Meltblown Nonwoven systems

Meltblown systems use a one-step process in which high-velocity air blows a molten thermoplastic resin from an extruder die on to a conveyor to form a fine fibrous and self-bonding web. The fibres in the meltblown web are laid together by a combination of entanglement and cohesive sticking. The ability to form a web directly from a molten polymer without controlled stretching gives meltblown technology a distinct cost advantage over other systems.

Key benefits of FET Meltblown systems

As a result of innovative development work by FET, nonwoven structures can now be readily made from “difficult to process” polymers. The new processing technology is a unique adaptation of the meltblowing process and makes possible the conversion of a wide range of polymers into nonwoven webs, using a single processing stage.

For many of our clients, the benefits of single stage manufacturing and the flexibility provided solve many processing problems and give them a substantial competitive edge.

Melt spinning for Nonwoven applications (FET-102) is available as part of the FET-100 Series, which allows for multiple process options

Process applications

New processes have been developed in particular for polymers that have properties which would in normal circumstances make them unsuitable for meltblowing, such as high melt viscosity or susceptibility to degradation. These versatile systems enable the extrusion of meltblown nonwovens with a broad span of structures and mechanical properties, including:

  • Bio-medical applications using resorbable polymers
  • Those required for filtration and niche applications
  • Structures which exploit polymer properties such as thermal and chemical resistance

Meltblown webs offer a wide range of product characteristics such as random fibre orientation, low to moderate web strength. About 40% of meltblown material is used in the uncombined (monolithic) state. The remainder of meltblown materials are composites or laminates of meltblown webs with another material or nonwoven. The largest end-uses for monolithic meltblown materials are oilsorbents, air and liquid filtration media.

Nonwovens are frequently developed as sustainable fibres and FET is at the forefront of melt spinning technology used for applications like compostable coffee filters. Find out more on our Sustainability Page.