Commodity Production Costs Report

Polypropylene Nonwoven Production

Nonwoven Operating Costs & Plant Construction Costs

10 kta United States-based plant | 107 Pages | Issue A | Q3 2024
Starting at $1,999 USD | See Report Editions Prices

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.

Key reference(s): ?

Nonwoven Production Cost Report 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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Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
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 80 Pages | 22 Tables | 9 Images

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Table of Contents


Features
  • Production Process Information
  • Process Consumptions
  • Labor Requirements
  • Plant Capital Cost Summary
  • Operating Cost Summary
  • Production Costs Datasheet
  • Plant Capital Cost Details
  • Operating Cost Details
  • See All Features

 90 Pages | 28 Tables | 13 Images

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Updated with Q3 2024 Data

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Table of Contents


Features
  • 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
  • Costs in Different Countries Add-on
  • See All Features

  • 107 Pages | 34 Tables | 22 Images
  • Print-enabled PDF Format Add-on
  • Updated with Q3 2024 Data
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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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