Developments in Nonwovens for Wipes by Pira International Ltd

By Pira International Ltd

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It targets the wipes and medical apparel markets. While airlaced global output capacity is still relatively low, more than a 100,000 tonnes of capacity has been installed globally since 2002. Total world spunlace output for all kinds of nonwovens grew to more than 450,000 tonnes in 2005. Hydroentanglement has gained considerable importance lately, as developments in this also benefit airlaid products. Reduced energy consumption, lower material loss, reduced water consumption through the use of optimised filter systems as well as reliability and minimum maintenance requirements for production lines, are decisive factors for the use of hydroentanglement with airlaid products.

The evolution of bonding methods has also added to the flexibility of airlaid applications. In addition to traditional chemical bonding there is:  Thermal bonding using synthetic fibres (typically bi-component);  Multi-bonding process licensed by M&J and Dan-Web (Aarhus, Denmark), a mix of bonding methods;  Hydrogen bonding with controlled humidity and pressure for high basis weight absorbent core materials. Combining other processes with airlaid opens other avenues for substrate design.

Rayonier built a small demonstration line of 10,000 tonnes using a new patented process built around hydrogen bonding. Its business plan called for a 100,000 tonne line in two years, once the core nappy market began to materialise. McAirlaid, in Europe, built a Page 39 © Copyright Pira International Ltd 2006 Developments in Nonwovens for Wipes Processing developments larger 20,000 tonne hydrogen bonded line. Hydrogen bonded airlaid was touted as a low capital cost, low production cost version of airlaid.

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