Long gone are the times when spunbonded fabrics were always smooth. Nowadays, with the right downstream components, very different nonwovens can be created: Thin, smooth, fleecy, water-resistant, hydrophilic. The new properties make spunbonded fabrics interesting for industrial use, as geotextiles, and in this way as an alternative for carded nonwovens.
With calendering, the filaments are punctually fused and gummed up. The nonwoven is guided through a heated pair of rolls composed of one smooth and one embossed roll. Calendering functions at high production speeds of up to 1,200 meters per minute. It is the standard process for hygiene products.
Typical products:
Diapers, bags, furniture, agricultural covers
During Hydroentanglement, a water jet hits the nonwoven at high speed. The filaments are caught, reorientated and partially knotted. In this way, the nonwoven acquires great strength and a rather soft textile feel. Water jet strengthening is possible for production speeds of up to 800 meters per minute.
Typical products:
Cleaning wipes
Needle punching is suitable for PP and PET nonwovens. During needle punching, the filaments are reoriented by a needle so that they intertwine into a friction fit. In this way, the nonwoven becomes voluminous and is given a felt-like appearance. Needle punching is possible at production speeds of up to 50 meters per minute.
Typical products:
Roof insulation sheeting, construction, bitumen supports
During the highloft process, the filaments are connected by thermal bonding into an especially voluminous and soft nonwoven. Highloft can be used for production speeds of up to 600 meters per minute.
Typical products:
Top sheets, back sheets, ADL Coarse filters
In the humidifier, naturally water-resistant nonwovens are transformed into water-permeable nonwovens by applying surface active substances. In the "Kiss Roll", these substances are applied onto the nonwoven evenly over the entire width or in zones, at production speeds of up to 1,200 meters per minute.
Typical products:
Top sheet and core wrap in diapers
If the nonwoven has been treated with a humidifier, it is essential to dry it afterwards. The most commonly used process is convection drying (air flowing through) with a perforated cylinder drier. Production speeds of up to 1,200 meters per minute are possible.
Typical products:
Top sheet and core wrap in diapers
With the inline winding concept, the nonwoven is wound on cardboard cores and directly cut into webs for subsequent processing. The concept is especially suitable for production where frequent product changes are planned, or where a low space requirement of the winder is depended on.
Usual roll diameter
800 – 1,200 mm
Usual web width
100 – 250 mm
Line speed
Up to 600 m/min
During offline winding, the nonwoven is wound with a master-roll winder on drums with a roll diameter of up to 3,500 mm. Storage stations between the master-roll winder and a downstream rewinder serve as intermediate storage for the jumbo reels. Only in the rewinder are the large rolls unwound, cut and wound again.
Usual roll diameter
800 – 1,200 mm
Usual web width
100 – 250 mm
Line speed
Up to 1,200 m/min
