Nonwoven Custom Manufacturing Service: Full Customization of Basis Weight, Function & Structure

BOSTONE offers a one-stop nonwoven product customization solution. Whether you require ultra-soft BICO structures (PP/PE), high-efficiency SSMMS filtration, or special PET/PLA functionalities, we configure and deliver the most suitable customized production line to ensure the final nonwoven fabric perfectly matches your market needs.

Four Dimensions of Nonwoven Customization

Structure and feel

Single-component (S/SS/SSS), composite (SMS/SSMMS), bicomponent (BICO core-sheath/side-by-side), ultrafine denier fiber.

Weight and width

Weight range (10 g/m² to 150 g/m²), effective width (1.6 m to 4.2 m).

Functionality

Single-component (S/SS/SSS), composite (SMS/SSMMS), bicomponent (BICO core-sheath/side-by-side), ultrafine denier fiber.

Raw materials

Single-component (S/SS/SSS), composite (SMS/SSMMS), bicomponent (BICO core-sheath/side-by-side), ultrafine denier fiber.

Bostone’s customization capabilities cover every key parameter of nonwoven products. We don’t just provide equipment; we configure a manufacturing platform to precisely achieve your market goals. Our customization services unfold in four dimensions: from the structure that determines the feel of the product, to the functionality that ensures the application range, to the weight and width required for mass production, to the special raw materials that lead the trend of environmental protection. We ensure that every nonwoven customization parameter you set can be perfectly realized through our production line, creating a unique competitive advantage for you. Contact us today to customize your nonwoven products.

How we customize your nonwoven fabric

Melt Composite Technology – Precision Customization of Filtration and Barrier

SSMMS/SSMMSM Structure Configuration: Customized configurations of two or three independent meltblown dies are provided based on customer requirements for bacterial filtration efficiency (BFE) and hydrostatic pressure, with precise adjustments to the spinneret orifice diameter, air pressure, and DCD (Die-to-Collector Distance).
Multi-level Barrier Customization: By optimizing the strength of the spunbond layer (S) and the microfiber density of the meltblown layer (M), customized layered barrier performance is achieved, ranging from basic medical applications to high-risk virus protection (such as P95/N95).
Key Supporting Facilities: The meltblown die is equipped with a high-precision Roots blower and air heater to ensure stable airflow temperature and pressure, guaranteeing the ultra-fine denier and uniformity of the meltblown fibers.

Multi-Component & Structural Shaping – Enabling Ultra-Softness and Elasticity

Customized BICO Spinnerets: To meet customer requirements for product softness, we customize sheath/core spinnerets, precisely controlling the ratio and eccentricity of the sheath (e.g., PE) and core (e.g., PP) to achieve optimal low-temperature thermal bonding and a soft touch.
Customized High Elasticity: For high-elasticity materials, we configure side-by-side BICO structures. By precisely controlling the difference in thermal shrinkage rates between the two polymers, we stably achieve fiber self-curling, providing products with superior bulk and elasticity.
Key Supporting Facilities: Utilizing dual independent high-precision metering pumps, we precisely control the output flow rate of the two-component melt, ensuring accurate 50:50 or 80:20 fiber ratios.

High-Speed High-Output Process – Achieving Low-Cost Mass Production

Optimized Drawing System: For S/SS/SSS yarns, a customized high-performance tubular or positive-pressure airflow drawing device ensures stable operating speeds up to 450 m/min while maintaining fiber tensile strength.
Width and Uniformity Guarantee: Equipped with an ultra-wide web-forming machine (e.g., 4.2 m) and a high-precision airflow uniformity system, ensuring uniform fiber web formation and edge quality across the entire width, even at high speeds.
Key Supporting Facilities: Utilizing a three-roll/four-roll high-precision hot rolling mill, uniform temperature and pressure control ensures consistent product basis weight and final bond strength at high speeds.

Specialized Raw Material Customization Solutions

PLA Hydrolysis Prevention: The production line must be equipped with an ultra-efficient molecular sieve drying system to control the moisture content of PLA particles below 50 ppm. A specially designed screw is used to reduce shear heat and completely eliminate the risk of hydrolysis.
PET High-Temperature and High-Pressure Stability: The PET line is equipped with a high-torque extruder and a multi-stage precision temperature control system to ensure stable extrusion of the melt at ≥260℃, guaranteeing high fiber strength and heat resistance.
Key Supporting Facilities: The mesh and flow channel design of the melt filter are customized for each specialty raw material to prevent melt degradation and extend maintenance cycles.