Stories
11.07.2022
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Meltblown line: What comes after the mask boom?

At the beginning of the Covid-19 pandemic, many manufacturers built up capacity to produce urgently needed meltblown nonwovens for medical applications. Now, demand is in sharp decline. However, manufacturers can use the lines to open up new applications and markets.

Manufacturers of nonwovens for medical protection are currently experiencing how quickly peak demand can turn into overcapacity. At the start of the Covid-19 pandemic, the supply chain for protective face masks and medical protective clothing from Asia came to a standstill. As a consequence, it was impossible to deliver assured nonwoven qualities and therefore protective functions. Face masks for protection against infection were suddenly in short supply in Europe. Masks were sold at record prices and governments subsidized the setting up of local production facilities.

Only two years later, the situation has changed drastically. Demand has collapsed and Asian manufacturers are flooding the market with goods at dumping prices and questionable quality. As a result, there is overcapacity on the market and prices have nosedived. In some cases, manufacturers have been left sitting on their masks. "It is very unfortunate that governments are not continuing to support these producers. However, producers of meltblown nonwovens that find themselves stuck in this situation do not have to shut down their lines," says Lars Leu, acting as advisor to Reicofil customers in such situations. "Instead, they should think about alternative applications."

Meltblown producers have three options

1
Stay on the same market but modify the application


Nonwovens produced on Reifenhäuser Reicofil Meltblown lines consist of very fine fibers that make the fabric highly efficient in filtering out tiny particles. This property is not only ideal for masks but other applications as well, for example, air filters in cleanrooms, engine filters, liquid filters, and vacuum cleaner bags

2
Switch to other markets with the existing line configuration


However, switching to other markets may also be an option for manufacturers - for example, by using different raw materials or modifying process settings. The range of possible products extends from high-end filters to simple absorbers for liquids or sound insulators.

3
Venture onto other markets and modify the line configuration accordingly


However, in order to move to a different target market, it may also be necessary to modify the meltblown line. For example, if the target nonwoven product is a wipe, one of the upgrades required is an additional hydrophilic spray system to allow moisture absorption.

Alternative applications for your meltblown production

Option

Raw material

Possible products/properties

Possible modifications (depending on requirements)

1

PP

Vacuum cleaner bags

1-3

PP

Air filter (HEPA, pleatable, HVAC)

Hydrocharging, different die tip

2

PP

Absorbance (liquids, chemicals and oils)

Different die tip

2-3

PP

Wipes (cleaning, abrasive)

Hydrophilic spray system; unwinder for lamination, different die tip

2-3 

PP

Absorbents (acoustics)

3

PBT

Liquid filtration (fuel, blood, water)

Polymer dryer, temperature-resistant dosing system, different die tip

3

PLA

Biobased filters for different classes

Polymer dryer, temperature-resistant dosing system, different die tip

Many of these alternatives have enormous potential. For example, there has been steady growth on markets for water filtration or wipes for several years. "The first step for producers is to ask themselves which market they want to invest in," explains Lars Leu, Sales Manager. "For example, what are the markets where they can capitalize on successes, where they see potential growth, or whether there are possible tie-ins to other products within the company."

The effort required for a production switch then largely depends on the target product and its requirements. “Consider the pros and cons: How do the requirements for the target product fit in with the existing line - this then determines the next steps,” says Lars Leu. "We support our customers with our process know-how during product development and advise them on necessary line upgrades for their Reifenhäuser Reicofil Meltblown lines.”

Advantages of Reicofil meltblown technology

  • Broad range of applications:
    Option to switch between Singlerow and Multirow technology
  • Different fiber diameters:
    Singlerow: 500µm – 5µm
    Multirow: 3µm - 10µm
  • High nonwoven quality: 99% filtration efficiency
    (N99 / FFP3 standard)
  • Uniform quality:
    guaranteed product properties
  • Reliable machine technology:
    maximum line availability