Cotton By The Numbers


C
otton data, when analyzed over the five-year time series from the 2000-01 through 2004-05
marketing seasons, illustrate the global shifts in the development of cotton production and the
growth of the textile industry represented by cotton consumption. China, India, Pakistan, Turkey,
the United States and Brazil lead the world in both cotton production and consumption. But
significant markets for consumption, like Indonesia, Thailand, Mexico and Bangladesh, point to
growing usages not supported by domestic production.

In terms of exports, Uzbekistan is second to the United States in global cotton exports. The
Africa Franc Zone, Australia, Syria, Egypt, Turkmenistan, Tajikistan and Kazakhstan are not to be
ignored as significant suppliers some with the potential for developing a domestic consumption
base.

There is much more to the global cotton story than simply matching a country’s cotton
production with its cotton consumption. Cotton shipments span the globe, with cotton traded and
purchased to meet the quality and production needs of industry. Domestic production may not meet
the consumption criteria of a country, and imported cotton may be necessary to meet those demands.
However, growth rates of a country’s supply and consumption of cotton do shed some light on the
shift in both the global business of growing cotton and the global business of textiles.

Increasing consumption rates clearly illustrate the growth in the cotton sector of a
country’s textile industry. Increases in cotton production when there is a lack of domestic
consumption point to a country’s development as an exporter of cotton fiber.

Although some people may assume that a country’s economic development level may influence
whether the country is a cotton supplier or cotton consumer, this is an assumption not
substantiated by the data. Such an assumption is falsely based on the idea that agriculture and
manufacturing do not share at some level in the improvement associated with the development level
of the country. There are efficiencies in the consumption and production of cotton that dictate
activity levels in these separate yet linked industries.

A domestic supply of quality cotton is a competitive advantage for a domestic cotton textile
industry. The market factors facing this consumption, however, can negate that competitive
advantage. This is illustrated by the United States with falling consumption and a developed
country with rising production.

CotNumCot


The Top Four

China, India, Pakistan and Turkey collectively consumed 50.3 million 480-pound bales of cotton
in the 2000-01 marketing season, accounting for 54 percent of the total global consumption of 92.3
million bales for the season.

In 2004-05, with total global consumption rising to 108.7 million bales, these same four
countries represented 66 percent — a full two-thirds — of the global consumption of cotton.

On the supply side, China, India, Pakistan and Turkey collectively increased output from 48
percent, or 43 million bales, to 53 percent, or 63.5 million bales, of the total global cotton
supply during the measured period — from the 2000-01 season through the 2004-05 season.

Among these four countries, a roughly 20 million-bale growth in consumption was met with a
roughly equal 20 million-bale growth in supply.

cottonbynumbersjpeg



China, China, China…

US Department of Agriculture cotton data reinforce what one might expect about the growth of
China’s cotton consumption in the last five years. From the 2000-01 to the 2004-05 seasons, China’s
cotton consumption increased by 64 percent — from 23.5 million to 38.5 million bales.

In 2000-01, the country exceeded its domestic supply of cotton by 3.2 million bales. By the
end of the 2004-05 season, China out consumed its 29 million-bale domestic supply by 9.5 million
bales.

China is the world’s largest consumer and producer of cotton. Early figures for 2005-06 point
to continued expansion.





India Sees Increases In Consumption And Supply

India, like China, is another high-growth story, but with a twist. From the 2000-01 season
through the 2004-05 season, India increased its cotton consumption by 11 percent — from 13.5
million to 15 million bales.

In domestic supply, India made significant increases during the same five-year period,
increasing domestic supply of cotton by 8.1 million bales — from 10.9 million to 19 million bales —
a 74-percent increase in production.


Pakistan On The Move

Pakistan demonstrated even growth in the production and consumption of cotton. As the worlds
third-largest consumer of cotton, Pakistan increased cotton consumption by 33 percent from 8.1
million to 10.8 million bales from the 2000-01 season through the 2004-05 season.Over the same
period, Pakistan grew domestic production of cotton by 3.1 million bales, from 8.2 million to 11.3
million bales, or 38 percent.


Consumption And Supply Rise In Turkey

Expanding consumption of cotton by 35 percent, from 5.2 million to 7 million bales over the
measured period, Turkey is a net importer of cotton. Even though it increased domestic production
by 17 percent, from 3.6 million to 4.2 million bales, Turkey exceeded domestic supply by 1.6
million bales in 2000-01 and 2.8 million bales in 2004-05.


US Consumption Declines, Supply Increases

As the fifth-largest cotton consumer and the second-largest cotton producer, the United
States has a unique position in the world of cotton. US cotton consumption has fallen by 25
percent, from 8.9 million bales in 2000-01 to 6.7 million bales in 2004-05.

Cotton production in the United States is up over the same period by 35 percent, from 17.2
million bales to 23.3 million bales. Over the measured period, the United States has gone from a
consumption level that represents 52 percent of domestic production to 29 percent of domestic
production. The United States also has shifted from third place in global consumption to fifth,
after Pakistan and Turkey.




Brazil:

Level Consumption, Increasing Supply


Brazil has had level consumption over the measured period, using 4.2 million bales of cotton.
Domestic supply has increased from 4.3 million to 5.9 million bales, so while consumption is flat,
domestic supply has risen 37 percent.


The Future

As economies continue to develop, the rising appetite for consumer goods should bode well for
the future of cotton. Innovations related to both the growth and the consumption of cotton continue
to expand the possibilities for this ancient fiber. Textile manufacturing systems continue to
advance, creating the necessary flexibility to increase quality as well as yield. Textile finishes
show promise in providing consumers with durability, performance and aesthetics, which aid in the
marketing of cotton products and satisfy the demands of a growing marketplace.

March/April 2006

GTP Accessories Offers HybridPower 151

Weaving accessories supplier GTP
Accessories, part of Belgium-based Picanol NV, now offers Greenville-based Steel Heddle Inc.’s
HybridPower 151 harness frame for weaving machines.

The frame features a combination of lightweight aluminum profile and high-strength carbon
fiber, which makes it 50-percent stronger than previous designs, according to the company. A new
center support and reinforced third drive point offer further frame strengthening and allow
wide-width weaving at high speeds. In addition, high profile and side brace stress are reduced by
the R-Flex corner connection, which connects the frame’s braces.

The patented heddle rod is adhesive-bonded, eliminating fatigue breakage caused by riveting
and adding to the profile’s strength. The frame also comes equipped with heddle dampers.

The HybridPower 151, already a standard accessory for the Picanol OMNIplus 800 air-jet
weaving machine, now is available for all brands of new and older models of weaving
machines.


March/April 2006

Teijin Twaron Launches Sulfron® 3000 Granule


TechSulTeijin
Twaron BV, The Netherlands, reports its para-aramid Twaron® fiber derivative, the Sulfron® 3000
granule, substantially increases the lifetime and performance of sulfur vulcanized rubber
compounds, and is currently being studied by all major tire producers. According to the company,
Sulfron improves tire durability by at least 15 percent; rolling resistance by 20 percent, leading
to a 5-percent fuel consumption decrease; and cut, chip and chunk resistance.

In addition to use in the transportation sector, Sulfron may have other applications,
including conveyor belts, belt and carcass stocks and bridge bearings, according to Gert Frederiks,
commercial director, Teijin Twaron.


March/April 2006

Autobahn Introduces Textile Screen Printing Presses

Autobahn Inline Screen Printing Equipment (SPE) Inc., Temecula, Calif., has developed a new line of
automatic textile screen printing presses that feature a maximum 18- by 22-inch image area, print
speeds of up to 85 dozen screens per hour, electric printheads and print stroke capability ranging
from one to 10. Customers can choose to print between six and 56 colors.

Autobahn Inline SPE’s Inline Double Decker automatic textile screen printing press
Because the machines are rectangular and therefore take up 50 percent less space
than its competitors, the line of presses can fit in shops of all sizes, according to Autobahn. The
presses are 53.8 inches wide with varying lengths, according to the number of colors needed. They
are shipped fully assembled.
March/April 2006

Karl Mayer Launches GOM 8 Basic Sample Warper

Germany-based Karl Mayer
Textilmaschinenfabrik GmbH has introduced the GOM 8 basic sample warping machine — a simplified,
economical version of the GOM 16 sample warper. The company reports the GOM 8 — which costs
approximately 30 percent less than the GOM 16, while offering the same sample warping technology —
is a viable solution for standard operations typically performed in Asian mills and for newcomers
with limited investment capital and/or undetermined needs.

Suitable for producing shirting fabric and for processing short runs of cotton, silk or wool
in a variety of patterns, the GOM 8 offers half the number of package positions as the GOM 16 and
fewer options; but it still runs at 1,200 meters per minute, has a virtually unlimited pattern
range with one rotary creel and allows color changes at full speed. Warps of up to 420 meters may
be produced, and warp beams have a lease at both ends.


March/April 2006

Norcross Viscosity System Controls Up To Three Stations

Newton, Mass.-based Norcross Corp.’s
new Norcross VISC1000 Viscosity Control System can monitor and control one to three stations for
in-line or in-tank processes, including coating, adhesive and printing ink.

The system’s touch screen displays trend data and process parameters — such as set point,
alarms, automatic/manual mode and actual viscosity — for each station. The system’s software allows
users to change parameters at each station separately, and plot trends over one hour and up to
seven days.


March/April 2006

WestPoint Home Announces Plant Closures

Home fashions producer WestPoint Home Inc., West Point, Ga., reports it will close its sheet
weaving Calhoun Plant, Calhoun Falls, S.C., in May 2006, in an effort to consolidate domestic bed
products manufacturing. The Calhoun Falls closure follows the companys recent decision to close the
Clemson Greige, Finishing, Fabrication and Distribution operations, Clemson, S.C., in April
2006.

Some 300 Calhoun facility workers and about 290 Clemson Centre employees will be affected by the
closures, according to Elinor Crowder, assistant vice president, communications, WestPoint Home.
The company will maintain Clemson Centre offices for such functions as product development,
finance, information technology and customer service and planning.

Saying that the company appreciated the efforts of its associates throughout the years, John
Hurston, vice president, manufacturing, added that the Calhoun Falls closure is another necessary
step in the company’s strategy for realigning and streamlining our domestic manufacturing.

“To compete successfully in the global market, we must gain the most effective balance between
what we manufacture domestically and what we can best source,” Hurston said.

March/April 2006

AF&Y Adds Capacity, Jobs

Because of a doubling in demand for
its Marquesa® and Innova® high-performance yarn in the past two years, Chapel Hill, N.C.-based
American Fibers and Yarns Co. (AF&Y) is increasing its extrusion capacity by 30 percent and
texturing capacity by 25 percent. The increase is occurring mostly at its Bainbridge, Ga., plant,
which also houses the AF&Y Technology Center. In connection with the expansion, the company
expects to hire 25 to 30 new employees.

According to AF&Y, its yarns increasingly are replacing cotton, polyester and acrylic in
apparel, upholstery, mattress fabrics, and other home and contract textile applications. This
growth in demand, coupled with the doubling of the company’s export business every year for the
last three years, spurred the decision, AF&Y reported.

In other company news, AF&Y’s Marquesa® man-made yarn technology is now featured in
Cologne, N.J.-based Absecon Mills Inc.’s Cantara fabric collection, which features cotton’s look
and feel with yarn-inherent stain resistance, durability, colorfastness and bleach
cleanability.


March/April 2006

Textile Mill Expansion New Operations Announced In Carolinas

Expansions and launches of new
textile manufacturers in North and South Carolina are mitigating some of the effects of shuttered
textile operations announced in recent weeks and months. The news involves moves by three companies
that plan to expand and add employees to existing operations, or are newly formed with plans to
take over abandoned facilities and operations.

Suminoe Textiles of America Corp., a Gaffney, S.C.-based subsidiary of Japan-based Suminoe
Textile Co. Ltd., will invest $8 million to add 45,000 square feet of manufacturing space and 55
employees to its operation. The company, which opened the Gaffney plant in 2004 to manufacture seat
covers and head liners for Japanese auto makers Honda, Nissan and Toyota, will employ a total of
130 people upon completion of the expansion.

Tahoe LLC, Blacksburg, S.C., is investing $3 million to purchase the defunct Elizabeth
Weaving mill and begin producing woven textiles for home decorating. The fabrics will be marketed
under the Elizabeth Home Fabric and Elm Road Classic brands.

Tahoe, formed in 2005 through a merger of commission weaver Elite Textile, Albermarle, N.C.,
and National Contract Associates, Roswell, Ga., currently employs more than 50 people in its new
venture.

In Tarboro, N.C., newly formed Tarboro Textiles LLC is essentially a reincarnation of the
Tarboro workforce formerly employed by Glenoit Fabrics (HG) Corp., New York City, to manufacture
sliver knit fabrics for faux fur.

Glenoit closed its Tarboro plant in
late 2005 with the intention of moving its production to China and Canada. Instead, Tarboro
Textiles, owned and operated by former Glenoit Fabrics Plant Manager Jerry Howard, has resumed that
production under contract to Glenoit in the Tarboro plant. Howard has already hired 73 former
Glenoit employees and expects ultimately to employ a total of 140 people.


March/April 2006

Encouraging Signs


E
arly 2006 activity continues to hold up tolerably well despite still-rising import
levels. The January report from the Tempe, Ariz.-based Institute for Supply Management – a
grassroots group that surveys the nation’s leading purchasing executives – puts textiles and
apparel on the list of industries reporting growth in both new orders and production. To be sure,
the sample of firms queried is small and might well be slightly off the mark.

Nevertheless, these findings lend credence to the feeling that the bottom isn’t about to drop
out from under the textile market. In any event,

TW
‘s near-term forecasts for domestic production of basic textiles like yarns and fabrics over
the next six months or so suggest little more than a 4-percent annual rate of decline. Moreover,
any losses in this sector could be partially offset by steady to even a bit higher activity in the
more highly fabricated home furnishings and floor covering areas.

BFChart0206


A Long Look Ahead


There’s also some indication the long-term prognosis for the industry isn’t all that bad. Key
evidence here comes from brand-new production projections by the Bureau of Labor Statistics (BLS).
A just-released 10-year study calls for an average annual decline of only about 3.2 percent overall
for basic textile mills – with no specific subsector expected to experience any catastrophic
decline. While hardly bullish, this does seem to suggest the American textile industry is here to
stay. In looking a bit closer at three key basic textile subgroups, a 3.7-percent average annual
decline over the next decade is seen for fabric mills; 2.8 percent for textile and fabric finishing
and coating mills; and 2.4 percent for fiber, yarn and thread mills. Moving over to the textile
product mill area, some small gains are forecast – 2.5 percent overall – with a higher 3.1-percent
advance seen for textile furnishing mills. On the other hand, as might be expected, apparel
manufacturing output will continue to disappoint, falling by about 2.9 percent annually over the
next 10 years.


A Smaller Workforce


The downward pressure on textile and apparel employment, however, looks a little more
disturbing, primarily because of expectations for continuing solid industry productivity gains –
advances that will allow each employee to turn out more units of product for each hour worked. More
to the point, BLS projections call for these substantial productivity advances: 3.5 percent a year
for basic textile mills; 4.5 percent for textile product mills; and 5.8 percent for apparel. While
all this should be great for holding costs down, such efficiency gains will tend to intensify job
losses, which for the basic textile mill sector are as follows over the next decade: overall, 6.7
percent a year; fabric mills, 7.5 percent; and textile and fabric finishing and coating mills, 6.2
percent. Average job declines for the textile mill product sector should be somewhat more modest –
about 2 percent a year, with the textile furnishing mills subsector dropoff put at only 1.3 percent
a year. Look for considerably rougher sailing for the hard-pressed apparel industry, where an
average annual 8.7-percent employment decline is anticipated.


Imports


Some hints on how the ongoing US/China trade conflict may play out are emerging. US
officials, in an effort to slow down Chinese import gains, are not calling for much tougher
enforcement of existing trade laws. Results of next month’s Washington meeting between President
George W. Bush and Chinese President Hu Jintao will also bear close monitoring. White House
officials are expected to argue the yuan is still grossly undervalued and press for a much more
significant upward yuan revaluation, pointing out the US trade deficit with China – the largest for
any single country – rose to a record $202 billion last year – more than 20-percent above 2004’s
level. The textile and apparel subsector deterioration was even greater – with 2005 Chinese
incoming shipments here soaring 44 percent on a square-meter-equivalents basis. To be sure, 2005
overall textile and apparel imports rose by a much smaller 8.3 percent, but only because the huge
Chinese influx was partially offset by sizeable declines in shipments from Taiwan, Hong Kong and
Korea.



March/April 2006

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