Trützschler Nonwovens has introduced a new standard in air-through bonding technology by offering the world’s only processing solution capable of producing nonwovens with ultra-fine sheath-core bicomponent microfibers as fine as 0.4 denier. The technology makes it possible to produce lightweight single- to four-layer webs with excellent softness, loft, and skin friendliness, while also maintaining high production speeds and machine efficiency.

Processing fibers below 1 denier is considered a major technical achievement because the difficulty level increases significantly. Ultra-fine fibers are delicate, highly sensitive to airflow changes, contamination, and mechanical stress, and they tend to interact unpredictably. This makes accurate carding, even web formation, and stable long-term production much more challenging.

The machine design uses carefully balanced suction systems, casings, and geometries to create controlled airflow inside the equipment. This reduces fiber fly and prevents excessive fiber build-up, helping to achieve uniform web formation, efficient material use, and lower cleaning requirements, resulting in higher machine availability.

For hygiene-focused ATB production lines, Trützschler Nonwovens also offers the specially developed NC-X nonwoven card. It is designed to process ultra-fine fibers carefully at every stage of carding. Its internal structure supports smooth airflow and reduces air turbulence, helping achieve better fiber alignment, blending, uniform web formation, low nep levels, and consistently lofty structures that contribute to softness and performance.