Polypropylene Nonwoven Production
Nonwoven Production Costs Report | Issue A | Q3 2024
| Report Details |
| 10 kta United States-based plant | Q3 2024 | 107 pages |
This report presents a cost analysis of a 10 kta (kilo metric ton per annum) United States-based plant. You can add a customized cost analysis, assuming another location (country), when ordering a premium edition of this report.
Report Abstract
This report presents the economics of Nonwoven production from polypropylene via spunbond technology. The economic analysis performed assumes a plant located in the United States.
The report provides a comprehensive study of Nonwoven production and related Nonwoven production cost, covering three key aspects: a complete description of the Nonwoven production process examined; an in-depth analysis of the related Nonwoven plant capital cost (Capex); and an evaluation of the respective Nonwoven plant operating costs (Opex).
The Nonwoven production process description includes a block flow diagram (BFD), an overview of the industrial site installations, detailing both the process unit and the necessary infrastructure, process consumption figures and comprehensive process flow diagrams (PFD). The Nonwoven plant capital cost analysis breaks down the Capex by plant cost (i.e., ISBL, OSBL and Contingency); owner's cost; working capital; and costs incurred during industrial plant commissioning and start-up. The Nonwoven plant operating costs analysis covers operating expenses, including variable costs like raw materials and utilities, and fixed costs such as maintenance, labor, and depreciation.
Process Schematic
The process under analysis comprises three major sections: (1) Web Formation; (2) Web Bonding; and (3) Finishing.
Web Formation. Initially, the polypropylene is mixed with resin modifiers, pigments and/or other additives. The mixture is fed to an extruder where it is melted, homogenized, filtered and passed through a spinneret, originating filaments that are subsequently solidified by means of cool air quenching. The filaments are accumulated on a moving perforated belt, forming a random Nonwoven web, which is conveyed to a web bonding step, downstream.
Web Bonding. Here the web formed is bonded to provide fabric integrity, by means of thermal bonding. The web is passed through heated rolls, being partially melted and bonded together, and then through cooled rolls, in such a way that a cohesive bonded fabric is formed.
Finishing. The final step consists mainly in slitting and winding operations. The fabric is slit, in order to provide fabric rolls with accurate dimensions. Then, according to consumers requirements, the fabrics are wound into rolls with specific width and diameter, packed and sent to storage facilities.
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Production Process Information
Process Consumptions
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Production Costs Datasheet
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Operating Cost Details
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Production Process Information
Process Consumptions
Labor Requirements
Plant Capital Cost Summary
Operating Cost Summary
Production Costs Datasheet
Plant Capital Cost Details
Operating Cost Details
Plant Cost Breakdowns
Plant Capacity Assessment
Process Flow Diagrams
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Content Highlights
Plant Capital Cost Summary
Summary outlining the capital cost required for building the Nonwoven production plant examined
Plant Capital Cost Details
Detailing of fixed capital (ISBL, OSBL & Owner’s Cost), working capital and additional capital requirements
Plant Cost Breakdowns
Breakdown of Nonwoven process unit (ISBL) costs and infrastructure (OSBL) costs; plant cost breakdown per discipline
Operating Costs Summary
Summary presenting the operating variable costs and the total operating cost of the Nonwoven production plant studied
Operating Cost Details
Detailing of utilities costs, operating fixed costs and depreciation
Plant Capacity Assessment
Comparative analysis of capital investment and operating costs for different Nonwoven plant capacities
Production Process Information
Block Flow Diagram, descriptions of process unit (ISBL) and site infrastructure (OSBL)
Process Consumptions
Raw materials and utilities consumption figures, by-products credits, labor requirements
Process Diagrams
Process flow diagrams (PFD), equipment list and industrial site configuration
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