The Fiber Year 2012

Issue 12, May 2012
The Fiber Year 2012
World Survey on
Textiles & Nonwovens
supported by
Table of contents
Page
1.
Foreword and Summary………………………………………………………………………………………………………………………………………………………….
1
1.1
Foreword……………………………………………………………………………………………………………………………………………………………………………………….
1
1.2
Summary……………………………………………………………………………………………………………………………………………………………………………………….
3
1.3
List of Sources……………………………………………………………………………………………………………………………………………………………………………..
4
1.4
Contributions from Industry Experts…………………………………………………………………………………………………………………………………..
5
2.
World Economy from the Perspective of Textiles and Apparel.…………………………………………………………………………..
6
3.
Upstream Feedstock Industry……………………………………………………………………………………………………………………………………………..
7
3.1
Cotton Cultivation…………………………………………………………………………………………………………………………………………………………………….
7
3.2
Sheep Farming……………………………………………………………………………………………………………………………………………………………………………..
14
3.3
Dissolving Pulp 2005 - 2015…..……………………………………………………………………………………………………………………………………………….
17
3.4
Petrochemicals……………………………………………………………………………………………………………………………………………………………………………
20
3.4.1
Paraxylene (PX) 2005 - 2015…………………………………………………………………………………………………………………………………………………….
22
3.4.2
Purified Therephthalic Acid (PTA) 2005 - 2015…………………………..……………………………………………………………………………………
23
3.4.3
Dimethyl Terephthalate (DMT) 2005 - 2015………...………………………………………………………………………………………………………….
24
3.4.4
Mono Ethylene Glycol (MEG) 2005 - 2015………..……………………………………………………………………………………………………………..
25
3.4.5
Caprolactam (CPL) 2005 - 2015………...………………………………………………………………………………………………………………………………...
26
3.4.6
Summary and Outlook on Raw Material Availability…………………………………………………………………………………………………….
26
4.
Staple Fibers…………………………………………………………………………………………………………………………………………………………………………………
28
4.1
Natural Fibers ………………………………………………………………………………………………………………………………………………………………………………
29
4.1.1
Cotton…………………………………………………………………………………………………………………………………………………………………………………………….
30
4.1.2
Wool……………………………………………………………………………………………………………………………………………………………………………………………….
32
4.1.3
Other Fibers…………………………………………………………………………………………………………………………………………………………………………………
33
4.2
Cellulosic Fibers…………………………………………………………………………………………………………………………………………………………………………
45
4.2.1
Viscose Fibers……………………………………………………………………………………………………………………………………………………………………………..
45
4.2.2
Acetate Tow………………………………………………………………………………………………………………………………………………………………………………..
48
4.3
Synthetic Staple Fibers….……………………………………………………………………………………………………………………………………………………….
49
4.3.1
Polyester Staple Fibers……………………………………………………………………………………………………………………………………………………………
51
4.3.2
Acrylic Staple Fibers………………………………………………………………………………………………………………………………………………………………..
53
4.3.3
Polypropylene Staple Fibers…………………………………………………………………………………………………………………………………………………
54
4.3.4
Polyamide Staple Fibers……….…………………………………………………………………………………………………………………………………………………
54
5.
Filament Yarns…………………………………………………………………………………………………………………………………………………………………………
55
5.1
Polyester Filament…………………………………………………………………………………………………………………………………………………………………..
55
5.1.1
Polyester Textile and Carpet Yarn……………………………………………………………………………………………………………………………………..
56
5.1.2
Polyester Industrial Yarn……………………………………………………………………………………………………………………………………………………….
58
5.2
Polyamide Filament.………………………………………………………………………………………………………………………………………………………………..
61
5.2.1
Polyamide Textile and Carpet Yarn……………………………………………………………………………………………………………………………………
62
5.2.2
Polyamide Industrial Yarn……………………………………………………………………………………………………………………………………………………..
63
5.3
Polypropylene Filament.………………………………………………………………………………………………………………………………………………………..
65
5.4
Cellulosic Filament.………………………………………………………………………………………………………………………………………………………………….
66
6.
Other Manmade Fibers…….……………………………………………………………………………………………………………………………………………………..
68
6.1
Carbon Fibers………………………………………………………………………………………………………………………………………………………………………………..
68
6.2
Aramid Fibers………………………………………………………………………………………………………………………………………………………………………………..
72
6.3
Spandex Fibers…………………………………………………………………………………………………………………………………………………………………………….
72
7.
World Fiber Market 2011….……………………………………………………………………………………………………………………………………………………..
75
7.1
Summary on World Fibers and Yarns……………………………………………………………………………………………………………………………………
75
7.2
Filament and Spun Yarn…………………………………………………………………………………………………………………………………………………………….
78
7.3
Conclusions from Feedstocks to Fibers………………………………………………………………………………………………………………………………
79
8.
Nonwovens and Unspun Applications……………………………………………………………………………………………………………………………….
84
8.1
Spunbond……………………………………………………………………………………………………………………………………………………………………………………….
86
8.2
Carded……………………………………………………………………………………………………………………………………………………………………………………………..
87
8.3
Airlaid………………………………………………………………………………………………………………………………………………………………………………………………
88
8.4
Wetlaid……………………………………………………………………………………………………………………………………………………………………………………………
88
9.
Textile and Clothing Trade 2011……………….………………………………………………………………………………………………………………………….
89
9.1
PR China………………………………………………………………………………………………………………………………………………………………………………………….
90
9.2
India…………………………………………………………………………………………………………………………………………………………………………………………………
93
9.3
Bangladesh…………………………………………………………………………………………………………………………………………………………………………………….
95
9.4
Turkey……………………………………………………………………………………………………………………………………………………………………………………………..
96
9.5
Pakistan…………………………………………………………………………………………………………………………………………………………………………………………..
98
9.6
Taiwan…………………………………………………………………………………………………………………………………………………………………………………………….
99
9.7
Indonesia……………………………………………………………………………………………………………………………………………………………………………………….
100
9.8
Thailand………………………………………………………………………………………………………………………………………………………………………………………….
101
9.9
Vietnam………………………………………………………………………………………………………………………………………………………………………………………….
102
9.10
South Korea………………………………………………………………………………………………………………………………………………………………………………….
103
9.11
Sri Lanka…………………………………………………………………………………………………………………………………………………………………………………………
105
9.12
Cambodia……………………………………………………………………………………………………………………………………………………………………………………….
106
9.13
Peru………………………………………………………………………………………………………………………………………………………………………………………………….
107
9.14
Mexico…………………………………………………………………………………………………………………………………………………………………………………………….
108
9.15
Brazil………………………………………………………………………………………………………………………………………………………………………………………..……..
109
9.16
Switzerland……………………………………………………………………………………………………………………………………………………………………………………
111
9.17
Russia………………………………………………………………………………………………………………………………………………………………………………………………
113
9.18
Japan………………………………………………………………………………………………………………………………………………………………………………………………..
114
9.19
European Union…………………………………………………………………………………………………………………………………………………………………………..
115
9.20
United States………………………………………………………………………………………………………………………………………………………………………………..
118
10.
Statistical Appendix…………………………………………………………………………………………………………………………………………………………………
120
10.1
World Fiber Market……………………………………………………………………………………………………………………………………………………………………
121
10.2
World Fiber Use…………………………………………………………………………………………………………………………………………………………………………..
122
10.3
Natural Fibers Consumption…………………………………………………………………………………………………………………………………………………..
123
10.4
Cotton Production and Use……………………………………………………………………………………………………………………………………………………
124
10.5
Staple Fibers Consumption…………………………………………………………………………………………………………………………………………………….
125
10.6
Production of Manmade Fibers…………………………………………………………………………………………………………………………………………….
126
10.7
Production of Synthetic Fibers………………………………………………………………………………………………………………………………………………
127
10.8
Production of Cellulosic Fibers……………………………………………………………………………………………………………………………………………..
128
10.9
Major Fiber Types' Market Share…………………………………………………………………………………………………………………………………………..
129
10.10 Staple Fiber Competition………………………………………………………………………………………………………………………………………………………..
130
10.11
Production of Manmade Fibers by Country………………………………………………………………………………………………………………………
131
10.12 Production of Manmade Fibers by Material……………………………………………………………………………………………………………………..
132
10.13
Top 3 Producing Countries……………………………………………………………………………………………………………………………………………………..
133
10.14 Manmade Fiber Industry 2011/10 - Polyester Fibers and Polyamide Filament Yarn……….…………………………………
134
10.15 Manmade Fiber Industry 2011/10 - Staple Fibers of Acrylic, Polyamide and Cellulosic…………………………………..
135
10.16 Global Yarn Production……………………………………………………………………………………………………………………………………………………………
136
10.17 Dynamics in Yarn Production…………………………………………………………………………………………………………………………………………………
136
10.18 Fiber Types in Spun Yarn Production…………………………………………………………………………………………………………………………………..
136
10.19 Major Textile & Clothing Trading Countries………………………………………………………………………………………………………………………
137
10.20 Major Exporters in Textiles & Clothing………………………………………………………………………………………………………………………………
138
10.21 Major Importers in Textiles & Clothing……………………………………………………………………………………………………………………………..
139
Foreword and Summary
Andreas W. Engelhardt
General Manager
The Fiber Year GmbH
Speicher, Switzerland
www.thefiberyear.com
Dear Readers,
It is my great pleasure to announce that the textile yearbook I do hope this piece of information will be useful to conduct
will be supported by the Lenzing Group as from now to en-
your business. This survey hopefully makes a contribution to
sure the continuation of this traditional and well-established
the transparency of global industry trends, individual market
report. All market data are the result of the independent
segments and fiber competition.
research by The Fiber Year GmbH. Although Lenzing supports the Report the statements and conclusions in the re- At this point I would like to express my gratitude to all who
port do not necessarily reflect the assessment of the Lenzing
have made a valuable contribution by providing an article,
Group.
supporting me in data collection and exchanging views on
the industry.
The basic idea of reporting annual production figures traces
back more than fifty years to Vereinigte Glanzstoff-Fabriken Enjoy reading and please let me know your comments. I very
AG, the former world market leader in manmade fibers. It
much appreciate your suggestions to further improve quality
was Dr. E. H. Vits, chairman of the board from 1940 to 1969,
of this survey. If you feel additional market segments should
who used to inform at press conferences about the status of
be included do not hesitate to share your view with us.
the international manmade fiber industry. On the occasion
of a presentation on February 8, 1966 he expressed that this
industry would enjoy dynamic growth in the years to come. Yours sincerely,
A truly appropriate evaluation when manmade fiber output
was 5.5 million tonnes back then.
In the meantime the scope of market segments being integrated into this report was significantly enlarged. This was
due to the range of textile machines of Saurer where I initiated this service more than ten years ago. A continuous upgrading is scheduled in particular in the direction of sustainable, eco-friendly, recycled and bio-based fiber material.
1
supported by
Dr. Peter Untersperger
Chief Executive Officer
Lenzing AG
Lenzing, Austria
www.lenzing.com
Dear Readers!
The “Fiber Year” is being published this year for the first time In reality, a series of macroeconomic distortions led to
under the patronage of Lenzing AG. It is a great pleasure for
uncertainties on the marketplace. In turn, this triggered a
us as the global market leader for man-made cellulose fibers
cautious approach among many market participants and
to support the regular publication of one of the most im-
along the value chain, which subsequently resulted in a more
portant reference works for the fiber industry. Even if we at
restrained purchasing behavior and price decreases. I am
the Lenzing Group successfully supply the entire global fiber
convinced that an upturn will come on the heels of this
market, it is essential for all of us in the industry to gain a
downturn. Fibers for textiles and nonwoven applications are
precise knowledge about this market in all its facets. With
a continually expanding part of our modern life.
“The Fiber Year” we have an objective and reliable source of
information at our disposal.
This makes it even more important to analyze market volatilities as precisely as possible. Every market participant should
The objective of “The Fiber Year” is to show the major mar-
be able to draw his own conclusions that are right for him. In
ket trends, but also to ensure that a relevant level of detail is
this respect, “The Fiber Year” with its excellent data has
provided on the basis of precise data collection. This goal
become an important decision-making basis for the fiber
was once again fulfilled by the new issue of the publication
industry. With this in mind, I wish all readers an informative
for the year 2011.
and enjoyable read and a successful fiber year in 2012.
The year 2011 was characterized by extensive market volatility. Rarely have we seen so many rapid changes in prevailing
market conditions in recent years as we encountered in 2011. Yours sincerely,
Whereas the first half-year featured a very good fiber business, the second half was impacted by a perceptible slowdown which became evident in a relatively short time. In my
opinion, this downswing was not attributable to the inability
to generate sufficient fiber sales any longer. On the contrary,
from Lenzing AG’s perspective, volume demand was very
positive throughout the entire year.
2
supported by
Summary
The production volume in the world textile industry in 2011
The logical consequence was an enlarged supply. Competing
rose by 6.4% to 85.9 million tonnes. This includes increases in
fibers‘ prices were out of sync, thus, benefiting from relative
all segments. Natural fibers were up by 7.1% to 33.2 million
advantages to cotton. This has mainly favored polyester and
tonnes and manmade fibers went up by 6.0% to 52.7 million
cellulosic fibers. The both fibers enjoyed growth rates in the
tonnes.
range of 7%. In other words, high cotton prices have further
fueled replacement.
It is a matter of common knowledge that natural fiber production is not precisely projectable due to climatic changes, This enthusiastic sentiment of rising cotton prices had also an
insect attacks and other natural conditions. Thus, a more re-
impact on machinery investments. Last year‘s installations of
liable figure seems to be the annual usage of fibers. As global
short-staple spindles marked a new ten-year high, almost
cotton stocks have been traced by international organiza-
double the level of 2009. Growth rates in rotor and long-
tions like ICAC consumption figures for cotton are included
staple spindles were even higher. While investments in rotor
in a world-fiber-use figure. This data delivers a more accurate
spinning almost achieved the pre-crisis level, expansion of
indication for further processing volumes.
long-staple spindles stayed well below the ten-year average.
Referring to this approach, last year‘s use of fibers amounted The manmade fibers segment has witnessed considerable exto 82.0 million tonnes, up by 2.4%. Apart from the crisis year
pansions in polyester spinning and texturing, nylon filament
2008, it was the slowest growth rate in ten years.
in particular in PR China and viscose staple fiber. Talks with
industry experts confirm that the propensity to invest seems
The first indication released in the preview beginning of the
to be more sustainable than in cotton spinning.
year was lower for two reasons. This detailed report refers
to downwardly revised production data for the year 2010 The comprehensive view from feedstocks to the spinning inand, secondly, some Asian output for the fourth quarter tur-
dustry has come to the result that the polyester industry
ned out to be better than expected. To a certain extent, gro-
may face some pricing pressure as a consequence of tighte-
wing stocks of manmade fibers may have lifted this volume.
ning supply in some petrochemical sectors.
The market size of 82.0 million tonnes corresponds to an Fiber prices and textile products in general will be subject to
average per capita consumption of 11.8 kg. Last year‘s growth
appreciation. This follows from a sharp drop in next season‘s
rate does not come up to the long-term growth rate of 2.7%
cotton production while the consumption is expected to
since 1970 or the short-term average annual growth of 3.3%
recover. Further speculation is added by the Indian export
since the year 2000. The recent acceleration of fiber demand
policy and China‘s increasing national reserve. Additionally, a
reflects the impact of rapidly rising disposable incomes in
number of rises in minimum wages and high inflation will lift
populous nations like the BRIC-countries.
world retail prices.
The world slowdown in textile demand was result of the eco- A rising oil price, concern for the entire synthetic fiber indusnomical uncertainties and sluggish demand from major deve-
try, is rather fueling growth of carbon fibers. Major carbon
loped nations. Therefore, export activities of several major
fiber applications do have a positive correlation between
countries have worsened in the second half of the year.
crude oil price and consumption like in aircraft, wind energy,
automotive. Hence, production reached a new peak level. A
From a fiber type‘s view the main topic was the sensational
number of joint ventures and new manufacturing sites will
upswing in cotton prices, starting in August 2010 and coming
stimulate the market. At present small in size, the automoti-
to an abrupt end a year later. This unprecedented price in-
ve sector may have the biggest potential to tremendously
crease has encouraged farmers to expand cotton cultivation.
lift carbon fiber demand in the next decade.
3
supported by
Contributions from Industry Experts:
Peter Ackroyd
Dr. Wilhelm Rauch
President
Managing Director
IWTO
IVC
Brussels, Belgium
Frankfurt/Main , Germany
www.iwto.org
www.ivc-ev.de
Michael Carus
Katharina Schaus
Managing Director
Managing Director
EIHA
it fits
Huerth, Germany
Constance, Germany
www.eiha.org
www.itfits.de
Anke Domaske
Dr. Christian Schindler
CEO
Director General
Qmilch GmbH
ITMF
Hanover, Germany
Zurich, Switzerland
www.qmilk.eu
www.itmf.org
Hans-Peter Egler
Jens Soth
Head of Trade Promotion
SECO
HELVETAS Swiss Intercooperation
Bern, Switzerland
Zurich, Switzerland
www.seco-cooperation.admin.ch
www.helvetas.org
Andreas Eule
Wang Tiankai
CEO
President
CORDENKA GmbH
CNTAC
Obernburg, Germany
Beijing, China
www.cordenka.com
http://english.ctei.gov.cn
Uday Gill
Friedrich Weninger
President Polyester Business
COO
Indorama Ventures Limited
Lenzing AG
Jakarta, Indonesia
Lenzing, Austria
www.indorama.net
www.lenzing.com
Dr. Alejandro Plastina
Economist
ICAC
Washington DC, United States
www.icac.org
4
supported by