How Is Spunlace Nonwoven Fabric Made? A Step-by-Step Manufacturing Guide

How is spunlace nonwoven fabric made?

Unlike woven fabrics, which are produced by interlacing yarns, or spunbond fabrics, which are generally made from continuous polymer filaments, spunlace nonwoven fabric is produced by forming a web of staple fibers and mechanically entangling those fibers with high-pressure water jets.

This process is called hydroentanglement.

The basic production sequence is:

Fiber preparation → Opening and blending → Web formation → Pre-entanglement → Hydroentanglement → Dewatering → Drying → Finishing → Inspection → Slitting and winding

However, this simplified sequence does not explain why two suppliers can produce spunlace fabrics with the same GSM but noticeably different softness, absorbency, strength or linting performance.

For buyers, understanding the spunlace manufacturing process is useful because every major production stage can affect the final material.

Spunlace Manufacturing Process at a Glance

A typical spunlace production process can be divided into the following stages:

The exact equipment configuration can vary between manufacturers and production lines.

Step 1: Selecting the Fibers

The first step in making spunlace nonwoven fabric is selecting the appropriate fibers.

Unlike spunbond, which commonly starts with polymer resin and forms continuous filaments directly during production, spunlace normally starts with staple fibers.

Common fiber choices include:

• Viscose

• Polyester

• Cotton

• Lyocell

• Other regenerated cellulose fibers

• Blends of different fibers

The fiber selection determines the basic characteristics that the manufacturer can achieve.

Typical fiber characteristics

These should be regarded as general tendencies rather than fixed rules.

Actual performance depends on fiber specifications, blend ratio, web structure, hydroentanglement conditions and finishing.

Step 2: Fiber Opening

After the raw fibers arrive at the factory, they are generally compressed into bales.

The fibers cannot be fed directly into web formation in their compressed state.

They first need to be opened.

The opening process separates the fibers and prepares them for more uniform processing.

The main objectives are to:

• Break up fiber clumps

• Loosen compressed fibers

• Improve fiber distribution

• Remove some foreign matter

• Prepare fibers for blending and web formation

Poor opening can create downstream problems.

For example, insufficiently opened fibers may contribute to uneven web formation and local differences in fabric density.

Step 3: Fiber Blending

If the product uses more than one fiber type, the fibers must be blended at a controlled ratio.

For example:

70% viscose + 30% polyester

is very different from:

50% viscose + 50% polyester

even if both fabrics are produced at exactly 50 GSM.

Blending consistency is particularly important for high-volume applications such as wipes.

A variation in fiber composition can affect:

• Absorbency

• Wet strength

• Dry strength

• Softness

• Appearance

• Cost

• Converting performance

For this reason, a reliable manufacturer should control the raw-material feeding and blending process rather than relying only on final-product inspection.

Step 4: Web Formation

Once the fibers have been opened and blended, they must be formed into a web.

This is one of the most important stages in the spunlace production process because the arrangement of fibers influences the structure of the finished material.

Carding is commonly used to form a controlled fiber web.

The fibers are separated and arranged into a relatively uniform layer.

At this point, the material is still a loose web.

It does not yet have the mechanical integrity of finished spunlace fabric.

Why web formation matters

Web formation influences:

• Basis-weight uniformity

• Fiber orientation

• MD/CD strength balance

• Thickness

• Surface uniformity

• Absorbency behavior

If the web is uneven, later hydroentanglement cannot necessarily compensate for all of the variation.

Step 5: Cross-Lapping and Web Weight Control

Depending on the production line, the web may be cross-lapped or otherwise arranged to achieve the required basis weight and fiber distribution.

This stage helps control the final GSM and directional structure.

For example, a highly directional web may produce different MD and CD mechanical properties from a more balanced structure.

This matters for applications where the fabric will be:

• Pulled through converting equipment

• Folded

• Perforated

• Cut

• Laminated

• Converted into wipes

Therefore, GSM should not be viewed independently from fiber orientation.

Step 6: Pre-Entanglement

The loose web is then stabilized before the main hydroentanglement process.

Water jets can be used to begin mechanically entangling the fibers.

The purpose is to give the web enough integrity to continue through subsequent processing.

Pre-entanglement helps:

• Stabilize the web

• Reduce fiber displacement

• Begin mechanical bonding

• Prepare the structure for stronger hydroentanglement

The exact number and configuration of pre-entanglement stages depends on the production line and product specification.

Step 7: Hydroentanglement — The Core of Spunlace Production

This is the defining stage of the entire process.

Fine high-pressure water jets are directed onto the fiber web.

The jets penetrate the web and cause individual fibers to move, bend and wrap around neighboring fibers.

Repeated water-jet treatment produces a mechanically entangled fiber network.

The basic mechanism

Water jet

↓

Fiber displacement

↓

Fiber bending and movement

↓

Fiber entanglement

↓

Three-dimensional fiber network

↓

Spunlace nonwoven fabric

The process does not depend primarily on conventional adhesive bonding.

This mechanical entanglement is the fundamental reason the technology is called hydroentanglement.

How Does Hydroentanglement Bond the Fibers?

Imagine a loose layer of fibers lying on a support surface.

If high-speed water jets pass through the layer, the water exerts forces on the individual fibers.

Some fibers move downward.

Others move sideways.

Some bend around neighboring fibers.

As the process is repeated, the fibers become mechanically intertwined.

The final fabric therefore obtains its integrity from a large number of fiber-to-fiber interactions.

This is fundamentally different from:

• Thermal bonding

• Chemical adhesive bonding

• Stitch bonding

The resulting structure can provide a useful combination of:

• Softness

• Flexibility

• Strength

• Absorbency

• Textile-like hand feel

What Controls the Hydroentanglement Process?

Hydroentanglement is not simply a matter of using "high-pressure water."

The final fabric depends on the interaction of multiple variables.

These parameters need to be optimized together.

Simply increasing water pressure does not necessarily produce a better fabric.

Excessive processing can increase energy and water consumption and may alter the desired balance between softness, strength and fabric structure.

Step 8: Water Filtration and Recycling

Water is central to the hydroentanglement process.

A modern production system therefore needs effective water management.

The process water can contain:

• Loose fibers

• Fine particles

• Processing residues

• Other contaminants

Filtration systems help maintain water quality and protect the consistency of the hydroentanglement process.

Depending on the production system, process water may also be treated and recirculated.

For large-scale manufacturing, water management affects both:

• Production stability

• Manufacturing efficiency

This is an important but often overlooked part of the spunlace manufacturing process.

Step 9: Dewatering

After hydroentanglement, the fabric contains a substantial amount of water.

The water must be removed before the fabric can be properly dried.

Dewatering systems extract excess water from the web.

Effective dewatering helps reduce the load on the subsequent drying stage.

This is important because drying a highly saturated web requires significant energy.

Dewatering therefore affects:

• Energy consumption

• Production speed

• Moisture control

• Fabric handling

• Overall production efficiency

Step 10: Drying

After dewatering, the fabric enters the drying process.

The remaining moisture is removed under controlled conditions.

The objective is not simply to make the fabric dry.

The manufacturer also needs to maintain the desired fabric structure and avoid unnecessary changes to the material.

Drying conditions can influence:

• Final moisture content

• Dimensional stability

• Surface characteristics

• Hand feel

• Production efficiency

For some applications, moisture control is particularly important because residual moisture can affect storage stability and downstream converting.

Step 11: Finishing Treatments

Not every spunlace product is finished in exactly the same way.

Depending on the intended application, the fabric may receive additional treatments.

Possible finishing requirements include:

• Hydrophilic treatment

• Hydrophobic treatment

• Softening

• Antistatic treatment

• Color treatment

• Other application-specific surface treatments

For example, a wipe designed to absorb liquid quickly may require different surface characteristics from a material designed for a dry cleaning application.

The finishing process should therefore be selected according to the final product.

Step 12: Cutting, Slitting and Roll Winding

Once the fabric reaches the required specifications, it is converted into rolls.

The production line may control:

• Roll width

• Roll length

• Roll weight

• Core diameter

• Roll diameter

• Edge quality

This stage is commercially important because the roll configuration needs to match the buyer's converting equipment.

For example, a wipe manufacturer may have specific requirements for:

• Parent-roll width

• Unwinding direction

• Core size

• Roll diameter

• Maximum roll weight

A fabric that meets the technical specification but cannot run efficiently on the customer's converting machine is still a poor purchasing choice.

Step 13: Quality Inspection During Production

Quality control should not begin only after the final roll has been produced.

A reliable production system monitors critical characteristics throughout manufacturing.

Important checkpoints can include:

Raw material inspection

• Fiber type

• Fiber specification

• Fiber composition

• Batch information

Web inspection

• GSM uniformity

• Fiber distribution

• Surface appearance

• Web defects

Finished-fabric inspection

• GSM

• Width

• Thickness

• Tensile strength

• Elongation

• Tear strength

• Wet strength

• Absorbency

• Appearance

• Linting where applicable

The exact testing program should be based on the customer's application.

Which Spunlace Properties Are Created at Each Production Stage?

One useful way to understand the process is to connect manufacturing stages directly to final performance.

This relationship explains why a supplier's manufacturing capability can matter as much as the nominal specification.

How Fiber Choice Changes the Manufacturing Process

Different fibers do not behave identically during hydroentanglement.

Viscose

Viscose is widely used when manufacturers want:

• Soft hand feel

• Good absorbency

• Cellulose-based fiber characteristics

It can be suitable for many wipe and personal-care applications.

Polyester

Polyester is often selected when the product requires:

• Higher durability

• Good dry strength

• Synthetic-fiber characteristics

Viscose/Polyester Blends

Blending can provide a compromise between:

• Absorbency

• Softness

• Strength

• Cost

For example, a 70/30 blend and a 50/50 blend can produce different performance and cost profiles.

Therefore, buyers should specify the actual composition instead of simply asking for "spunlace."

How GSM Changes the Production Process

GSM influences how the web behaves during hydroentanglement.

A lightweight web and a heavy web do not respond identically to the same processing conditions.

As GSM increases, the manufacturer may need to adjust the production process to ensure that the water jets adequately penetrate and entangle the fiber structure.

GSM also affects:

• Fabric thickness

• Strength

• Absorbency

• Roll length per unit weight

• Finished-product cost

• Container loading efficiency

For this reason, production parameters should be optimized for the target GSM rather than copied from another product.

How Fiber Orientation Affects Spunlace Fabric

Fiber orientation is one reason MD and CD properties can differ.

Suppose a fabric has:

MD tensile = 80 N

and

CD tensile = 45 N

The difference indicates that the fabric does not behave identically in both directions.

For a converting application that pulls the fabric strongly in the machine direction, this may be acceptable.

For another application requiring balanced mechanical performance, a different structure may be preferable.

This is why professional buyers should request directional mechanical data when it matters to the finished product.

Why Two Suppliers Can Produce Different 50 GSM Spunlace

This is a common sourcing problem.

Two suppliers may both quote:

50 GSM spunlace nonwoven fabric

Yet the fabrics may feel and perform differently.

Possible reasons include:

• Different fiber composition

• Different fiber fineness

• Different fiber length

• Different web formation

• Different fiber orientation

• Different hydroentanglement intensity

• Different drying conditions

• Different finishing treatment

• Different production tolerances

Therefore:

Same GSM ≠ Same Fabric

And:

Same fiber composition ≠ Same Performance

This is why sample approval and specification control are important when sourcing spunlace internationally.

How Manufacturers Control Spunlace Quality

A mature production system generally uses multiple levels of control.

Raw Material Control

The manufacturer verifies incoming fibers before production.

This may include checking:

• Fiber type

• Batch

• Supplier

• Basic specifications

• Appearance

Process Control

During production, the manufacturer monitors parameters such as:

• Web weight

• Line speed

• Water pressure

• Hydroentanglement configuration

• Drying conditions

• Fabric width

Finished Product Control

Finished rolls are inspected against the agreed specification.

Typical checks include:

• GSM

• Width

• Thickness

• Tensile strength

• Elongation

• Tear

• Wet strength

• Absorbency

• Appearance

The exact tests should be defined according to the product application.

How Is Spunlace Fabric Tested After Production?

Testing should answer a simple question:

Will the fabric perform consistently in the customer's actual product?

A useful testing framework is:

Physical tests

• GSM

• Width

• Thickness

• Roll length

• Roll weight

Mechanical tests

• MD tensile

• CD tensile

• MD elongation

• CD elongation

• Tear resistance

• Wet strength

Functional tests

Depending on application:

• Absorption capacity

• Absorption rate

• Liquid retention

• Linting

• Surface softness

• Air permeability

Application testing

The most valuable final test is often an actual production trial.

For example, a wet-wipe manufacturer can run the fabric through its converting line and evaluate:

• Unwinding

• Cutting

• Folding

• Lotion absorption

• Wet handling

• Packaging

• Final wipe performance

A Simplified Factory Production Flow

The complete process can be summarized as:

1. Fiber selection

↓

2. Bale opening

↓

3. Fiber blending

↓

4. Carding / web formation

↓

5. Cross-lapping or web arrangement

↓

6. Pre-entanglement

↓

7. High-pressure hydroentanglement

↓

8. Water removal

↓

9. Drying

↓

10. Finishing

↓

11. Online and laboratory inspection

↓

12. Slitting

↓

13. Roll winding

↓

14. Packaging

↓

15. Shipment

This is the basic answer to how spunlace nonwoven fabric is made, but the real manufacturing process involves continuous optimization of fiber, water, web and production-line conditions.

What Should Buyers Ask a Spunlace Manufacturer?

When evaluating a supplier, do not ask only:

"Can you produce spunlace?"

Ask more specific questions.

Raw material

• What fiber composition do you use?

• What fiber types are available?

• Can you produce viscose/polyester blends?

• Is the material virgin, regenerated or recycled where applicable?

Production

• What GSM range can you produce?

• What maximum fabric width is available?

• What hydroentanglement technology is used?

• What finishing options are available?

Quality

• How do you control GSM?

• How do you test tensile strength?

• Can you provide wet-strength data?

• How do you control roll-to-roll consistency?

• Can you provide a technical data sheet?

Commercial

• What is the MOQ?

• What is the standard lead time?

• What roll configurations are available?

• How many rolls or containers can you produce per month?

These questions reveal much more about a supplier's manufacturing capability than a simple factory tour or equipment photograph.

What Is the Difference Between Spunlace Manufacturing and Spunbond Manufacturing?

The two technologies start from different raw-material systems and use different bonding mechanisms.

This difference is important when choosing the appropriate nonwoven technology.

Common Manufacturing Problems in Spunlace Production

Uneven GSM

Possible causes include:

• Inconsistent web formation

• Uneven fiber feeding

• Poor blending

• Production-line instability

Uneven surface

Possible causes include:

• Uneven fiber distribution

• Hydroentanglement inconsistency

• Nozzle or water-system issues

Low wet strength

Possible causes can include:

• Fiber selection

• Insufficient entanglement

• Fiber structure

• Finishing conditions

The correct cause must be confirmed through production testing rather than assumed from the finished appearance.

Excessive linting

Potential contributors include:

• Fiber selection

• Fiber length

• Fiber entanglement

• Surface structure

• Processing conditions

Excessive variation between rolls

Possible contributors include:

• Raw-material batch differences

• Process instability

• Inadequate quality control

• Inconsistent finishing

• Poor specification control

These issues demonstrate why manufacturing consistency is often more important than a single laboratory result.

Why Hydroentanglement Is So Important for Wipes

Wipes place several demands on the fabric simultaneously.

The material may need to be:

• Soft enough for the intended use

• Absorbent enough to carry liquid

• Strong enough when wet

• Flexible during folding

• Stable during converting

• Low-linting for certain applications

Hydroentanglement allows manufacturers to engineer the fiber network to balance several of these properties.

However, there is always a trade-off.

Increasing one property may influence another.

For example, a fabric optimized for extreme softness may not have the same wet strength as a more durable industrial wiping material.

Therefore, good spunlace manufacturing is fundamentally an optimization problem rather than a search for one maximum performance number.

How Manufacturers Optimize Spunlace for Different Applications

The production target changes according to the end use.

Wet wipes

Focus on:

Absorbency + wet strength + softness + converting performance

Facial wipes

Focus on:

Softness + surface quality + absorbency + low linting

Household cleaning wipes

Focus on:

Wet strength + absorbency + durability + cost efficiency

Industrial wipes

Focus on:

Strength + tear resistance + wet performance + linting + chemical compatibility

The manufacturing process is therefore adjusted according to the required performance rather than producing one universal spunlace fabric.

Final Takeaway

The answer to how is spunlace nonwoven fabric made can be summarized in one sentence:

Spunlace nonwoven fabric is made by forming a web of staple fibers and mechanically entangling those fibers with high-pressure water jets, followed by dewatering, drying, finishing, inspection and roll conversion.

But for buyers, the more important lesson is that the hydroentanglement stage is only one part of the process.

The final fabric is the result of:

Fiber selection

→ Fiber preparation

→ Web formation

→ Fiber orientation

→ Hydroentanglement

→ Dewatering

→ Drying

→ Finishing

→ Quality control

→ Roll conversion

This complete process determines whether a spunlace fabric actually meets the requirements of the finished product.

When comparing suppliers, therefore, do not compare only GSM and price per kilogram. Compare fiber composition, mechanical performance, absorbency, wet strength, linting, tolerances, roll configuration and production consistency.

For large-volume buyers, the best supplier is not necessarily the one offering the lowest nominal price. It is the manufacturer that can repeatedly produce the required specification with stable quality and predictable converting performance.