After a period of significant expansion in spunlace nonwovens during the coronavirus pandemic, from 2020-2021, investment has slowed. The wipes industry, the biggest consumer of spunlace, saw a huge surge in demand for disinfectant wipes during that time, which has led to an oversupply today.

“In relatively few years, spunlace has gone from a globally balanced supply to demand market to a significantly oversupplied market,” says Phil Mango, nonwovens consultant, Smithers. “Overexpansion in primarily Turkey and China now have both Europe and Asia oversupplied. North America, so far, has avoided this condition, but cheap imports are already affecting this market.”

According to Serkan Gogus, CEO and general manager of Turkish nonwovens manufacturer Mogul, during the pandemic period there was a significant increase with consumption of wet wipes due to hygiene concerns, and although this demand has gone down after the pandemic, some of the habits gained during the pandemic have helped increase consumption compared to the pre-pandemic era.

“The growth in the wipes industry in spunlace nonwovens in the future will be influenced by the increased rate of new applications and environmental regulations shaping the industry,” he explains. “Spunlace nonwovens, which account for 82% of the European wipes industry, will be highly affected with the European Union’s increasing sanctions on disposable plastics in the coming years. So, the future of spunlace will be shaped by new sustainable fiber developments or [it will] have a high risk of losing marketshare to technologies that allow for the manufacturing of flushable and disposable goods such as airlaid and wetlaid.”

Shehryar Ihsan, director of marketing for Pakistani nonwovens producer Ihsan Sons, says the market for spunlace at the moment is incredibly competitive with many companies struggling to fill capacity and having some lines sitting idle. “Still more lines are coming on stream and at the moment there isn’t the demand for these lines unless they are offering something unique,” he says. “These businesses should prioritize innovation, to strengthen their market position and achieve a competitive advantage. Technological advancements and sustainable solutions stimulate competitiveness as market players strive to differentiate themselves by offering high quality products for end use industries by investing more in R&D and filling the gaps in the market.”

Smithers projects both a slowing of expansion globally and some closures of older, less efficient lines. “Perhaps accelerating the process of closing older lines is the addition of newer spunlace processes more efficient at addressing ‘plastics-free’ wipes,” says Mango. “Carded/wetlaid pulp spunlace and hydroentangled wetlaid spunlace lines both make the addition of wood pulp and the production of plastics-free products less costly and higher performing. As these newer lines enter the market, older lines become even more obsolete.”

Growth prospects are still excellent, Mango adds, as spunlace end-use markets remain healthy. “Wipes are still in the growth phase, though maturity in this market is probably only five to 10 years away. The desire for plastics-free products in many other markets helps spunlace in markets like hygiene and medical. The overcapacity situation, while disadvantageous for spunlace producers is advantageous for spunlace converters and customers, who have ready supply and lower prices. This will encourage growth in spunlace tons consumed if not in sales dollars.”

In 2023, world consumption of spunlace nonwovens totaled 1.85 million tons with a value of $10.35 billion, according to the latest study from Smithers—The Future of Spunlace Nonwovens to 2028. Detailed market modelling forecasts this segment of the nonwovens industry will increase at a compound annual growth rate (CAGR) of +8.6% by weight across 2023-2028—reaching 2.79 million tons in 2028, and a value of $16.73 billion, at constant pricing. 

New Capacity

Although the pace of spunlace investment has slowed, some new assets that were announced during the Covid pandemic have recently come onstream.

Last year Fitesa officially entered the spunlace market when it started its first spunlace line in Jacareí, Brazil, at a site acquired from Freudenberg Performance Materials in 2019. The line is already supplying customers in the hygiene and healthcare markets, according to Mariana Mynarski, corporate marketing & ESG, Fitesa.

Fitesa’s spunlace technology is mainly targeting the wipes market. “Although the Latin American demand is concentrated in hygiene, and especially baby care, healthcare applications are growing above the market average, and new industrial/household segments are being developed,” Mynarski says.

Meanwhile, Fibertex Nonwovens completed work on its second high performance spunlace nonwovens line last year in Grey Court, SC, at a site it had acquired from Mogul Nonwovens in 2019. The nearly $50 million investment was intended to meet the growing need for locally made nonwovens in North America. Fibertex also acquired an 84-acre industrial lot adjacent to this site with a view toward additional expansion.

The Danish nonwovens producer is also planning to finish work on a similar line in the Czech Republic this year. These two new lines were part of a global investment strategy, announced in early 2021, aimed at bringing the company’s sales above $400 million by 2026. In addition to the two spunlace lines, this plan includes the addition of finishing and coating lines at its site in Turkey, which specializes in spunlacing.

In Turkey, Teknomelt San. ve Tic. A.S., with manufacturing locations in Kahramanmaras and Istanbul, announced the availability of fully and partially biodegradable nonwoven fabrics under the brand names Biona and Econa, respectively. The company’s €50 million investment includes a state-of-the-art carded-carded-pulp (CCP) spunlace line that blends two technologies—spunlace and wetlaid—and transforms Teknomelt into a global player in sustainable nonwovens. The new facility will use bio-based fibers such as viscose and wood pulp to produce a high-performance and sustainable wiper with the same technical product characteristics and performance as a conventional wiper made of synthetic fibers, while protecting the environment at the same time.

Teknomelt will also support its customers using the line’s configuration flexibility which can be altered to produce pure spunlace, Wetlace CP or Wetlace CCP. This allows a wide range of different wipes to be produced.

Taking Action

Government legislation such as the EU’s Single Use Plastics Directive, similar measures being considered in some U.S. states, and a proposal to ban plastic in certain wet wipes in the U.K. have accelerated efforts to remove plastics from wipes. Consumer preferences for natural materials is also motivating companies and their supply chains to offer more sustainable products.

“Sustainability is a critical need and potential advantage for the spunlace market,” Mango says. “Spunlace is one of the nonwoven technologies which can use 100% biodegradable raw materials and still produce high strength, high performance products. Now, its largest market, wipes, has strong regulatory demands in Europe and growing potential demands globally for plastics-free products. While other nonwovens can meet some of these needs, none can do so as well as spunlace.”

Recognizing the significance of sustainability, Mogul continues to expand its product offerings such as Bio PET, bamboo, rPET fibers, bast fibers besides cotton, PLA, viscose and Tencel and for hi-tech applications such as its Metatex and Dynatex products. 

“The European Union’s stance toward disposable items has created a shift in the industry,” says Gogus. “As per studies made, disposable plastics, baby diapers and wet wipes are major sources of environmental pollution, but biodegradable raw materials are taking steps to contribute to the sector’s change as a result of studies and research conducted to reduce plastic use.”

Javier Falcón, sales director, of Spanish nonwovens producer Papel Aralar, says the wet wipes industry is being redefined. “Materials that were accepted until recently will gradually disappear from various categories, in favor of more sustainable ones.”

Since its founding in 1937, Aralar has focused on the production of cellulosic material for technically demanding applications. Aralar’s first wetlaid-spunlace machine began production in 2015 and the company started up its second wetlaid-spunlace line at the end of 2020. The combined capacity of these lines is 40,000 tons. All the material manufactured in Aralar is made exclusively with cellulosic fibers and is dispersible, and the company has never used any plastic fibers.

“Aralar offers wet wipe manufacturers a future-proof substrate,” Falcón says. “This is most pertinent in a context of developing legislation that will make plastic-based, non-flushable wipes costlier and more difficult to market.”

Much of the recent growth experienced in Aralar’s portfolio of cellulosic, biodegradable and dispersible materials has come from the baby wipe segment. “Flushability has traditionally been restricted to moist toilet tissue,” he explains. “The concept has now outgrown that category and is increasingly finding acceptance in the baby segment.”

A key challenge, according to Falcón, is the confusion by the average consumer between the concepts of biodegradability and flushability. “Given the backlash against plastic-based baby wipes, numerous brands have opted to switch towards a 100%-viscose substrate. This material is not dispersible at all. As a result, this approach does not solve the problem that the whole industry is painfully aware of: consumers will continue to throw wipes into toilet bowls, regardless of the number of logos and warnings printed on packs. All sewage content analysis done everywhere attests to that: truly flushable wipes have a negligible presence in sewage, while plastic and viscose-based wipes continue to wreak havoc on water infrastructure.”

This presents an existential problem for the industry, Falcón adds. Consumers and brands may opt to give up wet wipes altogether if they perceive them as “always bad, no matter what.” “The recent decision by Mustela to ditch its wet wipes business, on environmental and moral grounds, is testament to that,” he says. “Only with a realistic approach that does not pass the responsibility to the consumer, but that redefines how a wet wipe must be made to be truly sustainable and dispersible will we create a paradigm that does not backfire on our industry.”

Acmemills is also targeting the flushable wipes market with its launch of flushable and compostable wipes called Natura. Recognizing the urgency to tackle the issues posed by non-flushable wipes in municipal water systems, Acmemills commissioned new state-of-the-art equipment to enhance Natura’s production capabilities. With the introduction of a 2.4-meter and 3.5-meter-wide hydroentangle line, Acmemills is equipped to meet the increasing demand for flushable wipes.

Natura utilizes 100% natural fibers, derived from sustainable bamboo pulp. Bamboo, renowned for its rapid growth and minimal ecological impact, serves as the primary source fiber for Natura production.

According to the company, the need for flushable alternatives has become particularly pressing due to recent legislation introduced in California and Europe. These regulations target the disposal of plastic personal hygiene wipes and aim to minimize their impact on wastewater treatment systems. Natura’s solution addresses these concerns head-on by offering flushable wipes that are compatible with municipal water systems, reducing the strain on infrastructure and minimizing the risk of environmental damage.

“We are thrilled to introduce Natura as the ultimate solution to the environmental challenges posed by non-flushable wipes,” says Matt Utley, CSO of Acmemills. “Our investment in cutting-edge technology, combined with our commitment to sustainable sourcing, demonstrates our dedication to providing eco-conscious consumers with a reliable and responsible choice. Natura not only offers an effective alternative, but it also contributes to the well-being of our planet.”

Meanwhile, Chinese nonwovens manufacturer Winner Medical uses cotton jacquard spunlace fabric as a raw material for wet wipes products. According to Zongbo Tang, R&D manager, Winner Medical, the mesh and concave-convex structure designed by the jacquard spunlace fabric make the wet wipe material have better friction and thickness, which does not only improve the cleaning power of wipes but can also improve the appearance and thickness of the wipes.

In addition to wet wipes, disposable cotton towels (dry wipes) have great opportunities, Tang adds. Purcotton, a Winner Medical brand, has created a new product, disposable cotton towels, which can be used both dry and wet, are soft and skin-friendly, and can be used as an alternative to paper tissues, solving the pain points of traditional paper tissue that cannot be used wet and are not eco-friendly. “At present, this product is the core product of the Purcotton,” says Tang. “It has sold No.1 in China for 14 consecutive years, with cumulative sales of 53.7 billion sheets and a reduction of 12.36 million trees.”

For its part, Welspun’s ability to run cellulosic fibers has enabled the company to provide quality alternatives to its customers in the European Union, who are subject to the Single Use Plastics (SUP) Directive, says Kiran Warrier, global category head – Advanced Textile, Welspun.

“The key to Welspun’s Advanced Textiles business lies in the vision to produce future-focused value-added products, which enables them to retain their leading position in the realm of advanced textiles,” says Warrier.

The Indian nonwovens producer, equipped with state-of-the-art Trützschler and Andritz machinery, is capable of processing all known varieties of cellulosic fibers, including cotton, bamboo, viscose and lyocell between 25-200 grams per square meter. “This allows Welspun to cater to a range of applications including, but not limited to the manufacture of hygiene, femcare and personal care products, industrial cleaning apparatus disposables, as well as medical disposables,” Warrier says.

Last year, under its subsidiary WAMIL (Welspun Advanced Material India Limited), the company opened an advanced textiles facility comprising of a state-of-the-art high-speed line for manufacturing spunlace nonwovens in Chandanvelly, Telangana. With this investment of Rs. 500 crores, Welspun says it has become the largest producer of spunlace nonwovens in India with a total annual capacity of 27,000 metric tons. 

Meanwhile, Ihsan Sons (Pvt) Ltd., Pakistan’s largest fully integrated cotton personal care product manufacturer, specializes in 100% organic conventional cotton spunlace nonwoven fabric that caters to various applications including hygiene, medical and wipes.

According to Ihsan, spunlace wipes are becoming more competitive in price when compared to many other types of wipes, even from other nonwoven technologies. “This could be the main growth area, spunlace taking market share away from other technologies,” he says. “This growth has been significantly driven by the increasing demand for wipes in various industries. Cotton wipes have become popular due to their convenience, hygiene and versatility and as a result, this has become a crucial component in the production of wipes.”

Ihsan says that new opportunities must be in the biodegradability of wipes, which has become the main focus for so many companies now. “Ihsan Sons is at the forefront of that opportunity. The growth of spunlace nonwovens will continue to be central to the growth of the wipes market, driven by increasing demand across various industries as new opportunities for wipes will arise from technological advancements, changing consumer preferences, and the focus on sustainability.”

Ihsan Sons believes that technological advancements can be a potential for growth, as the introduction of new materials and methods, such as the usage of biodegradable and eco-friendly fibers, has opened up new opportunities for wipes. 

Also contributing to the growth of wipes are changing consumer preferences as consumers are becoming more health-conscious and seeking products that offer better hygiene and convenience. The demand for single-use wipes, particularly in personal care and hygiene, is expected to grow, Ihsan says. 

Additionally, increasing awareness of sustainability will spur growth as consumers are seeking sustainable and eco-friendly products. “It is our belief that this is where the major growth will be over the coming years,” says Ihsan.

Glatfelter, a leading global supplier of engineered materials, diversified its portfolio to include spunlace manufacturing with the 2021 acquisition of Jacob Holm Industries. With a significant emphasis on bio-based, plant-based and plastic-free product offerings, Glatfelter’s innovation efforts are focused on meeting evolving consumer needs and sustainability demands, enabling the company to create and capitalize on new opportunities within the hygiene, wipes, and other specialty products markets.

Under its range of spunlace products, the nonwovens producer develops carded (conventional spunlace), Sontara proprietary technology and Hybrid technology, which combines airlaid and hydroentanglement.

In response to increasing demand for sustainable products, Glatfelter introduced Sontara EC Green, a compostable, 100% cellulosic, plastic-free version of its highest performing Sontara EC wipe. Unlike other nonwoven production technologies, Sontara only uses water to form a strong and absorbent web without the need for binders, adhesives, or other chemicals. This ultra-pure wipe offers consumers exceptional critical cleaning power while being environmentally responsible.

Another recent launch from the company is GlatPure, a full range of bio-based absorbent hygiene components derived from renewable materials. By leveraging natural and organic fibers instead of fossil-based raw materials, this new generation of absorbent hygiene product components consists of a fully functional topsheet, an acquisition distribution layer, an absorbent core, a newly improved backsheet, and a landing zone. Each element is crafted with 100% plant-based renewable cellulose fibers and biodegradable materials, enriched with organic binders, making it the industry’s first fully functional and biobased range of solutions.

Through advanced spunlace technology, Glatfelter’s range of GlatPure Topsheets, offers a diverse selection of premium, plant-based and natural fiber options for environmentally conscious consumers. Designed with sustainability in mind, each variant, such as GOTS-certified organic cotton, raw cotton, raw cotton and hemp blend, and 100% lyocell, delivers fast liquid handling, softness and comfort, achieving the ideal balance between the hydrophobic and hydrophilic attributes each fiber provides. Whether it’s the hypoallergenic appeal of cotton or eco-friendly hemp and lyocell, these topsheets are uniquely tailored to meet various consumer preferences. Demonstrating remarkable liquid handling capabilities, this range not only exemplifies Glatfelter’s sustainability values but also improves the user experience for those searching for environmentally conscious hygiene products.

In other new product news, Finnish nonwovens producer Suominen recently launched Biolace with cotton to the American market. Biolace with cotton is a 100% biodegradable and compostable cotton enhanced wipe. The product is suitable for wiping the skin in baby care, personal care, medical and hygiene uses.

This specially designed cotton enhanced product has premium softness and opacity. Its design helps prevent fluid migration, which results in appropriate wetness in every sheet and potentially less add-on needed.

“The ability to resist fluid migration in the package better than the equivalent made with 100% viscose helps ensure that wipes do not dry out prematurely,” explains Andrew Charleston, manager, Category Management, Americas.

Biolace with cotton is made by combining multiple sustainable fibers using filtered water. This material can help reduce solution add-on requirements compared to other 100% sustainable options due to a combination of fiber selection and process techniques. This could help reduce converting costs without the need to compromise on delivering optimal cleaning from a sustainable material.

Another new addition to the Biolace range is Biolace with a Nubtex micro-dot pattern designed for applications looking for more intense cleaning. The unique Nubtex micro-dot pattern combined with sustainable fibers for fluid management provide an exceptional material design for difficult cleaning tasks. The product is a 100% biodegradable and compostable nonwoven suited for personal care, household and workplace use.

”Compared to a standard dot pattern, the Nubtex pattern creates a more abrading surface area that aids in loosening dirt and debris for improved pick-up and removal from surfaces and skin,” Charleston explains.

Beyond Wipes

Spunlace manufacturers are also looking outside of the wipes market for growth. Other categories that are being targeted include hygiene, medical, filtration and automotive, among others.

Gogus, of Mogul, says with new market developments and R&D initiatives, spunlace offers significant potential not just in wipes but also in other industries. Usage of new and highly technical fibers will help developments in industrial areas, in applications such as automotive, building, shoes, home textiles and cosmetics.

Spanish-owned Murtra Nonwovens produces spunlace nonwovens for technical sectors, mainly automotive, including headliner and engine bay applications. In the current spunlace market scenario, one of the most prominent challenges lies in the need to transition towards sustainable materials, with a particular focus on creating mono-product items that facilitate and enhance recyclability, according to Nadia Felfli, key account manager, Murtra Nonwovens.

“Growing environmental awareness and the demand for eco-friendly solutions have elevated the importance of developing nonwovens that not only meet performance standards but also proactively address environmental concerns,” she says. “The shift towards sustainable materials involves sourcing from renewable sources, reducing environmental impact during production and end-of-life disposal, and adopting practices that minimize the carbon footprint.”

Murtra is carrying out many procedures and protocols to combine these main concerns like the analysis of the Life Cycle Assessment of its materials, waste management protocols and getting the certification of ISO14001 (scheduled for this year—phase one passed with success) from many other actions included in its “green” action plan. Murtra has also expanded its material portfolio including biodegradable, compostable and recycled nonwovens.  

For its part, Ihsan Sons has identified several potential markets outside of wipes for spunlace technology. These opportunities are driven by the versatile nature of spunlace, which offers a wide range of characteristics, such as high absorbency, softness and strength, according to Ihsan.

One of the primary markets for spunlace technology outside of wipes is the hygiene sector, where spunlace materials are used in the production of baby diapers, adult incontinence products and feminine hygiene items. “The use of spunlace in these products offers benefits such as improved comfort, increased absorbency and better liquid retention, resulting in a more effective and user-friendly product,” he says.

Another significant opportunity for spunlace technology lies in the medical sector as this sector requires high-quality, hygienic materials for their single-use medical products. 

“Ihsan has a large customer base for spunlace nonwoven fabric; these customers use our product for sanitary pads, examine sheets, face mask and cleaning products, etc.,” Ihsan concludes.

Welspun expects to see high growth for spunlace usage in femcare as well as industrial segments, and medical is another segment where the company sees opportunities because of the potential value addition that spunlace can offer. Additionally, with enough research, the company thinks spunlace usage can become a game changer in the diaper industry, according to Warrier.

Meanwhile, Winner Medical’s cotton spunlace nonwoven is currently mainly used in personal hygiene care, medical consumables and other fields.

“At present, the topsheet materials of disposable sanitary products such as sanitary pads, diapers and other products are mainly made of synthetic fiber materials,” says Tang. “With the carbon peak and carbon neutrality policies introduced around the world, the application of sustainable materials in disposable sanitary products is an important issue. According to the trend, the application of cotton spunlace nonwoven fabrics in disposable sanitary products has increased the market share over many years.”

As a result, the company will accelerate the research and development and application of cotton spunlace nonwoven fabrics in sanitary pads, especially for the dryness technology to solve wetness problems.