The demands for fabrics have increased sharply. Conventional textiles are not able to meet the production cost and higher cost of upgradation along with demanding consumers in new fields of consumption. With better customization of characteristics into the fabric and appropriateness to certain end uses being advantages, nonwovens have emerged rapidly as the fabrics of the future.

Nonwoven fabrics presents many advantages over conventional fabrics, the clearest benefit is cost savings. In recent couple of years the nonwoven industry has emerged at a rapid speed, offering a huge range of products to several diversified fields. Conversely, nonwoven fabrics hold some natural characteristics, which led them to be counted for non-usable in certain applications. At present, many research and development has been conducted on enhancing the characteristics of nonwoven fabrics. Nonwovens are also entering into some astonishing fields, with making its mark in fashion apparel also.

Currently, three fibers lead the worldwide market:

Polypropylene (synthetic – 63 percent)

Polyester (synthetic – 23 percent)

Cellulosic staple fiber (natural-based 8 percent)

Manufacturing Process

To manufacture a nonwoven fabric, first a web is made, and then it is tied (bonded together) to give strength. Usually, Nonwoven fabrics are made from two processes, a one-step or two-step.

One-step process: In this process, the formation of web and bonding is conducted continuously. The processes, spunbond and melt blown are considered under one-step.

Spunbond process: The thermoplastic fibers are extruded via a spinneret, and then is it spread on a conveyor belt to make a web. Following the process, the web is bonded by passing it through two calendar rollers.

Melt blown process: The thermoplastic fibers

The textile materials mostly produce by synthetics in various decompositions, utilized in the mode of either woven or nonwovens. The fabric form is broadly utilized in the places where tensile strength and dimensional stability are measured to be compulsory for caring the plantations from natural circumstances.

The application of agro textiles will be helpful in terms of products with enhanced quality, higher production, less damages and bearable losses. It also allows us to apply less numbers of weed killers and pesticides. Alternatively, it helps the society by avoiding various hazards due to environmental pollution, etc.

The benefits of applying agrotextiles are:

. They increase crop production

. They avoid the soil from drying out

. They decrease the requirement of fertilizers, pesticides and water

. They make product quality better

. They increase the early maturing of crops and non-seasonal plants

There is various type of agrotextiles considered to train or tie up plants. Their object is

. To avoid branches from breaking

. To increase the cleanliness of the crop

. To make harvesting easy

. To give large space

HaiI protection fabrics

Hail protection fabrics supports shield vines from the fruit damage and defoliation connected with hail yet lets through adequate sunlight. The weightless netting is harsh, tear resistant, and extremely UV stabilized and processes an extra advantage of protecting vines from wind and birds. These fabrics are also applied to protect fruit, herb, and vegetable crops which are to be healthier and offer greater production when cared from the havoc of hail. The fabric provides light shading as well as safeguarding from wind and birds. These fabrics are produced by UV stabilized polyethylene mono filaments both woven and knitted form.

Structural aspects

. Diameter of monofilament: 0.25 to 0.30 mm

. Mesh width: 10 x 4 mm

. Weave : Leno

. Knitted Design: Raschel warp diamond design.

Advantages

. Hail shielding with smallest amount shading.

. Improved crop production.

. Durable, tear-resistant netting.

. Greatest ultraviolet stabilization for long life.

. Extra protection from birds and wind.

. Service life: 15-20 years.

Wind control fabrics

Wind control fabrics can get fruit quality better by decreasing bruising, shoot tip scorching. Trees that are cared from wind are normally healthier, achieve complete growth more fastly, and have greatest production. Wind break fabrics safeguard crops from wind, and in particular situations, orchard temperatures can be raised by decreasing wind speed. Windbreak fabrics start obstructing wind without delay, don’t harbor insects, consider less maintenance, and will not compete with crops for water and nutrients. UV stabilized fabrics offer years of wind safeguarding for crops. These fabrics are also produced by UV stabilized polyethylene mono filaments both woven and knitted form.

Advantages

. Instant wind protection.

. Less bruising, wind rub, and shoot tip scorch.

. Very useful and safety of orchard spraying.

. Unlike tree barriers, no competition for water and nutrients.

. May raise orchard temperatures by decrement of wind speed.

. Strong, long lasting fabrics.

Characteristics

. About 45 percent wind blockage.

. Protects nearly 8x windbreak height.

. UV and abrasion resistant.

Fabrics for weed safeguarding

Of all landscape maintenance programs, control or removal of weed progression is a foremost part. Weeds are not needed because of aesthetic detraction; competition for light, water, nutrients, and space; prerequisite of insect and disease habitats; and possible allelopathic growth suppression.

Nearly all landscape maintenance plans depends on hand weeding, herbicides, and mulches (alone or in combination) to suppress and manage weeds. Black plastic has traditionally been applied by majority landscapers to improve the effectiveness of organic and inorganic mulches, but many reports noted unfavorable effects on landscape plant growth because of its application.

In the last few years, a new group of synthetic materials has been established for use with mulches for landscape weed control. These geo-textiles (also describe landscape fabrics or weed barriers) have one key benefit over plastics – they allow the exchange of water and air between the soil and the atmosphere. Many reports have been observed on the weed-suppressing effects of these geo-textiles, with combination of results. While the majorities are quite effective at controlling annual weeds, managing perennial weeds is often weak. The producers suggested using a 2-3-inch layer of mulch atop the geo-textiles for aesthetic reasons, and as a consequence, numerous problems have been noted, mainly when organic mulches (pine bark, pine straw, hardwood bark, etc) are utilized.

Sunshade fabrics

The fabrics produced by polypropylene monofilament strands in both woven and knitted form are applied to provide as sun shade fabrics to improve a microclimate for plantation of flowers, ornamental plants and fruits.
Woven sunshade fabrics

It is produced by 100 percent polypropylene monofilament strands. The resin is prepared with additives and pigments to offer resistance to sunlight and weathering. Black pigmentation gives a high degree of sunlight resistance. It is UV stabilized to restrain under the most intense solar settings. It can be applied for several of uses like wind and privacy screen, shading for sports and recreation, livestock, patio, dog kennels and solar protection for plants.

Knitted sunshade fabrics

Knitted sunshade cloth is produced by 100 percent UV stabilized polyethylene. Its exclusive lock stitch structure permits customers the facility to cut the fabric with scissors without further unraveling. Knitted shade fabric is offer in several of colors and stripes. Its lightweight and durability make it a greater selection for all types of shade uses.

Uses

. It improves the condition of growth.

. Soil is not dehydrated.

. It provides savings in irrigation cost.

Insect repellent fabrics

A variety of pests like Whitefly, a number of insects harm some ornamental plants and vegetables regularly. Many viruses infect these plants. The affected leaves of the plants offer increment to the creation of black fungus due to the honey dew on the leaves left by the viruses. The creation of insect repellent fabrics has provided a way to protect the plants and vegetables. This kind of fabrics are extended from corner to corner in the open-air plantations so that the pests can no longer affected to the plants and also the climate will not be unstable in any way.

Setting up of areas cover:

. The whole walls of green-houses.

. On the roof-openings and vent openings of green-houses.

Structural aspects

. Weave: Linen

. Material: Polyethylene mono filament yarns

. Yarn Diameter: 0.25 mm

. Cloth density: 24 ppcm x 11 ppcm

Temperature control fabrics

Temperature control fabric is a nonwoven, spunbonded polyester fabric made to safeguard crops from cold, frost, insects and a range of unfavorable environmental aspects. Temperature control fabric supports in capturing heat on sunny days and keeps heat radiating from the ground at night. This helps in safeguarding precise ornamentals, nursery stock and foliage 24 hours a day.

Cold and frost control fabrics

Frost & cold protection fabric safeguards plants from frost kill in sudden late cold snaps and unseasonably early ones. Frost & cold protection fabric can be placed appropriately on the plants, unlike plastic covers that can draw attention to frost and burn any leaves that contact them. Cold safeguarding tough fabric row covers are ideal for safeguarding less developing, high value field crops from frosts, wind, cold, and birds. The woven, semi-clear fabric permits sunlight, air, and water through to the plants. The fabric can be applied unaided or over wire hoops. The covers are tough, and can survive in long run, for a lot of growing seasons.

Advantages

. Facilitate trap ground heat to warm crops.

. Permits sunlight and water through to crops.

. Prevents extreme heat build up.

. Re-applicable for many seasons

Rain protection fabrics

Rain protection fabrics safeguard the flowers and berries from harm in rainfall. The fabrics may have network like configuration to offer the purpose of saving from rain.

Conclusion

The practice of textiles is also now widen to safeguard the agro products like plants, vegetables and fruits from weather, weed and birds, etc, by method of agro textiles which has provided a novel applications to technical textiles.

These are generally made up of woven, non-wovens and knitted type of fabrics. Geo-Textiles are the largest group of geo-synthetics in terms of volume and are used in geo-technical engineering, heavy construction, building and pavement construction, hydro-geology, environment engineering. Technical Textiles is the fastest growing branch of textile industries worldwide with bright prospects. The total global sale of Technical Textiles in 1995 was US$42 bn. It is estimated to be US$72 bn in 2005 and is expected to reach US$126 bn by 2010. Asia is the chief producer and consumer of Technical Textiles.

Uses of different types of Geo-Textiles are as follows:

Woven geo-textiles concrete bases used for coastal works, water ways, embankments and in forming geocell for road

Nonwoven geo-textiles used for Filtration, drainage, reinforcement between soil stone or aggregate and in roads, railways works, erosion prevention and separation. As filter fabric for dams, under drainage system liners for pile foundation, coated pvc and bitumen s to skin traction

Knitted geo-textiles used Knitted bags for protection of dam’s riverbank etc. Warp knitted fabric of Kevlar yarns used in automobile and marine application.

It is also used with foundations, soil, rock, earth or any other related material as an integral part of human man made project, structure or system.

The first example of a geosynthetic textile application is the use of a prefabricated pocket style vertical drain made from a nonwoven filter jacket specialized as a PVD filter material. The purpose of this product was to reduce the time needed for construction by quickly discharging water in the ground which speeds up the soil consolidation process. Overall, it proved to reduce construction time and speed up the consolidation of soft ground in a variety of different situations including road construction, the development of building sites, construction of gas and oil storage facilities, and bank revetment.

The second example of how geosynthetic textiles can provide solutions to civil engineering problems is the polyester woven geotextile mat. It is created from a high tenacity polyester filament which is highly dense. This particular geosynthetic textile has been used to reinforce soft ground and embankments, separate layers of sand and soft ground, prevent the uneven settlement of soft ground, and securing a safe path of travel for heavy equipment across soft ground.

The third example is a silt curtain or fence created by geosynthetic textiles. A silt curtain is installed in the water to prevent the spread of environmentally dangerous contaminants. These contaminants often result from coastal and Riverside construction projects although it can also be used in the event of an open water spill or leak. It has been shown effective at preventing the spread of fine soil and sand induced by construction. It can also prevent the contamination of the nearby seaports and help preserve sea farming and area beaches.

The fourth and final example of geosynthetic textiles assisting with civil engineering problems is the polyester needle punched nonwoven geotextile. It is typically made of continuous filament fiber to promote fast drainage and filtration. It has been used to help prevent landslides, control erosion on banks, protect waterproof layers in landfills, prevent road tracking, and protect waterproof sheets and tunnels.

There is no doubt geosynthetic textiles will continue to play a greater role in finding workable solutions to civil engineering problems across the globe. As their production continues to scale, prices will decrease which will lead to an increase in availability as well as further research and development.

This insight refers to all industrial nonwovens which are sold business to business and are used mostly in commercial operations. Applications are diverse, and include automobile body degreasing, hard surface cleaning and skin preparation. In 2012, the global consumption of industrial non-wovens was 3.30 million tonnes, and this is forecast to reach 4.95 million tonnes by 2017.

In this insight, we examine: what are the main drivers behind this impressive growth of industrial nonwovens?

1.) Low raw material supply and cost
Industrial nonwovens are less expensive to produce than most alternative products. This low cost is measured not only in currency but in consumption of raw materials. Nonwovens use a significant percentage of European and American wood pulp, which is not petroleum based, and is also renewable and relatively inexpensive. As oil is expected to increase in both demand and price until 2017, use of natural fiber for nonwovens in the place of petroleum based material is favourable.

Water is also becoming a scarce resource as industries and populations compete for supplies. Woven cotton textiles require a great deal of freshwater irrigation, as well as chemical fertilizers and pesticides. The replacement of woven cotton textiles with wood pulp and/or rayon-based nonwovens therefore not only saves money, but valuable resources.

2.) Advantageous manufacturing processes
Nonwovens are usually made using relatively new technologies and use less energy, produce minimum effluent and require fewer raw materials than older methods of production. For example, the now common spunbonding process is only around 50-60 years old, whereas textile spinning and paper-making have been around for a few thousand years.

There are also fewer resources required during the nonwoven production process. Spunlaid, needlepunch, carded and airlaid nonwovens use little or no water, while spunlace uses almost no chemicals and recycles 99% of the water it uses. Nonwoven processes are typically very flexible. This has meant that many industrial processes can rapidly and inexpensively change to produce multiple different products, allowing a much greater degree of product diversification than is possible with wovens or other materials.

3.) Regulation and sustainability concerns
Environmental responsibility influences the manufacturing methods of most industrial products, and nonwovens are no exception. Regulatory pressures and retailer proactivity have meant that movement towards sustainability is now common in this market.

Those in the nonwovens industry feel that sustainability is a need driven by both consumers and governments, and the time to act is now rather than later. For example, while packaging has been the main area of emphasis, Walmart has acknowledged that other areas, such as nonwovens, are also important.

This impacts both the consumer nonwovens market and the industrial nonwovens sector, and the suggestion that the world’s largest retailer might judge and select nonwovens based on the environmental performance of the suppliers has had an immense effect. A wide variety of products have begun changing for environmental reasons: airlace, with woodpulp replacing rayon in traditional spunlace for wet wipes, airlaid pulp replacing highloft polyester in automotive insulation, and a new ‘repurposed cotton’ fiber for use in spunlace are now marketed.

4.) High performance
In some cases, industrial nonwovens materials deliver properties unattainable by other materials, leading to their increased popularity. Exemplary materials include clean-room wipes, which provide a highly entangled web with high strength and abrasion resistance. The large quantity of water used at high pressure tends to remove all loose fibers or particles all at high speed and relatively light basis weights. There are no woven products comparable.

There are dozens of other instances where nonwovens just perform better than equivalent products, from industrial wipes to automotive insulation, from packaging to battery separators. Sometimes the pure performance of a product rather than cost or convenience drives this market.

5.) New and competitive materials
The nonwovens market continues to evolve and adapt in order to best serve the needs of various industries, especially in terms of cost and performance. In spunlace, a precursor web containing segmented bicomponent fibers makes it possible to produce both a cost-effective and high performance microfiber substrate, useful in filtration and industrial wipes.

Airlaid is already 80-90% wood pulp, one of the most sustainable raw materials in nonwovens. Low-density versions are a suitable replacement for foam plastic packaging, and combined with a dispersible binder, airlaid is perfect for repulpable packaging or flushable wipes. This constant adaptation to keep up with a fast-moving industry has meant that the global market for nonwovens shows no signs of slowing down anytime soon.

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