Reducing fiber shedding during the production of industrial wipes is a core aspect of improving product quality and enhancing user experience. This requires a comprehensive approach encompassing raw material selection, process optimization, equipment improvement, post-processing technology, and quality inspection to form a complete fiber control system.
Raw material selection is fundamental to reducing fiber shedding. The base material for industrial wipes typically uses spunlace nonwoven fabric or hot-air nonwoven fabric. These materials combine softness and absorbency, but fiber shedding is significantly affected by raw material quality. High-quality raw materials must possess high uniformity, low impurity content, and good fiber bonding strength. For example, using fine denier fibers can reduce inter-fiber friction and lower the risk of shedding. Simultaneously, raw materials must meet the hygiene requirements of the "Hygienic Standard for Disposable Sanitary Products" to prevent fiber degradation due to microbial growth. Furthermore, some high-end products add additives such as paper-plastic purifiers to neutralize the negative charge on the fiber surface, reduce electrostatic repulsion, and promote the aggregation and retention of fine fibers, thereby reducing the shedding rate.
Process optimization is key to reducing fiber shedding. Hydroentangling uses high-pressure water jets to pierce the fiber layer, forming a three-dimensional structure that significantly enhances the mechanical entanglement between fibers. However, strict control of hydroentangling pressure and speed is crucial—excessive pressure can lead to fiber breakage, while insufficient pressure results in inadequate bonding. Hot air processing requires optimized hot air temperature and velocity to ensure uniform fiber melting and bonding, preventing fiber loosening due to localized overheating or underheating. Furthermore, folding processes require precise adjustments; when using folds in half, three, or four, it's essential to ensure smooth fold edges to prevent fiber breakage caused by concentrated mechanical stress.
Equipment improvements are vital for enhancing fiber bonding strength. Cutting equipment needs high-precision blades to reduce fiber pulling and burr generation during cutting; soaking equipment requires optimized liquid circulation systems to ensure uniform absorption of the liquid formula by the nonwoven fabric, preventing fiber loosening due to insufficient localized wetting; and rolling equipment needs controlled pressure and speed to remove excess liquid while avoiding excessive compression that damages the fiber structure. Some companies also introduce ultrasonic welding technology, using high-frequency vibration to generate frictional heat between fiber molecules, achieving a strong bond without additives and further reducing shedding rates.
Post-processing techniques are supplementary measures to consolidate fiber stability. The drying process requires low-temperature, slow drying to avoid fiber embrittlement caused by high temperatures. Surface treatment techniques, such as coating or spraying, form a protective film on the fiber surface, enhancing inter-fiber friction and peel resistance. For example, some products use silicone oil or polyurethane coatings to improve the lubricity of the wipes and reduce fiber shedding; other companies use plasma treatment technology to alter the chemical properties of the fiber surface, enhancing its hydrophilicity and adhesion.
Quality testing is the final hurdle to ensure the fiber shedding rate meets standards. It requires a comprehensive evaluation of the wipes' fiber shedding through microscopic observation, friction testing, and simulated use experiments. For example, friction testing involves reciprocating a standard friction head on the wipe surface, collecting the weight or quantity of shed fibers to quantitatively assess its anti-shedding performance; simulated use experiments can be conducted for specific applications, such as wiping precision instruments or oily surfaces, to test the wipes' fiber shedding performance in actual use.
From an industry trend perspective, the fiber control technology of industrial wipes will develop towards intelligence and precision in the future. By introducing AI algorithms to optimize process parameters or using IoT technology to monitor the production process in real time, precise control of fiber shedding rate can be achieved. At the same time, with the increasing environmental protection requirements, the application of biodegradable fibers and bio-based additives will also become a new direction for reducing fiber shedding rate.
