Nonwoven Fabric Process for Wadding & Key Machinery Used
- Sep 22
- 3 min read
Updated: Sep 30
Wadding is a nonwoven fabric that has a great impact on the feel, volume, and heat retention of a product. Therefore, the properties of the polyester fibers used and the precision of the carding/bonding process are the key to quality.
In this post, we will learn about the nonwoven fabric process for wadding and the main machines used in the process.
What is nonwoven fabric for wadding?
Wadding nonwovens are a type of nonwoven fabric that is made by loosely stacking or intertwining fibers to create a voluminous and fluffy structure. The main uses are bedding (quilt filling), clothing padding, soundproofing, and insulation.
Nonwoven production process flow for wadding
STEP 1 : Raw material opening process
Unwind the compressed PSF bales and distribute them evenly.
Pre-opener → Fine-opener removes foreign substances from the fibers and creates fluff.
The main machines used in the opening steps are as follows:.
Machine Name | Function |
Bale Opener | Opens compressed PSF bales and feeds the fiber |
Pre Opener | Performs primary opening of fiber tufts and removes large clumps |
Fine Opener / Cleaner | Removes fine dust, lint, and foreign materials |
The major manufacturers of opening machines and carding machines are:
Trützschler (Germany) : https://www.truetzschler.com/en/
Autefa (Austria) : https://www.autefa.com/autefa-solutions-group
Yingyang (China) : https://www.china-nonwovens.com/
STEP 2 : Carding process
The opened fibers are finely and evenly spread to form a fiber web.
This process adjusts the orientation and uniformity of the fibers.
One or more drum carders may be used in this step.
The main machines used in the carding process are as follows:
Machine Name | Function |
Carding Machine (Carder) | Aligns and forms opened fibers into a flat fiber web |
Double Carder (Optional) | Used for producing high-density or wide-width products |
STEP 3: Cross-Lapping process
The thin fiber web from the carding machine is layered by cross-lapping it from side to side.
In this stage, the thickness and resilience (elasticity) of the wadding are determined.
This is the process where the layering density and loft (bulkiness) are adjusted.
The main machines used in the layering stage are as follows:
Machine Name | Function |
Cross Lapper | Moves the carded web back and forth to form multiple layered structures |
STEP 4 : Bonding process
The wadding is bonded by applying heat or adhesives to fix the fiber layers in place.
Bonding methods include thermal bonding, chemical (self) bonding, or needle punching. Among these, thermal bonding is typically used in combination with low-melting (LM) fibers.
The main machines used in the bonding process are as follows:
Machine Name | Function |
Hot Air Oven / Heat Chamber | Thermal bonding – melts and bonds low-melt fibers |
Spray Bonding Machine | Chemical bonding – applies binder via spray method |
Needle Loom (Optional) | Provides physical entanglement through needle punching (for strength & loft) |
Sail Nonwoven Machinery (China) : http://snk-nonwovenmachine.com/
STEP 5: Cooling / Cutting / Winding process
This stage involves cooling, scaling/size adjustment, and sheet cutting operations.
It also includes post-processing treatments such as flame retardant finishing and other surface treatments.
The main machines used in the post-treatment stage are as follows:
Machine Name | Function |
Cooling Chamber | Stabilizes dimensions and shrinkage after bonding through cooling |
Calendering Machine (Optional) | Flattens surface and adjusts thickness/density using rollers |
Slitting & Cutting Machine | Adjusts width and cuts into roll or sheet units |
Winder / Roll Packer | Packs final product into rolls or compresses for packaging |
Slitter/Cutter manufacturers : Xinda, Santex, local OEM
Example of Fiber Specifications Used for Wadding Nonwoven Fabric
Item | General Specification |
Denier (D) | 3D ~ 15D |
Cut Length | 32mm ~ 64mm |
Characteristics | 4~8 cpi crimp, LM fiber blend available |
Material | Recycled PET / Virgin PET |
DK FIBER supplies PSF (Polyester Staple Fiber) for wadding applications in a wide range of specifications.
We also offer blended fibers with Low-Melt Fiber (LMF) for thermal bonding and eco-friendly recycled fibers certified by GRS (Global Recycled Standard).