No manufacturing process is perfect. Even with modern extrusion lines and strict quality controls, polypropylene spunbond nonwoven fabric can occasionally have defects.
The difference between a good supplier and a great one is not whether problems occur — but how quickly they are identified, understood, and fixed.
In this article, we'll walk through the most common quality issues in PP spunbond nonwoven, what causes them, and — most importantly — how to solve them.
Whether you're a buyer, a converter, or a fellow manufacturer, this guide will help you spot problems early and work with your supplier to resolve them.
The Problem: Small, visible holes or thin spots in the fabric that allow light to pass through. These compromise barrier properties, tear strength, and appearance.
Common causes:
Solutions:
The Problem: The fabric weight (GSM) is not consistent across the roll or along the length. Some areas are heavier, some lighter. This leads to uneven strength, poor print, and customer complaints.
Common causes:
Solutions:
The Problem: The fabric does not meet the specified tensile strength — it tears too easily in machine direction (MD) or cross direction (CD). This compromises durability for bags, covers, and gowns.
⚠️ This is one of the most common — and most frustrating — issues in the industry.
Root causes of low tensile strength:
A. Incorrect Basis Weight (GSM Too Low)
The fabric is simply too light for the application. A 50gsm fabric will never have the tensile strength of a 100gsm fabric. If the supplier is offering "high strength" at a very low GSM, the numbers may not add up. Strength requires polymer mass — there's no shortcut.
B. Insufficient PP Content — Excessive Fillers
Some manufacturers reduce cost by adding fillers (e.g., calcium carbonate, talc) to the polymer. This lowers the actual PP content per square meter. Fillers do not bond or provide strength — they weaken the fabric. A roll with 30% filler will have roughly 30% lower strength than a 100% virgin PP roll of the same GSM.
C. Low-Quality PP Resin from Substandard Suppliers
Not all PP resin is the same. Off-spec resin, recycled resin of unknown origin, or resin with inconsistent MFI (melt flow index) can cause weak filaments. Some small, unregulated suppliers offer resin at very low prices — but the resulting fabric fails tensile tests consistently. Quality resin costs more for a reason.
D. Poor Process Parameters
Even with good resin, a manufacturer that doesn't adjust its production parameters carefully will produce weak fabric. This includes:
A manufacturer must actively monitor and adjust these parameters during the run — not just set them once and walk away.
Red flag: If a supplier offers spunbond fabric at a price that seems too good to be true — it probably is. The savings likely come from fillers, low-grade resin, or corners cut in production. The cost of field failures and customer complaints will far outweigh the upfront savings.
The Problem: When laid flat on a table or on a converting machine, the fabric does not lie smoothly. It shows waves, ripples, or buckling — especially near the edges. This is often called "wavy edges," "baggy fabric," or "camber."
Why this matters: An uneven surface prevents smooth printing, causes misalignment in bag-making, and creates wrinkles in laminated products. In automated lines, it can cause jams and rejects.
Common causes:
Solutions:
The Problem: The edges of the fabric curl upward or inward, making it difficult to unwind, feed through machines, or print on. This is especially problematic for bag making and converting lines.
Common causes:
Solutions:
The Problem: The fabric generates static electricity during unwinding or converting. This attracts dust, causes layers to stick together, and can interfere with automated equipment or electronic components.
Common causes:
Solutions:
The Problem: The roll is not uniform — layers slide sideways (telescoping) or the width varies along the roll length. This makes it impossible to run on automated lines.
Common causes:
Solutions:
The Problem: Visible blemishes on the fabric surface — white spots (unmelted resin), dark specks (carbonized polymer or contaminants), or streaks (uneven melt flow). These ruin print quality and appearance.
Common causes:
Solutions:
Quality IssueLikely Root CauseQuick Check
| Pinholes | Clogged spinneret or contamination | Hold fabric to light; check for repeats |
| GSM variation | Pump fluctuation or quench air imbalance | Weigh samples from edge, center, edge |
| Low tensile strength | Low GSM, fillers, poor resin, or bad process parameters | Test MD and CD; check ash content for fillers |
| Uneven surface | Winding tension or calender temperature variation | Lay flat on table; check for waves |
| Edge curling | Uneven calender pressure or winding tension | Lay flat; measure curl height |
| Telescoping roll | Winding tension or edge guide problem | Check roll ends; measure width |
Quality issues in spunbond nonwoven are preventable, detectable, and solvable. The key is having a supplier that understands the root causes and has the systems in place to prevent them.
Most quality problems trace back to three things:
Choosing a supplier who invests in quality resin, careful production will save you headaches — and money — in the long run.
Looking for a reliable supplier of PP spunbond nonwoven with consistent quality? We manufacture single-layer spunbond from 10gsm to 250gsm, with stringent quality controls, good quality new virgin PP resin, and 22 years manufacture experience at nonwoven production.
Contact us for samples or a quote – Quality you can rely on, from roll to roll.
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E-mail : marketing@henghuanonwoven.com
Ajouter : No.260 Liqi Road Hangcheng Street, Changle District, Fuzhou City, Fujian Province, China
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