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• Introduction
• Types of nonwoven fabrics
• Nonwoven web forming methods
• Nonwoven bonding techniques
• Finishing of nonwovens
• Commercial nonwoven products
• Nonwoven in technical textiles
Presentation Content
INTRODUCTION
Polymers
Fibers
Yarns
Woven Knitted Braided Non-woven
Fabrics
Application
Woven structure Knitted structure Braided structure
NONWOVENS IN GENERAL
Definition of nonwovens
Nonwoven is a sheet, web, or batt of natural and/or man-made fibers or filaments,
excluding paper, that have not been converted into the yarns, and that are bonded together
in different ways
It may also having other names such as Shaped Fabrics (or) Yarn free Fabrics
Non-Woven structure
Brief about Nonwoven
• Fibers are the basic element of Nonwovens. Theselection of raw fibers, determines the propertiesof the final nonwoven products.
• Fiber selection purely depend on Application,customer requirement and cost of Product.
• The fibers can be in the form of stable form (or)filament form. Any natural or synthetic fiber couldbe used in the production of non woven.
• Synthetic fibers provide specialized properties ,uniformity, and consistency of supply whichcannot be achieved by natural fibers.
• Bi component fibers are a manufactured fiberhaving two distinct polymers components mayalso used in nonwoven manufacturing.
• Nano fibers, Glass micro fibers also used in
nonwoven Industry
• To distinguish nonwovens from papers by a Identified material
should contains 30% - 50% of mass content is made up of
fibers (excluding chemicall fibers)
• Length to diameter ratio mare than 600.
• Density of the fabrics is less than 0.4 g/cm3
• Stitching the fibers or filaments in place
• Thermally fusing the fibers or filaments to each other or to
other meltable fibers or powders.
• Nonwoven structures may incorporate monofilaments or yarns
• A nonwoven may be a structural component of a composite
Identification of nonwoven
Production Rate
To produce 500,000 meters of woven sheeting
requires
2 months of yarn preparation
3 months of weaving on 50 looms
1 month for finishing and inspection
Non-woven fabric can deliver the same quantity
within 2 months from the order received
Nonwoven Production cycle
Types of
Nonwoven Fabrics
Fabric production stages
The production of nonwovens can be described in three stages,
although modern technology allows an overlapping of some stages, and in
some cases all three stages can take place at the same. That three
unavoidable main stages are:
1) Web formation
a) Fiber to Fabric (Ex: Carded, Air Laid, Wet Laid)
b) Polymer to fabric (Ex: Spun Bond, Melt Blown, SMS)
2) Web bonding
3) Finishing Treatments
Nonwoven Web Forming
Methods
Web Forming by Carding process
Web
• A web is the basic structure of
fiber to fabric nonwovens
• It is a loose mat of fibers
• Webs require bonding for stability
Carded fabric Applications:
• All fiber to fabric products
• Bandages
• Some pre-moistened wipes
• Apparel Interlinings
Air Laid
Wet Laid
Wet laid is similar to papermaking. In Papermaking uses pulp but inWet laid uses longer fiber, perhapsblended with wood pulp
If more than 70% of material iswood pulp, then that is a paper
Application areas:
Automotive
Hygiene
Insulation
Wipes
Medical
Spun Bonding
Spun Bonding
Products
Surgical gowns
• Home furnishing/ Bedding
• Geotextile fabrics
• Diaper cover stocks
• House Wrap
• Roofing
Products
• Filters (Air & Liquid)
• Insulation
• Face masks
• Barriers in Medical diapers
• Hazmat Applications (Oil split Sorbents)
Polymers
Gear
pumps
Air Air
Melt blown techniques
Products
Baby diapers- standing leg cuff
Adult diapers
Medical Products
Industrial protective apparel
Spun bond - Melt blown - Spun bond (SMS)
SMS Production stages
Spun bond filament
Quenching
Melt blown layer
forming
Stretching
SMS fabric output
Spun bond filament over
laying
Calendaring
Nonwoven Bonding Techniques
Different Bonding Techniques
• Needle punching
Hydro-Entanglement
Mechanical Bonding Products
Products
Felt
Geotextiles
Blood filters
Synthetic leather
Blankets
Automotive interior trim
Carpets etc.,
Thermal Bonding Products
Products
Upholstery
• Cussion pads
• Heat insulation
• Sound insulation
• Medical Products
• Automotive heat insulation
• Protective wrapping material etc.,
Nonwovens with
bonding agents
Infrared
heat source
Reflector
Infrared treatment
Embossed roll calendaring
Hot smooth
calender
Embossed
cylinder
web
cug
Adhesive bonding
Chemical Bonding Products
Powder bonding
• Products
Roofing : Acrylic Weatherability
Water repellency etc.,
Automotive : PVC copolymers-
Sealing performance
Flame retardancy etc.,
• Print bonding
•
FINISHING OF
NON WOVENS
Finishing of Nonwovens
The production of nonwoven fabrics is carried out as a
continuous process, with fiber or resin as the input
material and a roll of fabric as output, or as a series of
batch processes.
Correspondingly, fabric finishing is carried out either in
tandem with web formation and consolidation or off-line
as a separate operation.
Nonwovens may be given one or more of a variety of
finishing processes as a means of enhancing fabric
performance or aesthetic properties.
Performance properties include functional
characteristics such as moisture regain and absorbency
or repellency, flame retardancy and frictional behavior.
Finishing Methods
Chemical Mechanical Thermal-mechanical
Chemical finishing involves the application of chemical
agents as coatings to fabric surfaces or the impregnation of
fabrics with chemical additives or fillers.
Mechanical finishing involves altering the texture of fabric
surfaces by physically reorienting or shaping fibers on or
near the fabric surface.
Thermal-mechanical finishing involves altering fabric
dimensions or physical properties using of heat and
pressure
Finishing types
Dry Finishing methods
Shrinkage
Glazing
Crabbing
Calendering
Pressing
Perforating
Wet Finishing methods
Coloration
Printing
Anti static finishing
Hygiene finishing
Dust bonding treatment
Absorbent and Repellent finishes
(Oil, Static, Water, etc.,)
Products
Roofing Felts
Boat Hulls
Floor Coverings
Wall hangings
Dusters etc.,
Commercial Nonwoven
Products
• Nonwovens are designed to offer particular characteristics, suitable for
certain use. Their various properties are combined together in order to
create the required functionalities.
• The modern nonwoven technologies are permits to simulate required
structures and properties as per market need. Some of the
commercially available products are listed below:
2012 Asian Nonwovens Market 2.6 million tones
Source: INDA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)
Nonwoven in
Technical Textiles
Technical Textiles are textile materials manufactured
mainly for their technical performance and functional
properties.
Nonwovens are the only Technical textiles which
offers different qualities to economical solutions for a
wide range of applications.
35
Some examples of Day-to-Day use of
Technical Textiles
FurnishingShoulder Pads
Collar / Cuff Interlinings
Waddings in Jackets
Clothing Floor Mops
Tea Bags
Coffee Filters
Kitchen
Carpets
Vertical Blinds
Wall Coverings
Railway Tracks
Soil Erosion
Slope Stabilizations
Flyovers Landfills
Civil Engineering
Masks, Gowns,
Caps, Bandage,
Baby Diaper,
Sanitary Napkin
Hospital
Factory
Dust Collection Filter Bags
Liquid Filtration
Battery separators
Carpets, Roof-liners, Seat belts, Tyres,
Airbags
Car
Agrotech – Horticulture,
Agricultural, Forest
Meditech – Personal
Hygiene, Medical
Mobiltech – Car, Ships,
Aircraft, Space
Buildtech – Construction,
Lightweight engineering
Oekotech – Recyling,
Waste Disposal
Clothtech – Garment,
Shoes
Packtech - Packing
Geotech – Road & Rail
Infrastructure
Protech – Person &
Property ProtectionHometech – Furniture &
Furnishing
Sporrtech – Sports &
Leisure
Indutech – Filtration &
Chemical Engineering
Classification
PRODUCT APPLICATION IN AGRICULTURE ANIMAL
HUSBAN-
DARYCROP
PRODUCE
FLORICUL -
TURE
HORTICUL-
TURE
POST
HARVESTING
NONWOVEN FABRICS
MULCHMAT * * *
CATTLE SHED
UNDERLAY*
PROTECTIVE
CLOTHING* * * * *
AGRO TEXTILE
• Special textiles that are manufactured for agricultural applications. These
textile structures are used as controlling environment for plants/animals in
applications like Agriculture, Horticulture , Animal husbandry
• Benefits of Agrotextile Products
Used in Protected Cultivation For Indian Agriculturists for improved
Productivity & Quality of Produce and lower Cost of Production
Nonwovens are used effectively for optimizing the productivity of crops,gardens and greenhouses.
In horticultural applications, nonwovens protect the plants againsttemperature extremes by day and by night, thus creating the foundation forearlier harvests with excellent results.
Agriculture & Horticulture
39
MEDICAL TEXTILES
Surgical Extra Corporeal Healthcare &
Hygiene
Implantable Non-Implantable
Soft Tissue Hard Tissue Cardiovascular
Modern disposable absorbent hygiene products have made an
important contribution to the quality of life and skin health of millions
of people.
Products
Artificial skin
Wound-contact layer
Wadding, Scaffold
Plasters
Elastic bandages
Non-elastic bandages
Compression bandages
Gauze dressing
Products
• Surgical drapes
• Surgical gowns
• Surgical caps
• Absorbent layer
• Cover stock
• Surgical cloths
• Surgical gowns
• Masks
• Wipes
• Outer layer
• The surgical disposables primarily consist of masks, caps, drapes,
gowns, covers and shoe covers made of polypropylene spunbond
fabric (non-woven) with or without polyethylene film.
• Ultra disposable surgical gowns protects the medical professionals
against the transmission of AIDS, hepatitis and other blood-borne
infections.
• Surgical masks protect medical and dental professionals from
acquiring or transmitting infections.
• Non-woven shoe covers protect surgeons from infections and the
discharge and adverse effects of static electricity.
Ex:SURGICAL GOWN DATA:-
Bacterial filtration efficiency : 95% to 98%
Air permeability : 25-30 cm3/cm2/sec
This shows not only these are safer, these are much more comfortable.
Advantages of
Disposable products
Nonwoven Geotextiles are thicker and made either from short and
continuous filaments, carded or laid in even patterns and then mechanically
(needle punched) or thermally bonded.
GEO TEXTILES
Benefits of using Nonwoven in
GeoTextiles
• Cheap and easy to manufacture.
• Superior chemical resistance in even the
aggressive environment application.
• Highly porous structure
• Staple fibers needle punched together to form
fabric capable of withstanding construction
installation stresses.
One of the fastest growing segments in the
nonwovens industry, filtration is characterized by dozens
of end use areas and applications.
Nonwovens can be engineered very precisely to
meet exacting specifications and stringent regulatory
requirements for the filtration of air, liquid, bacteria, dust,
gas and a myriad of other areas.
Examples of nonwoven application:
Air filtration
Liquid filtration
Automotive filtration
FILTRATION
Micron Air particle filters, with their high arrestance Microfiber nonwovens,
protect driver and passengers of a vehicle from pollen, dust, soot and other harmful
particles penetrating inside their car via the intake air flow.
Air Filtration
Air filters for intake, exhaust and recirculated
air filtration in indoor climate control systems:
Filter mats
Pocket filters
Activated-carbon
Combination filters
Cassette filters
HEPA/ULPA filters
Depth-loading filter cartridges
High-temperature filters
• Nonwovens for filtering coolants and lubricants, as well as
washing, phosphating and coagulation baths in the metal-
processing industry.
• Nonwovens for filtering milk, frying fats, drinking water, and
blood plasma.
• Membrane support nonwovens for filtering fruit juices,
enzymes, electro-dip coating and effluents.
Liquid Filtration
Special Filtration
• Respirators
• Vacuum cleaners
• Kitchen hood filters
• Dust removal
- Sound insulation
- Anti-radiation-type construction textiles will be very important in the future.
- Foil, a special film, combined with materials such as foam thermal insulation products
- Resistance to hydrolysis with water, which is important in areas where contact is inevitable PU-ether-based chemical applied to the use of textiles.
- Breathable, wind-and rain-proof light houses.
Nonwoven applications in
CONSTRUCTION
Household Textiles
Nonwoven fabrics can be used in the
following household textile applications:
– Floor coverings
– Upholstery materials
– Webbings, etc.,
Nonwoven wall hanging
China nonwoven carpet
Automotive Interiors
Facings and structural reinforcement materials are
used in a variety of different applications Includes:
Headliners
Trunk liners
Door trim
Package trays
Sun visors
Seats
In Shoes
A broad spectrum of applications including:
- Liners
- Counter liners
- Inter-liners and
- Reinforcing materials
Membranes and insoles ensure a healthy foot
climate and a high degree of foot comfort.
Advantages of using nonwovens
• Easy to recycle and compost
• Easy to convert into pads and shapes
• High tear resistance
Rice Bag
Example Product:
• Food wrap: Meat
• Cheese and fish wrappers
• Food contact packaging
• Tea & coffee bags
• Absorbent pads
• Sacks, bags & sachets
• Envelopes
• Sacks and bags
• Protection
• Sheets, bags, sacks, wraps for delicate
products
(Ex: electronic products, car bumpers,
leather goods)
PACKAGING
Pesticide Protective Materials
Three layered Chemical Protective Fabric
Spunbond Pillow Cover Spunbond Grocery Bag
Moistened Hand WipesInsulation High Lofts
Spunlace Wet Wipes
Typical Surgical Gown
(Spunbond - Meltblown - Spunbond)
References
• Giovanni Tanchis,“The Nonwovens-Reference books of Textile
technologies”, April 2008
• Wilhelm Albrecht, “Nonwoven Fabrics”, 2003
• Bernard P Corbman, “Textiles : Fibre to Fabric”, McGraw Hill BookCo., Singapore, 1983
• Pushpa B and Sengupta A K , "Industrial Application of Textiles forFiltration and Coated fabrics", Vol.14, 1992
• The Indian Textile Journal, September 2008
References
• http://www.towel-roll.com
• http://www.ittaindia.org
• http://www.edana.org
• http://www.inda.org
• http://zend123.en.made-in-china.com
• http://www.made-in-china.com
• http://www.textileworld.com
• http://www.nonwoven-material.cn
• http://www.imerys-perfmins.com
• http://silvix.koreasme.com
• http://engineering.indiabizclub.com
