Pulp Spunlace

 

Background technology of pulp spunlace
Spunlace nonwoven fabric is a kind of fabric that does not need to be spun and woven. It is formed by orienting or randomly arranging textile short fibers or filaments to form a fiber mesh structure, and then using mechanical, thermal bonding or chemical methods to reinforce it. Spunlace nonwoven fabric breaks through the traditional textile principle and has the characteristics of short process flow, fast production speed, high output, low cost, wide application, and multiple sources of raw materials. Spunlace nonwoven fabric uses a water jet with a pressure of 3-25Mpa to shoot at the fiber mesh laid on the support net. Since the support net has a reflection effect on the water jet, the fibers move with the impact and rebound of the water flow, making the fiber mesh entangled with each other to form a spunlace nonwoven fabric. Its biggest feature is that it can combine two or more fiber meshes of completely different properties together, which is a purely physical "flexible" combination.

The purpose of the above-mentioned technologies is to combine wood pulp short fibers with ordinary non-woven fabrics through spunlace, increase the cotton content of non-woven fabrics, that is, wood pulp, improve the water absorption and other properties of non-woven fabrics, and reduce production costs.

 

 

 

 

Woodpulp spunlace technic focus
The technical problem to be solved by this process is to provide a method for producing wood pulp spunlace non-woven fabrics, which can effectively solve the problems that the products produced by existing processes cannot take into account the strength, hygroscopicity, and feel of the products.
In order to solve the above technical problems, the process adopts the following technical scheme: a method for producing spunlace nonwoven fabrics, characterized in that: filaments are used for spinning, web forming and the first spunlace, wood pulp is added to the filaments after the first spunlace and introduced into the compounding machine for compounding, and the second spunlace is performed after compounding, and finally water pressing and drying are performed.
Further, the filament spinning process is to heat the filament slices to a temperature of 160-220°C, pressurize the molten fluid to 5-20MPa, use a filter with a filter mesh ≥200 mesh to filter out impurities in the fluid, and then flow into the spinning box, and enter the drafting air duct through the spinneret, and use 5-15°C refrigerated air for drafting and cooling, so that the spinning reaches less than 2 deniers.
Further, the filaments are selected from polyolefin fiber polypropylene PP, or polyester fiber polyester.
Then the wood pulp is made into wet paper sheets online by wet web forming, and the wet paper sheets are introduced into the compounding machine to be compounded with the filaments after the first water spunlace, and the wet paper sheets do not need to be dried before entering the next process, which saves energy consumption.
Furthermore, the wet web forming process is to crush the wood pulp into wet paper pulp by the wood pulp beater, enter the pulp storage tank, and pump it into the inclined net forming machine through the pulp pump, filter out the water through the net curtain, and then press, absorb water, and output the wet paper sheets, and introduce the wet paper sheets into the compounding machine from the front through the net curtain.
Furthermore, the water from the first water spunlace is returned to the water source for water spunlace after water treatment, and the water from the second water spunlace and squeezing is returned for wood pulp wet web forming, which makes full use of water resources, recycles without waste, does not pollute, and reduces production costs.
Further, the wood pulp is pulped by a pulping machine to become wet paper pulp, enters the pulp storage tank, and is pumped into the inclined net forming machine through a pulp pump. The water is filtered out through the net curtain, and then the wet paper sheets are output through pressing, water absorption, and the wet paper sheets are introduced into the compounding machine from the front through the net curtain.
Further, the first spunlace uses 2 to 3 spunlace heads with a pressure of 3 to 15 MPa.
Further, the second spunlace uses 3 to 5 spunlace heads with a pressure of 3 to 15 MPa.
Further, the drying temperature is 120 to 150°C.
This process adopts the above technical solution, with a short production process and low equipment investment. It effectively combines spinning spunlace technology, wood pulp wet web technology and spunlace composite technology, with high speed and high production capacity. The raw materials are directly spun into webs with filament slices and wet webs with log pulp, and then composited with spunlace. The entire production process makes full use of water, energy, and materials, and is a "one-step" production with low production costs. The products produced fully reflect the advantages of the three technologies, with the strength of long fibers, the hygroscopicity of wood pulp, the feel of short fiber spunlace fabrics, and no lint and easy to degrade. At the same time, through online thermoforming, online finishing and other processes, composite non-woven fabrics with various patterns and functions can be produced to increase the added value of the products. Therefore, it has a broad market in the fields of wiping cloth, filter materials, oil absorption materials, household, medical, personal hygiene, etc., and is a "green and environmentally friendly" composite non-woven new product.

Illustrations of pulp spunlace non wovens

Specific implementation method
A method for producing spunlace nonwoven fabrics, wherein polyolefin fiber PP or polyester fiber PET chips are fed into a hopper through a suction machine and enter a screw extruder, the chips are heated to a temperature of 160-220°C, pressurized to a molten state of 5-20MPa, and the impurities in the fluid are filtered out by a filter with a filter mesh ≥200 mesh, and then flow into a spinning box, and the fibers are spun through a spinneret into a drafting duct, and are drafted and cooled with 5-15°C refrigerated air to make the spinning reach less than 2 deniers. The spun filaments reach a web-making machine at a speed of >5000m/min and are laid into a uniform filament messy web. The filaments are continuously output from the web curtain, pre-wetted by water spraying through a water spray pipe, and enter the spunlace machine for the first spunlace. The spunlace machine uses 2-3 spunlace heads with a pressure of 3-15MPa. After the first spunlace, the filament web has a certain entanglement force, and the water coming out of the first spunlace is returned to the spunlace water source after water treatment. At the same time, the wood pulp is crushed by a pulper to become wet pulp, which enters a pulp storage tank and is pumped into an inclined mesh forming machine through a pulp pump. Water is filtered out through a mesh curtain, and then the wet paper sheets are output through squeezing, absorbing water, and then introduced into the compound machine through the mesh curtain from the front. After being overlapped and pressed with the filament mesh sent after the first spunlace, it enters the second spunlace. The spunlace machine uses 3 to 5 spunlace heads with a pressure of 3 to 15 MPa. After squeezing, the water coming out of the second spunlace and squeezing is returned for wet web forming of wood pulp. When the returned water is in excess of the water source in the wet web forming, it can be returned as a water source for spunlace after water treatment. Finally, it is dried at a temperature of 120 to 150°C, heat-set into various patterns, and can be rolled up and slit.

 

Pulp spunlace Weston offers:
Weston produces spunlace of pulp mixed with following biodegradable fibers:
 Cotton pulp spunlace

Cotton source: Naturally grown without the use of synthetic pesticides or fertilizers.
Process: Uses natural farming techniques, which reduce water consumption and soil degradation.
Environmental Impact: Minimizes chemical runoff and soil contamination, promoting biodiversity and healthy ecosystems.

 Bamboo pulp spunlace

Source: Bamboo, a rapidly renewable resource.
Process: Mechanical processing (crushing bamboo and using natural enzymes) is eco-friendly, though chemical processing methods exist and can be less sustainable.
Environmental Impact: Bamboo grows quickly without the need for pesticides or fertilizers, and it requires less water compared to cotton.

 Hemp pulp spunlace
Source: Hemp plant.
Process: Can be processed mechanically using water retting or dew retting, which are less harmful to the environment compared to chemical retting.
Environmental Impact: Hemp cultivation improves soil health, requires minimal pesticides, and has a high yield per acre.

 Lyocell pulp spunlace

Source: Wood pulp from sustainably managed forests.
Process: Produced using a closed-loop process where solvents are recycled with minimal emissions and waste.
Environmental Impact: The production process is energy-efficient, and the fiber is biodegradable.

 Soy Silk (Soybean Fiber) pulp spunlace:
Source: By-products of soybean processing.
Process: Uses leftover materials from tofu or soy milk production, processed into fiber using minimal chemicals.
Environmental Impact: Utilizes waste materials, reducing overall waste and promoting a circular economy.

 Pineapple leaf fiber pulp spunlace:
Source: Leaves of the pineapple plant.
Process: Leaves are collected and fibers are extracted using mechanical processes.
Environmental Impact: Utilizes agricultural waste, reducing the need for additional land and resources.

 

Medical care and protection application
Wood Pulp Spunlace Nonwoven Fabrics in the Medical Field
Wood pulp spunlace nonwoven fabrics are extensively used in the medical field due to their excellent absorbency, softness, strength, and biodegradability. The unique properties of these fabrics make them ideal for a variety of medical applications, providing both functionality and comfort to patients and healthcare providers. Here are some key applications:
1. Surgical Gowns and Drapes:
* Barrier Protection: These fabrics provide effective barrier protection against fluids and pathogens, ensuring a sterile environment during surgeries.
* Comfort and Breathability: The softness and breathability of wood pulp spunlace fabrics enhance comfort for healthcare professionals during long procedures.
2. Medical Dressings and Bandages:
* Absorbency: The high absorbency of wood pulp makes these fabrics suitable for wound dressings, helping to keep wounds dry and promoting faster healing.
* Hypoallergenic Properties: Wood pulp nonwovens are gentle on the skin, reducing the risk of irritation and allergic reactions.
3. Face Masks and Respirators:
* Filtration Efficiency: Spunlace nonwoven fabrics can be engineered to provide excellent filtration properties, essential for protecting against airborne pathogens and particles.
* Comfort: The lightweight and breathable nature of these fabrics ensures that face masks and respirators are comfortable to wear for extended periods.
4. Medical Wipes:
* Disinfecting Wipes: The strong and absorbent nature of wood pulp spunlace fabrics makes them ideal for disinfecting surfaces and equipment in medical settings.
* Personal Care Wipes: These fabrics are used in patient care wipes, providing gentle and effective cleaning for patients' skin.
5. Surgical Sponges and Pads:
* High Absorbency: These fabrics are used in surgical sponges and pads to absorb blood and other fluids during surgical procedures.
* Sterility: Spunlace nonwovens can be easily sterilized, maintaining the hygiene standards required in medical environments.
6. Sterilization Wraps:
* Protection: These fabrics are used to wrap surgical instruments and other medical devices, protecting them from contamination before use.
* Durability: The strength and durability of wood pulp spunlace fabrics ensure that sterilization wraps remain intact and provide reliable protection.
7. Patient Gowns and Bedding:
* Disposable Gowns: Wood pulp spunlace nonwovens are used to make disposable patient gowns that are soft, comfortable, and hygienic.
* Bedding and Linens: Pulp spunlace fabrics are also used for disposable bedding and linens, providing a clean and comfortable environment for patients.
8. Laboratory and Pharmaceutical Applications:
* Surface Cleaning: Woodpulp spunlace nonwovens are used for cleaning and maintaining sterile surfaces in laboratories and pharmaceutical manufacturing areas.
* Component Wipes: Pulp spunlace fabrics are used for wiping and cleaning components during pharmaceutical production, ensuring contamination-free processes.

 

Pulp Spunlace Tray Liners: Disposable liners used in food trays to absorb moisture and maintain hygiene.
Advantages of Using Wood Pulp Spunlace Nonwoven Fabrics in Food Service:
Hygienic: Disposable nature reduces the risk of cross-contamination, maintaining high hygiene standards.
Highly Absorbent: Capable of quickly absorbing liquids, making them ideal for cleaning spills and wiping surfaces.
Strong and Durable: Can withstand rigorous use, making them suitable for various cleaning tasks.
Soft and Gentle: Suitable for use on sensitive surfaces and for personal hygiene applications.
Convenient and Cost-Effective: Disposable products simplify cleanup and reduce the need for laundering, saving time and resources.