Showing posts with label INDA Vision Orlando 2013. Show all posts
Showing posts with label INDA Vision Orlando 2013. Show all posts

Friday, 21 June 2013

Diaper Design Optimisation

Carlos Richer of Richer Investments (USA) dominated the opening day of this year's INDA VIsion Conference in Orlando with a first-class workshop on diaper design and production for new entrants, especially those in the developing economies.  He commenced with the biology resulting in the production of urine and how the quantities produced vary with fluid intake, age and climate.  He  moved on to practical  diaper designs and factors affecting absorbency, retention and leakage before considering skin irritation, comfort and the ways to optimise diaper design for different markets.  He concluded with a tour of the latest constructions and some speculation about future products. Noteworthy points follow:

·         Whereas on a normal day 62% of fluid is lost as urine, 18% as sweat, 16% as respiration and 4% as faeces, on a hot day sweat increases to 30% at the expense of urine. This reduction in urine output is more pronounced and more important for design in the under-developed markets.
·         Disposable diaper sales decrease in hot sunny weather due mothers preferring to use washables when they can be line dried – at least in markets where disposables penetration is lower than in the USA.
·         Most new diaper producers define their absorbency for a medium size and then adjust the capacity for other sizes in proportion to baby’s weight.  However, a 2kg baby produces about 200mls urine/day and a 26kg baby produces 1650 ml/day from a much larger bladder.  Mls/kg/hour of urine should be considered and this goes down as baby grows.
·         Diapers are worn for 4.5 hours on average before changing but this increases to 6.5 hours as baby grows and varies dramatically with culture.  Japan and Korea change much more frequently.
·         Probability of diaper leakage decreases as the amount of urine absorbed increases.  This is because leakage failure is usually occurs on first urination through the cuffs due to poor construction.

Thursday, 23 May 2013

Sustainability and the Consumer: Green Marketing Statistics

Lee Ann Head, VP Research, Shelton Group has explored “sustainability” from the viewpoint of the average consumer.  Asked what do you think Sustainable means in the phrases Sustainable Products or Sustainable Practices the top 6 of widely varying answers were “No Idea” (21%), “Long lasting and Durable” (14%),  “Environmentally safe and friendly” (10%), “Renewable – easily replaced” (10%), “Preserves resources – non-depleting” (7%), “Keeps going” (7%).  Only 7% came close to the Meeting our needs while preserving the ability of future generations to meet theirs definition which the EPA favours. 


70% of those questioned were searching for Greener products, mainly to reduce energy use (71%) , but also for Home Cleaning (61%), Laundry (59%), Kitchen towels (58%), food (47%) and personal care products (46%).  How do they identify Greener products? Mainly by reading the ingredients list and the claims on the packs, but some do their own research on the web and believe the recommendations of Certifiers such as “Energy Star” and “Good Housekeeping”.  However, due to the recession they were losing interest in green products which did not have an immediate payback and felt that most Green home cleaning products were disappointing.  They were also rejecting toilet paper and kitchen wipes which claimed to use recycled paper and try to justify a premium.  For the consumer, recycled means cheaper.

So, convenience and comfort continue to trump the environmental arguments and people want products with fewer chemicals and more Made in the USA content.  More want personal care products with fewer chemicals rather than more bio-biobased content.

Perhaps of most interest was the emergence of end-of-life disposal as an issue this year.  74% thought the producer should take responsibility for end-of-life disposal and 61% thought the retailer should.

Asked whether the consumers’ view of disposable diapers was changing as a result of the changes evident in this survey, Ms Head thought they were not.  The convenience of disposable diapers far-outweighed any negative thoughts about their sustainability or disposal.

Monday, 20 May 2013

Polymeric Delivery Systems for Sustainable Nonwovens

Robert Lochhead, Professor and Director of the School of Polymers and High Performance Materials at the University of Southern Mississippi couldn’t get to Orlando but provided a voice-over for the slide show which was mainly a review of the latest patents of interest to sustainable nonwovens. 
  • He proposed reducing the water content of lotions for wet wipes by using Shinoda’s 1964 principle of phase inversion to make more concentrated emulsions.
  • USP 8327579 B2 (Dec 2012) proposes using waste nonwovens with PU foams to make floating islands which protect small fishes and could be pre-seeded to grow crops.
  • US Application 2013/0012093 A1 suggests using fibres made of polyethylene extended with vegetable waxes to deliver perfumes etc.
  • US 8268738 B2 (Sept 2012) from Kimberly Clark proposes overcoming the brittleness of PLA spunbonds by using PEG plasticiser compatiblized with maleinized PP.
  • US Application 2011/0152818 A1 suggests cellulose acetate butyrate/polyhydroxybutanoate to make thermally bondable nonwovens
  • US Application 2011/0300382 from P&G suggests making nonwovens from alkyd resins made spinnable into fibres by vitrification.
  • US Application 2013/0023608 A1 proposes using biobased thermoplastic elastomers and thermoplastic starches to make bicomponent fibres.
  • US Application 2013/0023176 A1 proposes making nonwovens from the currently wasted coir fibre from coconut farming.
  • US Application 2012/0027838 A1 covered ingestible nonwovens made from Ethylex 2035 starch used as a carrier for drugs.
There were numerous applications for patents from P&G on dissolvable fibres comprising surfactants, PVA polymers, plasticisers and rheology modifiers under the headings “What if nonwovens could be detergents”, “Nonwoven shampoo”, “Nonwoven laundry detergent”.

Thursday, 16 May 2013

INDA 2011 Statistics Highlights

Rory Holmes, Past President of INDA provided the latest (2011) INDA statistics:
  • Of the 1817 kt on nonwovens produced, 964kt were spunbond, 598kt carded, 165 kt airlaid and 90 kt wetlaid. 
  • 638kt of the spunbond was PP (SB or SMS). Polyethylene accounted for 54kt and was presumably mainly Tyvek.
  • 314kt of the carded was needlepunched, 201kt spunlaced and 83kt thermal or resin bonded.
  • By 2016 the total tonnage will rise to 2329kt, 1270kt of which will be spunbond.
  • For Disposables, hygiene nonwovens will grow from 370kt in 2011 to 416kt in 2016, medical from 166 to 194kt, wipes from 309 to 414kt and filtration from 171 to 213kt.  Oil Sorbents will grow from 59 to 75kt.
  • For Durables over the same 5 years, automotive nonwovens will grow from 53 to 76kt, furniture/bedding from 90 to 130kt, geotextiles from 125 to 141kt and agricultural from 30 to 37kt.

Monday, 13 May 2013

New quality standards for Adult Incontinene products


Nancy Muller, Executive Director of the National Association for Continence (NAFC) pointed out that the US wastes $750bn/year in health care spending, including $210bn on unnecessary services, $190bn on unnecessary administration, and $130bn on inefficiency.  Fraud accounts for a loss of $75bn.  Savings are sought and one of these relates to the Medicaid Nursing Home Waiver whereby the State saves on Nursing Homes by covering the cost of community-based long term care.  This means helping the family to look after elderly relatives. Often the home-based carers themselves are elderly, physically impaired and in need of education about inco management and the available products.

Skin gets increasingly vulnerable with age and skin-care for incontinence sufferers is a key problem.  Even with skilled nurses in excellent long-term care homes, incontinence-related skin erosion and ulceration is a serious problem.  So, as care moves into the community, State authorities are concerned that they could be overwhelmed by such problems and admit to having no idea what type of products they should be recommending to minimise the issue. 

NAFC has therefore pulled together a group of suppliers (K-C, SCA, Attends, First Quality, Medline, PBA) and State Authorities ( CA, MA, MN, SC, and TX) who have teleconferenced  monthly for the last 2 years.  They have rejected the ISO “absorbent capacity is key” philosophy and are incorporating threshold performance standards and recommendations for strikethrough time, rewet weight and retention under load.  The numbers vary according to whether the briefs are “Standard” or “Premium” priced, and whether the wearer suffers from Light/Moderate or Moderate/Severe incontinence.  Recommended values for a medium size – presumably measured on the whole pad - range from 35-60 seconds for strikethrough, 0.5 to 2 gms for rewet and 250-400gms retention.
6 sizes are recommended; all components must be FDA/OSHA/EPA approved; closure systems must allow multiple use; and the garments must be breathable without leaking.  Test results are to be shared between States and there will be regular audits to reduce product variability and prevent inferior products being used.

Saturday, 4 May 2013

South America Nonwoven Update

Rick Jezzi of A D Jezzi and Associates updated the SA demographics noting that the birth-rate was now decreasing (down 1% per year) as religious principles waned and more women worked.  The female population (15-49) was increasing at 1% per year and the over 65’s at 3.8%/pa.  The average PPP/cap will be $12500 in 2017, the wealthiest countries being French Guyana, Chile and Argentina.  Brazil, the most populous country in SA, accounted for half the people and 60% of the GDP, and will have a PPP/cap of $10500 in 2017. 
  • Diapers will grow at 5.6% CAGR through 2017.  There are numerous producers but the two biggest (unnamed) take half of the total sales.  Penetration will rise from 53 to 62% (2011-17)
  • Femcare will grow at 6.1% CAGR through 2017 and here again of the numerous producers, the 2 majors take 54% of pantyliner sales and 42% of pads. Penetration will rise from 67 to 85% (2011-17)
  • The embryonic adult inco market is expected to grow at 10% CAGR through 2017. Penetration will rise from 20 to 27% (2011-17)
  • Baby wipes will also grow at 10% but use lower basis weights and more spunbond than NA.  Household wipes are practically non-existent. Penetration will rise from 39 to 62% (2011-17)
Mr Jezzi expects to see the industry consolidate and many smaller players to disappear.  Mass merchandising will grow and the whole industry will become more professional as technology is transferred from NA.  Brazil is leading the sustainability movement with its highly available low-cost bio-feedstock.  Braskem and Dow are already producing “drop-in” bio-PE.  Industrial PHB/PHV’s are becoming available and Solvay is producing bio-PVC.  An airlaid nonwoven producer is needed in the region.

Tuesday, 30 April 2013

Indian Nonwoven Market Update

Rich Chapas of Chapas, Chinai and Associates provided news from the subcontinent.
  • Per capita income for 2011 was $3663 (PPP basis)
  • There are 26.2 million births/year; the middle class population is 375 million of whom 60 million are engineers and scientists; 30% of the population lives in cities.
  • The diaper market is >1% penetrated and the femcare market 15% penetrated by disposables.
  • Nonwovens use is 0.5kg/capita/year now and is expected to grow to 2.5 kg/capita/year by 2025.
  • Nonwovens production was 190,000 tonnes in 2011, of which only 18,000 were disposables.  These numbers are expected to double by 2015.
  • 48% of nonwoven production is spunbond and 36% is needlepunch.  11% is spunlace.
  • The culture is anti-disposables and there is insufficient infrastructure to support rapid growth.
  • Carpets and backing, packaging, geotextile and automotive durable nonwovens make up 75% of nonwoven sales.  Hygiene is only 8%.
  • New product development should involve use of local natural products, not synthetics.  However India, like Brazil, would be a good base for developing bio-based synthetics.
  • K-C are partnering with Lever to develop the diaper and femcare market.

Friday, 26 April 2013

INDA's Visionary Award Finalists: Kimberly Clark, Allasso Ind. and Vitaflex

Tim van Himbergen of Kimberly Clark Corp. used the platform to promote the whole range of Poise Wellness products, the latest addition to which is the Panty Freshener, a small 4-layer circular pad containing perfume and intended to be stuck on the outside of the pants.  The layers are perfume-containing nonwoven, film, adhesive, and release paper.  4 hours of freshness are promised.
The other Poise Wellness products mentioned were Personal Lubricant, cooling Gel, Cooling Towelettes, and Feminine Wash, launched July 23rd 2012 in the US and Canada.

Walter Chappas of Allasso Industries Inc., described the company as being spun-off from NC State University develop applications for their multi-limbed fibre made using bico spinning technology.  A segment-pie bico with about 40 soluble segments in a nylon pie is produced and converted into papers, nonwovens or textiles. The segments are then removed in hydroentanglement or dissolved to leave the very high surface area multilimbed nylon core.  In addition to the cosmetic facial mask shown (a 50gsm nylon spunlace impregnated with creams and lotions), applications in filters, wipes, medical, insulation, composites and apparel are envisaged.


Nonwovens using the fibre are currently produced in Korea for air filters on a 2-metre wide line.  The fibres are oval with dimensions of about 10 to 20 microns.

Al Blalock CEO of Vitaflex LLC demonstrated a primary head protection balaclava made of three layers of elastic spunbond PP.  The soft stretch breathable fabric allows a comfortable one-size-fits all product which covers the entire scalp, face and neck but for a narrow eye-slot over which goggles can be worn.  It is intended to protect the wearer from all airborne sprays, dust or splashes while working indoors or to reduce wind-chill, sunburn and scratches during outdoor activities.  It could also have applications in food and medical product preparation and maybe in surgery.


It looked ideal for protecting the hair from paint while painting the ceiling.

...And the Winner Was Dude Wipes

Friday, 19 April 2013

INDA's Visionary Award Finalists: Diversitech and Dude

Keith Platt of the Diversitech Corporation described how they came to develop the MERV 8+/9+ pleated filter.  Diversitech wanted to make and sell pleated filters for air conditioning units etc but found the standard cardboard-framed design costly to make and too bulky ship economically.  Their experience with plastic mouldings led them to believe that the pleated PP spunbond filter element could be overmoulded with a PP plastic frame to make “nestable” filters which could be stored in half the volume.  The resulting rugged and durable filters also showed lower pressure drop due to absence of cardboard and could be recycled.

Sean Riley, Chief Executive Dude of Dude Products Inc. is targeting 25-35 year old males who tend to “toilet” more away from home than at home.  The resulting individually-wrapped Dude Wipes are intended for all male clean-up jobs, the list including wet-toilet tissue, post-gym clean-up, bedroom festivities and hand/face cleaner.  Dude Wipes are in fact dispersible and flushable multi-function male grooming wipes with a pleasant masculine scent.  Mr Riley expects to extend the range into larger Quick Dude Shower (QDS™) wipes.


Marketing is Twitter-linked and humorous with “social” packaging which works as a conversation starter.  Dude Wipes were developed in conjunction with Rockline Industries and launched in July 2012. They are currently sold online and in a number of small specialty stores.

Tuesday, 16 April 2013

Europe and Asia Nonwoven Market Update

Ian Bell, Tissue and Hygiene Research Manager at Euromonitor observed that Western Europe’s share of the global nonwoven market had fallen from 26% in 2002 to 19% in 2012 largely due to the preponderance of growth in Asian markets.  Over the same period, and in contrast to declines in WE as a whole, the UK birth rate had increased by 15%.  Here the retailers were aggressively pushing private label diapers as evidenced by the “Tesco loves Baby” promotion.  The withdrawal of “Huggies” will benefit PL and “Pampers” with the majority of the KC 15% share going to PL.
Germany’s population is growing mainly in the over-65’s group where there are now 27% more people than in 2002.  As a consequence of this and the falling birth rate most of the value growth in disposables now comes from incontinence products.  40% of diapers and 15% of incontinence pads are sold as PL.  Incontinence product sales are expected to overtake diaper sales in 2017.
Spain is an economic catastrophe with 27% unemployment overall and 55% in the under 24’s.  Disposable income has fallen by 7% since 2008. The only categories of disposables still growing are flushable wet wipes.
Eastern Europe is growing well mainly due to the Russian baby-boom, and this region is now the 3rd Global Growth area behind China and Brazil.  The government’s “Mothers Capital” scheme, started in 2007 now grants $13,000 to women having babies before the end of 2016.
Turkey hopes to join the EU and will be the next big growth area.
Asia-Pacific as a whole now accounts for 35% of the Global hygiene market, up from 26% in 2002.  China remains the largest market with India running about 25 years behind China.  India, outside the cities, lacks infrastructure to handle disposal (see below).
China’s hygiene sales at retail have grown from around $3bn in 2002 to $10bn now and are expected to reach $37bn by 2020.  In 2002 femcare accounted for the ~90% of sales.  By 2020 femcare will be around 35% and diapers around 60%, the rest being emerging inco.  GDP and per capita income growth have both fallen from the 20% pa peak in the middle of the last decade to around 10%p.a. now and are expected to continue at this rate through 2020.  China is now best viewed city-by-city with Xiamen (9% CAGR), Tianjin (18% GDP Growth in 2011) and Shenzen (7% CAGR) being key growth areas. 
Japan is struggling with low growth and an ageing population.  By 2017 incontinence pad sales will reach $2.5bn, up from $1.2bn in 2002, while diaper sales will fall to $1.7bn from $2bn.
South Korea was singled out as the new market with greatest potential.  Here the per capita income is only $13,000 but already 45% of the diapers sold are bought on the web.  For comparison, only 4.5% of diapers are bought on the web in the USA.

Friday, 12 April 2013

The Adult Incontinence Market in North America

Rory Holmes, Past-President of INDA said AI in NA was now worth $4.3bn and the market now consumed 11 billion pads per annum.  For comparison the figures for femcare and diapers are $5.39bn/46.9bn units and $7.36bn/29.4bn units respectively.  AI is now consuming 87,000 tonnes of nonwovens compared with 47,000 tonnes in femcare and 236,000 tonnes in diapers.  Of the body-worn AI nonwoven tonnage, 44,300 went through retail and 15,500 through hospitals and care homes.  23,500 tonnes went into underpads and 3,800 tonnes went to all AI products in Mexico. 


By 2017, 13bn units of AI products would be sold in NA, and this represented a growth rate of 3.5%, compared with 1.5% for diapers and 2.1% for femcare.  In tonnage terms the AI nonwoven use would be 103,500 tonnes compared with 52,000 of femcare and 261,000 tonnes for diapers.

The main growth driver is the increasing availability of well designed disposable light incontinence garments which are much thinner (i.e. use composite cores) and more like normal underwear.  They are stretchable, breathable and can incorporate odour control and wetness indicators for institutional use.

With 16% of the NA population expected to be over 65 by 2020, and the government encouraging home-care of the elderly, the home-care use of AI products is accelerating.  State agencies and retail organisations are therefore developing performance standards for AI.

Asked about the low growth of diaper sales, Dr Holmes thought the recession could be to blame.  What proportion of over 65’s has an incontinence problem? About 1/3rd, but the proportion rises to about 70% for the over 80’s.  Incontinence in middle aged men due to prostate problems and in middle aged women after childbirth is also on the increase. There is as yet no surgical cure for the problem.

Saturday, 6 April 2013

The State of the Nonwovens Industry

This the first of a series of summaries of papers presented at the INDA Vision Conference in Orlando, in January this year.

David Rousse, President of INDA reviewed the global nonwovens industry scene, reminding us that when a country’s Purchasing Power Parity rose above $1500 per capita per year, the disposable femcare market would begin to develop.  Above $3500/year, $8000/year and $10000/year, disposable diapers, wipes and incontinence products (respectively) would commence to be in demand.  $10000/year equated to an annual nonwoven consumption of about a kilo/capita and this consumption rose roughly linearly with PPP to reach about 5 kg/capita at the North American income of $50,000/capita. 
  • Globally 7.9 million tonnes of nonwovens were produced in 2012 and this was expected to reach 11.3 million by 2017, a CAGR of 7.6%
  • NAFTA was stuck in a low growth mode (~2%) but the dollar was stable and interest in environmental protection and sustainability was increasing.  NAFTA consumed 24.5% of global nonwovens.
  • The EU is a no-growth or declining area overall with a declining Euro and a high and increasing interest in the environment.  The EU consumed 25.5% of global nonwovens
  • Japan was declining, the population ageing, and incontinence products were now outselling disposable diapers.
  • China was growing, but less strongly, had an appreciating currency and was flirting with sustainability issues.  Population age was stable, but labour costs were increasing. China consumed 23% of global nonwovens.
  • India is where China was 25 years ago.  The rupee is down and the population is still growing. There’s no interest in sustainability and no infrastructure (outside the cities) to allow disposable use.
  • China and ROW were the growth regions.  China now operated a quarter of the world’s SMS machines.
  • Spunbond, needlepunch and spunlaced technologies were growing most (~8%/year to 2017 globally).
  • Wipes and Filtration markets were the growing most rapidly (17%/year to 2017) while nonwovens for Automotive (15%) and Construction (12%) were also doing well.
Mr Rousse suggested we pay particular attention to the following “gamechangers”:

Friday, 8 February 2013

Dude Wipes win INDA Vision Award

CARY, NC — February 5, 2013 — Incorporating social packaging and humorous, niche-driven branding, Dude Wipes from Dude Products was named the recipient of the prestigious 2013 Visionary Award, presented at the VISION 2013 Consumer Products Conference in Orlando, Florida. The Visionary Award is given to the most innovative new consumer product that utilizes nonwoven fabrics in its final form.
Dude Wipes was selected over four other finalists by the attendees at the 12th annual VISION Conference, which was held from January 28-31, 2013 at the Rosen Centre Hotel in Orlando.
Celebrating its 12th consecutive year as the most important conference bringing together the worlds of consumer products and nonwovens, the VISION Consumer Products Conference, organized by INDA, Association of the Nonwoven Fabrics Industry, attracted over 325 attendees from around the world. Through presentations and workshops by industry experts, the event once again focused attention on the growing role of nonwovens in consumer products.
The five finalists made presentations during VISION 2013 and conference attendees voted for the recipient of the 2013 Visionary Award.
Dude Wipes utilizes its novel packaging and humorous branding in its goal to change male hygiene routines and behavior. The product is wallet-sized, flushable and biodegradable and contains vitamin E and aloe.
“Dude Wipes is a superb example of innovating through clever positioning, packaging and marketing to meet the needs of a specific target market,” says Dave Rousse, President of INDA. “There were five outstanding products representing many aspects of consumer products and they were all winners by being selected as finalists in the 2013 competition.”
The other four 2013 Visionary Award finalists were:
* DiversiTech Merv 8+ and Merv 9+, DiversiTech Corporation. A pleated filter that has a full frame but takes up half a much storage space as a conventional cardboard filter because it is nestable when stacked.
* Poise® Panty Fresheners, Kimberly-Clark. These feminine fresheners are equipped with a clean and fresh scent that lasts up to four hours.
* Winged Fiber™ Facial Mask, Allasso Industries. Cosmetic facial mask made using a nylon Winged Fiber™ spunbond is loaded with essential moisturizing and rejuvenating oils and creams.
* VitaFlex Soft-Stretch Hood™, VitaFlex LLC. Utilizes a latex-free elastic nonwoven fabric to provide greener and less expensive primary head protection.
Source: INDA


Friday, 1 February 2013

INDA Vision Orlando - Day 3

...and the winner of the 2013 Visionary Award is:
David Rousse, President of INDA presents the 2013 Visionary Award to Sean Riley, Chief Executive Dude of Dude Products Inc.  Their individually wrapped wet-wipe fresheners for dudes attracted the highest number of votes from the audience.


Lee Ann Head, VP Research, Shelton Group reviews consumer understanding of Sustainability and ways of selling sustainable products in future.

Thursday, 31 January 2013

INDA Vision Orlando - Day 2

Here are a few snaps from the second day including most of the Visionary Award candidates...




 Rich Chapas describes the Nonwoven scene in India



Rick Jezzi covered nonwovens in South America









Ian Bell deals with nonwovens in the EU and Asia























Tim van Himbergen of Kimberly Clark introduces Poise Panty Fresheners

Sean Riley, Chief Operating Dude of Dude Products introdudes wet wipes for blokes

Keith Platt of Diversitech shows off the 100% PP pleated filter


Nancy Muller of the National Association for Continence Care talks absorbents in the home


Rory Holmes again, this time on Nonwovens in North America 


 Walter Chappas introduces the Winged Fibre mask



Wednesday, 30 January 2013

INDA Vision opens in Orlando

INDA's Vision Conference opened today at the Rosen Centre Hotel in Orlando with over 300 delegates in attendance




 Carlos Richer opens the conference with a 3 hour tour-de-force on diaper design


  A delegate from SCA takes issue with a point of detail


 David Rousse the new INDA President welcomes the delegates and presents the State of the Industry address


 Dick Kimberly (ex Kimberly Clark), now President of Kimberly Consulting analyses the effect of the US Presidential election on the industry


 Rob Wallace of Wallace Church anticipates his talk...


(Summaries of these papers will appear in Nonwovens Report International magazine and on this site in due course.)