Nonwoven fabrics do not have a separate academic discipline in universities; rather, they are taught as part of textile engineering courses. Even in universities abroad, there is no independent field specifically named “nonwoven textiles.” We are always seeking new opportunities to understand the global state of the nonwoven industry and to discover what’s new. We aim to participate in as many exhibitions as possible, and we often regret that, due to various challenges, we are unable to purchase new machinery. However, we attend these exhibitions to gather ideas and keep our knowledge up to date.
When did nonwoven textiles gain attention, and when did their industrial production begin?
The production of nonwoven textiles dates back hundreds of years to ancient Iran, where felt-making was a prominent craft, widely used among nomadic tribes and communities. The practice of felt production eventually spread to other parts of the world, giving nonwoven textiles a longer history compared to woven fabrics. In other countries, the manual felt-making process gradually evolved into mechanized systems. Initially, the use of nonwoven textiles and their production was limited, with most layers serving as fillers. However, nonwoven textile production in Germany and England has a long-standing history, and gradually, their production expanded and developed. As a result, each part of this industry was established in one country and then spread to others.
All countries strive to produce nonwoven layers that closely resemble fabric, aiming for greater strength while maintaining a lower cost compared to traditional textiles.
What share does nonwoven textiles currently have in the global textile market, and how do you see its future?
In recent years, nonwoven textiles have become one of the most active industries. As you may know, the textile industry in Europe no longer enjoys the same prosperity it once had. Production has shifted to countries in the Far East and regions like Indonesia, Malaysia, China, and India, due to lower labor costs. As a result, traditional textile production has faced a downturn. However, when it comes to nonwoven textiles, I am pleased to say that the industry has continued its growth trajectory over the years. Nonwoven textiles are fundamentally different from traditional textiles, with the materials used in their production being distinct from those used for fabric production.
Nonwoven textiles have not experienced a downturn in recent years, and I am optimistic about their future. They have established a strong presence across various sectors, such as construction, healthcare, and more. Due to their low cost, high production speed, and greater output per unit area compared to woven textiles, they have garnered significant attention from manufacturers and industry professionals. For example, the production speed of layers for garments and sanitary napkins can reach 400-500 meters per minute. As production speeds increase, labor costs are distributed over a larger output, making the final product more affordable.
Growth of Nonwoven Textiles in Different Regions Worldwide from 2021 to 2026
The nonwoven textiles sector is expected to continue expanding globally, driven by demand in sectors like construction, healthcare, and hygiene products. This growth is fueled by their versatility, cost-efficiency, and the rising need for materials that combine strength with affordability.
Is it possible that the development and advancement of nonwoven textiles will reach a point where they are used in everyday applications, such as clothing?
One of the latest technologies in nonwoven layers is spunlace, which uses water pressure for bonding and has found some applications in general uses. However, it has not yet entered the apparel industry, as nonwoven layers generally lack the necessary strength to replace fabric in clothing production. In the context of everyday clothing, elasticity is crucial, but this issue has not yet been resolved in nonwoven production.
Another key point is that nonwoven textiles do not have a woven structure with warp and weft, which results in less longitudinal and transverse strength compared to woven textiles. Currently, nonwovens also lack the diversity in colors, patterns, and designs required for outer layers and visible surfaces. For example, the nonwoven layers used in the footwear industry are typically only available in white or black, with less emphasis on other colors. In the case of fusible interlinings used in garments, only white, black, and mixtures of the two are available, and there is no significant demand for color variety.
Most nonwoven textiles are produced as intermediate products, where color is not a critical factor unless they are intended for use as outer layers. While some research has begun exploring the use of nonwovens in everyday applications, it has not yet yielded widespread results or applications in the apparel industry.
What are the strengths and weaknesses of the nonwoven textiles industry?
Nonwoven textile fibers are primarily made from polyester, polypropylene, viscose, nylon, polyamide, and acrylic, which are not biodegradable. This characteristic can be considered a weakness of nonwoven textiles, as they do not easily return to nature. However, one positive aspect of the nonwoven industry is its focus on utilizing factory waste and converting it into other types of layers. If the fibers are recyclable, they can be melted down and used as additives in the plastics industry, thus contributing to a more sustainable use of resources.
When explaining or choosing between fabric and nonwoven layers for a specific process, it is essential to compare their characteristics. Nonwoven textiles generally do not have significant drawbacks and can even be more economically viable than woven fabrics. In the past, for producing the outer layers of diapers and sanitary napkins, using fibers with petroleum bases was prohibited, and only nonwoven layers made from viscose fibers were accepted. However, after numerous meetings with the Institute of Standards and Industrial Research of Iran, we demonstrated that PP (polypropylene) fibers could replace viscose.
Using PP fibers increased production speed, though PP lacks some desired characteristics, such as absorption capacity. However, its permeability is excellent—liquids pass through the PP layer and are absorbed in the inner layers. In contrast, with a viscose system, when the top layer gets wet, it retains moisture, staying in contact with the child’s skin, causing discomfort due to constant wetness.
Previously, most nonwoven layers used in the diaper and sanitary napkin industries were imported. During that time, foreign manufacturers upgraded their old systems to new thermobond systems and replaced viscose with PP fibers. As a result, Iranian companies also had to adopt new layers made entirely from PP because the production of viscose-based layers for these industries had ceased due to high costs and low production speed. Simultaneously, domestic producers like Iran Risseh and Roz Fibers began producing hygienic polypropylene fibers, and new thermobond production lines were established in Iran under the supervision of the Institute of Standards.
Today, spunbond layers are also used in the diaper and sanitary napkin industry, especially in the production of complete diapers where greater strength is required. However, in general, the softness of thermobond layers is superior to that of spunbond layers.
