By Arun Rao
India-based KTEX Nonwovens is among the few nonwoven fabric manufacturers that have introduced the concept of circularity in textiles as part of their sustainability initiatives. The company has installed a regranulation machine at its plant to support this effort.
The nonwoven fabric waste generated during slitting is processed into granules using the regranulation machine. These recycled granules are then reintegrated into the production process as raw material. This approach significantly reduces waste by reusing the slit portion of the fabric, which would otherwise be discarded. It helps minimize landfill contribution and supports a more circular and responsible manufacturing approach.
“Due to our new state-of-the-art production line, it is also possible for us to downgauge the GSM of a fabric,” said Mr. Nikhil Vaswani, Global Sales & Marketing Head at KTEX Nonwovens. “For example, if a customer is currently using 9 or10 GSM fabric for converting, we can offer the same tensile strength and technical parameters in a 7 GSM fabric. This translates into significant savings for converters and makes the product more sustainable, as less raw material is used during production. This has been made possible due to our new six-beam production line.”
As part of its broader sustainability commitment, KTEX is also investing in renewable energy. Both a solar plant and a windmill farm are in the pipeline. KTEX holds several compliance certifications, including ISO 9001, ISO 14001, and ISO 13485.
KTEX Nonwovens began its journey in 2018 with a single production line featuring the latest five-beam SSMMS nonwoven technology and an initial monthly capacity of approximately 450 tons. Over the last six years, the company has grown its capacity by 600% by adding two additional production lines — both from Reifenhauser. One of these is a bi-component SMS line, and the other is a six-beam SSMMMS line with a width of 4.2 meters.
“With the addition of these two lines, our monthly capacity has increased to around 2,800 tons, making us one of the fastest-growing nonwoven fabric manufacturers in India and the second-largest player in the hygiene nonwoven fabrics segment,” Mr. Vaswani added.
The bi-component line allows KTEX to blend various polymers, such as polypropylene and polyethylene, into a single fabric. “Bi-component nonwovens are especially suited for applications requiring softness and comfort, such as premium diapers. These fabrics offer a cotton feel and better breathability. We also supply fabrics with botanical treatments such as olive oil, aloe vera, and vitamin E — all of which enhance user comfort and provide a rash-free experience,” he explained.
KTEX also operates a 3D carding machine that produces fabrics with a bulky, bubble-wrap-like texture, further enhancing softness and comfort. “These features also contribute to superior odour control and breathability,” he informed.
The KTEX production facility is located in the city of Rajkot and spans approximately 500,000 sq. feet of built-up area. The company employs around 140 people at its plant and another 25 at its Mumbai office, primarily in sales and marketing roles.
KTEX exports its products worldwide, including to East Asia, Africa, and South American countries such as Colombia and Brazil. Its primary export markets, however, are the United States and European countries like France, the Netherlands, and Portugal.
KTEX’s technical leadership is headed by Mr Emil Toman, a seasoned expert from the Czech Republic with decades of experience working for top-tier nonwoven manufacturers across multiple countries. He leads product development and has played a key role in making KTEX leaner and more cost-efficient, allowing the company to offer competitive pricing to its customers.
“India’s baby diaper market presents a massive opportunity. “With approximately 25 million babies born every year, the potential is staggering. The market is projected to generate USD 6.8 billion in 2025 and is expected to grow to over USD 10.6 billion by 2030,” Mr Vaswani mentioned.
“What’s driving this growth? Rising hygiene awareness, increasing disposable incomes, especially in urban households, and the convenience offered to young working parents are all major factors. In addition, the rise of e-commerce has made baby care products more accessible, with the online baby care market expected to grow at over 14% CAGR in the coming years,” he stated.
“This is why we at KTEX continue to invest in capacity, innovation, and softness-enhancing technologies — to serve the evolving needs of this rapidly growing and increasingly quality-conscious market,” he concluded by saying.