MELTBLOWN/MICROFIBER ELECTROSTATICALLY CHARGED NONWOVENS &
NANOFIBER FILTER MEDIA WORLDWIDE

(Forecast 2004 - 2010)

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July, 2003


By Lutz Bergmann
FILTER MEDIA CONSULTING, INC.

Copyright © 2003 FILTER MEDIA CONSULTING, INC.

 

TABLE OF CONTENTS

PAGE

 

 

 

SUMMARY AND HIGHLIGHTS

5

 

 

 

GENERAL COMMENTS

7

 

 

 

ESTIMATED CAPACITY/PRODUCTION OF MELTBLOWN
     PRODUCERS - WORLDWIDE

8

 

     GENERAL COMMENTS

8

 

     NORTH AMERICA

9

 

     SOUTH AMERICA / MIDDLE EAST

11

 

     EUROPE

12

 

     JAPAN

14

 

     ASIA/PACIFIC - CHINA

15

 

     TAIWAN, KOREA & OTHERS

16

 

     SUMMARY CAPACITY/PRODUCTION
       WORLDWIDE 2003

17

SCOPE

18

 

 

 

MELTBLOWN/MICROFIBER TECHNOLOGY

19

 

 

ELECTROSTATICALLY CHARGED NONWOVENS

20

 

 

 

ELECTROSTATIC SPINNING

20

 

 

 

ELECTROSTATICALLY CHARGED SPLIT FILM/FIBER
   NONWOVEN

21

 

 

NANOFIBER TECHNOLOGIES

22

 

GENERAL COMMENTS

22

 

 

 

NANOFIBER FILTER MEDIA, NANOFIBER PROCESSES
   AND TECHNOLOGIES FOR FILTRATION

23

 

 

 

CAPACITIES/PRODUCTION WORLDWIDE

29

 

GENERAL COMMENTS

29

 

MELTBLOWN/MICROFIBER MANUFACTURERS
   WORLDWIDE

29

 

PRODUCTION/CAPACITY WORLDWIDE

29

 

 

 

COMPANY PROFILES (BRIEF)

32

 

GENERAL COMMENTS

32

 

NORTH AMERICA

 

 

EUROPE

35

 

JAPAN, ASIA & ROW (Rest of the World)

38

 

 

 

LIST 1012 - MELTBLOWN/MICROFIBER & ELECTRET
   NONWOVEN MANUFACTURERS WORLDWIDE

41

 

 

 

APPLICATIONS/MARKETS - DRY/AIR

55

 

GENERAL COMMENTS

55

 

HVAC (Heating, Ventilation & Air Conditioning)

56

 

     Residential Market

58

 

          Market Assessment

59

 

     Industrial/Commercial Market

61

 

          Typical Filter Configurations

63

 

          Filter Media

64

 

          Markets - Synthetic Meltblown/Microfiber/Electrets

65

 

HEPA/ULPA Filtration

67

 

     Patents and Latest Developments

70

 

     List 0109 - Fabricators of HEPA Filters

70

 

     Markets

72

 

FACE MASKS/RESPIRATOR PROTECTION

73

 

     Industrial/Disposable Face Masks

74

 

     Surgical/Medical Masks

74

 

     Canister Type

75

 

     Markets 76

76

 

VACUUM CLEANER

78

 

     General Comments

78

 

     Filter Media Aspects in Europe

79

 

     Post FILTER MEDIA CONSULTING, INC.

80

 

     Market Situation in North America

80

 

     List 1023

83

 

     Filter Media Market - Asia/Pacific

85

 

     Market Summary

86

 

AIR PURIFIERS/AIR CONDITIONER

88

 

     List 0109

88

 

     Markets

90

 

     Market Statistics

92

 

AUTOMOTIVE FILTRATION

94

 

     General Comments

94

 

     Cabin Air 95

95

 

     2002/2003 Estimated Cabin Air Filter Units Worldwide

97

 

     Estimated Media Roll Goods Worldwide

97

 

     Diesel Fuel Filters

98

 

COMPUTER DISK DRIVE FILTERS

100

 

     Filter Media

101

 

     Markets

101

 

MEDICAL DEVICES BREATHING FILTERS,
   HEART/LUNG MACHINE VENTING, ETC…

103

 

     Filter Media 1

105

 

     OEM 1

105

 

     2002/2003 Nonwoven Meltblown Composite
         Media Only

105

 

OFFICE EQUIPMENT, KAREOKE MUSIC BOX, ETC…

106

 

     Markets

107

 

CIGARETTE FILTERS

108

 

2002/2003 TOTAL MARKET SUMMARY -
   AIR/DRY FILTRATION

109

 

 

 

APPLICATIONS - LIQUID FILTRATION

110

 

Pleated Disposable Liquid Cartridges

111

 

     Filter Media

112

 

     Applications

113

 

     Market of Meltblown/Microfiber Filter Media for
        Pleated Disposable Liquid Cartridges

114

 

     Meltblown/Spray-Spun Cartridges

115

 

          Markets

116

 

     µM Rated Vessel Bags

117

 

          Markets

118

 

     Coolant Filtration

120

 

     Blood Filtration

121

 

          2002/2003 Blood Filtration Media Worldwide

124

 

     Market Summary - Liquid Filtration

125

 

 

 

FORECAST

126

 

 

 

DISCLAIMER

127

  

SUMMARY & HIGHLIGHTS

The total capacity/production of meltblown microfiber worldwide, according to this report, amounts to approximately 345 MM lbs. - 157,000 tons. Filtration represents worldwide approximately 34% - 115 MM lbs. - 53,000 tons. The estimate of meltblown materials is difficult because of the discrepancies between capacity and production and the great difference of yield in the meltblown process.

*******************

With regard to raw materials, we believe that polypropylene polymer still represents at least 85% - 90%. The remaining but growing portion is represented by PET, PE, PBT, PA, ECTFE (HALAR®), PAL and others.

********************

In calculating meltblown products, notably SMS and SMMS materials, we decided previously that the meltblown portion represents about 10% - 15% of the total product by weight with the balance being mostly spunbonded nonwovens.

********************

The total number of companies producing meltblown microfiber and nanofiber nonwovens has increased during the last few years to approximately 115 - 120. In the year 2000, we were able to identify 108 companies with address and additional details, not counting 30-40 smaller manufacturers in China.

********************

Our market estimates by companies are based on approximately $2.80 - $3.50/lb. of meltblown material for filtration, although certain products are being sold at significantly higher prices, notably pleated micro filtration cartridge media or media for blood filtration.

********************

In the year 2000, the market for meltblown microfiber electret nonwovens grew to approximately $300 million in sales. Air/dry filtration represented 60% and $180 million and 40% in liquid filtration amounted to approximately $120 million.

********************

In the year 2003 we expect that Meltblown/Microfiber/Electret nowoven roll goods will grow to $ 518.00 MM in sales. AIR/DRY Filtration $340.00 MM -65%, in liquid filtration $ 178.00 MM - 35% -. Our "courages" forecast for 2010 calls for $ 785.00 MM.

********************

Bio-terrorism has changed the way people look at filtration. The changes are significant and reflected in HVAC filtration for buildings - new systems for instance for the postal service letter distribution systems - and other applications.

********************

Of all nonwoven applications " BLOOD FILTRATION MEDIA will see the most dramatic growth, since we expect by 2006 that all blood donated will be filtered prior to be administered to patients.

********************

We used exchange rates as of mid/late June 2003:

 

$1.00 = €0.84

€1.00 = $1.18

£1.00 = $ 0.60

$1.00 = ¥120

$1.00 = RMB 8.20

$1.00 = WON 1,200

$1.00 = RAND 8.0

$1.00=$1.50 (Australia)

$1.00 = $1.35 (Canada)

 

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