Airlaid Paper

Fiber Preparation

a. Raw Material Selection

Cellulose Fibers: The primary raw material used is cellulose fibers, typically derived from wood pulp. These fibers are chosen for their natural absorbency and softness.
Synthetic Fibers: To enhance specific properties, synthetic fibers such as polyester or polypropylene may be added.
b. Pulping and Refining
The selected fibers are pulped and refined to achieve the desired consistency and length. This ensures that the fibers are adequately prepared for the airlaying process.

Fiber Distribution

a. Airlaying Machine Setup

The airlaying machine, equipped with a series of formers and conveyors, is set up to create the airlaid web.
b. Fiber Dispersion
The refined fibers are dispersed into an airstream using a high-velocity air blower that separates and evenly distributes the fibers.
c. Web Formation
The dispersed fibers are directed onto a moving forming belt. As the fibers settle on the belt, they create a web with uniform thickness and density. The airflow ensures that the fibers interlock randomly, enhancing the web’s strength and absorbency.

Bonding

a. Thermal Bonding

In this method, the fiber web is passed through heated rollers or ovens. The heat activates thermoplastic binders within the fibers, causing them to melt and bond at the intersections. This method is commonly used when synthetic fibers are included.
b. Latex Bonding
A latex emulsion is sprayed or printed onto the fiber web. The web is then dried, and the latex forms bonds between the fibers. This method provides flexibility and softness while maintaining strength.
c. Hydrogen Bonding
This method relies on the natural bonding properties of cellulose fibers. Water is added to the fiber web, causing the cellulose fibers to swell and bond through hydrogen bonds as they dry. This method is more environmentally friendly as it avoids the use of synthetic binders.

Drying and Finishing

a. Drying

The bonded web is passed through drying units to remove any remaining moisture, ensuring the final product has the desired dryness and stability.
b. Calendering
The dried web is then calendered, where it is passed through a series of rollers to smooth and compress the paper. This step improves the texture and appearance of the final product.
c. Cutting and Winding
The finished airlaid paper is cut to the desired size and wound into rolls or sheets. These rolls or sheets are then prepared for further processing or packaging.

Hygiene Products

Baby Diapers: Airlaid nonwovens are used as absorbent cores in baby diapers, providing excellent fluid management and keeping babies dry and comfortable.
Feminine Hygiene Products: Airlaid materials are incorporated into sanitary pads and panty liners for their superior absorption and softness.
Adult Incontinence Products: Airlaid fabrics are crucial components in adult diapers and incontinence pads, offering high absorbency and discretion.

Medical and Healthcare

Wound Dressings: The soft, absorbent, and breathable nature of airlaid fabrics makes them ideal for wound dressings, promoting healing and patient comfort.
Surgical Gowns and Drapes: Airlaid materials are used in disposable surgical gowns and drapes, providing a barrier against fluids and bacteria.
Medical Wipes: Airlaid nonwovens are commonly used in medical wipes for their softness, absorbency, and ability to hold cleaning solutions effectively.

Other Applications
Tabletop Products: Airlaid materials are used in tablecloths, napkins, and placemats for their aesthetic appeal, liquid absorbency, and ease of disposal.
Filtration: Airlaid fabrics can be engineered for specific filtration applications, such as air filters and liquid filtration media.
Packaging: Airlaid nonwovens are used as protective packaging materials for fragile items due to their cushioning and impact-absorbing properties.