Nonwoven Products Research Articles

Selected Recent Advances in the Utilization of Biopolymers for Nano‐ and Microfiber Materials and Nonwovens Production

AbstractWhen the variety of synthetic polymers came up in the 20th century, they expectedly replaced many fiber materials which were made so far from biopolymers since ancient times (e.g., for textiles, medical products, etc.). Meanwhile, to some extent, there is a strong revival of various fibers from biopolymers regarding their utilization for various applications, based on their interesting structures, availability, sustainability, costs, and other factors. Regarding bioeconomy and sustainability, there has thus been an intensive market dynamic for biopolymers. Therefore, especially a variety of fiber materials have recently been described that are based on different biopolymers as, e.g., polysaccharides and biopolyesters. For this, a variety of enhanced polymer structure modification and sophisticated processing methods are applied. Instead of a complete and comprehensive overview (which would be beyond the scope of this Perspective format), the aim of this article is to elucidate some selected recent advantages in this field and to focus on the special features of these examples.

Nonwoven surface treatments for disposable hygiene products

AbstractBaby diapers, adult incontinence products, feminine hygiene items, and wet wipes are extensively utilized nonwoven products. The properties of nonwovens are significantly influenced by surface treatments. These treatments impart hydrophilicity, hydrophobicity, skincare benefits, adhesion reduction, odor control, enzymatic inhibition, pH control, probiotics, prebiotics, controlled release of active agents, and antimicrobial activity, all of which enhance the performance and user experience of these products. This study reviews surface treatments for nonwoven disposable hygiene products, focusing on their types, effects, performance, and safety considerations. Most research focuses on hydrophilicity and hydrophobicity due to the absorbent nature of these articles. Small molecule applications are prominent, though polymer‐based formulations offer greater versatility. Smart materials, nanofibers, and nanoparticles are becoming increasingly popular in the field. Concerns regarding sustainability, biodegradability, biocompatibility, product safety, and compliance with emerging environmental regulations are increasing. Focusing on these areas will drive the development of next‐generation disposable hygiene products that meet changing regulations, consumer demands and concerns.Highlights Innovative agents improve user comfort and hygiene in surface treatments. Small molecule treatments are common although polymers provide more versatility. Smart coatings and nanomaterials offer advanced surface treatments. Biodegradable treatments lead the shift towards sustainable hygiene products. Consumer preferences shape the next generation of hygiene articles.

Experimental analysis on fiber diameter of spunbond nonwoven fabrics through Plackett–Burman and Box–Behnken designs and its impact on mechanical properties

AbstractThe COVID‐19 pandemic sparked a surge in demand for nonwoven protective materials, prompting a significant increase in nonwoven fabric production. To advance understanding, particularly in the Spunbond process, we conducted experiments to analyze the effects of various input parameters on fiber diameter, and mechanical tests to study how fiber diameter influences the mechanical properties of spunbond nonwoven fabrics. Employing Plackett–Burman design and Box–Behnken design with Minitab 18, we have examined different process parameters and study the cause‐and‐effect relationships between input parameters and the response. A set of experiments were carried out with nine varying parameters, including polymer melt index, initial polymer temperature, and air velocity. By regression modeling, we assessed the effects and interactions of these factors on fiber diameter. The Box–Behnken approach revealed that only three factors significantly influenced fiber diameter. Our analysis unveiled valuable insights for optimizing process parameters to achieve a target fiber diameter of 31.0 μm, crucial for enhancing nonwoven fabric production. Moreover, the results of the tensile property tests show that fiber diameter influence mechanical properties of nonwoven fabrics. As the fiber diameters increase, the mechanical properties of the nonwoven fabric are increased.Highlights Market research of textile industry, particularly of nonwoven sector. Identification of the parameters of the Spunbond process. Selection of Placket–Burman and Box–Behnken designs to analyze, optimize, and predict fiber diameter. Evaluation of the designs results (analysis of variance, Pareto, Regression model …), determination of the optimal conditions and the factors that has most effect on fiber diameter. Investigation of the effect of fiber diameter on mechanical properties.

Non-standard adhesives for wood-based composites: powder adhesives and bicomponent fibers

Powder adhesives and bicomponent fibres are widely used for composite manufacturing; mainly, they are used for glueing fibres during non-woven production. However, in the woodworking industry, they are rarely used. This study aims to investigate the possibility of powder adhesive and bicomponent fibres utilisation for gluing wood. For this purpose, epoxy-polyester powder adhesive and polyester (PES) bicomponent fibres were selected, and one-component moisture-curing polyurethane adhesive was used as a reference. The selected wood species were spruce, beech, oak and wenge. The differences between powder adhesive- and bicomponent fibre-glued wood joints were observed using scanning electron microscopy (SEM) and energy dispersive spectroscopy (EDX). Mechanical properties of glued wood joints were characterised by tensile shear strength and modelled using finite element modelling (FEM). The adhesives were further characterised using Fourier-transform infrared spectroscopy (FTIR) and differential scanning calorimetry (DSC). The wood joints produced by all combinations of selected wood species and adhesives were comprehensively characterised. The highest values of tensile shear strength were reached by powder epoxy-polyester adhesive (14.85 MPa), whereas joints bonded by bicomponent fibres (5.19 MPa) reached lower values than reference samples.

Study on the properties of water-retted Cymbopogon citratus pseudostem fibres and their nonwoven fabric characteristics

Purpose This study aims to analyse cellulose fibres extracted from the pseudo-stems of Cymbopogon citratus and evaluate their properties in non-woven fabric production. Design/methodology/approach The water retting method was used for fibre extraction, and intrinsic fibre qualities were examined to assess their suitability for textile applications. A thermal bonding technique, using a hot press machine and polylactic acid powder as a binder, was applied for non-woven fabric development. Findings The retted fibres had an average length of 156 mm and a fineness value of 5.73 tex. The fibre’s tenacity and elongation values were 1.33 gf/denier and 12.78%, respectively. Fourier transform infrared analysis confirmed the presence of major cellulose components. The fibre’s crystallinity and friction coefficient were 50% and 0.3, respectively. C. citratus fibre exhibited hygroscopic characteristics with a moisture regain of 10.65%. Experimental non-woven fabrics (70% C. citratus fibre, 30% polylactic acid powder) demonstrated consistent weight and thickness, with variations in tensile strength. Moisture regain values for non-woven fabrics were approximately 7.6%. Originality/value The features of C. citratus fibre, obtained with the water retting process, exhibited suitability for textile applications. Three experimental non-woven fabrics comprising of C. citratus fibre and polylactic acid powder were produced with three different pressing temperatures. The tensile strength properties of these fabrics were influenced by pressing temperature.

PRODUCTION AND EXPORT PERFORMANCE OF COIR PRODUCTS IN INDIA

The coir sector is an important agro-based industry in India that plays an important role in employment opportunities and economic development. India is the world's largest producer and exporter of coir and coir products, exporting coir and its products to more than a hundred countries. It is the by-product of coconut's outer shell, which is used to produce coir fiber, coir yarn, different mats, mating rugs, non-woven products, non-woven mats, coir geo-textiles, coir pith, garden articles, curled coir, needle felt, hand knotted netting, coir ply articles, coir braid, coir rope, coir tea leaf bags, coir brushes, lunch bags, office bags, chapels, pouches, and many more. It is a 100 percent natural and biodegradable product that helps to store water molecules in soil to improve its fertility. The aim of the study is to determine the trend in production of coir fiber and its products in India and to know the export performance of coir fiber and its products in India during the last ten years. According to the study release, there are good opportunities in the world market for the coir products. KEY WORDS: coir fiber, coir products, production, exports, value, countries etc.

Novel method for finishing nonwoven fabrics from domestic raw materials with flame retardant and antimicrobial properties

This study aims to obtain a non-woven material with flame retardant and biocidal properties, considering the use of salicylic acid, copper sulfate, and guanidine hydrochloride in a finishing composition, based on preliminary studies. The concentrations of copper sulfate, guanidine hydrochloride, and salicylic acid were varied, respectively, within 1–5 g/L, 5–15 g/L, and 3–7 g/L. The conditions of the finishing process involved the application of the aqueous solutions, by spraying on the surface of the material, followed by drying at 120 °C for 5 min and heat treatment at 180 °C on a thermal press. In the production of nonwovens, treatment with a flame retardant and biocidal composition can be combined with emulsification of a mixture of fibers, or carried out after the formation of the canvas with subsequent heat treatment and calendering. The untreated sample of non-woven material, when tested for flammability with an ignition time of 15 s, burns completely in 40 s. For the sample treated by the proposed method, the self-burning is reduced to zero (DIN 53906). To study the biocidal activity, a microbiological essay was conducted according to ASTM E2149. It was found that the tested sample exhibits fungicidal activity against the tested strains. In addition, tests conducted on the skin-irritating effects of nonwovens treated with the proposed method have shown its safety for human health.

A Systematic Literature Review for Addressing Microplastic Fibre Pollution: Urgency and Opportunities

Microplastic fibre (MPF) pollution is a pressing concern that demands urgent attention. These tiny synthetic textile fibres can be found in various ecosystems, including water and air, and pose significant environmental risks. Despite their size (less than 5 mm), they can harm aquatic and terrestrial organisms and human health. Studies have demonstrated that these imperceptible pollutants can contaminate marine environments, thereby putting marine life at risk through ingestion and entanglement. Additionally, microplastic fibres can absorb toxins from the surrounding water, heightening their danger when consumed by aquatic organisms. Traces of MPFs have been identified in human food chains and organs. To effectively combat MPF pollution, it is crucial to understand how these fibres enter ecosystems and their sources. Primary sources include domestic laundry, where synthetic textile fibres are released into wastewater during washing. Other significant sources include industrial effluents, breakdown of plastic materials, and atmospheric deposition. Additionally, MPFs can be directly released into the environment by improperly disposing of consumer products containing these fibres, such as non-woven hygienic products. A comprehensive approach is necessary to address this pressing issue, including understanding the sources, pathways, and potential risks of MPFs. Immediate action is required to manage contamination and mitigate MPF pollution. This review paper provides a systematic literature analysis to help stakeholders prioritise efforts towards reducing MPFs. The key knowledge gaps identified include a lack of information regarding non-standardised test methodology and reporting units, and a lack of information on manufacturing processes and products, to increase understanding of life cycle impacts and real hotspots. Stakeholders urgently need collaborative efforts to address the systematic changes required to tackle this issue and address the proposed opportunities, including targeted government interventions and viable strategies for the industry sector to lead action.

Efficient and sustainable production of intelligent nonwovens as indicators of food spoilage through solution blow spinning of proteins and natural pigments from agri-food waste

The efficient manufacturing of food spoilage indicators based on intelligent nonwovens represents a promising alternative to enable the application of these materials in food quality monitoring. The objective of this study was to rapidly produce intelligent nanofiber nonwovens made of zein/gelatin (Z/G) functionalized with various concentrations (5–15% w/w on the matrix) of anthocyanin-rich food-residue extracts from purple cabbage (CAE) or purple sweet potato (PAE) using the solution-blow-spinning (SBS) technique for use in food-quality-monitoring applications. The addition of CAE or PAE to the Z/G matrix reduced the viscosity of the solution and (consequently) the nanofiber diameters from 999 nm to 882 and 583 nm, respectively. Such incorporation also improved the mechanical, thermal, and water-related properties of the nanofibers and endowed them with antioxidant capacities. Nonwovens composed of Z/G nanofibers with added CAE or PAE, especially at concentrations of 15%, exhibited visible color changes (ΔE ≥ 3) that rapidly altered in response to pH (3–10) and when exposed to ammonia vapor. The nonwovens were successfully used to monitor the deterioration of pasteurized milk and fish fillets. They reveal a visual color change from pink at 0 h to a more intense pink at 48 h in response to milk deterioration and a color change from pink at 0 h to light brown after 48 h when the fish fillets were considered deteriorated. The use of these nanofiber nonwovens to monitor changes in food quality highlights the significant potential of the SBS technique and the use of anthocyanins from agri-food waste to produce new intelligent packaging materials for use in food applications.

Expected Value of the Occupation Times of Brownian Motion

Occupation times of a stochastic process describes the amount of time the process spends inside a spatial interval during a certain finite time horizon. It appears in the fiber lay-down process in nonwoven production industry. The occupation time can be interpreted as the mass of fiber material deposited inside some region. From application point of view, it is important to know the average mass per unit area of the final fleece. In this paper derive an expression for the expected value of the occupation times in terms of Gaussian error functions.

Development of technology for nonwovens with antimicrobial properties

The article presents data on the development of nonwovens with antimicrobial properties using anavidin, polyethylene glycol and copper sulfate. The production of nonwovens is booming all over the world. In terms of their properties, nonwovens successfully compete with fabrics and replace them, and in some properties they are superior to traditional textile materials. For the production of non-woven fabrics, more than half is still accounted for by natural fibers: cotton, wool and linen fibers, waste from the processing of natural fibers, regenerated fibers. In this work, the goal is to obtain nonwovens with antimicrobial properties. Technologies have been developed that give nonwovens stable antimicrobial properties. The physicochemical properties and mechanism of interaction of the applied components have been investigated. The optimal technological parameters for the production of antimicrobial nonwovens have been determined. The development of a new technology of nonwovens with improved physical, mechanical and functional properties will help to apply nonwovens in medicine and other areas that require bacteriostatic, bactericidal and fungicidal properties of textile materials. Therefore, in order to obtain nonwovens that would meet all the requirements of domestic and foreign enterprises, it is advisable to modify both fibers and impregnating compositions.

Design Potential of Technical Hemp and PLA Nonwovens

ABSTRACT The main purpose of the article is to present the potential use of hemp fibers as reinforcement in composites, but from a design perspective. The authors ask whether sustainable nonwovens, produced based on natural fibers, have the potential as a material for designers and artists and not only as a technical textile. Technical production of nonwovens like carding, punching and laser cutting was used to achieve not just functional, but also aesthetic quality of the samples. The possibilities of utilizing natural materials for design endeavors were presented. The production process of these items was described, along with the main design concept. Research was carried out through a series of interdisciplinary activities, using the knowledge and tools typical for textile and materials engineering, as well as the methodology and strategies derived from the fields of visual art and design. It has been shown that during the development of a new sustainable material significant attention should be paid to design aspects, so it shows its full potential, as not just being eco-friendly, but also functional and aesthetic. While technical hemp and PLA composites have been produced and studied before, the design aspect is unique in the current study.

Towards autonomous learning and optimisation in textile production: data-driven simulation approach for optimiser validation

AbstractThe textile industry is a traditional industry branch that remains highly relevant in Europe. The industry is under pressure to remain profitable in this high-wage region. As one promising approach, data-driven methods can be used for process optimisation in order to reduce waste, increase profitability and relieve mental burden on staff members. However, approaches from research rarely get adopted into practice. We identify the high dimensionality of textile production processes leading to high model uncertainty as well as an incomplete problem formulation as the two main problems. We argue that some form of an autonomous learning agent can address this challenge, when it safely explores advantageous, unknown new settings by interacting with the process. Our main goal is to facilitate the adoption of promising research into practical applications. The main contributions of this paper include the derivation and formulation of a probabilistic optimisation problem for high-dimensional, stationary production processes. We also create a highly adaptable simulation of the textile carded nonwovens production process in Python that implements the optimisation problem. Economic and technical behavior of the process is approximated using both Gaussian Process Regression (GPR) models trained with industrial data as well as physics-motivated explicit models. This ’simulation first’-approach makes the development of autonomous learning agents for practical applications feasible because it allows for cheap testing and validation before physical trials. Future work will include the comparison of the performance of different agent approaches.

Numerical investigation of roping in multi-die meltblowing

This work aims at conducting a numerical investigation of the effect of the inter-die distance on the probability of roping during meltblowing. The results are qualitatively compared with the experimental data obtained by the present group in studies of roping in a model situation of solution blowing. The effectiveness of nonwoven products as filter membranes and others depends on the fiber size and geometrical fiber distributions in fiber mats. Jet roping in meltblowing results in a distortion of the laydown structure, which is detrimental to the product's efficiency. A quasi one-dimensional model is utilized here to predict the probability of jet–jet intersection in flight leading to roping, which was observed experimentally in the prior works of this group. The results of the present work are expected to be helpful in optimizing operating parameters to minimize roping in meltblown products.

A novel non-woven fabric from bamboo fiber in medical lifestyle products

The present study aims to investigate the appropriate size of bamboo fibers derived from waste bamboo and determine the optimal duration for soaking in bio-fermented water to facilitate fabric molding. Additionally, we seek to explore the properties of non-woven fabric products manufactured from bamboo fibers. The study factors encompass three grades of bamboo fibers, designated A, B, and C, as well as five levels of fermentation time: 2, 4, 6, 8, and 10 days. A Completely Randomized Design (CRD) experiment is planned to assess both physical and microbial properties. Furthermore, we will analyze the inhibition of Staphylococcus aureus (S. aureus) and Escherichia coli (E.coli) bacteria in accordance with AATCC test standards and determine the optimal ratio for non-woven fabric molding. Regarding the ratio of bamboo fiber to polyester fiber, we will investigate three levels: 50:50, 70:30, and 100:0, with the objective of designing medical lifestyle products.Preliminary findings indicate that grade B bamboo fibers exhibit a light brown color and a relatively thin structure, with lengths ranging from 1 to 3 cm, rendering them suitable for most fabric production processes. Notably, unfermented bamboo fibers demonstrate higher inhibition of S. aureus and E.coli bacterial growth compared to their fermented counterparts. Additionally, our results suggest that the ingredient ratio significantly impacts the molding process, with a 99.94% effect. Remarkably, a blend of bamboo fiber and polyester fiber in a 70:30 ratio can be mechanically processed to create needle-pressed fabric, utilizing a method that involves pressing and tight weaving. This innovative approach facilitates the production of antibacterial non-woven fabric products suitable for elderly individuals, ready for practical use in community settings as a best practice solution.

Scalable, high-strength, wear-resistant, antibacterial polyethylene micro-nano fiber protective materials

Polyethylene (PE) fibers, known for their exceptional mechanical and protective properties, have found valuable applications in personal protective equipment during the COVID-19 pandemic. However, traditional PE fibers lack inherent antibacterial properties, making them susceptible to microbial contamination and potentially contributing to the secondary transmission of pathogens. Therefore, the development of antibacterial PE fibers holds paramount importance. Here, we successfully develop high-strength, wear-resistant, and antibacterial PE fibers by applying a dip-coating process with polylactic acid (PLA) solutions containing ZnO-Ag nanoparticles onto the surface of PE fibers. These antibacterial PE fibers exhibit an impressive antibacterial rate exceeding 99.9% against common bacteria, a tensile strength of 33.7 MPa, along with outstanding wear resistance, wearing comfort, and washing stability. Furthermore, continuous production of antibacterial PE nonwovens is achieved by combining roll-to-roll and dip-coating processes. Therefore, the excellent properties and industrial-scale production potential of antibacterial PE fibers position them with broad application prospects in the fields of medical protection, biochemical protection, and beyond.

Remediation of Per- and Polyfluoroalkyl Substances in Nonwoven Production and Paper Sectors: A Brief Review

Per- and polyfluoroalkyl substances are a growing concern in the paper and nonwoven industry, as current research provides alarming results regarding the abundance and persistence of these substances from food packaging producers. It was reported that per- and polyfluoroalkyl substances have been detected in blood serum of thousands of individuals originating from food packaging that contains per- and polyfluoroalkyl substances. In addition, 20–56% of all products tested had detectable levels that immensely contribute to dietary exposure. Paper mills are also a significant source of exposure due to environmental contamination surpassing emission regulations set by the Environmental Protection Agency by over 100,000 parts per trillion. These studies exemplify the necessity for paper-based product producers to not only abide by regulations but also demonstrate the implementation of remediation efforts. With current research on novel remediation techniques and increased restrictions surrounding per- and polyfluoroalkyl substance usage for water repellency, decreased contamination and exposure will be achieved throughout the world. This article serves as a brief review that focuses on the nonwoven manufacturing sector, which includes pulp, paper, and tissue related to per- and polyfluoroalkyl substance contamination in the environment and drinking water sources. This review addresses the statistical evaluation of per- and polyfluoroalkyl substance levels throughout the world from paper and nonwoven product manufacturing, along with remediation methods and legislation to reduce contamination and exposure. To the best of our ability, this important and sensitive subject area has been researched extensively. However, many data gaps are present within the field, and limited studies have been conducted contributing to this brief review, which highlights the importance of further studies surrounding per- and polyfluoroalkyl substances in the paper and nonwoven sectors. This article encompasses all available information in the paper and nonwoven sector regarding per- and polyfluoroalkyl substances that can be used for reference by the general public and by manufacturers in the nonwoven production industry.

The tension fluctuation and packaging quality control of nonwoven winding

In order to improve the package quality of nonwoven and reduce the defects in the nonwoven production process, the tension fluctuation in the winding process is studied. A winding device is built to package nonwoven, and the measured data of tension fluctuation is obtained. The tension fluctuation characteristic of the measured data is analyzed, and different tension fluctuation simulation curves have been set. Under different simulation curves, the corresponding package stress distribution is calculated, and the influence of tension fluctuation on package quality is analyzed. Accordingly, a fuzzy proportional integral differential (PID) control strategy is proposed to optimize the winding device to improve nonwoven product quality. Matlab establishes the PID and fuzzy PID simulation models, proving that fuzzy PID can significantly improve the system control performance.

Comparison of structure and aerobic disintegration of air-laid, foam-laid and carded biobased nonwovens

Composting offers a potential sustainable end-of-life pathway for nonwoven products that may aerobically disintegrate and eventually biodegrade. Enhancing the biodegradation of nonwovens typically involves incorporating biobased biodegradable fibres. This study explores how nonwoven web formation and consolidation impact aerobic disintegration in composting. Laboratory-scale air-laid, foam-laid and carded sheets (40, 60, and 100 g/m2) with 80 wt% viscose and 20 wt% polylactic acid (PLA) fibres were prepared and thermally bonded. The sheets were characterised by physical and tensile properties, air permeability, water absorption, surface morphology, pore structure and aerobic disintegration in synthetic biowaste media. The nonwoven web formation process affected sheet density and air permeability, while tensile strength and elongation showed dependency on fibre length and orientation. Over 62 days, carded nonwovens showed the highest degree of aerobic disintegration (81%–88%) followed by foam-laid (64%) and air-laid (47%) nonwovens. Scanning electron microscopy (SEM) and X-ray tomography revealed less effective bonding within the carded sheets with 38 mm mono-component PLA fibres compared to the air-laid and foam-laid sheets containing 6 mm bi-component PLA fibres. Denser thermally bonded fibre clusters in air-laid and foam-laid sheets reduced degree of aerobic disintegration. These findings highlight the significance of fibre length, bonding and sheet homogeneity in aerobic disintegration, emphasising the importance of nonwoven web formation and consolidation processes.

Process Prediction and Feature Visualization of Meltblown Nonwoven Fabrics Using Scanning Electron Microscopic (SEM) Image-Based Deep Neural Network Algorithms

Meltblown nonwoven fabrics are used in various products, such as masks, protective clothing, industrial filters, and sanitary products. As the range of products incorporating meltblown nonwoven fabrics has recently expanded, numerous studies have been conducted to explore the correlation between production process conditions and the performance of meltblown nonwoven fabrics. Deep neural network algorithms, including convolutional neural networks (CNNs), have been widely applied in numerous industries for tasks such as object detection, recognition, classification, and fault detection. In this study, the correlation between the meltblown nonwoven fabric production process and performance was analyzed using deep neural network algorithms for classifying SEM images. The SEM images of meltblown nonwovens produced under various process conditions were trained using well-known convolutional neural network models (VGG16, VGG19, ResNet50, and DenseNet121), and each model showed high accuracy ranging from 95% to 99%. In addition, LRP (Layer-wise Relevance Propagation) and Gradient-weighted Class Activation Mapping (Grad-CAM) models were applied to visualize and analyze the characteristics and correlation of the SEM images to predict the meltblown nonwoven fabric production process.