Research in textile science has recently allowed for the invention of what has been coined spunbond nonwovens. Different from traditional textiles, rather than converting fibers to fabrics, spunbond nonwovens convert polymers to fabrics. The process of converting polymers to fabrics, in the case of spunbond nonwovens, begins with the extrusion of semi-crystalline polypropylene (PP) into a dope. The dope is deposited, in a random fashion, on a moving conveyor. A calendaring process is then used to create the nonwoven fabric, as well as crosslink the PP. Crosslinking, in effect, creates a mechanical interlock between adjacent filaments, giving the fabric strength. There are a number of other properties of spunbond nonwovens which include low moisture regain, low surface energy, oil/grease resistance, and a lightweight structure.
Nonwovens from polypropylene can be used in various markets including Healthcare, Agriculture, Commercial and Industrial and other packaging and filtration markets. Nonwovens outperform traditional woven or paper products in filtration. Emerging trends on the western coast of India show investments in both material and process to engineer high performance technical, functional and sustainable fabrics. Investments in fabric structures ensure a competitive edge for the industry.
Chemical Durability
Spunbond nonwovens are structure and physically-bonded webs of molecular dimensions, which provide them with the ability to withstand extreme environments and mechanical loadings. As a nonpolar polymer, PP spunbond non woven fabric manufacturer in gujarat do not attract nor retain moisture, therefore, these fabrics are waterproof and fungus proof. Spunbond fabrics are resistant to most common chemicals and alkalis. Special properties of spunbond fabrics are the result of additives, if any, used during extrusion. These properties may include, but are not limited to, flame retardancy, anti-static, and hydrophilic.
Nonwovens are an important barrier against contamination and biohazards in the healthcare and personal care industry. The micro-porous structure of Spunbond allows for the passage of air, and therefore, provide a barrier against air-born particulates and liquid splashes. A balance has to be struck between the barrier and air permeability to ensure that the user is not uncomfortable while using the product and can easily breath. Light weight and flexibility of nonwovens and membranes make them suitable for use in linings in shade houses, green houses and floating row covers. Other applications of technical nonwovens in agricultural engineering includes protective covers, bin liners, and fruit and vegetable baskets and boxes.
Critical Role in Healthcare and Personal Hygiene Infrastructure
Nonwoven polypropylene is a core component of the barrier technology in the healthcare and personal hygiene industry. Spunbond materials are particularly efficient in blocking airborne particles and viruses and also liquid splashes. Spunbond nonwovens are breathable, which results in user comfort and ease in breathing. Nonwoven materials are used in the production of surgical face masks, medical isolation and surgical gowns and other personal protective equipment (PPE). Pure polypropylene, being biologically inert, is skin safe and hypoallergenic, making it ideal for PPE used over prolonged periods of time, as it will not cause skin irritation or allergic reactions. In the field of personal hygiene, spunbond nonwoven materials are used in the acquisition distribution and back sheets of diapers.
Agricultural Engineering Potential
Tech nonwovens are used in several protective covers in agricultural engineering. As floating row covers and greenhouse linings, they offer crop protection from adverse weather conditions, pests and birds. Depending on the cover structure, they are able to create beneficial microclimates for crops and also help with seed germination. Shade barriers help with crop protection from scorching sun and heavy rains. Nonwovens can be effective as a physical barrier to control insects and pests and/or birds and airborne weed spores, thus reducing the use of pesticides and herbicides. Nonwovens, for instance, allow passage of air, water and light, and thus can help retain soil moisture. This can help achieve improved and balanced crop growth.
In healthcare and personal hygiene, polypropylene non-woven fabrics are a critical barrier to contamination and biological risks. A micro-porous structure of spunbond nonwovens enables passage of air, thereby providing a barrier against airborne particulates and allowing the passage of liquid splashes. There should, however, be a balance between achieving a barrier against a potential biohazard and allowing sufficient air to pass through the fabric to ensure ease of breathing by the user.
Spunbond Nonwovens in packaging
There are many applications of Spunbond Nonwovens in packaging, filtration, and furniture making industries. As single use packages are a growing concern for environment and landfills, Spunbond Nonwovens can be used as replacement of thin film packages. Some manufacturers of Spunbond Nonwovens have already manufactured reusable tote bags and luggage covers. Since Spunbond Nonwovens have high load capacity, they can be used in air and liquid filtration. Spunbond Nonwovens are made of randomly laid ultrathin filaments which can provide a path for dust and oil. Therefore they can be used for filtration in industrial HVAC systems and processing lines. Nonwovens can also provide anti-sag and sound dampening properties. Therefore, Nonwovens have been used for a long time in pocket spring enclosures, dust linings and other furniture linings. Nonwovens and membranes can be used in lightweight, floating row covers, linings for greenhouses and shade structures. Other agricultural engineering applications include protective covers and bin liners, fruit and vegetable baskets and boxes.
Advantages of a Regional Manufacturing Hub
In industrial procurement, a leading non-woven manufacturer in Gujarat has several advantages including, but not limited to, technology and infrastructure as well as an efficient supply chain. Gujarat is at the forefront of polymer and technical textiles processing. Some of the most recent, state-of-the-art, nonwoven lines in Gujarat incorporate multiple beam extrusion and SMS systems, thereby enabling the production of nonwovens with weight uniformity and high tensile strength. With its manufacturing units located in the proximity of refineries, Gujarat has the added advantage of relatively low cost supply of polymer resins. Furthermore, the state has world class infrastructure and the easily accessible, west coast, ports of India which help transport goods to the International markets of North America, Europe, Africa and the Middle East.
Environmental Sustainability and Circular Economy
Continued growth in the regulation of the industrial supply chain increases the demand for efficiency of the use of resources and decreases the negative impact of industrial activities on the environment. Nonwoven fabrics produced from polypropylene (Spunbond PP nonwovens) are highly recyclable and extremely sustainable, technical textiles. Complex, multi-material, woven fabrics, produced from numerous different types of natural and man-made fibers (chemically or rubber bound together), end up in landfills. Spunbond nonwovens, melted and reformed, can be collected and returned to the industrial supply chain. This process is truly closed-loop and nearly waste-free. Off-spec product and edge trims are immediately re-melted and re-processed to re-enter the raw material feed. Nonwovens, in general, and Spunbonds, in particular, can be a replacement for single or multi-use plastic and paper wraps and carriers and serve the circular economy.
Conclusion
Nonwovens from polypropylene have potential in various markets such as Healthcare, Agriculture, Commercial, Industrial and other Packaging and Filtration markets. Nonwovens outperform traditional woven or paper products in the Filtration market. New developments in the textile industry, on the western coast of India, are in the direction of designing high-performance technical, functional and sustainable textiles. Process and material innovation help fabrics gain a competitive edge in the textile industry.
Nonwovens is a section of textile science that has a lot of prospects for research. Traditionally, Hydrophilic non woven fabric used for packing desiccant pouches are made by interlocking threads to create a web. In a process similar to producing fabrics, a thermoplastic polymer is melted to produce a dope that is extruded to produce a web that is deposited on a moving surface. Nonwovens are used in making products like surgical gowns, implantable cardiac pacemakers and filters. Polypropylene is a thermoplastic polymer and the largest volume synthetic polymer. It is melted and extruded to produce Spunbond nonwovens.
Frequently Asked Questions (FAQs)
What is PP Spunbond Non Woven Fabric and how is it produced?
PP Spunbond Non Woven Fabric is produced from polypropylene. In a process similar to producing fabrics, a thermoplastic polymer is melted and extruded to produce a continuous filament. The filament is randomly distributed and fused on a moving surface to form a web.
What are the key industrial advantages of spunbond nonwovens over traditional woven fabrics?
Spunbond nonwovens are lightweight, water/chemical resistant, air permeable, flexible, have high tensile strength, and are less expensive to produce than traditional fabrics. Also, the process of producing nonwovens is less labor intensive than the process of producing fabrics.
How is PP spunbond nonwoven fabric used in agricultural crop protection?
Spunbond nonwovens are used in floating crop covers and greenhouse liners that protect crops from environmental conditions such as frost and heat and from pests such as insects and hail. These fabric covers allow the passage of air, water and light.
Who is the largest supplier of PP Spunbond Non Woven Fabric?
Singhal Landscape Geotextile is one of the largest suppliers of PP Spunbond Non Woven Fabric.
What are the benefits of Nonwoven Materials?
The PP Spunbond Non Woven Fabrics manufactured by Singhal Landscape Geotextile are weatherproof, have high tear strength and other characteristics and are customized as per your requirement in terms of GSM and color. These fabrics are used in agriculture, industry, medicine and other allied fields.
