Non woven fabric machine manufacturing involves several processes:
Fiber production
Fibers such as polypropylene, polyethylene, polyester, etc. are produced and cut into short lengths called staple fibers. The staple fibers are then opened, cleaned and blended into a uniform fiber mix.
Web formation
The fiber mix is fed into a nonwoven web forming machine. The most common web forming methods are:
Spunbonding
Fibers are extruded into filaments, stretched and laid on a moving belt to form a random web. Spunbond webs are porous and lightweight.
Meltblowing
Fibers are extruded into filaments and blown by hot air onto a moving belt. Meltblown webs are very porous and fine.
Wet laying
Fibers are dispersed in water to form a slurry and laid onto a moving screen to drain excess water. Wet laid webs have high strength and absorbency.
Air laying
Fibers are blown by air onto a moving screen and form a fluffy web. Air laid webs are bulky, porous and lightweight.
Carding
Fibers are mechanically combed and aligned into a sheet. Carded webs have high strength in the fiber direction.
Bonding
The nonwoven web then goes through a bonding process to provide strength and integrity. Common bonding methods include thermal bonding, mechanical bonding (needling), chemical bonding and hydroentanglement.
Finishing
Nonwoven fabrics can be treated with a finishing process such as printing, embossing, laminating, coating, dyeing, sterilization, perfuming, etc. depending on the end use application.
Converting
The finished nonwoven fabric is wound into rolls and converted into its final form and size for various applications like diapers, wipes, medical fabrics, geotextiles, filters, etc.
Packaging
The converted nonwoven products are packaged and distributed for commercial use.