Karen McIntyre, Editor02.01.22
As demand for disposable wipes continues to be driven by infection control efforts, consumer needs for convenience and a general proliferation of new products in the category, manufacturers of spunlaced nonwovens have responded with a steady stream of line investments both in developed and developing markets. These new lines are not only increasing the overall global capacity of the technology but are also broadening raw material choices for producers who are seeking more sustainable solutions for their customers.
According to a report recently published by Smithers, the global market for spunlace nonwovens was expected to reach $7.8 billion in 2021 as new wipes production lines are added to respond to the surge in demand caused by Covid-19.
As enhanced concerns over infection control will help spunlace production resist any recessionary downturn, the technology is expected to see a 9.1% compound annual growth rate (CAGR) forecast for 2021-2026. This will push total market value to above $12 billion in 2026, as producers also benefit from wider use of the material in coating substrates and hygiene applications.
Smithers’ data set shows that over the same time period the total tonnage of spunlace nonwovens will rise from 1.65 million tons (2021) to 2.38 million tons (2026). While volume of spunlace nonwovens will rise from 39.57 billion square meters (2021) to 62.49 billion square meters (2026) – equivalent to a CAGR of 9.6%—as manufacturers introduce lighter base weight nonwovens.
According to Marco Fano, CMO of equipment supplier Autefa Solutions, the demand for sustainable nonwovens is clear and a leading topic in most discussions with customers in all fields of spunlaced nonwovens from wipes to geotextiles and clothing.
“The fact that spunlaced products can be made with up to 30% less energy consumption, compared to existing traditional spunlace technologies is opening up new markets, even in high fashion products like artificial leather based on natural leather waste and other sustainable products,” he adds.
Autefa Solutions contributes to the increasing importance of resource saving. The V-Jet Injector enables customers to modernize existing production lines with the latest Autefa technology. The crosslapper of the Topliner series, combined with WebMax and closed loop system, prevents the increased weight of the fabric in the edge areas, called the smile effect. This results in an excellent uniformity in the fabric and, thanks to a considerable saving of materials, a reduction in material costs.
A global market leader of spunlaced nonwovens and other wipe substrates, Suominen has taken a lead when it comes to sustainability. “Sustainability is of growing importance to our customers and other stakeholders,” says senior vice president Lynda Kelly. “We help our customers to achieve their own environmental targets by offering them products made from e.g. renewable, recycled, compostable and plastic-free raw materials.”
These new product entries included Biolace Pure, a 100% plant-based product with superior cleaning power, Biolace Bamboo, a bamboo-based substrate. Both of these products provide clear advantages in terms of reducing the CO2 footprint and a lower environmental impact.
As part of a sustainability-focused business strategy introduced last year, Suominen has a goal of increasing sales of sustainable products by 50% by 2025 and to have more than 10 sustainable product launches per year.
Investment Continues
According to David Price, principal of Price Hanna Consultants, the pace of investments in spunlaced nonwovens continues to evolve as the coronavirus and its variants continue to threaten populations across the globe. While overcapacity in the technology existed in nearly all world regions at the start of the pandemic, this capacity was immediately used in the fight against Covid-19 and additional capacity was ordered.
“We don’t think the level of year-over-year investment in hydroentangled or spunlaced nonwovens is significantly different as compared to that in the pre-pandemic period,” he says. “We do think that somewhat elevated capacity growth will continue to be present for a longer period of time as compared to prior periods.”
Smithers data shows that, wipes (baby care, home care, industrial, personal care) account for around 64.7% of all spunlace media produced in 2021. Through to 2026, the fastest growth rates are forecast for personal care wipes, and adult and toddler moist toilet tissues. Demand in durable applications will be more suppressed; although there will be new market opportunities in consumer hygiene with spunlace presenting a sustainable alternative to competing polyester or polypropylene-based nonwovens in applications such as ultrathin topsheets for feminine hygiene pads.
As the imminent threat of Covid recedes, the leading transformative trend across the first half of 2020s will be developing more sustainable nonwovens. Generally, this will benefit spunlace producers, as they work towards the goal of developing a fully plastic-free wipe. This driver will continue to receive a stimulus from the EU’s Single-use Plastics Directive, but there is also strong interest from brand owners in polymer-free wipes that can be marketed as premium eco-friendly products. The main route to achieve this is wider use of rayon, lyocell, wood pulp, cotton and other biodegradable fibers, with a corresponding relative decrease in use of spunbond polypropylene and polypropylene fiber.
In November, Welspun announced it would add a complete neXline spunlace line capable of processing a variety of fibers from Andritz for the production of nonwoven roll goods and wipes for its new plant in Hyderabad, Telangana, India. The line has a capacity of up to three tons per hour.
This line is allowing Welspun to process various types of synthetic or natural fibers, such as polyester, viscose and cotton. The final products will have fabric weights ranging from 25 to 120 gsm, thus covering many applications. This neXline spunlace line also offers the option to integrate a third component from a selection of smart layers, to enable Welspun to manufacture products for the healthcare and hygiene sectors.
“Spunlace manufacturers had already long been experimenting with 100% sustainable products partly or wholly with their portfolio. However, SUP directive in Europe has fast forwarded this process and now from the consumer side there is increased demand of products that are sustainable and that meet all the requirements,” says Tirthankar Mukherjee of Welspun. “On the technology, front the technology providers are also providing various innovations with standalone machine or retrofitting in the existing machine to enable products which can use 100% sustainable plant-based products or in various blend combinations. However, the acceptance of these products largely depends on the requirements of the end use segments.”
Elsewhere in India, industry newcomer Tufropes, a global leader for ropes and netting, is adding a spunlace line Gujarat, India. It is estimated that the line will be commissioned during the first quarter of 2022. Proprietary refinements, which were developed with partners Truetzschler and Voith, will allow Tufropes to produce any possible hydroentangled nonwoven material, including biodegradable, natural fiber, eco-friendly high-performance nonwovens.
Meanwhile, China has been leading the world with investment, both from domestic and international machinery providers, where penetration of disposable wipe products has until recently been low. As this market grows and evolves, new spunlace lines will be needed.
In 2021, Chinese spunlace maker Zhejiang Saintyear Textile Co., Ltd., announced it would add a second spunlace line for the production of premium-quality nonwoven roll goods, just nine months after its initial investment. The line is scheduled for start-up during the third quarter of 2022.
Andritz will provide a full line with state-of-the-art equipment – from web forming to drying. The scope of supply includes the precise opening and blending machinery from Laroche – newly acquired by the Andritz Group, two inline TT cards, a proven JetlaceEssentiel unit for hydroentanglement, and the efficient neXdry through-air dryer.
Li Yi Ming, CEO, says, “Spunlace nonwovens are definitely a must nowadays due to their versatility, and we want to offer our customers the best-quality nonwovens. Hence, we had to go for the benchmarking company in the production of premium roll goods. This is why we have decided to rely on an Andritz nonwovens system offering the best performance and runnability. We have already purchased one complete spunlace line recently from Andritz that will go into operation in mid-2022. Project execution is running so smoothly so far that we did not hesitate to renew our trust by ordering a second line.”
Meanwhile, investment continues in developed markets like Europe and North America in response to increasing demand for wipes as well as more sustainable options for spunlace. In 2021, Fibertex Nonwovens announced investments in spunlace technology at its plants in the Europe and the U.S. In Europe, the company is investing $50 million (DKK300 million) in new capacity at its plants in the Czech Republic and Turkey.
“Demand for our nonwovens has increased significantly in recent years. It concerns particularly the more specialized applications and high-performance materials for the healthcare sector, industrial products, specialist acoustic products for the automotive industry, nanofiltration for industrial purposes, etc. Our business development and research activities over the past 10 years have afforded us a leading position in both Europe and the U.S.,” explains Jørgen Bech Madsen, CEO of Fibertex Nonwovens.
He adds that the coronavirus pandemic has led to an explosive demand for hygiene products, such as disinfectant wipes. Fibertex Nonwovens ability to produce specialized products with unique properties at relatively low costs is increasingly recognized in the market.
The bulk of this investment will be spent on a new spunlace production line at its plant in Svitavy in the eastern Czech Republic.
“We’ve got a lean and high-tech production setup with clear focus on innovation, and the new production line is to serve the huge demand for disinfection wipes from the healthcare sector. This demand was rising even before the coronavirus pandemic, but we expect it to increase even further in the coming years. With this new investment, we’ll be able to offer new and sustainable product properties that will help meet the demands of the future in this field. At the same time, we’re freeing up capacity at several of our other European plants, allowing us to explore new opportunities within the manufacture of acoustic products for the automotive industry and products for filtration,” Bech Madsen continues.
Fibertex Nonwovens acquired its Turkish spunlacing operation in 2015 from Ribatek. As part of this investment, the company will expand the capacity on existing lines at the site and add additional lines with finishing and coating capabilities to allow it to manufacture specialized nonwovens products.
“The plant in Turkey complements the production units of our other European and U.S. plants by manufacturing high-tech products. For example, we’re experiencing growing demand for various forms of finishing, which allow us to add entirely unique properties to the products,” says Bech Madsen.
Meanwhile, in the U.S. Fibertex Nonwovens is adding a new spunlace line at its site near Greenville, SC, where it has also acquired an adjacent land tract suitable for future expansion at the site. Fibertex acquired this facility from Turkish nonwovens producer Mogul in early 2019. At the time, the site contained one spunlace line; in 2020, the company added a production line at the site based on advanced needlepunch technology.
The latest technology will respond to demand for products with a focus on health and hygiene, more emphasis on local production and added focus on sustainability, which is also to the company’s benefit.
“With this new investment, we’ll be able to build an extremely strong position in the important North American market for, among other things, high-performance wipes for sanitizing and disinfection purposes in the healthcare/medical sector, sustainable personal care products, a range of industrial applications as well as in the automotive industry and the construction sector,” Bech Madsen adds.
Another company ambitiously investing in spunlace is Berry Global. The company is expanding its spunlace output in Europe as well as its Spinlace continuous filament technology to better serve the global wipes market in North America. Together, these two lines represent a more than $110 million investment to help the company better serve the hard surface disinfectant wipes market. According to executives the investment is a direct result of increased demand for home cleaning and disinfectant wipes, which has been boosted during the Covid-19 pandemic.
“We strategically partner with many of the world’s leading brands with wipe materials, ensuring our investments align with demand for today and for the future. The reliability of our capacity and scale are paramount to our customer support and the trusted relationships we desire to maintain,” says Curt Begle, president of Berry’s Health, Hygiene, and Specialties Division.
This new European asset will add to the company’s existing spunlace platform, further expanding its sustainable wipes portfolio. Recognizing its customers’ ongoing environmental sustainability goals, the new asset will incorporate the production of biodegradable or recycled nonwoven substrates, increasing Berry’s capacity in Europe by more than 300 million square meters. Berry has not announced a location for the new line which is expected to be commercially available in the September 2022.
“This multimillion-dollar investment further completes our industry-leading portfolio. Through flexible assets such as this installation in Europe, we can better serve our customers with reliable, sustainable solutions for the wipes market,” says Achim Schalk, EVP and general manager, EMEIA for Berry’s Health, Hygiene, and Specialties Division.
Meanwhile, in the U.S., Berry is adding a fourth line featuring its proprietary Spinlace technology for wipes applications. The investment has a targeted commercialization date of March 2023.
“This investment reflects the commitment we have in support of our customers’ growth plans and it is a clear signal of our intent to provide the best products in the disinfectant wiping space worldwide,” says Mark Siebert, EVP and general manager, U.S. and Canada, Healthcare and Specialties at Berry.
Berry’s Spinlace technology is a critical component of its growth in the wiping space, as it enables the company to produce and deliver innovative nonwovens to customers across multiple market segments including home care, personal care, commercial, transportation, and healthcare. The new line will be flexible in its production capabilities, with the ability to supply materials for wipes, filtration, personal care incontinence and healthcare applications.
Before being acquired by Glatfelter Corporation late last year, Jacob Holm Industries, a leading supplier of nonwoven materials to the global wipes market, embarked upon a comprehensive global investment plan to boost its output.
Dubbed Project Boost, the investment program will ultimately add 500 million square meters to the group’s annual capacity across its sites in the U.S., France and Germany. It is expected to be complete this year. In addition to nonwovens capacity additions, the program was intended to target a clear upgrade of the capabilities for utilizing renewable raw materials. Additionally, the upgraded production methodology will further reduce waste and improve production efficiency, thus lowering the carbon footprint of the group’s product portfolios.
Even as investment in larger markets like India and China in Asia or North America and Europe continues to be strong, opportunities for spunlace are being seen in smaller markets like Romania, Belarus and Uzbekistan thanks not just to increased demand but to trade and shipping issues that have made localized production necessary.
“Producers who usually dedicated their rolls to the export market have had to face an unprecedented increase in the sea freight shipping rates. In order to remain competitive, these companies have decided to build plants in Europe in order to be closer to the market and address the local demand,” says Andre Michalon, sales director, Andritz Perfojet France.
“At the beginning of the pandemic, the demand boomed, especially for disinfecting products as they were in short supply,” adds Arnaud LaRoche, head of sales, Andritz Perfojet France. “Most manufacturers then had to increase their existing capacity and decided to make new investments to meet the demand. In the meantime, however, converters were starting to experience difficulties because the supply of spunlace rolls on the market was running out. As a result, they also decided to invest in spunlace lines to secure their sourcing.”
Already in 2022, lines have been announced in the Ukraine and Uzbekistan, both from companies that are new to nonwovens manufacturing.
In the Ukraine, Biosphere, a leading manufacturer of household and hygiene products, has invested in an Andritz-supplied spunlace line, which will enable the company to produce fabrics from 30 to 70 gsm, with an hourly output of up to 3000 kilograms after the second commissioning phase. Start-up is scheduled in two stages – the first one in the first quarter of 2022 and the second in early 2023, when it will reach full production capacity.
The high-capacity spunlace line will double the company’s current production capacity and is designed to process various types of fibers, such as polyester/viscose blends and natural fibers. It is dedicated to the production of household, medical and hygiene fabrics, such as cosmetic, disinfecting and baby wipes.
“Our goal is to carry on creating innovative and premium-quality products,” says Andriy Zdesenko, founder and CEO of Biosphere Corporation.
Biosphere was founded in 1997, and is a market leader in the production and distribution of household and hygiene products in the Ukraine and the CIS as well a key converter player in Eastern Europe and Central Asia.
Meanwhile, in Uzbekistan cotton spinning specialist Texygen Textile LLC has invested in a neXline spunlace nonwovens line, which is the first known spunlace line in the country. Start-up is scheduled for the first quarter of 2023.
This line will process high-quality cotton fibers in a fully integrated production line, from bleaching to winding. With this new line, Texygen Textile LLC will be able to produce top-class spunlace wipes made of 100% cotton, thus opening up new market opportunities for both the company and the country.
“We are very proud to be a pioneer in the spunlace industry in our country,” says company owner Rasulov Ikrom. “We have commissioned Andritz to supply our first spunlace line, and their know-how relating to the carding machine, among other units, will enable us to produce premium-quality, nonwoven cotton roll goods.”
As these new investments ramp up across the globe, the question will be whether or not the wipes market—or other applications for spunlaced nonwovens—can support them. According to Price, much of these new lines have been founded on the expectation that strong, or even increasing demand, for wipes would continue to exist.
“We believe the motivation to acquire this additional capacity was founded on the expectation that a higher level of demand would continue to exist in a post pandemic world and that investment in advanced technology capable of producing a bundle of sustainable fibers was justifiable,” he says. “We think that demand for disinfectant and cleaning wipes will remain at a level higher and that the use of wipes will be more acceptable and convenient to consumers moving forward. Given these assumptions, we think that additional capacity will enter the market and be utilized to meet both health and sustainability trends.”
According to a report recently published by Smithers, the global market for spunlace nonwovens was expected to reach $7.8 billion in 2021 as new wipes production lines are added to respond to the surge in demand caused by Covid-19.
As enhanced concerns over infection control will help spunlace production resist any recessionary downturn, the technology is expected to see a 9.1% compound annual growth rate (CAGR) forecast for 2021-2026. This will push total market value to above $12 billion in 2026, as producers also benefit from wider use of the material in coating substrates and hygiene applications.
Smithers’ data set shows that over the same time period the total tonnage of spunlace nonwovens will rise from 1.65 million tons (2021) to 2.38 million tons (2026). While volume of spunlace nonwovens will rise from 39.57 billion square meters (2021) to 62.49 billion square meters (2026) – equivalent to a CAGR of 9.6%—as manufacturers introduce lighter base weight nonwovens.
According to Marco Fano, CMO of equipment supplier Autefa Solutions, the demand for sustainable nonwovens is clear and a leading topic in most discussions with customers in all fields of spunlaced nonwovens from wipes to geotextiles and clothing.
“The fact that spunlaced products can be made with up to 30% less energy consumption, compared to existing traditional spunlace technologies is opening up new markets, even in high fashion products like artificial leather based on natural leather waste and other sustainable products,” he adds.
Autefa Solutions contributes to the increasing importance of resource saving. The V-Jet Injector enables customers to modernize existing production lines with the latest Autefa technology. The crosslapper of the Topliner series, combined with WebMax and closed loop system, prevents the increased weight of the fabric in the edge areas, called the smile effect. This results in an excellent uniformity in the fabric and, thanks to a considerable saving of materials, a reduction in material costs.
A global market leader of spunlaced nonwovens and other wipe substrates, Suominen has taken a lead when it comes to sustainability. “Sustainability is of growing importance to our customers and other stakeholders,” says senior vice president Lynda Kelly. “We help our customers to achieve their own environmental targets by offering them products made from e.g. renewable, recycled, compostable and plastic-free raw materials.”
These new product entries included Biolace Pure, a 100% plant-based product with superior cleaning power, Biolace Bamboo, a bamboo-based substrate. Both of these products provide clear advantages in terms of reducing the CO2 footprint and a lower environmental impact.
As part of a sustainability-focused business strategy introduced last year, Suominen has a goal of increasing sales of sustainable products by 50% by 2025 and to have more than 10 sustainable product launches per year.
Investment Continues
According to David Price, principal of Price Hanna Consultants, the pace of investments in spunlaced nonwovens continues to evolve as the coronavirus and its variants continue to threaten populations across the globe. While overcapacity in the technology existed in nearly all world regions at the start of the pandemic, this capacity was immediately used in the fight against Covid-19 and additional capacity was ordered.
“We don’t think the level of year-over-year investment in hydroentangled or spunlaced nonwovens is significantly different as compared to that in the pre-pandemic period,” he says. “We do think that somewhat elevated capacity growth will continue to be present for a longer period of time as compared to prior periods.”
Smithers data shows that, wipes (baby care, home care, industrial, personal care) account for around 64.7% of all spunlace media produced in 2021. Through to 2026, the fastest growth rates are forecast for personal care wipes, and adult and toddler moist toilet tissues. Demand in durable applications will be more suppressed; although there will be new market opportunities in consumer hygiene with spunlace presenting a sustainable alternative to competing polyester or polypropylene-based nonwovens in applications such as ultrathin topsheets for feminine hygiene pads.
As the imminent threat of Covid recedes, the leading transformative trend across the first half of 2020s will be developing more sustainable nonwovens. Generally, this will benefit spunlace producers, as they work towards the goal of developing a fully plastic-free wipe. This driver will continue to receive a stimulus from the EU’s Single-use Plastics Directive, but there is also strong interest from brand owners in polymer-free wipes that can be marketed as premium eco-friendly products. The main route to achieve this is wider use of rayon, lyocell, wood pulp, cotton and other biodegradable fibers, with a corresponding relative decrease in use of spunbond polypropylene and polypropylene fiber.
In November, Welspun announced it would add a complete neXline spunlace line capable of processing a variety of fibers from Andritz for the production of nonwoven roll goods and wipes for its new plant in Hyderabad, Telangana, India. The line has a capacity of up to three tons per hour.
This line is allowing Welspun to process various types of synthetic or natural fibers, such as polyester, viscose and cotton. The final products will have fabric weights ranging from 25 to 120 gsm, thus covering many applications. This neXline spunlace line also offers the option to integrate a third component from a selection of smart layers, to enable Welspun to manufacture products for the healthcare and hygiene sectors.
“Spunlace manufacturers had already long been experimenting with 100% sustainable products partly or wholly with their portfolio. However, SUP directive in Europe has fast forwarded this process and now from the consumer side there is increased demand of products that are sustainable and that meet all the requirements,” says Tirthankar Mukherjee of Welspun. “On the technology, front the technology providers are also providing various innovations with standalone machine or retrofitting in the existing machine to enable products which can use 100% sustainable plant-based products or in various blend combinations. However, the acceptance of these products largely depends on the requirements of the end use segments.”
Elsewhere in India, industry newcomer Tufropes, a global leader for ropes and netting, is adding a spunlace line Gujarat, India. It is estimated that the line will be commissioned during the first quarter of 2022. Proprietary refinements, which were developed with partners Truetzschler and Voith, will allow Tufropes to produce any possible hydroentangled nonwoven material, including biodegradable, natural fiber, eco-friendly high-performance nonwovens.
Meanwhile, China has been leading the world with investment, both from domestic and international machinery providers, where penetration of disposable wipe products has until recently been low. As this market grows and evolves, new spunlace lines will be needed.
In 2021, Chinese spunlace maker Zhejiang Saintyear Textile Co., Ltd., announced it would add a second spunlace line for the production of premium-quality nonwoven roll goods, just nine months after its initial investment. The line is scheduled for start-up during the third quarter of 2022.
Andritz will provide a full line with state-of-the-art equipment – from web forming to drying. The scope of supply includes the precise opening and blending machinery from Laroche – newly acquired by the Andritz Group, two inline TT cards, a proven JetlaceEssentiel unit for hydroentanglement, and the efficient neXdry through-air dryer.
Li Yi Ming, CEO, says, “Spunlace nonwovens are definitely a must nowadays due to their versatility, and we want to offer our customers the best-quality nonwovens. Hence, we had to go for the benchmarking company in the production of premium roll goods. This is why we have decided to rely on an Andritz nonwovens system offering the best performance and runnability. We have already purchased one complete spunlace line recently from Andritz that will go into operation in mid-2022. Project execution is running so smoothly so far that we did not hesitate to renew our trust by ordering a second line.”
Meanwhile, investment continues in developed markets like Europe and North America in response to increasing demand for wipes as well as more sustainable options for spunlace. In 2021, Fibertex Nonwovens announced investments in spunlace technology at its plants in the Europe and the U.S. In Europe, the company is investing $50 million (DKK300 million) in new capacity at its plants in the Czech Republic and Turkey.
“Demand for our nonwovens has increased significantly in recent years. It concerns particularly the more specialized applications and high-performance materials for the healthcare sector, industrial products, specialist acoustic products for the automotive industry, nanofiltration for industrial purposes, etc. Our business development and research activities over the past 10 years have afforded us a leading position in both Europe and the U.S.,” explains Jørgen Bech Madsen, CEO of Fibertex Nonwovens.
He adds that the coronavirus pandemic has led to an explosive demand for hygiene products, such as disinfectant wipes. Fibertex Nonwovens ability to produce specialized products with unique properties at relatively low costs is increasingly recognized in the market.
The bulk of this investment will be spent on a new spunlace production line at its plant in Svitavy in the eastern Czech Republic.
“We’ve got a lean and high-tech production setup with clear focus on innovation, and the new production line is to serve the huge demand for disinfection wipes from the healthcare sector. This demand was rising even before the coronavirus pandemic, but we expect it to increase even further in the coming years. With this new investment, we’ll be able to offer new and sustainable product properties that will help meet the demands of the future in this field. At the same time, we’re freeing up capacity at several of our other European plants, allowing us to explore new opportunities within the manufacture of acoustic products for the automotive industry and products for filtration,” Bech Madsen continues.
Fibertex Nonwovens acquired its Turkish spunlacing operation in 2015 from Ribatek. As part of this investment, the company will expand the capacity on existing lines at the site and add additional lines with finishing and coating capabilities to allow it to manufacture specialized nonwovens products.
“The plant in Turkey complements the production units of our other European and U.S. plants by manufacturing high-tech products. For example, we’re experiencing growing demand for various forms of finishing, which allow us to add entirely unique properties to the products,” says Bech Madsen.
Meanwhile, in the U.S. Fibertex Nonwovens is adding a new spunlace line at its site near Greenville, SC, where it has also acquired an adjacent land tract suitable for future expansion at the site. Fibertex acquired this facility from Turkish nonwovens producer Mogul in early 2019. At the time, the site contained one spunlace line; in 2020, the company added a production line at the site based on advanced needlepunch technology.
The latest technology will respond to demand for products with a focus on health and hygiene, more emphasis on local production and added focus on sustainability, which is also to the company’s benefit.
“With this new investment, we’ll be able to build an extremely strong position in the important North American market for, among other things, high-performance wipes for sanitizing and disinfection purposes in the healthcare/medical sector, sustainable personal care products, a range of industrial applications as well as in the automotive industry and the construction sector,” Bech Madsen adds.
Another company ambitiously investing in spunlace is Berry Global. The company is expanding its spunlace output in Europe as well as its Spinlace continuous filament technology to better serve the global wipes market in North America. Together, these two lines represent a more than $110 million investment to help the company better serve the hard surface disinfectant wipes market. According to executives the investment is a direct result of increased demand for home cleaning and disinfectant wipes, which has been boosted during the Covid-19 pandemic.
“We strategically partner with many of the world’s leading brands with wipe materials, ensuring our investments align with demand for today and for the future. The reliability of our capacity and scale are paramount to our customer support and the trusted relationships we desire to maintain,” says Curt Begle, president of Berry’s Health, Hygiene, and Specialties Division.
This new European asset will add to the company’s existing spunlace platform, further expanding its sustainable wipes portfolio. Recognizing its customers’ ongoing environmental sustainability goals, the new asset will incorporate the production of biodegradable or recycled nonwoven substrates, increasing Berry’s capacity in Europe by more than 300 million square meters. Berry has not announced a location for the new line which is expected to be commercially available in the September 2022.
“This multimillion-dollar investment further completes our industry-leading portfolio. Through flexible assets such as this installation in Europe, we can better serve our customers with reliable, sustainable solutions for the wipes market,” says Achim Schalk, EVP and general manager, EMEIA for Berry’s Health, Hygiene, and Specialties Division.
Meanwhile, in the U.S., Berry is adding a fourth line featuring its proprietary Spinlace technology for wipes applications. The investment has a targeted commercialization date of March 2023.
“This investment reflects the commitment we have in support of our customers’ growth plans and it is a clear signal of our intent to provide the best products in the disinfectant wiping space worldwide,” says Mark Siebert, EVP and general manager, U.S. and Canada, Healthcare and Specialties at Berry.
Berry’s Spinlace technology is a critical component of its growth in the wiping space, as it enables the company to produce and deliver innovative nonwovens to customers across multiple market segments including home care, personal care, commercial, transportation, and healthcare. The new line will be flexible in its production capabilities, with the ability to supply materials for wipes, filtration, personal care incontinence and healthcare applications.
Before being acquired by Glatfelter Corporation late last year, Jacob Holm Industries, a leading supplier of nonwoven materials to the global wipes market, embarked upon a comprehensive global investment plan to boost its output.
Dubbed Project Boost, the investment program will ultimately add 500 million square meters to the group’s annual capacity across its sites in the U.S., France and Germany. It is expected to be complete this year. In addition to nonwovens capacity additions, the program was intended to target a clear upgrade of the capabilities for utilizing renewable raw materials. Additionally, the upgraded production methodology will further reduce waste and improve production efficiency, thus lowering the carbon footprint of the group’s product portfolios.
Even as investment in larger markets like India and China in Asia or North America and Europe continues to be strong, opportunities for spunlace are being seen in smaller markets like Romania, Belarus and Uzbekistan thanks not just to increased demand but to trade and shipping issues that have made localized production necessary.
“Producers who usually dedicated their rolls to the export market have had to face an unprecedented increase in the sea freight shipping rates. In order to remain competitive, these companies have decided to build plants in Europe in order to be closer to the market and address the local demand,” says Andre Michalon, sales director, Andritz Perfojet France.
“At the beginning of the pandemic, the demand boomed, especially for disinfecting products as they were in short supply,” adds Arnaud LaRoche, head of sales, Andritz Perfojet France. “Most manufacturers then had to increase their existing capacity and decided to make new investments to meet the demand. In the meantime, however, converters were starting to experience difficulties because the supply of spunlace rolls on the market was running out. As a result, they also decided to invest in spunlace lines to secure their sourcing.”
Already in 2022, lines have been announced in the Ukraine and Uzbekistan, both from companies that are new to nonwovens manufacturing.
In the Ukraine, Biosphere, a leading manufacturer of household and hygiene products, has invested in an Andritz-supplied spunlace line, which will enable the company to produce fabrics from 30 to 70 gsm, with an hourly output of up to 3000 kilograms after the second commissioning phase. Start-up is scheduled in two stages – the first one in the first quarter of 2022 and the second in early 2023, when it will reach full production capacity.
The high-capacity spunlace line will double the company’s current production capacity and is designed to process various types of fibers, such as polyester/viscose blends and natural fibers. It is dedicated to the production of household, medical and hygiene fabrics, such as cosmetic, disinfecting and baby wipes.
“Our goal is to carry on creating innovative and premium-quality products,” says Andriy Zdesenko, founder and CEO of Biosphere Corporation.
Biosphere was founded in 1997, and is a market leader in the production and distribution of household and hygiene products in the Ukraine and the CIS as well a key converter player in Eastern Europe and Central Asia.
Meanwhile, in Uzbekistan cotton spinning specialist Texygen Textile LLC has invested in a neXline spunlace nonwovens line, which is the first known spunlace line in the country. Start-up is scheduled for the first quarter of 2023.
This line will process high-quality cotton fibers in a fully integrated production line, from bleaching to winding. With this new line, Texygen Textile LLC will be able to produce top-class spunlace wipes made of 100% cotton, thus opening up new market opportunities for both the company and the country.
“We are very proud to be a pioneer in the spunlace industry in our country,” says company owner Rasulov Ikrom. “We have commissioned Andritz to supply our first spunlace line, and their know-how relating to the carding machine, among other units, will enable us to produce premium-quality, nonwoven cotton roll goods.”
As these new investments ramp up across the globe, the question will be whether or not the wipes market—or other applications for spunlaced nonwovens—can support them. According to Price, much of these new lines have been founded on the expectation that strong, or even increasing demand, for wipes would continue to exist.
“We believe the motivation to acquire this additional capacity was founded on the expectation that a higher level of demand would continue to exist in a post pandemic world and that investment in advanced technology capable of producing a bundle of sustainable fibers was justifiable,” he says. “We think that demand for disinfectant and cleaning wipes will remain at a level higher and that the use of wipes will be more acceptable and convenient to consumers moving forward. Given these assumptions, we think that additional capacity will enter the market and be utilized to meet both health and sustainability trends.”
