How Downcycling Supports the Growing Nonwovens Industry

How the Growing Nonwovens Market Is Increasing Demand for Downcycled Materials

In recent years, the textile industry has made significant shifts toward sustainability and innovation. One of the key areas driving this transformation is the market for nonwoven textiles. These materials are produced by bonding or interlocking fibers through mechanical, thermal, or chemical processes instead of traditional weaving or knitting methods. Nonwovens are gaining traction in the industry due to their versatility, cost-effectiveness, and environmental benefits.

Last year, the capacity of nonwovens in North America reached 5.713 million tons, an increase from 2022 of over 230,000 tons, according to INDA’s North American Nonwovens Supply Report. What’s more, the nonwovens market is expected to grow from $14.85 billion in 2024 to $18.52 billion in 2028, according to The Business Research Company.

Alongside the growth of the nonwovens market is an increasing demand for downcycled materials, particularly those made from excess pre- and post-consumer textiles. These materials are used in a wide variety of applications, such as home insulation, carpet padding, concrete binding, and acoustic tiles.

Below, we’ll dive deeper into the dynamics of the nonwoven textile market and the industry’s growing interest in downcycled materials.

3 key advantages of nonwoven materials  

Unlike traditional woven fabrics, like the cotton used to make a t-shirt, nonwoven materials do not require weaving or knitting, making them less labor-intensive and often more economical to produce. These textiles generally have three key advantages:

1. Cost-Effectiveness: Nonwoven materials can be produced at a lower cost than woven fabrics, making them an attractive option for various industries, from construction to automotive to healthcare.
2. Versatility: These materials can be engineered to have specific properties, such as absorbency, liquid repellency, resilience, stretch, softness, and strength.
3. Environmental Benefits: Many nonwoven materials, like the ones we’re gearing up to produce at Looptworks, are made from recycled materials. They can be designed to be biodegradable, further contributing to a company’s sustainability goals.

Where downcycling comes into play

First things first—what is downcycling exactly? It’s a process that involves breaking down textiles that are not high enough quality for fiber-to-fiber textile recycling into small fiber components via mechanical separation. Downcycling is crucial for keeping textile waste out of landfills and keeping textiles in use for as long as possible. Downcycled materials from excess textiles are increasingly being used in unique applications across a variety of industries.

• Construction
  Nonwoven materials are used for roofing and thermal insulation due to their durability and ease of installation. Since homes are built to last for many years, this is a great way to extend the life of textiles for several decades while improving a home’s energy efficiency and comfort.

Downcycled textiles can also be used to make carpet padding, providing cushioning and extending the life of carpets. This application not only diverts waste from landfills but also offers an affordable alternative to traditional carpet padding materials.

Some downcycled material is used to make acoustic tiles, which are used in building interiors to reduce noise levels and improve sound quality. This application is valuable in offices, schools, and entertainment venues.

Lastly, downcycled fibers can be used as additives in concrete to enhance its strength and durability. These fibers help improve the mechanical properties of concrete, making it more resistant to cracking and increasing its lifespan.

• Automotive
  Nonwoven textiles are used for interior components and filtration systems. They are also commonly used in thermal and acoustic insulation, helping reduce energy consumption and improving a vehicle’s soundproofing.

• Healthcare
  Nonwoven fabrics are used in medical supplies, such as surgical gowns, masks, and wound dressings due to their hygienic and disposable nature.

• Consumer Goods
  Products like diapers, wipes, and hygiene products rely heavily on nonwoven textiles.

The future of the nonwovens market

The market for nonwoven materials is influenced by several factors that help explain why the industry is set to experience growth of nearly $1B a year over the next four years.

For starters, governments and regulatory bodies are increasingly enforcing environmental regulations that promote recycling and waste reduction. These regulations drive manufacturers to adopt sustainable practices, such as using downcycled materials to construct a new building.

Innovations in recycling technology are also making it easier and more cost-effective to downcycle textiles and nonwoven products. Advanced sorting and processing techniques, powered by robotics and AI, are improving the quality and usability of downcycled materials.

Finally, industry collaborations and partnerships play a significant role in promoting the use of downcycled materials. Companies are working together to develop new products and applications, leveraging each other’s expertise and resources.

Challenges and opportunities

While the market for nonwoven textiles holds a lot of promise, it also faces some key challenges. For example, ensuring downcycled materials meet the required quality and performance standards can be difficult. We know firsthand that manufacturers must invest in research and development to improve the properties of downcycled materials.

The cost of collecting, sorting, and processing excess textiles for downcycling can also be high. However, as technologies advance and economies of scale are achieved, these costs are expected to decrease.

Finally, convincing consumers and industries to adopt products made from downcycled materials can be challenging. Education and awareness campaigns are essential to promote the benefits of downcycled materials.

Despite these challenges, the market for downcycled textiles offers significant opportunities for manufacturers, such as a smaller environmental footprint, more innovative product designs, and an improved brand image.

Think your excess textiles are a good fit for downcycling? Let’s talk!

Contact Looptworks today to discuss how our downcycling solutions can help breathe new life into your company’s excess materials.