Recycled Fiber Spunlace Nonwoven Fabric Products

I. Spunlace Nonwoven Fabric Production Process

The core of recycled fiber spunlace nonwoven fabric lies in the combination of recycled raw material processing and spunlace technology to achieve a balance between "environmental friendliness and performance". Changshu Yongdeli spunlaced Nonwoven Fabric Co., Ltd. ensures the compliance, stability, and reliability of each batch of products through refined process control. The specific process is as follows:

Selection and Pre-treatment of Recycled Raw Materials (Core Step):

Raw material selection: Preferentially select recycled polyester and recycled polypropylene fibers that meet national environmental protection standards (such as GB/T 38413-2019 "Evaluation Requirements for Green Factories in the Recycled Chemical Fiber (Polyester, Polyamide) Industry"). The raw materials come from recycled plastic bottles and waste textiles, processed by regular manufacturers. Each batch of raw materials must provide "recycled material traceability certificate" and "environmental test report" to ensure no heavy metals or harmful chemicals.

Pre-treatment of Raw Materials: Due to the complexity of the source, the recycled fibers need to be first sorted using equipment to remove impurities (such as metal debris, impure fibers); then enter the loosening equipment, using a low-tension loosening process to avoid fiber breakage due to slightly lower strength than original fibers; after loosening, the short fibers and dust are removed by a decontamination machine to ensure the cleanliness of the recycled fibers at over 99%, laying the foundation for subsequent mixing and web formation.

Fiber Ratio and Mixing: According to the performance requirements of the product (such as strength, softness, breathability), scientifically adjust the ratio of recycled polyester and recycled polypropylene (the conventional ratio is 6:4 to 8:2, with recycled polyester enhancing strength and recycled polypropylene enhancing softness), and add a small amount of recycled viscose fiber (to improve skin contact). The mixing process uses a dual-axis blending machine, ensuring uniform distribution of fibers through variable frequency stirring to avoid fiber agglomeration and guarantee the consistency of web formation.

Combing into Web (Optimization for Recycled Fiber) : The mixed fibers enter a high-precision combing machine, considering the shorter length and slightly lower strength of recycled fibers, using low-damage needle fabric and low-speed combing parameters (the combing speed is reduced by 10%-15% compared to original fibers), reducing fiber breakage; at the same time, adjusting the roller spacing to ensure straightness and uniformity of fibers, with the thickness deviation controlled within ±2.5%, providing a stable substrate for subsequent water stitch reinforcement.

Spunlace Reinforcement (Strength Assurance Process): Adopting "multi-stage progressive spunlace " technology to balance the strength of recycled fibers and the stability of the fabric surface:

First-stage low-pressure spunlace (pressure 6-8 MPa): Initially fix the web structure to prevent excessive displacement of recycled fibers due to high-pressure impact;

Middle-stage directional spunlace (pressure 10-12 MPa): Using an inclined water jet head (at an angle of 30° to the web) to direct water injection, enabling the recycled fibers to intertwine and enhance the longitudinal strength of the fabric surface;

High-pressure all-in-one spunlace (pressure 13-15 MPa): Using high-density spunlace heads for coverage, it enhances the density of fiber entanglement, ensuring that the longitudinal tensile strength of the product is ≥ 8 N/5 cm and the transverse tensile strength is ≥ 5 N/5 cm (tested according to GB/T 24218.3-2010), meeting the requirements of regular use.

Dehydration and drying (environmentally friendly and energy-saving design): The wet non-woven fabric after spunlace reinforcement is first sent to the vacuum dehydration equipment (dehydration rate 75%-85%), during the dehydration process, the wastewater is filtered through the company's self-built water recycling system and reused, increasing water resource utilization by 30%; then it enters the hot air drying equipment, using heat recovery technology (drying temperature 80-110℃, 10℃ lower than the conventional process), reducing energy consumption while avoiding the aging of regenerated fibers due to high temperature, and the final product moisture content is controlled within 5%.

Post-treatment and cutting (function customization): According to customer requirements, post-treatment includes: hydrophilic treatment (for hygiene products scenarios, improving liquid absorption speed), antibacterial treatment (for medical auxiliary scenarios, inhibiting bacterial growth), and anti-static treatment (for industrial wiping scenarios, reducing static adsorption); after post-treatment, it is cut into rolls or sheets by a high-precision cutting machine according to preset widths (1-3.2 m) and lengths, the cutting process adopts tension closed-loop control to avoid the stretching deformation of the regenerated fiber substrate.

Quality inspection and warehousing (full-dimensional testing): In addition to the regular appearance, strength, and air permeability tests, the quality inspection process also includes "recycled attribute testing" and "environmental testing": through infrared spectroscopy, the recycled fiber composition is verified (ensuring the recycled material ratio is ≥ 90%), and through a third-party testing institution, the detection of heavy metals (lead, cadmium, etc.) and formaldehyde content (all meeting GB 18401-2010 A-class standards) is conducted; at the same time, the degradability of the product (natural environment 180-day degradation rate ≥ 60%, meeting GB/T 28018-2011 standards) is also tested. Only qualified products can be warehoused.

II. Core advantages of recycled fiber spunlace non-woven fabric

Environmental attributes are prominent, promoting low-carbon development: The core raw material of the product is recycled polyester and recycled polypropylene, for every 1 ton of recycled fiber spunlace non-woven fabric produced, 6-8 tons of primary plastic are reduced, and about 3 tons of carbon dioxide emissions are reduced, which is in line with the "dual carbon" policy and the green supply chain requirements of downstream customers. At the same time, the product can be partially degraded (a mixture of recycled fibers and a small amount of primary fibers) or reused through the recycling system, forming a "resource - product - waste - recycled resource" circular closed loop, suitable for customers who value the environmental brand image.

Performance is comparable to primary fibers, with high cost-effectiveness: Through pre-treatment of raw materials and optimization of spunlace technology, the product performance is close to that of primary fiber spunlace non-woven fabric: longitudinal tensile strength ≥ 8 N/5 cm, transverse tensile strength ≥ 5 N/5 cm, air permeability ≥ 300 L/m²·s, wear resistance ≥ 300 times (tested by Martindele abrasion tester), meeting the requirements of regular scenarios such as hygiene, home, and industry. At the same time, the cost of recycled raw materials is 15%-20% lower than that of primary raw materials, ensuring performance while reducing procurement costs for customers and enhancing product market competitiveness.

Raw material source is compliant and safe: The company strictly selects recycled raw material suppliers, all recycled fibers come from qualified and regular enterprises, providing complete "recycling - processing - factory" traceability documents, ensuring that the raw materials do not contain prohibited chemical substances. The product has been tested by authoritative institutions such as SGS and CNAS. The formaldehyde content is ≤ 20mg/kg, and the heavy metal content is ≤ 10mg/kg. It complies with international environmental protection standards such as the EU REACH regulations and the US CPSIA, and is safe for use in hygiene products and household items that come into contact with the human body.

The process is highly adaptable and customizable: The regenerated fiber spunlace non-woven fabric can be adapted to various post-treatment processes, such as hydrophilic, antibacterial, and antistatic. It also supports customization of different texture structures (such as mesh, plain weave, and embossed) (refer to the company's mesh and embossed spunlace processes). According to different industry needs, the ratio of regenerated fibers can be adjusted (such as increasing the proportion of regenerated polypropylene to enhance softness, and increasing the proportion of regenerated polyester to enhance strength), flexibly meeting the diverse needs of hygiene product surfaces, industrial wiping cloths, agricultural covering fabrics, etc.

Four. Characteristics of Regenerated Fiber Water-Jet Non-Woven Fabric Products

Stable structure, strong durability: Using multiple spunlace reinforcement processes, the regenerated fibers are closely intertwined, and the fabric structure is stable, with no phenomena of fiber separation or damage. After being tested, the product maintains its complete structure after repeated friction for 500 times (such as for wiping and covering), and the elongation at break ≥ 25%, meeting the requirements for multiple repeated uses (such as industrial wiping cloths, household cleaning cloths).

Soft and skin-friendly, comfortable to use: Through the addition of regenerated polypropylene fibers and low-damage combing process, the product has a soft and fine feel, with a skin sensation score (according to ISO 12826 standard) of over 4.0, and there is no irritation when in contact with the skin. It is suitable for scenarios where it comes into direct contact with the human body, such as hygiene product surfaces (such as adult incontinence product surfaces), household cleaning cloths (such as baby clothing wiping cloths), etc., avoiding skin discomfort.

Breathable and water-permeable, functionally adaptable: The micro-pore structure formed by the water-jet process and the porous characteristics of the regenerated fibers combine, with a ventilation rate of ≥ 300L/m²・s and a water permeability rate of ≥ 10mL/s (according to GB/T 24218.7-2010 testing). It is suitable for scenarios requiring ventilation and water permeability, such as agricultural seedling covering cloth (breathable and moisturizing, promoting seed germination), hygiene product drainage layer (quickly draining water to keep the skin dry) etc.

Good chemical resistance, wide applicability: Regenerated polyester and regenerated polypropylene fibers have good chemical resistance and are resistant to common acids (pH 4-8), alkalis (pH 8-12), and detergents. It is suitable for industrial wiping cloths (such as machine oil stain wiping, laboratory mild chemical reagent wiping), kitchen cleaning cloths (such as oil stain cleaning) and other scenarios that require ventilation and water permeability.

Five. Weight Range of Regenerated Fiber Spunlace Non-Woven Fabric

The spunlace non-woven fabric produced by Changshu Yongdeli Spunlace Non-Woven Fabric Co., Ltd. has a weight range covering 25g/㎡ - 120g/㎡, which can be flexibly adjusted according to the ratio of regenerated fibers and application scenarios. The characteristics and applicable scenarios of each weight range are as follows:

Low weight products (25g/㎡ - 45g/㎡): Light and soft, with a high proportion of regenerated polypropylene (30%-40%), mainly suitable for hygiene product surfaces (such as adult incontinence product surfaces, thin wetting base materials), medical auxiliary materials (such as disposable medical caps lining, mask inner layer), and lightweight packaging inner linings (such as electronic product dust-proof inner lining). For example, a 30g/㎡ product is used as an adult incontinence product surface, with good ventilation and water permeability, reducing skin heat sensation.

Medium weight products (46g/㎡ - 80g/㎡): Balanced strength and softness, with the proportion of regenerated polyester increased to 70%-80%, suitable for household cleaning cloths (such as kitchen wiping cloths, bathroom cleaning cloths), agricultural seedling covering cloth (such as vegetable seedling covering), and disposable household items (such as disposable tablecloths, shopping bags). For example, the 60g/㎡ product can be used as a kitchen cleaning cloth, being wear-resistant and oil-resistant, and can be reused 5-10 times. Its cleaning efficiency is close to that of the original fiber products.

High-weight products (81g/㎡ - 120g/㎡): They have high strength and good stiffness, with a recycled polyester content of ≥ 80%. They are suitable for industrial wiping cloths (such as machine oil stain wiping cloths, mechanical part cleaning cloths), agricultural weed prevention cloths (if garden weed prevention), and heavy packaging cloths (such as industrial product transportation protection cloths). For instance, the 100g/㎡ product is used as an agricultural weed prevention cloth, being resistant to aging and tear-resistant. It can be used outdoors for 1-2 years, and the mesh structure allows rainwater to penetrate without affecting crop growth.

V. Application Scope of Recycled Fiber Spunlace Nonwoven Fabrics

Hygiene Products Market: For the demand of mid-range hygiene products and environmentally friendly hygiene products, the products can be used as the surface layer of adult incontinence products (low weight 30-40g/㎡, breathable and water-permeable, reducing skin irritation), thin wet wipes base material (40-45g/㎡, soft and skin-friendly, meeting environmental protection requirements for degradability), and one-time care pad drainage layer (50-60g/㎡, rapid liquid drainage, maintaining the surface dryness). For example, a hygiene products company used the company's 35g/㎡ recycled fiber spunlace nonwoven fabric as the surface layer of incontinence products, and the product was favored by elderly care homes and community hospitals due to "environmental protection + high cost-effectiveness", with an order volume increase of 25%.

Home Cleaning and Daily Products Market: With the improvement of consumers' environmental awareness, the products have become the preferred choice for home cleaning products: the medium-weight 50-70g/㎡ products are used for kitchen cleaning cloths (wear-resistant and oil-resistant, washable and reusable), bathroom wiping cloths (soft and non-scratching tiles); the 60-80g/㎡ products are used for one-time tablecloths (breathable and non-stuffy, degradable after disposal), shopping bags (high strength, replacing plastic bags, meeting the "plastic restriction" requirements). For example, home cleaning cloths use a diamond-shaped mesh design (refer to the company's mesh process), with a cleaning efficiency 30% higher than ordinary recycled fabrics, and easy to clean without residue.

Industrial Wiping Market: For the wiping needs of the industrial field with "low cost + environmental protection", high-weight 80-110g/㎡ products are used for machine oil stain wiping cloths (strong oil absorption capacity, no fiber residue after wiping), electronic industry cleaning cloths (anti-static treatment, suitable for precision instrument cleaning), laboratory mild chemical reagent wiping cloths (good chemical resistance, avoiding reagent corrosion). The product has a better cost performance than the original fiber wiping cloths, and meets the requirements of industrial enterprises for green production. After use by a mechanical manufacturing enterprise, the procurement cost of wiping materials decreased by 18%.

Agricultural Market: In the agricultural field, the products, with the advantages of "environmental protection + durability", are used for seedling covering cloth (medium weight 45-60g/㎡, breathable and moisturizing, promoting seed germination, avoiding pest damage), weed prevention cloth (high weight 90-120g/㎡, inhibiting weed growth, allowing rainwater penetration, degradable after decomposition, not polluting the soil), and flower packaging cloth (50-70g/㎡, soft and protecting flower branches and leaves, beautiful packaging and environmentally friendly). For example, the weed prevention cloth uses black masterbatch dyeing (recycled fibers are suitable for dyeing process), with a shading rate of ≥ 90%, significant weed prevention effect, and can be degradable, avoiding the environmental pollution problem of traditional plastic weed prevention cloth.

Packaging Market: For the demand for environmentally friendly packaging, the products are used for lightweight industrial product packaging cloths (medium weight 60-80g/㎡, such as small mechanical parts packaging, scratch-resistant and environmentally friendly), gift packaging inner lining (50-70g/㎡, such as environmental-friendly gift box inner lining, enhancing the brand's environmental image), and courier cushion packaging (80-100g/㎡, replacing foam, reducing white pollution). After being adopted by an e-commerce enterprise, the environmental complaint rate of packaging materials decreased by 40%, and the brand's favorability increased. VI. Company Environmental Commitment and Service Assurance

Changshu Yongdeli Spunlaced Nonwoven Fabric Co., Ltd. has established a "Full Life Cycle Environmental Control" system for recycled fiber staple nonwoven fabrics: At the raw material end, only compliant recycled fibers are purchased, and inferior recycled materials are rejected; At the production end, energy-saving processes such as water recycling and waste heat recovery are adopted to reduce production energy consumption and pollution; At the finished product end, "environmental inspection reports" and "traceability documents for recycled materials" are provided to ensure that customers use compliant products.

At the same time, the company can provide customized services according to customer needs: Adjusting the ratio of recycled fibers (such as high recycled polyester, high recycled polypropylene), customizing texture structures (mesh, plain, embossed), adding exclusive post-treatment functions (antibacterial, anti-static, hydrophilic); For bulk customers, free sample testing services are provided to assist customers in optimizing product design, ensuring that the recycled fiber staple nonwoven fabrics perfectly fit downstream application scenarios.

In the future, Changshu Yongdeli Spunlaced Nonwoven Fabric Co., Ltd. will continue to increase its investment in the research and development of recycled fibers, exploring "recycled fibers + functional" composite products (such as recycled antibacterial nonwoven fabric, recycled waterproof nonwoven fabric), and expanding their applications in high-end hygiene products, medical auxiliary materials, etc. It aims to provide global customers with higher-quality and more environmentally friendly nonwoven fabric solutions, jointly promoting the green and sustainable development of the industry.