Nonwovens in medical industry - Ahlstrom-Munksjö - Home · PDF file ·...
Transcript of Nonwovens in medical industry - Ahlstrom-Munksjö - Home · PDF file ·...
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Nonwovens in medical industry
Ahlstrom CorporationPaul Marold, Senior Vice President, Advanced NonwovensRami Raulas, Senior Vice President, Sales & MarketingJune 15, 2009
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Agenda
1. Ahlstrom today
2. Medical nonwovens market
3. Ahlstrom solutions in medical nonwovens
4. Single-use vs. reusable medical fabrics
5. Nonwovens in the prevention of pandemics
6. Summary
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1. Ahlstrom today
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Ahlstrom today
• Leading supplier of fiber-based materials
• 6,100 employees in over 20 countries on six continents
• Business segments• Fiber Composites • Specialty Papers
• Listed on the NASDAQ OMX Helsinki since 2006
• IPO proceeds used for growth mainly in BRIC-countries (Brazil, Russia, India, China)
• Net sales EUR 1.8 billion in 2008
• Founded in 1851
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Ahlstrom locationsSales officesPlants
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Roll goods producer
Pulp producers
Synthetic fiber producers(PET, PP, glass)
Chemicalsuppliers
Printers (label, decor, poster, wallcover...)
Label metalizers
Siliconizers
Automotive industry suppliers (filter, gasket)
Compositeindustry
World class consumer or industrial brands
Raw material supplier
Primaryproduction
Converter Marketer/seller
Consumers
Industrial customersNatural
fibers (wood,cotton, hemp)
Oil/petro-chemicals
Ahlstrom in the value chain
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romNet sales by business area (Q1/2009) & end useapplication examples
Glass & IndustrialNonwovens
Release & LabelPapers
Technical Papers
Home & PersonalNonwovens
Filtration
AdvancedNonwovens
Building
GraphicsTransportation
Healthcareand hygiene
Food and industrialpackaging
Utilities
17%
15%
12%
28%
17%
12%
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Specialty papers market position (1)
Leading supplier of fiber-based materials
Nonwovens market position (2)
1) Source: Pöyry 2008 2) Source: Nonwovens Industry, September 2008
First Quality
Buckeye
Fibertex
Johns Manville
PGI
Ahlstrom
Kimberly-Clark
Freudenberg
DuPont
0 500 1000 1500$'m
Koehler
International Paper
Wausau Paper
Stora Enso
NewPage
UPM
Arjowiggins
Felix Schoeller
Ahlstrom
MeadWest-vaco
1000Tons'000
0500
Fiberweb
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Leading position in most product lines
Ahlstrom is the market leader ornumber two in:• Transportation filtration• Glass fiber tissue• Pre-impregnated decor paper• Nonwoven wipes• Wallpaper and poster paper• Crepe paper• Food nonwovens food casings &
infusion• Genuine vegetable parchment• Release base paper• Medical nonwovens• Abrasive paper• Glass fiber specialty reinforcements• Metalized label papers• Post-it papers
Key competitors
• Filtration: Andrew Industrial, H&V, Neenah
• Glass Nonwovens: Johns Manville, OCV, Saertex
• Technical Papers: ArjoWiggins, M-real, Neenah, Nordic Paper, SAPPI
• Release & Label Papers: ChamPaper Group, Delfort, New Page, UPM
• Advanced Nonwovens: PGI, Dupont, Kimberly-Clark
• Home & Personal Nonwovens: Jacob Holm, Kimberly-Clark, PGI
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2. Medical nonwovens market
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What are medical nonwovens?
• Nonwovens are used in many medical and surgical applications:• Surgical drapes• Surgical garments such as gowns, caps, scrubs, aprons, and
shoe covers • Sponges, swabs• Dressings and wound-contact pads of any kind• Face masks
• Nonwovens can be used outside the operating room as well in applications like home healthcare, temperature management and personnel protective equipment (PPE)
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Medical applications
Surgical Gowns
Surgical Drapes
Facemask components
Sterile Barrier Systems
Facemask
GownsPPE
TEMPERATURE MANAGEMENTHOME
HEALTHCARE
Warming Blankets
OPERATING ROOM
Warming Blankets
BVBHOSPITAL
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romThe Medical Nonwovens market exceeds EUR 1.4 billion
Rest Of the World24 %
North America42 %
Europe34 %
Medical nonwovens market size by geographical area 2008
Source : Internal Ahlstrom Intelligence, INDA Report, 2008
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Global Disposable Market split by product segment
Facemasks8 %
Drapes42 %
SterileBarrier
Systems21 %
Gowns29 %
Product segments by volume (tons)
Source : Internal Ahlstrom Intelligence, INDA Report, 2008
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Global growth potential per region 2007-2012
0102030405060708090
100
NorthAmerica
Europe AsiaPacific
ROW
Global market demand (single-use medical fabrics)
% in
tons Growth estimate for
2007-2012Volume in 2006
Source: D. Rigby – Nonwovens End-Use produtcs; INDA; World Demand and Supply Outlook for Spunbonded Polypropylene and Spunbonded/Melt Blown Composites, John R. Star, Inc. – June 2002; internal discussions; Freedonia 2006
3 %
5.6% 7.2%
6.7%
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romGlobal growth potential per product segment2007-2012
0102030405060708090
100
Drape Gown SterilizatonWrap
Facemasks
Global market demand
% in
tons Growth estimate for
2007-2012Volume in 2006
5.1%
5.1% 4.1%
11.1%
Source: D. Rigby – Nonwovens End-Use produtcs; INDA; World Demand and Supply Outlook for Spunbonded Polypropylene and Spunbonded/Melt BlownComposites, John R. Star, Inc. – June 2002; internal discussions; Freedonia 2006
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Key growth drivers
• Rising standard of living in Asia Pacific
• Aging population worldwide • (APPENDIX: population pyramids in India, China, USA & Finland)
• Ongoing awareness of and concern over hospital acquired infections (HAI)
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Growth drivers by market area• USA
• Medical market is mature – growth is slowing due to saturated market• US Market is highly penetrated – thus little opportunity for growth
Surgical drapes: 90-95% of all major surgical proceduresSurgical gowns: 80% of all major surgical procedures
• Europe• Projected to experience high growth in medical nonwovens sector in the
coming years • Local national standards being harmonized into European Standards (EN) –
e.g. medical devices, protective equipment• APAC
• Rising standard of living, particularly in China, facilitates higher healthcare expenditures
• India• Traditional major disposable markets of absorbent hygiene, surgical apparel
and patient drapes are underdeveloped, yet large potential markets • Indian market still very oriented to cotton (reusable textiles)• Healthcare industry growing at a rate of over 20%
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Medical nonwovens value chain
Raw Materials Roll GoodsManufacturing
Converter Customer
Input: Fibers Input: Roll goods
Resin
Bale Fiber
Web Formation
Bonding
Finishing Cutting/Slitting
Sewing
Folding
Packaging
Sterilization
Distributor
Wholesaler
Hospital
Clinics
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3. Ahlstrom solutions for medical nonwovens
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Advanced Nonwovens business area
Medical Fabrics
Food Nonwovens
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Medical fabrics
• Manufacturing in the USA, Europe and (starting in early 2010) India
• Material attributes provide infection control,sterility and guarantee patient, doctor and staff safety
• Ahlstrom provides single-use medical fabrics for operating rooms and other protective applications worldwide
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Market positioning
• Medical Sales
• 5 Technology Platforms : SpunlaceFilm based composites (BVB)Spunmelt (SMS)Spunlace CompositeWetlaid
• Ahlstrom is 2nd largest supplier in medical nonwovens
• Leader in technology and innovation: 36 % of revenue comes from new products
• Major wet-laid supplier for medical applications
• Leader in facemask coverstock
Europe14 %
North America
76 %
Asia10 %
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Ahlstrom products for medical nonwovens
• Surgical drape• Back Table Cover• Drape sheet
• Surgical gown• Procedure/ Isolation gown• Scrub suit
• Facemask materials• Operating room• Dentist office
• Sterile barrier systems• Sterilization wrap• Tray liner
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Our manufacturing platform
PlantsSales offices
Windsor Locks, CT, USA
Chirnside, UK
Mundra, IndiaStart up in early 2010
Ställdalen, Sweden
Pont-Audemer, France
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Pioneering into the medical market
• Ahlstrom entered the market through the DexterNonwovens acquisition in 2000 (EUR 275 million)
• Sterilization wrap• Surgical drape and accessories• Facemask materials
• Ahlstrom then invested in new technologies• Nonwoven composites combined with specialty films - 2001• Impacting the market in North America for surgical drapes and the globe
for gowns (BVB - Breathable Viral Barrier) - 2002
• Ahlstrom continues to invest• New plant starting up in India - 2010
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Customer references
• Ahlstrom works with the major marketers in established markets:• Europe #1, #2 & #4• North America #1, #2 & #3• Japan #1 & #2
• Customer relationships are based on joint development and supplychain optimization
• Customers include e.g.• OneMed• Mölnlycke Health Care
• Ahlstrom is recognized for product innovation, quality, and after-saleservice
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New medical fabrics plant in India
• After an investment of EUR 38 million, Ahlstrom will start a new spunmelt nonwoven plant in Mundra, in the western Indian state of Gujarat
• Mainly targeting the medical market, it will manufacture a full range of multi-layer spunmelt fabrics for applications in gowns, drapes and facemasks
• Strategically located close to suppliers and customers
• Consolidates Ahlstrom’s position as one of the top-three global nonwoven suppliers
• Commercial production will start in early 2010
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4. Single-use vs. reusable medical fabrics
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Background
• In Europe up to 1970 - 1975 all hospital garments were reusable made with conventional textiles (cotton & cotton polyester)
• Conventional reusables have been linked to the increase of Hospital Acquired Infections (HAI) hospital infection
• In the early 1970’s wetlaid single-use surgical drapes & gowns started to replace cotton & cotton polyester in the USA and later in Europe
• In the late 1980’s the textile industry responded with introduction of new textiles (Goretex and Micro –fibres)
• Single-use fabrics have evolved over the last few years from paper to cloth-like (Spunlace, SMS, Triplex, Bicomponent)
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Background
• Developed countries have high single-use penetration, with growth expected in emerging countries (BRIC)
Estimated single-use penetration in % vs. conventional textiles
4 5 10 15
40
55 60
95
0
10
20
30
40
50
60
70
80
90
100
%
Africa Russia South America Asia Arabic countries Europe Australia USA
Source: management estimate
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Trends
• Many hospitals are still treating wound infections rather than pro-actively avoiding infections
• Abuse of antibiotics has created resistance to treatment in hospitals
• Throughout the world new Viruses and Multi Resistant Bacteria (MRSA) are becoming a factor in HAI’s (Hospital Acquired infection)
• Worst-case scenario: a Pandemic (Mutated H5N1 Avian Flu ~ H1N1 Swine Flu)• WHO just announced that Swine flu is a pandemic (June 11, 2009)
• Governments are reducing healthcare budgets
• Private insurance costs are increasing
• Need to reduce/eliminate hospital infections and mortality rates
• The aged population is increasing
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RegulationsSINGLE - USE REUSABLE
COMPLIANCE WITH GLOBAL STANDARDSCOMPLIANCE WITH GLOBAL STANDARDS
BARRIER PROTECTION BARRIER PROTECTION
FLEXIBILITY IN USE FLEXIBILITY IN USE
CONSISTENCY IN USECONSISTENCY IN USE
YES
Completely fulfill global standards
YES
From blood-borne pathogens and cross contamination
YES
When incision needs to be enlarged/modified
YES
Always new and clean, consistent in performance
NO
Conventional textiles do not
NO
Do not give any protection
NO
Reduced flexibility
NO
Textile can be compromised during laundering process (dirt, virus parts, blood…)
VS.
VS.
VS.
VS.
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Environmental impactSINGLE-USE REUSABLE
ENVIROMENTALLY “GREEN”ENVIROMENTALLY “GREEN”
WAREHOUSE STORAGEWAREHOUSE STORAGE
YES
Single use products are incinerated generating energy (2000T per day creating 200 million KWh yearly)
Single use drapes and gowns represent only 2% of hospital waste (hospital waste only 2% of municipal waste)
Synthetic fibers need 0 hectare agricultural area
Less than 1% of crude oil globally is actually consumed in production of man-made fibers
NO
Stock continually replenished
NO
High amount of detergent needed to launder and possible fluoro-carbonates (textiles need repeated impregnation)
Hospital or external laudries drain “contaminated wash water”
Cotton needs 1.3 hectare agricultural area/ton fiber
Cotton fields need lots of water (25000m3/ton) fertilizer pesticides, herbicides which destroy land by chemical pollution
YES
Substantially more storage space – stock, prepared and used must be stored
VS.
VS.
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Cost comparison
SINGLE - USE REUSABLELOWER FIXED COSTSLOWER FIXED COSTS
HIGHER VARIABLE COSTSHIGHER VARIABLE COSTS
YES
Fixed costs to hospitals
NO
NO
Unexpected repair/replacement costs
YES
Sorting, segregation, sharp instruments damage, laundering, inspection, folding,
packing
LOWER OTHER COSTSLOWER OTHER COSTS
YES
Reduced costs to hospitals due to reduced HAINO
VS.
VS.
VS.
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5. Nonwovens in the prevention of pandemics
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The facts of influenza
• Influenza, also known as the flu, is caused by a virus
• Antibiotics will not cure influenza
• In the last century: three pandemics
• Spanish Flu (1918-19), 40 million people died
• Asian Flu (1957-58), estimate 1 million people died
• Hong Kong Flu (1968-69), estimate 1 million people died
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Pandemic influenza
1. Influenza pandemics are recurring events
2. All countries must be prepared
3. Existing medical supplies are not inadequate
4. Causes large number of deaths
5. Causes economic and social disruption
6. WHO will alert the world when a pandemic threat increases
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PREVENTION
• Education/awareness
• Animal extermination
• Travel restrictions, closure of borders
• Quarantine
• Vaccine inventory
PROTECTION
• Proper hygiene techniques
• Source protection• Poultry workers• Healthcare providers
• Protective Apparel• Eye, face, glove, garment
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Ahlstrom BVB applications
• BVB = Breathable ViralBarrier
• Surgical gowns • Reduce cross-
contamination between medical staff and patient’s body fluids
• PPE (Personal Protective Equipment) apparel :
• Protection for pandemic Influenza
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BVB technology
• Construction• Outer layer: additional fluid
repellency & strength • Middle layer: responsive,
monolithic membrane for impervious barrier
• Comfort layer: soft touch to the wearer’s skin
• Protection against bacteria and viruses, as small as 0.027 micron (Avian flu/Swine flu: 3x larger=0.08-0.12 microns)
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BVB: Product benefits
• Barrier against viruses such as:• Hepatitis, HIV, AIDS, CJD
• MRSA (bacteria)
• SARS, Avian influenza, Swine influenza
• Liquid barrier• Reduces cross-contamination between medical
staff and patient’s body fluids
• In compliance with international standards
• Comfortable to use: light weight, breathable, cool
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Global standards compliance (2009)
Europe
EN 13975parts 1,2,3
MDD 93/42/EEC
PPE 89/686/EEC
Endorsed by AFPP/NATN
Global
Recognized by Center for Disease Control
Certified by China CDC
North America
AAMI PB-70Level 4
ASTM F1670/1671OSHA Guidelines
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Where is Ahlstrom BVB used?
Under evaluation
In use
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6. Summary
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Ahlstrom medical fabrics – summary
• More than 25 years of expertise in the medical market
• Growth through innovation
• Customized solutions based on a broad technology base
• Globally expanding manufacturing and service network
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The future of medical nonwovens
• Continued focus on infection prevention
• Driven by innovation and cost-effectiveness
• The effect on demand of emerging markets and an aging population
• Leveraging Ahlstrom’s global reach
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APPENDIX
Population pyramids in the years 2000 and 2025
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India in 2000
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India in 2025
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China in 2000
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China in 2025
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Finland in 2000
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Finland in 2025
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USA in 2000
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USA in 2025