Airlaid Nonwovens Report

The airlaid nonwovens market is poised for growth. Among the factors driving the market forward are global growth in the wipes sector, the increasing use of period care products in developing countries and the rapid rise in the aging population in developed countries—leading to more users of adult incontinence products. Additionally, airlaid producers are looking outside of these traditional markets for growth.

Global consumption of airlaid is expected to rise from 574,750 tons in 2022 to 768,800 tons in 2027, according to The Future of Airlaid Nonwovens to 2027, a new report from Smithers. Across the same period, sales value will increase from $2.1 billion to $2.9 billion, at constant prices; equivalent to a compound annual growth rate of 7.7%.

Accelerating demand for more sustainable wipes, feminine hygiene goods and food industry products will be central to driving new consumption of airlaid nonwovens over the next five years, the report says.

In recent years, airlaid supply has been described as tight. After the market went through a period of expansion that led to excessive overcapacity in the early 2000s, recent investment has been modest, including new lines from Glatfelter in Arkansas (2018), Magic in Italy (2021), and a new line announced at Domtar’s Jesup, GA-based Engineered Absorbent Materials (EAM) facility that’s expected to come onstream in the first quarter of 2023.

According to Phil Mango, nonwovens consultant for Smithers, the airlaid market in 2022 is relatively tight in demand/supply. Globally, this is around 92%; both North America and Europe are in the mid 90% range with Asia in the mid 80% range.

“Glatfelter has a dominant position now, with about 30% of global capacity and a higher percentage of global production,” Mango says. 

The next five largest producers do not equal Glatfelter’s market share, and that includes EAM/Domtar’s new line, he adds. “Growth in airlaid has been moderate for several years as its major markets are mature (hygiene, wipes) and capacity has been tight.”

Although, there have recently been some new, non-traditional markets which he says have boosted airlaid growth by a percentage point or so, including packaging, insulation and molded consumer products. 

Geographically, while there is still very large potential growth in Asian hygiene markets, especially India and China, Mango says the currently expected economic slow down/recession globally as well as already slowing growth in China makes airlaid growth based on this market less likely short term. Among traditional markets, adult incontinence and food pads will grow at above average rates through 2027, and the newer, non-traditional markets like insulation, packaging and molded consumer products will provide a boost.

Airlaid Expansion

The expansion at Domtar’s EAM facility includes a large-scale Dan-Web airlaid production line. The machine will be fully operational in the first quarter of 2023, enhancing Domtar’s ability to supply both domestic and global customers with unique absorbent materials solutions. Domtar’s EAM facility has been developing and manufacturing innovative, high-quality absorbent core solutions since 1998.

“This expansion is a strategic step toward strengthening our value proposition as an essential partner to absorbent hygiene customers around the world,” says Vanécia Carr, General Manager, EAM.

Prevailing market conditions requiring additional airlaid capacity were among the reasons EAM decided to invest in the new line, according to Lori Venn, Vice President—Sales & Marketing, EAM. Consolidation within the market and choice—and therefore a need for a broader technology offering from EAM—were also factors.

“EAM/Domtar is in the unique position of offering a complete portfolio of airlaid materials: multi-bonded, thermal-bonded, and hydrogen-bonded airlaid, in addition to absorbent laminated products and pulp,” she says. “This investment will allow us to offer increased and more diverse product offerings.”

Molded pulp products, packaging products and filtration are some of the newer applications for airlaid that are driving growth. There is also continued growth in hygiene markets and the advancements into new categories of adult incontinence, Venn explains. Additionally, diversified product offerings to address niche markets, climate change or “green requirements,” and demand for specific products that cater to the range of needs of the younger generation are also driving growth for airlaid.

In Italy, Magic’s new airlaid line supplied by Campen Machinery can produce several types of thermal bonded airlaid products with or without tissue and nonwovens as a carrier sheet. Before investing in the new machinery, Magic acquired airlaid from external suppliers and was highly specialized in converting airlaid for the food, medical, personal care and safety and cleaning industries.

Several years ago, Magic developed Spongel, a super absorbent biodegradable powder, and from there the need to develop and produce their own airlaid arose. “Our need was to produce a new kind of high-absorbing and sustainable airlaid containing Spongel,” says Mauro Giani, owner and CEO of Magic Srl. “After Spongel development, we focused our efforts on the application of the powder in the airlaid material, and we realized that we needed to be able to control the whole production process.”

The Campen airlaid line was delivered in late 2019 and consists of hammer mill lines, fiber opener, drum forming heads, SAP dispenser, compactor, thermal bonding oven, a calender unit with cooling zone, process air filter and humidification system. An unwinder for tissue and winder for final winding of the product as well as a metal detector and in-line scanner system for measuring g/m2 are also part of the line.

“The high-tech airlaid machine from Campen transformed us from a converting company into a production company, as well as making it possible for us to create Airgel, a very exclusive and innovative product with Spongel,” says Giani.

Earlier this year, Magic launched the G-pad, a new biodegradable and compostable food pad.

In its continuous innovation process, G-pad is the natural outcome of Spongel and Airgel g-grade, a compostable airlaid – both certified OK Compost.

G-pad combines Airgel g-grade with a compostable film through a hot bonding process: no glue, no chemical additives, no adhesive are used, while the absorbent capacity is the same as traditional plastic film pads.

G-pad was inspired and conceived according to the principles of the circular economy, so that the new food pad at the end of its lifecycle can be disposed with household organic waste for industrial composting.

Glatfelter Grows

Within the last five years, Glatfelter has grown its airlaid business through acquisitions and investments, remaining a top player in this nonwoven technology. The company entered the airlaid business through the acquisition of Concert Industries in 2010, and since then has acquired Georgia-Pacific’s European operation in Steinfurt, Germany, in 2018, and its North American airlaid business, including G-P’s Mount Holly, NC, airlaid manufacturing operation, in 2020. The company also added a 20,000-ton line in Fort Smith, AR, in 2018.

According to company executives, the global markets served by Glatfelter airlaid materials continue to have significant potential for growth. Glatfelter focuses on maintaining and expanding relationships with customers that are market-leading consumer product companies, as well as companies converting and distributing through private labels. Due to the continuous growth of the global population, the steady increase in health and hygiene standards and higher demand for comfort and convenience, Glatfelter airlaid products are well-received as distribution layers and cores for advanced absorbent hygiene products, fabrics for table tops and napkins and very efficient for baby wet wipes substrate. The most dynamic growth regions are in Asia, however, there are solid and steady increases in demand in more mature markets, according to the company.

In terms of innovation, the company’s newly designed and fully plant-based absorbent hygiene product line, GlatPure, includes an airlaid acquisition distribution layer and absorbent core. The airlaid ADL has a low-density cellulose fiber-based nonwoven material that generates the porosity needed for optimum fluid management enhanced with bio-degradable binders to improve fiber-to-fiber bonding. Meanwhile, its airlaid absorbent core has a highly densified cellulose fiber-based nonwoven which is enhanced with cellulosic binders for improved tensile strength and fiber integration to avoid surface abrasion, with the option to add plant-based superabsorbent components to improve absorption capacity. The GlatPure ADL and absorbent core provide security and comfort to all end users, according to the company. The GlatPure product range also includes a topsheet manufactured from Glatfelter’s spunlace technology and a paper-based backsheet made from wetlaid technology.

Glatfelter has also been looking outside of traditional airlaid applications for growth.

One of its latest ventures is a partnership with Blue Ocean Closures and ALPLA, and the recent development of a cellulose-based airlaid bottle cap. Blue Ocean Closures is reportedly the first company to develop an innovative concept for fiber-based screw cap solutions that are fully biobased, ocean biodegradable, and recyclable. This is achieved through excellence in material know-how and a cost-effective production concept using advanced, proprietary press forming. Glatfelter won the IDEA Sustainability Innovation Award for this product concept this year and is also a finalist for the Packaging Europe Pre-Commercialized Sustainability award. The company says developing new applications from airlaid material is one of its top priorities.

In July, Glatfelter, Blue Ocean Closures and ALPLA announced they were working with The Absolut Company to develop an innovative natural fiber-based screw cap for Absolut Vodka’s iconic bottle.

Glatfelter and ALPLA will support BOC and their partnership with The Absolut Company by developing a cellulose-based cap that will be used on Absolut Vodka’s existing glass bottles. These uniquely designed caps will be made from airlaid material, resulting in a product that is recyclable and ocean biodegradable. Prototyping and final design of the caps will be completed this year, with plans to launch commercially in 2023.

“This partnership brings together like-minded companies that share similar sustainability goals focused on protecting our environment through the use of natural fiber-based materials,” says Chris Astley, senior vice president and CCO of Glatfelter. “We are excited to expand our partnership with ALPLA and BOC, now working with Absolut Vodka, to make more innovative and eco-friendly packaging solutions that will benefit generations to come.”

Airlaid Manufacturers Directory

Airlaid A/S
Sverigesvej 2
DK-8450 Hammel
Denmark
+45 70 200 195
info@airlaid.dk
https://airlaid.dk

Bandz USA Inc. 
1000 Main St.
P.O. Box 219
Smelterville, ID 83868
208-784-1178
cmarshall@bandzusa.com
www.bandzusa.com

Carpenter Co.
5016 Monument Avenue
Richmond, VA 23230
256-525-1827
Dewayne.brock@carpenter.com
https://carpenter.com/

Convermat Corporation
111 Great Neck Road, Suite 514
Great Neck, NY 11021
516-487-7100
roy@convermat.com
www.convermat.com

Duni USA
263 Shuman Blvd, Suite 145
Naperville, IL 60563
828-772-0337
dunius@duni.com
www.duni.us

EAM
2075 Sunset Blvd.
Jesup, GA 31545
912-588-2617
lvenn@eamcorporation.com
www.eamcorporation.com

Fibematics
3313 Stokley St.
Philadelphia, PA 19140
215-226-0908
davidb@fibemat.com
www.fibematicsinc.com

Fitesa
Rua Siqueira Campos 1163/2º andar
Centro Histórico
Porto Alegre, 90010-001 Brazil
55 5134-8970 ext. 00
fitesamarketing@fitesa.com
www.fitesa.com

Freudenberg Performance Materials
Hoehnerweg 2-4
Weinheim, D-69469 Germany
00 49 6201 800
info@freudenberg-pm.de
www.freudenberg-pm.com

Gelok International Corporation
20189 Pine Lake Rd.
Bowling Green, OH 43402
419-352-1482
Slazenby@gelok.com
www.gelok.com

Glatfelter
4350 Congress Street, Suite 600
Charlotte, NC 28209
1-866-744-7380
info@glatfelter.com
www.glatfelter.com

Karweb
2. Organize Sanayi Bölgesi Batı 1. Cad. No:8 27600
Baspinar/Gaziantep
Tel: +90 342 337 32 35
Fax: +90 342 337 14 92
info@kholding.com.tr
www.selcukgroup.com

Magic Srl
Via Sempione,
104 A/B - 28047
Oleggio (NO) Italy
+39 0321 94100
info@magicsrl.com
https://magicsrl.com

Main SpA
Z.I. Valbasento-Isola 258
Pisticci Scalo (Matera), 75010 Italy
390 8354 6141 ext. 1
cinzia.astorino@mainspa.com
www.mainspa.com

McAirlaid’s Inc.
180 Corporate Drive
Rocky Mount, VA 24151
540-352-5050
contact@mcairlaids.com
www.mcairlaids.com

Napal Nonwovens
3 Atatürk Bulvarı,
Istanbul 34570 Turkey
90212736055
ebru@napal.com.tr
www.napal.com.tr

National Nonwovens
P.O. Box 150
Easthampton, MA 01027
413-527-3445
www.nationalnonwovens.com

Phoenix Fabrikations BV
Simon Homburgstraat 15
Cuijk, NL 5431NN The Netherlands
31 485 313 222
sales@phoenixfabrikations.com
www.phoenixfabrikations.com

Retex a.s.
894 Moravský Krumlov, Jihomoravský kraj
672 01 Czech Republic
420 774 924 307
urban@retex.cz
www.retex.cz

Sellars Nonwovens
6565 N 60th St.
Milwaukee, WI 53223
800-237-8454
dgoepel@sellarswipers.com
www.sellarsnonwovens.com

Sharpcell Oy
Toittilantie 5
FI-47400 Kausala
Finland
+358 29 007 4370
www.sharpcell.fi

Technical Absorbents Ltd
Energy Park Way, Grimsby
North East Lincolnshire, DN31 2TT
United Kingdom
4401472245200
info@exploreSAF.com
www.exploreSAF.com

TWE Group
Hollefeldstr. 46
Emsdetten, D-48282 Germany
4925722050
info@twe-group.com
twe-group.com