A professional insight into Spunbond fabrics

Introduction

When we hear the word “fabric,” we often think of traditional woven textiles — those interlaced with warp and weft threads.
However, in the modern world of textiles, there exists a family of fabrics that are produced without weaving or knitting. These are known as non-woven fabrics.
One of the most important and widely used members of this family is the Spunbond fabric — a lightweight, economical, and versatile material whose presence can be found everywhere: in medical, hygiene, agriculture, industry, packaging, and even in our everyday life.

Definition and Nature of Spunbond

Spunbond is a non-woven textile made from continuous polypropylene filaments.
These fibers are bonded together — without weaving — through thermal, mechanical, or chemical processes, resulting in a uniform sheet of lightweight yet durable fabric.

A remarkable feature of Spunbond is its wide GSM range — from as low as 10 g/m² to as high as 200 g/m².
This flexibility allows it to be used for lightweight applications such as medical masks, as well as heavy-duty uses in agriculture and industry.

Spunbond Manufacturing Process

The production of Spunbond is a precise yet rapid process.
The main stages include:

1. Raw Material

The primary material is polypropylene granules (PP) — known for being lightweight, chemically resistant, and cost-effective.

2. Melting and Extrusion

The granules are melted and extruded through fine nozzles (spinnerets) into continuous filaments.

3. Cooling and Drawing

The fibers are cooled by cold air and stretched to reach the desired diameter.

4. Web Formation

The drawn fibers are laid randomly on a conveyor belt, forming a uniform web layer.

5. Bonding

The web is bonded using one of the following methods:

• Thermal bonding: Using heated rollers.
• Mechanical bonding: By needle punching.
• Chemical bonding: Using adhesives or resins.

6. Collection

The final fabric is wound into large rolls for distribution.

🔹 Spunbond fabrics can be single-layer (S), double-layer (SS), triple-layer (SSS), or even multi-layered.
For specialized uses, Spunbond is often combined with Meltblown layers to form SMS fabrics — the most common material used in medical masks.

Physical and Chemical Properties

Spunbond fabrics possess unique characteristics that distinguish them from other textiles:

• GSM (Weight): 10 to 200 g/m²
• Roll Width: Typically 160 to 320 cm
• Variable Thickness: Depending on application
• Lightweight and Breathable: Allows air and vapor to pass through
• Customizable: Can be treated to become antibacterial, water-resistant, UV-protected, or antistatic
• Printable Surface: Logos and patterns can easily be printed
• Eco-Friendly: Made from recyclable polypropylene

Applications Across Industries

1. Medical and Hygiene

The largest consumer of Spunbond fabrics includes:

• Medical face masks (outer and inner layers made of Spunbond)
• Surgical gowns, caps, and shoe covers
• Baby and adult diapers
• Sanitary napkins
• Disposable wet wipes

2. Agriculture

In agriculture, Spunbond serves as plant covering material:

• Protects crops from cold, strong sunlight, and birds
• Controls weed growth
• Used as mulch fabric in gardens

3. Packaging and Advertising

One of the most familiar uses of Spunbond is non-woven shopping bags:

• Replaces plastic bags
• Lightweight, strong, and recyclable
• Suitable for high-quality printing

4. Industrial and Filtration

• Air and water filtration systems
• Separation layers in oil & gas industries
• Reinforcement layers in composites

5. Automotive Industry

• Sound and heat insulation layers
• Seat covers and floor liners

6. Furniture and Footwear

• Mattress inner layers
• Affordable upholstery
• Shoe linings

7. Household Uses

• Disposable covers and wipes
• Tablecloths and cleaning cloths
• Furniture and equipment covers

Advantages and Disadvantages

✅ Advantages

• Economical and cost-effective
• Lightweight and portable
• Breathable and comfortable
• Fast, high-volume production
• Recyclable material
• Customizable properties (antibacterial, waterproof, etc.)

⚠️ Disadvantages

Shorter lifespan under heavy use

Low resistance to high temperatures

Weaker mechanical strength than woven fabrics