Embossed Nonwoven Fabric Products

I. Embossed Spunlace Nonwoven Fabric Process Flow

The core of embossed spunlace nonwoven fabric is to form stable textures on the surface of spunlace nonwoven fabric through precise embossing technology. Changshu Yongdeli Spunlaced Nonwoven Fabric Co., Ltd. implements full-process meticulous control to ensure the clarity, three-dimensionality and performance stability of each batch of products. The specific process is as follows:

Raw material selection and ratio adjustment: According to the performance requirements and embossing effect of the product application scenarios, high-quality fiber raw materials are selected, including polyester, viscose fibers, pure cotton fibers, bamboo fibers or mixed fibers (such as polyester-viscose blend, cotton-polyester blend). The technical team will scientifically adjust the fiber ratio, for example, for the beauty care scene, increase the proportion of viscose fibers to enhance skin comfort and absorbency; for the home decoration scene, increase the proportion of polyester to enhance wear resistance and stiffness, ensuring the basic performance and compatibility of the product from the source.

Opening and blending fibers: The packaged fiber raw materials first enter the opening and blending equipment, where mechanical force is used to disperse the fiber clusters and remove impurities and short fibers, making the fibers loose. Then， the dispersed fibers enter the blending equipment according to the preset ratio， and multiple sets of mixing devices are used to achieve uniform mixing of different fibers， avoiding fiber agglomeration or uneven distribution， laying the foundation for the stability of the subsequent combing and embossing processes.

Combing into a net： The blended fibers enter the high-precision combing machine， where the needle cloth components rotate at a specific speed， performing fine separation， straightening and directional arrangement of the fibers， forming a continuous， uniform thickness (thickness deviation controlled within ±1.5%)， without obvious defects， as the basic fiber net. Compared to ordinary spunlace nonwoven fabric， embossed products have higher requirements for the uniformity of the fiber net， ensuring consistent fiber net density to avoid uneven embossing patterns due to local density differences.

Spunlace reinforcement： The combed fiber net is transported to the spunlace machine. The spunlace machine uses multiple sets of high-pressure water nozzles， spraying high-pressure water vertically or at a small angle (pressure 6-12 MPa) to the fiber net. The water pressure acts on the fiber net， causing the fibers to intertwine and interweave， forming spunlace nonwoven fabric base cloth with certain strength and flexibility. Technicians will monitor the water pressure， spraying frequency and fiber net running speed in real time to ensure that the basic performance of the base cloth， such as strength and breathability， meets the standards， providing a stable substrate for the subsequent embossing process.

Embossing treatment (core process)： This is the key step for embossed spunlace nonwoven fabric to form unique textures. The company adopts two mainstream embossing processes according to customer requirements：

Hot embossing process： The spunlace nonwoven fabric base cloth is transported to the hot embossing machine. The hot embossing machine consists of a pair of heating rollers with specific textures (such as dots， stripes， diamonds， flowers， custom patterns， etc.). Through precise control of heating roller temperature (80-150℃， adjusted according to fiber material)， pressure (5-15 MPa) and running speed， the fibers on the base cloth melt and deform under the heat pressure， and cool down to form a three-dimensional embossed pattern consistent with the roller surface texture. This process is suitable for scenarios that require clear and stable textures, such as home decoration and packaging materials.

Cold embossing process: For fiber substrates that are not resistant to high temperatures (such as pure cotton and bamboo fiber), the cold embossing process is adopted. The cold embossing machine uses a pair of high-strength embossing rollers with textures to apply a specific pressure (10-20 MPa) to the spunlace non-woven fabric base at room temperature, causing the fibers on the base fabric to undergo physical deformation and form embossed patterns. This process can retain the characteristics of natural fibers to the greatest extent and is suitable for hygiene products, beauty care, and other scenarios where products come into direct contact with the human body.

Regardless of which process is used, technicians will adjust parameters through trial production to ensure that the embossed patterns are clear, have strong three-dimensionality, and do not affect the basic performance of the base fabric.

Drying and cooling (optional): If the hot embossing process is used, the embossed products need to enter a cooling and shaping device, where they are quickly cooled by cold air or cooling rollers to ensure stable shaping of the embossed patterns and avoid texture deformation during subsequent use. If the cold embossing process is used and the base fabric has a high moisture content, it needs to enter a hot air drying equipment (temperature 80-100°C) to control the moisture content of the product to within 5%, while further consolidating the embossed effect.

Post-treatment and cutting: According to the individualized needs of customers, the embossed products are subjected to targeted post-treatment. Common processes include: hydrophilic treatment (to improve the absorption speed of hygiene products and beauty care products), antibacterial treatment (suitable for medical and hygiene scenarios), softening treatment (to enhance the comfort of skin-contact products), and anti-static treatment (to meet the packaging requirements of the electronics industry). After post-treatment, the products enter the cutting equipment, where they are precisely cut according to the preset width (1-3.2m), length, or roll specifications to ensure that the size error of the finished products is less than ±0.5cm, meeting the processing and usage requirements of downstream customers.

Quality inspection and warehousing: The quality inspection phase focuses on "embossed characteristics" and basic performance. In addition to routine appearance inspections (checking for defects and color differences on the fabric surface) and physical performance inspections (tensile strength, elongation at break, abrasion resistance), an additional "embossed quality inspection" is conducted through visual inspection and tactile assessment to ensure that the clarity of the embossed patterns (texture depth deviation less than ±0.1mm), three-dimensionality, and consistency are met. At the same time, the performance differences between the embossed area and the non-embossed area (such as breathability, strength) are also tested. All qualified products can be warehoused for shipment, ensuring that each batch of products delivered to customers is of reliable quality.

II. Advantages of embossed spunlace non-woven fabric

Aesthetically pleasing and highly differentiated: Through customized embossing processes, various textures such as dots, stripes, diamonds, flowers, and cartoon patterns can be formed on the fabric surface. Some processes can also achieve local three-dimensional raised effects, making the product appearance more design-oriented and three-dimensional. Compared to ordinary plain spunlace non-woven fabric, embossed products can quickly attract consumers' attention, helping downstream customers create differentiated products and enhance market competitiveness, especially in fields that emphasize appearance, such as beauty, home, and gift packaging.

Function and aesthetics combined: The embossing process not only enhances the appearance of the product but also optimizes the product function to some extent. For example, specific textures (such as grid patterns, wave patterns) can increase the surface specific area of the fabric, improving its absorbency and breathability; the three-dimensional embossed structure can enhance the stiffness of the product, facilitating processing into specific shapes (such as folding wet wipes, three-dimensional ear loops for masks); at the same time, the fiber density in the embossed area is higher, improving local wear resistance and extending the product lifespan.

High customization level: The company can customize embossing patterns, texture depth, and density according to the brand positioning of customers and application scenario requirements. Whether it is small-batch personalized patterns (such as brand logos, holiday-themed patterns) or large-batch regular textures, it can be achieved by adjusting the design of the embossing rollers and production parameters. At the same time, by combining the fiber raw material ratio and post-treatment processes, we can create "appearance + function" dual-customized products that meet the diverse needs of customers.

Excellent skin-friendliness and comfort: The embossing process uses precise temperature and pressure control to avoid making the fabric surface rough due to excessive processing. The surface texture of the product is smooth without burrs, and when in contact with the skin, it has a soft and delicate touch without any frictional irritation. If using natural fiber raw materials, the skin-friendliness is further enhanced, effectively reducing the discomfort reactions of people with sensitive skin, and suitable for scenarios where products need to come into direct contact with the human body, such as hygiene products, beauty care, medical dressings, etc.

III. Characteristics of Embossed spunlace Nonwoven Fabric

Stable texture, strong durability: Using advanced hot-pressing or cold-pressing setting processes, the embossed texture is closely combined with the base material. During subsequent processing (such as cutting, sewing, washing) and use, it is unlikely to have texture blurring, detachment or deformation. After testing, the product's embossed texture clarity can still maintain over 85% of the initial state after 10-20 washes. It is suitable for scenarios that require repeated use or washing (such as household cleaning cloths, reusable wet wipes).

Environmentally friendly and safe, without harmful substances: During the production process, only physical water-stitching and embossing processes are used, without adding adhesives, fluorescent agents, formaldehyde, etc., avoiding potential harm to human health from chemical residues. The product has been tested by authoritative institutions and meets environmental protection and safety standards such as GB 18401-2010 "National Textile Product Basic Safety Technical Specifications" and EU REACH regulations. If using natural fiber raw materials, it can be naturally degraded (with a degradation rate of over 85%), conforming to the green development trend, and suitable for scenarios with high safety requirements, such as medical, infant products, and high-end beauty products.

Performance adjustable, wide adaptability: Although the embossing process gives the product a unique appearance, by adjusting the types and ratios of fiber raw materials, the pressure and embossing parameters of spunlace, it is possible to flexibly control the strength, breathability, moisture absorption, and wear resistance of the product. For example, increasing the spunlace pressure and embossing density can enhance the product's strength and waterproof performance; using cotton fiber raw materials and lowering the embossing temperature can enhance moisture absorption and softness, and can be customized with specific performance embossed spunlace nonwoven fabrics according to the differentiated needs of different industries.

Good processing compatibility: The embossed products still maintain good processing performance and can easily adapt to various processing techniques such as printing, compounding, cutting, sewing, heat sealing. For example, the ink adheres evenly on the textured surface during printing, and the combination of texture and color can enhance the product's aesthetic appeal; when combined with films or other non-woven fabrics, the micro-gaps formed by the embossed texture can enhance the tightness of the adhesion and avoid air bubble formation; during cutting, the edges are neat, and the presence of texture does not cause fiber detachment, significantly reducing the processing difficulty for downstream customers.

IV. Embossed Spunlace Nonwoven Fabric Weight Range

The embossed spunlace nonwoven fabric produced by Changshu Yongdeli Spunlaced Nonwoven Fabric Co., Ltd. has a wide range of weight coverage, which can be flexibly adjusted according to the complexity of the embossed texture and the performance requirements of the application scenarios. The specific weight range is 30g/㎡ - 150g/㎡. The characteristics and application scenarios of each weight range are as follows:

Low-weight products (30g/㎡ - 50g/㎡): Light and thin texture, soft fabric surface, with mainly shallow patterns and fine textures (such as fine stripes, small dots), excellent breathability. They are mainly suitable for the surface of hygiene products (such as the surface of high-end baby diapers, female hygiene products), beauty care products (such as makeup cloths, makeup wipes, disposable cleansing towels), and inner layers of medical masks (with a shallow pattern design to enhance wearing comfort and breathability) and other scenarios that are sensitive to product thickness and weight and focus on delicate texture and appearance. Medium-weight products (51g/㎡ - 100g/㎡): They combine lightness and certain strength. The embossed patterns are mainly medium-depth and moderately complex (such as rhombic patterns, wave patterns, and flower patterns), with an appropriate sense of three-dimensionality. The moisture absorption and wear resistance are enhanced together. They are widely used in wet wipes substrates (such as high-end baby wet wipes, adult care wet wipes, where the embossing enhances the absorption capacity and wiping feel), household cleaning cloths (such as kitchen lightweight cleaning cloths, bathroom wiping cloths, where the texture improves the dirt removal ability), medical dressing substrates (such as decorative layers for band-aids, lightweight medical protective cloths, where both aesthetics and hygiene are considered), and gift packaging linings (such as jewelry and cosmetics packaging linings, where it enhances the product grade) and other scenarios.

High-weight products (101g/㎡ - 150g/㎡): They have moderate thickness, high strength, and good stiffness. The embossed patterns are mainly deep patterns and complex three-dimensional textures (such as three-dimensional grid patterns, large flower patterns, customized LOGO patterns). The wear resistance and tear resistance are excellent. They are suitable for industrial wiping cloths (such as precision instrument cleaning cloths, where the texture enhances dust absorption ability), household decoration materials (such as tablecloths, napkins, curtain fabrics, where the textured patterns enhance the decorative effect), heavy-duty packaging cloths (such as high-end gift packaging cloths, electronic product protective packaging cloths, where the texture enhances slip resistance and protection), agricultural covering cloths (such as flower packaging cloths, seedling protection cloths, where thick patterns enhance durability) and other scenarios with high requirements for product strength, wear resistance, and textured three-dimensionality.

V. Application Scope of Embossed Water-Blended Nonwoven Fabrics

Makeup and Personal Care Market: It is the core application field of embossed water-blended nonwoven fabrics. With its delicate texture and beautiful appearance, it becomes the ideal substrate for high-end makeup products. Low-weight (30 - 40g/㎡) products can be used to make makeup pads and makeup removal pads. The shallow pattern design enhances the uniformity of liquid absorption, and the touch is soft when applying makeup or removing makeup, without fiber shedding; disposable facial cleansing wipes use 40 - 50g/㎡ products, with medium-fine textures to enhance cleaning ability while maintaining skin comfort, suitable for sensitive skin groups. For example, a high-end makeup brand that uses the company's 35g/㎡ embossed makeup pads with fine stripes, the product received widespread praise for its "delicate texture and high appearance level", and the repeat purchase rate increased by 35%.

Hygiene Products Market: In the high-end hygiene products field, embossed spunlace nonwoven fabrics, with their dual advantages of appearance and function, have a continuously growing application demand. Low-weight (30 - 45g/㎡) products are used as the surface layer of high-end baby diapers, with shallow dots or fine stripes embossing can reduce the contact area with the skin, improve air permeability, and enhance the speed of urine drainage, reducing the risk of red buttocks; the surface layer of women's hygiene products uses 35 - 45g/㎡ products with shallow patterns, which is breathable and anti-sweating, and has a more designable appearance, meeting the needs of high-end consumers; adult incontinence products use 50 - 60g/㎡ medium-pattern products, balancing comfort and durability.

Home and Cleaning Market: With the improvement of consumers' requirements for the quality of home life, embossed spunlace nonwoven fabrics are continuously expanding their application in the home sector. Medium-weight (50 - 80g/㎡) products can be used to make high-end household cleaning cloths, such as kitchen cleaning cloths using rhombic patterns or grid patterns embossing, which enhances the oil stain absorption ability, and when wiping, it is less likely to scratch the surface of tableware; bathroom wiping cloths use soft wave patterns embossing, with a comfortable touch, and can effectively clean tiles and glass surfaces; disposable tablecloths and napkins use 80 - 100g/㎡ products with three-dimensional patterns, replacing traditional plastic tablecloths, having both environmental friendliness and decorative properties, suitable for family gatherings and hotel banquets.

Medical and Health Market: Relying on the characteristics of being environmentally friendly, safe, beautiful, and functional, it is widely used in mid-to-high-end scenarios in the medical and health field. Medium-weight (50-70g/㎡) products can be used as decorative or protective layers for medical dressings, such as the simple patterned embossed layer on wound bandages, enhancing the aesthetic appeal of the product and alleviating the psychological discomfort of patients during use; Lightweight medical protective fabric uses 60-80g/㎡ products with shallow patterns, balancing breathability and protection, suitable for outpatient and physical examination scenarios; Medical packaging liners use 70-90g/㎡ products, with enhanced texture for better anti-slip properties, protecting medical devices from damage due to collisions during transportation. The products comply with medical standards such as YY/T 0334-2022 "Medical Deodorized Cotton", and GB 19083-2010 "Technical Requirements for Medical Protective Masks", and can pass third-party authoritative testing.

Packaging and Decoration Market: In the high-end packaging and decoration sector, embossed spunlace non-woven fabric, with its three-dimensional texture and environmental-friendly properties, has become the preferred alternative to traditional packaging materials. Products with medium to high weight (80-120g/㎡) can be used as inner liners for gifts (such as jewelry, watches, and high-end cosmetic packaging) or decorative layers for gift boxes. The three-dimensional patterns enhance the product's grade and elegance; for electronic product packaging, products with 100-130g/㎡ and anti-slip texture are used as protective liners to protect the products from scratches and collisions; in the home decoration field, products with 120-150g/㎡ can be used to make simple curtains, decorative fabrics, wall coverings, etc. The combination of three-dimensional texture and colors creates a warm and beautiful home atmosphere.

Changshu Yongdeli Spunlaced Non-Woven Fabric Co., Ltd. always focuses on customer needs and continuously optimizes the production process of embossed spunlace non-woven fabric. It can customize embossed patterns (including brand LOGOs, exclusive design patterns), texture depth, fiber raw materials, weight, and post-treatment functions (such as antibacterial, hydrophilic, and anti-static) according to the specific needs of customers, providing "appearance + function" dual-customized solutions for different industries. In the future, the company will further enhance the refinement level of embossing technology and develop new embossing technologies such as "gradual texture" and "composite texture" to expand its application in high-end medical, luxury packaging, and smart home decoration fields, and work with customers to achieve win-win development.