airlay

Airlay, also known as airlaid or air-laid, refers to a method for forming nonwoven fiber webs by air deposition. In this process, dry fibers are entrained in a high-velocity air stream and guided to a forming area where they accumulate on a moving support to create a cohesive mat. The technique is capable of handling a range of fibers, including natural cellulose fibers, pulp fluff, viscose, polyester, and polypropylene, and it is commonly used to produce high-loft, soft nonwovens.

Formation and bonding are the key stages. After deposition, the loose web is bonded to impart strength, using thermal bonding, chemical binders, or mechanical methods such as needling or calendering. The choice of fibers, degree of bonding, and subsequent finishing influence properties such as absorbency, softness, tensile strength, and drape. Airlaid materials can be designed with varying densities and can incorporate pulp or other fillers to enhance specific performance characteristics.

Applications are broad and include absorbent products, filtration media, insulation, and specialty wipes. In the hygiene sector, airlaid nonwovens are widely used for baby diapers, adult incontinence products, and feminine care products due to their softness, thickness, and absorbency. They are also used in consumer wipes, where a combination of softness and structure is valued, and in some industrial filtration and insulation applications.

Industry notes and terminology: the term is sometimes used interchangeably with “air-laid” or “airlaid” nonwovens, and it sits alongside other nonwoven technologies such as spunbond and wet-laid. The choice of process is influenced by the desired balance of cost, performance, and end-use requirements.