| HS Code | 780830 |
| Product Name | 3.0 dtex Thermobonded PP Staple Fiber for Hygiene & Medical Nonwovens |
| Fiber Type | Thermobonded polypropylene staple fiber |
| Polymer | Polypropylene (PP) |
| Linear Density | 3.0 dtex |
| Fiber Length | 38 mm, 40 mm, or 51 mm |
| Crimp Type | Mechanical crimp |
| Crimp Frequency | 8-12 crimps per 25 mm |
| Cross Section | Circular |
| Surface Finish | Hydrophilic/nonionic |
| Finish Content | 0.3-0.6% |
| Tenacity | 2.5-4.0 cN/dtex |
| Elongation At Break | 40-100% |
| Melting Point | 160-170 °C |
| Density | 0.90-0.91 g/cm³ |
| Moisture Regain | <0.1% |
| Thermal Bonding Temperature | 140-155 °C |
| Color | White/natural |
As an accredited 3.0 dtex Thermobonded PP Staple Fiber for Hygiene & Medical Nonwovens factory, we enforce strict quality protocols—every batch undergoes rigorous testing to ensure consistent efficacy and safety standards.
| Packing | 3.0 dtex Thermobonded PP Staple Fiber for Hygiene & Medical Nonwovens: 250 kg PP-wrapped bales, strapped, palletized. |
| Container Loading (20′ FCL) | 20′ FCL container loaded with palletized 3.0 dtex thermobonded PP staple fiber bales, moisture-protected, securely braced for hygiene/medical nonwovens shipment. |
| Shipping | 3.0 dtex thermobonded PP staple fiber for hygiene and medical nonwovens ships as non-hazardous, non-regulated cargo. It is baled, compressed, wrapped in polyethylene film, and palletized. Keep dry, away from ignition sources, moisture, and contaminants. Handle carefully to prevent bale damage during loading, transit, and unloading. Not DOT/IMDG/IATA regulated. |
| Storage | Store in a clean, dry, well-ventilated warehouse at ambient temperature. Keep original packaging sealed and place on pallets, off the floor and away from walls. Protect from moisture, rain, direct sunlight, heat, sparks, and open flames. Avoid contact with oils, chemicals, strong oxidizers, and contaminants. Observe stacking limits, use FIFO, and prevent compression or dust accumulation. Do not store outdoors. |
| Shelf Life | Store cool, dry, away from UV; shelf life typically 24 months in original unopened packaging, subject to manufacturer validation. |
In air-through bonded acquisition/distribution layer (ADL) production for infant diapers and adult incontinence inserts, 3.0 dtex thermobonded PP staple fiber is introduced as the heat-fusible matrix component within a blended carded web, typically dosed at 25–40 wt% against 60–75 wt% coarse hollow PET or coarse PP fiber in the 6.7–15 dtex range. The carded web, formed on a high-speed nonwoven card running inline at 120–180 m/min web take-off, is subsequently conveyed into a through-air drum or flat-bed oven where the PP fiber surface temperature must be raised into the 145–152°C interval without exceeding the bulk melting onset of 160–165°C for isotactic polypropylene homopolymer. Differential scanning calorimetry per ISO 11357-3 typically records peak melting at 162–165°C with an onset at 155–158°C for this fiber grade; the corresponding melt flow rate of the parent resin, measured per ISO 1133-1:2022 at 230°C/2.16 kg, falls between 15–25 g/10 min, a range that governs fiber draw response and downstream thermal bonding kinetics. Published data for this specific configuration is limited to equipment manufacturer commissioning bulletins and EDANA/INDA workshop proceedings; however, the accepted production envelope in industrial practice is a set-point window of approximately ±5°C, above which fiber-to-fiber fusion transitions from discrete crossover bonds to film-like sheet collapse, and below which bond points remain mechanically weak, causing web delamination at diaper converting speeds exceeding 600 units/min. Air velocity through the drum is maintained at 1.5–2.5 m/s with dwell time of 4–8 s; when basis weight increases from 30 g/m² to 60 g/m², dwell time must be extended by 15–20% and air velocity reduced to the lower bound of the same range to avoid core insulation and surface over-bonding. Batch-to-batch variance in PP fiber crimp frequency, measured at 10–14 crimps/25 mm by supplier datasheet, interacts with carding performance: lower crimp values reduce card web cohesion but raise loft because fiber-to-fiber contact points are fewer, while higher crimp improves card stability at the expense of through-air bulk retention.
Compliance for ADL components is anchored to ISO 9073-2:1995 for thickness under 0.5 kPa load, ISO 9073-3:1989 for tensile strength and elongation at break, and WSP 120.5 for liquid strike-through time on a 5 mL saline challenge. FDA 21 CFR 177.1520 governs olefin polymers intended for repeated and single-use food-contact surfaces where ADL roll goods may be co-converted into feminine hygiene or light incontinence products subject to food-adjacent packaging demands. REACH Annex XVII entries 51 and 52 restrict residual phthalates and extractable organotin stabilizers; OEKO-TEX Standard 100 class I extractable heavy metal limits are 0.1 mg/kg for lead and 0.01 mg/kg for mercury. Terminal product types include die-cut ADL sheets for infant diaper sizes 3–6, ADL cores for pull-up training pants, and dual-layer acquisition strips for moderate-to-heavy adult incontinence pads, supplied as roll goods at 60–100 g/m² or pre-cut blanks to converters running at 600–900 units/min.
| Through-air oven set point (°C) | Web loft retention (%) | Cross-direction tensile (N/50 mm) | Strike-through time (s, WSP 120.5) | Bond failure mode |
|---|---|---|---|---|
| 140 | 92–95 | 3.5–4.0 | 1.2–1.5 | Adhesive failure at fiber crossover |
| 145 | 88–92 | 5.0–6.0 | 1.0–1.3 | Mixed cohesive/adhesive |
| 150 | 75–82 | 7.0–8.5 | 1.5–2.0 | Cohesive, partial film formation |
| 155 | 40–50 | 9.0–10.0 | 3.0–4.5 | Sheet collapse, film-like failure |
Carded webs destined for sanitary napkin and panty liner cover stock are consolidated on a three-roll calender stack where the engraved roll carries a diamond pattern with 18–25% land area and the opposing rolls are ground smooth. Formulation is typically 100% 3.0 dtex PP homopolymer fiber at staple length 38–51 mm, although some converters blend 10–20% of 1.7–2.2 dtex finer PP fiber to reduce surface friction and improve hand without compromising bond strength. Roll surface temperature must be held at 142–150°C, with the lower bound dictated by PP softening onset and the upper bound constrained by fiber melt-through at bond points, which produces pinholes in the final sheet. Nip pressure is set to 70–120 N/mm across a working width of 2.5–4.2 m; insufficient pressure produces weak bond points that fail during converting, while excess pressure crushes web loft and reduces coverage factor. Line speed is limited by carding throughput and calender dwell; typical production ranges are 200–400 m/min for 18–25 g/m² cover stock. Pre-drying of fiber is required when warehouse relative humidity exceeds 60%, as surface moisture creates non-uniform heat transfer at the calender nip and induces bond-point pinholes. Compliance references include WSP 110.4 for tensile strength at break, ISO 9073-4 for trapezoidal tear resistance, ISO 9073-6 for liquid absorption capacity, and ISO 10993-5:2009 for in vitro cytotoxicity when the cover stock is supplied to medical-grade feminine products. Terminal products include sanitary napkin cover stock, panty liner top sheets, and hygiene layer components folded into adult bladder-control pads.
Core wrap for adult incontinence and infant diaper absorbent cores is frequently produced at 14–18 g/m² from 100% 3.0 dtex PP staple fiber through calender point bonding at 140–148°C, with bond area restricted to 15–20% to preserve sufficient open area for rapid urine penetration into the fluff pulp and superabsorbent polymer core. At this basis weight, lightweight web handling becomes the dominant process constraint rather than thermal bonding itself: carded web tensile strength before bonding is below 0.3 N/50 mm, requiring vacuum-assisted transfer to the calender, and edge curl during calender extraction at speeds above 250 m/min causes frequent web breaks. The terminal product is the nonwoven envelope encasing fluff pulp and superabsorbent polymer mixtures in adult incontinence briefs and infant diaper cores, where the PP web must pass ISO 9073-3:1989 machine-direction tensile of at least 9–12 N/50 mm and ISO 9073-6 absorption capacity of 0.9–1.2 g/g to maintain pad integrity during wear. Relevant skin-contact compliance is ISO 10993-5:2009 for cytotoxicity and FDA 21 CFR 177.1520 for polymer compositional requirements. This application represents a well-established, low-iteration practice on calender lines; published data for specific production configurations is limited.
Disposable medical underpads, also designated as chux or bed protectors, are produced by needle-punching a carded cross-laid batt of 50–70 wt% 3.0 dtex PP staple fiber blended with 30–50 wt% viscose rayon (1.7–3.3 dtex) or PET fiber, then stabilizing the needled structure by passing it through a through-air oven at 145–152°C. The needle-punching stage operates at 250–350 punches/cm² with barbed needles of 36-gauge at penetration depth 11–13 mm to achieve pre-bond tensile strength of 15–20 N/50 mm. Thermal bonding after needling performs two functions: it suppresses loose-fiber release at the pad surface, which is critical for patient contact, and it locks the needled batt thickness at a target loft of 1.5–2.5 mm measured under 0.5 kPa per ISO 9073-2:1995. A process conflict emerges when through-air temperature exceeds 152°C: PP fiber partially fuses onto the viscose component, creating stiff fused zones that reduce absorbent capacity and produce patient discomfort; below 145°C, surface fiber shedding returns on the converting line and pad edges delaminate during folding. Post-bonding thickness recovery of 85–92% relative to as-needled loft is achievable if the through-air drum conveyor maintains low web tension, typically below 0.1 N/mm of working width. Compliance for medical underpads includes ISO 10993-5:2009 for in vitro cytotoxicity, ISO 10993-10:2010 for skin irritation and sensitization potential, and EN 13795-1:2019 for performance requirements and testing of surgical drapes and gowns where underpads are part of a sterile field assembly. Gamma sterilization at doses above 25 kGy is contraindicated for this PP fiber due to oxidative chain scission and measurable tensile loss of 30–40% after 12 months of accelerated aging, a limitation documented in ISO 11137-2 sterilization dose auditing prior to product release. Terminal products include rectangle medical underpads at 60 × 90 cm and 76 × 90 cm formats, veterinary absorbent pads, and underlay sheets for long-term care facilities, supplied as bulk-packed or individually folded units.
Lamination of a calender-bonded PP staple-fiber reinforcement layer into a Class II surgical drape composite introduces an interfacial adhesion constraint that single-layer tensile data does not capture. The 3.0 dtex PP fiber is first carded and point-bonded at 18–22% land area to produce a 22–30 g/m² sub-layer, then fed into an ultrasonic lamination station between two spunbond PP outer layers, each at 12–15 g/m², on a production line running at 80–150 m/min. The reinforcement layer accounts for 20–35% of the total drape composite mass; at addition fractions above 35%, the composite stiffens beyond the drapeability required in EN 13795-1:2019 for surgical drapes, while below 20%, the reinforcement contribution to tear propagation resistance is statistically indistinguishable from the spunbond-only control in ISO 9073-4 trapezoidal tear testing. Ultrasonic horn pressure of 0.2–0.5 MPa and anvil spacing of 0.4–0.8 mm must be re-verified after every 40,000 linear meters of lamination because PP wear debris accumulates on the horn face and creates irregular bond islands. Terminal products include three-ply laminated surgical drapes, procedure pack base sheets, and reinforced gown zones.
| Standard designation | Test parameter | Requirement / classification basis |
|---|---|---|
| ISO 22610:2006 | Resistance to wet bacterial penetration | Log reduction ≥ 2.5 after challenge |
| ISO 22612:2005 | Resistance to dry microbial penetration | No colony-forming units detectable |
| AAMI PB70:2012 | Liquid barrier performance | Level 3 or Level 4 for surgical use |
| EN 13795-1:2019 | Surgical drape tensile and tear | MD tensile ≥ 20 N/50 mm; tear ≥ 10 N |
| ISO 10993-5:2009 | Cytotoxicity, L929 cell line | Viability ≥ 70% of control |
| ISO 10993-10:2010 | Skin irritation, sensitization | No erythema grade > 1.0; no sensitization |
Dosed at 25–35 wt% into a fluff pulp and superabsorbent polymer matrix, the 3.0 dtex PP staple fiber functions as the thermal-bonding agent in airlaid absorbent cores intended for moderate-to-high exudate wound dressings. The airlaid forming line combines hammer-milled cellulose fluff, SAP granules at 20–40 wt%, and the PP fiber on a rotating drum former at 80–150 m/min; the resulting 120–300 g/m² airlaid web is then consolidated in a through-air oven at 135–142°C, a deliberately lower window than diaper ADL bonding because prolonged exposure above 142°C degrades the SAP ionic crosslinks and reduces free swell capacity under ISO 9073-6 absorption testing by 18–25%. The PP fiber's three-dimensional crossover bonds immobilize the particulate phase and reduce SAP dusting on the converting line, a production-scale failure mode documented in airlaid machine operator logs and supplier defect reports. Compliance for wound contact applications requires ISO 10993-5:2009 cytotoxicity with L929 cells, ISO 10993-10:2010 irritation and sensitization, USP <87> in vitro biological reactivity, USP <88> Class VI systemic toxicity evaluation, and EN 13726-1:2002 test methods for primary wound dressings including absorbency and moisture vapour transmission rate. Ethylene oxide sterilization residuals require forced-air desorption at 50–60°C for 24–48 h until residual EO concentration falls below 4 mg/device under ISO 10993-7:2008 acceptance criteria. Terminal products include sterile wound dressing absorbent cores, burn care pads, and fenestrated dressing base layers, supplied as die-cut blanks or roll goods for converter lamination.
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Polypropylene staple fiber with nominal linear density of 3.0 dtex is supplied for carded and airlaid nonwoven structures in hygiene and medical applications. The product is defined by linear density, cut length, crimp, and finish chemistry rather than by a universal model code; supplier designations vary. The decitex value, determined according to ISO 1973:2021, corresponds to 3.0 g per 10 000 m of filament. At a solid polypropylene density of 0.91 g/cm³, the circular-equivalent filament diameter is 20.5 µm. Commercial specification sheets for hygiene/medical grades normally include a cut length of 38 mm or 40 mm, crimp frequency of 11–15 crimps per 25 mm, and finish add-on of 0.10–0.20% by mass. The finish is formulated as an antistatic/low-friction system rather than a hydrophilic coating; the fiber itself remains hydrophobic. Thermal bonding occurs when the homopolymer surface softens sufficiently at a calender nip to form load-bearing bond points. In hygiene nonwovens, the 3.0 dtex product is used in coverstock, acquisition/distribution layers, and elastic attachment zones; in medical nonwovens, it is used in spunbond/carded composites, surgical drape reinforcement, and face mask inner layers. Compared with 1.7 dtex coverstock fiber, the 3.0 dtex grade provides larger fiber diameter and a more open web; compared with 6.7 dtex acquisition fiber, it provides softer tactile properties and better cover.
The primary difference is thermal. A homopolymer PP fiber has a single melting endotherm with onset near 155°C to 165°C when measured by differential scanning calorimetry according to ISO 11357-3. The base resin melt flow rate for hygiene-grade PP staple is commonly 19–25 g/10 min at 230°C and 2.16 kg when measured by ISO 1133-1:2022; this moderate viscosity permits melt spinning and subsequent staple drawing while retaining enough molecular weight for fiber strength. A PE/PP sheath-core staple of the same linear density has a polyethylene sheath that melts near 125°C to 132°C while the PP core remains solid. Calender bonding of homopolymer PP therefore requires a higher roll-surface temperature and a narrower process band. If the engraved roll temperature is too low, bond points display inadequate peel strength; if it is too high, the homopolymer flattens into translucent film regions and the web loses drape. The advantage of the homopolymer surface is that bond points are entirely PP, which removes interfacial incompatibility when the carded web is laminated to PP spunbond layers in SMS constructions. The limitation is that low-temperature through-air bonding, common with bicomponent PE/PP, is not available to homopolymer PP; through-air processing of homopolymer fiber requires the entire web to approach the softening range and is more likely to cause nonuniform bonding and shrinkage. The 3.0 dtex homopolymer product is therefore specified predominantly for calender-bonded lines, not for high-loft through-air bonded acquisition layers unless the line is designed for PP homopolymer thermal fusion. Published data for through-air bonded homopolymer PP in this exact dtex is limited; line trials are required.
Production-scale carding of 3.0 dtex polypropylene staple is typically performed on a double-doffer card with working widths of 2.5 m or 3.0 m, followed by crosslapping and calender bonding. At 40 mm cut length, the fiber population is approximately 83 000 fibers per gram; at a web weight of 20 g/m², one square meter contains approximately 1.7 million fiber segments. This population is high enough to produce a uniform web but low enough to avoid excessive fiber-to-metal contacts that generate static. The carding room is typically controlled at 55–65% relative humidity and 20–25°C. Card clothing specification and doffer speeds are adjusted for crimp frequency; if crimp is below 10 crimps per 25 mm, web cohesion drops, and if crimp exceeds 16 crimps per 25 mm, card loading can increase. For a 20 g/m² coverstock web, the crosslapper entry speed and calender draw ratio are set to maintain a machine-direction to cross-direction fiber orientation ratio close to 3:1. This orientation ratio can be altered by changing the crosslapper carriage speed and calender take-up speed; higher draw increases machine-direction tensile strength but lowers cross-direction elongation. The bond roll is normally engraved with a bond area of 18–22%. Nip pressure in the range of 40–80 N/mm is used on steel-cotton or steel-rubber calender systems. The bond roll surface temperature for homopolymer PP is commonly maintained in the 148–156°C band, with the smooth roll 5–10°C lower. These settings are not universal; published data for a specific fiber lot is limited, and the correct window should be established on the line by measuring dry tensile strength according to ISO 9073-2:1995 and bending length according to ISO 9073-7:1995 after bonding.
On high-speed double-doffer cards operating above 180 m/min, 3.0 dtex PP staple with inadequate finish build-up can generate static-induced lap-ups on the doffer and stripper rolls. The failure mode is usually visible as fiber wrapping on the doffer or irregular cloud formation at the web edge. Finish add-on below 0.08% by mass increases metal-to-fiber friction and promotes fiber breakage; add-on above 0.25% can transfer to card clothing and reduce web cohesion. The finish composition is therefore specified as an antistatic ester-based system with controlled viscosity, not a hydrophilic surfactant that would compromise the hydrophobic barrier of the final nonwoven. Crimp stability at calender temperature is also critical: if the crimp collapses under heat, the web loses thickness and the acquisition layer loses void volume. A differential crimp with primary and secondary curvature is specified for some 3.0 dtex hygiene grades to improve card web openness. Fiber-on-fiber friction, measured as saw-tooth carding cohesion or via a rotating drum charging test, is used by suppliers to monitor finish uniformity. Published data for this exact configuration is limited; fiber producers typically provide a processing-lubricant technical data sheet rather than carding-speed trial data.
Fluid handling differences among dtex grades are directly tied to pore architecture. In a 20 g/m² thermobonded web, 3.0 dtex produces a broader pore-radius distribution than 1.7 dtex and a narrower distribution than 6.7 dtex. Strike-through time, liquid run-off, and rewet are measured by EDANA/INDA NWSP 070.1, NWSP 080.1, and ISO 9073-13 depending on the final nonwoven use. The larger filament diameter of 3.0 dtex creates greater void volume than 1.7 dtex, which supports rapid liquid acquisition; however, the same openness can increase rewet if the layer is directly under a topsheet. For coverstock, 3.0 dtex may exhibit higher surface roughness than a 1.7 dtex fiber layer; if direct skin contact is required, a 1.7 dtex or bicomponent soft-touch layer may be placed above it. Compared with PET staple fiber of similar linear density, PP has lower density and a lower melting temperature, which allows calender bonding at lower energy input but limits thermal stability. Compared with viscose staple, PP is nonabsorbent and hydrophobic; it provides fluid passage rather than fluid retention. In airlaid absorbent hygiene cores, 3.0 dtex PP staple functions as a structural distribution fiber, while fluff pulp and superabsorbent polymer provide absorption. The PP fiber does not swell or lose wet strength when exposed to saline, whereas viscose swells and can lose structural integrity. Published data for a specific 3.0 dtex thermobonded PP in this application is limited, and fluid handling should be measured on the final nonwoven.
Table 1 compares calculated fiber geometry and typical web applications for circular PP staple at 38 mm cut length.
| Parameter | 1.7 dtex | 3.0 dtex | 6.7 dtex | Basis |
|---|---|---|---|---|
| Calculated circular diameter | 15.4 µm | 20.5 µm | 30.6 µm | ISO 1973:2021 and density 0.91 g/cm³ |
| Fiber count per gram at 40 mm cut length | 147 000 | 83 000 | 37 000 | Mass/length calculation |
| Specific surface area | 0.285 m²/g | 0.215 m²/g | 0.144 m²/g | Calculated from diameter and length per gram |
| Typical web application | 10–18 g/m² top sheet | 18–35 g/m² coverstock/ADL | 30–70 g/m² acquisition layer | Supplier technical literature |
These geometric differences affect tensile strength development in calender bonding. At equivalent web weight, a 3.0 dtex web has fewer fiber segments per unit area than a 1.7 dtex web, which can reduce the number of potential bond points but increase the size and integrity of each bond point. Coarser 6.7 dtex fibers further reduce bond-point density, which improves openness and acquisition but creates a harsher surface and reduces cover factor. The 3.0 dtex product is therefore positioned where a single layer must balance surface smoothness, bond-point strength, calender process tolerance, and fluid handling.
Raw fiber compliance does not substitute for finished nonwoven safety validation. For medical devices, the finished nonwoven is assessed under ISO 10993-1:2018; the fiber supplier usually provides a material description and a biological evaluation dossier only at the raw material level. Cytotoxicity testing is performed on the final nonwoven according to ISO 10993-5:2009; sensitization according to ISO 10993-10:2010; and irritation according to ISO 10993-23:2021. Surgical drapes and gowns made from SMS or laminate containing carded PP must meet ISO 22610 for wet bacterial penetration and ISO 16604 for blood penetration; these are finished-product barrier tests, not fiber-level tests. The 3.0 dtex layer contributes to opacity and mechanical stability but not to barrier performance alone. 3.0 dtex polypropylene is not inherently antimicrobial, and the fiber is not a barrier to viruses or bacteria unless the nonwoven structure is designed and tested for that purpose. The polymer may be supplied with a radiation-stabilized additive package when gamma sterilization is specified. Unstabilized PP exposed to gamma irradiation above 25 kGy can undergo oxidative chain scission and lose tensile strength. For ethylene oxide sterilization, the nonwoven must allow gas penetration and aeration; residual ethylene oxide limits are set by ISO 10993-7:2008. Steam autoclaving at temperatures above 121°C may cause shrinkage or thermal creep in PP, so it is rarely the first choice for 3.0 dtex PP nonwovens unless dimensional stability is proven on the finished article.
| Compliance area | Standard or regulation | Typical position for 3.0 dtex PP staple |
|---|---|---|
| Linear density | ISO 1973:2021 | 3.0 dtex ± 0.30 dtex |
| European chemicals | REACH EC 1907/2006 | SVHC statement; <0.1% w/w |
| Olefin polymer food-contact use | FDA 21 CFR 177.1520 | Applicable to single-use food-contact nonwovens; not a substitute for ISO 10993 |
| Medical device biological safety | ISO 10993-1:2018 | Finished device validation required |
| Cytotoxicity | ISO 10993-5:2009 | Final nonwoven test; no raw-fiber claim |
| Sterilization by ethylene oxide | ISO 10993-7:2008 | Residuals tested on final article |
Storage of 3.0 dtex PP staple before carding should be in a dry area below 30°C and 60% relative humidity. The fiber is hydrophobic and does not absorb water; re-exposure to high humidity can affect carding static but not fiber weight. Contact with oxidizing agents, strong acids, and certain solvents should be avoided because they can attack the finish or the polypropylene surface. Ultraviolet exposure should be minimized because PP degrades by photo-oxidation unless a UV stabilizer is present. In a medical nonwoven, the fiber should not be considered a finished product; performance claims for barrier properties, linting, and biocompatibility must be established on the final nonwoven under the intended use. Published data for this specific 3.0 dtex thermobonded PP product configuration is limited; when a new line or application is qualified, the manufacturing window should be verified by trial runs rather than assumed from adjacent dtex grades.
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