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Staple Nonwovens Lab

The Nonwovens Institute at North Carolina State University offers state-of-the-art technology and deep expertise in staple fiber-based nonwoven applications.

The Nonwovens Institute’s many years of in-house knowledge in staple nonwovens are supported by the Staple Nonwovens Pilot Lab, which is equipped with Trützschler feeding equipment and extensive opening systems that allow for blending of various types of fibers and composite formations.

The facility is outfitted with two separate feeding systems from the opening equipment, which can be used independently to feed the card or a Scanfeed system for high-loft substrates.

This facility also includes a 1-meter wide Trützschler High-Speed Nonwoven EWK 413 Card, which processes fibers from 0.9 to 20 denier with basis weights ranging from 20 to 100 g/m2 direct lay.

An Andritz Profile 415-FD Crosslapper provides automatic batt width adjustment, automatic overlap control and adjustment, and full control over the number of layers, with automatic computation of the necessary delivery speed on the floor apron. This equipment is capable of producing very heavy batts. The Profile technology, as the name implies, can shape the outgoing material to optimize weight distribution from center to side of the fabric.

The Scanfeed is situated behind the Crosslapper to allow for manufacturing of high-loft webs. The batt can be fed directly to the needle-punch equipment or used to form a layered composite with the lapped web from the card and the Crosslapper.

Meet the Lab Manager:
Eric Lawrence

After starting his career in industry, Eric joined The Nonwovens Institute (NWI) in 2013, supporting projects in the Staple Carding Lab. Over the years, Eric has progressed to his current role as a Lab Manager, with responsibility for overseeing student research projects and industry trials in NWI’s Fiber and Polymer Science, Filament Spinning and Staple Carding labs.

Eric Lawrence, The Nonwovens Institute, NC State University

The facility includes two bonding technologies – needle-punch and through-air bonding. The pre-needler is a Trützschler single-board needle loom ENL followed by an Andrtiz A.50-RL needle loom, DF-4 version with 4-boards; two up, two down stroke. The needle loom has a highly flexible needle pattern and results are repeatable with industrial-scale machines. For through-air bonding, the lab is outfitted with a Fleissner flat 4-zone impingement/through-air oven.

Additional bonding technologies such as calendering or hydroentangling are available in NWI’s other pilot facilities.

If you have questions about running trials at NWI, please email us at

If you wish to use the pilot equipment or have some testing done, you will need to have a Fabrication & Testing Agreement in place.

For each pilot equipment, we provide the following guidelines and templates. The guidelines contain the specification of the relevant machinery as well as the cost of using the various options. The trial plan provides a starting point outline of important test configuration options and choices, as well as test matrix design to ensure needs are met.

Equipment Specifications

Trützschler Nonwovens EWK 413 Card
No. of Beam1.0Width (m)1.0
Line speed (m/min)1.0 to 100 (Direct Lay)Fiber (Denier)0.9 to 20
Web Weight (g/m2)20 to 100 direct lay random webFiber Length (mm)20 to 76

Trützschler Scanfeed
Web Width (m)1.0Fiber (Denier)0.5 to 20
Max Throughput (Kg/h/m)400Fiber Length (mm)50 to 100
Web Weight (g/m2)300 to 1500
Andritz Profile 415-FD Crosslapper (née Asselin)
Delivery Width (m)1.0No. of Folds2.0 to 50
Max Input speed (m/min)100Stroke Freq (RPM)1200
Trützschler Needle Loom ENL
No. of Board1.0Needles/mUp to 5000
Line speed (m/min)20Stroke Freq (RPM)1200
Andritz A.50-RL Needle Loom (née Asselin)
No. of Board4 – configurations: 2 up or 2 down; 1 up and/or 1 downNeedles/mUp to 5000
Line speed (m/min)30Stroke Freq (RPM)1200
Max Width (m)1.4
Fleissner Oven
Line speed (m/min)1.0 to 15Max Temp (C)230
Max Width (m)1.2
Parkinson Winder
Line speed (m/min)1.0 to 20

If you have questions about running trials at NWI, please email us at