Osaka, Japan
www.toyobo-global.com
2024 Nonwovens Sales: $135 million

Key Personnel
Koji Nishizaka, head of sales section, nonwoven material of Toyobo MC; Masahito Nakao, president of Kureha

Plants
Tsuruga, Iwakuni and Shiga, Japan

Processes
Spunbond, needlepunch, chemical bonded, spunlace, thermal bonded, stitchbonded

Brand Names
Volans, Ecule, Bonden, Kurelock, Dynac, Breathair

Major Markets
Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases

Earlier this year, Japanese nonwovens producer Toyobo sold Kureha and Yuho, its nonwovens manufacturing subsidiaries, to its partner in its Toyobo MC joint venture, which was formed in April 2023. Additionally, the company sold its filter manufacturing subsidiary, Toyobo Kankyo Techno to NIKKE, a subsidiary of Japan Wool Company, which also  purchased former Toyobo brand, Kureha, in April 2024.

While the company continues to produce 12,000 tons of polyester spunbonded nonwovens per year, sources say it is considering outsourcing this operation production to a Taiwanese company. Although the extent of the downsizing is unclear, efforts so far have already significantly reduced Toyobo’s nonwoven output.

In recent years, Toyobo’s sales to automotive applications in Japan and the U.S. have increased due to higher automobile production but other markets like civil engineering, construction and automotives in China have been sluggish due to increased competition.

Plants: Tsuruga, Iwakuni and Shiga, Japan
Processes: Spunbond, needlepunch, chemical bonded, spunlace, thermal bonded, stitchbonded
Brand Names: Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases

The production capacity of PET spunbond nonwovens at Toyobo MC is 12,000 tons/year. Kureha, a subsidiary of Toyobo MC, produces chemical bonded, needlepunch, thermal bonded, and spunbond nonwovens at a capacity of approximately 7000 tons/year. Yuho, also a subsidiary of Toyobo MC, produces needlepunch, spunlace and stitchbonded nonwovens at a capacity of about 3000 tons/year.

Nonwovens sales at Toyobo MC in 2023 for automotive applications increased due to higher automobile production. In the civil engineering-related sector, construction periods are lengthening due to labor shortages and restrictions on working hours, and demand for nonwovens is stagnating as a result. Sales of nonwoven construction fabrics for concrete structures were strong, but those for wooden housing decreased. In overseas markets, sales of nonwovens were also sluggish in China due to a decline in production by Japanese automakers, but in the U.S., sales of nonwovens were strong due to an increase in production by Japanese automakers.

In April 2023, Toyobo launched Toyobo MC, a joint venture with Mitsubishi, and transferred its nonwovens business to Toyobo MC. Toyobo MC is 51% owned by Toyobo and 49% by Mitsubishi, and Kureha and Yuho, previously subsidiaries of Toyobo, are now subsidiaries of Toyobo MC. In addition to nonwoven fabrics, various functional materials that Toyobo has developed are transferred to Toyobo MC. The joint venture was formed to develop functional materials globally by combining Toyobo’s technology with Mitsubishi’s overseas network. For example, overseas sales of automotive nonwovens have been limited to Japanese-affiliated automakers, but the collaboration with Mitsubishi will enable the company to approach non-Japanese automakers as well, which is expected to expand the company’s business performance in the future.

Toyobo MC’s nonwovens are doing particularly well with Breathair, which is used for cushioning materials. This is a nonwoven made of thick fibers of polyester thermoplastic elastomer, which has high air permeability and high resilience and is used for various cushioning materials. Among other things, it is widely used as a cushioning material for seats in railroad vehicles and is also used in bed mattresses. Breathair has a manufacturing facility in Japan with a capacity of 2200 tons/year and a facility in Germany with a capacity of 1100 tons/year. Toyobo MC is developing a technology to recycle used Breathair and reuse it as raw material. The virgin raw material is mixed with 25% recycled material to make the nonwoven. It is also developing biodegradable products, which can be composted under industrial composting conditions.

Plants: Tsuruga, Iwakuni and Shiga, Japan
Processes: Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitch bonded
Brand names: Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major markets: Geotextiles, roofing sheets ,carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases

Production capacity of PET spunbond nonwoven fabrics at Toyobo is 12,000 tons per year. Kureha, an affiliate of Toyobo, produces chemical bonded, needlepunch, thermal bonded and spunbond nonwovens with a capacity of about 7000 tons per year for each technology. Similarly, Yuho, another affiliate of Toyobo, manufactures needlepunch, spunlaced and stitchbonded nonwovens with a capacity of about 3000 tons each. While sales increased in 2022, profits declined due to rising raw material prices.

In April 2023, Toyobo established Toyobo MC, a joint venture company with Mitsubishi and transferred its nonwovens business to the company. Toyobo MC is owned 51% by Toyobo and 49% by Mitsubishi, and the former Toyobo subsidiaries became owned by Toyobo MC. The purposes of this joint venture company is to promote the growth of functional nonwoven products globally by combining Toyobo’s technology know-how with Mitsubishi’s global network.

Main products for the PET spunbond include automotive, construction and civil engineering. In automotive applications, tonneau covers made of spunbond nonwoven fabrics have been trending favorably and other applications include carpet backing, insulator surface materials, fender liners and under covers. In construction applications, it is mostly used for roofing sheets. In civil engineering applications, demand is beginning to expand with the adoption of a new product, a heavy metal ions adsorption sheet. In the production development of the PET spunbonded nonwoven fabrics, the company is developing nonwoven fabrics with superior formability. This development enables advanced, three-dimensional moldings by raising the module of the nonwoven fabrics from 40-50% to nearly 300%. In addition to this, the company is developing a spunbond nonwoven fabrics, under the trade name Bio-Volans, made from bio-PET resins and a spunbond nonwoven fabric, under the trade name e-Volans, made from recycled PET resins.

Plants: Tsuruga, Iwakuni and Shiga, Japan
Processes: Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitchbonded
Brand Names: Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases

Toyobo makes PET spunbond nonwoven fabrics with a capacity of 12,000 tons per year and Kureha, a member of the group, has been making chemical bonded, needlepunch, thermal bonded and spunbonded nonwovens with a capacity of 7000 tons per year. Similarly, Yuho, another member of the Toyobo group, has made needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.

Toyobo has been focused on the development of PET spunbond nonwovens using recycled PET and bioPET resins to create more sustainable products. The PET resin is made using recycled water bottles and is mixed with virgin PET to make nonwovens under the e-Volans brand name. e-Volans are being used in geotexitles, and Toyobo is working to increase the percentage of recycled PET used in these applications.

Plants: Tsuruga, Iwakuni and Shiga, Japan
Processes: Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitch bonded
Brand Names: Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases

Toyobo has made PET spunbond nonwoven fabrics with a capacity of 12,000 tons per year and Kureha, a member of the group, has been making chemical bonded, needlepunch, thermal bonded and spunbonded nonwovens with a capacity of 7000 tons per year. Similarly, Yuho, another member of the Toyobo group, has made needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.

In 2020, many of Toyobo’s core markets like automotives, engineering and construction, were weakened by shutdowns caused by the coronavirus pandemic. While the automotive business rebounded later in the year, it was unable to compensate for earlier problems.

Meanwhile, the company’s filtration business in air filters and face masks grew significantly.

Additionally, in 2020 Toyobo took advantage of government subsidies to diversify its business into polypropylene-based nonwovens. The company will soon begin making both spunbond and meltblown polypropylene-based nonwovens.

Plants: Tsuruga, Iwakuni, Shiga, Japan
Processes: Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitchbonded
Brand Names: Volans, Ecule, Bonden, Kurelock, Dynak, Breathair
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases

Toyobo produces polyester spunbond nonwovens with the capacity of 12,000 tons/year, and Kureha, in the Toyobo group, manufactures chemical bonded, needlepunch, thermal bonded and spunbond with the capacity of approximately 7000 tons/year. And Yuho, also in the Toyobo group, produces needlepunch, spunlace and stitch bonded nonwovens with the capacity of 3000 tons/year.

In recent years, demand in motor vehicle use has grown Toyobo’s polyester spunbond nonwovens but in 2020 this business has been negatively impacted by the coronavirus pandemic, manufacturing shutdowns and weakened consumer demands.

Kurebulker is a bulky nonwoven fabric with cushion characteristics, and bulky sense and soundproofing characteristics are provided if it is spread under the carpet. It is used as sound absorption material for motor vehicles.

In July, Toyobo Co., Ltd. and 11 other companies forming a plastic value chain have jointly established a new company called R Plus Japan, Ltd., which will facilitate the recycling of used plastics to help solve plastics-associated problems and create a more sustainable society. R Plus Japan, which started operating in June, is headed by President Tsunehiko Yokoi and located in Minato-ku, Tokyo. The 11 companies are: Suntory MONOZUKURI Expert Ltd.; Rengo Co., Ltd.; Toyo Seikan Group Holdings, Ltd.; J&T Recycling Corporation; Asahi Group Holdings, Ltd.; Iwatani Corporation; Dai Nippon Printing Co., Ltd.; Toppan Printing Co., Ltd.; Fuji Seal International, Inc.; Hokkai Can Co., Ltd.; Yoshino Kogyosho Co., Ltd. R Plus Japan will continue seeking additional investors, and companies such as Sumitomo Chemical Company are currently considering joining.

Toyobo Group has provided many products and technologies to help solve social problems since its inception, based on its corporate philosophy “Jun-Ri-Soku-Yu” (Adhering to reason leads to prosperity) that embodied the spirit advocated by its founder Eiichi Shibusawa. The group is determined to create a more sustainable society by developing products and technologies that reduce society’s impact on the environment. For example, Toyobo has raised the proportion of recycled resin and plant-derived raw materials in its main plastic products and manufactured and sold highly functional bioplastics.

Toyobo has long admired a technology U.S. biochemical venture company Anellotech, Inc., developed to make raw materials for polyester from wood. Since 2017, Toyobo has been involved in a project in which Anellotech, the Suntory Group and other companies in Japan and elsewhere are developing polyethylene terephthalate (PET) bottles made entirely of plant-derived materials. Application of this groundbreaking technology likely will pave the way for effectively recycling used plastics and the increased cyclical use of plastics.

Plants: Tsuruga, Iwakuni, Shiga, Japan
Processes: Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitchbonded
Brand Names: Volans, Ecule, Bonden, Kurelock, Dynak, Breathair
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases

Toyobo produces polyester spunbond nonwovens with the capacity of 12,000 tons/year, and Kureha, in the Toyobo group, manufactures chemical bonded, needlepunch, thermal bonded, and spunbond with the capacity of approximately 7000 tons/year. And Yuho, also in the Toyobo group, produces needlepunch, spunlace and stitch bonded nonwovens with the capacity of 3000 tons/year.

Demand in motor vehicle use has grown Toyobo’s polyester spunbond nonwovens. Above all, the increase in tonneau covers is remarkable. The demand for seats coated with a heavy metal ion adsorbent to the polyester spunbond nonwovens (trade: name Cosmofresh NANO) has come into wide use. A lot of heavy metal derived from nature is included in soil in Japan, and the law requires dealing with heavy metal not being able to flow out from temporary storage space of the remaining soil occurring in the case of the building of public works or in the case of reutilization. Construction of the linear central Shinkansen (railway lines) has begun in Japan this year. As for this Shinkansen, there will be a many tunnels. So, a large quantity of remaining soil will be calculated by this tunnel construction, and the water including the heavy metal ion may flow out from remaining soil. Cosmofresh NANO is suitable to remove the heavy metal ion from the channel. The construction of the linear central Shinkansen will be continued for a long term in the future, and, 86% of the full length of the line are tunnels, so great demand is expected.

Kureha lays emphasis on sale of Kurebulker produced by the spunbonding method. Kurebulker is a bulky nonwoven fabric with cushion characteristics, and bulky sense and soundproofing characteristics are provided if it is spread under the carpet. It is used as sound absorption material for motor vehicles.

Plants: Tsuruga, Iwakuni, Shiga, Japan
Processes: Spunbond, needlepunch, chemical bonded, spunlaced, thermal bonded, stitchbonded
Brand Names: Volans, Ecule, Bonden, Kurelock, Dynak, Breathair
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases

Toyobo has been producing polyester spunbond nonwoven fabrics with 12,000 tons of capacity per year while its subsidiary Kureha makes 7000 tons of chemical bonded, needlepunched, thermal bonded and spunbonded nonwovens per year. Yuho, also a subsidiary, makes 3000 tons of needlepunched, spunlaced and stitchbonded nonwovens per year.

Polyester spunbond nonwoven fabric has been made at two plants in Tsuruga and Iwakuni, as well as at an OEM production facility in China. As the ratio of OEM production has risen, Toyobo is going to raise its in-house production in terms of quality and costs. Capital spending at Toyobo is necessary for that purpose and Japan, Asia and North America are all being considered for the company’s next production center.

The use of Toyobo’s polyester spunbond fabrics has been increasing as the use of these materials in cars has been increasing, particularly in the seat covers. The cover material made by Toyobo is a leather-like processed nonwoven fabric. The material is lightweight and superior in durability and, most importantly, it complies with VOC regulations. This has been driving demand in China where environmental regulations are increasing.

In Kureha, the demand for air filters for the car engine air filtration, its main product, has been sluggish because of the increasing use of electric cars which don’t use as many filtration materials. To make up for these decreases, Kureha is developing sound absorption materials, or sound absorbers for cars and battery cooling filtration media, which are still widely used in electric cars.

Plants: Tsuruga, Iwakuni and Shiga, Japan
Processes: Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded and stitch bonded
Brands: Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bending sheets, plaster bases

Toyobo makes 12,000 tons of polyester spunbond nonwovens. Kureha, a subsidiary of Toyobo, makes resin bonded needlepunched, thermal bonded and spunbonded nonwovens, each with an annual capacity of 7000 tons per year, and Yuho, another subsidiary of the company, has been making needlepunched, spunlaced and stitch bonded nonwovens with a capacity of about 3000 tons per year.

The three major applications for polyester-based spunbond nonwovens are automotives, engineering and construction. The use of the materials in automotives is expanding while it is retracting in engineering and construction. Toyobo’s nonwovens are used in various automotive parts and its business is growing particularly strongly in China and North America. Business is so strong in North America, in fact, the company is considering establishing a production base there—either with another company or alone.

Sales of Kureha’s main automotive filters have been decreasing as the market is shifting from drylaid to wetlaid nonwovens. However, the use of Kureha’s filters in every other market is growing quickly, not just in Japan, but also in Thailand and the U.S., and the company is developing new applications for its filter media.

Plants: Tsuruga, Iwakuni and Shiga
Processes: Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded and stitch bonded
Brand Names: Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bending sheets, plaster bases

Toyobo makes 12,000 tons of polyester spunbond nonwovens as well as an additional 1500 tons on a pilot plant. Kureha, a subsidiary of Toyobo, makes resin bonded needlepunched, thermal bonded and spunbonded nonwovens with an annual capacity of 7000 tons per year , and You, another subsidiary of the company, has been making needlepunched, spunlaced and stitch bonded nonwovens with a capacity of about 3000 tons per year.

The use of polyester spunbonded nonwovens for automotives has increased mainly driven by growth in North America which offset declines in construction materials in 2015. Toyobo has not yet made PET spunbond nonwovens outside of Japan and instead outsources production to five nonwovens manufacturers abroad. Therefore, sales of spunbond nonwovens exceed capacity.

Growth of spunbond polyester in Japan has been difficult, so growth in the future will depend on exports. Kureha hopes to increase the percentage of exports from 20% to 40%. To achieve this, establishing a production base outside of Japan is being considered. Two main strategies are focusing on exports to the U.S. and working with Chinese OEMs.

Kureha is a large producer of air filters for mobile engines and they make these filters in Japan, Thailand, Taiwan and the U.S. Because of filters for engines tending to shift to the paper type of wetlaid nonwovens, the production of filters for engines failed to rise while sales of cabin filter media has increased. Although the business performance of Kureaha Thailand showed favorable trends in automotives, sales have decreased in the U.S.

Plants: Tsuruga, Japan; Iwakuni, Japan; Shiga, Japan
Processes: Spunbond, needlepunch, resin bonded, spunlaced, thermal bonded, stitch bonded
Brand Names: Volans, Ecule, Bonden, Kurelock, Dynac, Breathair
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases

The production capacity of Toyobo’s PET spunbond nonwovens is 12,000 tons/year, but a pilot plant producing 1500 tons/year was introduced last year. Toyobo’s subsidiary Kureha has produced resin bonded, needlepunched, thermal bonded and spunbond nonwovens, each with the capacity of about 7000 tons/year. Kureha is a major producer of air filters for mobile engines, and has produced filters in Japan, Thailand, Taiwan and the U.S. Another leading product for Kureha is its plaster based cloth, but due to the decrease in domestic demand for the material, part of the production facility making it was altered to produce materials for automotives.

Yuho, another subsidiary of the company, has also produced needlepunched, spunlaced and stitch bonded nonwovens each with the capacity of about 3000 tons/year.

According to the company, among its products for consumer and industrial uses, sales of Breathair, a functional cushion material, held firm, and sales of its spunbond nonwovens—mainly supplied to the civil engineering and construction industries—expanded.

Breathair is a polyester nonwoven of a thermoplasticity elastomer. Toyoba’s Tsuruga facility has a capacity of 2200 tons/year on two lines and its Orbenburg facility in Germany has a capacity of 1100 tons/year on one line. Because of the characteristics of Breathair, a breathable material that’s lightweight, is superior in durability and workability, and maintains a bulking power even when it’s used long term, demands for the finished goods are increasing for seat cushioning in the railway vehicles, bed mats, couches, mats for care, mats for leisure, etc.

Due to the increasing demand, the company may add 1100 tons/year in 2017, and add another 1100 tons/year by 2020.’’

Plants: Tsuruga, Iwakuni, Shiga
Processes: Spunbond, needlepunch, resin bonded, spunlace, thermal bonded, stitch bonded
Brand names: Volans, Ecule, Bonden, Kurelock, Dynac
Major markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases

Installation of a new pilot line, capable of making 1,500 tons of spunbond polyester material per year is currently underway. When complete the new line will enable Toyobo, which already operates a 12,000-ton PET spunbond line, to improve its focus on new product development. In 2013, the company reported increased sales of this technology, owing to favorable conditions in engineering, construction and automotive markets.

Within automotives, Toyobo, sources spunbond polyester from two Chinese companies, which it then sells in the Chinese market. The company is reportedly hoping to enter the North American market soon either with a similar outsourcing setup or through its own manufacturing assets.

According to the company, demand for civil engineering products have grown in Japan following the great earthquake in 2011. As repairs continue the company has seen increased need for geotextile products.

Meanwhile, Kureha, Toyobo’s subsidiary, can make resin bonded, neeldepunched, thermal bonded and spunbondned materials, all with a capacity of 7000 tons per year, as well as needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3,000 tons per year.

Kureha is a large producer of air filters for mobile engines and has made filters in Japan, Thailand and Taiwan and may soon establish a production base in India possibly with its current Indian partner, Arvind. Kureha already operates a joint venture with Arvind in India making needlepunch nonwovens for bag filters. Established in June 2014 and capable of making 1,500 tons of material, the joint venture relies on Kureha’s technical guidance and Arvind’s manufacturing assets.

Plants: Tsuruga, Iwakini, Shiga
Processes: Spunbond, needlepunch, resin bonded, thermal bonded, spunlaced, stitch bonded
Major Markets: Geotextiles, roofing sheets, carpet backings, automotive interiors, automotive filters, needlepunch carpets, hot melt bonding sheets, plaster bases

Production capacity of Toyobo is 12,000 tons per years. Kureha is a subsidiary of Toyobo and has a capacity of about 7000 tons per year within resin bonded, needlepunch, thermal bonded and spunbond technologies. Another subsidiary, Yuho, makes needlepunched, spunlaced and stitchbonded nonwovens with a capacity of 3000 tons per year.

Although the polyester spunbond nonwovens made by Toyobo failed to raise sales in 2012, sales in this segment are increasing in 2013 due to the fallout from the great earthquake in east Japan. This has increased demand for materials used in the reconstruction of the disaster area, namely geotextile materials which are produced by Toyobo.

Meanwhile, Kureha is a large producer of air filter material for mobile engines and is producing the filters in Japan and Thailand. To meet Chinese demand, the company exports products from Kureha Thailand, which is also meeting increasing demand for products domestically.

To help Kureha meet demand, both within Thailand and abroad, the company updated its facilities in June 2013. Other growth areas include Indonesia.

In new product news, Toyobo has developed a cushion material out of polyester nonwovens, which are being sold under the trade name Breathair as seat cushioning in trains and mattresses. Breathair is both breathable and durable and can be recycled without releasing harmful gases. Toyobo will next expand production of these materials to Europe where demand for environmentally sound and recyclable products is strong. A new facility able to make 1000 tons of the material per year is currently beginning operation.