Improving the biodegradability and environmental performance of Semi-Cross Spunlace Nonwoven - Production process optimization

1. Improving water recycling rate and reducing water consumption
The core of the spunlace nonwoven process is high-pressure water jetting to entangle the fibers into a web, which consumes a lot of water. Optimizing water resource management can significantly reduce environmental impact.
(1) Adopting a closed-loop water circulation system
Traditional spunlace nonwoven production uses a lot of clean water, but by establishing a closed-loop water treatment system, wastewater in the production process can be recycled and purified to reduce the consumption of new water.
Advanced ultrafiltration (UF), reverse osmosis (RO) or nanofiltration (NF) technology can effectively remove fiber debris, impurities and microorganisms, increasing the water resource recycling rate to more than 80%.
(2) Improving spunlace jet efficiency
Using high-efficiency and energy-saving nozzles, optimizing water flow pressure and jet angle, improving the spunlace effect while reducing unnecessary water waste.
Through the intelligent jet control system, the water flow pressure is dynamically adjusted according to the thickness and fiber type of different products to reduce excess water consumption.

2. Use low-energy drying technology to reduce carbon emissions
After the production of Semi-Cross Spunlace Nonwoven, it needs to be dried to remove excess moisture. The traditional drying process has high energy consumption, and the following links need to be optimized:
(1) Use an efficient hot air circulation drying system
The traditional drying method relies on high-temperature steam or gas heating, which consumes a lot of energy.
The use of a hot air circulation drying system can recover waste heat and use air flow to accelerate the drying process, which can reduce energy consumption by 20%-30%.
The use of far-infrared or microwave drying technology has higher heating efficiency and can reduce traditional drying time.
(2) Low-temperature energy-saving drying technology
Low-temperature drying can reduce fiber damage, improve product performance, and reduce carbon emissions.
Combined with heat pump technology, the heat recovery system is used to reduce the drying temperature and improve thermal efficiency.

3. Use a chemical-free binder process to reduce pollutant emissions
In traditional non-woven fabric production, some products will add chemical binders (such as synthetic resins) to enhance strength or give special properties, but this may affect the degradability of the product. More environmentally friendly processes need to be adopted:
(1) Pure physical fiber intertwining technology
Relying on water spunlace high-pressure jet technology, the fibers are intertwined physically without the need for additional adhesives, thereby improving the biodegradability of the material.
Using multi-layer water spunlace technology (such as two-step or three-step water spunlace) to increase the degree of fiber interweaving, make the product stronger and more durable, and reduce the need for chemical adhesives.
(2) Using bio-based or degradable additives
Traditional chemical additives such as polyvinyl alcohol (PVA) or acrylic adhesives can be replaced by biodegradable polymers (such as polylactic acid PLA, starch-based adhesives) to ensure the environmental friendliness of the product.
Research on the use of natural adhesives such as starch, alginate, chitosan, etc. to improve the adhesion between fibers and enhance biodegradability.

4. Intelligent production process and improved energy utilization
Intelligent manufacturing technology can optimize production efficiency, reduce energy consumption and waste, and improve product sustainability.
(1) Adopt AI and automated control systems
Through AI monitoring systems, production data can be analyzed in real time to optimize spunlace energy, fiber distribution, water circulation, etc., and improve resource utilization.
The automated system can adjust production parameters according to order requirements, reduce raw material waste, and improve production flexibility.
(2) Digital twin technology
Establish a digital production simulation system to predict energy consumption and material loss in the production process through data modeling and optimize resource use.
Combined with IoT (Internet of Things) sensors, real-time monitoring of the operating status of production equipment can be carried out to prevent excessive energy consumption or equipment failure in advance and reduce maintenance costs.

5. Reduce carbon emissions in the production process
In the non-woven fabric production process, energy consumption is the main source of carbon emissions, and low-carbon strategies need to be adopted:
(1) Adopt renewable energy
Reduce the use of fossil fuels through renewable energy such as photovoltaic power generation and wind power supply.
Use energy-saving motors and variable frequency control technology to improve the energy utilization of production equipment.
(2) Low-carbon logistics optimization
Use a localized supply chain to reduce carbon emissions during the transportation of raw materials.
Optimize product packaging, reduce plastic packaging, and use degradable or recyclable packaging materials.