Nonwoven

Nonwoven

The engineered fabric structure used in nearly all wet wipes, created by bonding fibers without weaving or knitting.

Definition

A nonwoven is a sheet of fibers bonded together through physical or mechanical processes - without weaving (like cloth) or knitting (like textiles). Nonwovens are essential to the wipes industry because they enable customizable softness, strength, absorbency, and dispersibility.

How Nonwovens Are Made

The production of nonwoven fabric generally includes the following steps:

• fiber preparation - cellulose, viscose, or synthetic fibers,
• web forming - layering fibers into a loose mat,
• bonding - strengthening the web using hydroentangling, thermal bonding, or chemical binders.

Flushable wipes almost always rely on hydroentanglement (spunlace), which uses high-pressure water jets to entangle fibers naturally without plastic binders.

Types of Nonwovens Used in Wipes

1. Spunlace (Hydroentangled)

• soft and cloth-like,
• excellent for skin contact,
• ideal for flushable wipes when plastic-free.

2. Thermal Bonded

• uses heat to melt synthetic fibers,
• strong but not dispersible,
• common in cleaning and baby wipes.

3. Chemically Bonded

• uses adhesives or binders,
• not suitable for flushable applications.

Why Nonwovens Are Used in Wet Wipes

Nonwovens allow manufacturers to tune key performance characteristics:

• softness,
• strength,
• absorbency,
• surface texture,
• thickness,
• dispersion (flushability).

Nonwovens in Flushable vs. Non-Flushable Wipes

Flushable Wipes

• 100% plant-based (cellulose, viscose, lyocell),
• hydroentangled without plastic binders,
• designed to lose strength when wet,
• capable of dispersing under agitation.

Non-Flushable Wipes

• contain polyester or polypropylene,
• may use thermal bonding (melted plastic),
• high strength but no dispersion,
• common in baby and cleaning wipes.

Environmental Profile

Plant-based nonwovens:

• biodegrade quickly,
• do not form microplastics,
• break apart in water.

Synthetic nonwovens:

• remain intact for years,
• cause sewer blockages when flushed,
• accumulate in landfills and waterways.

Example: Plushwipes’ Nonwoven Structure

Plushwipes uses a plant-based, hydroentangled nonwoven made without synthetic fibers or thermal bonding. This design supports rapid dispersion and provides a soft, skin-friendly feel.

While Wipepedia is neutral and educational, Plushwipes is an example of how advanced nonwoven engineering improves both flushability and user comfort.

Key Takeaways

• Nonwovens are fiber webs bonded without weaving or knitting.
• Hydroentangled nonwovens are ideal for flushable wipes.
• Plant-based nonwovens disperse; synthetic nonwovens do not.
• Bonding method determines strength, softness, and flushability.
• Plushwipes demonstrates a modern, plastic-free nonwoven structure.

Understanding nonwoven engineering reveals why some wipes disperse safely - while others remain intact and clog plumbing systems.