Nonwoven fabric production lines use various methods to form fiber webs, which are the initial stages of creating nonwoven textiles. These methods determine the structure and properties of the nonwoven fabric. Here are some common methods of forming fiber webs:

Carding:

Process: Carding is a mechanical process that separates and aligns fibers to create a uniform web. It involves passing the fibers through a series of carding machines equipped with rotating drums or rollers covered in fine wire teeth. As the fibers pass through the machines, they are opened, combed, and oriented into a thin web.

Application: Carding is commonly used for producing nonwoven fabrics that require good uniformity, such as medical textiles, wipes, and hygiene products.

Airlaid:

Process: Airlaid is a method that uses air to distribute and bond fibers onto a moving conveyor or forming belt. Fibers are suspended in an airstream and deposited onto a porous belt, creating a loosely formed web. The web is then bonded using various methods, such as thermal bonding or latex bonding.

Application: Airlaid nonwoven fabrics are often used in absorbent products like diapers, feminine hygiene products, and industrial wipes.

Spunbond:

Process: Spunbonding involves extruding molten polymer through spinnerets to create fine continuous filaments. These filaments are laid onto a moving conveyor to form a web. The web is then bonded using heat or other methods.

Application: Spunbond nonwovens are used in a wide range of applications, including agricultural covers, geotextiles, and disposable protective clothing.

Meltblown:

Process: Meltblown is a method where polymer resin is melted and extruded through fine nozzles. High-velocity air streams blow the molten polymer into microfibers, which are collected on a moving conveyor to form a fine web. Meltblown fabrics are known for their fine filtration properties.

Application: Meltblown nonwovens are commonly used in filtration media, medical face masks, and respirators.

Needlepunching:

Process: Needlepunching is a mechanical process that involves passing a loose fiber web through a bed of barbed needles. As the web passes through the needles, the fibers become entangled, creating a cohesive fabric. Multiple passes can be used to achieve desired thickness and properties.

Application: Needlepunched nonwovens are used in applications like automotive interiors, felt fabrics, and carpets.

Hydroentanglement (Spunlacing):

Process: Hydroentanglement, also known as spunlacing, uses high-pressure water jets to entangle and bond the fibers in a web. The water jets create mechanical entanglement, and the web is typically dried after this process.

Application: Spunlaced nonwovens are used in medical wipes, industrial wipes, and cleaning cloths.

Wet Laid:

Process: Wet laid nonwovens are created by suspending fibers in a water-based solution and depositing the fiber mixture onto a forming wire or belt. The water is drained or squeezed out, and the web is then dried and bonded.

Application: Wet laid nonwovens are used in specialty applications such as battery separators and medical dressings.

Dry Laid:

Process: Dry laid nonwovens of Nonwoven fabric production lines are formed by distributing dry fibers onto a moving conveyor or forming belt. Bonding is typically achieved through thermal, chemical, or mechanical methods.

Application: Dry laid nonwovens are used in a wide range of applications, including filtration, automotive, and construction materials.