Laminating Nonwovens
Nonwovens are lightweight, breathable and cost-effective to produce. By laminating nonwovens with film, fabric or foam, properties can be added that nonwovens alone don’t possess. This page explains what laminating nonwovens involves, when it’s the right technique, and how Zwartz approaches this process.
Laminating nonwovens
Laminating is a production technique where nonwoven fabrics are bonded to one or more other layers using heat, pressure and adhesive. The bond between layers is achieved with thermoplastic adhesives or reactive hotmelt.
Nonwovens are delicate materials requiring careful processing. Unlike woven textiles, nonwovens have an open, loose structure. Excessive temperature can melt fibres, too much point pressure can puncture the material. This is why laminating nonwovens requires precise temperature control and knowledge of how different nonwoven types (spunbond, meltblown, needlepunch) react to adhesive and heat.
Why laminate nonwovens?
Laminating is suitable when nonwovens need specific properties that the materials alone don’t offer. Through laminating, nonwovens gain additional functionality without losing their core advantages.
Properties that can be added:
Water resistance – Liquid barrier for applications where water or other liquids must be blocked.
Insulation – Heat or sound insulating properties through addition of insulating layers.
Stiffness – Extra rigidity and dimensional stability for applications requiring structural stability.
Odour absorption – Odour-binding properties for specific applications.
Anti-slip – Friction-enhancing properties for grip and safety.
Flame retardancy – Increased fire safety through addition of flame-retardant layers.
Ballistic resistance – Protective properties for security applications.
Self-adhesive layer – Applying adhesive layer for further use in production processes.
Through laminating, these properties are added to nonwovens, making them suitable for technical applications with specific functional requirements.
Application areas
Laminated nonwovens are deployed across various sectors:
- Construction: insulation materials, vapour barriers, underlays
- Medical: sterile packaging, absorption materials, barrier materials
- Automotive: interior trim, acoustic insulation, filter materials
- Filtration: air purification, liquid filtration, dust separation
- Hygiene: absorption and barrier materials
- Packaging: protective packaging materials
- Agriculture: protective materials, water-permeable ground cover
Possibilities depend on the nonwoven type and desired properties.
For product development, test samples can be made first to find the right material combination before large volumes are produced.
Systems for laminating nonwovens
Laminating nonwovens at Zwartz uses three systems, each developed for specific applications.
Belt calender
The belt calender operates roll-to-roll and is suitable for continuous production in large volumes. The system processes materials that must be treated uniformly across the full width.
Hotmelt systeem
The hotmelt system applies molten adhesive directly, after which the second layer is applied. The system can work with dot coating (point pattern) or full coverage coating for complete bonding. Suitable for applications where speed is important.
Flatbed systeem
The flatbed system is deployed for prototypes, test series and thicker material combinations. The system offers active cooling and is ideal for development trajectories where different combinations are tested before scaling up to roll-to-roll production.
The Zwartz team advises which system best suits the application and material.
Adhesive systems for nonwovens
For laminating nonwovens, thermoplastic adhesives are used that contain no solvents. Thermoplastic hotmelt is applied at controlled temperature and forms a strong bond after cooling. For applications requiring extra adhesive strength, reactive hotmelt can be used.
With dot coating, nonwovens remain breathable because adhesive is only applied at specific points. With full coverage coating, a completely sealed barrier is created. Zwartz advises which adhesive system suits the specific nonwoven type and end application.
Why choose Zwartz for laminating nonwovens
Expertise in different nonwoven types
Three systems available
Each system can process nonwovens up to 250 cm wide. Belt calender for large volumes and roll-to-roll production, hotmelt for speed and precise adhesive control, flatbed for prototypes and thicker combinations. Zwartz advises which system best suits the application.
Contract laminating available
Zwartz handles the laminating process for clients who supply nonwovens. Through the expertise Zwartz has in-house, advice can always be provided on the best approach. From prototypes to series production, from thin nonwovens to thicker combinations.
Get in touch
Need advice on laminating nonwovens for a specific application? Questions about which nonwoven types suit, which adhesive is suitable or which system delivers the best results? The Zwartz team is happy to collaborate.
Frequently asked questions
Which nonwoven types can be laminated?
All nonwoven types: spunbond, meltblown, needlepunch, thermally bonded and chemically bonded nonwovens. Each type requires specific process settings. Zwartz advises which approach suits the specific nonwoven.
Which system does Zwartz use for laminating nonwovens?
Depending on the application: belt calender for large volumes and roll-to-roll production, hotmelt system for fast production and precise adhesive control, or flatbed system for prototypes and thicker combinations. We advise which system works best.
Can nonwovens remain breathable after laminating?
Yes. Through dot coating, adhesive is only applied at specific points, keeping gaps open so nonwovens remain breathable. This is used for applications requiring barrier properties but air permeability.
Are prototypes and test series possible?
Yes. All three systems are suitable for prototypes and small series. For laminating nonwovens, testing is important because each combination can react differently. Test samples can be made quickly to find the right process settings.
Can Zwartz process customer nonwovens?
Yes. Contract laminating is possible where clients supply the nonwovens (and possibly other layers). Zwartz handles the laminating process and advises on the best approach for the specific nonwoven type.
Which adhesives are used for laminating nonwovens?
Thermoplastic hotmelt without solvents. For applications requiring extra adhesive strength, reactive hotmelt can be used. Zwartz advises which adhesive suits the nonwoven type and application.
