Exhibiton Presentation

8/8/2019 Exhibiton Presentation

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Nonwovens manufacturing

processes

Mehran Khattak


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Definition

A sheet, web of natural, man-made fibers or

filaments that have been bondedto each

other by any of several means.

Two staged manufacturing (low cost)

Web formation

Web bonding

(same production facility)


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Web formation

WEB FORMATION

WET LAID DRY LAID

SPUNBOND

MELTBLOWN

ELECTROSPINNING

random layed fibersfibers layed in parallel,

crosswise

CARDING AIR LAID SPUN LAID


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Web bonding

WEBBONDING

MECHANICAL CHEMICAL

CALENDERING

THROUGH AIR

BONDING

SONICBONDING

NEEDLE PUNCH

SPUN LACED

(STITCH BONDED)

(TUFTING)

THERMAL

IMPREGNATING

FOAM COATING

SPRAYING

PRINT BONDING


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Nonwoven market

Classification % of total

Hygiene 33.1

Building/roofing 12.5

Liquid and gas filtration 6.5

Civil engineering 5.4 Automotive 3.9

Medical/surgical 3.5

Wipes, personal care 8.1

U pholstery/table linen/household 6.8

Garments& Interlinings 2.9

Shoe leather goods 1.9 Coating substrates 2.4

Floor covering 2.3

Others/unidentified 5.3


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Nonwoven market

1994-2004 8% growth

2004-2009 10.5 growth

Wo rldw ide Out look for Nonw oven s Produc t ion

9 ,1

16,4

23,3

2 ,24 ,5

6 ,4

0

5

10

15

20

25

1994 2004 2009

Billionsdollars,

millionstons

Billions dollarsMillions tons


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Nonwoven market

Western EU 33%

North America 31%

Asia Pacific 25% ( Japan, China,

S.Korea)

Others 11%


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Production processes

WEB FORMATION

WET LAID DRY LAID

SPUNBOND

MELTBLOWN

ELECTROSPINNING

random layed fibersfibers layed in parallel,

crosswise

CARDING AIR LAID SPUN LAID


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Wet laid web formation

3 stages of production

Dispersion forming

Dewaterig and webformation

Drying and bonding

Fiber dispersion

Dewatering and

web formation


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Air laid and carded web


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Air laid and carded webAdvantages and disadvantages of airlaid over

carded web

Isotropic and randomly arranged webs

Voluminious webs

Low mass uniformity

Low level of opening fiber material bylickerin roller

Possible entangling of fibers in air streamWide variety of processable fibers in both

processes


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Applications of Airlaid and

carded web Interlinings

shoe linings

high loft" products for the garment and furniture and insulation

synthetic leather

waddings;

geotextiles,

filter materials;

needle blankets; carpets ,wall coverings;

technical felts insulation felts; mattress felts,


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Spunbond

Spinneret

Gearpu p

Fila en

tAir

Stretchingpipe

Deflector

Collector

Suction

eb

Stretching

nozzle


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Melt blown


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Meltblown vs Spunbond

Spun bond agianst Meltblown

Stronger

Flexible

Cheaper

More investment

Larger pore size


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Applications

Spunbond

Backing, packing, cover stock, roof

sheeting, geo textile, reinforcemnt

Meltblown

Filtration, insulation, hygeine, medical

textile, floppy disks lining, battrey

separators


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Web bonding

WEBBONDING

MECHANICAL CHEMICAL

CALENDERING

THROUGH AIR

BONDINGSONICBONDING

NEEDLE PUNCH

SPUN LACED

(STITCH BONDED)

(TUFTING)

THERMAL

IMPREGNATING

FOAM COATING

SPRAYING

PRINT BONDING


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Needle punched nonwoven


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Uses

Filters, tennis balls, carpets, floor covering,

Geo textile

Automotive


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Spunlace

Dewatering

system

Water jets

Water circulation Support screen

(drum or belt)

Drying

system

Winding

Fibrous web

Water suction zoneWater purification

support screen


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Spunlace properties

very good textile drape (low stiffness) and very soft handle

no chemical or melt binders; it is possible to prepare 100 % naturalfibers, suitable for sanitary products, suitable to recycling

strenght is much higher than after mechanical needling (for the some

area weight); similar to woven textiles wide range of textile structure (depending especially on the perforated

belt structure) wide range of textile properties

uniform surface due to more fine interlacing of fibers (compared withneedling)

very high textile production: up to 300 m/min for carded and airlaid

webs and up to 500 m/min for wetlaid and spunbond (meltblown);textile width up to 6000 mm.


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Spunlace applications


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1. Hospital use:

surgical gowns and drapes (fig.1),

operational cover sheets, bed

sheets, towels...

2. Medical use:

wound dressings (fig.2), gauze,

wet tissue, cotton products, pads

(fig.3)

3. Sanitary products:

baby wipes (fig.4), facial clean

wipe, face masks, disposable

pants...

Fig. 1

Fig. 2 Fig. 3

Fig. 4

Spunlace Applications


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4. Household products:

cleaning wipes (fig.5), protection

fabric for electronics, home

furnishing fabrics: table cloths and

napkins (fig.6), curtains (fig.7)

5. Industrial textiles:

industrial wipes (fig.8), filtration

(fig.9), roofing, water insulation

(fig.10), protective apparell(fig.11), liquid absorbents

Fig. 5

Fig. 6Fig. 7

Fig. 8

Fig. 9

Fig. 10

Fig. 11

Spunlace applications:


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Chemical bonding

dhesive po

der

otating brush

Web

Po

der metering

Screen roll

Squeegee

ating roll

Web

Binder

Po der bondingChemical bonding


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Thermal bonding

ayer 1

ayer 2

In rared

heat source

e lector

Hot roll

Cold roll

Hot roll

Hot roll

Double and one side

calenderingIn ra red bonding


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Embossed roll calendering

Hot smooth

calender

Embossed

cylinder

web

Patterned calendaring


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Applications

Wipes and towels

Medical nonwovens

Roofing products

Apparel interlinings

Filter media

Coating substrates

Automotive trim

Carrier fabrics

Bedding products (high loft)

Furniture applications (high loft) Apparel

Pillows (high loft)


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THANKS

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Exhibiton Presentation