Introduction

The nonwoven manufacturing industry is a dynamic sector that plays a crucial role in various applications, from healthcare to automotive and construction. As we progress into 2024, the industry is marked by significant trends in sustainability, technological advancements, and shifting market dynamics. Companies increasingly adopt eco-friendly practices, leverage cutting-edge technologies, and expand their global footprint to meet the rising demand for high-performance nonwoven materials. This article delves into the top 10 nonwoven manufacturers of 2023, exploring how they are navigating these trends and solidifying their positions in the market.

Sustainability, Technology, and Market Dynamics

Sustainability Trends:

The nonwoven manufacturing industry increasingly focuses on sustainability to meet regulatory requirements and demand for eco-friendly products. Many companies are investing in renewable raw materials and reducing their carbon footprint. For instance, Freudenberg Group has set a goal to be climate-neutral by 2045, highlighting its commitment to long-term environmental stewardship. Similarly, Suominen Corporation has made significant strides in incorporating renewable fibers into its products, with 62% of its production using renewable natural resources in 2022. These efforts reflect a broader industry trend towards adopting circular economy principles, which emphasise recycling and the use of biodegradable materials.

Technological Advancements:

Technological innovation is pivotal in driving the nonwoven industry forward. Advances in production technologies, such as spunbond, melt-blown, and air-laid processes, are enhancing product performance and expanding application areas. Berry Global, for example, has invested in Reicofil 5 spunmelt lines, which offer improved softness, sustainability, and barrier properties for hygiene and healthcare applications. Additionally, the integration of smart technologies, like the “Internet of Things” and A.I., in manufacturing processes is optimising efficiency and reducing waste. Companies are also developing advanced nonwoven materials with enhanced functionalities, such as antimicrobial properties and improved filtration efficiency, to cater to emerging market needs in healthcare and personal protection.

Market Dynamics:

The nonwoven fabrics market is experiencing robust growth, driven by increasing demand in the healthcare, hygiene, automotive, and construction sectors. The COVID-19 pandemic significantly boosted the demand for medical and hygiene products, such as face masks and disinfectant wipes, highlighting the critical role of nonwovens in public health. Furthermore, the automotive industry’s shift towards electric vehicles is creating new opportunities for nonwoven materials used in battery separators and thermal insulation. Geographic expansion is also notable, with Asia-Pacific emerging as a key market due to rapid industrialisation and urbanisation. Companies are expanding their regional manufacturing footprints to capitalise on the growing demand.

Overall, the nonwoven manufacturing industry is navigating a dynamic landscape marked by sustainability initiatives, technological advancements, and evolving market demands. These trends are reshaping the industry, driving innovation, and opening new avenues for growth.

01. Kimberly-Clark Corporation

Revenue: $20.4 Billion
Headquarters: Irving, Texas, USA

Kimberly-Clark Corporation, headquartered in Irving, Texas, is a global leader in personal care products. Established in 1872, the company reported $20.4 billion in revenue for 2023 and employs approximately 42,000 people worldwide. Known for brands like Huggies, Kleenex, Scott, and Kotex, Kimberly-Clark’s nonwoven fabrics are integral to its hygiene products, and they are renowned for their softness, absorbency, and durability.

The company is dedicated to sustainability, focusing on responsible raw material sourcing, reducing greenhouse gas emissions, and promoting circular economy practices. Kimberly-Clark aims to achieve 100% renewable electricity by 2030 and halve its environmental footprint. In 2023, it invested significantly in new technologies and processes to enhance sustainability.

With a strong commitment to innovation and sustainability, Kimberly-Clark continues to improve the quality of life globally through its trusted products and responsible practices.

02. Freudenberg Group

Revenue: $13.01 Billion
Headquarters: Weinheim, Germany

Freudenberg Group, headquartered in Weinheim, Germany, is a global technology company specialising in innovative solutions across various industries, including automotive, healthcare, and consumer goods. Established in 1849, the company reported a revenue of €11.9 billion in 2023 and employs approximately 52,241 people worldwide. The nonwovens division is a significant contributor to its revenue, producing materials for automotive interiors, construction, apparel, and medical supplies.

Freudenberg is committed to sustainability with a goal to achieve climate neutrality by 2045. In 2023, the company invested €604 million in research and development to create sustainable and high-performance materials. Initiatives include developing smart medical products, enhancing battery systems, and advancing fuel cell technology. Freudenberg’s dedication to innovation and sustainability ensures it remains a leader in the nonwoven industry while continuously improving its environmental footprint and delivering advanced solutions to its customers.

03. Berry Global Inc.

Revenue: $12.7 Billion
Headquarters: Evansville, Indiana

Berry Global Inc., headquartered in Evansville, Indiana, is a leading global manufacturer and marketer of plastic packaging products. In fiscal year 2023, the company reported revenues of $12.7 billion. Berry Global employs approximately 47,000 people across its numerous manufacturing facilities worldwide. The company is renowned for its diverse product portfolio, which includes containers, films, tapes, and nonwoven materials, serving industries such as healthcare, personal care, and consumer packaging.

Berry Global is committed to sustainability, with initiatives to achieve net-zero emissions by 2050. Their efforts include developing circular plastics, engaging in value-chain partnerships, and investing in renewable energy. Through its innovative and sustainable packaging solutions, Berry Global continues to drive success in the competitive nonwoven industry.

04. DuPont

Revenue: $12.1 Billion
Headquarters: Wilmington, Delaware, USA

DuPont, formally known as E.I. du Pont de Nemours and Company, is a renowned American multinational conglomerate established in 1802 by Éleuthère Irénée du Pont. Initially focusing on gunpowder production, DuPont has evolved into a leading science and technology company. Headquartered in Wilmington, Delaware, DuPont operates across various sectors, including electronics, biotechnology, and advanced materials.

DuPont’s nonwovens division is a significant contributor to its revenue, with a wide array of products like Tyvek, Sontara, and Kevlar. These materials are pivotal in industries such as medical, construction, automotive, and personal protection. Tyvek, for instance, is widely used in protective garments, medical packaging, and building envelopes due to its durability, lightweight, and resistance to water and chemicals.

DuPont is committed to sustainability and innovation, investing heavily in research and development to produce environmentally friendly and high-performance materials. The company aims to achieve zero emissions by 2050, focusing on circular economy principles and renewable energy.

With a legacy of over two centuries, DuPont continues to lead in innovation, providing advanced solutions that address global challenges and improve daily life.

05. Ahlstrom-Munksjö

Revenue: $3.25 Billion
Headquarters: Helsinki, Finland

Ahlstrom-Munksjö, headquartered in Helsinki, Finland, is a global leader in sustainable and innovative fiber-based solutions. Formed in 2017 through the merger of Ahlstrom Corporation and Munksjö Oyj, the company leverages over 160 years of combined experience. In 2023, Ahlstrom-Munksjö reported a revenue of €2.97 billion and employed approximately 6,931 people worldwide.

Ahlstrom-Munksjö specialises in producing high-performance fiber materials for diverse industries, including filtration, healthcare, food packaging, and building materials. Their product portfolio includes decor papers, release liners, nonwoven fabrics, and specialty papers, renowned for their quality and sustainability. The company emphasises the use of renewable fibers, which constitute 95% of its total fiber usage.

The company is deeply committed to sustainability, aiming to achieve climate neutrality by 2045. Initiatives include reducing its environmental footprint, enhancing product recyclability, and developing eco-friendly solutions. In 2023, Ahlstrom-Munksjö invested significantly in new technologies and processes to support these goals, ensuring they remain at the forefront of the nonwoven industry.

06. Johns Manville Corporation

Revenue: Over $3 Billion
Headquarters: Denver, Colorado

Johns Manville Corporation is a leading American manufacturer of insulation, roofing materials, and engineered products. Headquartered in Denver, Colorado, Johns Manville has a rich history dating back to 1858. Over the years, the company has evolved to become a significant player in the nonwoven materials industry. It is currently a wholly-owned subsidiary of the massive Berkshire Hathaway, which posted $501 billion in revenue in 2023.

Johns Manville’s nonwoven products are integral to various applications, including building insulation, commercial roofing, and mechanical insulation. The company’s diverse portfolio also extends to filtration media, geotextiles, and advanced fibers. In 2022, Johns Manville reported a revenue of over $3 billion, underscoring its strong market position.

Johns Manville serves a global customer base with 44 manufacturing facilities across North America and Europe. The company is known for its innovation and quality, continuously enhancing its product offerings to meet industry demands. Johns Manville is also committed to sustainability, focusing on reducing its environmental impact through energy-efficient manufacturing processes and sustainable product development.

Employing over 8,000 people, Johns Manville’s mission is to provide solutions that improve energy efficiency, comfort, and safety. The company’s dedication to innovation, quality, and sustainability continues to drive its success in the competitive nonwoven industry.

07. Glatfelter Corporation

Revenue: $1.4 Billion
Headquarters: Charlotte, North Carolina, USA

Glatfelter Corporation is headquartered in Charlotte, North Carolina. It is a global leader in producing engineered materials. Founded in 1864, the company has evolved significantly over the years, shifting from a traditional paper manufacturer to a major player in the nonwoven fabrics industry. Glatfelter specialises in air-laid, wetland, and spun-bond nonwoven materials, which are essential components in a variety of applications, including personal hygiene, healthcare, and industrial sectors.

In 2023, Glatfelter reported revenues of approximately $1.4 billion, reflecting its robust market presence and expanding capabilities. The company’s nonwoven products are integral to items such as baby wipes, adult incontinence products, tea bags, and home improvement materials. With 12 manufacturing facilities across North America, Europe, and Asia, Glatfelter serves a global customer base, ensuring high-quality and reliable supply chains.

Glatfelter is committed to sustainability and innovation. It focuses on reducing its environmental footprint through sustainable sourcing of raw materials, energy-efficient manufacturing processes, and the development of eco-friendly products. The company’s strategic initiatives include continuous investment in research and development to meet the evolving needs of its customers and drive future growth.

08. Fitesa

Revenue: $1.4 Billion (2022)
Headquarters: Porto Alegre, Brazil

Fitesa, headquartered in Porto Alegre, Brazil, is a global leader in the nonwoven fabrics industry, primarily serving the hygiene and healthcare markets. Established in 1973, Fitesa has grown to become a massive producer of nonwoven spun melt textiles, with a strong presence in the Americas, Europe, and Asia. The company operates 23 manufacturing plants across 13 countries, emphasising its extensive global reach.

In 2022, Fitesa voluntarily reported revenues of $1.4 billion, driven by its diverse product portfolio that includes spun melt, carded, air-laid, films, and elastics. These nonwoven materials are used in various applications, such as feminine hygiene products, baby care, adult incontinence, medical supplies, and agricultural and industrial products. Fitesa is known for its innovative approach, with five innovation centers and three pilot lines dedicated to advancing nonwoven technology.

Sustainability is a core value for Fitesa, which invests significantly in sustainable practices and eco-friendly product development. The company’s commitment to sustainability shines through in its renewable energy sources and efforts to minimise its environmental impact. Fitesa’s continuous investment in innovation and sustainability ensures its leadership position in the nonwoven fabrics industry.

09. Suominen Corporation

Revenue: $493 Million
Headquarters: Helsinki, Finland

Suominen Corporation, based in Helsinki, Finland, is a prominent player in the nonwoven fabrics industry, particularly known for its expertise in producing nonwovens for wiping, hygiene, and healthcare applications. In 2023, Suominen reported net sales of EUR 450.9 million and employed approximately 673 people globally.

Suominen operates production facilities in the United States, Brazil, Spain, Italy, and Finland, serving markets worldwide. The company is dedicated to sustainability, with a diverse portfolio of products made from renewable, recycled, or plastic-free raw materials. In 2023, 79% of Suominen’s sales came from sustainable products, reflecting the company’s strong commitment to environmental responsibility.

Recent initiatives include the New Fiber Center project, which explores the potential of organic fibers like hemp, flax, and straw. Suominen continues to innovate and expand its sustainable product offerings, ensuring its leading position in the nonwoven fabrics market.

10. TWE Group

Revenue: $450 Million
Headquarters: Emsdetten, Germany

TWE Group, headquartered in Emsdetten, Germany, is a significant privately-owned player in the nonwoven fabrics industry. Founded in 1912, TWE Group has grown to become a leading manufacturer of nonwoven materials, serving a variety of markets, including hygiene, automotive, construction, filtration, and healthcare. The company’s products are essential in applications such as hygiene products, automotive interiors, and construction materials.

In 2022, TWE Group voluntarily reported revenues of $450 million, underscoring its strong market presence. The company operates multiple manufacturing facilities across Europe and Asia, ensuring a reliable supply chain and global reach. TWE Group is particularly noted for its innovative and sustainable product lines, such as the RePEat product range, which includes materials made from recycled fibers or customer waste. This commitment to sustainability is further demonstrated by TWE’s focus on reducing its environmental impact through responsible sourcing and production practices.

TWE Group’s continuous investment in advanced technologies and sustainable solutions ensures its competitive edge in the nonwoven fabrics market. The company’s pursuit of quality and innovation positions it as a leader in providing high-performance nonwoven materials for various applications.

Conclusion

In conclusion, the nonwoven manufacturing industry is experiencing a transformative period driven by sustainability, technological innovation, and dynamic market demands. Leading companies like Berry Global, Freudenberg Group, DuPont, and Kimberly-Clark are at the forefront, pioneering advancements that enhance product performance and promote environmental stewardship. The industry’s drive to lower its environmental impact and adopt smart manufacturing technologies is paving the way for sustainable growth. As the market continues to expand, particularly in regions like Asia-Pacific, these companies are well-positioned to capitalise on new opportunities and maintain their leadership in the global nonwoven fabric industry.