What Is Airlaid? Understanding the Engineered Fabric Behind Absorbent Products

Airlaid

Airlaid is a nonwoven fabric made by dispersing short cellulose fibers (typically wood pulp) in air rather than water and bonding them with synthetic fibers or binders. This process produces a soft, bulky, and highly absorbent material used in everything from diapers and sanitary pads to medical wipes and industrial absorbents.

How Is Airlaid Fabric Made?

Unlike traditional paper or textile manufacturing, airlaid technology uses air streams to form fiber webs. Here's how the process works:

  1. Pulp Breakdown: Fluffed cellulose fibers are separated and aerated.

  2. Web Formation: Air carries the fibers to a forming drum or belt, where they settle into a uniform mat.

  3. Bonding: The web is stabilized through one of several bonding methods:

    • Thermal bonding using heat and synthetic fibers (like bicomponent fibers)

    • Latex bonding using chemical adhesives

    • Hydrogen bonding (pressure + moisture), typically used in tissue-like applications

The result is a soft, porous sheet with a high liquid absorbency and excellent bulk and softness.

Key Properties of Airlaid Materials

PropertyBenefit
High AbsorbencyCan hold multiple times its weight in liquid
Soft and CushionyIdeal for skin-contact products like wipes and pads
Dust-Free and CleanPreferred in medical and food-safe applications
Customizable ThicknessCan be engineered for light or heavy-duty use
Binder FlexibilityAllows tuning between softness and strength

Common Uses of Airlaid

Airlaid is a versatile material used across multiple industries:

1. Hygiene Products

  • Feminine hygiene pads

  • Baby diapers

  • Adult incontinence pads

2. Wipes

  • Disposable cleaning cloths

  • Wet wipes

  • Cosmetic wipes

3. Medical & Surgical

  • Absorbent drapes

  • Wound care pads

  • Operating table sheets

4. Food Packaging & Tableware

  • Napkins

  • Table mats

  • Absorbent meat pads

5. Industrial & Automotive

  • Oil and liquid absorbent pads

  • Filtration components

Airlaid vs. Other Nonwovens

FeatureAirlaidSpunlaceMeltblown
AbsorbencyVery highModerateLow
SoftnessExcellentHighLow
CostModerateHigherLower
Bonding MethodThermal/Latex/HydroWater jet (no binders)Heat + melt polymers

Airlaid stands out for its balance of absorbency, strength, and softness, especially where liquid handling is critical.

Sustainability & Airlaid

Airlaid is typically made from renewable cellulose fibers, often with biodegradable binders, making it more sustainable than fully synthetic nonwovens. Newer innovations include:

  • Binder-free airlaid: Using hydrogen bonds instead of synthetic glues

  • Biodegradable & compostable options

  • Recyclable product applications in packaging and hygiene

Manufacturers are also moving toward closed-loop systems and recycled pulp sources to further reduce environmental impact.

Frequently Asked Questions About Airlaid

Q: Is airlaid the same as tissue paper?
A: Not quite. While both use pulp, airlaid is thicker, more absorbent, and made without water during the forming process—making it stronger and more versatile.

Q: Can airlaid be used for wet wipes?
A: Yes, it’s widely used for dry and wet wipes because it holds moisture well and is soft on skin.

Q: Is airlaid material biodegradable?
A: Most airlaid products are primarily biodegradable, especially those made from 100% cellulose and natural binders.

Q: Is airlaid recyclable?
A: In most cases, no. It’s considered disposable, especially when bonded with latex or synthetic fibers. However, innovations in compostable airlaid are changing this.

Q: What are the main drawbacks of airlaid?
A: Airlaid is more expensive than traditional paper and may lack tensile strength unless properly bonded.

Q: Can airlaid be reused?
A: Typically, no. It’s designed for single-use, especially in hygiene or food-related applications.

Final Thoughts

Airlaid may be unseen by most consumers, but it plays a crucial role in absorbent products across hygiene, medical, and food industries. With its blend of softness, absorbency, and flexibility, it’s a powerful solution for disposable goods—especially as manufacturers seek more sustainable, high-performance alternatives.

Would you like this article adapted into a product page, visual comparison chart, or presentation slide? Let me know, and I can format it to match your goals! 

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