Producing pulp‑based nonwovens
Nonwovens made from cellulose pulp are increasingly used in hygiene products such as dry and wet wipes as well as moist toilet tissue. Processing very short cellulose fibers requires specialised concepts for web formation and consolidation – this is exactly where our line concepts come into play.
One fiber - two technologies
In WLS processes (Wet‑Laid/Spunlace), the entire web is formed by wet‑laying and subsequently bonded by hydroentanglement. This makes the process ideal for flushable products such as moist toilet tissue, as well as for wipes with higher strength requirements. CP processes (Carded/Pulp) combine a wet‑laid pulp layer with a carded web made from longer fibers. Both layers are bonded together by high‑pressure water jets. The resulting end products are wipes for baby care and personal hygiene.
Our line concept offers maximum product flexibility, enabling the production of CPC (Carded/Pulp/Carded), CAC (Carded/Airlaid/Carded) and SPC (Spunbond/Pulp/Carded) products as well.
What are pulp‑based nonwovens??
Cellulose pulp is the basic raw material of the paper industry and is therefore cost‑effective and widely available worldwide.
However, a mechanically bonded pulp‑based nonwoven never consists of 100% pulp. A proportion of longer fibers must always be added to ensure sufficient strength of the end product.
Raw materials are:
- Wood or non-wood pulp
- All natural or man-mede fibers that can be singled out (dispersed) in water
What are pulp‑based nonwovens?
Cellulose pulp is the basic raw material of the paper industry and is therefore cost‑effective and widely available worldwide.
However, a mechanically bonded pulp‑based nonwoven never consists of 100% pulp. A proportion of longer fibers must always be added to ensure sufficient strength of the end product.
NBSK pulp from plantation softwood such as pine, fir and spruce
Non‑wood pulp, for example from bamboo
Cellulose‑based man‑made fibers such as viscose or lyocell
Natural or synthetic fibers that can be dispersed in water
Why is pulp a smart choice for single-use wipes?
From renewable resources
Wood or non-wood based pulp plus viscose or lyocell cellulosic fibers
Biodegradable
Cellolose-based Nonwovens typically fully biodegrade within 10–12 weeks in soil environments – leaving no microplastics behind
Small CO₂ footprint
Favorable CO₂ balance for pulp due to biogenic carbon uptake
Future-fit
Sustainable single‑use products are becoming a regulatory imperative
Pulp as a raw material – properties and processes clearly explained
Which products are made from wet-laid, pulp-based nonwovens?
WLS and CP nonwovens - and other coposite nonwovens such as CPC, CAC and SPC - are converted into wipes that are commercially available on supermarket and drugstore shelves:
- dry wipes
- wet wipes
- flushable wipes
WLS Moist Toilet Tissue
EDANA-certified
65 gsm
80% Pulp / 20% Lyocell
WLS structured wipe
60 gsm
80% Pulp / 20% Lyocell
CP wipe
60 gsm
80% Pulp unbleached /
20% Lyocell
CP 2-sided wipe
45 gsm
25 gsm Pulp unbleached /
20 gsm Viscose
Our technologies for manufacturing pulp-based nonwovens
Several process steps of the “standard” production process must be adapted in order to process pulp efficiently. Since the end products are mass‑market goods, production has to be as cost‑effective as possible – meaning high speeds, low energy consumption and minimal material losses.
Web forming
Early on, our partner Voith further developed its proven wet‑laying technology for the production of specialty nonwovens. Voith’s sheet‑forming technology produces a homogeneous web in WLS and CP lines, either from 100% pulp (for CP processes) or from a blend of pulp and additional short fibers (e.g. cellulosic fibers, PET, etc.). In CP processes, our TWF-NCT-X card adds a carded web layer to the overall process.
The result: uniform basis weights, reproducible product quality, and excellent look & feel.
Web bonding
Spunlacing the web with our AquaJet mechanically bonds the fibers – and optional web layers – purely by high-pressure water jets.
This enables the production of soft, highly absorbent yet strong nonwovens without the use of chemical binders.
Drying
During hydroentanglement, pulp absorbs a large amount of water. However, the nonwoven can only be partially dewatered mechanically in order to maintain web structure and bulk.
With the MPD (Modular High‑Performance Dryer), we offer a powerful and energy‑efficient drying solution for this process step.
The result: each nonwoven is precisely dried so desired material properties are preserved..
Our production lines for pulp‑based nonwovens
Trützschler Nonwovens offer various efficient machinery and production line concepts.
Line characteristics for both WLS and CP lines
Web weights: 30 to 100 gsm
Fibers: pulp, short-cut viscose, lyocell, PET and other dispersible fibers
Output: more than 20.000 tons per year
(depending on fiber type, web weight and working width)
Typical end products: flushable wipes and high-quality wet wipes for baby or body care
Wet-Laying/Spunlacing – Engineered for productivity
WLS is the ideal concept for manufacturers who want to produce flushable as well as fully bonded nonwovens made from pulp and short fibers – achieving maximum productivity with minimal pulp loss.
Our preferred raw material blend consists of softwood NBSK pulp combined with short-cut viscose, lyocell or PET fibers between 8 and 12 mm.
A wet-in-wet WLS production line for flushable or full-strength wipes
Carded/Pulp – Engineered for flexibility
CP lines are particularly suitable for manufacturers who aim to produce different types of nonwovens on a single line – ranging from cost‑efficient, pulp‑based products to classic hydroentangled carded nonwovens. The flexibility of the CP concept reduces investment risks and increases market agility.
Multi-layer composite nonwovens
Based on CP technology, additional multi‑layer composite nonwovens can be produced. The basic configuration consisting of a wet former and a card can be selectively expanded, for example by adding an additional card to manufacture CPC nonwovens (Carded/Pulp/Carded) for premium wipes applications. When a dry former is used, a CAC nonwoven (Carded/Airlaid/Carded) is formed. Alternatively, additional material layers can be fed into the CP process via unwinders. By adding a spunbond layer, for example, an SPC nonwoven (Spunbond/Pulp/Carded) can be produced.
These composite nonwovens expand the product portfolio of CP lines and underline their flexibility.ed).
A flexible production line for carded/spunlaced, WLS and CP nonwovens
Two concepts, many possibilities: your questions about WLS and CP
Pulp‑based nonwovens as a foundation for future‑ready wipes
Nonwovens with wood or non-wood pulp offer manufacturers a powerful way to balance sustainability, performance and cost efficiency. Across global markets, regulations on biodegradability, microplastics and environmental safety are becoming increasingly strict – directly impacting hygiene products such as baby wipes, body wipes and especially flushable applications.
By choosing pulp‑based WLS and CP substrates, producers are able to meet these tightening requirements while future‑proofing their product portfolios. Trützschler supports manufacturers not only technologically but also strategically—from initial trials through line design to scalable mass production.