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Popularity & Utility of Non-Woven Fabrics Today and Its Future

There is a nonwoven fabric almost anywhere you sit or stand. It can be a coffee filter, a teabag, a mask, diapers, lens tissues or similar other things. The current pandemic situation has given greater importance to this fabric but, its market was growing over the years.

What is Non- Woven?

Non-woven fabrics are the oldest and simplest textile fabrics. They are not knitted or woven. These fabrics are web structures or sheets that are bonded together by tangling filaments or fiber chemically, thermally or mechanically. These are tufted or flat porous sheets made from different plastic film, molten plastic or fibers. Since they are not woven or knitted, these fabrics do not need to be converted to yarn.

Some oil-based products and recycled fabrics are used for producing non-woven fabrics. Certain nonwoven fabrics can also be recycled under proper facilities and treatment. That is why, nonwoven fabrics are considered to be more ecological for some applications especially in industries like luxury accommodations, nursing homes, schools and hospitals.

How Non-Woven Fabrics are Use

Non-woven fabrics are used in multiple industries like protective, geotextile, construction, filtration, automotive, apparel and medical. This fabric is widely used nowadays and has become and it seems that life will be incomprehensible without non-woven fabric. This fabric is of two types – disposable and durable. 60% of the fabric is durable and 40% of it is disposable. The distinct properties of non-woven fabric are –

  • Filtration
  • Acoustic insulation
  • Thermal insulation
  • Cushioning
  • Flame retardancy
  • Strength
  • Softness
  • Stretch
  • Resilience
  • Liquid repellence
  • Sterility
  • Absorbency

The industries where non-woven fabrics are used are –

  • Household
  • Furnishing
  • Packaging
  • Medical
  • Apparel
  • Acoustics
  • Transportation
  • Industrial
  • Construction and Geotextiles
  • Health and Hygiene

From diapers, surgical gowns and protection clothing to packaging materials and pillows, non-woven fabrics are used everywhere.

Why Use Non-Woven Fabrics?

Non-woven fabrics are essential, adaptable, decomposable, versatile and creative. Yarn preparation is not required in production of this fabric since they are produced directly from fibers. Hence, their manufacturing process is also easy and short. It takes 6 months for producing 5,00,000 meters of woven fabric whereas the same amount of non-woven fabric can be produced in 2 months. The production cost of non-woven fabrics is also low and they have some specific properties.

It is said that non-woven fabrics have opened up the opportunity for “everyday convenience”. In this COVID-19 situation, demand for medical and hygiene products made from non-woven fabrics has increased a lot.

Find the best Meltblown Non Woven Fabric Manufacturer.

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How To Distinguish Between The Woven And Non-Woven Fabrics?

Fabric is a man-made material created on antiquated occasions and still has incalculable utilizations right up ’til today. As an agreement maker, we have long periods of work on sourcing the ideal materials for a venture dependent on the requirements of the customer. The primary fabric distinguisher is whether the fabric is woven or non-woven. How the fabric is made can contribute to what it is utilized for.

Woven Fabrics

Woven fabrics are the more customary of the two fabrics. Weaving various strings together oppositely to one another makes woven fabrics. The strings that run upward through the fabric are the twist strings, and the weft is the string that runs evenly. Basically, the weft is the cross string and the blend of twist strings is the base. To weave, you essentially substitute going over and under a twisted string with a weft string. Ideally, the way toward weaving would happen with the twist strings extended on a loom. The strength of the woven fabric relies upon the sort of string or yarn utilized, and the way that it very well may be created from various filaments makes a woven fabric flexible. An incredible dominant part of garments fabric is made utilizing weaving, including shirts, pants, and even denim.

Non-Woven Fabrics

Non-woven fabrics are long strands that have been reinforced together utilizing some sort of warmth, substance, or mechanical treatment. There is no weaving or manual development included. Non-woven fabrics have a wide range of employments; including fluid repellence, stretch, warm protection, and can go about as a bacterial obstruction. Non-woven fabrics have a scope of qualities and can be made more grounded by adding extra help backing. They also will in general be the more moderate decision, as these fabrics are more affordable to deliver and speedier to fabricate. By and large, woven fabrics are more tough and solid than non-woven. This is because of the way that woven fabrics are supported by string crossing string, which makes a solid hindrance.

While there are episodes that a non-woven could be more grounded than woven fabric, non-woven fabrics solidness is altogether subject to how it is made. For instance, an expendable plastic pack and a careful outfit are the two instances of non-woven materials, but it is clear which should be more grounded.

If you are planning an item, it’s essential to gauge the highlights that you need the item to have to choose what kind of fabric you need. “Woven” and “non-woven” are umbrella classifications to different kinds of fabrics – nylon, denim, cotton, polyester, and so on Concluding whether to utilize a woven versus a non-woven is an incredible spot to start the fabric choice cycle.

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Are Meltblown Fabrics Suitable for N95 and Surgical Masks?

Scientists are doing research to find a highly efficient fabric that can provide the best protection against Coronavirus. The efficiency of a filtration material has become even more critical after recent studies proved that COVID is air-borne. Authorities recommend covering faces with good quality fabric in this coronavirus pandemic.

WHICH MATERIAL GIVES THE BEST PROTECTION?

Now, the question is, after several trials and research, have we found the material that offers the greatest protection? Experts have tried varied materials from vacuum bags, flannel pyjamas, pillow covers for making DIY masks. They have checked a wide range of items. Simply covering the face can lessen the contamination of coronavirus from some infected person through his sneeze or cough. But now, experts say that we have to move a step ahead than just covering the face to combat this air-borne spread, especially in some closed ambience.

HOW ARE SURGICAL AND N95 MASKS DIFFERENT?

N95 and surgical masks are made of highly efficient Spunbond and Meltblown filter fabric. Surgical masks are made from a rectangular piece of Meltblown filter media having pleated design and elastic ear loops. N95 are the best quality medical masks, and they can filter almost 95% particles which can be as minute as 0.3 microns. The surgical masks also have 60% to 80% filtration capacity.

WHY SHOULD WE HAVE MULTIPLE LAYERS IN MASKS?

A mask should not only have high efficiency but also must be made of multiple layers. The air filters should be able to shed off small fibers inhaling which can be risky to health. So, for proper filtration, there should be a layer of fabric between two cotton fabric layers. Multiple layers give utmost protection.

HOW MUCH BREATHABLE ARE NORMAL FABRICS?

There are some fabrics that can drastically reduce the breathability of masks. But, Meltblown fabrics have high efficiency and hence, offer the best breathability.

Features of Meltblown Fabric for Respirators and Masks

  • Meltblown fabric for FFP1, FFP2, FFP3
  • This filtration media has the efficiency of 99.8%, 99%, 95%
  • Their BFE > 99.99% and are suitable for surgical wear.
  • Have antimicrobial coated media.

Features of Spunbond for Outer and Inner Layer

  • They are available in 8 Gsm to 120 Gsm.
  • They are hydrophobic.
  • Hydrophilic
  • Their roll width is customizable according to the specific need.

Features of Surgical Wear

  • Media for head caps, shoe covers, surgical gowns.
  • Media are made for surgical applications.

Meltblown and Spunbond are the best fabric for making masks.

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Medical Grade Textiles – What are the Advantages?

Medical grade fiber or textile is a type of medical garment that has all the qualities and properties that are necessary for a medical or clinical setting. It can be used to make wearable organ holsters, wearable medical garments etc and also used for medical implants as flexible mesh. This kind of textile is often made with the help of biomaterial experts.

Meets hospital regulatory requirements

It is true that this kind of textile can be ideal to use in a medical or hospital setting. This is able to satisfy the regulatory requirements in a hospital, which means that the standards of hygiene, safety etc can be adhered to more easily with this type of fabric.

Comes with the assurance of biocompatibility

Any textile that is supposed to be used in a hospital or clinical environment must be biocompatible. When there is Biocompatibility, you can be assured that the textile will be able to integrate with the person who uses it, with no adverse effects.

Extensively clinically tested

One of the most major advantages of this kind of textile is the fact that it is extensively tested clinically. If there is a risk of malfunction in the type of clothing that is used in the medical world, there could be death or permanent damage. Thus, a wearable medical garment of this type – which is tested over and over again to ensure properness, is a better choice any day.

Can last for a long time

It is also true that this kind of textile can last for a long time, as it is supposed to, and you can find it being able to sustain a reasonable amount of wear. This is a durable garment and can also be used for implant purposes. During the clinical trials, it is put to test and found to come up with no issues or risks. As this type of textile can last for a really long time, it can be easier for clinical institutions to afford these. These can help offer better value for the money that is invested in the purchase of the same.

Washable

This type of textile is washable as well and can be kept clean with no major issues. Thus, it does not contaminate the user or lead to any infection. This kind of textile is safer to use for medical therapy and is found to be crucial for the maintenance of universal health and safety.

Reusable

It is also true that this kind of textile can be used over and over again, as a reusable medical garment or a medical wearable vest. A medical-grade textile, everything considered, maybe a gauze dressing for a wound, a hospital surgical tray cover, a sterile bandage or something simple likewise.

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What Makes PP Melt Blown Filter Media Perfect for Face Masks?

Designed to utmost perfection, face masks can ensure a lot of safety and hygiene to users. These are very safe to use, given that these contain no chemical or synthetic fiber that can pose health risks to users. These are a product of many hours of research and scientific studies. Find out why PP Melt Blown Filter Media happens to be the best non-woven medium for the creation of face masks, during the times of the Covid-19 pandemic.

 

Superior filtering characteristics:

Molten polymer resins are extruded by Melt blowing with the help of high-velocity air. Then, the air gets heated and fine fibers are formed by the resins. It indicates that these gather onto a screen, and can develop a nonwoven adhesive web which comes with various properties such as High opaqueness, Randomized fiber layer, Continuous fibers in length, Smooth surface texture and high surface area. Due to these qualities, melt blown webs are more appropriate for necessary filtration characteristics.

 

Standard melt blown webs come with fibers ranging in size between 2 and 5 microns on an average, and having a wide diameter distribution. Due to the kind of process and the usage of polymer, the fibers are not strong necessarily. However, the barrier properties of the fabrics are excellent and serve as perfect filter media materials. There is extensive usage of Melt down webs either standalone or as a component of composite structures for the purpose of very fine filtration, for the removal of bacteria and other fine particles, and in numerous applications as an absorbent product.

 

Improved porosity:

The properties of Melt blown adhesive makes them more advantageous over various other options, for the purpose of filtration media bonding, like High dirt holding capacity, High porosity and improved filtration efficiency. Thus, it is possible for Melt blown adhesive to have some prominent benefits over other filtration media bonding options.

 

The randomized fiber layer of Melt blown adhesives makes these extremely porous. These never penetrate the filter media deeply. Otherwise, these can have an effect on the efficiency of the same. It is also extraordinarily absorbent, and is hence – regarded as a great raw material for making face mask media and disposable surgical masks used by the masses today.

 

Eco-friendly:

The Modified meltblown process happens to be a one-of-a-kind approach for the production of submicron fibers that are much higher in magnitude and rates than industrial grade electrospinning can make possible. The meltblown technology is able to deal with many polymer blends and polymers. In this process, there is no difficulty with handling the solvent, environmental pollution or solvent residues in webs.

 

This is an eco-friendly material and the production process is friendly to the environment as well. Naturally, during the times of the Covid-19 pandemic, PP Melt Blown Filter Media has been regarded as the best kind of non-woven medium for making various face masks. It makes a terrific filter media for the filtration of air, and can work as a perfect protective measure.

Find the best Non woven fabric manufacturer for medical products.

 

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Why is PP Melt Blown Filter Media Best for Making Face Masks?

On these extraordinary occasions, it is obvious that great air filtration media that are utilized in masks is high in need. Attributable to which Melt blown innovation [PP Melt blown channel media] has seen a rising interest chart, particularly inside the clinical and cleanliness industry. In addition, the interesting attributes of melt-blown channel media by the way toward framing a web from liquid polymers without extending make the method phenomenal and exceptionally cost-productive.

Because of the uncommon absorbent properties of the PP Melt blown nonwoven texture filaments, they are viewed as superb crude material for planning expendable careful and N95 facemask media. Careful and N95 Masks producers across the globe are searching for acceptable quality melt-blown non-woven channel media to supply facemasks to the medical services/pharma and cleanliness industry.

Here, let us find out about the fundamentals of meltblown innovation, the crude materials used to plan nonwoven channel media, its advantages, and its applications.

What is Melt blown innovation?

Melt blown non-woven innovation is one of the incomparable and profoundly progressed procedures to get ready solid, remarkable, and dynamic channel media. The key fixings utilized are thermoplastic tar/PP that has significant absorption and durable properties.

What is the Melt blown assembling measure?

In the initial step, the thermoplastic pitch is warmed to a semi melting temperature. Whenever it is melted, the crude material is constrained out immediately through an extruder planned with an enormous number of openings; it is put in extremely close in the request of 1000-4000 openings for every meter.

These openings are made either by mechanical penetrating or direct combination of two plates that contain scratched channels. The pore size is intended to guarantee better filtration productivity and ensuring that it should not need extra help from another web. The melted color will be provided by a metering siphon.

High-speed blowers are set at specific points outside the extruder guaranteeing a fine stream fiber. The polymer goes through three different warming zones.

The thermoplastic tar as such changes into unlimited strands that are super meager and long and everything occurs in a matter of milliseconds.

What are the couples of most significant crude materials utilized for nonwoven channel media?

Particularly in these seasons of the pandemic, a top-notch PP melt blown nonwoven channel media is the most extreme material to fabricate top caliber, high filtration, and cleanliness material, beginning from N95 mask media to careful masks, to all body cover and other cleanliness material needed by cutting edge laborers and other clinical staff.

Picking the correct material is very interesting, however. The decision of material relies on the sub-atomic weight distribution and how effectively it tends to be transformed into fine filaments. The most well-known polymer utilized for melt blown innovation is Polypropylene normally known as PP. There are few assortments like polyester, polyamide, and polyethylene but that relies upon the need.

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How India ramped-up PPE Kit manufacturing during Pandemic?

Until January 2020, it was never thought that India will be manufacturing PP Coverall or PPE Kit. India started manufacturing these kits during pandemic situation. Earlier there were no PP Coveralls with seam tapes – the ones manufactured in India. India had around 2.75 lakh PP kits in January last year but most of them were imported from other countries. However, within a very short time, India ramped up and performed well in its production of PPE kits such that it produced 2 lakh kits in one day.

Efforts of PP Coverall manufacturers and Meltblown nonwoven fabric manufacturers of this country has enabled health workers to get the support in their emergency times and fight effectively against COVID 19. This support from the manufacturers has also allowed the workers to help people to recover fast.

WHY DID INDIA TAKE PROACTIVE MEASURES FOR PPE KIT MANUFACTURING?

PPE kits and PP Coveralls were mostly manufactured in China and they were also of poor quality. In the pandemic, anti-Chinese sentiments escalated amongst health workers and people globally. On the contrary, PPE kits and PP Coveralls became critical to ensure the safety of frontline health workers. So, Indian Meltblown fabric manufacturing and PP Coverall fabric manufacturing companies took measures for bulk production of these kits and Coveralls.

WHAT ARE PPE KITS MADE OF?

PPE kits have become an essential part of health workers nowadays. The kit consists of –

  • PP Body Coverall made of Microporous fabric which is further composed of Nonwoven Fabric having lamination of Micro-porous film.
  • N95 masks
  • Surgical masks
  • Headcovers
  • Gowns
  • Face shields
  • Shoe covers

The kit is made to provide comprehensive protection to healthcare professionals against coronavirus.

THE UTILITY OF PP BODY COVERALL OR PPE KITS

The primary goal of PPE Kits is to provide comprehensive and robust protection to the body, nose, eyes and mouth from infected droplets of coronavirus or other infectious viral or bacterial microbes. High-quality PP Coverall gives complete protection to the skin from any kind of virus and offer high resistance. PP Body Coverall and PPE Kits must be resistant to various body fluids like blood, phlegm, salivary droplets, mucus and so on.

Fit and form of these Kits and Coveralls should be maintained and for this reason, the fabric has to be high quality and the best microporous nonwoven. To have quality fabrics it is necessary that Meltblown nonwoven fabric manufacturer is a recognized one in the industry.

INTERESTING FACTS REGARDING PP BODY COVERALL AND PPE KITS

  • The government recognized domestic PPC Fabric manufacturers are of 110 varied types.
  • Ministry of Health and Family Welfare has provided guidelines for rational and optimum using of PPE kits.
  • Special instructions are also given governing the use of raw materials like Meltblown fabric, Spunbond fabric and other such materials required in the manufacturing of the kits and coveralls.

In other words, India has shown outstanding performance in manufacturing PPE kits and PP Coveralls.

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The Nonwoven Fabric Materials As The Most Environment Friendly Raw Materials

Nonwoven fabrics are materials that are often used for making products that are highly valued in the commercial and industrial sectors. They are known to be environment friendly and this is reflected by the fact that they are breathable, water repellant, incombustible and flexible materials. The nonwoven fabrics are also known for their innocuity and lack of any stimulation elements. These days the nonwoven fabrics can be found in different kinds of rich colors. The material that is used for making the nonwoven fabrics can undergo natural decomposition only within the span of about 90 days when they are placed outdoors. On the other hand, these fabrics can go through natural decomposition in about 8 years when they are kept indoors. The nonwoven fabrics can burn in tasteless and non-toxic fumes without leaving any residues. This means that nonwoven fabrics do not cause environmental pollution in any way.

The nonwoven fabrics are known to be very soft and breathable and they have a planar structure that is in line with the requirements of the New Type fiber items. There are many advantages to using these fabrics for production tasks. For instance, they can be used for making lint that is durable, tough and silky soft. They can also work as a powerful reinforcement and have a feel of high-quality cotton. The bags and other products that are made with the nonwoven fabrics are not only easy to construct but also quite cheap and affordable. Most of the companies that work with nonwoven fabrics typically use polypropylene non-woven fabrics. It is to be kept in mind that the plastic bags crafted out of polyethylene are very much different from the finished goods made from nonwoven fabrics.

One of the reasons to why the nonwoven fabrics have become so much popular in the recent times is that distinct chemical structure of the polyethylene material renders it great strength and stability, and it hardly ever decomposes naturally over the course of time. It can take around 300 years for the polyethylene bags to decompose. Polypropylene materials have got a rather weak chemical structure. Its molecular chains can break easily which means that it can degrade in its non-toxic form into the next cycle. Shopping bags made up of nonwoven materials can go through decomposition within a span of 90 days. The best thing about nonwoven bags is that they can be used several times.

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All That You Need To Know About Meltblown Fabric

What is meltblown nonwoven fabric? To put it plainly, it is like women’s sanitary napkins.

Execution qualities of soften blown nonwoven fabric:

  • Agreeable, soft and incredible hand feel, can straightforwardly contact the skin;
  • The upsides of fine filaments, little pores, and great solid boundary properties;
  • Brilliant uniformity of natural assurance and cleanliness.
  • Hydrophobic and lipophilic.

On account of the capacities referenced above, meltblown nonwoven fabric is broadly utilized in filtration and cleanliness materials, particularly veils. Dissolve blown nonwoven fabric feels as soft like paper but somewhat different, but its crude material is equivalent to the spun-reinforced nonwoven fabric. It is PP, which is polypropylene, and a modifier called IRGATEC CR76 is added to the meltblown non-woven fabric, spun-bond nonwoven fabrics, and SMS have their remarkable improved properties.

Coming up next is a short prologue to the capacities and application fields of meltblown non-woven fabric.

  • Channel/filter material

Filtration is a detachment cycle. Its permeable and little pores’ actual properties decide its solid hindrance properties, that is, fantastic filtration execution. If electrets treatment is added to build the electrostatic exhibition, the filtration impact can also be expanded. The above attributes of liquefy blown nonwoven fabric make it broadly utilized in clinical covers, indoor forced air system channel materials, channel materials, and so on

  • Clinical and wellbeing products

The crude material of the meltblown non-woven fabric is PP natural assurance material, so ecological insurance and sterilization execution also create it very well may be utilized in clinical items, for example, clinical covers, careful outfits, and so forth

  • Ecological security materials.

Its incredible adsorption impact can be utilized to adsorb grimy oil, for example, marine oil slicks, oil slicks from industrial facility gear, and sewage treatment.

  • Warm materials.

Meltblown nonwoven fabric has innate properties, for example, slenderness, softness, warmth, and great air penetrability. These attributes also make it utilized in apparel materials.

  • Other application territories. For example, electronic stomach materials.
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What Are The Main Technical Requirements For The Medical Nonwovens?

Nonwoven fabrics are widely used in the medical sector and they are preferred for numerous applications. For instance, they are used for making common masks, gloves and other types of protective clothing items. Specially chosen raw materials are used for making the medical nonwovens. These materials are not only good for making domestic disinfection components as well as cotton packaging tools. These materials can greatly prevent cotton dust pollution and as a result they are extensively used these days.

The medical nonwoven materials are used for wrapping the instrument boxes in order to prevent any kind of secondary contamination of the sterilized devices. The nonwoven materials are known for being flexible, breathable, non-toxic, waterproof and non-irritating, which is why they are loved by medical professionals. They are also known to deliver excellent results when it comes to working with pressure steam, low-temperature plasma, ethylene oxide as well as other types of sterilization packaging needs.

Main quality requirements of the medical nonwovens

The nonwoven packaging materials have to meet the following requirements:

  • Microbial barrier
  • Breathability
  • Water resistance
  • Saltwater resistance
  • Compatibility with human tissues
  • Toxicology experiments
  • Overhang
  • Surface absorption
  • Equivalent aperture
  • Tensile strength
  • Breaking resistance
  • Wet tensile strength

These are the requirements that nonwoven fabrics must adhere to in order to be considered suitable for medical use.

Storage environment requirements

The storage of the medical nonwovens should be performed in keeping with the YY/T0698.2-2009 specifications.

This means that the packaging, inspection and sterilization should be carried out in areas where the temperature should vary between 20° C and 23° C and the relative humidity should be between 30% and 60% with 1h mechanical ventilation 10 times. The cotton dressing packaging area must stay separated from equipment packaging center so that cotton dust pollution can be avoided for all related equipments as well as the nonwoven packaging materials.

Size requirements

Equipment packages in operating room

When it comes to the surgical room instrument car’s size, in case the device used for nonwoven packaging is laid on top of instrument car countertop, it is important for the size of the nonwoven fabric to reach the car device surface for about 30cm.

Irregularly shaped instruments

If you are working with irregularly shaped instruments like electric drills, breast openers and other tools, you must see to it that the nonwoven fabric packaging materials are used after you work with the net basket. The cotton ball cylinder as well as other round containers must be placed in the center of the nonwoven fabric. The right and left sides of this cloth should side back folded and roll forward and then back to back of wrap side for about 3 cm to 5 cm after the seal.

Frame hook-type instruments

The nonwoven fabric can be fastened with a tape so that it does not get loose while creating the inner packaging for the frame hook-type instruments.