Some products use thick materials, and many products use lighter materials to provide better comfort, especially in wearable products. Products made of lightweight composite materials include: masks, surgical gowns, feminine hygiene products, diapers, filtration products

When producing non-woven composite materials(Composite Nonwovens On Sales), it is important to ensure that the composite process does not damage each layer of composite materials, especially for the production of lightweight composite materials that are thinner and more fragile than high-quantity composite materials.

With this in mind, three methods can be used to increase the output of lightweight composite non-woven fabrics while minimizing the risk of defective products.

1. Use high-quality raw materials

The raw materials used to produce composite materials(Home Textile Nonwovens Company) will play a huge role in final weight and strength. When it comes to non-woven fabric raw materials, products that are thin and light at the same time with good tensile strength are needed. Synthetic fibers and natural fibers can be used, and they can be used in any combination.

Synthetic fibers, such as polyester fiber, polypropylene, polystyrene and other polymers, are the best choice for strong and lightweight raw materials, which can be made into waterproof, breathable, high temperature resistant, soft and printable materials. In order to improve the comfort and breathability of the product, wear-resistant and lightweight raw materials such as cotton can be added.

Regarding the bonding material, the polyethylene film will provide the best adhesion while maintaining the lightness, softness and flexibility of the entire composite material. In addition, polyethylene film can be used in different composite processes to provide an efficient waterproof barrier, high strength and tear resistance.

2. Lifting tension control

Tension control is one of the most important factors in the production of high-quality composite non-woven products(Composite Non Woven Fabric Wholesale). If the fabric tension is too high or too low in either direction, it may tear and damage one or more layers of the composite material. This is especially true for lightweight materials: they are thinner and lighter, and the non-woven composite materials produced are more easily damaged. Improper tension control can also cause wrinkles, areas where the bonding is not complete and the widths of the layers are incompatible.

It is important to fully understand the tensile strength of the raw materials used in composite materials: For lightweight materials, the tension setting must be absolutely precise, because even the smallest deviations can damage the material.

In this case, it is best to use an intelligent composite system, such as the A.Celli F-LineⓇ system, which uses sensors, cloud technology and software to monitor every step of the process-unwinding, compounding, slitting and reeling.

When the entire process can be viewed from a bird's eye view, and the system can detect defects and transmit production data in real time, the tension setting can be fine-tuned without stopping production. This can ensure that the tension setting is always maintained at the best condition, resulting in a high-quality final product.

3. Control the production speed

In the entire composite process, the speed of the production line must also be controlled, because the speed will affect the tension of the fabric. In addition, especially when winding the final composite material, improper speed will cause end face expansion and contraction, wrinkles and air retention, resulting in defective rolls.

Ideally, it is desirable to produce as fast as possible without affecting the quality of the final product. In non-woven fabric compounding, this means that the unwinding speed of each layer and the speed of feeding into the compounding equipment, the speed of the compounding equipment and the speed of slitting and winding to form the finished roll are all essential for obtaining high-quality products. .

As with tension, equipment equipped with sensors and cloud services can measure equipment speed and detect defects in materials at all stages of the process. These data can be analyzed and transmitted, so the necessary adjustments to the equipment speed can be made during the operation. This function will ultimately enable you to find the best production speed and ensure the integrity of each layer of composite non-woven fabric produced and the integrity and quality of the final product.

When these three aspects of the composite process are precisely controlled, a compact, soft, and comfortable lightweight non-woven composite material can be produced, and the risk to the integrity of the individual layers and the final composite material is minimized.