyobo; Masakazu Saito, president of Kureha
Plants
Tsuruga, Iwakuni and Shiga
Processes
Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded and stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bending sheets, plaster bases
Toyobo makes 12,000 tons of polyester spunbond nonwovens as well as an additional 1500 tons on a pilot plant. Kureha, a subsidiary of Toyobo, makes resin bonded needlepunched, thermal bonded and spunbonded nonwovens with an annual capacity of 7000 tons per year , and You, another subsidiary of the company, has been making needlepunched, spunlaced and stitch bonded nonwovens with a capacity of about 3000 tons per year.
The use of polyester spunbonded nonwovens for automotives has increased mainly driven by growth in North America which offset declines in construction materials in 2015. Toyobo has not yet made PET spunbond nonwovens outside of Japan and instead outsources production to five nonwovens manufacturers abroad. Therefore, sales of spunbond nonwovens exceed capacity.
Growth of spunbond polyester in Japan has been difficult, so growth in the future will depend on exports. Kureha hopes to increase the percentage of exports from 20% to 40%. To achieve this, establishing a production base outside of Japan is being considered. Two main strategies are focusing on exports to the U.S. and working with Chinese OEMs.
Kureha is a large producer of air filters for mobile engines and they make these filters in Japan, Thailand, Taiwan and the U.S. Because of filters for engines tending to shift to the paper type of wetlaid nonwovens, the production of filters for engines failed to rise while sales of cabin filter media has increased. Although the business performance of Kureaha Thailand showed favorable trends in automotives, sales have decreased in the U.S.
www.toyobo.co.jp
2015 Nonwoven Sales: $137 million
Key Personnel
Shigeki Tanaka, general manager, spunbond division of Toyobo; Masakazu Saito, president of Kureha
Plants
Tsuruga, Iwakuni and Shiga
Processes
Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded and stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bending sheets, plaster bases
Toyobo makes 12,000 tons of polyester spunbond nonwovens as well as an additional 1500 tons on a pilot plant. Kureha, a subsidiary of Toyobo, makes resin bonded needlepunched, thermal bonded and spunbonded nonwovens with an annual capacity of 7000 tons per year , and You, another subsidiary of the company, has been making needlepunched, spunlaced and stitch bonded nonwovens with a capacity of about 3000 tons per year.
The use of polyester spunbonded nonwovens for automotives has increased mainly driven by growth in North America which offset declines in construction materials in 2015. Toyobo has not yet made PET spunbond nonwovens outside of Japan and instead outsources production to five nonwovens manufacturers abroad. Therefore, sales of spunbond nonwovens exceed capacity.
Growth of spunbond polyester in Japan has been difficult, so growth in the future will depend on exports. Kureha hopes to increase the percentage of exports from 20% to 40%. To achieve this, establishing a production base outside of Japan is being considered. Two main strategies are focusing on exports to the U.S. and working with Chinese OEMs.
Kureha is a large producer of air filters for mobile engines and they make these filters in Japan, Thailand, Taiwan and the U.S. Because of filters for engines tending to shift to the paper type of wetlaid nonwovens, the production of filters for engines failed to rise while sales of cabin filter media has increased. Although the business performance of Kureaha Thailand showed favorable trends in automotives, sales have decreased in the U.S.
Osaka, Japan
www.toyobo.co.jp
2016 Nonwovens Sales: $125 million
Key Personnel
Shigeki Tanaka, general manager, spunbond division of Toyobo; Masakazu Saito, president of Kureha
Plants
Tsuruga, Iwakuni and Shiga, Japan
Processes
Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded and stitch bonded
Brands
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bending sheets, plaster bases
Toyobo makes 12,000 tons of polyester spunbond nonwovens. Kureha, a subsidiary of Toyobo, makes resin bonded needlepunched, thermal bonded and spunbonded nonwovens, each with an annual capacity of 7000 tons per year, and Yuho, another subsidiary of the company, has been making needlepunched, spunlaced and stitch bonded nonwovens with a capacity of about 3000 tons per year.
The three major applications for polyester-based spunbond nonwovens are automotives, engineering and construction. The use of the materials in automotives is expanding while it is retracting in engineering and construction. Toyobo’s nonwovens are used in various automotive parts and its business is growing particularly strongly in China and North America. Business is so strong in North America, in fact, the company is considering establishing a production base there—either with another company or alone.
Sales of Kureha’s main automotive filters have been decreasing as the market is shifting from drylaid to wetlaid nonwovens. However, the use of Kureha’s filters in every other market is growing quickly, not just in Japan, but also in Thailand and the U.S., and the company is developing new applications for its filter media.
www.toyobo.co.jp
2016 Nonwovens Sales: $125 million
Key Personnel
Shigeki Tanaka, general manager, spunbond division of Toyobo; Masakazu Saito, president of Kureha
Plants
Tsuruga, Iwakuni and Shiga, Japan
Processes
Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded and stitch bonded
Brands
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bending sheets, plaster bases
Toyobo makes 12,000 tons of polyester spunbond nonwovens. Kureha, a subsidiary of Toyobo, makes resin bonded needlepunched, thermal bonded and spunbonded nonwovens, each with an annual capacity of 7000 tons per year, and Yuho, another subsidiary of the company, has been making needlepunched, spunlaced and stitch bonded nonwovens with a capacity of about 3000 tons per year.
The three major applications for polyester-based spunbond nonwovens are automotives, engineering and construction. The use of the materials in automotives is expanding while it is retracting in engineering and construction. Toyobo’s nonwovens are used in various automotive parts and its business is growing particularly strongly in China and North America. Business is so strong in North America, in fact, the company is considering establishing a production base there—either with another company or alone.
Sales of Kureha’s main automotive filters have been decreasing as the market is shifting from drylaid to wetlaid nonwovens. However, the use of Kureha’s filters in every other market is growing quickly, not just in Japan, but also in Thailand and the U.S., and the company is developing new applications for its filter media.
Osaka, Japan
www.toyobo-global.com
2017 Nonwovens Sales: $135 million
Key Personnel
Shigeki Tanaka, general manager, spunbond division; Masakazu Saito, president, Kureha
Plants
Tsuruga, Iwakuni, Shiga, Japan
Processes
Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynak, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo has been producing polyester spunbond nonwoven fabrics with 12,000 tons of capacity per year while its subsidiary Kureha makes 7000 tons of chemical bonded, needlepunched, thermal bonded and spunbonded nonwovens per year. Yuho, also a subsidiary, makes 3000 tons of needlepunched, spunlaced and stitchbonded nonwovens per year.
Polyester spunbond nonwoven fabric has been made at two plants in Tsuruga and Iwakuni, as well as at an OEM production facility in China. As the ratio of OEM production has risen, Toyobo is going to raise its in-house production in terms of quality and costs. Capital spending at Toyobo is necessary for that purpose and Japan, Asia and North America are all being considered for the company’s next production center.
The use of Toyobo’s polyester spunbond fabrics has been increasing as the use of these materials in cars has been increasing, particularly in the seat covers. The cover material made by Toyobo is a leather-like processed nonwoven fabric. The material is lightweight and superior in durability and, most importantly, it complies with VOC regulations. This has been driving demand in China where environmental regulations are increasing.
In Kureha, the demand for air filters for the car engine air filtration, its main product, has been sluggish because of the increasing use of electric cars which don’t use as many filtration materials. To make up for these decreases, Kureha is developing sound absorption materials, or sound absorbers for cars and battery cooling filtration media, which are still widely used in electric cars.
www.toyobo-global.com
2017 Nonwovens Sales: $135 million
Key Personnel
Shigeki Tanaka, general manager, spunbond division; Masakazu Saito, president, Kureha
Plants
Tsuruga, Iwakuni, Shiga, Japan
Processes
Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynak, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo has been producing polyester spunbond nonwoven fabrics with 12,000 tons of capacity per year while its subsidiary Kureha makes 7000 tons of chemical bonded, needlepunched, thermal bonded and spunbonded nonwovens per year. Yuho, also a subsidiary, makes 3000 tons of needlepunched, spunlaced and stitchbonded nonwovens per year.
Polyester spunbond nonwoven fabric has been made at two plants in Tsuruga and Iwakuni, as well as at an OEM production facility in China. As the ratio of OEM production has risen, Toyobo is going to raise its in-house production in terms of quality and costs. Capital spending at Toyobo is necessary for that purpose and Japan, Asia and North America are all being considered for the company’s next production center.
The use of Toyobo’s polyester spunbond fabrics has been increasing as the use of these materials in cars has been increasing, particularly in the seat covers. The cover material made by Toyobo is a leather-like processed nonwoven fabric. The material is lightweight and superior in durability and, most importantly, it complies with VOC regulations. This has been driving demand in China where environmental regulations are increasing.
In Kureha, the demand for air filters for the car engine air filtration, its main product, has been sluggish because of the increasing use of electric cars which don’t use as many filtration materials. To make up for these decreases, Kureha is developing sound absorption materials, or sound absorbers for cars and battery cooling filtration media, which are still widely used in electric cars.
Osaka, Japan
www.toyobo-global.com
2018 Nonwovens Sales: $146 million
Key Personnel
Kazuyuki Kawata, general manager, AC, SB division of Toyobo; Hironori Tanaka, president of Kureha
Plants
Tsuruga, Iwakuni, Shiga, Japan
Processes
Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynak, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo produces polyester spunbond nonwovens with the capacity of 12,000 tons/year, and Kureha, in the Toyobo group, manufactures chemical bonded, needlepunch, thermal bonded, and spunbond with the capacity of approximately 7000 tons/year. And Yuho, also in the Toyobo group, produces needlepunch, spunlace and stitch bonded nonwovens with the capacity of 3000 tons/year.
Demand in motor vehicle use has grown Toyobo’s polyester spunbond nonwovens. Above all, the increase in tonneau covers is remarkable. The demand for seats coated with a heavy metal ion adsorbent to the polyester spunbond nonwovens (trade: name Cosmofresh NANO) has come into wide use. A lot of heavy metal derived from nature is included in soil in Japan, and the law requires dealing with heavy metal not being able to flow out from temporary storage space of the remaining soil occurring in the case of the building of public works or in the case of reutilization. Construction of the linear central Shinkansen (railway lines) has begun in Japan this year. As for this Shinkansen, there will be a many tunnels. So, a large quantity of remaining soil will be calculated by this tunnel construction, and the water including the heavy metal ion may flow out from remaining soil. Cosmofresh NANO is suitable to remove the heavy metal ion from the channel. The construction of the linear central Shinkansen will be continued for a long term in the future, and, 86% of the full length of the line are tunnels, so great demand is expected.
Kureha lays emphasis on sale of Kurebulker produced by the spunbonding method. Kurebulker is a bulky nonwoven fabric with cushion characteristics, and bulky sense and soundproofing characteristics are provided if it is spread under the carpet. It is used as sound absorption material for motor vehicles.
www.toyobo-global.com
2018 Nonwovens Sales: $146 million
Key Personnel
Kazuyuki Kawata, general manager, AC, SB division of Toyobo; Hironori Tanaka, president of Kureha
Plants
Tsuruga, Iwakuni, Shiga, Japan
Processes
Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynak, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo produces polyester spunbond nonwovens with the capacity of 12,000 tons/year, and Kureha, in the Toyobo group, manufactures chemical bonded, needlepunch, thermal bonded, and spunbond with the capacity of approximately 7000 tons/year. And Yuho, also in the Toyobo group, produces needlepunch, spunlace and stitch bonded nonwovens with the capacity of 3000 tons/year.
Demand in motor vehicle use has grown Toyobo’s polyester spunbond nonwovens. Above all, the increase in tonneau covers is remarkable. The demand for seats coated with a heavy metal ion adsorbent to the polyester spunbond nonwovens (trade: name Cosmofresh NANO) has come into wide use. A lot of heavy metal derived from nature is included in soil in Japan, and the law requires dealing with heavy metal not being able to flow out from temporary storage space of the remaining soil occurring in the case of the building of public works or in the case of reutilization. Construction of the linear central Shinkansen (railway lines) has begun in Japan this year. As for this Shinkansen, there will be a many tunnels. So, a large quantity of remaining soil will be calculated by this tunnel construction, and the water including the heavy metal ion may flow out from remaining soil. Cosmofresh NANO is suitable to remove the heavy metal ion from the channel. The construction of the linear central Shinkansen will be continued for a long term in the future, and, 86% of the full length of the line are tunnels, so great demand is expected.
Kureha lays emphasis on sale of Kurebulker produced by the spunbonding method. Kurebulker is a bulky nonwoven fabric with cushion characteristics, and bulky sense and soundproofing characteristics are provided if it is spread under the carpet. It is used as sound absorption material for motor vehicles.
Osaka, Japan
www.toyobo-global.com
2019 Nonwovens Sales: $146 million
Key Personnel
Kazuyuki Kawata, general manager, AC, SB division of Toyobo; Hironori Tanaka, president of Kureha
Plants
Tsuruga, Iwakuni, Shiga, Japan
Processes
Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynak, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo produces polyester spunbond nonwovens with the capacity of 12,000 tons/year, and Kureha, in the Toyobo group, manufactures chemical bonded, needlepunch, thermal bonded and spunbond with the capacity of approximately 7000 tons/year. And Yuho, also in the Toyobo group, produces needlepunch, spunlace and stitch bonded nonwovens with the capacity of 3000 tons/year.
In recent years, demand in motor vehicle use has grown Toyobo’s polyester spunbond nonwovens but in 2020 this business has been negatively impacted by the coronavirus pandemic, manufacturing shutdowns and weakened consumer demands.
Kurebulker is a bulky nonwoven fabric with cushion characteristics, and bulky sense and soundproofing characteristics are provided if it is spread under the carpet. It is used as sound absorption material for motor vehicles.
In July, Toyobo Co., Ltd. and 11 other companies forming a plastic value chain have jointly established a new company called R Plus Japan, Ltd., which will facilitate the recycling of used plastics to help solve plastics-associated problems and create a more sustainable society. R Plus Japan, which started operating in June, is headed by President Tsunehiko Yokoi and located in Minato-ku, Tokyo. The 11 companies are: Suntory MONOZUKURI Expert Ltd.; Rengo Co., Ltd.; Toyo Seikan Group Holdings, Ltd.; J&T Recycling Corporation; Asahi Group Holdings, Ltd.; Iwatani Corporation; Dai Nippon Printing Co., Ltd.; Toppan Printing Co., Ltd.; Fuji Seal International, Inc.; Hokkai Can Co., Ltd.; Yoshino Kogyosho Co., Ltd. R Plus Japan will continue seeking additional investors, and companies such as Sumitomo Chemical Company are currently considering joining.
Toyobo Group has provided many products and technologies to help solve social problems since its inception, based on its corporate philosophy “Jun-Ri-Soku-Yu” (Adhering to reason leads to prosperity) that embodied the spirit advocated by its founder Eiichi Shibusawa. The group is determined to create a more sustainable society by developing products and technologies that reduce society’s impact on the environment. For example, Toyobo has raised the proportion of recycled resin and plant-derived raw materials in its main plastic products and manufactured and sold highly functional bioplastics.
Toyobo has long admired a technology U.S. biochemical venture company Anellotech, Inc., developed to make raw materials for polyester from wood. Since 2017, Toyobo has been involved in a project in which Anellotech, the Suntory Group and other companies in Japan and elsewhere are developing polyethylene terephthalate (PET) bottles made entirely of plant-derived materials. Application of this groundbreaking technology likely will pave the way for effectively recycling used plastics and the increased cyclical use of plastics.
www.toyobo-global.com
2019 Nonwovens Sales: $146 million
Key Personnel
Kazuyuki Kawata, general manager, AC, SB division of Toyobo; Hironori Tanaka, president of Kureha
Plants
Tsuruga, Iwakuni, Shiga, Japan
Processes
Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynak, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo produces polyester spunbond nonwovens with the capacity of 12,000 tons/year, and Kureha, in the Toyobo group, manufactures chemical bonded, needlepunch, thermal bonded and spunbond with the capacity of approximately 7000 tons/year. And Yuho, also in the Toyobo group, produces needlepunch, spunlace and stitch bonded nonwovens with the capacity of 3000 tons/year.
In recent years, demand in motor vehicle use has grown Toyobo’s polyester spunbond nonwovens but in 2020 this business has been negatively impacted by the coronavirus pandemic, manufacturing shutdowns and weakened consumer demands.
Kurebulker is a bulky nonwoven fabric with cushion characteristics, and bulky sense and soundproofing characteristics are provided if it is spread under the carpet. It is used as sound absorption material for motor vehicles.
In July, Toyobo Co., Ltd. and 11 other companies forming a plastic value chain have jointly established a new company called R Plus Japan, Ltd., which will facilitate the recycling of used plastics to help solve plastics-associated problems and create a more sustainable society. R Plus Japan, which started operating in June, is headed by President Tsunehiko Yokoi and located in Minato-ku, Tokyo. The 11 companies are: Suntory MONOZUKURI Expert Ltd.; Rengo Co., Ltd.; Toyo Seikan Group Holdings, Ltd.; J&T Recycling Corporation; Asahi Group Holdings, Ltd.; Iwatani Corporation; Dai Nippon Printing Co., Ltd.; Toppan Printing Co., Ltd.; Fuji Seal International, Inc.; Hokkai Can Co., Ltd.; Yoshino Kogyosho Co., Ltd. R Plus Japan will continue seeking additional investors, and companies such as Sumitomo Chemical Company are currently considering joining.
Toyobo Group has provided many products and technologies to help solve social problems since its inception, based on its corporate philosophy “Jun-Ri-Soku-Yu” (Adhering to reason leads to prosperity) that embodied the spirit advocated by its founder Eiichi Shibusawa. The group is determined to create a more sustainable society by developing products and technologies that reduce society’s impact on the environment. For example, Toyobo has raised the proportion of recycled resin and plant-derived raw materials in its main plastic products and manufactured and sold highly functional bioplastics.
Toyobo has long admired a technology U.S. biochemical venture company Anellotech, Inc., developed to make raw materials for polyester from wood. Since 2017, Toyobo has been involved in a project in which Anellotech, the Suntory Group and other companies in Japan and elsewhere are developing polyethylene terephthalate (PET) bottles made entirely of plant-derived materials. Application of this groundbreaking technology likely will pave the way for effectively recycling used plastics and the increased cyclical use of plastics.
Osaka, Japan
www.toyobo.co.jp
2020 Nonwovens Sales: $127 million
Key Personnel
Kozi Nishizaka, general manager, spunbond; Hironori Tanaka, president, Kureha
Plants
Tsuruga, Iwakuni and Shiga, Japan
Processes
Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo has made PET spunbond nonwoven fabrics with a capacity of 12,000 tons per year and Kureha, a member of the group, has been making chemical bonded, needlepunch, thermal bonded and spunbonded nonwovens with a capacity of 7000 tons per year. Similarly, Yuho, another member of the Toyobo group, has made needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.
In 2020, many of Toyobo’s core markets like automotives, engineering and construction, were weakened by shutdowns caused by the coronavirus pandemic. While the automotive business rebounded later in the year, it was unable to compensate for earlier problems.
Meanwhile, the company’s filtration business in air filters and face masks grew significantly.
Additionally, in 2020 Toyobo took advantage of government subsidies to diversify its business into polypropylene-based nonwovens. The company will soon begin making both spunbond and meltblown polypropylene-based nonwovens.
www.toyobo.co.jp
2020 Nonwovens Sales: $127 million
Key Personnel
Kozi Nishizaka, general manager, spunbond; Hironori Tanaka, president, Kureha
Plants
Tsuruga, Iwakuni and Shiga, Japan
Processes
Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitch bonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo has made PET spunbond nonwoven fabrics with a capacity of 12,000 tons per year and Kureha, a member of the group, has been making chemical bonded, needlepunch, thermal bonded and spunbonded nonwovens with a capacity of 7000 tons per year. Similarly, Yuho, another member of the Toyobo group, has made needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.
In 2020, many of Toyobo’s core markets like automotives, engineering and construction, were weakened by shutdowns caused by the coronavirus pandemic. While the automotive business rebounded later in the year, it was unable to compensate for earlier problems.
Meanwhile, the company’s filtration business in air filters and face masks grew significantly.
Additionally, in 2020 Toyobo took advantage of government subsidies to diversify its business into polypropylene-based nonwovens. The company will soon begin making both spunbond and meltblown polypropylene-based nonwovens.
Osaka, Japan
www.toyobo.co.jp
2021 Nonwovens Sales: $114 million
Key Personnel
Kozi Nishizaka, general manager, spunbond; Hironori Tanaka, president, Kureha
Plants
Tsuruga, Iwakuni and Shiga, Japan
Processes
Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo makes PET spunbond nonwoven fabrics with a capacity of 12,000 tons per year and Kureha, a member of the group, has been making chemical bonded, needlepunch, thermal bonded and spunbonded nonwovens with a capacity of 7000 tons per year. Similarly, Yuho, another member of the Toyobo group, has made needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.
Toyobo has been focused on the development of PET spunbond nonwovens using recycled PET and bioPET resins to create more sustainable products. The PET resin is made using recycled water bottles and is mixed with virgin PET to make nonwovens under the e-Volans brand name. e-Volans are being used in geotexitles, and Toyobo is working to increase the percentage of recycled PET used in these applications.
For Toyobo's 2020 top company profile, click here.
www.toyobo.co.jp
2021 Nonwovens Sales: $114 million
Key Personnel
Kozi Nishizaka, general manager, spunbond; Hironori Tanaka, president, Kureha
Plants
Tsuruga, Iwakuni and Shiga, Japan
Processes
Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitchbonded
Brand Names
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Toyobo makes PET spunbond nonwoven fabrics with a capacity of 12,000 tons per year and Kureha, a member of the group, has been making chemical bonded, needlepunch, thermal bonded and spunbonded nonwovens with a capacity of 7000 tons per year. Similarly, Yuho, another member of the Toyobo group, has made needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.
Toyobo has been focused on the development of PET spunbond nonwovens using recycled PET and bioPET resins to create more sustainable products. The PET resin is made using recycled water bottles and is mixed with virgin PET to make nonwovens under the e-Volans brand name. e-Volans are being used in geotexitles, and Toyobo is working to increase the percentage of recycled PET used in these applications.
For Toyobo's 2020 top company profile, click here.
Osaka, Japan
www.osaka.co.jp
2022 Nonwovens Sales: $108 million
Key Personnel
Soichi Inoue, head of sales section, nonwoven material; Hironori Tanaka, president of Kureha
Plants
Tsuruga, Iwakuni and Shiga, Japan
Processes
Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitch bonded
Brand names
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major markets
Geotextiles, roofing sheets ,carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Production capacity of PET spunbond nonwoven fabrics at Toyobo is 12,000 tons per year. Kureha, an affiliate of Toyobo, produces chemical bonded, needlepunch, thermal bonded and spunbond nonwovens with a capacity of about 7000 tons per year for each technology. Similarly, Yuho, another affiliate of Toyobo, manufactures needlepunch, spunlaced and stitchbonded nonwovens with a capacity of about 3000 tons each. While sales increased in 2022, profits declined due to rising raw material prices.
In April 2023, Toyobo established Toyobo MC, a joint venture company with Mitsubishi and transferred its nonwovens business to the company. Toyobo MC is owned 51% by Toyobo and 49% by Mitsubishi, and the former Toyobo subsidiaries became owned by Toyobo MC. The purposes of this joint venture company is to promote the growth of functional nonwoven products globally by combining Toyobo’s technology know-how with Mitsubishi’s global network.
Main products for the PET spunbond include automotive, construction and civil engineering. In automotive applications, tonneau covers made of spunbond nonwoven fabrics have been trending favorably and other applications include carpet backing, insulator surface materials, fender liners and under covers. In construction applications, it is mostly used for roofing sheets. In civil engineering applications, demand is beginning to expand with the adoption of a new product, a heavy metal ions adsorption sheet. In the production development of the PET spunbonded nonwoven fabrics, the company is developing nonwoven fabrics with superior formability. This development enables advanced, three-dimensional moldings by raising the module of the nonwoven fabrics from 40-50% to nearly 300%. In addition to this, the company is developing a spunbond nonwoven fabrics, under the trade name Bio-Volans, made from bio-PET resins and a spunbond nonwoven fabric, under the trade name e-Volans, made from recycled PET resins.
www.osaka.co.jp
2022 Nonwovens Sales: $108 million
Key Personnel
Soichi Inoue, head of sales section, nonwoven material; Hironori Tanaka, president of Kureha
Plants
Tsuruga, Iwakuni and Shiga, Japan
Processes
Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitch bonded
Brand names
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major markets
Geotextiles, roofing sheets ,carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases
Production capacity of PET spunbond nonwoven fabrics at Toyobo is 12,000 tons per year. Kureha, an affiliate of Toyobo, produces chemical bonded, needlepunch, thermal bonded and spunbond nonwovens with a capacity of about 7000 tons per year for each technology. Similarly, Yuho, another affiliate of Toyobo, manufactures needlepunch, spunlaced and stitchbonded nonwovens with a capacity of about 3000 tons each. While sales increased in 2022, profits declined due to rising raw material prices.
In April 2023, Toyobo established Toyobo MC, a joint venture company with Mitsubishi and transferred its nonwovens business to the company. Toyobo MC is owned 51% by Toyobo and 49% by Mitsubishi, and the former Toyobo subsidiaries became owned by Toyobo MC. The purposes of this joint venture company is to promote the growth of functional nonwoven products globally by combining Toyobo’s technology know-how with Mitsubishi’s global network.
Main products for the PET spunbond include automotive, construction and civil engineering. In automotive applications, tonneau covers made of spunbond nonwoven fabrics have been trending favorably and other applications include carpet backing, insulator surface materials, fender liners and under covers. In construction applications, it is mostly used for roofing sheets. In civil engineering applications, demand is beginning to expand with the adoption of a new product, a heavy metal ions adsorption sheet. In the production development of the PET spunbonded nonwoven fabrics, the company is developing nonwoven fabrics with superior formability. This development enables advanced, three-dimensional moldings by raising the module of the nonwoven fabrics from 40-50% to nearly 300%. In addition to this, the company is developing a spunbond nonwoven fabrics, under the trade name Bio-Volans, made from bio-PET resins and a spunbond nonwoven fabric, under the trade name e-Volans, made from recycled PET resins.
