The shape of the shopping bag is made from spunbonded nonwoven fabric, which serves as an environmental protector against white pollution. China's spunbond industry has seen rapid development within the nonwoven sector, yet it still lags behind the internationally advanced spunmelt industry. Despite the broad market potential for spunbonded nonwovens, the entire industry requires further adjustment. Following the "plastic limit order," a new product emerged—super-humidity bags that became more popular than traditional spunbonded nonwoven fabrics. As thin plastic bags declined significantly, many faced the question of what kind of equipment to invest in, and the market continues to evolve.
Not long after, many businesses chose to produce polypropylene, polyester, and nylon fabric shopping bags using the non-woven viscose method. White pollution is influenced by government regulations, varying weight requirements, and the growing environmental awareness of citizens. These materials are easy to coat, composite, or counterfeit into shopping bags, making them widely applicable. Their role as an environmental guardian highlights their promising future in the market.
Polyester spunbond nonwoven fabric is mainly used as an adhesive nonwoven fabric. It finds applications in geotextiles, anti-seepage materials, waterproof building products, composite reinforcement materials, automotive components, technical key fabrics, cushioning materials, and shoe chemical sheets. In the nonwoven manufacturing process, spunbonded polypropylene nonwoven fabrics are widely used due to their production technology, performance, and material versatility.
When shopping, spunbonded nonwoven pockets have replaced plastic bags as the main choice. They offer clear advantages in efficiency and other aspects, contributing to their rapid development over the past 30 years. Today, they remain a core technology in the spunbond production process. Spunbonded nonwovens have entered the textile, paper, and film industries, but the sector still needs refinement.
Approximately 40% to 50% of the country’s nonwoven fabric production uses the conventional drafting method, which is mechanical. Due to the large number of spunbonded nonwoven fabric producers, most enterprises are small-scale, with limited technical capabilities. The melt spinning method, which includes spunbonding, melt-blown, and fiber monofilament processes, often results in uneven laying and coarse fibers. With polypropylene as the main raw material, challenges such as outdated equipment, poor management, and insufficient R&D capabilities persist.
In some advanced countries, air-jet drafting technology has gained popularity due to its advantages, driving growth in the spunbonded nonwoven field. Recently, many companies have adopted this method as their primary production technique. At the end of the 20th century, nonwoven fabrics saw three major developmental paths in spunbond production lines.
The spunbond nonwoven industry has expanded, particularly in North America, where both tubular and wide slit drafting methods are used. This leads to intense competition, with spunbonded nonwovens accounting for more than half of the total nonwoven market. Stretching, narrow seam drafting, and other techniques result in better elongation, tear strength, and other properties compared to dry-laid methods.
Despite these advancements, the ordinary spunbond method remains the primary approach for polymer direct-laid nonwovens. Wet methods, meltblown nonwovens, and sticky products still maintain a market presence. To address this, one key spinning technology involves extruding polymers, using polypropylene and polyester, which have seen significant growth in production scale and technology in recent years.
After high-level stretching, continuous filaments, long filaments, and polyamides (nylon) have developed rapidly due to market demand, while also meeting multi-level needs. Laying the fibers into a net creates self-adhesive structures, with the molecular structure of polyamide influencing crystallization and enhancing thermal bonding, chemical bonding, or mechanical reinforcement.
Spunbonded nonwovens in China have notable strengths, including high tensile strength, heat resistance, UV resistance, and elongation. However, the spunbond method is not as effective as melt-blown in improving fiber properties. The production of spunbonded nonwoven fabric is booming, but it still faces challenges compared to international standards.
Looking ahead, the development focus will be on high elongation, stability, permeability, corrosion resistance, and stable crystallization. Improving physical and mechanical properties, while addressing issues like poor abrasion resistance and high production costs, will be crucial. Functional nonwovens with soundproofing, tamper-proof, and non-toxic features are becoming increasingly important.
Advanced technologies such as hollow, two-component, and three-dimensional fibers, derived from spunbonding and melt-blown processes, are being explored. Companies like Exxon have developed new products with different lengths and complementary features, including degradable fibers. On the market side, the dry-spinning method is rapidly gaining traction, expanding into medical and health applications.
Current production involves melt extrusion, filtration, and the use of synthetic polymers with sticky and melt-blown composite technologies. The set productivity ranges between 13% to 15%, with developments in wire laying, cooling, air drafting, and dry nonwoven processing. This eliminates the need for dedicated spunbond-meltblown composite nonwoven facilities.
In terms of equipment, the world’s most advanced systems are being adopted, featuring wire laying, pre-acupuncture, fiber curling, cutting, packaging, transportation, and mixing. This integrated structure makes full use of porous spinnerets, multi-head spinning machines, winding, and finishing into a final product. These processes allow for continuous and large-scale production, combining the advantages of both technologies and the versatility of nonwoven fabrics.
The goal is to create multi-variety, multi-layer composites with diverse raw materials. This reduces product costs, improves vertical and horizontal strength, and ensures uniformity. Features like low consumption, low denier, and low gram weight make these fabrics highly competitive in the market. Compared to traditional chemical fiber spinning, they use lower-quality raw materials but maintain stable quality and strong market appeal.
High-speed, high-yield, air-jet drafting, and direct web forming enhance liquid-repellent, heat-insulating, and filterable properties. These characteristics make them suitable for a wide range of applications, from disposable to durable products.
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