Nonwovens & its applications

This presentation gives idea about the non woven fabric types and its applications in the present market.

1. Prepared by
S.RAJESH KUMAR
PSG TECH
E-mail : [email protected]

2. •Introduction
•Types of nonwoven fabrics
•Nonwoven web forming methods
•Nonwoven bonding techniques
•Finishing of nonwovens
•Commercial nonwoven products
•Nonwoven in technical textiles
Presentation Content

3. INTRODUCTION

4. Polymers
Fibers
Yarns
WovenKnitted BraidedNon-woven
Fabrics
Application
Woven structure Knitted structure Braided structure

5. 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

6. Brief about Nonwoven
•FibersarethebasicelementofNonwovens.The
selectionofrawfibers,determinestheproperties
ofthefinalnonwovenproducts.
•FiberselectionpurelydependonApplication,
customerrequirementandcostofProduct.
•Thefiberscanbeintheformofstableform(or)
filamentform.Anynaturalorsyntheticfibercould
beusedintheproductionofnonwoven.
•Syntheticfibersprovidespecializedproperties,
uniformity,andconsistencyofsupplywhich
cannotbeachievedbynaturalfibers.
•Bicomponentfibersareamanufacturedfiber
havingtwodistinctpolymerscomponentsmay
alsousedinnonwovenmanufacturing.
•Nanofibers,Glassmicrofibersalsousedin
nonwovenIndustry

7. •TodistinguishnonwovensfrompapersbyaIdentifiedmaterial
shouldcontains30%-50%ofmasscontentismadeupof
fibers(excludingchemicallfibers)
•Lengthtodiameterratiomarethan600.
•Densityofthefabricsislessthan0.4g/cm
3
•Stitchingthefibersorfilamentsinplace
•Thermallyfusingthefibersorfilamentstoeachotherorto
othermeltablefibersorpowders.
•Nonwovenstructuresmayincorporatemonofilamentsoryarns
•Anonwovenmaybeastructuralcomponentofacomposite
Identification of nonwoven

8. Production Rate
Toproduce500,000metersofwovensheeting
requires
2monthsofyarnpreparation
3monthsofweavingon50looms
1monthforfinishingandinspection
Non-wovenfabriccandeliverthesamequantity
within2monthsfromtheorderreceived
Nonwoven Production cycle

9. Types of
Nonwoven Fabrics

10. Fabric production stages
Theproductionofnonwovenscanbedescribedinthreestages,
althoughmoderntechnologyallowsanoverlappingofsomestages,andin
somecasesallthreestagescantakeplaceatthesame.Thatthree
unavoidablemainstagesare:
1)Webformation
a)FibertoFabric(Ex:Carded,AirLaid,WetLaid)
b)Polymertofabric(Ex:SpunBond,MeltBlown,SMS)
2)Webbonding
3)FinishingTreatments

12. Nonwoven Web Forming
Methods

13. WebForming by Carding process
Web
•Awebisthebasicstructureof
fibertofabricnonwovens
•Itisaloosematoffibers
•Websrequirebondingforstability
Carded fabric Applications:
•All fiber to fabric products
•Bandages
•Some pre-moistened wipes
•Apparel Interlinings

14. AirLaid
WetLaid
Wetlaidissimilartopaper
making.InPapermakingusespulpbutin
Wetlaiduseslongerfiber,perhaps
blendedwithwoodpulp
Ifmorethan70%ofmaterialis
woodpulp,thenthatisapaper
Application areas:
Automotive
Hygiene
Insulation
Wipes
Medical

15. Spun Bonding

16. Spun Bonding
Products
Surgical gowns
•Home furnishing/ Bedding
•Geotextile fabrics
•Diaper cover stocks
•House Wrap
•Roofing

17. Products
•Filters (Air & Liquid)
•Insulation
•Face masks
•Barriers in Medical diapers
•Hazmat Applications (Oil split Sorbents)
Polymers
Gear
pumps
Air Air
Melt blown techniques

18. Products
Baby diapers-standing leg cuff
Adult diapers
Medical Products
Industrial protective apparel
Spun bond -Melt blown -Spun bond
(SMS)
SMS Production stages
Spun bondfilament
Quenching
Meltblown layer
forming
Stretching
SMS fabric output
Spun bondfilament over
laying
Calendaring

19. Nonwoven Bonding Techniques

20. DifferentBonding Techniques

21. •Needle punching
Hydro-Entanglement
Mechanical Bonding Products
Products
Felt
Geotextiles
Blood filters
Synthetic leather
Blankets
Automotive interior trim
Carpets etc.,

22. 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 calendaringHot smooth
calender
Embossed
cylinder
web

23. 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
•

24. FINISHING OF
NON WOVENS

25. 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 andabsorbency
or repellency, flame retardancyand frictional behavior.

26. Finishing Methods
Chemical Mechanical Thermal-mechanical
Chemicalfinishinginvolvestheapplicationofchemical
agentsascoatingstofabricsurfacesortheimpregnationof
fabricswithchemicaladditivesorfillers.
Mechanicalfinishinginvolvesalteringthetextureoffabric
surfacesbyphysicallyreorientingorshapingfibersonor
nearthefabricsurface.
Thermal-mechanicalfinishinginvolvesalteringfabric
dimensionsorphysicalpropertiesusingofheatand
pressure

27. 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.,

28. Commercial Nonwoven
Products

29. •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:

33. 2012 Asian Nonwovens Market 2.6 million tones
Source: INDA Estimates & Rory Holmes, INDA-CAB Conference 2012 (www.inda.org)

34. Nonwoven in
Technical Textiles
TechnicalTextilesaretextilematerialsmanufactured
mainlyfortheirtechnicalperformanceandfunctional
properties.
NonwovensaretheonlyTechnicaltextileswhich
offersdifferentqualitiestoeconomicalsolutionsfora
widerangeofapplications.

35. 35
Some examples of Day-to-Day use of
Technical Textiles
Furnishing
Shoulder 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

36. 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 Protection
Hometech –Furniture &
Furnishing
Sporrtech–Sports &
Leisure
Indutech –Filtration &
Chemical Engineering
Classification

37. PRODUCT APPLICATION IN AGRICULTURE ANIMAL
HUSBAN-
DARY
CROP
PRODUCE
FLORICUL -
TURE
HORTICUL-
TURE
POST
HARVESTING
NONWOVEN FABRICS
MULCHMAT
* * *
CATTLE SHED
UNDERLAY
*
PROTECTIVE
CLOTHING
* * * * *
AGRO TEXTILE
• Specialtextilesthataremanufacturedforagriculturalapplications.These
textilestructuresareusedascontrollingenvironmentforplants/animalsin
applicationslikeAgriculture,Horticulture,Animalhusbandry
•Benefits of Agrotextile Products
Used in Protected Cultivation For Indian Agriculturists for improved
Productivity & Quality of Produce and lower Cost of Production

38. Nonwovensareusedeffectivelyforoptimizingtheproductivityofcrops,
gardensandgreenhouses.
Inhorticulturalapplications,nonwovensprotecttheplantsagainst
temperatureextremesbydayandbynight,thuscreatingthefoundationfor
earlierharvestswithexcellentresults.
Agriculture & Horticulture

39. 39
MEDICAL TEXTILES
Surgical Extra Corporeal Healthcare &
Hygiene
Implantable Non-Implantable
Soft Tissue Hard Tissue Cardiovascular
Moderndisposableabsorbenthygieneproductshavemadean
importantcontributiontothequalityoflifeandskinhealthofmillions
ofpeople.

40. Products
Artificial skin
Wound-contact layer
Wadding, Scaffold
Plasters
Elastic bandages
Non-elastic bandages
Compression bandages
Gauze dressing

41. Products
•Surgicaldrapes
•Surgicalgowns
•Surgicalcaps
•Absorbentlayer
•Coverstock
•Surgicalcloths
•Surgicalgowns
•Masks
•Wipes
•Outerlayer

42. •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:SURGICALGOWN DATA:-
Bacterial filtration efficiency : 95% to 98%
Air permeability : 25-30 cm
3
/cm
2
/sec
This shows not only these are safer, these are much more comfortable.
Advantages of
Disposable products

43. NonwovenGeotextilesarethickerandmadeeitherfromshortand
continuousfilaments,cardedorlaidinevenpatternsandthenmechanically
(needlepunched)orthermallybonded.
GEO TEXTILES

44. 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.

45. Oneofthefastestgrowingsegmentsinthe
nonwovensindustry,filtrationischaracterizedbydozens
ofenduseareasandapplications.
Nonwovenscanbeengineeredverypreciselyto
meetexactingspecificationsandstringentregulatory
requirementsforthefiltrationofair,liquid,bacteria,dust,
gasandamyriadofotherareas.
Examplesofnonwovenapplication:
Airfiltration
Liquidfiltration
Automotivefiltration
FILTRATION

46. MicronAirparticlefilters,withtheirhigharrestanceMicrofibernonwovens,
protectdriverandpassengersofavehiclefrompollen,dust,sootandotherharmful
particlespenetratinginsidetheircarviatheintakeairflow.
AirFiltration
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

47. •Nonwovensforfilteringcoolantsandlubricants,aswellas
washing,phosphatingandcoagulationbathsinthemetal-
processingindustry.
•Nonwovensforfilteringmilk,fryingfats,drinkingwater,and
bloodplasma.
•Membranesupportnonwovensforfilteringfruitjuices,
enzymes,electro-dipcoatingandeffluents.
Liquid Filtration
SpecialFiltration
•Respirators
•Vacuum cleaners
•Kitchen hood filters
•Dust removal

48. -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

49. 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

50. Automotive Interiors
Facings and structural reinforcementmaterials are
used in a variety ofdifferent 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.

51. 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

52. Pesticide Protective Materials
Three layered Chemical Protective Fabric

53. Spunbond Pillow Cover Spunbond Grocery Bag
Moistened Hand WipesInsulation High Lofts

54. Spunlace Wet Wipes
Typical Surgical Gown
(Spunbond -Meltblown -Spunbond)

55. References
•GiovanniTanchis,“TheNonwovens-ReferencebooksofTextile
technologies”,April2008
•WilhelmAlbrecht,“NonwovenFabrics”,2003
•BernardPCorbman,“Textiles:FibretoFabric”,McGrawHillBook
Co.,Singapore,1983
•PushpaBandSenguptaAK,"IndustrialApplicationofTextilesfor
FiltrationandCoatedfabrics",Vol.14,1992
•TheIndianTextileJournal,September2008

56. 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