Nonwovens – current trends and forecasts of the outgoing year

Global nonwovens industry. The forecast is up to 2029.

In 2024, the global consumption of nonwovens will amount to 15.2 million tons in the equivalent of 62.8 billion US dollars.

It is predicted that in 2029, the consumption of nonwovens in the world will reach 21.3 million tons.

Disposable end-use hygiene products (diapers, underpants for babies, hygiene items for adults suffering from incontinence) and wipes will become the largest sectors between 2024 and 2029 in terms of consumption volumes.

According to forecasts, nonwovens will only benefit from an oversupply on the global market (their supply will be determined by lower cost and availability). The consumption of nonwovens will increase due to segments that are either recession-resistant (for example, baby diapers) or strengthened by the recession (for example, geotextiles/construction nonwovens for infrastructure projects).

Nonwovens «spanlace». The forecast is up to 2028.

The global drive to reduce/eliminate the use of plastic in napkins is conducive to the development of spunlace technology. Several new variants of the same name materials for napkins that do not contain plastic have been developed. Spanlace will remain the main nonwoven fabric for the production of napkins until 2028.

In 2023, the consumption of spunlace nonwovens amounted to 1.8 million tons worth 10.3 billion US dollars. In physical terms, spanlace will account for 12.7% of the market in 2023, and by 2028 this share will increase to 14%. In value terms, spanlace will occupy 17.5% of the market in 2023; by 2028, this figure will increase to 20%. The projected growth rate of the market from 2023 to 2028 is 8.65% in volume and 10.1% in value.

In 2020, spanlace was used in products such as disinfectant wipes, antibacterial wipes, other medical wipes and medical clothing, which played a crucial role in combating the spread of Covid-19. This demand persisted as most governments identified the production of spanlace materials, and its conversion into end products, as the most important industries. Most manufacturers and processors were operating at full capacity in 2020 and 2021.

Manufacturers of nonwovens spanlace report difficult current conditions. There are a lot of questions about what to do with excess stocks as a result of oversupply, which was stimulated by the pandemic. Spanlace is by far the most active technology that has responded to the call for the production of plastic-free products. Napkins are the main end product of spanlace, and spanlace is the main nonwoven fabric used in napkins.

Components of hygiene products. The forecast is up to 2027.

Globally, final hygiene products are relatively recession-resistant, and therefore, by 2027, their growth is projected to be about 20-25% faster than projected global GDP.

According to forecasts, by 2027, the market for hygienic components made of nonwovens will reach 8.3 million tons, which is estimated at $ 33.4 billion.The growth rate for 2022-2027 is 6.3% both in terms of value and market volume.

The global market for hygienic components made of nonwovens includes the largest segment of nonwovens, as well as a large segment of films and paper napkins. Many hygiene products such as baby diapers and feminine hygiene products have become essential items. But these products also need to evolve. Global issues of sustainable development, cost reduction and productivity improvement should be addressed in the development of hygiene products and their components. The need for an improved hygienic product generates a need for new and improved components. Some components are really new: fabric-like backstitches, breathable backstitches and middle layers (core) without the use of cellulose did not exist ten years ago.

Despite the global drive to increase sustainability and reduce the use of plastics, the amount of polymer materials and fibers in hygiene components will actually increase slightly between 2022 and 2027. This will happen for several reasons: large installed capacities for the production of nonwovens based on polymers and plastics, the lack of products based on more "sustainable" (green) materials, as well as the lack of capacities for the production of components and nonwovens that would be more stable or do not contain plastics. However, in general, the growth rate of plastic use has slowed down, and the use of plastic in hygiene products and components is expected to decrease in the future.

Napkins. The forecast is up to 2027.

In 2022, the global nonwoven napkin market consumed 1.5 million tons or 27.5 billion meters of² nonwovens worth 20.8 billion US dollars. It is predicted that in 2027, the global napkin market will consume 2.1 million tons or 41.6 billion m² nonwovens worth 29.0 billion US dollars. The projected growth rates for 2022-2027 are 7.4% (tons), 8.6% (m²) and 6.8% (sales in US dollars).

While the growth of some segments will continue to slow down in response to global economic challenges, other segments will thrive as the pandemic has accustomed consumers to disinfect and clean in larger volumes than it was done before.

Although Covid-19 had a strong impact on individual segments of the napkin business in 2020, this effect was limited and short-lived. Demand for most consumer wipes increased in 2020, while demand for most industrial wipes decreased; the overall effect was to accelerate the growth rate of demand for all wipes by about 3% in 2020, followed by a return to almost normal rates in 2021-2022.

Some segments, including disinfectants and medical wipes, are projected to remain above historical levels until 2027.

Conversely, it is predicted that napkins for catering establishments and general-purpose industrial napkins will lag behind historical levels until 2027.

Nonwovens "wetlaid". Forecast to 2027

Global consumption of nonwovens "wetlaid" in 2022 amounted to 687,300 tons worth 2.1 billion US dollars. The growth rates for 2017-2022 amounted to 6.3% (tons), 6.5% (m²) and 6.2% (US dollars). The growth rates reflect the impact (negative and positive) of Covid-19 to final product markets.

Key trends: the use of nonwovens in electric vehicles (in lithium-ion batteries as separators); potential bans on single-use plastics; the general movement for sustainable development; the development of the segment of washable wipes.

Growth rates for 2022-2027 are projected at 5.7% (tons), 6.4% (m²) and 6.4% ($).

Meltblown. Forecast to 2028

The global consumption of nonwovens produced by melt extrusion is estimated at $1 billion in 2023.

Global consumption of meltblown nonwovens in 2023 will amount to 253,500 tons or 4.0 billion (m²) worth 1 billion US dollars.

The growth rates for 2018 and 2023 amounted to 5.6% (tons), 5.3% (m²) and 6.3% (US dollars). As the surge caused by Covid subsides, the growth rate returns to a level that is slightly above historical averages.

The sharp recent fluctuations in sales of meltblown nonwovens ended in 2023. After the Covid-induced increase in consumption by more than 70% between 2019 and 2020, there was a corresponding correction in 2021 and 2022, when consumption decreased by almost 0%. Consumption in 2023 remained about 20% higher than in 2019. For the entire period of 2018 and 2028, the cumulative annual growth rate of meltblown materials is projected at 5.3%. This is only slightly higher than the growth rates that were predicted before Covid.

Meltblown nonwovens have played a crucial role in the fight against Covid-19. In particular, the most popular meltblown products were face masks, especially N95 type masks, respirators, other personal protective equipment, medical clothing, filters, etc.

In 2019, most of the nonwovens produced by melt extrusion were produced in Asian countries, and meltblown accounted for less than 1% of total nonwovens production in Asia. In 2020, global consumption increased to 367,800 tons/g, an increase of 77.4%. Production of meltblown for masks increased by more than 800% in tons.