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#Techtextil / Texprocess 2013

Gherzi: Challenges and Opportunities for EU companies in Technical Textiles

The world market for Technical Textiles in 2012 is estimated by Gherzi at 22 million tons p.a., corresponding to an industrial sales volume beyond 160 billion USD (including downstream value added steps like technical make-up, resin impregnation, etc.).
The largest Technical Textile enterprises in the world – such as e.g. Ten Cate (NL), DuPont (USA), Ahlstrom (S), Cytec (USA), etc. – are achieving well over 1 billion USD in sales.Worldwide, Technical Textiles already represent 25 % of all textiles produced. In countries like Germany, the Technical Textiles share in tonnage is already reaching over 50 % of all textiles produced and is expected to reach 60 % by 2015.

Technical Textiles in the above described context include high performance composite reinforcements like glass or carbon fabrics (15 % world TechTex share), nonwovens (35 % world TechTex share) and other woven, knitted, braided or yarn type products (50 % world TechTex share). Looking at individual company performance in European Technical Textiles, it is apparent that this field has offered a fertile ground for above average returns: 12% to almost 20% EBITDA return on sales are not uncommon. The sector also allows for listing on the stock market, as demonstrated by Ten Cate (NL) or Low & Bonar (UK).

The key critical issues which - in Gherzi’s view - this industry has to face in Europe, is to a lesser extent the import threat from ready-made products coming into Europe from Asia butmore so the erosion of the European manufacturing base of key synthetic fibres needed for the production of Technical Textiles. This holds true especially for the field of Polyester industrial yarns, where China in 2010 already controlled 55 % of world production and is moving up to beyond 75 % by 2015.

On the other hand, the European Technical Textiles industry can also profit from positive trends in some key technologies and markets which are growing faster than the Technical Textiles industry as a whole.

Nonwovens clearly continue to be a higher than average growth industry (CAGR Europe 5.7% between 2000 and 2010) with some Non-Woven technologies – such as spunlacing (hydro-entanglement of carded webs) or spunbond (spunmelt nonwovens ex chips) –showing higher growth rates than nonwovens overall.

This is certainly due to the fact that nonwoven technologies are becoming more and more flexible, leading to nonwovens entering fields so far reserved for, e.g., wovens. The market introduction of Meta-Aramide based nonwovens for protective garments (‘Protech’) – which were historically based on wovens – is one indication for this trend. Spunlace nonwovens for decorative car interiors (replacing knits) are another.

Another above average growth area is to be found in textile reinforcements for high performance continuous filament reinforced plastics ‘composites’).Historically based on glass, Para-Aramide or carbon and driven by industries like aerospace, boat-building, sports equipment and wind turbines, continuous filament fabric based composites are now entering the automotive sector as well as areas like high end luggage (with PP tape based wovens), Medtech (prosthesis), Medical equipment, etc.Such typically woven, stitch-bonded or unidirectional (‘UD’) fabrics are – when combined by the fabric supplier with thermoset or thermoplastic matrix material - called ‘prepregs’ (preimpregnated continuous filament based textile surfaces).

Here, clearly thermoplastic matrix materials (like PA or TPU) are growing in importance at the expense of thermoset (like epoxy or phenolic resin). Thermoplastic prepregs are typically employed in ‘organic sheets’, a market where large amounts of R&D – especially by the auto industry – are currently invested.

The trend toward the use of thermoplastic ‘organic sheets’, which can be deep-drawn and overmoulded, represents a new market for European textile enterprises. By combining thermoplastic matrix material (such as PA, TPU or PPS) with textile reinforcements (like Glass, Aramide or Carbon wovens) on a laminator, a mouldable sheet is formed, which is then further processed by various deep-drawing technologies into structured parts (like structural elements of car seats or sports equipment) by the downstream non textile manufacturers (n.b.: lamination technology in general can be considered as another Technical Textile segment showing above average growth rates).

Prepregs are growing worldwide and as such offer opportunities for the textile fabric manufacturer to move down the value chain and build up plastic resin related intellectual property (‘IP’).

Looking at the larger picture one can state that the big megatrends ‘comfort increase’, ‘aging population’ and ‘weight savings’ all play in favour of the European Technical Textile industry.

This concerns Non-Wovens (e.g. for hygiene) as well as wovens (e.g. for composites).The future should thus be marked by continuous growth of Technical Textile demand in existing, emerging and new market segments, requiring, nevertheless, also a continuous high level of investment in R&D, product certification as well as plant and equipment.

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