Leveraging Cellulose In Nonwovens Sustainability

By Katharina Gregorich

It is well understood in today’s society, that single use plastics can lead to dramatic global waste problems when ending up into the environment where they pollute oceans and land.

The responsibility on preserving the environment for next and future generations is close to the heart of Lenzing AG. Lenzing sees itself therefore in a pioneering task to bring forward LENZING™ Nonwoven technology (formerly known as LENZINGTM Web technology), a unique emerging spinning technology consolidating the full supply chain on Lyocell-based cellulosic nonwoven roll good production.

This technology platform can directly produce 100% cellulosic, certified biodegradable and binder free nonwoven materials using the sustainably sourced wood. This unique processing spins endless cellulosic filaments, which are laid down in a wet process directly into a web formation. The combination of the natural bonding of the filaments and further hydroentanglement allows to produce materials without the use of any finishes or binders.

The technology controls to control fabric properties like liquid management and fabric haptics by setting the filament diameter distribution and the amount of filament binding (merging). LENZING™

Nonwoven Technology materials are characterized by their homogeneous filament distribution and high dimensional stability. It is currently scaled to a pilot scale which is capable to seed small markets in the basis weight areas of 15 to 100 gsm in roll widths up to 70 cm.

Due to the versatility of fabric properties which can be achieved with this cellulosic materials, a wide range of application fields can be covered, from cosmetic sheet masks, over durable nonwovens like filtration, the hygiene sector and wipes sector. For the wipes sector, this patented manufacturing process allows for adjusting the abrasiveness of the material in dry and wet state according to the required cleaning tasks. The inherent properties of cellulosic filaments naturally regulate liquid absorption and release. This leads to a fast uniform distribution of the liquid within the material, whether during converting or in use as a wipe. Especially in the wipes sector, Lenzing has come a long way by prototyping the final wipe in flow pack and canister application, being able to showcase unique fabric properties like the increased dimensional stability of the low elongating wet wipes.

The filtration sector can benefit from an adjustable air permeability within the materials and the hygiene sector, like diapers or feminine pads, from an adjustable liquid distribution with this new technology’s material. Furthermore the fact, that the materials are binder and finish free, make them an ideal choice for personal care products.

The technology platform will be further enhanced through a wetlaid pulp technology integration to further broaden offered fabric properties such as softness and scale technology output. The pulp is thereby integrated solely over spunlacing into the Lyocell based carriers, creating binder free pulp composite fabrics. The produced fabrics can serve a broad application field as well, for example in wipes, absorbent hygiene products, durable nonwovens and filtration sector. They have, especially for the wipes sector, an increased soft touch versus the pulp free materials and show increased liquid spreading properties.

Lenzing is interested in co-developing material and optimizing the technology platform together with a partner. Currently, Lenzing is seeding small markets with commercial versions of these innovative materials. This will enable converters and brands to produce next generation sustainable nonwoven materials and test consumer preference.

Katharina Gregorich studied biotechnical engineering at the University of Applied Sciences, lower Austria and finished her master studies in 2010. Additionally, she graduated with a MBA in Innovation Management and Entrepreneurship in 2023. She started her career in Lenzing Fibers GmbH, Heiligenkreuz, Austria beginning of 2011 as a process engineer for Lyocell process and joined then an international program working on various Lenzing sites. In 2013 she joined Lenzing’s Global R&D department as project manager in the area of product development. Since a few years she is a member of the LENZING™ Nonwoven Technology team, leading the product development activities and is also responsible for market related activities. She is happy to be recently announced as part of the global fiber congress program committee.

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