Plants: Okazaki and Tarui, Japan; Pathumthani, Thailand
Processes: Spunbond, spunlace
Brand Names: Marix, Eleves, Appeal, Wiwi, Alcima, Dilla, Terramac, Cottoace
Major Markets: Agriculture materials, carpet backings, geotextiles, cable wraps, wipes, storing bags, coverstock, roofing sheets

Unitika produces PET spunbond and spunlace nonwovens. Its PET spunbond nonwovens are produced in Japan and Thailand (TUSCO), with a total production capacity of 30,000 tons/year: 20,000 tons/year in Japan and 10,000 tons/year in Thailand. This company has a 5000 ton/year capacity for spunlace nonwovens, while a joint venture (UMCT) with Marusan Industry produces spunlace nonwovens with a 5000 ton/year capacity. In 2023, Unitika’s PET spunbond nonwovens for automotive applications performed well due to increased automobile production, and PET spunbond nonwovens for civil engineering applications also increased. However, sales of PET spunbond nonwovens for agricultural use decreased, and those for residential use were sluggish due to a decline in new construction starts. Spunlace nonwovens were forced to decline due in part to stagnant inbound demand. Overall, sales of the nonwovens business declined slightly. In addition, the cost of raw materials and fuel rose due to the weakening of the yen and other factors, and the company raised the price of nonwovens several times. However, the company was unable to keep up with the cost increases, and profit margins declined. Unitika’s PET spunbond nonwovens are produced in Japan and Thailand, and the company plans to reduce costs by consolidating grades, producing in Japan and Thailand in optimal locations, and streamlining production. In addition, TUSCO of Thailand plans to strengthen sales of spunlace nonwovens produced in Japan.

TUSCO of Thailand produces PET spunbond nonwovens at a capacity of 10,000 tons/year and also produces spunbond polylactic acid nonwovens, although in smaller quantities. TUSCO exports more than 80% of the nonwovens it produces to Europe, the U.S., and other countries. The main application is carpet base fabric, which is used for carpet tiles, automotive floor mats, and other base fabrics, accounting for about 60% of the total for base fabrics. Currently, the company is expanding sales of environmentally friendly nonwovens, which include nonwovens made from recycled raw materials and polylactic acid nonwovens. Spunbond nonwovens made of recycled PET resin are used for carpet base fabrics, and are being fully marketed as building materials in the U.S. starting in 2023. Spunbond nonwovens made with polylactic acid are used for civil engineering materials and tea bag wrappers and are beginning to be used for agricultural materials and lifestyle-related materials in

Europe, the U.S. and Australia. Since NatureWorks will start polylactic acid production in Thailand in 2025, TUSCO will be able to procure raw materials in Thailand, which will allow the company to take advantage of cost benefits.

Plants: Okazaki, Tarui
Brand Names: Marix, Eleves, Appeal, Wiwi, Alcima, Dilla, Terramac, Cottoace
Major markets: Agriculture materials, carpet backings, geotextiles, able wraps, wipes, storing bags, coverstock roofing sheets

Unitika has produced PET spunbonded and spunlaced nonwoven fabrics. PET spunbond nonwoven fabrics are produced in Japan and Thailand (TUSCO company), with a production capacity of 20,000 tons a year in Japan and 10,000 tons in Thailand. The company also makes 5000 tons of spunlaced materials per year in Japan.

In 2022, PET spunbond sales were negatively impacted by slowdowns in the automotive market, however sales of automotive, carpet backings, filters, lifestyle-related materials and others were more favorable. As a result sales of spunbond nonwovens were higher last year than in 2019 before the pandemic. Nevertheless, profits declined due to a rise in fuel costs. Sales of the spunlaced nonwovens fabric were higher than in 2021 but lower than in 2019.

Unitika has obtained Oeko-Tex Standard 100 certification for three products as a new environmental measure for nonwoven fabrics. This certification system is an international safety standard to prove that a product is free from toxic chemical substances, and these three products have obtained the highest level, class 1, which can be suitable for infants and toddlers up to 36 months. The certified product are Marix, a PET spunbonded nonwoven fabrics; Eleves, a spunbonded nonwoven fabrics made of bicomponent fibers using PET and PE; Cottoace, a spunlaced nonwoven fabric made of 100% cotton.

Furthermore, the company is developing a spunbonded nonwoven fabric made from recycled resins and polylactic acid in environmentally friendly nonwoven fabrics. Ekomix, made from recycled resins, is a spunbonded nonwoven made of core-sheath bicomponent fibers with a core consisting of recycled PET resins and a sheath consisting of virgin PET resins. Bicomponent fiber contains 50% or more recycled PET resins. Terramac is a spunbonded nonwoven fabric made of polylactic acid, which is used in geotextiles that decompose and disappear in soil.

Plants: Okazaki and Tarui, Japan
Processes: Spunbond, spunlace
Brand names: Marix, Eleves, Appeal, Wiwi, Alcima, Dilla, Terramac, Cottoace

Unitika makes and sells polyester spunbond nonwovens and spunlaced nonwoven fabrics. The company can make 20,000 tons of polyester spunbond nonwovens in Japan as well as another 10,000 tons in Thailand at its TUSCO subsidiary. In spunlace, Unitika can make 5000 tons of spunlaced nonwovens in Japan as well as another 5000 tons through its joint venture with Marusan Industry, UMCT.

In 2021, demand for medical gowns and wet tissue regained stability while volumes in the automotive markets were negatively impacted by the semiconductor crisis.

Plants: Okazaki and Tarui, Japan
Processes: Spunbond, spunlace
Brand Names: Marix, Eleves, Appeal, Wiwi, Alcima, Dilla, Terramac, Cottoace

Unitika makes and sells polyester spunbond nonwovens and spunlaced nonwoven fabrics. The company can make 20,000 tons of polyester spunbond nonwovens in Japan as well as another 10,000 tons in Thailand at its TUSCO subsidiary. In spunlace, Unitika can make 5000 tons of spunlaced nonwovens in Japan as well as another 5000 tons through its joint venture with Marusan Industry, UMCT.

In 2020, demand for Unitika’s materials in isolation gowns increased significantly. The company developed a new type of gown containing a nonwoven and a slightly porous film under the brand name Unisofia. The company is now making one million pieces of the gowns per month with the help of about 50 domestic sewing factories.

Plants: Okazaki and Tarui, Japan; Bangkok, Thailand
Processes: Spunbond, spunlace
Brand Names: Marix, Eleves, Appeal, Wiwi Alcima, Dilla, Terramc, Cottoace
Major Markets: Agriculture materials, carpet backings, geotextiles, cable wraps, wipes, storing bags, cover stock roofing sheets

Unitika manufactures and sells polyester spunbond and spunlace nonwovens. The polyester spunbond operation, with a capacity of 20,000 tons per year, is in Japan. is operated in Japan with the capacity of 20,000 tons/year. Tusco, a subsidiary of Unitika, also makes polyester spunbond with the capacity of 10,000 tons/year in Thailand. This includes a new facility, capable of making 6000 tons/year, which began operation in April 2017. This expansion allowed Unitika’s total capacity of polyester spunbond nonwovens to reach 30,000 tons/year. Unitika’s spunlace capacity is 5000 tons/year. In addition, the UMCT, a joint business venture with Marusan Industry, has been manufacturing spunlace nonwovens with the capacity of 5000 tons/year.

Unitika has developed a concrete cure sheet made of cotton spunlace. Aquapack is made of a two layered structure, laminated cotton nonwoven fabric with a PET film, and water is impregnated to a nonwoven fabric and stuck on the concrete face. Silicate, which has the reforming effect of the concrete face, is added in the nonwoven. When the water is supplied to the concrete face, the face is reformed to make the concrete structure high quality.

Plants: Okazaki and Tarui, Japan; Bangkok, Thailand
Processes: Spunbond, spunlace
Brand Names: Marix, Eleves, Appeal, Wiwi Alcima, Dilla, Terramc, Cottoace
Major Markets: Agriculture materials, carpet backings, geotextiles, cable wraps, wipes, storing bags, cover stock roofing sheets

Unitika manufactures and sells polyester spunbond and spunlace nonwovens. The polyester spunbond operation, with a capacity of 20,000 tons per year, is in Japan.  is operated in Japan with the capacity of 20,000 tons/year. Tusco, a subsidiary of Unitika, also makes polyester spunbond nonwovens with the capacity of 10,000 tons/year in Thailand. This includes a new facility, capable of making 6000 tons/year, which began operation in April 2017. This expansion allowed Unitika’s total capacity of polyester spunbond nonwovens to reach 30,000 tons/year. Unitika’s spunlace capacity is 5000 tons/year. In addition, the UMCT, a joint business venture with Marusan Industry (Marusan Industry 65%, Unitika 35%), has been manufacturing spunlace nonwovens with the capacity of 5000 tons/year.

In 2018, Unitika’s polyester spunbond nonwovens reported sluggishness in some markets including interior and building materials but as a whole remained strong. The spunlace market has done well supported by excellent demand for skin care products. Furthermore, natural materials have been revised recently under the influence of the issue of marine plastic garbage.

Unitika has developed a concrete cure sheet (trade name: Aquapack) made of cotton spunlace. Aquapack is made of a two layered structure, laminated cotton nonwoven fabric with a PET film, and water is impregnated to a nonwoven fabric and stuck on the concrete face. Silicate, which has the reforming effect of the concrete face, is added in the nonwoven. When the water is supplied to the concrete face, the face is reformed to make the concrete structure high quality. Unitika is working on construction companies to adopt.

Plants: Okazaki, Tarui, Japan
Processes: Spunbond, spunlace
Brand Names: Marix, Eleves, Appeal, Wiwi Alcima, Dilla, Terramc, Cottoace
Major Markets: Agriculture materials, carpet backings, geotextiles, cable wraps, wipes, storing bags, cover stock roofing sheets

Unitika manufacturers polyester spunbond nonwovens and spunlace fabrics in Japan and Thailand. It can make 20,000 tons of PET spunbond nonwovens per year in Japan as well as 10,000 tons per year at its Tusco subsidiary in Thailand. This capacity was expanded from 6000 tons per year in April 2017 with a 5.8 meter wide spunlace line capable of making core sheet type fibers. The majority of nonwovens is exported to China, Southeast Asia, Europe and the U.S.

Unitika also makes 5000 tons per year of spunlaced nonwovens. Additionally its joint venture with Marusan Industry makes 5000 tons of spunlaced nonwovens. The company mainly uses cotton fibers in spunlace. Much of this cotton is sourced from Marusan.

In 2017, sales of both PET spunbond nonwovens and spunlaced nonwovens increased. Domestic sales of polyester spunbond nonwovens benefited from gains in building and agriculture while spunlace growth was driven by products for skin care use.

Unitika also makes materials for cars like engine covers, fender liners and under covers with polyester spunbond nonwovens using Tusco. The nonwoven is a core sheath type composite fabric, which is composed of a core made of polyester and sheath made of PET with a lower melting point.

The fabric is needlepunched and molded with a heat press machine then the sheath part melts by heating and fiber fuses and the nonwoven fabric is formed. When the nonwoven fabric is thick, heat could not pass through to the inside and the internal layer offers improved processing and better reliability.

Plants: Okazaki, Japan; Tarui, Japan
Processes: Spunbond, spunlace
Brands: Marix, Eleves, Appeal, Wiwi, Alcima, Dilla, Terramac, Cottoace.
Major Markets: Agricultural materials, carpet backings, geotextiles, cable wraps, wipes, storing bags, coverstock, roofing sheets

Unitika produces 20,000 tons/year of PET spunbond nonwovens and 4500 tons/year of spunlace nonwovens. Thai TUSCO, a subsidiary of Unitika, now makes 10,000 tons of PET spunbond nonwovens per year after the company expanded capacity by 6000 tons in April 2017. This investment brought the company’s total PET spunbond capacity to 30,000 tons per year, giving Unitika a top position in the Asian polyester spunbond market.

UMCT, a joint corporation with Marusan Industry (Marusan Industry 65%, Unitika 35%), produces 5000 tons of spunlace per year.

Within PET spunbond nonwovens, industrial materials sales have increased while sales in automotives, agriculture and geotextiles remained flat. Spunlaced nonwovens sales increased thanks to increased face mask sales.

Unitika’s spunlace nonwovens business fared well in 2016 but spunbond sales were sluggish, remaining flat. Meanwhile, sales of TUSCO in Thailand performed well thanks to demand for carpet fabrics in the automotives market. Currently, 70% of TUSCO’s PET spunbond material is exported, mainly to the U.S. and Europe.

Meanwhile, spunlace nonwovens sales are increasing in the skin care market and Unitika’s capacity in this segment is fully sold out. The company is planning to increase capacity in UMCT, which should also help it drive up sales in China and Southeast Asia, bringing its exports from 10 to 20%.

Plants: Okazaki, Japan; Tarui, Japan
Processes: Spunbond, Spunlace
Brand Names: Marix, Eleves, Appeal, Wiwi, Alcima, Dilla, Terramac, Cottoace.
Major Markets: Agricultural materials, carpet backings, geotextiles, cable wraps, wipes, storing bags, coverstock, roofing sheets

Unitika produces 20,000 tons/year of PET spunbond nonwovens and 4500 tons/year of spunlace nonwovens. Thai TUSCO, a subsidiary of Unitika, makes 4000 tons of PET spunbond nonwovens per year. Additionally, UMCT, a joint corporation with Marusan Industry (Marusan Industry 65%, Unitika 35%), produces 50,000 tons of spunlace per year.

Within PET spunbond nonwovens, industrial materials sales have increased while sales in automotives, agriculture and geotextiles remained flat. Spunlaced nonwovens sales increased thanks to increased face mask sales.

Unitika’s Thai operation, Tusco, is adding 6000 tons per year to its operation, an investment that should be complete in April 2017. This will bring Unitika’s Thai output to 10,000 and its total output of PET spunbond to 30,000 tons making it the largest maker of PET spunbond nonwovens in Asia.

Once the new equipment becomes operational, the manufacture of general-purpose grade nonwovens will be transferred to Tusco to improve the cost competitiveness of the operation. So far, the Thai operation has only made nonwovens for agriculture materials.

Unitika’s Eleves spunbond material, which is made from a core sheet fiber, is made in Japan. By moving the production of general purpose nonwovens to Thailand, Unitika will be able to increase capacity of this higher value nonwoven in Japan.

In Unitika’s spunlaced nonwovens business, 60-70% of the output is made from 100% cotton while the remaining are bicomponent nonwovens combining cotton, lyocell, rayon and PLA. These materials are used not only in Japan but are exports to China, Korea and Taiwan.

Plants: Okazaki, Japan; Tarui, Japan
Processes: Spunbond, Spunlace
Brand Names: Marix, Eleves, Appeal, Wiwi, Alcima, Dilla, Terramac, Cottoace.
Major markets: Agricultural materials, carpet backings, geotextiles, cable wraps, wipes, storing bags, coverstock, roofing sheets

Unitika produces 20,000 tons/year of PET spunbond nonwovens and 4500 tons/year of spunlace nonwovens. Thai TUSCO, a subsidiary of Unitika, has been producing PET spunbond nonwovens with the capacity of 4000 tons/year. Additionally, UMCT, a joint corporation with Marusan Industry (Marusan Industry 65%, Unitika 35%), has produced spunlace nonwovens with the capacity of 5000 tons/year.

Although, the output of PET spunbond nonwovens has increased overseas, domestic output decreased in 2014. Its spunlace nonwovens have increased mainly in the face mask sector, however, sales have slightly decreased for its overall nonwovens business.

Unitika has been planning to enlarge its PET spunbond nonwovens facility and will be introducing a line with the capacity of 6000 tons/year for its Thai TUSCO subsidiary. The new line will begin operations by April 2017.

Unitika develops PET spunbond nonwovens with a cross-section of the fiber, which shows a ‘form of cross’ and is marketed with the brand name Dilla. Dilla is a thick fiber of heteromorphic section with 16 dtex, and the nonwovens offer superior breathability and rigidness, while heat resistance and intensity are high. Because it’s a continuous fiber, it has low dusting characteristics. Such properties are suitable for the matrix of filters, and can be developed for agricultural materials and geotextiles.