IEN: What are the major concerns facing the materials sector, and how can they be addressed?
Norman: In the nonwovens industry, we are seeing that customers are focusing more on product differentiation and higher performance materials, particularly in the more mature segments of the business.
Of course, pricing is always a concern, especially with the unprecedented raw material increases this industry has been experiencing for polypropylene, polyester, rayon, and other petroleum-based materials.
At Polymer Group Inc (PGI), we compete in both the commodity and specialty markets. Our goal for both is simple -- to provide customers with the best value proposition in the industry. This means delivering superior innovation that enables customers to offer higher performing, better differentiated products to the marketplace, while working aggressively to minimize price fluctuations. (Incorporating its APEX® technology into spunlaced fabrics produced at its Benson, NC facility, as shown here, PGI creates unique fabrics with three-dimensional imaging for end uses ranging from industrial filtration to consumer wipes.)
IEN: How much progress do you see toward integrating the different segments of product development -- design, engineering, manufacturing, supply chain?
Norman: This type of integration has become one of the primary focuses of PGI. As we work to partner with customers, the innovation process encompasses the full spectrum of supply chain management, manufacturing capability and expertise, and product design and engineering.
We have worked with customers using exactly this process to develop products for use in the home cleaning market, filtration, new flame-retardant materials for the home furnishings market, and many other applications.
One example of this is Procter & Gamble''s Swiffer dry dusting cloth, which is the result of a strong partnership and collaborative development effort between PGI and Procter & Gamble. PGI utilized its Apex technology to create this cleaning cloth with three-dimensional depth and strength in a lightweight material.
We also worked closely with Donaldson Co, one of the world''s leading providers of filtration systems, to produce a new line of industrial baghouse filters using our Durapex media technology for a wide range of manufacturing operations. These new filters provide double the life of the traditionally used product.
IEN: What are the R & D hotspots? Which ones are closest to commercialization?
Norman: Among the areas where we are seeing increased R & D efforts are new flame-retardant fabrics for home furnishings, and highly functional, multidimensional fabrics for household cleaning and other uses.
A growing number of companies are developing products to meet California''s new open-flame mattress standard (Technical Bulletin 603), which goes into effect January 2005.
PGI has developed a new family of fabrics, manufactured with its Apex technology, to help bedding manufacturers comply with these regulations that offer a number of benefits including softness, comfort, high strength, and durability.
We also see more companies integrating the capabilities of fabrics. Customers expect more performance from fabrics than single functionality. For example, new wiping materials for household cleaning not only hold soap but also clean and exfoliate. In traditional textiles, fabrics continue to advance in their functionality to provide strength and temperature control plus moisture management. These highly functional fabrics are making their way into areas where single functional fabrics have traditionally been used.
IEN: Will Product Lifecycle Management play an increased role in design? Why/Why not?
Norman: Definitely. PGI is constantly innovating to upgrade its product line and to introduce new-to-the-world products. Our business can be heavily impacted by changes in product lifecycle. As such, it is imperative for us to include this aspect in our design function. As soon as we introduce a product, we immediately begin working on the next generation, sometimes before the first generation is fully commercial. It is important for us to ensure our technology is flexible enough to accommodate the step changes in product design to remain competitive on a long-term basis.