Tokyo, Japan
www.malifematerials.com/en/
2024 Nonwovens Sales: $295 million

Key Personnel
Kazuya Kusano, president

Plants
Yokkaichi, Nagoya, Moriyama

Processes
Spunbonded, meltblown

Brand Names
Tafnel, Syntex, Syntex Nano, Airyfa, Eltas, Smash, Precise, Semia, Pulshut, Ecorise

Major Markets
Coverstock, geotextiles, oil absorbing materials, filters, wipes, agriculture materials, household materials

Mitsui Chemicals Asahi Life Materials (MAL)  was established in 2023 as a joint venture between Mitsui Chemicals and Asahi Kasei. The new company integrates the spunbond and meltblown nonwovens of both companies, with Mitsui Chemicals holding a 60.62% stake and Asahi Kasei holding a 39.38% stake.

MAL produces 132,000 tons/year of PP spunbond nonwovens, 5500 tons/year of PET spunbond nonwovens, 3500 tons/year of nylon spunbond nonwovens, and 2000 tons/year of PET-SMS nonwovens (trade name: Precise). The production capacity of spunbond nonwovens is estimated to be 143,000 tons/year combined, and 2200 tons/year of meltblown nonwovens.

For PP spunbond nonwovens, the company has production facilities in Japan and Thailand, with production capacities of 55,000 tons/year in Japan and 77,000 tons/year in Thailand. The Japanese production company is Sunrex Industry, which was a subsidiary of Mitsui Chemicals but was transferred to a subsidiary of MAL. The production companies in Thailand are AKST and MHM. AKST is a subsidiary of Asahi Kasei with a production capacity of 47,000 tons/year, and MHM is a subsidiary of Mitsui Chemicals with a production capacity of 30,000 tons/year. Both AKST and MHM have been transferred to subsidiaries of MAL.

MAL’s sales for fiscal 2024 were ¥43.4 billion ($295 million) on a consolidated basis, including subsidiaries, and ¥16.9 billion ($115 million) on a non-consolidated basis. Although there was an increase on a non-consolidated basis, there was a decrease on a consolidated basis. MAL’s sales ratio is approximately 70% for sanitary materials such as diapers and approximately 30% for industrial materials, with diapers being the main product.

Since the venture was established in 2023, market conditions have deteriorated sharply in its key market. In 2020-2021, during the Coronavirus pandemic, production of polypropylene spunbonded nonwoven fabric was greatly expanded in China. As the pandemic—and demand for polypropylene spunbond nonwovens—subsided, there was an excess of equipment, and inexpensive Chinese-made nonwoven fabrics began to flood into Southeast Asia. As a result, AKST and MHM in Thailand faced intense competition and were forced to reduce their operating rates, causing their overseas businesses to struggle in fiscal 2024.

MAL is restructuring its operations to reduce the ratio of highly competitive diapers and increase the ratio of industrial materials. MAL plans to increase the ratio of industrial materials to 40% in fiscal 2027 and to 50% in fiscal 2030.

In industrial materials, the company plans to strengthen its position in the semiconductor field with meltblown nonwoven filters and to develop biodegradable nonwoven fabrics that can be composted in household composters for use in food packaging. For diapers, the plan is to further reduce costs and streamline operations, while shifting to higher price ranges through differentiation and high functionality.

Plants: Yokkaichi, Nagoya, Moriyama, Japan; Thailand
Processes: Spunbond, meltblown
Brand Names: Tafnel, Syntex, Syntex Nano, Airyfa, Eltas, Smash, Precise, Semia, Pulshut, Ecorise
Major Markets: Coverstock, geotextiles, oil absorbing materials, filters, wipes, agriculture materials, household materials

Established in 2023, Mitsui Chemicals Asahi Life Materials (MAL) is a joint venture between Mitsui Chemicals and Asahi Kasei. The new nonwovens manufacturer integrates the spunbond and meltblown nonwovens of both companies, with Mitsui Chemicals holding a 60.62% stake and Asahi Kasei holding a 39.38% stake.

MAL produces 132,000 tons/year of PP spunbond nonwovens, 5500 tons/year of PET spunbond nonwovens, 3500 tons/year of nylon spunbond nonwovens, and 2000 tons/year of PET-SMS nonwovens (trade name: Precise). The production capacity of spunbond nonwovens is estimated to be 143,000 tons/year combined, and 2200 tons/year of meltblown nonwovens.

For PP spunbond nonwovens, the company has production facilities in Japan and Thailand, with production capacities of 55,000 tons/year in Japan and 77,000 tons/year in Thailand. The Japanese production company is Sunrex Industry, which was a subsidiary of Mitsui Chemicals but was transferred to a subsidiary of MAL. The production companies in Thailand are AKST and MHM. AKST is a subsidiary of Asahi Kasei with a production capacity of 47,000 tons/year, and MHM is a subsidiary of Mitsui Chemicals with a production capacity of 30,000 tons/year. Both AKST and MHM have been transferred to subsidiaries of MAL.

MAL’s sales ratio is approximately 70% for sanitary materials such as diapers and approximately 30% for industrial materials, and the company plans to adjust the ratio of each to 50% by 2030. The company plans to increase sales to ¥60 billion in FY2025 and to ¥100 billion in FY2030. MAL’s main application is diapers, but demand for baby diapers is shrinking in Japan due to the country’s declining birthrate and aging population, and future expansion is unlikely. China is also seeing a decline in demand for baby diapers, while ASEAN and India are increasing but will likely stagnate in the future. The purpose of the integration of Mitsui Chemicals’ and Asahi Kasei’s nonwoven businesses was to implement structural reform to ensure their survival. The company plans to integrate and rationalize the production varieties of nonwoven fabrics for diapers, as well as consolidate and eliminate production facilities to increase production efficiency.

Furthermore, the company aims to strengthen and expand value-added applications in the automotive and electronics industries with nonwoven fabrics made of PET, nylon, polylactic acid, and other materials. The nonwoven businesses of Mitsui Chemicals and Asahi Kasei had a high ratio of diaper applications, which led to stagnation in the business performance of both companies. The growth of Chinese nonwovens manufacturers for diapers has increased competition and future growth in the market is no longer expected. For this reason, the two companies intend to remodel the business for diapers to increase efficiency and further strengthen the industrial materials field to create a more profitable business structure.

Plants: Japan, Thailand
Processes: Spunbond, meltblown, needlepunch, thermal
Brands: Tafnel, Synetx, Syntex Nano, Airyfa
Major Markets: Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agricultural materials, household materials

In February 2023, Mitsui Chemicals and fellow leader in the Japanese nonwovens industry Asahi Kasei, announced a plan to form a new integrated company combining their nonwovens businesses with a tentative start date of October 2, 2023. This plan will be carried out through a corporation-type demerger enabling the establishment of the new integrated company pending the approval of authorities in Japan and Thailand, where the two companies have operations.

Under the proposed plan, all of Mitsui Chemicals’ nonwovens businesses with the exception of its SWP fibrillated polyolefin fiber will be integrated with Asahi Kasei’s spunbond and cartridge filter business. The new company will be known as Mitsui Chemicals Asahi Life Materials Co. and it will be based in Tokyo, Japan. Mitsui will own slightly more than 60% of the company while Asahi Kasei will hold the remaining shares. Sales are estimated at ¥48.3 billion or about $370 million annually.

The Japanese sites for the company will include Mitsui’s Sunrex subsidiary in Mie, Japan as well as its Nogoya Works plant in Aichi. Meanwhile, Asahi Kasei’s plant in Moriyama will provide outsourced production. Overseas sites including both companies’ Thailand operations, will continue to carry out production and sales as subsidiaries of the integrated company. Asahi Kasei’s spunbond operation in Moriyama will be merged into the company by way of an absorption-type merger at a later date.

The main reason for the integration has been cited as intensifying competition in Asia, particularly among polypropylene spunbond manufacturers. The larger scale created by the merger of the two companies, which will produce 132,000 tons of polypropylene spunbond nonwovens per year initially, will improve the companies’ position within Asia, particularly in the Chinese diaper market where oversupply has been caused by decreasing birth rates. The Regional Comprehensive Economic Partnership (RCEP), enacted in January 2022, and the elimination of tariffs in East Asia has also contributed to increased competition, and escalating raw material prices have made achieving profitability more difficult.

Mitsui Chemicals currently makes 85,000 tons of spunbond nonwovens at sites in Japan and Thailand. In 2021, the company exited the Chinese market through the sale of its subsidiary there to a Chinese company. The company also makes meltblown nonwovens

Plants: Japan, Thailand
Processes: Spunbond, meltblown, needlepunch, thermal bond
Brand Names: Tafnel, Syntex, Syntex Nano
Major Markets: Hygiene, medical, face masks, filtration, agriculture

The big news at Mitsui Chemicals in 2021 was the divestment of its ownership in Mitsui Chemicals Nonwovens (Tianjin), its Chinese subsidiary to Foshan Nanhai Beautiful Nonwoven (BTF) Co. The site was opened in 2014 and is capable of making 15,000 tons of spunbond nonwovens per year. Prior to the deal, Mitsui and BTF, a manufacturer of medical and sanitary nonwovens with factories in China and the U.S., had a relationship for more than 15 years. The partnership included outsourced manufacturing of high-performance medical nonwovens.

Without the Chinese subsidiary, Mitsui now operates nonwoven production facilities in Japan and Thailand, which together can make 88,000 of commercial grade spunbond nonwovens—the Thai site also has a 6300 ton pilot line for the development and testing of high performance materials. Additionally, the company operates three meltblown lines and is in the process of adding a fourth line, which will be operational in April 2023 to target media for liquid cartridge filters.

Growth in technical markets like filtration is helping to offset declines in the hygiene market, particularly the baby diaper market, which has been challenged two-fold. The birth rate in China continues to decline, meaning fewer diapers are being used. Additionally, volumes of spunbond materials targeting hygiene applications grew significantly during the coronavirus pandemic for materials like face masks and gowns, which are seeing decreases in demand.

Plants: Japan, Thailand
Processes: Spunbond, meltblown, needlepunch, thermal bond
Brand Names: Tafnel, Syntex, Syntex Nano
Major Markets: Hygiene, medical, face masks, filtration, agriculture

In March 2021, Mitsui Chemicals sold 100% ownership of Mitsui Chemicals Nonwovens (Tianjin) Co., Ltd. (MCNT), its Chinese subsidiary for the production and sales of nonwovens, to Foshan Nanhai Beautiful Nonwoven Co., Ltd. The Tianjin site, which was opened in 2014, was capable of making 15,000 tons of spunbond nonwovens per year.

BTF is a prominent manufacturer of medical and sanitary nonwovens with production facilities not only in China but also in the U.S. Mitsui Chemicals has had a relationship with BTF for more than 15 years – including through outsourced manufacturing of high-performance medical nonwovens – and continues to see the company as an important partner for cooperation purposes moving forward.

Following this sale, Mitsui continues to make spunbond nonwovens at its sites in Japan and Thailand with a total production capacity of 88,000 tons per year and hopes to concentrate its efforts on Japan and the ASEAN regions. Its most recent investment in spunbond technology was in 2008 when the company added two lines—one in Japan capable of making 15,000 tons per year in Japan and a 6000 ton line Thailand.

Both of these investments increased Mitsui’s output of high performance nonwovens including its Airyfa nonwovens. Airyfa uses proprietary spinning technology to make a high performance nonwoven that is gentle on skin, allowing it to be strong and soft at the same time.

Mitsui also makes breathable films in Thailand under the Espoir brand name. The company’s  breathable film has been widely recognized by eastern and southeastern manufacturers for its excellent performance and good printability, both important requirements for premium diapers, and as a result has shown healthy sales growth.

As demand for diapers has decreased in Japan, Mitsui has worked on increasing sales of its masks and isolation gowns, which has been escalated during the coronavirus pandemic in 2021.

Outside of spunbond, Mitsui expanded its production facilities for meltblown nonwovens at wholly owned subsidiary Sunrex Industry Co., Ltd., starting operations in early 2021. The investment responded to growing demand for industrial-use meltblown nonwovens, and will increase the Mitsui Chemicals Group’s overall production capacity for these materials by 50%.

Plants: Yokkaichi and Nagoya, Japan; Tianjin, China; Rayong, Thailand
Processes: Spunbond, meltblown, needlepunch, thermal bonded nonwovens
Brand Names: Tafnel, Syntex, Syntex Nano, Airyfa
Major Markets: Coverstock, geotextiles, oil absorbing materials

In March 2020, Mitsui Chemicals announced it had expanded its production facilities for meltblown nonwovens at wholly owned subsidiary Sunrex Industry Co., Ltd., starting operations at the new facilities in January. The move comes as an effort to respond to growing demand for industrial-use meltblown nonwovens, and will increase the Mitsui Chemicals Group’s overall production capacity for these materials by 50%.

Mitsui Chemicals continues to position its nonwovens business as a growth sector, making efforts here to supply high-quality nonwovens as industrial materials for a variety of applications. This includes use in car seats (product name: Tafnel), masks (product name: Syntex) and agricultural sheets (product name: Syntex). With particular respect to Syntex MB nano, marketing efforts are going toward use in filters and other such applications that will take advantage of the meltblown nonwovens line’s superfine fibers, which are no more than several hundred nanometers in diameter.

Through this latest facility expansion, Mitsui Chemicals plans to further bolster and grow its business for nonwovens going forward.

Mitsui has pivoted its production output in response to the coronavirus. In April, the company started to supply nonwovens as raw materials for isolation gowns in an effort to support health care providers on the front lines in cutting-edge medical facilities. This effort comes as the increasing spread of the virus has made isolation gowns – for which Japan has been largely reliant on foreign imports – difficult to obtain amid the global pandemic.

To establish this supply, Mitsui Chemicals is making use of wholly owned subsidiary Sunrex Industry Co. Ltd., which serves as a major plant for nonwovens production. Mitsui Chemicals is taking production facilities here that normally produce nonwoven sanitary materials and repurposing these to begin production of nonwovens for isolation gowns.

In other efforts aimed at stopping the novel coronavirus, Mitsui Chemicals is already contributing significantly to domestic mask production by supplying meltblown nonwovens and nose clamps. But to help resolve the current mask shortage, Mitsui Chemicals is also pursuing plans for further production increase.

In March, Mitsui began working on the development of a new, reusable 3D-printed mask with Professor HORI Katsutoshi of the Graduate School of Engineering at Nagoya University and Friend Microbe Inc., a spinoff venture from Nagoya University.

The key feature of the mask design is that is can filter out viral particles but can also be reused. It consists of a reusable body and a disposable filter. Mitsui Chemicals will provide the nonwoven disposable filter, which removes viral particles. Professor HORI has produced the mask body using a 3D printer and is investigating enzyme preparations and various other antiviral agents that could be applied. Plans are to produce a mask with consideration of design and comfort while also ensuring that it provides outstanding protection against viruses.

Plants: Yokkaichi and Nagoya, Japan; Tianjin, China; Rayong, Thailand
Processes: Spunbond, meltblown, needlepunch, thermal bonded nonwovens
Brand Names: Tafnel, Syntex, Syntex Nano, Airyfa
Major Markets: Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials

Mitsui Chemicals’ annual production capacity of polypropylene spunbond nonwovens was 58,000 tons in Japan, 30,000 tons in Thailand, 15,000 tons in China, totaling 103,000 tons. The production capacity of its meltblown nonwovens was 1000 tons/year.

In terms of the nonwoven business in Japan in 2018, the quantities of production greatly decreased in the baby diaper category. Therefore, the demand for polypropylene spunbond nonwovens had declined, which led to a decrease in sales in the nonwovens business. New capacity of 15,000 tons/year was added in Mitsui’s Nagoya factory, while 6000 tons/year was added in the Yokkaichi factory in October 2018, bringing production capacity in Japan increased to 58,000 tons.

Although MHM, a subsidiary of the company, had produced polypropylene spunbond nonwovens with the capacity of 30,000 tons/year in Thailand, they added 6000 tons with equipment that was purchased from a Chinese enterprise. This new capacity is and included in production capacity of the commercial production because they are used in the trial manufacture of the development of products. Thus, the facilities line of MHM became three lines—14,000 tons/year (operated since 2003), 16,000 tons/year (operated since 2007) and 6000 tons/year (operated since 2018).

The diaper business holds the highest proportion of nonwovens for Mitsui Chemicals, therefore, the business results of nonwovens greatly depends on the production trends of diapers. Although the diapers produced in Japan were exported to China in large quantities, many of them were resale objects for Chinese brokers. However, these brokers are not as active as they once were causing a decline in Japanese diaper sales. This decline, however, does not necessarily reflect a decline in public demand for diapers and is expected to be a temporary decrease.

Special nonwoven fabric has been developed for diapers, such as spunbond nonwovens with hollow fibers (trade name: Airyfa). They could also be developed for purposes other than diapers. Mitsui Chemicals has produced meltblown nonwoven fabrics using nanofibers, and they are pushing forward to open new markets for meltblown nonwovens.

Plants: Yokkaichi and Nagoya
Processes: Spunbond, meltblown, needlepunch, thermal bonded
Brand Names: Tafnel, Syntex, Nano, Airyfa
Major Markets: Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials

Mitsui Chemicals can make 70,000 tons of polypropylene spunbond nonwovens per year in Japan as well as 30,000 tons of the material in Thailand and 15,000 tons in China, making global production 115,000 tons. In addition, Mitsui can make 1000 tons of meltblown nonwovens per year and sales of this material increased greatly in 2017.

Diaper market growth in Japan is driving demand for nonwovens sales not only in Japan but also in Thailand. In recent months, Mitsui has made two capacity investments, adding a 15,000-ton-per-year line in Nagoya and 6000 tons in Yokkaichi. The Nagoya plant was complete in November 2017 and the Yokkaichi investment was finished in June 2018. The company is reportedly considering making its next investment in India where many of its customers in the disposable diaper market are looking to penetrate.

Both new lines make high performance nonwovens featuring stretchable nonwovens with polyurethane fibers and polyolefin fibers at random. Nonwoven fabrics with crimped fibers like coils of the spring have also been produced at the new facility in Nagoya. This nonwoven fabric is superior in both flexibility and bulkiness.

Mitsui Chemicals has developed some high performance nonwoven fabrics for the premium diaper products and began full-scale production of this technology. Above all, the volumes of polypropylene spunbond nonwoven fabrics with hollow fibers, sold under the brand name Airyfa, have been increasing. Because its fibers are hollow, the material is light-weight but strong. It is mainly used for the gathering part of the diaper. It can be produced by changing the nozzles of existing facilities so the facilities can be changed relatively easily. Airfya is made using existing facilities in Yokkaichi, Japan, and production capacity is thought to be around 10,000 tons. In addition, one of the lines in Thailand was converted to be able to make Airyfa and started making it this summer. Full-scale production is also going to begin in China.

All of these nonwovens technologies are based on spunbonding technology, developed by Mitsui. They are all high value materials and adhere to Mitsui’s strategy of growing its nonwovens business through innovation.

Plants: Yokkaichi, Nagoya, Japan
Processes: Spunbond, meltblown, needlepunch, thermal bonded
Brands: Tafnel, Syntex, Syntex Nano
Major Markets: Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials

Japanese nonwovens producer Mitsui Chemicals makes 49,000 tons of polypropylene-based spunbond nonwovens in Japan, 30,000 tons in Thailand and 15,000 tons in China for a total of 94,000 tons per year. Additionally, the company makes 1000 tons of meltblown.

In 2016, sales increased slightly for the company to reach ¥22.6 billion. The sales increase in its overseas business somewhat offset declines in Japan, due to sluggish demand for spunbond materials in a stagnant diaper market.

Still, Mitsui is adding 21,000 tons of nonwovens capacity through investment projects at Nagoya, which is being expanded by 15000 tons, and Yokkaichi, where 6000 tons are being added. Both projects are expected to be complete in November 2017 and will start operation in March 2018.

Mitsui has been focused on providing high performance, higher value added nonwovens for diapers as demand for Japanese-made diapers is expanding steadily in China. Wealthy Chinese people are willing to purchase diapers made in Japan because they offer a higher quality than Chinese-made diapers. This trend is encouraging Japanese diaper manufacturers to expand their domestic diaper operations and this will boost demand for Japanese-made nonwovens in the near term while stifling demand for materials made in China and other parts of Asia.

Also in response for the Chinese consumers’ need for sophisticated diapers, Mitsui has developed high performance spunbond nonwovens with excellent stretch, elasticity and softness. These will be made on the new lines currently being added in Nagoya and Yokkaich.

Plants: Yokkaichi, Nagoya
Processes: Spunbond, meltblown, needlepunch and thermal bond
Brand Names: Tafnel, Synetx, Syntex Nano
Major Markets: Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agriculture materials, household materials

The latest news from Mitsui Chemicals is the addition of 6000 tons of spunbond nonwovens at its Sunrex facility in Yokkaichi, Japan. The company announced the expansion in June 2016 saying it supports growth in the baby diaper market in Japan and throughout Asia.

The new line, which is expected to be complete by the end of next year, will feature proprietary technology to make premium spunbond nonwovens. The nonwovens made on this new line will offer excellent flexibility and expandability accompanied by superior comfort. These attributes will help Mitsui expand its role in premium diaper markets.

According to executives, Mitsui’s mid-term plan is to position its healthcare business as a targeted business domain and the nonwovens business is a part of that segment. Expansion into the Asian diaper markets is considered a significant part of this plan.

This expansion follows a similar project, announced in mid-2015, to add a 15,000-ton-line in Japan. This new line is currently coming onstream in Mitsui’s Nagoya facility. Like the Sunrex investment, this new line is responding to growth in the Asian baby diaper market.

Together these two investments will bring Mitsui’s Japanese capacity from 49,000 tons to 70,000 tons.

Outside of Japan, Mitsui operates spunbond and spunmelt facilities in Thailand and China.

The Chinese operation, which currently contains one line capable of making 15,000 tons of nonwovens per year, opened up shop in 2014 in Tianjin after originally being announced in 2011. Meanwhile, the Thai operation, which was established in 2002, can make 30,000 tons of nonwovens on two lines.

Mitsui also makes 1000 tons of meltblown nonwovens per year. These nonwovens range from 300-600 nm and are largely used in filter cartridges.

Plants: Japan, China, Thailand
Processes: Spunbond, meltblown, needlepunch, thermal bonded
Brand Names: Tafnel, Syntex, Syntex Nano
Major markets: Coverstock, geotextiles, oil absorbing materials, air filters, wipes, agricultural materials, household materials

Mitsui Chemicals produces polypropylene spunbond nonwovens in three countries—Japan where it produces 49,000 tons per year on six lines; Thailand with 30,000 tons  on two lines; and China where it makes 15,000 tons a year ion one line. All told Mitsui’s global spunbond capacity is currently 94,000 tons/year.

Mitsui Chemicals’ production capacity of meltblown nonwovens is 1000 tons/year.

Sales were boosted in 2014 by Mitsui’s latest investment, a line making polypropylene spunbond nonwovens, which began operating in December 2013. However, despite the increase in sales, the company has not reached its targeted profit because of the increasing prices of crude materials due to the low yen rate.

About 80% of Mitsui’s nonwoven products are used for diapers, with the high quality polypropylene spunbond nonwovens being used in Japan but Mitsui is starting to see greater demand for high quality polypropylene spunbond in China as there has been demand for high functioning diapers. Because of this, Mitsui Chemicals plans to improve its equipment in China to produce high quality nonwovens. Although it’s planning to start a new line for polypropylene spunbond in 2017, the company has not yet decided which country to set up the industrial plant.

Mitsui’s expansion strategy, outside of diapers, includes medical materials, industrial materials and agricultural materials. In the medical sector, it is going to strengthen its gowns for surgery with spunbond or meltblown nonwovens—and in the industrial materials sector, filters by nanofiber nonwovens will be strengthened. Mitsui Chemicals has also introduced Syntex Nano, meltblown nanofiber nonwovens, for liquid filters.

Plants: Japan, China, Thailand
Processes: Spunbond
Brand names: Syntex
Major markets: Hygiene

While nonwovens counts as just one of many business segments targeted by Mitsui Chemicals, whose interests span from agrochemicals to electronics to construction, this market continues to be an important one to the Japanese corporation. In its mid-year 2011 strategic plan, the company targeted nonwovens as one of its priority businesses and pledged to expand its scope into new markets.

Since then, Mitsui certainly has proven its commitment to nonwovens through investment. Just last month, the company held a ceremony commemorating its new Chinese subsidiary, located in Tianjin. The site’s first line, a 15,000-ton spunbond line, will target the fast-growing hygiene market in China, according to executives. Mitsui announced the new site in November 2011.

Meanwhile, at its Japanese operation in Tokyo, Mitsui’s latest investment, a 15,000-ton line came onstream in April 2012, bringing that site’s capacity to 49,000 tons. Elsewhere in Asia, Mistui operates a two-line site in Thailand capable of making 30,000 tons of materials.

With a leading position in the spunbond markets in Japan as well as in Asia, Mitsui’s Syntex brand of spunbond nonwovens is projected to grow about 11% annually due to growth in the robust disposable diaper market. Currently, about 80% of the company’s nonwovens are sold into the disposable diaper market, and the company expects that investment in China and Thailand will help it grow in areas of Asia with low diaper penetration like China and Southeast Asia.

The nonwovens division is apart of Mistui’s functional chemicals division, which also includes healthcare, agrochemicals and fine and performance chemicals.

According to executives, Mitsui Chemicals’ strengths lie in its ability to engage in comprehensive production extending from the creation of base resins to final processing, its longstanding R&D capabilities, and its advanced quality management. Drawing on these strengths, the company has continued to differentiate itself from competitors through the production and sale of highly functional spunbonded nonwoven fabric.

Moving forward, Mitsui Chemicals says it will accelerate to a pace that allows it to harness its strengths while coordinating closely with customers. In this manner, the company will reinforce its standing as a leading provider of highly functional spunbonded nonwoven fabric in Asia.

Plants: Yokkaichi and Iwakuni, Japan
Processes: spunbond, meltblown, needlepunch, thermal bonded
Brands: Tafnel, Synetx, Syntex Nano

With a new line up and running in Japan and one under construction in Tianjin, China, Mitsui Chemicals’ global spunbond capacity is going to surpass 94,000 tons by the end of the year. The company operates six lines in Japan, two in Thailand and will start its first Chinese line, able to make 15,000 tons of material, this month.

Currently, about 80% of Mitsui’s output is geared toward hygiene applications while the remaining is sold into industrial markets. Within hygiene, Mitsui has an advantage over other nonwovens producers because it is also a major supplier of polypropylene and Mitsui makes its nonwovens using the highest grades of polypropylene, resulting in a soft and flexible product.

In addition to its spunbond business, Mitsui makes meltblown nonwovens with very low diameter, which are sold under the brand name of syntex Nano. Although the other nonwovens manufacturers make the meltblown nonwovens of 600 nm, Mitsui is the first company to make them with a 300 nm. These products have been used liquid filtration media.