How we design new materials for customers?

Many of our nonwoven projects are about solving our customers' problems. This in turn means that we often need to develop new materials. But what does such a process look like?

Step 1: SPECIFICATIONS

Often, customers have very specific requirements for the properties of the nonwoven material. It could also relate to how the material fits into the customer's production line. Sometimes it's about finding a cheaper way to produce a nonwoven with the same product properties as in existing materials.

Specifications can be contradictive. Such as that nonwoven should be soft against the skin but still incredibly strong. Or that it should be able to wipe away dirt but also be water-repellent. More and more often, customers are looking for circular or degradable materials that at the same time have to withstand a lot when in use.

But the specifications can also be very tough. Such as that the material must be able to withstand special chemical agents or UV light. Or maybe it should have minimal elasticity to be able to fit into a very rigid production line.

Sometimes the specifications can be a little vaguer, but then we are helped to set them. Clear specifications are important in order to find a suitable solution faster. Sometimes the specifications change along the way if the customer's priorities change or if they need to replace other components in their production. We are used to this.

Step 2: RESEARCH

When the specifications are ready, our research and probing of the market begins. We have an incredibly large network of nonwoven manufacturers around the world that we start contacting with to see if there is a material similar to what the customer needs. Sometimes there are materials that have some of the properties that are in demand - then we might be able to adjust or redesign the material so that it meets more criteria. Sometimes we need to start from scratch.

But our research is also about finding a manufacturer and supplier who can deliver on time and in the required volume. And at the right price, of course.

Step 3: DEVELOPMENT

When we have found a suitable material candidate or supplier to work with, the development of the material begins. At this stage the specifications become very important. We work closely with the manufacturer and act as a bridge between the manufacturer and the customer.

Our knowledge and experience of this type of development work is a key at this stage as we often help both the customer and the manufacturer find solutions going forward with experience from other projects. Often the challenges are about manufacturing methods and making sure that different properties in the material do not clash.

Step 4: TESTING

When we have a material candidate, the material needs to be tested. This step can go very quickly, but it can also take time if the requirements are complex. Both material properties and how the material works in the customer's production line need to be evaluated.

Along the way, we adapt and, in some cases, new specifications are added during this process that the customer did not anticipate at the beginning. But in the vast majority of cases, we find a solution that the customer can benefit from and use in their production for many years to come.

Step 5: PRODUCTION

When the material has been tested and everyone is satisfied, the production of the material begins. Often, the manufacturer delivers the material on large rolls that are not fit to the customer's production. Then we cut and reroll the material (or sheet it) at our facility in Kristianstad. We also help with storage and distribution of the material if needed.

If you want to know more or book a meeting to discuss a challenge you have, contact us at info@nonwoven.se. We also have Scandinavia's largest range of nonwovens and on the website you can order samples of nonwovens that we already have in our range.