6 Types of Manufacturing Processes for Non-Woven Filter Media Materials

Oct 16th, 2025

6 Types of Manufacturing Processes for Non-Woven Filter Media Materials

Filtration is an essential part of our daily lives. From coffee filters and air purifiers to water and automotive filters, numerous industries and consumers rely on high-quality filter media to purify the air they breathe, the water they consume, and to keep their machinery and vehicles functioning properly. In some cases, filter media can protect personal health and safety, and even save lives.

Although we are transitioning from the industrial age to the technological age, the filtration market continues to thrive. It is projected to grow by more than $13 billion by 2025. Within this market, air filtration is expected to increase by 6.6% (reaching $15.4 billion) by 2025. In terms of liquid filtration, this market is poised to grow to nearly $3 billion by 2026.

These forecasts bode well for the filtration market, particularly for the production of non-woven filter media. Non-woven materials can deliver high-quality products at a lower cost compared to woven materials.

Filter Media

The filtration of air and water is crucial for our health and safety. Filters come in various shapes and sizes and can be made from either woven or non-woven fabrics.

Woven fabrics are produced by weaving individual strands of material—such as monofilaments or fibrillated yarns—on a loom. In contrast, the manufacturing process of non-woven fabrics involves first bonding fibers together in an ordered or random manner, then adhering the layers of non-woven fabric with polymers to form a porous material suitable for filtration.

● 6 Different Methods for Producing Filter Media

The method used to manufacture filter media largely depends on the type of filtration required. There are six primary methods, as detailed below:

● Carding Process

Filter media produced via the carding process has traditionally been used in face masks and for filtering edible oils, coolant oils, and milk. Resins or thermal bonding are typically used in this method, though it has been replaced by other methods described below in some cases.

● Wet-Laid Process

The wet-laid process and wet-laid filter media are used in pool filters, coffee filters, and High-Efficiency Particulate Air (HEPA) filters. Their manufacturing process is similar to papermaking: on standard papermaking equipment, a mixture of short fibers (which can be synthetic, natural, or glass fibers) is formed into a paper-like medium.

● Melt-Blown Process

Melt-blown filter media is ideal for filtering particulates such as dust, asbestos, and smoke. This type of filter is commonly found in respiratory protectors and can be easily produced in large quantities. It is formed without using pre-made fibers; instead, molten polymer is blown into a micro-porous web.

● Spun-Bond Process

Spun-bond filter media is lightweight and suitable for both air and liquid filtration. Like melt-blown media, it does not require pre-made fibers; instead, it is formed by spinning materials such as nylon, polyester, or polypropylene together. Additionally, spun-bond media is lightweight and heat-resistant.

● Needle-Punching Process

The manufacturing of needle-punched filter media is a mechanical process that involves using barbed felting needles to position and interlock fibers in spun-bond or carded webs. The three-dimensional structure of needle-punched filter media makes it ideal for trapping particles both on the surface and inside the filter. This type of filter is commonly used for cleaning, for example, inlet water and wastewater.

● Lamination/Composite Process

Non-woven lamination (or composite processing) is a procedure that uses various techniques to bond multiple layers of non-woven materials and polymers into a composite material that combines the properties of each layer. In the manufacturing of filter media, layered composites are ideal for heating, cooling, and ventilation systems in homes, buildings, and automobiles.

Advantages of the Composite Process

Compared to other methods, the composite process for producing filter media offers numerous distinct advantages. After lamination, the material becomes:

  • Resistant to disinfection and cleaning with strong chemicals;

  • Highly stable at high temperatures;

  • Wear-resistant with a long service life;

  • Easy to manufacture with varying porosity, weight, and thickness;

  • Waterproof, breathable, and soft;

  • Versatile, suitable for any filtration requirement;

  • Cost-effective to produce.

Regardless of the type of filter media you need, it is important to consider production costs, ease of manufacturing, and the specific properties required for the final product. Non-woven fabrics have proven to be a versatile material for manufacturing filter media, which can be used in any scenario and field within the filtration industry—whether filtering water, air, blood, oil, or other substances.


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