The increasing demand for clean air and water continues to make filtration one of the fastest-growing sectors for nonwovens. To keep up with this demand, global producers of nonwovens for filtration media applications and manufacturers of filter products continue to focus on investment, new product development and new market areas to grow.

According to analysis from the recent Smithers study The Future of Industrial Nonwovens to 2029, filtration (excluding automotive filters and medical PPE face masks) is the second largest contemporary end-use, by value, in the industrial nonwovens sector.  Global sales for filtration applications will total $5.33 billion this year, consuming a total of 1.02 million tons of nonwovens.

According to Smithers, around 60% of sales come from liquid filtration, mainly wetlaid and meltblown variants employed in edible and hot oil filters, milk filters, pool and spa filters, water filters, blood filters, etc. The remainder of the market is air filtration – principally carded, wetlaid and needlepunch variants. This encompasses filters for both domestic and industrial heating, ventilation and air conditioning (HVAC) equipment, as well as other industrial applications, such as particulate filters at factories or power plants.

Overall, the market outlook for nonwovens in filtration is very positive. Smithers expert market forecasting shows that sales value will increase at a +17.5% compound annual growth rate (CAGR), across the next five years. This will see global value almost double to $11.93 billion in 2029; and see it overtake the building and construction segment as the most lucrative in the industrial nonwovens sector. Volume for filtration nonwovens will grow at a slightly slower rate, +12.8% CAGR, to reach 1.87 million tons in 2029.

According to Albert Hammerschmied, director Strategic Marketing Carpet, Filtration & Shoes EMEA, Freudenberg Performance Materials, several trends are affecting the filtration industry. First, increasing air pollution has led to stricter regulations to reduce emissions and ultimately to improve air quality. “This, in combination with increased awareness post-covid on indoor air quality, is driving long-term demand for high performance filtration,” he says.

Additionally, sustainability is top of mind. Thus, the filter media industry faces the challenge of providing reliable and comparable product carbon footprint data to help customers better understand a product’s impact. Freudenberg Performance Materials contributes to the industry through its industry association EDANA to establish a common framework for estimating the footprint of filter media.

Finally, he adds, there is a technology shift towards more functionality and features in a single media layer while maintaining high performance.

In the filtration market, Freudenberg’s filter media brand filtura offers a broad technology portfolio including multi-layer alternatives: spunbond, carded, meltblown, wetlaid and 3D-matting nonwovens, among others.

In HVAC, the company expanded its filtura media with products performing in the ranges of efficiency of ca epm1 50% to 80%. They are 100% synthetic and the perfect alternative to glass media, Hammerschmied says.

Freudenberg Performance Materials has also added alternatives for carrier materials to its filtura Support portfolio. This includes spunbond material that, at a reduced grammage (gsm), still performs at an equivalent level to heavier alternatives, without compromising unacceptably on key performance characteristics such as stiffness and pleatability. In addition, the filtura Support also offers low antimony PET spunbonds and tailored polymers to maximize compatibility with nanofiber applications.

Also, Freudenberg Performance Materials’ high capabilities and flexible production processes to manufacture filtura liquid filtration applications are unique in the industry, according to Hammerschmied. The products are characterized by highly uniform webs and pore size distribution, precise weight and thickness control and exceptional porosity. The continuously expanding product portfolio includes media options varying in weight, fiber fineness and thickness, utilizing both synthetic, including polyester and polyolefin, and bio-based fibers, specifically designed for liquid filtration applications e.g. oil filters and reverse osmosis applications.

“Filtration plays a vital role in ensuring the health and well-being of communities worldwide,” Hammerschmied says. “With increasing environmental challenges, the need for clean air and water has become more critical than ever. Increased consumer awareness and stricter standards for emissions or food safety make high quality filtration more and more mission critical. Urbanization will contribute to the long-term outlook. In a nutshell, filtration is an attractive while challenging market for Freudenberg Performance Materials.”

Ahlstrom Continues Investment Streak

Ahlstrom, one of the largest nonwoven manufacturers in the world, has invested more than €100 million during the past five to six years, which has strengthened the company’s global footprint and widened its high-performance offering in filtration segments.

Earlier this year, Ahlstrom announced an investment in a new production line for molecular filtration media in Turin, Italy. The new line is being designed to produce the highest-performance adsorbent materials for premium filtration applications, including next-generation cabin air and fuel cell air intake, as well as a complete range for HVAC and cleanrooms. It will enable Ahlstrom to offer solutions to support customers’ industrial filtration application development as well as the transition to electric vehicles.

Air quality in closed environments such as buildings and vehicles is a major concern in many areas of the world. In this context, particulate filter media play an important role in removing solid particles and aerosols from the air. “High performance molecular filter media are used in complement, removing gaseous pollutants, including volatile organic compounds, inorganic gases (such as sulfur dioxide, nitrogen oxides, ammonia) and odors. Therefore, the materials are delivering the cleanest air to people and processes,” says Noora Blasi, marketing manager, Filtration Division, Ahlstrom.

The investment is made in synergy with Ahlstrom’s Fine Fiber platform in Turin, which will be upgraded to produce HEPA filtration layers. Fine Fiber media can be combined with molecular filtration materials also to deliver the best protection against the finest particles.

“This new capability to produce molecular filtration solutions comes on top of recent investments in Europe, which reinforce our ability to better serve our customers by combining materials and technologies in multi-layer concepts,” states Giuseppe Costa, VP Filtration EMEA & Asia.

Meanwhile, in June, the company completed a €2 million investment for a new laminator at its Louveira, Brazil, plant, marking a significant expansion of its product offerings to the South American market for industrial air, industrial liquid and fuel filtration, including products currently produced in Europe and North America. Combining filtration materials by lamination offers several advantages including enhanced efficiency, extended service intervals and reduced energy consumption of filtration units.

As the filtration market evolves, these investments enable Ahlstrom to focus on new product development.

In June, Ahlstrom introduced fluoro-free technologies into a wide range of industrial air filtration applications to support filter manufacturers in creating products with long-lasting filtration performance without the use of fluorochemicals. The fluoro-free filtration materials are ideal for gas turbine air intake, air pollution control and heating, ventilation and air conditioning (HVAC) applications. The new range of materials offers water-repellent properties, which increase the durability and stability of the final filter in wet conditions. In global filtration markets, hydrophobic properties are essential to maintaining the highest filtration performance in challenging environments.

In air pollution control applications, for example, hydrophobic materials save energy by limiting the pressure drop increase in humid conditions. Specifically, in gas turbine applications, water repellency prevents liquid water ingress and dissolved salt penetration through a filter, protecting the turbine from corrosion.

“We are continuously innovating new solutions that are safe and sustainable by design, and launching our fluoro-free portfolio for industrial air filtration applications is another important step forward in enabling our customers to transition away from fluorochemistries,” says Tamara Quatrano, vice president, R&D and Product Development, Filtration. “We are paving the way for a cleaner, safer, and more sustainable future for filtration by offering our customers alternative fluoro-free solutions that meet their performance requirements.”

Another new product introduction from Ahlstrom is a dual-layer filtration media that offers up to double dust holding capacity compared to the single-layer design with each layer serving a distinct purpose to optimize the overall retention of particles in the depth of the material. 

In automotive engine air intake applications, the technology has proven to extend the filter lifetime by more than 50% in the same configuration. It also offers the possibility to reduce both size and weight of the filter element in vehicles where these parameters are important.  

Dual-layer filter materials are designed to comply with current and future engine air intake specifications, including fuel cells. The media can be customized with flame retardancy properties to increase safety in use without compromising performance. The technology is highly adaptable and can be extended to filter air and liquid in many other transportation and industrial applications.  

WPT Expands in Kentucky

In January, WPT Nonwovens Corp., a third-generation family-owned nonwoven manufacturer located in Beaver Dam, KY, started up a $19.5 million manufacturing facility in Ohio County, KY. The capital investment included a 75,000-s.f. manufacturing center with a state-of-the-art carded nonwoven production line, which added more than 12,000 annual metric tons of capacity for HVAC filtration media and hygiene fabrics to the company’s manufacturing capabilities.

What initially began as a $10.7 million investment in 2021 eventually grew significantly in scale in early 2023.  “WPT is excited to meet the growing demand for American-made nonwoven filtration media and even more excited to continue doing so in Ohio County and the incredible community of Beaver Dam,” says Travis Robbins, president of WPT.

The new carded through air bond nonwoven plant, which targets HVAC and some liquid filtration applications, manufactures bicomponent polyesters, bicomponent polypropylenes, polyester staple and low melt polyesters, Robbins says.

WPT observed a demand signal in the market for air filtration products in its region. The company’s geographic location is ideally suited for the air filtration industry and the converters of air filtration products, making it competitive in both freight and product pricing, according to Robbins. Given these advantages, he says it made perfect sense for the company to expand its market and product portfolio.

“Being a nonwovens manufacturer in the United States, you’re always combating the influx of cheap imported products; that’s just something you have to battle,” Robbins explains. “I think the edge that the domestic manufacturer has is the ability to respond—the service and support—and the reliability and performance of the products. Ultimately, we believe that outweighs, sometimes, price.”

He adds: “We’re excited to be fully operational at our new facility. We’re adding shifts, we’re adding jobs and we’re excited about what the future holds.”

Mann+Hummel Focuses on Sustainability

Filter manufacturer Mann+Hummel continues to diversify its product range to meet the evolving needs of various industries while adhering to its sustainability commitment.

In line with its Carbon Zero Strategy, the company plans to increase its share of renewables from 50% to 100% between 2023 and 2025. Starting in 2025, all of its filters will be produced using 100% electricity from renewable sources. Where renewables are not available, it will compensate with certificates that adhere to the RE100 standard. This initiative will neutralize the company’s scope 2 emissions to calculated CO2-free electricity, which accounts for 70% of its own scope 1 & 2 emissions (based on 2023 emissions).

“We are committed to constantly reducing energy consumption every year—in our company and along our supply chain,” says Kathrin Sauter, vice president Corporate Marketing & Communications, Mann+Hummel. “At the same time, we are working on optimizing our products and solutions in terms of energy efficiency and the circular economy.”

In addition to its sustainability initiatives, Mann+Hummel has continued to expand its product range. One of the company’s latest innovations is the front-end particulate filter, which significantly improves air quality in urban environments by efficiently trapping particulate matter and other pollutants. The company has also introduced advanced self-cleaning air filters utilizing impulse cleaning technology for heavy-duty applications, and acoustic cleaning technology that operates with just a power connection. These technologies extend the lifespan of filters and reduce maintenance requirements. Meanwhile, its BIO-CEL L+ ultrafiltration membranes offer low energy consumption and efficient wastewater treatment, delivering best-in-class total cost of ownership, Sauter says.

“Our filtration solutions are crafted to meet the highest industry standards and employ cutting-edge tools, while Life Cycle Assessments and eco-design thinking are integral components of our design and production processes,” she adds. “Additionally, we leverage advanced digital tools like our ‘smartFE’ digital design system and comprehensive product validation system, both of which use AI and machine learning to optimize filter designs and enhance performance. This combination of sustainability, innovation and digital integration makes our technologies unique in the market.”

Despite global crises, the global market for industrial filtration is expected to continue growing at a considerable rate in the coming years, according to Sauter.

“We believe that the future of filtration technology will undergo significant advancements, driven by the integration of digital technologies, a heightened focus on sustainability and the evolving needs of various industries,” she says. “At Mann+Hummel, we are committed to shaping this evolution by continuously investing in research and development, embracing digital transformation and prioritizing sustainable practices. Our goal is to stay at the forefront of filtration technology, delivering innovative solutions that contribute to a cleaner future.”

Hollingsworth & Vose Expands

Hollingsworth & Vose (H&V) continues to expand its manufacturing footprint as well as its range of products. The company’s $40.2 million investment in Floyd, VA, announced in January 2023, is expected to come online in late 2025. The new capacity will support the company’s  Trupor business, a revolutionary high performance liquid microfiltration media.

Meanwhile, in Europe, H&V has two major, ongoing expansion projects in Hatzfeld, Germany. These investments are planned to keep H&V at the forefront of innovation and will add new filter media technologies and capabilities for indoor air quality, cabin air, liquid, gas turbine, cleanroom and medical applications, according to Mike Clark, division president.

In new product news, H&V recently introduced PlusZero, a comprehensive line of high-performance solutions manufactured without using per- and polyfluoroalkyl substances, commonly known as PFAS. In addition to being environmentally sound, the PlusZero line it offers high-quality solutions that will help customers meet performance, reliability and affordability goals.

“We have a long tradition of innovation and sustainability at H&V, and PlusZero is our latest breakthrough furthering our commitment to both,” says Clark. “After years of research, we have developed a line of zero added PFAS solutions that are not only better for the environment, but smart for business.”

Leveraging H&V’s focus on research and innovation, PlusZero is grounded in the latest technology. The solutions in the PlusZero line have been developed to support the sustainability goals of H&V’s customers by eliminating the use of forever chemicals in the manufacturing process. At the same time, PlusZero solutions will deliver the same high performance in most applications and largely carry the same price as their legacy counterparts.

Although eliminating the use of PFAS in the manufacture of products is not yet required under regulations, H&V is committed to providing solutions that are sustainable and good for business, the company says.

Kimberly-Clark Professional Sees Increasing Demand

The demand for advanced filtration solutions continues to grow rapidly across multiple sectors, according to Scott Tennison, Kimberly-Clark Professional, North America, general manager Partnership Products. “Stricter environmental regulations and sustainable needs, along with heightened awareness on indoor air quality, are driving significant growth with solutions that support these areas of need and concern.”

Tennison says regulatory changes are encouraging users to provide filter solutions that are sustainable and support energy efficiencies. They are also driving an increased need for higher efficiency solutions that protect the people against the smallest and most dangerous sized particles.

For the filtration market, Kimberly-Clark Professional (KCP) offers a broad range of filter media to service a variety of HVAC applications including pleat, pocket and minipleat filters for commercial, industrial, and residential use. Its filter media range also provides key solutions for car cabin and air purifier applications as well as liquid filtration.

Among KCP’s latest products is its line of high-efficiency electret-charged, bicomponent spunbond filter media that can help to improve indoor Air Quality (IAQ) and reduce HVAC operating costs. Filtration efficiencies from MERV 8 – MERV 15 are available for pleat, pocket and minipleat filters.

“Producing filtration media, which provides cleaner indoor air quality, supports our purpose Better Care for a Better World,” Tennison says. “The Kimberly-Clark Filtration business is growing as we continue to address the needs of various industries and those who use our products.”

SWM Establishes U.S. Warehousing

A global developer of advanced materials, SWM International offers its MemBase portfolio, a premium range of 100% polyester membrane backing materials designed to excel in diverse filtration applications, from reverse osmosis and ultrafiltration to microfiltration and nanofiltration.

SWM’s strategic investment in U.S. storage solutions ensures that its American customers receive the best service possible. By establishing local warehousing, SWM enhanced its ability to manage supply chain fluctuations and respond swiftly to customer needs. “Having local storage means we can better manage supply fluctuations and provide faster service,” says Kerry O’Brate, regional sales director for America.

SWM’s U.S. facilities also offer the flexibility to handle on-site product reworking, packaging modifications and labeling adjustments, ensuring that MemBase products arrive precisely as its customers need them.

While its MemBase products are manufactured in Europe, SWM has implemented rigorous measures to ensure consistent quality during transit to the U.S. The company utilizes full-container shipping and conducts meticulous inspections at every stage to guarantee that its products maintain their integrity across the Atlantic. “We’ve established a comprehensive system for maintaining MemBase quality throughout its journey to the U.S.,” says Julien Plattier, R&D senior manager.

By transitioning to in-house storage, SWM has gained greater control over product handling, enhancing its ability to meet the evolving needs of the U.S. market while solidifying its position as a trusted supplier of high-quality filtration materials, the company says.