Top synthetic fiber producers, ranked by 2005 annual capacities in tons.
In its analysis of 2005’s top synthetic fiber producers, PCI Fibres noted that the companies represented reflect the dominance of Asia and particularly China. There are four Chinese-based companies in the top 10, and all except one of the other companies (Reliance) has fiber manufacturing investments in China. The Asian giant accounts for 52 percent of total polyester capacity, while no other country exceeds 10 percent of the total. The U.S. and Canada account for 28.5 percent of nylon capacity, while China has 21 percent. Polyester is by far the largest of the global synthetic fibers included in PCI Fibres’ analysis, with 80 percent of capacity, followed by nylon with 12 percent, acrylics with 7 percent and spandex and all others with 1 percent (polypropylene is not included in the analysis).
1. Formosa Plastics Group
Total: 1.38 million tons
Country: Taiwan
Formosa Plastics Group currently produces six types of fibers: polyester, acrylic, nylon, rayon, carbon and spandex. Formosa has become one of the largest textile and finishing and dyeing producers in Taiwan, producing different kinds of yarn, plain-weave fabric, knitted cloth and dyed products. FPG is currently expanding its operations by building a polyester plant in China. The $15 billion global enterprise is based in Taiwan, with 72,000 employees.
2. Reliance Industries LTD.
Total: 1.29 million tons
Country: India
With revenues of $22.6 billion, Reliance is the world’s largest polyester fiber producer. The company purchased Trevira Polyester Fiber in Germany last year. Its research and development arm has developed many new products, such as fluorescent shades on polyester fabrics, water- and oil-repellent finishes on Poly Wool and Lycra spandex stretch fabrics and flame-retardant fabrics, among others. Future R&D efforts will be concentrated on waterproof, color-fast fabrics for outdoor applications.
3. Invista
Total: 1.24 million tons
Country: U.S.A.
Invista, owned by Koch Industries, is the world’s largest producer of nylon and spandex, with plants in the Americas, Europe and Asia. Though Invista slipped from number one to number three this year, the Wichita, Kan.-based company has a manufacturing or marketing presence in every garment-making region worldwide. Invista brands include Lycra, Stainmaster, Thermolite and Coolmax, among others.
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4. Tuntex
Total: 900,000 tons
Country: Taiwan
Tuntex is a polyester manufacturing company with production operations in Thailand and China. Incorporated in July 1987 as a joint venture between a group of Thai shareholders and the Taiwanese Tuntex group, Tuntex manufactures high-quality polyester products (for nonwovens and yarn manufacturing applications) for global and Thai markets. The company also makes polyester chips and various filament yarns for weaving and knitting.
5. Yizheng Chemical Fiber Co. Ltd.
Total: 855,000 tons
Country: China
Yizheng is part of number 10-ranked Sinopec, but operates with a level of independence, according to PCI Fibres. As a leading producer of polyester fiber, the company recently formed a joint venture with Unifi of the U.S. to make specialty textured polyester in China. Last September, Yizheng began construction on a multifunctional polyester staple fiber production line. Yizheng has also recently begun devoting itself to the development of differential fibers.
6. Shaoxing Yuandong
Total: 820,000 tons
Country: China
Having grown from 100,000 tons in 1999 to 820,000 in 2005, Shaoxing Yuandong, with headquarters in China’s Zheijang province, has even more expansion plans, with projected growth to 1.6 million tons by 2007. Three years ago, Frankfurt-based plant engineering contractor Zimmer AG constructed a polyester staple fiber plant for Shaoxing. The plant was designed for a capacity of 300 tons per day.
7. Huvis
Total: 788,000 tons
Country: South Korea
According to PCI Fibres, South Korean synthetic fiber companies have been facing difficulties in competing with China. Huvis, formed in 2000, has reduced its capacity in South Korea and has instead added capacity in China. Now, close to 40 percent of Huvis capacity is outside South Korea. The polyester business at Huvis is centered on three sectors: filament yarn, chip and staple fiber. The Seoul-based company has large-scale polyester production factories located in Jeonju, Suwon and Ulsan in South Korea.
8. Jiangying Sanfangxiang
Total: 710,000 tons
Country: China
Established in 2001, Jiangying Sanfangxiang has two joint ventures and has been growing steadily since obtaining its import and export license in 1993. The company, located in Jiangsu, concentrates on polyester but also specializes in chemical fiber, textiles, and printed and dyed fabrics as well as chemicals.
9. Far Eastern textile ltd.
Total: 604,000 tons
Country: Taiwan
Founded in 1942 as Far Eastern Knitting Factory Co. Ltd., Far Eastern is a diverse group that encompasses everything from retail to cement, according to PCI Fibres. The synthetic fiber division has been a leader in the Taiwanese industry and now has facilities in China. In 2002, Far Eastern formed a new joint venture with DuPont U.S.A. The joint venture has acquired DuPont’s polyester plant in Suzhou, China, and transformed it to produce fibers for industrial and special applications.
10. Sinopec corp.
Total: 595,000 tons
Country: China
Sinopec is a vertically integrated energy and chemical company from oil exploration through refining to petrochemicals and synthetic fiber, as well as gas stations. The company was set up on Feb. 28, 2000, by China Petrochemical Corp. Sinopec is the number-one producer and supplier of major petrochemical products (including petrochemical intermediates, synthetic resin, synthetic fiber monomers and polymers, synthetic fiber and chemical fertilizer).
Source: Data provided by PCI Fibres from the “World Synthetic Fibres Supply and Demand Report–2005”; 2005 Annual Capacities (excluding polypropylene)