What is Spunlaced non-woven fabric?
Nonwoven fabrics are sheets formed by interlocking fibers rather than traditional weaving techniques. Spunlaced non-woven fabric is produced by entangling fibers using a high-pressure water jet system. This type of non-woven fabric is known for its lack of binders or adhesives, making it ideal for hygiene-sensitive applications such as clothing and other fabric products.
Spunlace nonwoven fabric, also known as hydroentangled fabric, is a type of nonwoven fabric produced using a high-pressure water jets bonding process. This process involves using fine streams of water to entangle and interlock fibers together to create a fabric without the use of adhesives or thermal binding. The resulting fabric has a soft, textile-like feel and can be made from a variety of fibers, including polyester, viscose, and nylon.
Spunlace nonwoven fabric is known for its breathability, high absorbency, and strength. It is commonly used in applications such as wipes, facial masks, medical gowns and drapes, and filtration media due to its ability to trap and hold fine particles. It is also used in the manufacture of personal care products such as towels, bedding, and clothing.
One of the advantages of spunlace nonwoven fabric is that it can be produced with a wide range of fiber blends, allowing for customization of the fabric’s properties. It is also environmentally friendly, as it does not produce harmful emissions during production and can be recycled after use.
Overall, spunlace nonwoven fabric is a versatile material that offers many benefits in various applications, making it a popular choice in industries such as healthcare, personal care, and filtration.
What is spunlace?
Spunlace is a nonwoven fabric manufacturing process that involves the entanglement of fibers through mechanical, hydraulic, or water-jet techniques to create a strong and durable material. This method is utilized to produce fabrics with a wide range of properties, making them suitable for various applications across industries such as healthcare, personal care, automotive, and household products.
The production of spunlace fabrics begins with the selection of raw materials, which can include natural fibers like cotton, viscose, and wood pulp or synthetic fibers such as polyester, rayon, and polypropylene. These fibers are initially opened and blended to form a homogeneous fiber web.
The spunlace process involves high-pressure water jets that propel the fibers onto a moving conveyor belt or screen. The fibers are entangled and intertwined through the force of the water jets, creating a cohesive fabric structure. The entanglement of fibers results in a fabric that is strong, tear-resistant, and has excellent tensile strength.
During the entanglement process, the water pressure and the arrangement of the fibers can be adjusted to achieve specific fabric characteristics. The resulting fabric can vary in terms of thickness, density, softness, and absorbency, making spunlace suitable for a diverse array of applications.
One of the key advantages of spunlace fabrics is their exceptional softness, which makes them highly desirable for use in sensitive applications such as baby wipes, facial wipes, and personal care products. The fabric’s gentle texture is often preferred for its comfort and suitability for delicate skin.
Moreover, spunlace fabrics possess excellent absorbent qualities, making them ideal for products like medical dressings, cleaning wipes, and industrial wipes. Their high absorbency allows them to effectively retain liquids, making them efficient for cleaning surfaces or absorbing fluids in medical settings.
In addition to their softness and absorbency, spunlace fabrics can be engineered to exhibit specific properties such as breathability, elasticity, and resistance to chemicals or abrasion, depending on the intended use.
The versatility of spunlace fabrics has led to their widespread adoption in various industries, including the manufacturing of hygiene products, medical supplies, filtration materials, apparel, and household wipes. As technology continues to advance, innovations in the spunlace manufacturing process contribute to the development of new applications and improved fabric characteristics, further expanding its utility across diverse industries.
What is the difference between Spunlace Nonwoven and Spunlace?
The terms “Spunlace nonwoven” and “Spunlace” are utilized within the textile industry to denote a particular fabric production method and the resulting fabric. While these terms may appear similar, a clear distinction exists between them, primarily based on their usage and context within the textile manufacturing process.
Spunlace Nonwoven Fabric:
Spunlace nonwoven fabric specifically refers to a type of nonwoven material created through the spunlace process. This manufacturing method entails entangling fibers using high-pressure water jets, eliminating the need for weaving or knitting. Typically composed of natural or synthetic fibers such as cotton, viscose, polyester, or blends thereof, spunlace nonwovens exhibit properties like strength, softness, absorbency, and tear resistance.
The production of spunlace nonwoven fabrics commences with the selection of raw fibers, which are then opened, carded, and formed into a loose web. This fiber web undergoes entanglement and interlacing through high-pressure water jets, resulting in a cohesive fabric structure. The versatility and desirable characteristics of spunlace nonwoven fabrics make them suitable for a wide array of applications across various industries, including hygiene products, medical dressings, industrial applications, filtration materials, apparel, and household cleaning wipes.
Spunlace Fabric:
The term “Spunlace” alone can have a broader connotation, encompassing both the spunlace process and the resulting fabric, depending on the specific context. In some instances, “Spunlace” may refer to a range of fabrics produced using this method, including those utilized as substrates for coatings or laminations to enhance functionalities like water repellency, flame resistance, or barrier properties.
In conclusion, the distinction between “Spunlace nonwoven” and “Spunlace” lies in their specificity: spunlace nonwoven denotes the fabric produced through the spunlace process, while “Spunlace” may include both the fabric and the broader process, incorporating variations that undergo additional treatments or enhancements beyond the basic spunlace nonwoven fabric.
Production process of spunlace nonwoven fabric
The production of spunlace nonwovens necessitates a thorough comprehension of the materials involved as well as advanced technical skills to oversee modern production equipment.
The type of fibers used and the specific process parameters can be adjusted to create spunlace nonwoven fabrics with different properties. For example, fabrics made with a high percentage of synthetic fibers will be stronger and more durable, while fabrics made with a higher percentage of natural fibers will be softer and more absorbent.
1. Procurement of Raw Materials
Our primary raw materials consist of rayon, polyester, and other staple fibers, sourced from reputable fiber manufacturers. These materials are compressed and packaged in batches weighing 200 to 300 kg, with the option to blend fibers based on specific property requirements.
2. Mixing and Loosen Fiber
The compressed fibers are meticulously loosened and mixed to ensure a consistent blending ratio and weight distribution, setting the foundation for the subsequent processing steps, such as carding.
3. Carding Process
Through a series of rolls equipped with tooth-shaped metal wires, the fibers are transformed into a sheet-like form known as a “web”. The uniformity of this web is crucial in the carding process, showcasing our advanced technological capabilities .
4. Fiber Bonding
Following carding, the fibers within the web are entangled using high-pressure water streams, creating a durable sheet with enhanced strength.
Fine streams of high-pressure water are used to entangle and interlock the fibers together. The water is sprayed onto the web and the pressure and speed of the water jets are adjusted to optimize the entanglement process.
5. Drying and Fusion Bonding
We employ a drying method to eliminate moisture from the sheet and achieve fusion bonding of heat-fusion fibers in a sheath-core structure, further enhancing the fabric’s integrity.
The fabric is then dried to remove excess moisture. This can be done through a variety of techniques, such as through hot air ovens or infrared radiation.
6. Quality Inspection
Every non-woven fabric undergoes a rigorous inspection process post-drying to identify and address any potential contaminants, ensuring a pristine final product.
7. Winding and Packaging
Upon successful completion of the inspection phase, the sheets are ready to be wound into various widths and lengths, facilitating efficient packaging and distribution.
The finished fabric is then treated with various finishes, such as softeners and antimicrobial agents, to enhance its properties.
Some of Nonwoven products
1. Airlaid nonwoven materials
A selection of different fibers and blends can be utilized to produce products that are suitable for a diverse range of applications.
When bonded thermally using air through, airlaid nonwoven materials can exhibit high elasticity and flexibility.
Airlaid nonwoven materials offer an excellent padding effect similar to textile fabric, making them a suitable alternative to foam in mattresses.
Due to their porous nature and ability to be densely packed, airlaid nonwoven materials are commonly used in applications that require sound insulation and absorption.
2. Carded thermalbond
Carded nonwovens are a suitable option when consistency and aesthetic appeal are of significance.
A diverse range of thicknesses, weights, and colors are accessible.
Different types of fibers and blends can be utilized, with textures ranging from soft to rigid.
These materials exhibit exceptional resilience, durability, and drainage properties, rendering them suitable for application as Geotextile fabric.
3. Needle punch
Needle punch nonwovens have excellent loft and elongation properties when no additional bonding or processing is applied.
When subjected to thermal bonding using a calender machine, needle punch nonwovens exhibit high toughness and tear resistance.
A wide range of fibers and blends can be utilized in the production of these nonwovens.
The characteristics of needle punch nonwovens, such as thickness, softness, toughness, and pliability, can be tailored to meet specific requirements.
Needle punch nonwovens are available in various thicknesses, weights, and colors to cater to diverse preferences.
4. Stitch bonded nonwovens
The texture of the material ranges from exceptionally soft to extremely stiff.
The surface is flat, making it suitable for a diverse array of printing techniques.
Stitch bonded nonwovens exhibit strong tensile strength.
They serve as an effective reinforcement for a variety of sports shoe linings.
These nonwovens possess high voluminosity, softness, good absorbent properties, elasticity, and air permeability.
Applications of nonwoven fabric in Apparel
Interlining & interfacings
The purpose interlining is to add warmth, body and drape to a garment, while the purpose of interfacing is to provide structure. Nonwoven fabrics are believed to improve the fit and overall look of a garment. Nonwoven fabrics can also help to improve the durability of a garment.
Shoe lining & insoles
Nonwoven fabrics play important roles on the production of shoes. The reason shoe manufacturers use nonwoven fabrics as shoe lining & insoles is to cut costs. Nonwoven fabrics are guaranteed to be cheaper than other material.
Underwear, bras & shoulder pads
Foams are usually used for padding on underwear, bras & shoulder pad. Due to the environmental awareness, more nonwoven fabrics are used. Nonwoven fabrics can be made very dense or soft, thick or thin, while maintaining good padding effects.
Applications of nonwoven fabric in Automotive
Headliners and flooring
Nonwoven fabric provides support, structure in headliners overhead system and carpet & flooring systems. It is easy to mould and can be shaped efficiently. Nonwoven fabric improves structural rigidity and offers significant weight saving compared to other material.
Seating
Different variety of nonwoven can be used on seating internal components. Nonwoven fabric gives seating comfort by adding support and isolation to spring. Airlaid nonwoven has a good padding effect yet very elastic and flexible, thus a perfect foam replacement due to more economical prize.
Interior components
Common use of nonwoven on automotive interior component is sound absorber. Nonwoven fabric can be engineered to be very dense in order to absorb engine and road noise. At the same time, it serves as a good insulation to provide comfort while travelling.
Applications of nonwoven fabric in Building and Construction
Roofing
Nonwoven fabrics are used in various roofing applications to provide structural integrity. Nonwovens can be made very strong and durable in order to endure daily wear-and-tear and occasional extreme weather events.
Insulation
Nonwoven fabrics have very good thermal insulation properties and excellent acoustic performance. The low moisture absorption guarantees consistently good insulation.
Floor covering
Nonwoven floor coverings are very easy to install and cheaper than other fabrics. Due to the durability, nonwoven fabrics are commonly used to protect floor in exhibitions and events.
Applications of nonwoven fabric in Geotextile
Separation
Nonwoven geotextiles are used to divide two levels of soil with varying particle sizes. It acts as a permeable separation, allowing water to pass while preventing soil and other materials from passing. Nonwoven fabrics are required to guarantee long-term functioning of the structure.
Reinforcement
Nonwoven geotextiles are used as reinforcement in soft soils. Nonwoven fabric distributes the weight across a huge area and it enhances the tensile strength and deformation resistance of the soil. It also increases the stability of building structure.
Erosion control
Nonwoven geotextiles are used in variety of applications in order to prevent erosion. It can be used as stabilization of highway, drainage of subsurface, railroad ballast separation, and many more.
Applications of nonwoven fabric in Home Textile
Spring isolator
Depending on the desired specifications, nonwoven fabric can be made extremely stiff and tough resistant. Nonwoven fabric prevents foam and other materials being damaged by the tension of the spring. It is required to guarantee long-term functioning of spring bed and sofa.
Carpet and rugs
Nonwoven fabrics have economical advantages compared to other fabric materials. Nonwoven fabrics are often used as carpet backing to reduce deformation. A wide variety of printing methods can be applied on the nonwoven fabric due to its flat surface. This makes nonwoven fabric good option for home decoration.
Foam replacement
Due to environmental awareness, nonwoven fabrics are becoming more popular foam replacement. In terms of padding effects and elasticity, nonwoven fabrics have similar or better characteristics than foam. The density of nonwoven fabrics can be customised depending on the desired needs.
What is Plant-based fiber?
Plant-based fibers are natural fibers derived from various plant sources. They are widely used in the textile industry to manufacture fabrics and textiles for different applications, including clothing, home furnishings, and industrial products. The most commonly used plant-based fibers include cotton, linen, hemp, jute, bamboo, and sisal.
For instance, Oceancash’s wet wipes are made from a combination of polyester and organic bamboo fiber, a fast-growing and eco-friendly plant-based fiber derived from the bamboo plant. Bamboo fiber is well-known for its softness, breathability, and moisture-wicking properties, so it’s a popular choice in clothing and bedding. Additionally, bamboo is an incredibly sustainable fabric because it uses less water and pesticides than cotton.
When added to Spunlace material, plant-based fibers can help retain moisture for an extended period, ensuring thorough cleaning and enhanced comfort for your loved ones. In addition, by incorporating plant-based fibers into our products, we can provide our customers with high-quality, sustainable materials that offer both superior performance and environmental benefits.
Other Nonwoven products we offer
Technical specifications
Basis Weight: 18g/m2 to 90g/m2
Layered: Single & Dual Layer Structure
Material: Bi-component Polyethylene/Polyethylene Terephthalate (PE/PET), Polyethylene/Polypropylene (PE/PP) Staple Fibre, Viscose, Cotton and Bamboo Fibre
Jumbo Roll Working Width: 2,100mm
Capacity: 12,900 MT/A
Feature: Air-Through bonding and Waterjet (Hydroentangled) bonding
Winding Selection: Pancake Roll & Spool Roll
Slit Width of Nonwoven for Pancake Roll: from 35mm to 2050mm
Pancake Roll Working Width: from 50(35)mm to 2050mm
Slit Width of Nonwoven for Spool Roll: from 35mm to 120mm.
Spool Roll Working Width: from 280mm to 800mm
Hand Feel: Soft, Cottony Soft, Silky Touch, & High Loft
Treatments: Hydrophilic or Hydrophobic
Lustre: White (Dull) or Extra White (Full Dull)
Colour: Blue, Green, Violet, & Black
Specialty: Low pH, Bacterial Control, Cotton (Organic or Bleached) Content, Activated Carbon and Organic Plant Based Fibre.
Design/Patterns: Aperture, Emboss, Laminating & Printing.
Nonwoven products Porfolio
For facial care, VNPOLYFIBER’s hydroentangled nonwoven technology offers exceptional strength, softness, and fluid retention properties in sheet masks. Made with a blend of viscose, lyocell, and cotton, our sheet masks provide nourishing benefits while adhering comfortably to the skin. Pamper and rejuvenate your skin with our luxurious sheet masks for a fresh and radiant complexion.
In the healthcare sector, VNPOLYFIBER provides top-of-the-line nonwoven materials for surgical masks that offer superior protection and comfort. Our innovative approach has enabled us to meet the rising demands of surgical mask manufacturers, earning the trust of medical professionals worldwide. With a dedication to excellence, we strive to provide cutting-edge solutions for the healthcare industry.
When it comes to gentle yet effective cleaning, VNPOLYFIBER understands the importance of quality materials. Our Spunlace nonwoven wipes are made from a blend of polyester and plant-based fibers, ensuring they are soft and safe for delicate skin. Highly absorbent and moisture-retentive, our wipes guarantee a thorough cleaning experience for your loved ones.
For the feminine hygiene market, VNPOLYFIBER offers a diverse range of premium nonwoven materials designed to prioritize health and safety. Our specially engineered nonwovens undergo rigorous testing to ensure exceptional absorption for high-viscosity liquids, providing women with maximum comfort and confidence. We are committed to innovation and customer satisfaction, offering reliable solutions for the feminine hygiene industry.
