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Ultimate Guide Spunlace Nonwoven Manufacturing Process in August 2024
- 2024-08-06
Wiping materials are indispensable cleaning materials in daily life and industrial production. Among them, spunlace wiping materials are disposable products that do not need to be washed and have strong cleaning ability, which greatly improves the production and living quality of users.
Different production processes have created a wide variety of spunlace wiping materials with different performances to meet the ever-changing market needs. At present, the production processes of spunlace wiping materials mainly include combing spunlace, wet spunlace, and spunbond spunlace, and then the subsequent finishing technology is used to improve the product performance.
1. Combing spunlace
Combing spunlace is the most common preparation process for spunlace wiping materials. The product has the characteristics of softness, skin-friendly, water absorption and moisture absorption, and good wiping effect. At present, the research focus of combing spunlace is to control costs, increase production, optimize performance and energy saving and environmental protection. This requires the combing spunlace equipment to develop in the direction of wide-width, high-speed, intelligent and low-energy consumption, and to develop new products with the purpose of seeking high-performance, low-cost and environmentally friendly new raw materials.
At present, the main fiber raw materials used in the production of combing spunlace wiping materials are polyester, cotton fiber, cellulose fiber, etc. With the industry's attention to environmental issues, the proportion of polyester fibers, which originally dominated the market, has been declining in recent years.
Cotton fiber is an excellent raw material for the production of combed spunlace wiping materials, but the output is limited and the price is high. The product needs to be degreased and bleached later, which will put a certain pressure on the ecological environment. Therefore, it is mainly used to produce high-end wiping materials and accounts for a low proportion of the entire spunlace wiping materials.
Cellulose fiber is currently the main fiber raw material for the production of degradable combed spunlace wiping materials. It has good hydrophilicity, soft skin-friendly, and controllable price. It can meet the performance requirements of ordinary wiping materials such as daily household and personal care cleaning. It is widely used in the fields of infant wipes and personal care wipes.
Combed spunlace products have a high degree of homogeneity and fierce competition in the industry. In order to increase the added value of products, natural fibers with specific properties have gradually entered the combed spunlace product market, such as flax fiber, cotton seed lint, etc. Hemp fibers can well replace polyester fibers to develop biodegradable combed spunlace wiping materials for household or industrial use.
Some industrial dust-free wiping materials are made of cotton lint through a spunlace process. This material has excellent liquid absorption, heat resistance, chemical resistance, antistatic properties, biodegradability and extremely low lint rate, and can be widely used in electronic industries such as semiconductors, solar cells, and touch screens. At present, the use of environmentally friendly fibers to replace traditional chemical fibers to develop wiping materials, or the use of recycled polyester fibers to produce spunlace wiping materials has become an important development trend.
2. Wetlaid spunlace
Wetlaid spunlace is a composite process that combines wet web formation with spunlace web fixation. The products produced by this process are not easy to shed and are usually used to produce high-end wiping materials. Wetlaid spunlace nonwoven materials are mainly made of wood pulp fibers and cellulose fibers, and are only reinforced by physical means, which is completely in line with the current pursuit of sustainable development.
Flushable wetlaid wipes material are a new type of wiping material that is as comfortable and skin-friendly as traditional wet wipes, and has better wet strength than paper products. The most important thing is that it is flushable, that is, after the waste is thrown into the toilet, it is easy to disperse and pass through the drainage pipe under the action of water flow. At the same time, after passing through the drainage pipe system, the waste is dispersed to a certain extent and cannot accumulate. After flushing out, it has the performance of complete degradation.
Soonercleaning started relevant research on flushable materials in 2010 and introduced multiple production lines. At present, Soonercleaning's flushable non-woven fabric series products are mainly used in wet toilet paper, baby hygiene wet wipes, nursing wet wipes and other fields.
With the rise of the flushable wet wipes market in recent years, as the mainstream production process for flushable wet wipes, the wet spunlace process has become one of the most popular and fastest-growing spunlace composite processes. Because the Soonercleaning wet spunlace process has a fast production speed, is easy to mix different fibers, and can well balance the wet strength and dispersion performance of the product, it is favored by flushable wet wipes manufacturers.
As disposable products, nonwoven wiping materials have a very short life cycle and produce a huge amount of waste. The subsequent environmental impact has always been the focus of the industry.
At present, there is still a certain gap between the strength of products prepared by wet spunlace process and the strength of carded spunlace products, so they are mainly used in the field of flushable wiping. However, due to its advantages such as fast production speed, natural degradation of products, and adaptability to ecological circulation systems, the spunlace industry is gradually not satisfied with only using wet spunlace products as flushable materials, but hopes to develop wet spunlace wiping products with higher strength and better toughness that can be applied to other fields such as industry and medical treatment, such as dust-free electronic wipes with extremely short service life.
At present, Soonercleaning improves the tensile strength and durability of products through the selection of fiber raw materials and the adjustment of wet and spunlace processes, thereby expanding the application range of products. It is one of the key directions of wet spunlace nonwoven material research.
3. Spunbond spunlace
The spunbond spunlace process is a composite process that combines spunbond web formation with spunlace web consolidation. No chemical additives are used in the reinforcement process. The product retains the mechanical properties of spunbond filaments while improving their softness and hygroscopicity. It has been widely used in the medical and health fields in recent years.
In the field of spunlace wiping, spunbond spunlace products also have certain advantages. One direction is to combine spunbond and wet method into a web, and then reinforce it through spunlace to form complementary advantages. At the same time, the mechanical properties and wiping efficiency of the wiping material are improved. The process of combining spunbond spunlace with wet method is simple and efficient, the product has high strength, strong liquid absorption, and is not easy to drop debris. It has become the most widely used composite spunlace wiping material.
Another direction is the two-component spunbond spunlace process, which uses the high-pressure water jet of spunlace to split the orange segment type and island type fibers to obtain ultrafine fibers with a diameter of several microns. Since the cross section of the orange-segment bicomponent spunbond fiber is similar to a triangle after being split by water jet, many fine pores are formed between the ultrafine fibers, which have a large specific surface area and good dust holding capacity. They can absorb dust particles 10 times their own mass, and the spunbond filaments are not easy to shed, so they are often used as wiping materials for optoelectronic equipment, precision instruments and other products.
The microfiber spunlace wiping material developed by Soonercleaning is to combine the polyester/nylon bicomponent orange-segment spunbond nonwoven material with conventional base fabrics through water jet to produce a wiping material with high porosity, not easy to shed, and different materials on both sides to meet different wiping needs. At present, the commonly used raw materials for orange-segment bicomponent spunbond nonwovens are polyester (PET)/polyamide 6 (PA6), polyethylene (PE)/PA6, polypropylene (PP)/PE, and PET/PE. Soonercleaning is actively developing environmentally friendly products of bicomponent spunbond spunbond wiping materials with good performance using degradable raw materials such as polylactic acid (PLA).
If you want to know more about spunlace nonwoven fabric, please contact us. Soonercleaning provides you with customized solutions and free samples.
E-mail: info@soonercleaning.com
Skype: +86 13810146753
In addition to the above spunlaced technologies, spunlaced non-woven fabrics can also be treated by spunlaced post-finishing process, which can have a positive impact on the structure and properties of non-woven fabrics. The next article will bring you a comprehensive understanding of spunlace non-woven fabric finishing process. For more information, please click:Spunlace nonwoven finishing technology - (soonercleaning.com)
