System and method for producing a bleached cotton, nonwoven web

Abstract

A continuous textile processing system and method are disclosed for producing a nonwoven web containing bleached cotton fibers in a single line which includes a supply of fibers such as a bale opening device which opens bales of cotton fibers. A plurality of fiber delivery lines transport the fibers through a fiber opening process where the fibers are individualized and opened. The opened fibers are collected and fed to a blending system which includes plural blending units. The blended fibers are formed into a web and processed in a continuous flow bleaching unit. The fibers flow continuously through the bleaching unit as transported in the form of a web. The bleached fibers in the web are passed through a drier oven. The dried web of bleached cotton fibers is broken up by a fiber opening unit which separates the fibers from the web and opens the fibers for delivery to a carding system where the opened bleached fibers are carded into nonwoven webs and cross-lapped. The cross-lapped web including multiple webs of bleached cotton fibers is subjected to a hydroentanglement unit where water jets further interlock and entangle the fibers to make an integral web structure. The final nonwoven web consisting of bleached cotton fibers may be made into highly purified and absorbent wipes, pads, and other articles for medical, industrial, or domestic use.