What is Nonwoven Fabric? 

Nonwoven fabrics are the fabrics that are produced directly with the use of fibers. Unlike woven fabrics, this fiber does not require to be converted into a yard to produce the final product. On the contrary, to produce them, small fibers are laid in the form of sheets and converted into fabric by bonding the fibers together. The bonding can be done chemically, mechanically, or with the help of heat or solvent treatment. There are several methods of producing nonwovens. Out of all the ways, spunbond is one such significant way of manufacturing unwoven materials. 

Some crucial processes of producing nonwovens are discussed below: 

Melt-blown Fabric 

Melt-blown fabrics are manufactured by using polymer fibers. The melted fibers are ejected from a spinnet consisting of holes. The material extrudes and stretches as a sheet. And finally, the stretched fibers are cooled by passing hot air through them and are converted into meltdown fabric rolls. 

The melt-blown fabric can be used for various purposes, including masks, PPE kits, air filtration cloths, liquid filtration equipment, cleaning cloths, oil-absorbing materials, shoe liners, bags, tea bags, and others. 

In the prevailing pandemic conditions, the melt-blown fabric has been widely used for producing healthcare products, including masks and PPE kits. They are manufactured using spunbond nonwovens, nonwoven melt-blown fabrics, and cotton fabric to ensure protection from harmful viruses in the air. 

Spunbond Nonwoven Fabric 

Spunlaid, or spunbond nonwovens, can be manufactured in a continuous process. In the process, the fibers used are primarily spun, and then with the help of deflectors, they are spread on a sheet. Spunbond is comparatively a faster way of producing polymer nonwovens as the technique results in faster belt speeds and manufactures low-cost products. 

The nonwoven materials manufactured using the meltdown technique have lower intrinsic strength than the spunbond. Consequently, the melt-blown fabrics are mixed with the spunbond fabrics to produce much stronger and more resilient nonwoven products through the technique of spun-melt-spun, also called SMS fabrics. These fabrics, made with polypropylene (PP), are waterproof and can be utilized for use-and-throw purposes. 

Staple Nonwoven Fabric

Using the staple method is another technique for producing nonwoven fabrics. Staple nonwovens are manufactured following four steps. In the first place, the fibers are spun and then put into bales, followed by the blending process. After the fibers are blended, they are spread over a convoy belt and are finally laid in a web to produce the final product. The thermal technique of bonding or resin is used for bonding the fibers to produce staple nonwovens. 

The aforementioned techniques are amongst the most famous ways of producing nonwoven fabric. However, other methods like air-laid and wet-laid methods are widely used to produce fabrics without yards.  Differences Between Woven and Non-Woven Fabrics

Besides the use of yarn for the production of woven materials, several other factors differentiate woven fabrics from nonwoven ones. Some prime differences between them are: 

Importance of Spunbond Nonwoven Fabrics 

Nonwoven spunbond fabrics do not require yards or sewing for their production. The manufacturing process is much easier than any woven fabric, which leads to the affordability and durability of the product. This makes them a drable for people, fashion enterprises, furniture manufacturing organizations, the healthcare sector, and sanitary producers. 

A few reasons why the importance of nonwoven spunbond fabrics has grown manifold over the years are: 

The above-mentioned benefits demonstrate why the fabric industry foresees a heavy rise in the market of spunbond nonwoven fabrics. Even today, many manufacturers and industries have switched to using nonwoven products for the advantages associated with their use. 

Applications of Spunbond Nonwovens 

Spunbond nonwovens can be consumed for multiple purposes like disposable masks, use and throw gloves, child diapers, sanitary napkins, house wraps, etc. However, the application of these types of nonwovens is not only limited to these uses. They are required for several other motives like: 

In addition to all the applications of spunbond nonwoven materials, what sets them apart are their environmentally friendly properties. In the modern-day, when the world can see and experience the repercussions of climatic change, industries must become conscious of their surroundings and adapt themselves to more sustainable ways of manufacturing products. With its biodegradable factors, many businesses and leading industries increase their use of nonwoven fabrics.