Spunlace nonwoven fabric — also called hydroentangled nonwoven — is produced by directing fine, high-pressure water jets onto a loosely laid fiber web, causing individual fibers to interlock mechanically. Unlike thermally bonded or chemically bonded nonwovens, no adhesives or heat are required. The result is a fabric with an exceptionally soft, textile-like hand feel combined with reliable wet strength, making it the dominant substrate for modern wet wipes worldwide.
The term "spunlace" comes from the combination of spunbond web formation and the entangling lace-like structure created by the water jet process. Since its commercialization in the 1970s, the technology has been refined to produce fabrics ranging from ultra-lightweight cosmetic wipes at 30 g/m² to heavy-duty industrial wipers exceeding 100 g/m².
For the wipes series market specifically, spunlace fabrics offer an unmatched combination of softness, absorbency, lint-free performance, and the ability to be formulated in both dry and pre-moistened configurations. This versatility explains why spunlace accounts for the majority of global wipes substrate production.
1. Fiber Opening & Blending. Baled fibers — viscose, polyester, or natural cellulose — are opened and blended to achieve uniform fiber distribution. This stage critically determines final fabric evenness and controls cost.
2. Carding & Web Formation. The blended fibers pass through a carding machine that aligns and forms a thin, uniform web. For isotropic fabrics used in premium wipes, cross-lapping is applied to balance MD/CD (machine direction / cross-direction) tensile ratios.
3. Hydroentanglement. The web passes under a series of injector manifolds that emit fine water jets at pressures of 40 to 200 bar. The jets penetrate the web, mechanically entangle fibers, and are recirculated through closed-loop water treatment systems. Multiple passes at increasing pressures progressively consolidate the structure. This is the heart of the process and the primary determinant of fabric strength and softness.
4. Drying & Surface Finishing. The wet fabric is conveyed through a through-air dryer (TAD) or heated drum dryer. Surface embossing or apertured patterning may also be applied at this stage to create textures like the pearl pattern popular in premium baby and cosmetic wipes.
5. Slitting & Roll Winding. Dried fabric is slit to customer-specified widths (commonly 100 mm to 3,200 mm) and wound onto master rolls at controlled tension. Aojia Nonwoven offers widths from 100 mm to 3,200 mm to serve converter lines of all scales.
The choice of fiber blend is arguably the most consequential design decision for a wipes nonwoven. The two primary fibers are viscose (regenerated cellulose) and polyester (PET), and their ratio governs the trade-off between softness/absorbency and tensile strength/durability.
| Fiber Type | Key Properties | Primary Use Case | Sustainability Note |
|---|---|---|---|
| Viscose (Rayon) | High softness, high absorbency, excellent skin feel, naturally derived | Baby wipes, facial cleansing wipes, premium personal care | Biodegradable; sourcing certification (FSC/PEFC) matters |
| Polyester (PET) | High tensile strength, good wet stability, low pilling, low absorbency | Industrial wipers, medical wipes requiring wet strength | Not readily biodegradable; recycled PET variants available |
| Viscose/PET Blend (70/30) | Balanced softness and strength; most common commercial specification | Baby & personal care wet wipes — mass market | Partially biodegradable depending on PET ratio |
| 100% Cellulose (Lyocell / Tencel) | Premium softness, closed-loop solvent production, fully biodegradable | Eco-premium facial wipes, sensitive skin applications | Fully compostable; certified biodegradable |
| Cotton Pulp / Wood Pulp | High liquid retention, natural origin, good for co-form products | Flushable wipes, toilet wipes, medical gauze pads | Readily biodegradable; flushability compliant |
At Aojia Nonwoven's wipes fabric, the standard substrate is crafted from premium viscose/polyester blends, engineered to deliver an ultra-soft, lint-free, and non-shedding surface with excellent wet strength — exactly the performance profile demanded by leading wipes converters globally.
When sourcing spunlace nonwoven for wipes applications, buyers and quality engineers evaluate a specific set of performance metrics. Understanding these parameters helps procurement teams specify the right fabric and ensures end-products meet consumer expectations and regulatory requirements.
| Parameter | Typical Range (Wipes Grade) | Test Method | Why It Matters |
|---|---|---|---|
| Basis Weight (GSM) | 40–60 g/m² | ISO 9073-1 / EDANA WSP 130 | Controls thickness, feel, and cost-per-wipe |
| Tensile Strength (Dry) | MD ≥ 40 N/5cm; CD ≥ 25 N/5cm | ISO 9073-3 / EDANA WSP 110 | Prevents tearing during use; critical for baby wipes |
| Wet Tensile Strength | MD ≥ 25 N/5cm (saturated) | EDANA WSP 110.4 | Determines performance once saturated with lotion |
| Absorption Capacity | ≥ 600% of fabric weight | EDANA WSP 10.1 | Determines how much lotion the wipe can retain and release |
| Lint (Fiber Shedding) | ≤ 0.5 mg / 10 wipes (typical) | Martindale abrasion adapted | Lint-free critical for optics, medical, and cosmetic wipes |
| pH Compatibility | Fabric pH 6.5–7.5 | ISO 3071 | Neutral pH prevents skin irritation |
| Thickness / Caliper | 0.3–0.8 mm at 0.5 kPa | ISO 9073-2 / EDANA WSP 120 | Affects tactile experience and stack height in packaging |
| Width Tolerance | 100–3,200 mm ± 3 mm | In-line measurement | Converter line compatibility and waste control |
The surface topology of a wipes nonwoven is not merely aesthetic — it directly influences cleansing efficacy, skin interaction, lotion saturation distribution, and drainage behavior. Aojia's wipes nonwoven is produced in three primary surface configurations:
The plain surface offers the most uniform fiber distribution and the smoothest skin contact. It is preferred for applications demanding maximum gentleness and consistent lotion delivery, such as sensitive-skin facial wipes and premium makeup removal wipes. The absence of surface relief also simplifies QC inspection for defects.
The pearl-embossed surface introduces a regular array of raised and recessed zones that enhance the wipe's mechanical scrubbing action without compromising softness. The pattern increases the effective surface area in contact with skin, improves grip feel, and creates small lotion reservoirs that improve distribution uniformity during use. This texture is widely specified for baby wipes and body cleansing wipes.
Apertured fabrics feature intentional open pores created by targeted water-jet action during production. These openings accelerate water dispersion during flushing, making the wipe compatible with standard wastewater infrastructure. Flushable wipes must meet the stringent INDA/EDANA Code of Practice for Flushable Nonwoven Products, which mandates rapid fiber dispersibility and freedom from plastic content.
