Welspun took the first step into the advanced textile segment by adding one thermal bonding nonwoven line in 2010 for making comforters and mattresses. The first spunlace machine was started in 2012 with a patented German line. Within two years, the company doubled the capacity. By 2016, Welspun entered the converting business (wet wipes) with modern automatic and high speed machine (mainly for the Indian market). In 2017, a needlefelt machine was added to cater to industrial applications with composites making facility along with downstream value addition (singeing, coating, printing, & calendaring).

In the first quarter of FY22, Welspun added a cosmetic face mask line and rolled out a new spunlace line making Welspun the largest Spunlace producer in India. Also, Welspun have had the largest market share in the Middle East since 2021. Welspun’s capacity augmentation in FY22 opens up the possibility of market penetration in additional geographies such as the Middle East and Oceania through enhanced product development and scaling-up capabilities. This can help Welspun add more value to its existing customers and attract new ones. Thus, the company is confident that its advanced textile business is positioned on a high growth trajectory, according to executives.

Currently, Welspun’s Advanced Textiles business provides a diverse range of nonwoven products and has the unique distinction of using three major technologies—spunlace, needlepunch, and thermobond. Each of these technologies has its own in-house downstream conversion unit to help it produce value-added products as per customer requirements.

Welspun’s ‘Multi-Layer Composite Filter Media and Method of Making Same’ has been patented in India as well as Europe. This business caters to the hygiene & femcare, personal care, industrial cleaning, medical disposables, filtration (automotive & industrial), artificial leather substrate, & various other applications.

A Global Business

Welspun Advanced Textiles business is strategically spread with a market mix consisting of both export and domestic markets. The bulk of the disposable products is in the matured U.S. & European markets, particularly for the wipes segment. Additionally, strong Research & Development as well as collaboration with MNCs & brands has enabled Welspun to earn higher business share in these markets.
Moreover, Welspun’s ability to run cellulosic fibers has enabled it to help its customers in the EU to deal with the Single-use Plastics (SUP) Directive.

In terms of technology breakdown, Welspun’s installed spunlace manufacturing installed capacity is approximately half a billion square meters across two units located at Anjar & Hyderabad in India.
Welspun has a capability of converting up to 100 million packs/annum in various fold formats. Its versatile needlepunch and thermal bond layout allows Welspun to be flexible while being ready to produce up to 3000 metric tons per year.

Looking ahead, Welspun expects to continue to invest  in new capacity consistently as its advanced textiles business has been doing since the beginning. Its latest investment, the Hyderabad plant, was commissioned earlier this year. This new plant is designed with the facility of up gradation / retro-fitment for future innovations in technology.

Globally, Covid created a huge demand-supply imbalance for all business segments. Since the demand for disinfectant products, particularly wipes, shot up multifold, the spunlace business was affected positively.
Due to a number of reasons, like the Russia-Ukraine conflict, ocean freight, container availability, energy crisis, and impending inflation to name a few, the world is still experiencing post-Covid ripple effects. While the magnitude varies from industry to industry, the spunlace business shows stable growth prospects over the next 3-4 years. However, the demand for acceptable biodegradable substitutes is rising, especially for disposable categories.

India’s Technical Textiles Scheme

In India, the market for technical textiles has accelerated over the previous five years and is now expanding at an annual pace of 8%. In the following five years, the Government of India wants to accelerate this growth to a range of 15-20%. The government’s National Technical Textiles Mission, which was launched in February 2020, has brought a laser sharp focus to this segment.

The Technical Textile trade balance which was negative (₹2,788 crores in 2018-19 and ₹1,366 crores in 2019-20), turned positive with ₹1,767 crores in 2020-21. During the year 2020-21, India’s major share of exports consisted of PPE kits, N-95 masks, and surgical masks.

GOI in September 2021 approved a PLI scheme worth ₹10,683 crores for domestic technical textiles firms and manufacturers of fabrics and apparel in the man-made fiber segment, provided such firms make a specific investment in greenfield projects and achieve stipulated turnover.

Beyond technical textiles, Welspun sees tremendous opportunities in the hygiene segment, the largest segment consuming spunlace in the U.S. and European markets. The company has worked tirelessly over the last five to 10 years to develop spunlace blends and structures with functional characteristics that are customer specific, which are hardwired into the end-use wipes and its functionality. This makes customers trust Welspun, to continue developing newer types of material as they go about finding consumers across various value points. Welspun group has a wide and distinct brand recall in both markets owing to an credible product portfolio from the home textile stable as well as line pipes business. With a very strong focus on ESG initiatives, Welspun aspires to better its performance across conventional rating standards (for e.g. currently rated 48 in DJSI) which makes, progressive-minded, large brands & MNCs trust Welspun.

The advanced textiles business is investing ahead of the curve to produce future-focused value-added products which remains key to its business. Welspun has successfully developed 100% cotton spunlace products for hygiene & femcare usage. Welspun can process all varieties of cellulosic fibers namely cotton, bamboo, viscose, lyocell, etc. In addition, it can process anti-microbial finishes, dyed-printed–coated fabrics, CSC products and uniquely produce five component blends. Its special strength lies in crafting uniquely engineered & customized products for many of its customers. Welspun is also able to provide the finest (lowest gsm) spunlace fabric in India, operating at two different manufacturing facilities at different locations assuring supply continuity to its customers.

Business Principles

Welspun firmly believes, being resilient during unprecedented circumstances while staying committed to the principles of innovation and ESG is a hallmark of sustainable businesses. The company has formulated its strategy in a way that it continues to enhance business drivers, increase standings in the global industry and create value for all of its stakeholders and society at large.

The capacities installed across the business has the potential to meet demand catering to almost a thousand crores of revenue (INR), with best-in-industry profitability. Welspun wishes to further consolidate its status as a prominent & trusted partner in the global nonwoven market with a focus on value-added & customized products.