Development of Needle-Punched Nonwoven Fabrics from Reclaimed Fibers for Air Filtration Applications

This paper reports an investigative study on the fabrication and measurement of the air permeability, mechanical properties, pore size distribution, and filtration efficiency of different nonwoven fabrics produced from reclaimed fibers by analytically changing the machine variables to manipulate the physical parameters of the nonwoven fabrics. Reclaimed fiber of cotton (60%) and polyester (40%) blend was used, so that the prospect of value addition to an inexpensive source of raw material could be explored. The changes in air permeability were interpreted in terms of fabric density profile and pore size distribution. The filtration parameters of filtration efficiency, dust holding capacity, and pressure drop were also calculated. Additionally, the effects of calendering on pore size and filtration properties were evaluated to discover the opportunity of fine-tuning and the performance of the filters. The outcome in this study reflected an overall development in all filtration characteristics due to the calendering operation.