Documente Academic
Documente Profesional
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DevenMehta
AGM Sales
AGM
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Agenda
PPNonwovenApplication/Markets
Propertiesofthefabric
Advantages
M k
Marketscenario
i
Whatisnonwoven?
M
ManufacturingProcess
f t i P
Atypicalmachinesetup
Rajoo ataglance
Rajoo
at a glance
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Applications
Automotive
Medical
Personalcareandhygiene
Home furnishings
Homefurnishings
Household
Stationery
Stationery
Agriculture
Geotextiles
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Applications
automotive
Floorcovers
Airfilters
Hoodsilencerpads
Sideliners
Side liners
Doortrimpanelcarpets
Door trim panel carpets
Dashinsulators
D hi l t
Frontandbackliners
Doortrimpanelpadding
Wheelhousecovers
Coverslipsheets
Carpettuftingfabricandunder
Seatapplications
Seat applications
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padding
Foamreinforcements
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Applications
medical
Surgical:
9disposablecaps,gowns,
9masksandshoecovers
Drapes wraps and packs
Drapes,wrapsandpacks
Sponges,dressingsandwipes
Bedlinen
Contaminationcontrolgowns
Examinationgowns
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Shrouds
Underpads
Procedurepacks
Heat packs
Heatpacks
Ostomy bagliners
Fixationtapes
Incubatormattress
ProtectiveCloth
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Applications
Personal care&hygieneproducts
Diapers
Di
i
Lenstissues
Sanitarynapkins
Handwarmers
Trainingpants
Vacuumcleanerbags
Incontinenceproducts
Teaandcoffeebags
Dryandwetwipes
Shoecovers
Cosmeticapplicators,removers
Buffpads
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Applications
homefurnishings
Furnitureconstructionsheeting
Beddingconstructionsheeting
Insulators,armsandback
Pillows&pillowcases
Pillows & pillow cases
Carpetbackings,carpets&
pads
p
Dustcovers
Dustcovers
Mattresspadcomponents
Blankets
Acousticalwallcoverings
A
ti l ll
i
Spring wraps
Springwraps
Tabledecoration
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Applications
house hold
Aprons
Placemats,napkins
Scouringpads
Scouring pads
Washcloth
Wash cloth
Fabricsoftenersheets
Tablecloth
Dustcloths,mops
CoatCover
Teaandcoffeebags
Tea and coffee bags
Carrybags
Carry bags
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Applications
stationery
Bookcovers
Promotionalitems
Mailingenvelopes,labels
Mailing envelopes labels
Postersandbanners
Posters and banners
Maps,signs,pennants
CDdiskliners
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Applications
leisure & travel
Sleepingbags
Tarpaulins,tents
Artificialleather,luggage
Airlineheadrests,pillowcases
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Applications
agriculture
CropCovers
Containers
TurfProtectionproducts
Capillarymatting
Nurseryoverwintering
Greenhouseshading
WeedControlfabrics
Seedblanket
Rootbags
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Applications
geotextiles
Asphaltoverlay
Golfandtenniscourts
Roadandrailroadbeds
Artificialturf
Soilstabilization
Sedimentationanderosioncontrol
Drainage
Damandstreamembankments
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DesirableProperties
Abrasionresistant
Absorbent
Antistatic
Breathable
Conductive
Colourfast
Crease resistant
Creaseresistant
Dense
Drapeable
Drycleanable
Durable
Durable
Dustfree
Elastic
Flameresistant
Foldable
ld bl
Heatsealable
Impermeable
Kindtoskin
Light
Longlasting
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Combinationofmanyfeaturespossiblewith
PPnonwovens
Lintfree
Mouldable
Nonconductive
Nonfading
Permeable
Porous
Printable
Printable
Protective
Sewable
Smooth
Soft
Soft
Stable
Sterilisable
Stiff
Strong
Tearresistant
Washable
Waterrepellent
Weatherproof
Weldable
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Advantages of Nonwoven
AdvantagesofNonwoven
Fabricatedmuchfasterwithgreaterflexibility
Fabricated much faster with greater flexibility
Canbeslitinbothdirectionswithoutfraying
y g
Heatsealed/seamed/folded/shapedinavarietyofways
Ultrasonicweldingpossible
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60%nonwovensusageisin
disposableproducts
Currentnonwoven
productionlevelin
Indiaisonlyabout
70,000tonsper
annumwhichwasthe
samelevelinChina,15
yearsago.
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What is PP Nonwovens?
WhatisPPNonwovens?
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PP Nonwoven Fabric
PPNonwoven
Flat flexible porous sheet structure
Produced by interlocking layers or networks of
fibers, filaments.
Classified as disposable or durable nonwovens
based on usage.
Disposable applications include Baby Diapers,
Adult incontinence products, Feminine Hygiene
products, Wet Wipes.
Durable applications include Filtration Media,
Protective Apparel, Geo textiles, Home
Furnishings, Automotive and Agricultural fabrics.
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12to25MFI
Spu
Spunbondedprocess
bo ded p ocess
20to35MFI
0 o 35
Meltblownprocess
450to1200MFI
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Basepolymercost
Basic cost of Filler (upto 50%)
BasiccostofFiller(upto50%)
EffectivecostperKgofRawmaterial
Rs.80/ Kg
Rs. 40 / Kg
Rs.40/
Rs. 60/ Kg
ConversionintoNonwoven
Directcost
=
Rs.9/ Kg
Indirectcost =
Rs.5/ Kg
Packingcost =
Rs.1/ Kg
SalesRealization
NettValueaddition
=
=
Rs.115/ Kg[uptoRs120/ ]
Rs. 35toRs. 45PerKg
GrossProfitat80%capacityutilization=Rs.1200M.Ton xRs.35,000
=Rs.420Lacs /year
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Prospecctsarerequestedtoch
heckthesenumbersindependently.Rajooisresponsibleforcorrrectnessofthisdata.
Manufacturing process
Manufacturingprocess
Nonwoveniscommonlymanufacturedby threeprocesses:
Spunbondedprocessdirectextrusionfollowedbyonlinethermalweb
bonding
Meltblownprocessfollowedbyonlinewebbonding
Staplefiberprocessfollowedbycarding
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Auxiliaryequipments
Extruder
Refrigerationforchilledair
RecycleExtruder
OilheatingSystem
Spinning&stretching
Webforming
Blower
Spinneretsultrasoniccleaner
Spinnerets ultrasonic cleaner
Thermalbonding
Coolingtower
Winding
Slitting /Rewinding
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RENW1513/1600 Finishedwidth1600mm
RENW1515/2400 Finishedwidth2400mm
RENW1515/3200 Finishedwidth3200mm
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mm
Screw length
30 & 15
Spinneret width
mm
1910
mm
1600
Fabric
Fabric weight range
gsm
12 to 150
Average output
kg/hr
225
mts/min
15.0 150.0
Filament denier
denier
1.8 to 3
kW
434.13
Space
S
requirement
i
t (LxWxH)
(L W H)
mm
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mm
Screw length
30 & 15
Spinneret width
mm
2710
mm
2400
Fabric
Fabric weight range
gsm
12 to 150
Average output
kg/hr
325
mts/min
15.0 150.0
Filament denier
denier
1.8 to 3
kW
528.37
Space
S
requirement
i
t (LxWxH)
(L W H)
mm
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mm
Screw length
30 & 15
Spinneret width
mm
3510
mm
3200
Fabric
Fabric weight range
gsm
12 to 150
Average output
kg/hr
450
mts/min
15.0 150.0
Filament denier
denier
1.8 to 3
kW
562.79
Space
S
requirement
i
t (LxWxH)
(L W H)
mm
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Filament spinning
Filamentspinning
The molten polymer is emitted through the spinneret holes. When the
emitted filaments pass through quench chambers, cool air is directed
across the
h filament
fl
b dl to cooll the
bundle
h molten
l
fl
filaments
sufficiently
ff
l to
cause solidification.
quenchingg can be done byy blowingg air with a twosided inflow q
quench
The q
air supply box.
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Web formation
Webformation
The filaments are deposited on a moving belt. High pressure air through a
blower is used to move the filaments and a vacuum under the belt helps in
f
forming
i the
th filament
fil
t web
b on the
th forming
f
i belt.
b lt The
Th filaments
fil
t are separated
t d by
b
aerodynamic force before reaching the belt to achieve maximum uniformity
and cover.
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Singlerowoffilamentsblownintofinefibers(1to10micron) byheatedairjet
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Melt
blown
fiber
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AGlimpseof
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Overview
Vision
Coreteam
Productportfolio
Infrastructure
Culture
Expandingfootprint
Credentials
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Vision
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Core team
Coreteam
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Product portfolio
Productportfolio
FabRex PPNonWovenFabricExtrusionLines
Foilex UpwardextrusionmonolayerblownfilmLines
Multifoil UpwardextrusionmultilayerblownfilmLines
Aquaflex Downwardextrusionmono&multilayerblownfilmlines
Lamina Monoandmultilayersheetlines
Fomex PhysicalandchemicallyfoamedPEsheetlines
p y y
Fomex EPS Foamedpolystyrenesheetlines
Dispocon Thermoformerssolid&foamed disposablesline
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Design centre
Designcentre
22Qualified
22
Qualified
DesignEngineers
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vertical
X3200
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CULTURE
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Culture Environment,healthand
Culture
Environment, health and safety
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going green
goingpaperless
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Culture wecare!
Culture
we care!
Blooddonationcamp
RELclub milkdistribution
activity
ti it
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Ruraleducationalprogram
Fl h ti b
Flaghostingbyruralkids
l kid
Trainingprogramfor
educationalInstitutes
d ti
l I tit t
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Expanding footprint
Expandingfootprint
I t ll ti
Installationsin52countries..
i 52
ti
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Colombia,Mexico,Ecuador,Argentina
Europe
E
UK,Germany,Spain
UK G
S i
NorthAmerica
USA
Gulf
Gulf
Iran,Kuwait,UAE,Oman,SaudiArabia,
Iran Kuwait UAE Oman Saudi Arabia
Egypt,Syria
EastAfrica
y ,
,
, g
Kenya,Tanzania,Malawi,Uganda
WestAfrica
Nigeria,Ghana
SouthernAfrica
RSA,Zambia,Leshoto,Botswana
AsiaPacific
Malaysia,Vietnam,Thailand,
SriLanka,Nepal,Pakistan,Bangladesh
Australasia
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PapuaNewGuinea
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Credentials
Commenced business as Rajoo
Engineers Pvt. Ltd. at Manavadar, a
small village In Junagadh district to
manufacture mechanical cutting
sealing machines.
1986
1988
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1990
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Credentials
1991
Introduced
the
first
ever
indigenously
designed
and
developed Oscillating Haul off
system for blown film lines and
displayed at Plastindia 1994 over
100 installations now.
1994
1995
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Credentials
G rooved feed extruder with barrier
screw first
fi t time
ti
i Asia
is
A i over 600
extruders operating worldwide
1995
1996
Internal bubble
during Plastindia
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cooling
system
1997
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Credentials
2000
5 layer stack die (UCD) with
horizontal first time in India and
4th in the world during Plastindia
2000 over 40 such
h dies
di
i
in
operation.
2000
2001
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Credentials
Introduced Indias first Electrohydro
pneumatic plugassist thermometer
with
inmould
cutting
for
Polypropylene & PS containers.
2002
2003
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2003
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Credentials
a)
2004
2005
a)
2006
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Credentials
2007
2009
2010
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Vacuum forming
V
f
i
machine
hi
with
ith
mould : model RECR 7086 XPS
received and award Machinery for
packaging operations from IPMMI
IMDIR 2009.
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Credentials
2010
Wonderpack merger : A unified approach for
the benefit of the thermoforming industry
Rajoo Engineers JV with Bausano of Italy :
plastic pipe manufacturing industry in India to
gett a fillip
filli
Rajoo Engineers forges ahead; Technical
collaboration with Hosokawa Alpine AG,
Germany
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Credentials
2011
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Thankyou
ww w .rajoo
j
.com
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