Application and consumption overview of staple fiber for nonwovens in the second half of 2019

In 2018, the global output of nonwovens reached 14.9 million tons, which is approximately 459 billion square meters. Inda and Edana predict that global nonwovens production will continue to grow, and predict that from 2018 to 2023, the average annual growth rate of the nonwovens industry will reach 4.8%, and the output will reach at least 18.7 million tons. Staple fibers account for nearly two-thirds (59%) of resins and staple fibers used in the nonwoven industry. In 2018, the staple fiber consumption of dry, wet and airlaid staple fiber nonwovens was approximately 8.8 million tons, an increase of 35% over five years ago. It is estimated that in 2023, fiber consumption will continue to grow at a rate of 4.0% per year, reaching 10.8 million tons. The global 2018 nonwoven staple fiber consumption man-made fiber (orange part in the figure) accounted for two thirds (62%) of the staple fiber consumption, while natural fiber (blue part) accounted for the remaining 38%. Whether it is virgin fiber or regenerated fiber, polyester staple fiber now accounts for more than half (58%) of man-made fibers, and more than 36% of the total staple fiber consumed by nonwovens (see picture). Although the high proportion of virgin polyester staple fibers can be attributed to the production of hydroentangled materials used in the rag industry, the vehicle sector (carpets, trunk liners, and other noise, vibration, and stability products) also consume a large amount of fibers, which are used for A heavier needle punched product made from recycled polyester fiber. It is estimated that by 2023, the consumption of polyester staple fiber will increase to 3.9 million tons, equivalent to an annual growth rate of 4.0%. The main single-use or disposable end markets of polyester staple fiber are wet wipes, filtration, surgical bags and outerwear (mainly produced by dry hydroentangling technology). Important durable end markets include home and office decoration, geosynthetics, interlining, and transportation, all of which are expected to expand globally. These figures do not include polyester staple fibers used in fiber filling-not produced in a non-woven process-such as bedding or clothing insulation. Worldwide, polyester used for fiber filling applications is estimated to be at least 900,000 tons. Polypropylene staple fiber consumed approximately 952,000 tons in 2018, accounting for 11% of global nonwovens consumption. Although the use of polypropylene staple fiber in the disposable market has declined, especially the demand for dry-laid thermal bonding covering materials (only partially compensated by the use of air-laid), this fiber is in the durable nonwoven market Continues to grow. Most of the durable end markets for polypropylene are needlepunch durables. The main markets where needle-punched polypropylene is used include geotextiles, automotive parts, coating substrates, indoor/outdoor carpets, blankets, upholstered furniture and mattresses. The forecast of global demand for polypropylene staple fiber in 2023 is 1.1 million tons. Compared with 2013, the global nonwoven fabric industry increased the consumption of viscose (rayon) staple fiber by 162,000 tons in 2018, mainly driven by the tissue and medical product industries. It is estimated that the global viscose consumption in 2018 was 682,000 tons, and it is expected to exceed 821,000 tons by the end of 2023. Nevertheless, the consumption of viscose in wiping applications is quite sensitive to the cost of replacing fibers. In fact, viscose is usually mixed with polyester to produce a hydro-entangled wipe substrate. The mixing ratio of wet wipes is usually 50/50 or 60/40. Because of its softness and hydrophilicity, viscose used to have a relatively high proportion in mixing. However, viscose staple fiber is more expensive than polyester. Therefore, you can change the blending ratio, reduce the amount of viscose, and increase the amount of polyester as a measure to reduce costs. The price of viscose, which is higher than that of polyester, will rise sharply, which will lead to an increase in the replacement rate and a decline in viscose's capacity prospects. The consumption of bicomponent and other synthetic fibers in 2018 was approximately 680,000 tons. The position of bicomponent fibers in nonwovens is becoming more and more important. There are several types of bicomponent fibers: (A) binder fiber, generally used in the production of filler materials and air-laid short fibers; (B) detachable bicomponent fiber, which can be divided into hydroentanglement process Micro-denier fibers; (C) Self-crimped fibers usually consumed in needle punching. The main markets for bicomponent fibers include absorbent/distribution layers for diapers and feminine hygiene products, air-laid nonwoven bonding fibers, needle punched and filled fibers. All these end markets are growing and will drive the consumption of bicomponent fibers. This market is expected to increase to 827,000 tons by 2023. Wood pulp In 2018, the total consumption of air-laid staple fiber, dry-laid water-entangled, spunbond-laid and wet-laid wood pulp was approximately 1,417,000 tons. By 2023, it is expected to increase to 1,725,000 tons. This is because people expect that air-laid staple fiber nonwovens will continue to replace linear absorbent cores in adult diapers and feminine hygiene production lines. This increase in volume did not translate into an increase in demand for wood pulp, but a replacement for the existing volume. Almost all women's napkins in North America use air-laid staple fibers, and the consumption of adult diapers is also high. Mineral fibers, including carbon, ceramic and metal fibers, are widely used in North America. According to INDA data, of the 1,245,000 tons used by the global nonwovens industry in 2018, the North American industry alone consumed 643,000 tons, of which 87% was consumed in the wet process. Glass fiber is made of very fine glass fiber. It is a lightweight, extremely strong and strong material. Glass fiber has a wide range of applications in filtration, transportation, construction, electronics, wind energy, industry and other fields. Mineral fibers are often used in the production of wet-laid nonwovens, but they are also used in air-laid staple fibers and dry needling processes. Natural fiber The global consumption of cotton fiber for nonwovens is still relatively small, and the use of other natural fibers such as jute, flax or hemp is increasing. Cotton and other natural fibers together, the proportion of non-woven fabric consumption does not exceed 3%. Cotton is also used in many other household and personal care products, such as medical sponges, medicine rolls, disposable wipes, sanitary napkins, cosmetic pads and other products. But these uses are generally not counted as nonwoven production.