NONWOVEN MATERIALS MARKET ANALYSIS

Global nonwoven materials market is expected to reach US$ 83.76 Bn by 2031, from US$ 50.61 Bn in 2024, exhibiting a compound annual growth rate (CAGR) of 6.5% during the forecast period.  Nonwoven materials are structures bonded together by interweaving filaments or fiber chemically, mechanically, or thermally. Nonwoven materials have applications as filtration materials, household fabrics, and are also used in personal care and hygiene products. The use of renewable resources in various industries for the production of polypropylene is expected to attract a larger customer base.

Carbon footprint and life cycle analysis are the main factors in the manufacturing of nonwoven material-based products. The disposal of nonwoven materials is a major concern for manufacturers. For instance, disposal of wet wipes, refreshing towels, and other similar products poses a threat to the environment. These products does not disintegrated fully, and can clog the sewage system when flushed, and this can lead to additional expenses for cleaning the sewage. These factors can prompt users to opt for alternative products made from cellulose, viscose, and others, and hamper the growth of the global nonwoven materials market.

Global Nonwoven Materials Market Regional Insights:

• Asia Pacific is the largest market for nonwoven materials, and accounted for a market share of 42% in 2023. Growing construction industry in the region, along with rising demand for nonwoven products, can drive the market growth in the region. Asia Pacific dominates the global nonwoven materials market due to rising demand for hygiene products.
• North America accounted for 30% of the market share in 2023. The market growth in the region can be attributed to increase in demand for medical and automotive products.
• Europe accounted for a market share of 18% in 2023. Growing automotive sector and increased online product delivery services across developed countries in Western Europe including Italy, the U.K., Germany, France, and Spain has positively influence the market growth in the region.

Figure 1. Nonwoven Materials Market Share (%), By Region, 2023

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Analyst’s Views:

Global nonwoven materials market growth is driven by increasing demand from hygiene and medical applications. Asia Pacific currently dominates the market and is expected to remain the largest as well as fastest growing regional market. Countries like China, India, and Indonesia are the major consumers and have a large untapped market potential. Other opportunities lie in applications like wipes, filtration, and geotextiles that are emerging as high growth segments.

However, the availability of cheaper alternatives can act as a restraint. Materials like cotton and wood pulp are competitive to nonwoven fabrics in certain applications. Volatility in raw material prices also impact the market as petroleum-based polymers are major raw materials. Fluctuations in crude oil prices directly affect the market profit margins.

Key players are focusing on capacity expansion as well as developing economies to benefit from their growing demand. Product innovation and the development of composite fabrics will allow greater market penetration. Strict environmental regulations regarding the disposal of non-biodegradable nonwovens is a challenge but increasing recyclability can emerge as an opportunity.

Global Nonwoven Materials Market Drivers:

Growth in hygiene and medical applications: Increasing awareness towards hygiene and importance of sanitation among consumers is a major factor driving the growth of the nonwoven materials market. Educating people about simple measures like hand washing, wearing masks during sickness, and use of napkins/tissues during coughing and sneezing can help prevent the spread of diseases. The demand for nonwoven products like wipes, face masks, sanitary napkins, and diapers has increased significantly in the last few years.

In the medical industry, nonwoven materials plays a vital role. Various types of gowns, drapes, and surgical packs used in operation theaters are made from nonwoven fabrics like spun bond and melt blown due to their exceptional fluid-barrier properties and breathability. These help doctors and nurses treat patients hygienically and avoid transfer of infections. Some studies show that nonwoven-based personal protective equipment (PPE) can help reduce surgical site infections by close to 70%. With rising healthcare expenditures and increasing number of surgeries worldwide, the need for high-quality nonwoven fabrics for medical applications will continue to grow.

Increasing use in the construction industry: The construction industry has seen a major rise in the use of nonwoven materials in recent years, and this is is expected to drive significant growth in the nonwoven materials market. Nonwoven materials are increasingly being used as alternatives to traditional construction materials due to their unique properties like high strength, durability, and cost effectiveness.

A number of key applications of nonwoven materials in the construction industry are fueling their higher demand. These are being widely used in manufacturing of insulating mats, soundproofing panels, roofing materials, and flooring solutions. Insulation is a critical component for energy efficiency in buildings, and nonwoven fiber batts or blown insulation allows for easy installation between walls or in attics. Similarly, nonwoven mats are versatile sound absorbers that are affordable options for soundproofing walls and ceilings. Their porous but solid structure makes them suitable for durable roofing mats and underlayment. Nonwoven geotextiles are also utilized in landscaping and civil engineering projects for soil stabilization, separation, and filtration.

Rise in the demand from feminine hygiene products: There has been increase in demand for feminine hygiene products over the past few years due to growing awareness about menstrual hygiene and women's health. This rise in demand has directly contributed to the growth of the nonwoven materials market as nonwoven is a core component in the production of sanitary pads, panty liners and other feminine care items.

Nonwoven materials such asspunbond, melt blown, and spun laced materials are widely used as top sheets and absorbent cores in pads and liners due to their excellent absorption capability and breathability. The lightweight and soft nature of these materials provide high wearing comfort over long durations. With more women adopting safe and hygienic menstrual practices, the demand for value-added feminine hygiene products with features like leak protection and odor control has increased substantially. This has encouraged manufacturers to invest more in nonwoven substrate innovation to deliver performance and wearer satisfaction.

Global Nonwoven Materials Market Opportunities:

Innovations in production technologies: Innovations in production technologies present a major opportunity for growth in the global nonwoven materials industry. Traditionally, most nonwoven fabrics are produced through mechanical and chemical processes like needle punching, spun bonding, and melt blowing. However, recent years have seen the rise of newer, advanced methods that allow for more customized fabrication at higher speeds and lower costs. Transitioning to these new digital and automated techniques could help manufacturers meet rapidly evolving demands while staying competitive.

One such innovative process gaining popularity is the 3D printing of nonwoven structures. Unlike conventional loom-based weaving, 3D printing enables the precise deposition of fibers in complex three-dimensional patterns customized for specific end-use requirements. This customizable production allows for novel material properties and performance characteristics. For example, 3D printed nonwoven face masks featuring gradient fiber density exhibited optimized breathability and filtration efficiency, according to World Health Organization (WHO) data from 2021. Adoption of such digitally-controlled fabrication presents opportunities to engineer tailored solutions across diverse applications in hygiene, medical, filtration, and construction.

Emerging applications development: Emerging applications development can indeed present a great opportunity for growth in the nonwoven materials market. As technology advances, new areas of application are emerging that allow nonwoven materials to replace traditional alternatives and open entire new categories. For instance, nonwoven materials are increasingly being utilized in the healthcare industry for a variety of medical devices and personal protective equipment. Their breathable, absorptive, and protective properties make them especially suitable for applications like surgical drapes, gowns, masks, and wound care dressings.

Emerging application areas like geotextiles and automotive: The nonwoven materials market has many promising emerging application areas that are poised to drive significant growth in the coming years. One such area is geotextiles, which are seeing increased usage in infrastructure projects around the world. Geotextiles made of nonwoven polymers are widely used in applications like road construction, erosion control, and drainage systems due to their strength and ability to separate differing types of soil. As countries expand and improve infrastructure to foster economic development, the demand for geotextiles from the nonwoven industry is projected to rise substantially. According to data from the World Bank, global infrastructure spending is estimated to be over US$ 94 billion by 2040, opening many opportunities for geotextiles producers.

Global Nonwoven Materials Market Trends:

Focus on sustainable and eco-friendly nonwovens: The trend towards more sustainable and eco-friendly products has significantly impacted the global nonwoven materials industry in recent years. Consumers are increasingly conscious of the environmental impact of the products they use and demanding options that are made from recycled or renewable materials. This shifting attitude is forcing companies in the nonwoven sector to invest heavily in developing new lines of nonwovens that are biodegradable, compostable, or derived from plant-based sources instead of fossil fuels or other petroleum-based ingredients commonly used today.

Many nonwoven manufacturers have pivoted their product development efforts to focus on solutions featuring post-consumer and post-industrial recycled materials. For example, Freudenberg, a technical nonwoven brand, launched a new line of cleaning cloths made from up to 100% recycled polyester fibers derived from plastic waste. Freudenberg collaborated with recycling specialists to develop the closed-loop production process. According to Freudenberg's 2021 sustainability report, the company doubled its use of recycled materials in nonwovens between 2019 and 2021.

Rising adoption of spun bond technology: The textile industry has seen a significant rise in the adoption of spun bond technology in recent years. Spun bond is a nonwoven fabric manufacturing process where thermoplastic polymers are melted, extruded through a spinneret to form many fine strands that are then drawn, laid on a moving mesh conveyor belt and bonded together. This technology offers manufacturers the ability to mass produce nonwoven materials in a continuous and cost-effective manner. As a result, many leading nonwoven fabric producers have heavily invested in setting up new spun bond lines. For example, as per the 2021 annual report of Dupont, one of the largest spun bond producers, it added three new production lines in Asia Pacific and Europe between 2020 and 2022.

Global Nonwoven Materials Market Restraints:

Stringent environmental regulations: Stringent environmental regulations are significantly restraining the growth of nonwoven materials market across various regions. Governments across developed economies like Europe and North America have implemented strict norms regarding disposal and recycling of nonwoven waste over the past few years. This is negatively impacting the demand for nonwoven materials from industries like healthcare, hygiene, geotextiles, etc.

The governments are putting pressure on manufacturers to adopt sustainable practices and use eco-friendly raw materials for production of nonwoven fabrics. Significant research and development investments are required to develop bio-based or recycled content nonwoven materials. This increases the production cost for the manufacturers. Many small and medium manufacturers find it difficult to comply with the new environmental standards. As a result, their operations are negatively impacted. Some manufacturers are even shutting down their production units.

Moreover, the governments are also imposing penalties on irresponsible waste disposal of used nonwoven materials. As per a report by the European Environment Agency published in 2022, the fines for improper disposal of nonwoven waste have increased substantially across European nations since 2019.

Counter Balance: To overcome this restrain, investing in new technologies to improve the quality and performance of their products, and the demand for sustainable nonwoven fabrics is witnessing significant growth. The surge in environmental concerns, government regulations, and consumer awareness about the negative impact of traditional textile manufacturing processes are contributing to market growth.   

High Research & Development (R&D) Cost: High research and development costs have been a major restraining factor for the growth of the nonwoven materials market. Developing new and innovative types of nonwoven materials made from advanced materials requires extensive research as well as testing. This R&D process is highly capital intensive involving cutting edge laboratories, experimentation using advanced technologies like nanotechnology, skilled scientists, and engineers.

For companies engaged in nonwoven material production, allocating a large portion of their financial resources to R&D cuts into their profit margins. This disincentives investments in developing newer product categories and applications of nonwoven materials that could potentially open up new markets. Sustaining high R&D expenditure year after year also impacts the balance sheets of companies.

Counterbalance: To overcome this restraint, increases the demand for sustainable nonwoven fabrics. The surge in environmental concerns, government regulations, and consumer awareness about the negative impact of traditional textile manufacturing processes are driving the market forward. Nonwoven manufacturers are investing in new technologies to improve the quality and performance of their products, and the demand for sustainable nonwoven fabrics is witnessing significant growth.

Figure 2. Global Nonwoven Materials Market Share (%), By Application, 2023

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Recent Developments:

• In August 2023, Toppan, Mitsui Chemicals Tohcello, and Mitsui Chemicals started pilot tests to horizontally recycle printed biaxially oriented polypropylene (BOPP) film into new flexible packaging. This collaborative effort seeks to establish recycling technologies and infrastructure.
• In March 2023, Innovia Films, a leading producer of specialty BOPP and cast polypropylene CPP films, expanded its Leipzig, Germany unit with an 8.8-meter-wide co-extrusion line to meet sustainability-driven demand for thin gauge label films. This unique technology, boasting 36,000 tons of annual capacity, prioritizes energy efficiency. Innovia Films, a division of CCL Industries, is an international manufacturer and supplier of Biaxially-oriented polypropylene films for specialty packaging, labelling, tobacco overwrap and industrial products.

Top Companies in the Global Nonwoven Materials Market

• Berry Global Group
• Toray Industries, Inc.
• Johns Manville
• Freudenberg SE
• DuPont de Nemours, Inc.
• Ahlstrom-Munksjo Oyj
• Kimberly-Clark Corporation
• H. Glatfelter Company
• Suominen Corporation
•  

*Definition: Nonwoven materials are innovative, high-tech, engineered fabrics made from fibers and are used in a wide range of consumer and industrial products. They are defined as sheet or web structures bonded together by entangling fibers or filaments, either thermally or chemically. These fabrics are flat, porous sheets that are made directly from separate fibers, molten plastic, or plastic film. Unlike woven or knitted fabrics, they are not made by weaving or knitting and do not require converting the fibers to yarn. Nonwoven fabrics are engineered to have a designed level of structural integrity by physical and/or chemical means, excluding weaving, knitting, or paper making. They are used in various applications, ranging from thin, lightweight nonwovens to strong and durable nonwovens, and are designed for specific applications through the selection of raw materials, formation and bonding methods, and finishing treatments