The Ultimate Guide to Non-Woven Fabrics And How They Are Used

Non-woven fabrics provide a cost-effective, durable, and sometimes superior alternative to woven fabric and plastic products like custom bags. These fabric alternatives are so versatile that they are used across industries for a wide array of applications. The food and beverage industry, retail industry, and agricultural industry are just some of the big users of non-woven fabric products. In this guide, we are going to tell you what these fabrics are, how they are used, and you can decide for yourself if they’re a good use case scenario for you.

What Are Non-Woven Fabrics?

Non-woven fabrics are typically made from plastic, with a small percentage being made out of a natural fiber like cotton and rayon. The fabrics are made by bonding the individual fibers together by using either heat, adhesive, or stitching them together.

Non-woven fabrics can be more efficient than typical fabrics in a variety of areas. For example, non-woven fabrics can be water-repellent and flame-resistant. They can be more breathable and lightweight than woven fabrics, as well as more cost-effective for businesses.

Non-woven fabrics are made using three bonding techniques. One of those techniques is chemical bonding, where adhesives are used to bring the fibers together to form a fabric. Another technique is to use heat to melt the fibers together to form a uniform fabric, and finally, mechanical bonding, which is the use of stitches to hold the fabric together.

Why Are They Used?

They have several unique qualities that make them win out over woven fabrics for certain applications. The fabrics are known for their favorable costs and for their performance in cases where breathability, filtering, and strength are important. 

Non-woven fabrics are used more and more in a variety of industries, including food and beverage, retail, construction, automotive, apparel, and medical. 

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Non-woven Fabric Products In Action

Non-woven fabric materials are used across industries for a variety of applications. Let’s look at some of the commonly used products from this non-traditional material.

Non-woven Fabric Bags

The green revolution has changed a lot of things in our world, and one of the biggest is how plastic bags have been pushed out for reusable bags. And that is where non-woven fabric comes in. Non-woven fabric bags are often used in the case of reusable shopping bags or promotional shopping bags. This fabric is used because of its lower cost and for its lightweight quality. 

But at the same time, these non-traditional material bags are also strong and durable for use as shopping bags, and a printing option is available too. The fact that non-woven materials are also quite water-resistant is a feature that's particularly important for grocery stores and other sellers of products with levels of condensation. 

Ultimately, businesses that want to provide their customers with a green option that isn't going to be as expensive to produce as woven bags like those made of canvas or cotton. Non-woven fabric bags provide that solution.  

Custom insulated cooler bags.

Custom insulated cooler bags are essentially reusable bags, but for the specific purpose of keeping the contents of the bags cool. Non-woven material insulated cooler bags are chosen because they are cost-efficient to make while also being sturdy without being heavy.

An equivalent woven bag is a lot more expensive to manufacture, and rigid materials are also quite heavy; they may not have the moisture control that non-woven custom insulated cooler bags do. For branding and marketing, non-woven bags do the trick as their surfaces are printable.

Cleaning wipes

Cleaning wipes are made with non-woven fabric because the fibers of non-woven material are able to absorb things like water and grease quite easily. Non-woven fabrics are disposable, and they're also a bit stronger than woven materials, even when they're wet.

Disposable aprons

Disposable aprons are made with non-woven fabrics. For use cases where. A large number of aprons will be used, and it is better for time efficiency to discard those aprons rather than having to launder each of them. Non-woven fabric disposable aprons are great because they are lint-free, breathable, and provide a dependable barrier. They also have microbial properties.

Coffee filters 

Coffee filters are made with non-woven materials due to their flexible porous nature. The pores are large enough to hold coffee granules in while letting water or the brewed coffee pass through. Non-woven fabrics don't have that danger of shedding fibers that could contaminate the coffee. Despite having all of those features, they remain inexpensive enough to throw away after a single use.  

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Why Are Non-Woven Fabrics Chosen Over Woven Fabrics

Without getting into any specific industry, non-woven fabrics are chosen for a variety of key reasons. One of those reasons is that they can be manufactured at high volume and at high speed, while woven fabrics often are slower to be manufactured. Non-woven fabrics are highly customizable, which means things like the strength and filtration capabilities, as well as texture, can be customized for individual applications.

One of the biggest reasons non-woven fabrics are used over woven is their cost efficiency on the whole. Non-woven fabrics are less expensive to manufacture and therefore less expensive for customers. Another reason that non-woven fabrics are used is for their barrier capabilities. Non-woven fabrics are great in use cases where particles as well as fluids require barriers.

fabrics are also chosen due to the fact that they can be made at high volume and on a large scale. One of the important use cases for non-woven materials is for items that are disposable. While you can dispose of woven fabrics, it is not environmentally friendly nor cost-efficient.

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Non-Woven Fabrics Use Cases

Non-woven fabrics are so versatile that they can be used in a wide variety of industries and applications. That’s thanks to a variety of factors, but one of the big ones is that the diameter of each fiber can be adjusted based on the application.  Let's look at the food and beverage industry first, as it is one of the biggest users of this type of fabric for packaging and in-house.

Food and Beverage

Non-woven fabrics are being used more and more in the food and beverage industry for a variety of reasons. But a big reason that they are good matches is because of non-woven fabrics’ ability to meet strict contamination and cleanliness standards. Absorbency is another issue that the food industry deals with when it comes to packaging, as well as in-house uses. This non-traditional fabric has features like low lint as well as customizable absorbency values.

Air Quality

Food and beverage processing plants have to protect their goods from all sorts of things that could contaminate them, like bacteria and dust particles. That’s why complex filters are used, and many of them, like air purifiers, HVAC filters, and dust collectors, use non-woven materials. 

Cleaning

Food processing facilities have strict standards when it comes to sanitation, including implementing measures that prevent cross-contamination when cleaning. Non-woven fabrics provide a variety of solutions for situations like that. For example, disposable wipes are great for cleaning without cross-contaminating. You can 223get non-woven wipes that will work with sanitizers or materials that are low-shed or lint-free.

Packaging 

Non-woven fabrics are used in a variety of packaging types within the food and beverage. Reusable bags like custom insulated cooler bags or branded in-store bags are often made out of non-woven fabrics, as are a variety of inserts used for breathability and moisture balance. 

Example 

Both coffee and tea have non-woven fabric elements in their use. In the case of coffee, the coffee filters are made with non-woven paper. That's because non-woven materials have the ability to cling to particles. And also because filters are made so that there's a certain liquid flow that can easily pass through them.

Woven fabric cannot be engineered to do the same thing. In the case of tea bags, the tea is placed in non-woven fabric bags. The reason for that is the fabric is efficiently porous, which allows for tea to seep out into the water without the actual tea leaf particles spilling through too.

Hospitality

Non-woven fabrics are often used in the hospitality sector specifically because they are cost-efficient. They can be used for things like disposable table covers and protective covers, and even for bed linens. Fabrics don't have to be laundered and can be disposed of, as opposed to woven fabrics and linens.

Example

Many venues use non-woven fabric table coverings, which allow them to set tables up quickly and take them down quickly. That's because fresh new disposable tablecloths are always ready-to-go, and once the event is done, traditionally, the tablecloths would be put into the laundry, but in this case, they can be thrown into the trash. All of that saves time and cuts down on labor costs.

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Filter Systems

Non-woven fabrics are used in a variety of filters, including HVAC, air, and other filters. Non-woven fabrics are used in this use case in particular because their pore sizes can be adjusted over a great surface area, which is optimal for filtration. They also have a greater capacity to hold dust and to improve airflow. 

Woven fabrics don’t have the same capacities because the way the fabric is spread out must be uniform, which means flexibility requirements for the filtration industry can’t be met. 

Example

Air filters are made with non-woven fabrics because they can catch micro particles, which woven fabrics can’t without losing some of their efficiency in other areas like airflow. 

Healthcare

Many healthcare and medical applications require disposable products like gloves, masks, gowns, and bandages. All of these can be made with non-woven fabrics and make for a cost-effective solution.

For healthcare, non-woven fabrics stand out over woven fabrics because, in addition to being disposable and cost-effective, they are breathable and lightweight. And because of their structure, they are better at filtration while also providing a barrier to fluid. Another thing that is particularly important for healthcare uses is that nonwoven fabrics have minimal shedding.

Example

In the case of surgical masks, two different forms of polypropylene non-woven fabric are used to create a very efficient surgical mask. Meltblown non-woven fabric is placed between two pieces of spunbound fabric, which creates a strong filter system. 

Meltblown Fabric

Meltblown fabric is extremely porous, with the diameter of the fibers being in the micrometers. This is achieved because of the meltblown technique. First, polypropylene pellets are melted, after which they are extruded, and then hot air is blown across those extruded fibers, which makes those fibers extremely fine. And those super fine fibers are put on a moving conveyor randomly to form the fabric.

Spunbound Fabric

In the case of spunbound fabric, the extruded polypropylene is directly placed on a moving conveyor and then bonded together using a process like thermal, mechanical, or chemical. 

Hygiene Products

Many hygiene products on the market todayAre made from non-woven.Fabric. That's because there are a variety of factors, which include the fact that non-woven fabrics can be very soft. Also, they are lightweight, great at fluid management, and highly absorbent. Perhaps one of the biggest things is that they are cost-effective.

Non-woven fabrics are used in the case of wet wipes, as well as diapers and other products. Similar products for adults, as well as sanitary products. And in those cases, fabrics need to be able to absorb moisture quickly. And that is something that woven fabrics are not as good at doing as non-woven fabrics. In addition, non-wovens can also be designed so that they can quickly move liquid away from the skin while having their structure stay intact. 

Example.

A good example of non-woven use in hygiene products is for diapers. Diapers use a number of non-woven fabric layers in order to be absorbable as well as breathable, and they wick moisture away from the skin. While there are woven diapers on the market, they serve a niche demographic. Non-woven diapers serve the mass market because they are disposable, whereas cotton ones require washing for reuse.

Automotive

Non-woven fabrics are used across the whole of the automotive industry in places like the backing of upholstery, as well as insulation, and in filters. Certain properties in non-woven fabrics that make them ideal for the automotive industry include the fact that they can be molded into very complex shapes, and they're also good for insulation.

That insulation includes noise insulation and thermal insulation. They're quite lightweight, and one of the biggest selling points of non-woven fabrics is that they are cost-efficient for the automotive industry. 

Example

One of the prime examples of non-woven fabrics being used in the automotive sector are in the panels of car doors for noise insulation, as well as for vibration. Woven fabrics just don't have that same ability to absorb the vibrations and sounds as non-woven fabrics do.

Engineering

Non-woven textiles are often used for roads and landscaping. They are often used as layers to separate soil as well as for filtering. Non-woven fabrics are also used in drainage systems. Additionally, they are used to protect surfaces, and they can be used as reinforcements too. Mostly, however, they are used for filtering and separation.

Non-wovens are often used because of their flexible pore adjustment systems and also because they are not as easy to tear. They are also quite adaptable to different types of surfaces.

Example

In the case of landscaping, non-woven fabrics are placed under gravel so that they can prevent soil from mixing.

Packaging

Non-woven plastics are often used in different types of packaging and particularly in bags. That's because non-woven plastics can often be cheaper to produce. And you can print on them, and they're also water-resistant.

Example.

Green grocery bags, also known as reusable bags, are often made with non-woven fabrics because they are both cost-efficient and durable.

Agriculture

Non-woven fabrics are often used in the agriculture industry for a variety of uses, including to protect crops, as well as to transport fruits, vegetables, and other crops. Non-woven fabrics are often chosen over woven fabrics because non-woven fabrics are more breathable and they're also more lightweight. Woven fabrics, on the other hand, can block the sun and reduce air flow.

Example 

During the cold months, frost covers are put onto crops, and those frost covers are made of non-woven fabric. That's because non-wovens allow air to move and moisture to exchange to protect the crops without suffocating them. 

The Future for Non-Woven Fabrics

Non-woven materials are evolving with the current green and smart climate. That means the non-woven materials industry is taking major steps towards ensuring their materials are eco-friendly by creating biodegradable and compostable versions.

They are also moving the needle on smart technologies by incorporating sensors into certain products like mailers. While non-woven fabrics are highly valued for their use in the healthcare industry, they are getting even better with fabrics that are treated with antimicrobials for high sanitization needs.

Wrap 

Non-woven fabrics can be found across industries in places many people don’t expect. That’s because non-woven fabrics are highly adaptable and therefore can be many things for many industries. One of the key selling features of non-woven fabrics is their high customization prospects. They can be adjusted for strength, permeability, weight, moisture control, and more. The versatility of non-woven fabrics is evident in the fact that they can be morphed into a useful fabric across so many very different industries. 

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