Web Formation Technologies

Web formation methods creating fiber assemblies: (1) Drylaid/Carding—staple fibers (25-100 mm) fed to carding machine (same as yarn production) forming thin web (10-50 GSM), cross-lapped or parallel-laid onto conveyor achieving target weight (20-400 GSM), speeds 100-250 m/min, random fiber orientation (parallel laid) or cross-directional (cross-lapped improving MD/CD balance), 40% of nonwoven production. (2) Airlaid—fibers (3-50 mm, including pulp, super-absorbent polymers) dispersed in airstream, deposited onto forming screen via vacuum creating uniform, isotropic webs (50-500 GSM), speeds 150-400 m/min, excellent absorbency for hygiene products, 8% of market. (3) Wetlaid—fibers suspended in water (0.01-0.1% concentration), deposited on screen similar to papermaking, forming ultra-uniform webs (20-200 GSM), speeds 200-500 m/min, used for wipes, medical products, specialty papers, 5% of production. (4) Spunbond—polymer extruded through spinnerets, filaments drawn and deposited directly onto conveyor forming continuous filament web (15-200 GSM) in single step, speeds 300-800 m/min, 35% of market. (5) Meltblown—polymer extruded and attenuated via high-velocity hot air creating microfibers (0.5-10 μm), directly deposited forming web (15-100 GSM), speeds 200-500 m/min, filtration, barrier fabrics, 12% of production.