Post on 09-Apr-2018
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Nonwovens manufacturing
processes
Mehran Khattak
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Definition
A sheet, web of natural, man-made fibers or
filaments that have been bondedto each
other by any of several means.
Two staged manufacturing (low cost)
Web formation
Web bonding
(same production facility)
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Web formation
WEB FORMATION
WET LAID DRY LAID
SPUNBOND
MELTBLOWN
ELECTROSPINNING
random layed fibersfibers layed in parallel,
crosswise
CARDING AIR LAID SPUN LAID
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Web bonding
WEBBONDING
MECHANICAL CHEMICAL
CALENDERING
THROUGH AIR
BONDING
SONICBONDING
NEEDLE PUNCH
SPUN LACED
(STITCH BONDED)
(TUFTING)
THERMAL
IMPREGNATING
FOAM COATING
SPRAYING
PRINT BONDING
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Nonwoven market
Classification % of total
Hygiene 33.1
Building/roofing 12.5
Liquid and gas filtration 6.5
Civil engineering 5.4 Automotive 3.9
Medical/surgical 3.5
Wipes, personal care 8.1
U pholstery/table linen/household 6.8
Garments& Interlinings 2.9
Shoe leather goods 1.9 Coating substrates 2.4
Floor covering 2.3
Others/unidentified 5.3
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Nonwoven market
1994-2004 8% growth
2004-2009 10.5 growth
Wo rldw ide Out look for Nonw oven s Produc t ion
9 ,1
16,4
23,3
2 ,24 ,5
6 ,4
0
5
10
15
20
25
1994 2004 2009
Billionsdollars,
millionstons
Billions dollarsMillions tons
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Nonwoven market
Western EU 33%
North America 31%
Asia Pacific 25% ( Japan, China,
S.Korea)
Others 11%
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Production processes
WEB FORMATION
WET LAID DRY LAID
SPUNBOND
MELTBLOWN
ELECTROSPINNING
random layed fibersfibers layed in parallel,
crosswise
CARDING AIR LAID SPUN LAID
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Wet laid web formation
3 stages of production
Dispersion forming
Dewaterig and webformation
Drying and bonding
Fiber dispersion
Dewatering and
web formation
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Air laid and carded web
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Air laid and carded webAdvantages and disadvantages of airlaid over
carded web
Isotropic and randomly arranged webs
Voluminious webs
Low mass uniformity
Low level of opening fiber material bylickerin roller
Possible entangling of fibers in air streamWide variety of processable fibers in both
processes
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Applications of Airlaid and
carded web Interlinings
shoe linings
high loft" products for the garment and furniture and insulation
synthetic leather
waddings;
geotextiles,
filter materials;
needle blankets; carpets ,wall coverings;
technical felts insulation felts; mattress felts,
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Spunbond
Spinneret
Gearpu p
Fila en
tAir
Stretchingpipe
Deflector
Collector
Suction
eb
Stretching
nozzle
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Melt blown
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Meltblown vs Spunbond
Spun bond agianst Meltblown
Stronger
Flexible
Cheaper
More investment
Larger pore size
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Applications
Spunbond
Backing, packing, cover stock, roof
sheeting, geo textile, reinforcemnt
Meltblown
Filtration, insulation, hygeine, medical
textile, floppy disks lining, battrey
separators
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Web bonding
WEBBONDING
MECHANICAL CHEMICAL
CALENDERING
THROUGH AIR
BONDINGSONICBONDING
NEEDLE PUNCH
SPUN LACED
(STITCH BONDED)
(TUFTING)
THERMAL
IMPREGNATING
FOAM COATING
SPRAYING
PRINT BONDING
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Needle punched nonwoven
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Uses
Filters, tennis balls, carpets, floor covering,
Geo textile
Automotive
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Spunlace
Dewatering
system
Water jets
Water circulation Support screen
(drum or belt)
Drying
system
Winding
Fibrous web
Water suction zoneWater purification
support screen
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Spunlace properties
very good textile drape (low stiffness) and very soft handle
no chemical or melt binders; it is possible to prepare 100 % naturalfibers, suitable for sanitary products, suitable to recycling
strenght is much higher than after mechanical needling (for the some
area weight); similar to woven textiles wide range of textile structure (depending especially on the perforated
belt structure) wide range of textile properties
uniform surface due to more fine interlacing of fibers (compared withneedling)
very high textile production: up to 300 m/min for carded and airlaid
webs and up to 500 m/min for wetlaid and spunbond (meltblown);textile width up to 6000 mm.
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Spunlace applications
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1. Hospital use:
surgical gowns and drapes (fig.1),
operational cover sheets, bed
sheets, towels...
2. Medical use:
wound dressings (fig.2), gauze,
wet tissue, cotton products, pads
(fig.3)
3. Sanitary products:
baby wipes (fig.4), facial clean
wipe, face masks, disposable
pants...
Fig. 1
Fig. 2 Fig. 3
Fig. 4
Spunlace Applications
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4. Household products:
cleaning wipes (fig.5), protection
fabric for electronics, home
furnishing fabrics: table cloths and
napkins (fig.6), curtains (fig.7)
5. Industrial textiles:
industrial wipes (fig.8), filtration
(fig.9), roofing, water insulation
(fig.10), protective apparell(fig.11), liquid absorbents
Fig. 5
Fig. 6Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Spunlace applications:
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Chemical bonding
dhesive po
der
otating brush
Web
Po
der metering
Screen roll
Squeegee
ating roll
Web
Binder
Po der bondingChemical bonding
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Thermal bonding
ayer 1
ayer 2
In rared
heat source
e lector
Hot roll
Cold roll
Hot roll
Hot roll
Double and one side
calenderingIn ra red bonding
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Embossed roll calendering
Hot smooth
calender
Embossed
cylinder
web
Patterned calendaring
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Applications
Wipes and towels
Medical nonwovens
Roofing products
Apparel interlinings
Filter media
Coating substrates
Automotive trim
Carrier fabrics
Bedding products (high loft)
Furniture applications (high loft) Apparel
Pillows (high loft)
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THANKS
QUESTIONS??????????????