Future of Spunbond & Meltblown Nonwoven Production Technologies

1. Trends of spunbonded nonwovens production technology

1) Low denier (fine denier )

Currently, spunbond nonwoven fabrics are trending towards the use of low-denier fibers. Spunbond fabrics made from fine fibers—defined as having a linear density of less than 0.5 dtex (equivalent to 0.45 denier)—exhibit improved performance, a superior hand feel, and enhanced barrier properties. Many of the functions of these ultrafine fibers can effectively replace those of meltblown fabrics.

2) Bi-component spinning, diversified fiber cross-sections

The BICO nonwovens’ performance can be greatly improved. Spunbond fabric made from bicomponent fibers can be consolidated at a lower calendering temperature, ensuring the fabric has a pleasant texture and adequate strength.

3) Used in the manufacture of durable clothing

Spunbond nonwovens were initially primarily used in the production of non-durable clothing. However, advancements in elastomeric polymers and bicomponent fibers have significantly enhanced the drape, elasticity, breaking strength, dimensional stability, and texture of spunbond nonwovens. These improvements have made it possible for spunbond nonwovens to be utilized in the manufacturing of durable clothing.

4) Interpenetration between different processing technologies

The penetration of spunbond, meltblown and other web-forming processes.

a. Spunbond technology assimilating features of melt-blown technology

This refers to manufacturing spunbond nonwoven fabrics by using technologies unique to meltblown process. This method consumes raw materials with a high melt index (app. MFI 700) and involves spinning at a higher speed (exceeding 6000 m/min) compared with traditional spunbond processes. As a result, it is possible to produce fibers as fine as 0.22 dtex (0.2 denier) or even finer.

Such process can produce nonwovens with characteristics similar to that of meltblown fabric. Since hot air stretching is not necessary, the production costs can be significantly reduced compared with traditional meltblown technology.

b. Apply functional treatment

Numerous new nonwovens with outstanding performance can be made by combining various web-forming processes and materials, of which the most common ones are:

Spunbond and meltblown (SM, SMS), spunbond and carded web (SC, SCS, CSC), spunbond, meltblown, and carded web (SMC), spunbond and airlaid (SA, SAS, ASA), spunbond, meltblown, and airlaid (SMA, SMAS), spunbond and wood pulp (SPS), spunbond and film composites (such as PE plastic film, breathable film, and metal film), etc.

2. Trends of meltblown nonwoven production technology

1) New polymers to be used for meltblown nonwovens

a. Diversified polymers

Although over 90% of meltblown nonwoven fabrics are produced from polypropylene (PP), some manufacturers have started to incorporate other materials such as polyester, polyester-based PBT, polyethylene (PE), elastic polyurethane (PU), polytrifluorochloroethylene, and nylon 6 to make high-performance nonwovens. Additionally, bi-component meltblown equipment has been introduced into production.

b. High temperature resistant polymers

Meltblown fabrics made from these polymers exhibit high strength and cannot be dissolved by any solvent below 200°C. They remain stable and do not degrade even at temperatures reaching 400°C. This innovative material holds great potential for applications in high-temperature air filtration and dust removal.

c.High elastic polymers

To address the issue of low elongation at break in conventional meltblown products, a special elastomer polyolefin resin has been developed. This new resin allows for the production of meltblown nonwovens with significantly enhanced elastic properties and can be processed on standard polypropylene equipment.

d. High performance polymers

A polymer has been developed for spinning filament that is over ten times stronger than conventional meltblown fibers. This material can be utilized in a spinning system to produce meltblown fabrics with SMS (spunbond-meltblown-spunbond) performance. In addition to significantly reducing production costs, it matches SMS products in terms of tensile strength, barrier properties, and filtration capabilities.

2) Advancements in meltblown manufacturing technologies

a. High hole density meltblown spinneret

The fiber diameter is significantly finer than that of typical meltblown products, resulting in improved performance.

b. Bi-component meltblown technology

The bicomponent meltblown equipment is capable of producing bicomponent fibers in various shapes, including sheath-core, side-by-side, tip trilobal, tip cross, and orange segment shapes. This advanced technology allows bicomponent meltblown fabric to address the limitations commonly found in standard meltblown nonwoven fabrics, such as low strength and poor wear resistance.

c. Meltblown technology assimilating features of spunbond technology

This also represents a convergence trend of various web-forming techniques. In this improved meltblown system, the traditional method of high-temperature hot air stretching has been replaced by a cooling process that utilizes devices such as water spray cooling, similar to the spunbond process. This change enhances the crystallinity and orientation of the fibers, addressing the previously low strength of meltblown fabrics. 

The fiber web is still self-bonded, and the finished product features high loft, appealing aesthetics, and good draping characteristics. Additionally, the elongation at break can reach 30% to 40%, making its performance comparable with that of spunbond products.

3) Meltblown nonwovens composited with other materials

In addition to the standard SM and SMS composite nonwovens, meltblown fabrics can be combined with various other materials. These include meltblown fabric combined with woven or knitted fabric, or other nonwoven fabrics, or different types of fiber webs.

When meltblown fabric is combined with other materials, the meltblown fibers are dispersed within the fiber structure of these materials and become entangled with one another. This process creates a new structure that enhances the fabric's characteristics, including softness, strength, uniformity, friction coefficient, and overall feel of the surface.

Meltblown composite fabrics are mainly used as materials for wiping, filtration, and hygiene, etc.

3. Trends of SMS composite nonwoven production technology

The production technology of SMS composite nonwovens is a comprehensive embodiment for melt spinning know-how.

At present, SMS production lines are advancing towards multiple spinning systems (6 to 8) with high line speeds and fine fiber denier, capable of producing bi-component fibers. Key performance parameters include a maximum width of 7000 mm, speeds of up to 1200 m/min, a minimum basis weight of 7 g/m², a spunbond capacity of 270 kg/(h·m), a minimum fiber fineness of 0.9 dtex, a meltblown capacity of 70 kg/(h·m) with a minimum fiber diameter of 1-5 μm.