Forecasts for spunlace nonwovens indicate healthy growth in the years ahead. According to market analyst Smithers, compound annual growth rates for the 2025-2030 period are projected at 8.8% in tons, 9.8% in square meters and 9.5% in market value. Notably, spunlace is the fastest-growing nonwovens process in the 2020-2030 period.

That growth trajectory was stronger in the early part of the decade, when demand for spunlace surged during the coronavirus pandemic as consumption of disinfecting wipes rose sharply. However, that rapid expansion has now left much of the industry dealing with oversupply.

Phil Mango, nonwovens consultant for Smithers, notes that spunlace nonwovens have a relatively expensive raw material base and that most regions are currently facing overcapacity. “Despite this being the case for a few years, some countries continued to expand at a high rate,” he explains. “As demand slowed, this continued expansion exacerbated the oversupply situation, but it now appears that expansion is notably slowing. While most likely there will still be an oversupply in 2030, the balance will be measurably closer.”

Regional dynamics vary. North America is the only region with a significant percentage of baby wipes using non-spunlace nonwovens, while SP (spunbond/pulp) spunlace is produced primarily for disinfecting wipes, according to Mango. Europe, meanwhile, has led the development of newer spunlace substrates, including flushable and plastic-free variants. Asia is the world’s largest consumer of nonwovens, equal to the combined Europe and North America tonnage consumed in 2020. China, in particular, has added more spunlace capacity since 2020 than any other country globally, despite known overcapacity, he adds.

Turkish nonwovens producer Teknomelt has observed this trend. S. Ziya Gumuser, the company’s general manager, says China has significantly expanded its spunlace manufacturing capacity in recent years, thereby intensifying global competitive pressure. European-based producers, by contrast, have maintained their market positioning by shifting toward high-value-added, application-specific and sustainability-driven spunlace products, rather than competing solely on production scale or cost.

Jun Yan, general manager of Chinese nonwovens manufacturer Kingsafe, says the global spunlace market is defined by a dual-track competition: fierce rivalry on standardized, high-volume products versus high-value competition in sustainable and functional niches. From a Chinese perspective, he adds, the supply chain landscape is pivotal.

While Asia, led by China, accounts for over 50% of global capacity, according to the China Nonwovens & Industrial Textiles Association (CNITA), Yan says the post-pandemic era has solidified China’s role not only as the “world’s factory,” but as an innovation accelerator, particularly in scaling bio-based and recycled fiber applications. “Demand is bifurcated,” he explains. “The Asia-Pacific region, with a 13% CAGR in hygiene product demand (driven by urbanization and premiumization in China and Southeast Asia), fuels volume growth, while western markets drive premium specifications (e.g., home compostable, EU Taxonomy-aligned).”

Yan notes that the key imbalance is a ~20% undersupply in certified sustainable spunlace globally, creating opportunities for integrated producers like Kingsafe, who control fiber sourcing and advanced process technology.

As competition has intensified and product homogenization has become more pronounced, Kingsafe’s customers have demanded higher performance from spunlace nonwovens, particularly in strength and thickness without increasing basis weight. To address this, the company has expanded production capacity for semi-crosslapped spunlace. “This advanced structure delivers superior tensile strength and enhanced loft compared to traditional parallel-laid materials at the same grammage, offering better value and performance for applications like premium wipes,” he says.

At the same time, to balance performance with cost-effectiveness, Kingsafe has introduced a 100% biodegradable three-layer “sandwich” spunlace structure designed specifically for China’s rapidly growing disposable face towel market. “These targeted innovations—ranging from enhanced semi-crosslapped products to cost-optimized composite structures—demonstrate our commitment to solving specific customer pain points and leading market evolution through material science,” he says.

Ersin Kösker, VP of sales for Mogul, a Turkish nonwovens manufacturer, also views the global spunlace market as highly competitive, with strong pressure on standard grades due to broad capacity availability in many regions. At the same time, he notes that demand continues to shift toward higher-performance and more specialized nonwovens, especially where customers need consistent technical properties, premium feel and reliable supply. “Overall, the growth outlook is positive, but success increasingly depends on differentiation, quality stability and application-focused product design,” he says.

Other producers share a similar assessment in the market. Yahya M. Ihsan, director of Pakistani nonwovens producer Ihsan Sons, also describes the market as highly competitive. “What is notable is that investment continues, with new lines coming onstream, while demand has not always kept pace with this capacity growth,” he explains.

Annika Månsson, technical & plant manager at IMS Nonwoven AB, based in Ystad, Sweden, says competitive intensity has increased as new capacity continues to come online in different regions. “Recent investments and start-ups—both in Europe and outside—are contributing to a feeling of more available capacity, which naturally puts pressure on pricing and lead times,” she says.

While spunlace continues to benefit from its versatility across wipes, medical and technical applications, she notes that customers are becoming more cautious, with stronger expectations around cost transparency, supply reliability and sustainability credentials. “Overall, the growth outlook remains positive,” she adds, “but it is increasingly a market where differentiation wins: consistent quality, application know-how, speed of development and credible sustainability positioning matter as much as capacity.”

Cotton Gains Ground

Despite the competitive landscape, Ihsan Sons is benefiting from its focus on a niche segment of the market as a developer of 100% cotton spunlace. “Demand for biodegradable and sustainable alternatives continues to rise, and cotton remains a strong consumer favorite with excellent marketing appeal,” Ihsan explains.

Sustainability and biodegradability are the primary drivers and challenges for the industry, he adds. Ihsan Sons has been focused on this since 2006, producing spunlace made from 100% cotton. “We were pioneers in this space, and while progress has taken time, consumers, regulators and ultimately our customers are now fully recognizing the benefits of cotton,” he says.

However, the shift to cotton-based spunlace is not without challenges. As a natural fiber, cotton brings its own complexities, and many spunlace producers find it difficult to make the transition. “It requires deep technical knowledge and access to the right raw materials,” Ihsan explains.

The clearest demand from its customers and the foundation of its success is supplying the cleanest possible 100% cotton nonwoven. “We have invested more than any other company in this area,” Ihsan claims.

Because the company produces from fiber to fabric, it has a level of control that others do not. “This allows us to deliver consistently superior cotton spunlace, which is especially critical for customers operating in the feminine care and diaper segments,” he explains.

More recently, Ihsan Sons has focused on continued investment in advanced inspection equipment to eliminate cotton contamination, which Ihsan says has been a major success, significantly improving both product quality and operational efficiency.

Winner Medical is another manufacturer producing 100% cotton spunlace, which originates from the extremely stringent performance requirements of medical-grade wound dressings. In medical applications, materials are in direct contact with wounds, where low infection risk, zero irritation and uncompromising safety are non-negotiable fundamentals. These medical imperatives form the very foundation of the company’s technology development, according to Zongbo Tang, R&D manager at Winner Medical.

From the outset, Winner’s R&D teams have adhered to medical-grade standards, continuously refining the process around three core criteria: low initial bioburden, zero fiber shedding and excellent biocompatibility. “This deeply ingrained medical logic has enabled Winner Medical’s cotton spunlace to break the long-standing industry dilemma in which safety and comfort were difficult to achieve simultaneously,” Tang says. “The material preserves the natural softness and skin-friendliness of cotton fibers, while process innovation delivers enhanced strength and durability—resulting in a unique combination of high safety, low irritation and long-lasting comfort.”

Today, Winner Medical’s cotton spunlace technology has expanded from a single medical dressing application into three major sectors: absorbent hygiene products (such as sanitary pads and diapers), premium wiping products (facial towels and household wipes) and medical protective products (including masks, surgical gowns and drapes).

According to Tang, the cotton spunlace market is at a critical turning point driven by environmental regulation and consumer upgrading. “China’s carbon-neutrality goals and green industrial policies, combined with growing consumer preference for natural, biodegradable and low-irritation materials, are accelerating the industry’s shift toward higher quality and sustainability,” Tang explains.

Smithers estimates that biodegradable materials accounted for about 20% of all materials used in nonwovens in 2025, but projected growth rates for biodegradable materials are higher than for non-biodegradable materials through 2030. “Biodegradable material percentage is much higher in wipes and some other consumer products,” Mango explains. “The trend to more sustainable materials is consistent, but changes in total consumption will be slow, as so many markets and processes in 2025 are solidly based on petroleum-based materials.”

Reducing Plastics

As regulatory pressure grows and brands rethink material choices, spunlace producers are accelerating efforts to reduce plastics while maintaining performance.

Kiran Warrier, global category head, Welspun Living Advanced Textiles, says the shift toward sustainable and plastic-free products is one of the most important trends shaping the spunlace market. “Brand owners and regulators are increasingly pushing for biodegradable, cellulosic-based materials, especially in wipes, hygiene and medical applications,” he explains. “This has accelerated innovation in fiber blends, lightweight structures and eco-certified spunlace products.”

Similarly, Månsson of IMS Nonwoven, which is part of the Spanish company Murtra Nonwovens, adds that several trends are shaping the spunlace market, including sustainability-driven specifications as customers accelerate requests for plastic-reduction and plastic-free concepts, improved end-of-life profiles and stronger documentation. In Europe, she also points to the Single-Use Plastics framework and associated marking rules, which have increased attention to material composition and consumer communication. “This influences material choices and product design,” she adds. 

Additionally, regulatory and brand pressure to reduce or eliminate PFAS is translating into concrete product requirements and faster substitution cycles. At the same time, Månsson cautions that sustainability targets often need to be met without compromising key performance attributes such as strength, softness, absorbency and lint control—or increasing costs. “Innovation has to be practical, not just green marketing,” she says.

Gumuser of Teknomelt, says regulatory initiatives aimed at reducing plastic usage, most notably the EU Single-Use Plastics Directive (SUPD) and the proposed Packaging and Packaging Waste Regulation (PPWR), along with rising environmental awareness, have accelerated the transition toward biodegradable, compostable and flushable nonwoven products. “Within this regulatory and market context, spunlace fabrics exhibit a clear competitive advantage over spunbond and chemically or thermally bonded nonwovens, owing to their binder-free structure and compatibility with cellulosic fiber systems,” he explains.

In response to increasing environmental awareness, and particularly the EU’s SUPD and PPWR regulations, Teknomelt has strategically positioned its investments in the spunlace field to actively support this transition. The commissioning of Teknomelt’s CCP spunlace line in 2024 represents a tangible reflection of the company’s sustainability and innovation vision, he says.

The CCP spunlace line offers significantly greater raw material and composition flexibility compared to conventional spunlace technologies, enabling the processing of cellulose-based raw materials, including pulp, viscose, lyocell and cotton, in various ratios and combinations. 

This flexibility also supports the development of low-synthetic-content spunlace under Teknomelt’s Econa brand, or entirely natural fiber-based spunlace fabrics through its Biona brand. Additionally, through its Triona brand, developed with cotton and bamboo fibers, Teknomelt is introducing next-generation, skin-friendly spunlace products to the market.

“The technical capabilities provided by the CCP line enable Teknomelt to develop innovative solutions in biodegradable, compostable and sustainable product segments,” Gumuser says. “Environmentally low-impact products such as compositions incorporating lyocell and cotton are continuously developed through dedicated R&D activities for applications in hygiene, cosmetics, cleaning and industrial sectors.”

The world’s largest nonwovens producer, Magnera, which operates spunlace capability across six sites worldwide, sees demand continue to show resiliency for sustainable, soft and high-performance nonwovens. “The versatility of the spunlace platform, particularly its ability to process a wide range of plantbased and natural fibers, while delivering inherent softness and strength, positions it well to meet growing needs across personal care and other consumer segments,” says Alan Wright, director—Product Line Management, Consumer Wipes, Magnera.

In November, Magnera’s professional wipes brand Sontara launched a sustainable wipes range, utilizing exclusively sustainable raw materials including recycled PET from PCR bottles, plastic-free fibers such as viscose, lyocell and cotton, and natural wood pulp. Made at its northern Spain production site, Sontara’s sustainable range includes products with up to 42% less CO2 emissions compared to its standard wipe equivalents and up to 70% reduced transport emissions against far eastern imports, according to the company.

Sontara’s sustainable off-the-shelf options are available in a variety of weights, colors and finishes, including four variations of the brand’s Sontara EC engineered cloth wipes and its Sontara TriFlo multilayer technology, all engineered without added binders, chemicals or silicones. 

“Sontara set out to address a clear gap: the lack of professional-grade wipes that deliver both uncompromising performance and genuinely sustainable construction,” Wright says.

Initially focused on pulp-based spunlace for different segments, mainly for wiping applications, Mumbai-based Elixrr Nonwovens has expanded into more sustainable blend options that can offer enhanced strength and absorbency. Innovations include eco-friendly pulp-based spunlace aligned with global sustainability goals, customized basis weights and embossing patterns for diverse applications and the exploration of industrial and medical-grade spunlace for higher-value markets.

Arvind Rao, global sales & marketing head, Elixrr, says key trends include a shift to plastic-free spunlace for wipes, with sustainability and biodegradability driving innovation. “Pulp-based spunlace directly addresses bans on plastic-containing wipes,” he says, adding that compared with spunbond and meltblown technologies, spunlace offers better biodegradability and consumer acceptance in eco-conscious markets.

Wipes Remain Central

As global regulations increasingly seek to limit the use of petroleum-based plastics in wipes, suppliers are accelerating the development of new fibers and substrates tailored to the wipes market.

Mango says the development of new staple fibers, such as Lenzing’s lyocell, Eastman’s Vestera cellulose acetate fiber and recycled cotton fibers from several suppliers, will allow spunlace to grow share, especially in the plastic-free wipes markets.

Meanwhile, the newest nonwoven variant is the CP wet or carded/wetlaid pulp spunlace, a process that can now incorporate fibers above 37.5 mm, he adds. “The hydroentangled wetlaid process is ideal for relatively low-strength flushable products; the CP hybrid process adds the potential for high-strength products. Both Trützschler/Voith and Andritz have already delivered commercial systems and several new lines in Europe and Asia have been announced. Line suppliers claim this is the most economical process for producing plastic-free products.”

According to Gumuser, the wipes market continues to account for the largest share of spunlace consumption and remains the primary driving force behind spunlace growth. “In particular, evolving consumption habits, sustainability expectations and regulatory frameworks within the personal care, hygiene and cleaning segments structurally reinforce demand for wipes. As a result, wipes continue to represent a strategic core market for spunlace technology,” he comments.

Welspun’s spunlace portfolio has evolved in direct response to how its customers’ needs and end-use markets have changed over the last few years. “While baby wipes and personal care remain important, we recognized early that long-term value would come from moving beyond commoditized segments into more specialized, performance-driven applications,” Warrier says.

This has led the Indian nonwovens manufacturer to significantly diversify its offerings through targeted innovation. Solutions such as WelQuat and Welscrub address enhanced functionality in hygiene and surface cleaning, while its biodegradable spunlace range reflects growing regulatory and consumer demand for sustainability. Welspun has also significantly expanded into dry wipe solutions, enabling customers to customize formulations and logistics. Additionally, innovations such as Fibrosplit and 3D-Swipe focus on improved strength, absorbency and cleaning efficiency, opening doors to demanding applications for the technology, Warrier explains.

At the same time, the company has deliberately broadened its market footprint, developing cotton-based femcare solutions and advancing into cleanroom and pharmaceutical wipes, composites, adhesive tapes, automotive interiors, homecare and heavy-duty industrial cleaning.

Yan, of Kingsafe, says wipes undoubtedly remain the volume anchor of the global spunlace market; however, the growth narrative is shifting. While traditional wet wipes continue to see steady demand, Kingsafe has identified dry wipes—specifically the segment propelled by disposable face towels—as the next major growth engine. “This trend is particularly pronounced in the Asia-Pacific region, especially within China’s booming beauty and personal care market, where convenience, hygiene and a focus on skincare routines are driving explosive adoption,” he says.

Kingsafe is responding to this shift. “Our innovation in dry wipes is not merely about substrate supply; it’s about engineering purpose-built solutions,” Yan says. “For instance, our development of ultra-soft, high-loft spunlace with controlled abrasiveness directly caters to the sensitive skincare needs of disposable face towels. Furthermore, we see adjacent opportunities for dry wipes in other personal care and premium household applications where softness, absorbency and strength are paramount.”

In Latin America, Fitesa operates a double-card, 2.5-meter spunlace line in Jacareí, Brazil. Commissioned in 2023, this line represents Fitesa’s entry into the regional wipes market. 

Mariana Mynarski, corporate marketing & ESG, Fitesa, says personal care wipes remain the primary driver of spunlace growth. However, she adds, spunlace is an exceptionally versatile technology, enabling a wide range of applications beyond personal care—including food service, healthcare, wound care, apparel and even fluff-less diaper core structures.

Beyond Wipes

While wipes and medical fabrics remain the major markets for spunlace, minor uses for the substrate are being used in garments, shoes, filtration, bedding and other coated fabric applications, according to Smithers. Spunlace is increasing its market share in certain markets, particularly for applications such as secondary topsheets in feminine hygiene pads and stretch ears in diapers, training pants and incontinence products.

Mogul sees strong and growing opportunities for spunlace nonwovens in technical and industrial segments, where customers reward performance and consistency—not just price, Kösker explains. Key areas include filtration, lamination applications, automotive interiors and insulation layers, industrial technical uses and defense-oriented specialty solutions, where fiber type and performance requirements are highly specific. 

This month, Mogul is introducing a new Micro-denier Microfilament product (100% PET), designed to deliver a more textile-like softness while supporting strong technical performance. With this launch, Mogul positions itself among the limited number of producers worldwide capable of manufacturing micro-denier microfilament structures at an industrial scale.
The microfilament structure targets high softness, low shrinkage and high strength, with a cost-advantaged positioning, Kösker explains. It is developed for high-volume sectors such as automotive, filtration, food-related applications, geotextiles and other technical packaging and hygiene applications, where consistency and performance are critical.

According to Wright of Magnera, the company continues to think outside of the box when it comes to different ways to drive spunlace growth. Beyond wipes, Magnera is seeing significant momentum in absorbent hygiene categories, including femcare and baby care. “These categories are increasingly adopting spunlace due to its sustainability profile, softness, absorbency and ability to deliver high performance without plastics,” he adds.

Magnera has recently launched a full portfolio of personal care absorbent product components, including backsheets, topsheets, waistbands and cores, for diapers, pants, period care and adult incontinence products. “By leveraging our spunlace platform and combining it with other technologies in our portfolio, such as lamination, imaging and printing, we deliver a differentiated value proposition: high‑strength, sustainable and highly customizable solutions for the absorbent products market,” Wright says.

The company is also continuing to expand its wipes and filtration offerings, integrating enhanced imaging capabilities, lower basis weights and new raw material options to meet evolving customer and consumer needs.

Meanwhile, cotton spunlace nonwovens are playing a key role as topsheet materials for sanitary pads, diapers and other absorbent hygiene products, aligning with core user needs like softness, comfort and safety, according to Tang of Winner Medical.

“Compared with fibers such as hemp, polyester, viscose, or vinylon, cotton offers a finer, softer hand feel, delivering gentle, low-friction skin contact,” Tang says. “Its natural hollow fiber structure and inherent moisture content (approximately 8%) provide excellent breathability and wearer comfort, reducing heat and stickiness. Equally important, cotton spunlace follows a natural, additive-free philosophy, making it particularly suitable for sensitive skin. Cotton’s long-standing use in medical applications—from wound dressings to surgical absorbents—further demonstrates its proven safety and biocompatibility with the human body.”

Italian Companies Form Joint Venture

Texol Srl and the Orsa Group have joined forces to form a new entity, Or-Tex Srl, co-owned 50/50 by the two companies. Under the terms of the agreement, Texol Srl sold all of its OR.MA. Srl shares and the Orsa Group sold 100% of its shares in Orsa Nonwoven to Or-Tex.

Orsa, founded in 1963 to produce polyurethane, began manufacturing needlepunched nonwovens in the 1970s and spunlace nonwovens in 1989. OR.MA., a Texol subsidiary, produces spunlace nonwovens for a variety of markets. Together, the two companies bring state-of-the-art equipment and installations for the production and finishing of different types of nonwovens to Or-Tex.

According to Cristiano Paron, CEO of Or-Tex, the joint venture fully leverages the commercial and manufacturing capabilities of both organizations, creating unique synergies to approach the market while offering a technical edge and a wider range of solutions in both production and R&D. “The joint venture is strongly based on a quality-oriented, sustainability-based and ‘Made in Italy’ approach, showing a powerful sign of confidence in the market and industrial commitment.”

Or-Tex combines complementary expertise from both companies. OR.MA. contributes high-capacity, consistent spunlace production, including its unique three-layered spunlace, together with a wide range of fiber and weight options, while Orsa adds spunlace and needlepunched technologies along with a wide array of finishing processes such as impregnation, splitting, calendering, brushing and lamination capabilities. “In this sense, we truly have no limitations,” Paron says.

Or-Tex serves diverse end markets, including automotive, reinforcements, medical, filtration, cosmetic, HoReCa, coating, insulation and upholstery, among others. While some of these segments are currently facing difficulties, Paron notes that such conditions are cyclical. “We are confident that we can offer both competitive rates and service to the underperforming markets and respond with the right R&D solutions for the growing ones,” he explains.

Paron says the main challenges are not reduced demand or specific criticalities in certain segments, but, more generally, uncertainty and lack of visibility.

“The market was severely tested in the past years by the pandemic, the energy spike and political instability, which are somehow creating a general cautiousness that is certainly not helping,” he says. “On the other hand, there is a clear path for Italian companies: double down on sustainability, quality, innovation and performance. This, united with the considerable number of sectors where spunlace nonwovens find ample applications, is still granting very significant opportunities. It is up to us to identify the areas where we can have extra room for growth or a better perception of our offer and capabilities.”