Artificial leather substrate
The base layer that PU and PVC coatings go on.
Capabilities
100–800GSM weight range
Up to 4 meterWidth
90 TonnesOutput per month
Where it goes
Applications
Filter fabrics
Needle-punched felt for dust and air filtration.
Absorbent non-woven
Takes up and holds liquid, for mats, pads and baby products.
Car interior fabrics
Floor mats, sound proofing, engine underlay, roof and trunk liners.
Rexine backing
Soft non-woven backing under PVC-coated artificial leather.
Protective layers
Linings, tents and air/sand filters.
The process
How needle-punch non-woven is made
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01 / 06
Opening and blending
Fibre bales are opened up and mixed evenly.
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02 / 06
Carding
The fibres are combed into a thin, even web.
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03 / 06
Cross-lapping
The web is layered back and forth to build up weight and width.
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04 / 06
Needle punching
Barbed needles punch through the layers and lock the fibres together.
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05 / 06
Finishing
Heat setting or calendering for the right thickness and surface.
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06 / 06
Rolling and cutting
The fabric is wound and cut to the width you ordered.
Need it laminated too? We bond our non-woven to a waterproof backing or face fabric in the same factory. See lamination
Lamination setup
How our laminating line works
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01 / 05
Two rolls load
The base non-woven and the face fabric, membrane or film sit on separate unwind stands and are fed in under steady tension.
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02 / 05
Adhesive goes on
Solvent-free PUR hot-melt is melted in a heated tank and rolled onto the base as a pattern of fine dots.
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03 / 05
Layers meet and press
The second layer joins the coated one and both pass between heated press rollers that bond them into one fabric.
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04 / 05
Cool and set
Cooling rollers bring the laminate down in temperature so the bond sets and the fabric holds its shape.
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05 / 05
Wind and cure
The finished fabric is wound onto a roll and left to finish curing before it is slit, checked and packed.
Need a sample?
Tell us the weight, width and end use.
Get in touch