Fibres Used In

Nonwoven Process
R.Senthil Kumar
sen29iit@yahoo.co.in
 Criteria for fibre selection
 The selection of fibre, to considerable degree determines the properties
of final nonwoven product.

 The selection of fibers also depend on customer requirement, cost,

process ability, changes of properties as a result of web formation and
consolidation.

 The fibers can be in the form of filament, staple fiber or even yarn.

 Although there are several natural fibers available for nonwovens,

wood pulp - which is far shorter in length than the conventional textile
fibers - is the only natural fiber used in very large amounts because of
its high water absorbency, bulk and low cost.
 Natural and synthetic fibres
 Cotton has excellent inherent properties for nonwovens fabrication.

 Viscose rayon has been widely used in the nonwovens industry in the area of
disposables and sanitary products.

 Rayon fibers can be easily made into webs and readily bonded into nonwovens
fabrics. All these cellulosics such as cotton, rayon and acetate are absorbent, act as
carriers for microbial agents, and give strength combined with biodegradability.

 Among the synthetic fiber polypropylene (PP) is widely used. PP is inexpensive and
has very good characteristics to form fine fibers. PP fibers are hydrophobic,
voluminous, and thermoplastic in nature.

 Polyethylene terephthalate (PET) is used where strength and mechanical properties

are of prime importance.

 Nylon fibers are used for their excellent recovery (resiliency) properties.

 Bicomponent fibers with different polymers in the core and sheath are widely used in
thermally bonded nonwovens
 World Consumption of Manmade fibres in
Nonwovens 1998-2007
Fibre 1998 1999 2000 2001 2005 2007

Polyester fibers 24 22.5 22.5 23 23 23

Polyamide fibers 1.5 1.5 1.5 1.5 1.5 1.5
Acrylic fibers 1.5 2 2 3 3 3
Polypropylene fibers 62 63 63 62.7 62.7 62.7
Viscose rayon fibers 8 8 8 7 7 7
Other synthetic fibers 3 3 3 2.8 2.8 2.8
100 100 100 100 100 100
Total consumption 2.4 2.6 3.3 2.5 3.7 4
 Various fibres in Nonwovens
Cotton:
 In nonwoven applications, the purity and absorbency of bleached
cotton are utilized in growing medical and healthcare
applications. Such fabrics usually are produced by the spunlace
process.
 Application of cotton in nonwovens is very low.

Polypropylene:
 Because of its superior performance characteristics and
comparatively low-cost, PP fiber finds extensive use in the
nonwovens industry.
 Applications : absorbent products, automotive products
Polyester:
 Spunbonded polyester in a variety of applications: a nonwoven
sheet fabric, fabric softener dryer sheets filtration media, apparel
interlining, carpet backing, furniture and bedding, automotive
seats and agricultural crop covers

 Dry and wet laid nonwovens made from a range of synthetic and
inorganic fibers are used in electrical insulation laminates and
electrical tape backing applications.

Rayon:
 Wipes represent the largest nonwovens market for rayon.
 Biodegradability and compatibility of rayon with both septic
tank and main sewage systems enables them to be used in the
manufacture of disposables.
Nonwoven consumption by region from
1983-2007
Year USA West Europe Japan China Rest of the
World

1983 52 31 8 - 9
1988 48 30 9 2 11
1995 38 30 9 6 17
1998 35 30 10 80 17
1999 34 30 9 10 18
2000 33 30 9 11 18
2005 31 31 9 11 18
2007 30 30 9 12 19
Nonwoven Production by Region(%)
Year USA West Europe Japan China Rest of the
World
1983 53 34 10 - 3
1988 53 34 9 1 3
1995 45 32 9 2 12
1998 41 30 8 3.5 17.5
1999 38 30 8 5 19
2000 37 29 8 6 20
2005 37 28 8 7 20
2007 36 28 8 7 21
Production Technology
Production of Nonwovens by Web-Forming Process

0,6
2001
0,5
2002
Million tons

0,4 2003

0,3

0,2

0,1

0
Spunlaid Carded Airlaid Wetlaid

Source: EDANA
World wide Nonwoven production
technology (%)
Worldwide Production of Nonwovens
Technology (4,5million tons)

Spunlaid
Carded
41%
47%

Wetlaid Airlaid
4% 8%