Shaping the future of fibre technology FiberVisions

SHAPING THE FUTURE OF FIBRE TECHNOLOGY

FiberVisions is the global leader in the development and supply of polyolefin monocomponent staple fibres for nonwoven applications. Philip Yorke talked to Garret Davies, the company’s director for strategy and business development, about its enhanced performance fibres and continuing global expansion.

FibreVisions grew out of the Fibres Division of Hercules Inc, which was established in the 1960s and initially produced fibres for the furnishings and carpet markets. Through its ongoing commitment to R&D and market development, the division created many new innovative applications, especially in the fast growing nonwoven fabric area. Through a number of strategic joint ventures and more recently in 2000 after a joint venture with JNC Corporation of Japan (formerly known as Chisso Corporation), the company significantly expanded its line of bicomponent fibres with the formation of ES FiberVisions.

In January 2012 a leading publicly traded company, Indorama Ventures Limited (IVL), acquired FiberVisions. Indorama Ventures is a leading producer in the polyester value chain with manufacturing sites in Asia, Europe and North America. Today the IVL Group employs over 10,000 people and in 2011 recorded consolidated sales of more than $5.5 billion. This new ‘marriage’ creates even greater development and manufacturing opportunities for FiberVisions and enhances still further the company’s position as the number-one global-player in both polyolefin staple fibres and bicomponent fibres. FiberVision’s state-of-the-art manufacturing facilities are located at five key sites around the world and produce innovative fibre solutions for a diverse range of industries, including those involved in hygiene, textiles, automotive and construction.

Focus on hygiene and highperformance fibres

FiberVisions is well known for its range of advanced polypropylene (PP) staple fibres, which are the lightest of all commercial fibres.

The low density allows users to make a nonwoven fabric in the same weight range as competing fibres, but with significantly improved coverage. Alternatively these fibres can be produced to make a fabric in a lighter weight range but with the same coverage resulting in lower material costs. PP fibres have high tensile strength, offer excellent resistance to chemicals, and can be made with a broad range of elongation properties.

In addition, FiberVisions offers a wide variety of products to meet its customers’ specific needs, with different diameters, finishes, colours, fibre lengths and special additives for enhanced performance. These value-added properties include variations in softness, wettability, opacity, adhesion, antimicrobial, and UV resistance. Many of these properties have been applied to its hygiene fibres for products such as baby

diapers, sanitary napkins, adult incontinence products and disposable wipes.

Mr Davies said, “The acquisition of FiberVisions by Indorama Ventures has provided added impetus to our R&D and manufacturing capabilities in a number of key areas. In particular I am talking about the hygiene and automotive sectors where we are building on a strong presence with a range of new innovative products. We have extensive R&D facilities in North America and Europe which are focused on the development of speciality fibres for a large base of applications in the hygiene area and a growing number of applications in automotive, filtration and insulation.

“We are proud of our track record as pioneers of new fibre technology which over recent years has included a range of fine PP fibres for carded thermal bond applications, special finish for air-laid fibres that reduces dusting in air-laid nonwovens containing fluff pulp, and disperse-dyeable PP staple fibres, in addition to many others.”

Mr Davies added, “Regarding new products, the majority of our product development efforts are customer-specific and so we are limited in what we can disclose. However, the major trends that we are responding to are lowering the cost-in-use, allowing customers to use a wider range of materials, such as the variety of materials that can be bound together, and offering them the opportunity to use different non-woven converting processes. In relation to our hygiene products, this means more softness, enhanced appearance and improved fit.

In the automotive sector, one growing area for our fibres is their use as binder fibres in combination with other synthetic and natural fibres, allowing the production of lightweight, strong and stiff composites that offer excellent stability and acoustic properties.

“We sell our fibres in all regions of the world with our largest markets being North America, western Europe and Asia. We see growth opportunities in all regions, particularly in the fast-growing Asian markets.”

More flexible bicomponent staple fibres

FiberVisions’ range of advanced bicomponent fibres are available through its joint venture, ES FiberVisions. These bicomponent fibres allow customers to manufacture nonwoven fabrics without the need for chemical binders. These fibres can also be heat sealable and laminatable to polyolefin-based materials without binders, as well as being heat-mouldable. ES FiberVisions supply a wide range of bicomponent fibres and their inherent flexibility offer varying cross-sections, different sheath materials, a wide variety of core materials and a range of special finishes to enhance overall performance.

Global R&D facilities

All ES FiberVisions’ R&D is carried out in a global environment with research labs in the USA, Denmark and Japan. These facilities include pilot production operations for fibres and nonwovens as well as full analytical labs. Some of the key benefits include fibre production lines which can vary in scale from small to large and can simulate a real-world production line. Furthermore, each site has pilot card lines with calendar and through-air bonding. In the USA, FiberVisions’ R&D facility has the capability to make air-laid products and its analytical labs have a range of polymer, fibre and non-wovens testing capabilities. Many of the world’s leading companies and converters use FiberVisions’ pilot lines for their new product creations, which offer a convenient and cost-effective way to make concept samples for new products. n

For further information about FiberVisions pioneering products and services visit: www.fibervisions.com