Abstract: A process for making a spunmelt nonwoven web including the steps of providing a mixture of recycled polypropylene, extruding the recycled polypropylene mixture to form a molten recycled polypropylene mixture, filtering the molten recycled polypropylene mixture through a filter to form recycled polypropylene filtrate, dosing the recycled polypropylene filtrate into the spunmelt production line by an amount of 80% to 100% by weight, passing the recycled polypropylene filtrate through at least one spinneret of the spunmelt production line to form filaments at a spinning speed of greater than 1200 meters per minute, cooling and drawing the filaments, and depositing the filaments on a moving belt to form at least one layer of the spunmelt nonwoven web made up of 80% by 100% by weight of recycled polypropylene fibers.

Abstract: A nonwoven composite fabric including a first nonwoven layer composed substantially of meltblown fibers, the fibers within the first nonwoven layer having diameters that vary in accordance with a first distribution, a second nonwoven layer composed substantially of meltblown fibers, the fibers within the second nonwoven layer having diameters that vary in accordance with a second distribution, and a third nonwoven layer composed substantially of meltblown fibers, the third nonwoven layer disposed between the first and second nonwoven layers, the fibers within the third nonwoven layer having diameters that vary in accordance with a third distribution that is greater than the first and second distributions.

Abstract: A method of forming a hydro-patterned nonwoven web including the steps of forming a nonwoven batt comprising continuous spunmelt fibers, calender bonding the nonwoven batt to form a thermobonded precursor nonwoven web with a bond pattern that defines bond impressions and unbonded areas between the individual bond impressions, and hydraulically treating the thermobonded precursor nonwoven by a plurality of steps of water injection as the thermobonded nonwoven web passes over a screen. The bond pattern has specific features that provide advantages in terms of mechanical properties and visual appearance of the final nonwoven product.

Abstract: A method of forming an apertured hydro-patterned nonwoven web including the steps of forming a nonwoven batt comprising continuous spunmelt fibers, calender bonding the nonwoven batt to form a fully bonded precursor nonwoven web with a regular bond pattern that defines individual bond impressions and unbonded areas between the individual bond impressions, the regular bond pattern having a percentage bond area of 10% to 25%, and hydraulically imparting the fully bonded precursor nonwoven web with a plurality of apertures, the step of hydraulically imparting comprising hydraulically treating the fully bonded precursor nonwoven web by a plurality of steps of water injection as the fully bonded nonwoven web passes over a plurality of pins.

Abstract: A multi-ply flushable wipe includes a ply having first and second exterior layers and a middle layer disposed therebetween. Each of the exterior layers includes at least 50% by weight natural fibers. When foam-formed, the middle layer includes at least 25% by weight natural fibers. In embodiments, the middle layer may include at least 75% by weight natural fibers. The middle layer also includes synthetic fibers that have a length within the range of 1 mm and 20 mm. The wipe may have a length weight weighted average fiber length of less than 4 mm and a wet CD strength of greater than 20 N/m. Each ply of the wipe may be formed by wetlaying the first and second exterior layers and a foam formed middle layer to form a web, imprinting the web with a structured fabric, and drying the web. The plies are then attached using a binder.

Abstract: A method to prepare, pulp, and bleach cannabis bast and hurd fibers to allow for the fiber to be incorporated into absorbent cellulosic structures on a wet-laid paper machine while keeping the pectin within the fibers. The wet laid paper machine can use the ATMOS, NTT, ETAD, TAD, or UCTAD method to produce the absorbent cellulosic structure. Absorbent cellulosic structures are produced with the cannabis bast and hurd fibers or with the bast fibers alone with the hurd fibers being combined with paper mill sludge or dust to form a fuel pellet.

Abstract: A multi-ply flushable wipe includes a ply having first and second exterior layers and a middle layer disposed therebetween. Each of the exterior layers includes at least 50% by weight natural fibers. When foam-formed, the middle layer includes at least 25% by weight natural fibers. In embodiments, the middle layer may include at least 75% by weight natural fibers. The middle layer also includes synthetic fibers that have a length within the range of 1 mm and 20 mm. The wipe may have a length weight weighted average fiber length of less than 4 mm and a wet CD strength of greater than 20 N/m. Each ply of the wipe may be formed by wetlaying the first and second exterior layers and a foam formed middle layer to form a web, imprinting the web with a structured fabric, and drying the web. The plies are then attached using a binder.

Abstract: A process for making a spunmelt nonwoven web including the steps of providing a mixture of recycled polypropylene, extruding the recycled polypropylene mixture to form a molten recycled polypropylene mixture, filtering the molten recycled polypropylene mixture through a filter to form recycled polypropylene filtrate, dosing the recycled polypropylene filtrate into the spunmelt production line by an amount of 80% to 100% by weight, passing the recycled polypropylene filtrate through at least one spinneret of the spunmelt production line to form filaments at a spinning speed of greater than 1200 meters per minute, cooling and drawing the filaments, and depositing the filaments on a moving belt to form at least one layer of the spunmelt nonwoven web made up of 80% by 100% by weight of recycled polypropylene fibers.

Abstract: An abrasive wipe includes a spunbond layer that forms a first outer surface of the wipe, a meltblown layer positioned over the spunbond layer so as to form an inner layer of the wipe and an abrasive layer positioned over the meltblown layer so as to form a second outer surface of the wipe. The spunbond layer, the meltblown layer and the abrasive layer are bonded together in a single bonding step, and, in an exemplary embodiment, the abrasive wipe has an MD tensile strength of at least 700 g/cm and a CD tensile strength of at least 500 g/cm.

Abstract: A nonwoven fabric including a first layer made of spunbond fibers and a second layer made of meltblown fibers, wherein the first layer is bonded with the second layer, and wherein the spunbond fibers of the first layer are interspersed with the meltblown fibers of the second layer so that the nonwoven fabric exhibits enhanced breathability and filtration properties. In exemplary embodiments, the nonwoven fabric may be used in personal protective equipment, such as, for example, face masks and respirators.

Abstract: A multi-denier nonwoven composite fabric having a nested structure is hydraulically treated by particular process parameters to improve softness and tactile feel.

Abstract: A method to prepare, pulp, and bleach cannabis bast and hurd fibers to allow for the fiber to be incorporated into absorbent cellulosic structures on a wet-laid paper machine while keeping the pectin within the fibers. The wet laid paper machine can use the ATMOS, NTT, ETAD, TAD, or UCTAD method to produce the absorbent cellulosic structure. Absorbent cellulosic structures are produced with the cannabis bast and hurd fibers or with the bast fibers alone with the hurd fibers being combined with paper mill sludge or dust to form a fuel pellet.

Abstract: A method to prepare, pulp, and bleach cannabis bast and hurd fibers to allow for the fiber to be incorporated into absorbent cellulosic structures on a wet-laid paper machine while keeping the pectin within the fibers. The wet laid paper machine can use the ATMOS, NTT, ETAD, TAD, or UCTAD method to produce the absorbent cellulosic structure. Absorbent cellulosic structures are produced with the cannabis bast and hurd fibers or with the bast fibers alone with the hurd fibers being combined with paper mill sludge or dust to form a fuel pellet.

Abstract: A nonwoven laminate having a SMS structure is hydraulically treated by particular process parameters to improve softness and tactile feel. The nonwoven laminate may also be imparted with one or more regular aperture patterns by additional hydraulic treatment processes, where the initial hydraulic treatment provides for improved aperture definition.

Abstract: A multi-layer through air dried tissue including a first exterior layer comprised substantially of hardwood fibers, an interior layer comprised substantially of softwood fibers, and a second exterior layer comprised substantially of hardwood fibers. The interior layer includes a first wet end additive comprising an ionic surfactant and a second wet end additive comprising a non-ionic surfactant.

Abstract: A nonwoven composite fabric including a first nonwoven layer composed substantially of meltblown fibers, the fibers within the first nonwoven layer having diameters that vary in accordance with a first distribution, a second nonwoven layer composed substantially of meltblown fibers, the fibers within the second nonwoven layer having diameters that vary in accordance with a second distribution, and a third nonwoven layer composed substantially of meltblown fibers, the third nonwoven layer disposed between the first and second nonwoven layers, the fibers within the third nonwoven layer having diameters that vary in accordance with a third distribution that is greater than the first and second distributions.

Abstract: A composite structure including at least one natural fiber web layer and at least one nonwoven web layer. In an exemplary embodiment, the natural fiber web layer is made of cotton fibers and the nonwoven web layer is a spunmelt layer. The composite structure may be used to form components of an absorbent article, such as top sheets or back sheets of a diaper.

Abstract: A multi-layer through air dried tissue including a first exterior layer comprised substantially of hardwood fibers, an interior layer comprised substantially of softwood fibers, and a second exterior layer comprised substantially of hardwood fibers. The interior layer includes a first wet end additive comprising an ionic surfactant and a second wet end additive comprising a non-ionic surfactant.

Abstract: A process for manufacturing tissue including providing a first pulp mix, delivering a wet-end additive to the first pulp mix at a first point in the process, forming a tissue web comprising the first pulp mix after the first point in the process, monitoring the tissue web for breaks and preventing delivery of the wet-end additive to the first pulp mix at the first point in response to detecting a break in the monitoring step. In an exemplary embodiment, a switching valve is used to control delivery of the wet-end additive to the first pulp mix.

Abstract: A multi-denier nonwoven composite fabric having a nested structure is hydraulically treated by particular process parameters to improve softness and tactile feel.