Spunlaced Nonwovens are a type of nonwoven fabric manufactured by spraying water jets over a fiber web. This process entangles the fibers, forming a fabric having specific strength and other properties that are not found in needle-punched nonwoven fabrics. This nonwoven is made from a number of different fiber raw materials and can be used for a wide range of applications including medical curtains, surgical gowns, medical gauze, wound dressings, and aero wipes.
There are many types of spunlace nonwovens, depending on the fiber raw materials and the production method. Commonly used fibers include polyester, nylon, polypropylene, viscose, chitin, superfine fiber, lyocell, silk, bamboo fiber and wood pulp.
Cellulose & Cotton Spunlace is a type of water jet interlaced spunlace nonwoven fabric (water jet interlaced nonwovens) based on a plant-derived fiber made mainly from eucalyptus (refined cellulose of Lenzing AG of Austria). This fabric has superior wiping properties and excellent durability due to the natural fiber and synthetic fiber blend.
A high-speed flowing, high-pressure water jet is sprayed over the web, which entangles the fibers and a certain amount of structural integrity is achieved. The physical properties of this fabric are very different from those of most needle-punched nonwovens and are the only nonwoven fabric that makes the final product resemble textiles in hand and performance.
The most common end uses for spunlace nonwovens are wipes, a leading category in the global market with 63.0% of consumption in 2019 and forecast to increase 12.1% to 1.4 million tonnes in 2024. Sustainability is a major driver for the development of this category, requiring material suppliers to identify more sustainable fibres and lower-priced polymers that can be used in this format.
There are several production processes, namely airlaid, wetlaid, and carding/crosslapping. Wetlaid processes use a few centimeters long staple fibers while airlaid and carding/crosslapping operate with longer staple fibers.
During the manufacturing process, the fibers are opened in a multistep process, dispersed on a conveyor belt, and then spread in a uniform web by wetlaid or airlaid. The web can then be double-sided spun to produce a fabric with a woven appearance.
The finished product can be a sheet or a woven fabric. It can be made to have a bacterial barrier, thermal insulation, filtration, washability, cushioning, flame retardancy, resilience, liquid repellence, and other properties.
This type of nonwoven can also be used for composite processing, allowing the development of new composite products with multiple purposes. It can be woven into a fabric with “sandwich” structures and is highly durable and flexible, with good high-temperature resistance.
A specialized manufacturing line is needed to make these fabrics. The machine should have a number of parts, such as mixer, carding machine, water jets, and more. These machines are mainly from China. They are Feilong, Zhengfangji etc.
This industry is a growing one, with the majority of lines installed in Asia, where the largest consumer base is located. The future growth of the market is driven by growing disposable wipes demand among emerging and aspirational middle classes in this region. In addition to this, increasing awareness of environmental issues has led to a push for biodegradable nonwovens that are more environmentally friendly and affordable.
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