Let me break down the whole spunlace non woven fabric manufacturing process for you in detail:
1. Fiber Prep (Opening & Blending)
Before anything else, we need to get our fibers ready. We take compressed fiber bales and:
Open them up using coarse and fine openers to break apart any clumps
Mix different fiber types (like polyester, viscose, or cotton) to get the perfect blend
Remove any junk – metal bits, dirt – using magnets and screens
2. Web Formation
This is where we build our fiber mat. Depending on what we’re making, we might:
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Use mechanical lappers that criss-cross the fibers for extra strength
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Or go with air-laid systems for super fine, fluffy webs
The key is getting that perfect, even spread at the right weight (grams per square meter)
3. Carding
Now we run our web through the carding machine – think of it like a giant hairbrush for fibers:
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Metal-wire rollers comb everything into alignment
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We carefully control the speed and spacing to prevent clumping
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The output is this beautiful, thin, uniform fiber layer
4. Hydroentanglement (The Water Jet Part)
Here’s where the real action happens with our high-pressure water jets:
We’re blasting water at 80-250 bar through tiny nozzles (just 0.1-0.15mm wide!)
The jets hit from both top and bottom to really tangle those fibers
We typically do 3-5 passes to get the perfect bond
Meanwhile, vacuum slots suck away all the excess water
5. Pre-Drying
Before the main drying, we need to get rid of most of that water:
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Powerful vacuum extractors pull out moisture
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Sometimes we’ll run it through squeeze rollers too
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We aim to get moisture down to 30-50% before the dryer
6. Drying
Now we finish the job with:
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Through-air dryers blowing hot air (100-150°C) right through the fabric
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Or sometimes drum dryers for thinner materials
The trick is drying it thoroughly without making it brittle
7. Quality Inspection
Nobody wants flawed fabric, so we:
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Use automated camera systems to spot any defects
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Also have trained inspectors checking manually
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Looking for oil spots, weak spots, or uneven areas
8. Winding
Finally, we roll it all up:
Using precision winders that maintain perfect tension
Making sure the edges stay aligned
Typically winding to 1-1.5 meter diameter rolls
The whole process is pretty amazing when you see it in action – no chemicals, just water and mechanical action turning loose fibers into strong, soft fabric. And we can tweak every step depending on whether we’re making medical gowns, cosmetic wipes, or industrial materials.
