Three dimensional non-woven process for hygiene apparel

The current method of producing three-dimensional hygiene apparel products is to make a two dimensional product (a cloth), and through cutting and joining seams turn it into a three dimensional product. This method requires secondary operations, which produce waste, use substantial amounts oflabour, and require extra production time. Therefore, the three dimensional non-woven process will be a revolution in the non-woven fibre field. With very limited research avai lable specific to this kind of process, it is ground breaking work, which eliminates some of the waste mentioned above. The aim of the project was to develop and implement the three-dimensional nonwoven fibre process so that it is capable of high volume manufacture of non-woven products. Pal International Limited is relying on this branch of products to enhance the current hygiene product market, and create greater opportunities within the markets both in England and abroad by revolutioni sing the product range. The initial equipment available was unsuitable for production purposes, as there were problems with all sections of the machine. Therefore a complete rework was req uired and undertaken to get it up to the desired standard and specification. A trilby hat has been chosen as the product to base all trials on. A literature survey was undertaken to discover theoretical improvements to the machine, and trials were generated to assist in proving or disproving theories. These trials consequently lead to rework of the machine. This report details the equipment available, issues with it and further work required to turn it into a production process. The end result is a machine that produces a trilby hat of the required quality and at the desired quantity with no rework necessary. Some compromises from the theory have had to be made in order to meet Pal Internationals requirements for cost purposes.