Spunlace in the hygienic industry of Russia and the CIS. Spunlace: technology, properties, application Manufacturers of medical products made from spunlace fabric

Spunlace is unique material, which is produced using a special technology for tightly connecting threads without adhesive additives. The fabric contains polyester and viscose fibers. The optimal proportion of these components makes it possible to obtain a chemically pure non-woven material with a lint-free structure.

Spunlace is ideal for use in the medical field, where the convenience and safety of products are of paramount importance. Non-woven fabric is used to make obstetric, surgical, dental kits, operating and bed linen, absorbent diapers, napkins, sheets and towels, as well as special protective clothing for doctors, patients and staff.

The material does not attract dust and does not lose its original properties after sterilization. It can be hydrophilic or hydrophobic depending on the method of weaving the fibers and composition.

In addition to the medical field, the fabric is used in cosmetology, car services, and any industries with increased requirements for cleanliness during the production process.

Material characteristics

Non-woven fabric Spunlace, thanks to a special technology of fastening fibers with jets of water under high pressure, acquires unique properties, including:

• Hygroscopicity. Absorbs and retains moisture and liquid components well. Thanks to their absorbency, spunlace products can replace traditional cotton wool and gauze.
• High degree of breathability. The fabric has the highest breathability rate among other non-bulky nonwoven materials. Excellent air permeability and ventilation of clothing.
• Lint-free structure. During surgical operations, lint is a potential threat to the patient. Particles that constantly move in the air can carry bacteria. This increases the risk of developing infections, and therefore the structure of the fibers without lint is primarily a guarantee of safety.
• Hypoallergenic. When in contact with the skin and mucous membranes, the non-woven material does not cause allergic reactions.
• Strength and elasticity. Spunlace is a thin but durable fabric that is tear-resistant. The longitudinal weave of the fibers gives it elasticity, the transverse weave gives it additional strength.

The production of nonwoven materials is one of the most promising areas of the textile industry. Over the past 10 years, it has grown in volume almost 3 times. Such high production growth rates are explained by the use of cheap and quick ways obtaining textile fabrics:

• Spandbond (from polymer melt);
• Spunlace (fastening fibers using water jets);
• SMS (from polymer blowing).

Being environmentally friendly, sterile and chemically inert products, nonwoven materials are widely used in the medical industry (obstetrics, gynecology, surgery). They acquired high protective properties thanks to coating with polymer compounds, which is especially important when used under sterile conditions. Today, non-woven materials are used to produce disposable clothing, sheets, napkins, towels, masks and much more.

Spunbond

This non-woven thermally bonded material, consisting of the finest polypropylene threads, is the main one in the production of disposable clothing and linen. Its advantages include bioinertness, strength and affordable cost. The most popular in Russia is polypropylene-based spunbond. Mandatory stages in its production are antistatic and bactericidal treatment.

At a density reaching 42 g/m2, spunbond is characterized by high moisture and breathability and ease of sewing. Spunbond can be welded, and printing on its surface is also possible. Non-toxicity and hypoallergenicity, the possibility of sterilization and a wide color palette perfectly explain its prevalence.

Spunlace

The material is produced by weaving fibers of polyester, viscose, polypropylene, cellulose using aqua currents high pressure. The most popular in Russia is spunlace based on viscose. The main characteristics of the material are:

• Elasticity,
• Strength,
• Ease,
• Environmental friendliness,
• Hygroscopicity,
• Volume,
• Barrier properties;
• No lint.

Distinctive characteristics of spunlace include the optimal ratio of thinness and strength, non-toxicity and antistatic properties. In terms of moisture absorption, spunlace is not inferior to cotton wool and gauze. Disposable wipes and towels made from this material are pleasant to the touch and do not cause allergic reactions or irritation. Density of spunlace used in the production of disposable medical clothing and Supplies, varies in the range of 30-80 g/m2.

SMS

SMS is a composite made from spunbond. It consists of 100% polypropylene fibers. A distinctive feature of this material is that between 2 layers of spunbond there is a layer of meltblown. SMS has high absorbent properties, but does not allow biologically active liquids to pass through, chemical compositions, fats. In its pure form, it is used to collect oil spills from the surface of the water.

SMS is widely used in the production of disposable medical clothing. Compared to traditional spunbond, the antibacterial properties of SMS are 7-10 times higher. Also, this material perfectly copes with the role of a filter element in protective masks. It is used to make headrests on trains and airplanes, sets of disposable bed linen for hotels, and much more.

Technology

Spunlace technology originated in the 60s. last century, but was first officially introduced in 1973 by DuPont (Sontara). Sontara is the result of DuPont and Chicopee, now largest producers spunlace. Since 1990 this technology has been improved and made available to other manufacturers.

Hydroweaving technology is based on interweaving material fibers with high-speed jets of water under high pressure. It is usually tightly fastened onto a perforated drum using high-pressure water jets from the injector beams (Figure 1). Due to these jets, the canvas fibers are connected to each other. As a result, the fabric obtained in this way has specific properties, such as softness and drape.

Picture 1

Carding of staple fibers (drylaid). Refers to the dry method of forming canvas. In this case, the canvas is formed from staple fibers and is formed as a result of carding the original fibers on carding machines. The fibers are combed by the working parts of a carding machine with a needle surface, and placed in a canvas on the receiver. This process is shown schematically in Figure 2.

Figure 2

Aerodynamic method of canvas formation (airlaid); This is the same dry method of canvas formation (dry-laid). However, with this method, the web is formed from very short staple fibers and is formed under the influence of air flow on the surface of a perforated drum or mesh conveyor. Pre-opened and mixed fibers are processed by a rapidly rotating carding drum (or several drums), separated from the carding set using an air jet and transported.

Figure 3

Hydraulic method of canvas formation (wetlaid). This method is also called paper-making (borrowed from the paper industry). Feature this method canvas forming is that the production of non-woven fabrics occurs by pouring an aqueous suspension onto the mesh part of a paper-making machine.

Figure 4

Spunlaid - spunbond; With this technology, the canvas is formed from continuous threads (filaments) obtained from a polymer melt. The threads are molded from polymer using the spun-blow method and almost simultaneously laid into the canvas.

Figure 5

It must be said that initially all spunlace fabrics were produced mainly using the dry-laid method of forming the canvas, i.e. Before the canvas was pierced by water jets, it was formed by carding staple fibers. However, now the situation is changing somewhat. The volume of production of canvases using airlaid and wet-laid technologies is increasing. In addition, the world's leading manufacturers of spunlace equipment (Rieter and Flessner) have recently been able to offer consumers equipment that combines two technologies - spunlaid (as a method of forming a canvas based on continuous threads from a polymer melt) and spunlacing (as a method of fastening the canvas). This “spunbond-spunlace” technology promises to be very popular in the future, since the product obtained using this production method combines the properties of both technologies.

Figure 6. Types of grating and finished canvas

Usually the canvas is punched alternately on both sides. The canvas can pass through jets of water a certain number of times (depending on the required strength of the canvas). The bonded fabric passes to a drying device, where it dries well.
At standard process conditions (6 rows (distributors) of jets, pressure 1500 psi, density 68 gsm) requires 800 lbs of water per 1 lb of product. Therefore, it is very important to develop a good filtration system that can efficiently supply clean water, otherwise the injector holes may become clogged.

The advantages of this technology are as follows:
- no damage to fibers ( mechanical impact on the internal structure of the fiber);
- technology allows you to use Various types fibers and their lengths
- the speed of web formation is enormous - 300-600 m/min;
- the production process is environmentally friendly
By its principle, the technology is sterile.

Raw materials

The starting materials for the production of spunlace fabrics are most often staple fibers obtained from viscose, polyester, polypropylene, cellulose, and cotton.

Viscose
A synthetic fiber obtained from pure cellulose.
The advantages of viscose materials are the same as those of natural fibers:
. pleasant to the touch;
. do not cause physiological reactions;
. have high absorption capacity;
. easy to finish.

Cellulose
Cellulose fiber is a wood fiber that is produced from wood and comes in the form of rolls or bales.

Properties:
. hydrophilicity;
. rapid absorption and reliable retention of water and other liquids;
. renewable resource;
. biodegradable;
. very favorable price compared to other natural and synthetic
fibers.

Polyester (polyester, PEF, PET, PET, polyethylene terephthalate)
Produced by melt molding. Today, PET fibers form the largest group of synthetic fibers.
Properties
. density 1.38;
. especially durable;
. elastic;
. abrasion resistant;
. light-resistant;
. is not affected by organic and mineral acids;
. water absorption is only 0.2 - 0.5%;
. Strength when wet is as high as when dry.

Polypropylene (PP)
A synthetic fiber produced by melt-spinning from isotactic polypropylene.
Properties:
. lower density 0.91;
. melting range 165-175°C;
. softening area 150-155°C;
. the fiber is resistant to aggressive chemicals;
. there is practically no moisture absorption;
. reliable abrasion resistance;
. sensitive to ultraviolet radiation;

Cotton
Cotton is a fibrous material that is widely accepted among consumers due to its natural origin.
Positive properties of cotton:
. absorption;
. biodegradability;
. gas permeability;
. ease of sterilization;
. heat resistance;
. high strength when wet;
. good insulating properties;
. lack of allergic properties;
. possibility of regeneration;
. softness.
Due to its high absorption capacity, good fabric-like structure with low lint shedding and high wet strength, cotton is the best material for medicine, appliances, cosmetics, personal consumption and wet wipes. Cotton processed using the spunlace method, in addition to the medical industry, can be successfully used for the production of sheets, napkins and tablecloths that can withstand 6 to 10 washing processes. Products made using this method look like linen and can be dyed and printed to achieve the required appearance.
Typically, the above fibers are used in blends. Synthetic fibers (polyester and polypropylene) are mixed with viscose or natural fibers (cotton, cellulose). Also, any of the described fibers can be used independently without impurities.
In accordance with world practice, the following spunlace compositions have become widespread on the market:
. viscose/polyester;
. viscose/polypropylene;
. viscose;
. polyester;
. cotton;
. polypropylene;
. cotton/polypropylene;
. cotton/polyester;
. cotton/viscose;
. cellulose/polyester;

The composition of spunlace determines the final area of ​​use of the material.

Dry/wet wipes: polypropylene/polyester + viscose;
Wet wipes: polypropylene/polyester + viscose; polypropylene/polyester + viscose + cotton;
Clothing and linen for operating rooms: polyester/polypropylene + viscose, cellulose + polyester; polypropylene/polyester + viscose + cotton;

Material properties

Thanks to bonding with water jets, spunlace nonwoven material acquires the unique properties of nonwoven materials, among which the following should be highlighted:
. High degree of absorption (high hygroscopicity);
. High breathability (the highest among non-bulky nonwovens);
. Softness and good tactile sensations, close to natural fabrics.

Besides, distinctive features and the advantages of this non-woven material are:
. Combination of strength and thinness;
. Tear resistance;
. Lint-free structure;
. Non-toxic;
. Antistatic;
. Good drapability;
. Dialergenic;
. No peeling;

Areas of use

According to world practice, spunlace can be used in various sectors of the national economy:

Spunlace nonwoven material is highly popular, and its main quality is high hygroscopicity. Spunlace in rolls is popular, from which products are then made wide application. The beginning of the era of spunlace production dates back to the 30s of the last century. Spunlace non-woven textile material is widely used for household and hygiene needs, as well as for the manufacture of medical clothing and technical applications. The main manufacturer of spunlace in Eastern Europe is Mogilevkhimvolokno, the products bear the trade name Sontara and consist of 50% cellulose and 50% polyester. There is laminated spunlace; during its manufacture, a thin layer of polyethylene is applied to one side of the fabric, which significantly expands the scope of its application. In the global production of spunlace nonwoven material, the composition can be different: viscose and polyester, viscose and polypropylene, cotton and propylene, cellulose and polyester, and many others.

Spunlace is a technology for the production of non-woven fabric, which consists of mechanically bonding the fibers (threads) of the canvas into the fabric through hydroweaving.

Production technology

Spunlace technology originated in the 60s of the last century, but was first officially introduced in 1973 by DuPont (Sontara). Sontara is the result of the activities of DuPont and Chicopee, now the largest manufacturers of spunlace. Since 1990 this technology has been improved and made available to other manufacturers.

Hydroweaving technology is based on interweaving material fibers with high-speed jets of water under high pressure. Usually tightly fastened on a perforated drum using high-pressure water jets from the injector beams. Due to these jets, the canvas fibers are connected to each other. As a result, the fabric obtained in this way has specific properties, such as softness and drape.

In fact, spunlace technology is just one of the ways to fasten canvas. In turn, the canvas itself can be formed in various ways, including:

. Carding of staple fibers (drylaid). Refers to the dry method of forming canvas. In this case, the canvas is formed from staple fibers and is formed as a result of carding the original fibers on carding machines. The fibers are combed by the working parts of a carding machine with a needle surface, and placed in a canvas on the receiver.

. Aerodynamic method of canvas formation (airlaid); This is the same dry method of canvas formation (dry-laid). However, with this method, the web is formed from very short staple fibers and is formed under the influence of air flow on the surface of a perforated drum or mesh conveyor. Pre-opened and mixed fibers are processed by a rapidly rotating carding drum (or several drums), separated from the carding set using an air jet and transported.

. Hydraulic method of canvas formation (wetlaid). This method is also called paper-making (borrowed from the paper industry). The peculiarity of this method of canvas forming is that the production of non-woven fabrics occurs by pouring an aqueous suspension onto the mesh part of the paper-making machine.

. Spunlaid - spunbond; With this technology, the canvas is formed from continuous threads (filaments) obtained from a polymer melt. The threads are molded from polymer using the spun-blow method and almost simultaneously laid into the canvas.

It must be said that initially all spunlace fabrics were produced mainly using the dry-laid method of forming the canvas, i.e. Before the canvas was pierced by water jets, it was formed by carding staple fibers. However, now the situation is changing somewhat. The volume of production of canvases using airlaid and wet-laid technologies is increasing. In addition, the world's leading manufacturers of spunlace equipment (Rieter and Flessner) have recently been able to offer consumers equipment that combines two technologies - spunlaid (as a method of forming a canvas based on continuous threads from a polymer melt) and spunlacing (as a method of fastening the canvas). This “spunbond-spunlace” technology promises to be very popular in the future, since the product obtained using this production method combines the properties of both technologies.

Thus, a typical spunlace production process consists of several stages, similar to most nonwoven fabric production technologies:
. Fiber drain;
. Formation of the canvas;
. Piercing the canvas with jets of water;
. Drying the canvas;

When passing through a water circulation system, the formed web (by any of the methods described above) is first compressed in order to remove all possible air bubbles, and then sealed. Water pressure usually increases from the first to the last injector. Approximate indicators for the hydroplexing process can be the following:
. pressure at 2,200 psi (pounds per square inch);
. 10 rows of injectors;
. the diameter of the hole in the injectors is 100-120 micrometers;
. distance between holes - 3-5 mm;
. number of holes in one row (25 mm) - 30-80;

It is tightly held together by water jets on a perforated drum. The vacuum in the drum sucks out excess water from the web in order, firstly, to prevent the product from becoming waterlogged, and, secondly, to reduce the penetration force of the jet.

The perforated drum grid (conveyor grid) plays a very important role in the process of formation of the finished product. The pattern of the final canvas depends on the pattern of the lattice. The special design of the lattice allows you to obtain a different structure of the surface of the canvas (corrugation, terry, “hole”, etc.).

Usually the canvas is punched alternately on both sides. The canvas can pass through jets of water a certain number of times (depending on the required strength of the canvas). The bonded fabric passes to a drying device, where it dries well.

At standard process conditions (6 rows (distributors) of jets, pressure 1500 psi, density 68 gsm) requires 800 lbs of water per 1 lb of product. Therefore, it is very important to develop a good filtration system that can efficiently supply clean water, otherwise the injector holes may become clogged.

The advantages of this technology are as follows:
. No damage to fibers (mechanical impact on the internal structure of the fiber);
. The technology allows the use of different types of fibers and their lengths
. The speed of web formation is enormous - 300-600 m/min;
. The production process is environmentally friendly
. By its principle, the technology is sterile;

Raw materials for spunlace production

The starting materials for the production of spunlace fabrics are most often staple fibers obtained from viscose, polyester, polypropylene, cellulose, and cotton.

Viscose
A synthetic fiber obtained from pure cellulose.
The advantages of viscose materials are the same as those of natural fibers:
. pleasant to the touch;
. do not cause physiological reactions;
. have high absorption capacity;
. easy to finish.

Cellulose
Cellulose fiber is a wood fiber that is produced from wood and comes in the form of rolls or bales.
Properties:
. hydrophilicity;
. rapid absorption and reliable retention of water and other liquids;
. renewable resource;
. biodegradable;
. very favorable price compared to other natural and synthetic
fibers.

Polyester (polyester, PEF, PET, PET, polyethylene terephthalate)
Produced by melt molding. Today, PET fibers form the largest group of synthetic fibers.
Properties
. density 1.38;
. especially durable;
. elastic;
. abrasion resistant;
. light-resistant;
. is not affected by organic and mineral acids;
. water absorption is only 0.2 - 0.5%;
. Strength when wet is as high as when dry.

Polypropylene (PP)
A synthetic fiber produced by melt-spinning from isotactic polypropylene.
Properties:
. lower density 0.91;
. melting range 165-175°C;
. softening area 150-155°C;
. the fiber is resistant to aggressive chemicals;
. there is practically no moisture absorption;
. reliable abrasion resistance;
. sensitive to ultraviolet radiation;

Cotton
Cotton is a fibrous material that is widely accepted among consumers due to its natural origin.
Positive properties of cotton:
. absorption;
. biodegradability;
. gas permeability;
. ease of sterilization;
. heat resistance;
. high strength when wet;
. good insulating properties;
. lack of allergic properties;
. possibility of regeneration;
. softness.
Due to its high absorption capacity, good fabric-like structure with low lint shedding and high wet strength, cotton is the best material for medicine, appliances, cosmetics, personal consumption and wet wipes. Cotton processed using the spunlace method, in addition to the medical industry, can be successfully used for the production of sheets, napkins and tablecloths that can withstand 6 to 10 washing processes. Products made using this process have a linen-like appearance and can be dyed and printed to achieve the desired appearance.
Typically, the above fibers are used in blends. Synthetic fibers (polyester and polypropylene) are mixed with viscose or natural fibers (cotton, cellulose). Also, any of the described fibers can be used independently without impurities.
In accordance with world practice, the following spunlace compositions have become widespread on the market:
. viscose/polyester;
. viscose/polypropylene;
. viscose;
. polyester;
. cotton;
. polypropylene;
. cotton/polypropylene;
. cotton/polyester;
. cotton/viscose;
. cellulose/polyester;
The composition of spunlace determines the final area of ​​use of the material. For the most popular spunlace products
Dry/wet wiping materials: polypropylene/polyester + viscose;
Wet wipes: polypropylene/polyester + viscose; polypropylene/polyester + viscose + cotton;
Clothing and linen for operating rooms: polyester/polypropylene + viscose, cellulose + polyester; polypropylene/polyester + viscose + cotton;

Spunlace properties

Thanks to bonding with water jets, spunlace nonwoven material acquires the unique properties of nonwoven materials, among which the following should be highlighted:
. High degree of absorption (high hygroscopicity);
. High breathability (the highest among non-bulky nonwovens);
. Softness and good tactile sensations, close to natural fabrics.

In addition, the distinctive features and advantages of this non-woven material are:
. Combination of strength and thinness;
. Tear resistance;
. Lint-free structure;
. Non-toxic;
. Antistatic;
. Good drapability;
. Dialergenic;
. No peeling.

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Spunlace) is a modern non-woven material, the production principle of which lies in the interweaving of canvas fibers with high-pressure water jets - the so-called hydro-jet method of fastening fibers in canvas. Currently, about 200 lines for the production of nonwoven materials using the hydrojet method are installed in the world. Developed various technologies and devices for producing nonwoven materials in this way. One of the latest innovations in this area is the use of spunbond (endless) bicomponent fiber of the “segmental” type, consisting of 70% polyester and 30% polyamide. When the fibers are held together by jets of water, the polyester and polyamide components of each fiber are separated, creating many microfibers. The surface of microfibers in such fabrics is 5-7 times larger than the surface of conventional fibers, so these materials absorb liquids approximately 1.5 times more than cotton or viscose materials.
The advantages of nonwoven materials produced using hydrojet technology include good adsorption capacity and high performance tactile comfort for humans, similar in effect to natural cotton. These indicators are most important for wet wipes, which is why spunlace is actively pushing wet wipes manufacturers out of the market airlaid materials.
The starting materials for the manufacture of these materials are cotton, viscose, polyester or polypropylene fibers. Depending on the final product, different fiber blends are used. For the production of wet wipes and other cleaning materials, a mixture of viscose and polyester (polypropylene) fibers is used. To produce cotton pads, either 100% cotton wool or a mixture of cotton and polyester fibers is used. For the production of disposable medical clothing, as well as for the production of patient care products, a mixture of cellulose and polyester fibers is most often used.
The main problem for the development of spunlace production for hygienic purposes in Russia is the almost complete absence of a domestic raw material base. Apart from polyester and polypropylene fibers, which account for only 20% of all fibers required for production, no other raw materials are produced in the CIS. Moreover, the production of viscose fiber, so necessary for these purposes, died out in Russia, and cotton fiber was never produced. Although there is hope that all is not lost, when negotiating with the head of the marketing department » a project for the production of viscose fiber was mentioned. It is worth noting that the enterprise already has production of viscose and viscose thread. As a result, all they have to do is purchase a staple line, and they can obtain the raw materials that are so necessary for the production of spunlace.
And now a little about projects.
In 2007, the Avangard company installed the first line in Russia for the production of spunlace materials at its production site in Tosno (Leningrad Region). As of December 2008, this line was the only one in the Russian Federation that allowed the production spunlace for the production of wet wipes. In May 2008, the Avangard company entered into a contract with the French company Rieter Perfojet for the supply of a second production line spunlace materials of various densities with a maximum roll width of 2.4 m.
In January 2007, BalEnergoMash LLC. (JSC BEM) signed a contract with the French company Rieter Perfojet for the purchase of equipment worth about 180 million rubles. Declared production volume spunlace at the new enterprise the production capacity will be 4000 tons per year, the maximum width of the fabrics produced is 2.4 meters. Completed for now installation work and a trial launch of the line is expected at the end of February, beginning of March 2009.
In 2008, Paper Mill LLC began installing equipment manufactured by Fleissner for the production of spunlace for the production of cosmetic cotton pads. At the end of February 2009, the company intends to begin production and by the end of the first half of 2009 required quality material, and by the end of the year reach 100% equipment utilization. At the first stage, production will work for the company’s own needs, but in the future the materials will go on free sale.
In January 2009RUE Svetlogorsk PA "Khimvolokno" » has started installing equipment for a new line for the production of spunbonded nonwoven hydro- and thermally bonded materials. For this project, a modern line for the production of non-woven fabric was purchased by extruding continuous thin polypropylene threads with their subsequent hydro- or thermal bonding. The equipment suppliers are Reifenhauser and Fleissner. The line's capacity will be 5 thousand tons per year. At the moment, this is the first project in the CIS for the production of nonwoven materials using hydrojet technology from endless threads.

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