NonWoven Solutions (NWS) was formed in May 2007 by a group of investor partners who saw a distinct void in the nonwovens supply chain that could only be filled with a new production line, and thus a new company offering very clean, very uniform needlepunched nonwovens centrally located in the United States.  Specified with the latest technology available, this line has been built inside the new 40,000 square foot building in Lakemoor, Illinois. NWS will operate the line according to GMP medical grade standards.

The Management team partnered with NSC Nonwoven to provide Excelle® machines with the latest process technology which includes the ProDyn® system which automatically adjusts the fiber weight according to the programmed width of the finished fabric.  This automatic regulation is achieved by internal speed variations of the card/crosslapper combination and keeps the web structure and the fiber tensions absolutely constant in the card web.  The corrections applied in the MD and CD compensate for the variable amounts of distortion caused by all bonding processes, both currently known and future.

ProDyn® offers a double advantage:  CV%≤1 and by working in double closed loop control, the effectiveness of the system is maintained whatever the nature of the fibers of the production of the line.

Products

NWS LLC has committed to run only white synthetic fibers from in denier ranges from 1d – 15d with blends of 3 intimate components. In addition to needlepunched nonwoven processing, the plant has been further equipped with flame singeing, calendaring, precision slitting in both roll-to-toll and single-knife style. Off-line needling for multi-layer composites and high density felts from layers can also be produced.

NWS maintains inventory of most basic fiber styles and can make custom orders and engineered fabrics within a very short notice. Products can be made from as low a weight as 2.2 oz/sy up to 48 oz/sy in widths from 1” to 172” (the maximum production width of the line).

Precision blends of up to three components can be made at rates up to 2,500 lbs per hour. Precision blends are maintained through the use of two fine openers and a full sized mixing bin system.  NWS can provide a great deal of technical expertise and product development in support of basic fabric production.

“We often work side by side with customers to develop a fabric based on a price point or performance criteria. All testing is performed in accordance with ASTM and IST standards along with critical requirements for skin contact applications as well as long term packaging stability”.