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Natural Fibers from Hemp to Jute on Rando Machinery

Natural fibers are having a moment. Fibers such as  Industrial hemp, flax, jute, and kenaf are moving from niche to mainstream as manufacturers look for renewable, low carbon, biodegradable alternatives to glass fiber and petroleum-based materials. The demand is growing across biocomposites, agriculture, and building insulation. The catch is that natural fibers are difficult to process: they are mixed denier, length, and dusty. Most nonwoven web forming and fiber opening and blending equipment was never built for them. Rando technology excels with natural fibers, from fiber preparation to web forming. 

Why natural fibers defeat ordinary equipment

Bast fibers like hemp, flax, jute, and kenaf are nothing like the clean, uniform synthetic staple most machines are tuned for. They often arrive bale with  variable inconsistent lengths, with coarse and fine fractions mixed together, plus dust and shive. They change from batch to batch, and even within a single bale. This inconsistency can be the virtue of a natural material subject to weather, growing conditions, soil quality, etc. The standard fiber machinery Equipment on the market  designed for fiber with regularity like polyester chokes on that variability. Rando’s entire history is running the fibers other machines struggle with, which makes natural fiber a production fit with Rando Machinery.

From baled fiber to a uniform web

Processing natural fiber well starts before the Rando web former, or before any airlay for that matter. Rando’s openers, blenders, and bale breakers take compressed, tangled bales and open them into a consistent, free-flowing fiber stream, mixing coarse and fine fractions and metering the material evenly. Depending on your goals, Rando can size fiber opening equipment to be as aggressive as needed for fiber preparation. That preparation is the difference between a lumpy, inconsistent web and a web with high uniformity.

From there, the Rando Webber lays the fiber in true random orientation, producing a uniform web with even weight and loft across the working width. Again here, Rando can size working widths to your specific needs. For instance, natural fiber construction materials may require 4ft or 8ft increments, where geotextile materials may require 10ft to 12ft increments. Natural fibers are often blended with a binder or bicomponent fiber for thermal bonding, so the Webber’s ability to combine dissimilar fibers into one consistent web matters. And the high-loft condenser forms webs from thin mats up to ten inches tall, which opens the full range of natural fiber products, from dense composite mats to lofted insulation batts.

Three markets, one platform

Biocomposites: Natural fiber mats are replacing glass fiber in automotive interior panels and construction composites, offering lower weight, renewable content, and strong mechanical performance. A uniform, isotropic web gives the consistent fiber distribution a good composite depends on.

Agricultural growing media: Natural fiber substrates are emerging as a renewable, biodegradable alternative to rockwool and peat for hydroponics, propagation, and controlled-environment agriculture. Here loft and uniformity govern water retention and root aeration, which are exactly the web properties the Webber is built to control.

Insulation:  Natural fiber batt insulation is one of the fastest-growing sustainable building materials, valued for renewable content, carbon storage, and healthier indoor air. Lofted, thermally bonded natural fiber webs are the core of the product, and high-loft air-laid forming is how they are made.

These three examples are just the tip of the iceberg. Innovation in natural fibers and natural fiber nonwovens are creating new and exciting markets for natural fiber materials. Rando can support you in developing your product concept on our trial line.

Renewable by nature, proven on the line

Natural fiber processing sits comfortably with Rando’s oldest instinct. The company was founded reclaiming waste cotton, and renewable and recycled fiber has been in its DNA ever since. Natural fibers extend that story: crops that store carbon as they grow, processed into products that can biodegrade at the end of their life.

Because natural fiber varies so much, proving a process before committing to a line matters more here than almost anywhere. Rando’s pilot line lets a manufacturer run their actual material, whether it is hemp from one region or jute from another, and see the web before buying the machine that makes it.

The natural fiber market is growing because the world wants renewable materials. Rando has spent 75 years building the machines that turn difficult, variable fiber into a uniform, useful web. From hemp to jute, that is exactly the kind of problem worth solving.

Try your natural fibers

See how Rando’s lineup handles natural fiber, or bring your hemp, flax, or jute to the pilot line and watch it form. 

Develop your Natural Fiber Material

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Everyday Household Items: Your Abrasive is Made on Rando

Abrasive pads are made of coarse fibers, Rando Machine is the leading manufacturer of machinery for producing nonwoven abrasive pads

Look under your kitchen sink. There is a good chance you will find a scrubbing pad, the kind you reach for to clean stubborn pan. Walk through a grocery store after hours and you will see a floor buffer gliding across the tile on a thick round pad. Open a toolbox and you will probably find a gray finishing pad for smoothing metal or wood. These products have almost nothing in common, except one thing: each began as individualized fibers formed into a web. There is a strong chance the machine that made that everyday material was built by Rando.

What a nonwoven abrasive actually is

An abrasive pad is not woven like cloth. It is a nonwoven, a three-dimensional web of fiber with open air space running all through it, coated with abrasive grit and bonded to hold its shape. That open, airy structure is by design. The web of fibers with airspace is what holds the grit, controls how aggressively the pad buffs, and decides how evenly it wears. With the right web formation, the pad performs for its intended application. 

Why air-laid forming wins in abrasive pads

This is exactly where Rando’s technology earns its reputation. Rando’s air-laid web forming lays fiber in true random orientation, so the web is uniform and open in every direction, what engineers call an isotropic structure. For an abrasive pad, that uniformity is everything. It spreads the grit evenly, gives a consistent contact across the whole surface, and produces the uniform contact across the width of the material. The consistency enabled by Rando airlay forming, like with the Rando Webber, is a big part of why Rando is recognized worldwide as a leading choice for commercial floor scrubber and buffer pads.

One technology, from the gentle pad to the heavy one

The Rando Webber is able to achieve a significant range of basis weights with a variety of abrasive fiber types. This makes the Rando Webber very versatile for abrasive pad manufacturers. The same air-laid technology makes a delicate hand pad and a heavy industrial floor pad, with web weights running from 25 grams per square meter can make abrasive pads all the way past 2,500 grams per square meter. With the range of basis weights also comes the ability to handle fibers from 3 to 200 denier, fine to super coarse. That span is why the soft pad you use on a nonstick pan and the aggressive pad that strips a warehouse floor can both come off Rando machinery.

The hard end of the range

The heavy end of densities and fiber deniers is where it manufacturing abrasive pads with traditional nonwoven machinery becomes difficult, if not impossible. The most demanding abrasive pads run stainless steel and other tough, wiry fibers that chew up equipment built for soft synthetics. For instance, the fiber opening and preparation technologies Rando has in its portfolio can be modified for stainless steel and similar fibers. Few machines can form a clean, uniform web from stainless steel fiber. Rando has done it for decades, and is core to why Rando has a presence across 6 continents.

Ordinary places, uncommon machinery

Rando abrasive webs end up in a lot of ordinary places: the scrub pads in the kitchen, the buffer pads under commercial floor machines, the finishing pads in workshops and factories. Millions of these products move through homes and businesses every year, formed on machines almost no one outside the industry has heard of.

That is the quiet story of Rando. For 75 years it has built the machines behind products people use every day without a second thought. An abrasive pad does not come with a label explaining how its web was formed. But the next time one makes quick work of a burnt pan with a scrubbing sponge, you can think to the start of this products life on a Rando machine.

Abrasive Manufacturers: Trial Rando Equipment on our Pilot Line

See how Rando’s abrasive web systems work, bring your fiber to the pilot line and form it for yourself. 

Trial Abrasive Fibers on the Pilot Line
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Nonwovens for NASA: Rando Air-Laid Web in Extreme Applications

Rando Machine makes Nonwovens for NASA space exploration, in a project exploring Heatshield for Extreme Entry Environment Technology

There is no more demanding test of materials than in the far reaches of our atmosphere and beyond. NASA has long explored the materials and methods of making materials that can help achieve space research objectives. Today, Rando is a key partner in engineering and manufacturing nonwoven materials for the demands of atmospheric entry. Why are the materials used in spacecraft development so important, and how is Rando turning fibers into materials to solve the most rigorous challenges?

A spacecraft hitting the top of an atmosphere at tens of thousands of miles per hour turns its leading surface into a wall of heat, hot enough to vaporize most materials. Polyesters, nylons, and conventional fibers are not suited for the job. Nonwoven heatshields with advanced fibers, however, are suited for the development of spacecraft thermal protection systems. Thanks to Rando’s airlaid technology, a new material is being explored to build the next generation of those heatshields.

The heatshield problem NASA is solving

NASA’s Heatshield for Extreme Entry Environment Technology program, known as HEEET, was created to protect probes entering the most punishing atmospheres in the solar system, beginning with Saturn and Venus. Its core is a dual-layer, three-dimensional woven material: a dense carbon-fiber layer that faces the heat, over a lower-density insulating layer that keeps it from reaching the vehicle. The system is engineered to survive peak heat flux well beyond 1,500 watts per square centimeter, and NASA has documented that it can do so at more than 40 percent less mass than conventional carbon phenolic it replaces. The woven material is produced by Bally Ribbon Mills. Woven materials have timetested performance, but often involve higher costs than nonwoven materials.

Where air-laid web forming enters the picture

Making that insulating layer thicker, more cost effective, and faster to produce, is an active area of NASA research, now aimed at scaling the material for Mars, low Earth orbit, and other planetary entry. In a 2024 NASA Phase II SBIR award, a team of companies from the textile, nonwoven, and space exploration industries are developing an Additive Insulation Layer for HEEET: a nonwoven web, made from the insulation layer yarn. The nonwoven layer is then needle punched onto the woven insulation to build up thickness while preserving the low fiber volume the insulation depends on.

In this sense, a Rando manufactured nonwoven technology works synergistically with a woven material. This early-stage development places Rando’s core technology and capabilities inside one of the most extreme material challenges there is.

Why air-laid is a natural fit for the job

The reason Rando’s Airlaid technology is a fit for this extreme application is the same reason Rando’s webs perform in industries like thermal insulation on Earth: randomized fiber webs laid with a consistent and isotropically formed structure trap air and resist heat and thermal flux. For a thermal insulation layer used in space, that uniformity matters, because heat finds inconsistency. Forming a controlled, low-density web from short, chopped, and difficult yarn is precisely the capability Rando has spent 75 years refining on industrial fiber. 

From waste fiber to the edge of space

The same random airlaid technology principle developed in 1949 that solved the problems of low value waste fiber recycling is now being explored to help protect a spacecraft entering another planet’s atmosphere. Rando’s greatest strength when it comes to its’ Rando Webber for airlay applications is its ability to handle virtually any fiber, and lay that fiber randomly and uniformly. We’re proud to created engineered solutions for demanding applications both on earth and beyond.

Explore our Capabilities

See how Rando’s air-laid web forming handles demanding fiber, or bring your material to the pilot line. 

Explore our Pilot Line

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The Rando Webber: Rando’s Airlaid Advantage

Every company has one machine that defines it. For Rando, it is the Webber. This machine is the airlaid web former that gave the company its name, and three quarters of a century later it is still the reason customers bring Rando their hardest fibers. The Webber does one thing exceptionally well: It lays loose fiber into a uniform web with true random orientation, and it does it with materials most equipment cannot touch.

Why random fiber orientation excels

There are many options for fiber web forming on the market. Many often look to carding machines for forming webs, and while carding certainly has its applications, it also has it’s limitations. Carding combs the fibers until they line up in the machine direction, which makes a web that is generally strong one way and weak the other. The Rando Webber does the opposite. It distributes fiber randomly and evenly in every direction, so the web has isotropic strength, meaning equal strength in all directions. That randomized uniformity the intention of the Rando Webber, and it is where the company got its name.

For a buyer, isotropic strength shows up as real performance: consistent weight, consistent loft, and uniform quality across the full width of the web. A web that behaves the same in every direction is easier to convert, more predictable in the field, and better suited to demanding applications from composites to filtration and everything in between.

One mechanism, built for control

The Webber forms the web with air, using a split air system that works the fiber with both pressure and vacuum, paired with AC variable-speed motors that give the operator fine control over how the fiber lands. That control is what produces the uniformity, and it is what lets a single platform run an unusually wide range of material and web geometry. Webs come off the machine anywhere from 12 to 110 inches wide, from thin veils to thick high-loft batts.

The Webber is also built on Rando’s wide options of configurations, it is not limited to a single configuration. It comes in three condenser styles, so the same platform can be tuned to the fiber and the web you actually need.

The SB condenser is built for heavier fibers, roughly 25 to 100 denier and above, forming at up to 66 feet per minute. The SD condenser handles the fine end, from nano fibers up to 100 denier, and runs fast, up to 150 feet per minute. The SHL condenser adds high loft to everything the SD can do, forming webs from three quarters of an inch to a full 10 inches tall.

What makes the SHL remarkable is the control. An operator moves loft across that entire range by adjusting speeds on the HMI, with no mechanical changeover. Many competitors lack the condenser optionality, and this optionality adds revenue generating potential for our customers.  It runs fiberglass, synthetics, and natural fibers like hemp, jute, wood, and cotton with equal ease. That span, from a nano-denier veil to a 10-inch batt, is why one Webber platform can serve markets that would otherwise need several different machines.

The fibers other machines refuse

The Webber’s real signature is what it will run. Rigid and specialty technical fibers, glass, carbon, ceramic, and metallic fibers cause significant complications on equipment built for polyester. Thanks to Rando’s supporting fiber opening machinery, the Rando Webber can bring in low-melt fibers like polyester or polyethylene bicomponents, blends of dissimilar lengths and deniers, and recycled and regenerated waste. 

Since 1949, Rando has taken pride in its ability to produce machinery that serves multiple industries. The same machine that runs stainless steel fiber for abrasive pads runs recycled shoddy for sustainable insulation, and even fiberglass edge trim reclaimed from a Rando’s bonded panel recycling machinery. With one forming platform, an enormous range of fibers are possible.

From the lab to the production floor

Rando builds its Rando Webber from pilot width up to wide commercial lines available in multi-meter width formats. With a visit to our trial facility in Victor, New York, a customer can prove a process on Rando’s pilot line and then buy the production version of the very machine they tested. The webs it forms end up in automotive components, filtration media, geotextiles, medical disposables, insulation, and more.

Since 1949, the Rando Webber has been our centerpiece machine for the fibers our competitors struggle with.

Book a trial on our Pilot Line today to see the Rando Webber in Action

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Rando Machine has been designing and manufacturing nonwoven technology since 1949

Rando Machine: Over 75 Years of Nonwoven Innovation

As the cotton industry boomed across the American South, the industry had a problem it could not throw away. Its cotton mills and associated industries were producing waste fiber by the ton: short, tangled, uneven, and useless to the machinery of the day. In 1949, Rando was founded to solve exactly that. The idea was simple: take the fiber nobody wanted, and turn it into something with value.

To do it, Rando helped pioneer random air-laid nonwoven forming, a method of using custom technology to form fibrous webs. This was Rando’s solution to utilizing a sub-grade cotton fiber, a messy input with limited value. This origin story, dating back to 1949, has opened the lane the company has occupied ever since. Today, Rando’s capabilities far exceed just random airlaid technology. The company has since pioneered methods to handle the toughest fiber challenges. From fiber blending, opening, bonded panel recycling, and more, Rando has found a niche as both a global pioneer of nonwoven fiber manufacturing technologies, while also being the only company in the United States to manufacture nonwoven solutions to this day.

From a workshop idea to a machinery company

Following the invention of unique air-laid forming technology in the 50’s and 60’s from a small workshop, Rando has grown into a company with a global portfolio of installations. The following decades broadened Rando’s narrow expertise of waste cotton fiber into a company capable of producing full lines of machinery. In 1974, Rando was formally incorporated as Rando Machine Corporation in Macedon, NY. What began as a way to reclaim waste cotton grew into fiber preparation, web forming, and recycling equipment, sold to manufacturers who needed custom built solutions for their most difficult challenges.

The thesis of Rando has stayed true: Rando’s reputation was built on applications that were too demanding, too specialized, or too unusual for standard equipment. That is still where the company wins today in 2026.

Why the old advantage is still the advantage

Rando’s core forming technology uses pressure and vacuum together to lay the web of fibers. The result is an isotropic structure, meaning the fibers are oriented randomly and evenly in every direction, rather than pulled into a grain, as is seen with carding technology. This randomized uniformity resulting from this technology even resulted in the namesake of the business, Rando Machine. It shows up as measurable performance in insulation and filtration, and it is difficult for competitors to replicate. It is the reason Rando is recognized worldwide as the best choice for commercial floor scrubber pads, and for most applications that run on stainless steel fiber.

Stainless steel fiber is a good illustration of the whole philosophy of Rando Machines. It is stiff, heavy, and abrasive, the kind of material that defeats equipment built for polyester. Rando has won global contracts for stainless steel abrasive nonwoven pads, and today it is recognized as the global leader for abrasive nonwovens. The same is true for short and difficult to process fibers, like carbon and aramid. These challenging fibers are a natural fit for Rando Machines. Today, with global textile waste requiring innovative solutions to solve recycling challenges, recycled and regenerated shoddy fibers containing cotton, polyesters, lyocell, and more also find a natural fit in Rando’s nonwoven manufacturing portfolio. 

What Rando is today

Three quarters of a century in, Rando designs and builds fiber preparation, web forming, and recycling equipment in New York, with machines running on six continents. The company found its next evolution in 2019, when Andy Wilcox, the owner of EIS and Inline Cleaning Solutions, acquired Rando Machine. With EIS and Inline Cleaning Solutions already possessing industrial machining technologies in its manufacturing center in Indiana, Rando has found ways to leverage production cost savings by extending its footprint beyond its New York State manufacturing hub. In a globally competitive environment for nonwoven OEM technology, Rando today is able to produce price competitive machines produced entirely in the United States.

Following the acquisition of Rando by Wilcox, substantial investments were made into Rando’s trial line. Wilcox, working with Rando’s brilliant engineering mind Bill Hardy, understood the importance of customers needing to build confidence in the technology through laboratory testing. From its workshop in Victor, New York, new and existing customers can prove out a process before they buy it. This trial line is one of the few places in North America to trial staple-fiber airlay at production scale. Rando’s trial line has processed cotton, textile shoddy, difficult natural fibers like hemp, flax, jute, and more. With an engineering-first mindset, Rando understands the importance of continued service and after-sales parts. Rando has a team of parts and field service technicians, able to work globally with their customers to ensure downtime is minimized and that production output is maximized. 

Sustainability from day one

The nonwoven and textile industry talks about the importance of fiber recycling and utilization as if it were new. For Rando it is the founding purpose. The company was born reclaiming waste cotton, and it has been building recycling machinery ever since. Today that means fiberglass edge trim recovery, bonded panel reclamation, and the recycled and regenerated fibers that started it all. The sustainability story writes itself: it’s the how and why of Rando’s founding.

Seventy-five years is a long time to keep solving the same problem, but the technology and the solutions have not stayed the same. Rando Machines portfolio of technology today handles fibers that weren’t part of the conversation in 1949. While Rando’s competition focuses on cost reduction and winning the easy categories, Rando stays ahead by focusing on the demanding applications, the difficult fibers, and the jobs that call for a true engineering partner. Since 1949, that is what Rando has built.

Explore what Rando’s machinery can do with your fiber, or bring your material to the pilot line and see Rando’s capabilities for yourself.

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Fiber Recycling - RandoMachine

Fiber Recycling

Fiber Recycling: What It Is, How It Works & Why It Matters in 2026

Introduction

Fiber Recycling - RandoMachine

What Is Fiber Recycling?

Nonwoven fiber recycling is the process of taking waste or scrap materials and breaking them down into usable fiber that can be used to manufacture new products.  Fibers can be recovered during the manufacturing process (before or after bonding), as well as recycling used materials such as textiles.  Some examples include:

  • reusing edge-trim in the manufacturing process
  • Re-fiberizing skeletons or scrap bonded material to recover and reuse the fiber
  • Shredding and re-fiberizing textile waste
  • Blending recycled fibers into virgin material streams to manufacture new products
  • Using chemical processes to break down textile waste into component fibers which can then be used to manufacture new products
  • Using mechanical processes such as shredding and re-fiberizing to create fibers which can be blended with virgin fiber to create new products

Types of Fiber Recycling

Fiber recycling is commonly divided into two main categories based on how materials are processed.

1. Mechanical Fiber Recycling

  • Shredding tears materials into small pieces which can be re-fiberized in an opener or card machine
  • Opening or re-fiberizing pulls shredded materials apart using wired rolls so the output can be used to manufacture new products
  • Quality loss factors include fiber length and color consistency. Many fibers can be mechanically recycled with quality similar or even surpassing virgin fiber.  Mechanical recycling can shorten fiber length for certain fibers such as cotton, which necessitate blending a percentage of virgin fiber with recycled fibers to maintain strength

2. Chemical Fiber Recycling

Chemical fiber recycling uses chemical processes to break down fibrous materials into molecular building blocks, which can then be used to create new high quality fibers equal in quality to virgin fibers.  Chemical recycling can be more energy intensive than mechanical recycling, and can also create chemical waste streams from the chemical inputs.  However chemical recycling can be used to recycle difficult materials such as contaminated materials or blended materials which are difficult to mechanically recycle.

3. Closed-Loop vs. Open-Loop Fiber Recycling

Closed-loop recycling turns waste textile materials into new high quality products of the same type, such as making new clothing from old clothing, or taking scrap or waste products from the end of the manufacturing process and reclaiming the fiber for re-introduction into the manufacturing process.  Open-loop recycling turns waste textiles into lower value products (such as turning used clothing into automotive insulation or stuffing).

Closed Loop Recycling examples:

  • Sound Absorbing Panels: Acoustical Panels are collected, shredded, and refiberized, and then formed into a new web to make new acoustical panels for buildings.
  • Cotton Face Pads: Rayon or Bleached Cotton fibers are airlaid into a web and then processed into rolls. Face pads are die cut from this web, and the remainder (skeleton) is shredded, refiberized, and introduced back into the manufacturing process to make new face pads.
  • Insulation Panels: Natural or Fiber Glass fibers are airlaid into a web to make products for the construction industry. Edge trimmings and non-conforming produce is shredded, refiberized, and then reintroduced to the manufacturing process for new panels.

Open Loop Recycling examples:

  • Plastic Bottles made into fiber for use in athletic clothing
  • Paper shredded and converted into cardboard

How Fiber Recycling Works (Step-by-Step Process)

  1. Collection of fiber waste. Industrial fiber waste is collected at the manufacturing facility, either directly inline (such as edge-trim waste), or at the end of the manufacturing process (such as skeletons or scrap material).  Post-consumer waste fiber is more difficult to collect and normally relies on facilities dedicated to specific materials such as used carpet or clothing to prevent contamination.
  2. Cleaning and decontamination. Initial sorting focuses on removal of contaminants or non-fibrous materials such as buttons, buckles, zippers, etc. After decontamination the materials are packaged in bales.
  3. Mechanical or chemical recycling. Materials are broken down into useable fibers or monomers (in chemical recycling) for use in new products

Benefits of Fiber Recycling

Environmental Benefits

  • Reduces landfill waste
  • Lowers carbon emissions
  • Preserves forests, crop land, and other natural resources

Economic Benefits

  • Low-cost raw material source
  • New revenue streams for manufacturers selling waste to recyclers instead of paying to dispose in landfills

Industry Benefits

  • Helps businesses meet environmental goals
  • Meets consumer demand for sustainably-produced products

Fiber Recycling in Key Industries

Fiber Recycling in Textiles (Apparel, Fashion, Home Furnishings)

  • Outdoor furniture edge trims recycled back into main product.
  • Clothing made into synthetic shoddy or cotton shoddy for other products.

Fiber Recycling in Packaging & Paper Manufacturing

  • Sheet pulp converted into Fluff Pulp to make Diapers .
  • Sheet pulp used to make pigs for oil spills.

Fiber Recycling in Construction Materials

  • Wood fibers converted into short wood fibers to make mats for erosion control.
  • Fiber Glass and Natural fibers recycled reclaimed from edge trimmings or skeletons and reintroduced into the manufacturing process.

Fiber Recycling in Automotive & Aerospace

  • Soft edge trims from cotton shoddy insulation products shredded and reintroduced into the manufacturing process.
  • Carbon fiber edge trims put back into main product for structural and insulation aerospace products.

Challenges in Fiber Recycling

  • Mixed fiber blends
  • Contamination
  • Dye removal
  • Loss of fiber strength.

Best Fiber Recycling Machines & Technologies

Include:

  • Fiber shredders which process bonded or post-consumer materials into small pieces suitable for a re-fiberizing machine
  • Re-fiberizer machines which pull fibers apart so the fibers can be reused in manufacturing processes
  • Industrial cleaning machines which remove contaminants, short, or long fibers so the fibers can be reused in production processes
  • Defibering machines which separate fiber from non-fibrous components. These machines are most often used in natural fibers such as coconut or sugar cane.
  • Solvent-recycling systems which separates fibers from a composite material or textile blend
  • AI optical sorters which use physical properties such as color or shape to sort material for mechanical or chemical recycling

Fiber Recycling vs. Virgin Fiber Production

FeatureFiber RecyclingVirgin Fiber Production
CostLowerHigher
Environmental ImpactLowHigh
Resource UseMinimalHeavy water & energy use
SustainabilityHighLow

Future of Fiber Recycling

  • AI & robotics integration are making recycling economically feasible for post-consumer materials which must be sorted before recycling
  • Zero-waste circular manufacturing is the end goal of every manufacturer as it can reduce economic costs, supply risk, and environmental impact
  • High-quality regenerated fibers are becoming the norm as both mechanical and chemical recycling processes improve to the point where the recycled fibers are equal to or higher quality than virgin fibers

Conclusion

FAQs on Fiber Recycling

  • What types of fibers can be recycled?

    Many types of fiber can be recycled.  The most common include natural fibers such as cotton or wood, polyester, nylon, and fiberglass.  Other materials such as contaminated or blended materials are more difficult to recycle and require specialized processes.

  • Is fiber recycling cost-effective?

    It depends on the material.  Many fibers are highly cost-effect to recycle, while others depend on many factors such as purity or distance to a recycling facility.

  • Can mixed fibers be recycled?

    Some mixed fibers can be recycled, especially by chemical processes.  While most fibers can be recycled, some are not economically feasible.

  • What industries benefit most from fiber recycling?

    • The textile and apparel industry is the largest user of recycled fiber, which is driven by consumer demand for sustainably-produced materials. Many clothing items include recycled polyester (rPET) from recycled plastic bottles.
    • The automotive industry in increasing it’s use of recycled fibers in materials such as insulation and soundproofing, carpets, fabrics, and recycled carbon fibers replacing heavier metal components.
    • The construction industry uses recycled materials (and natural fibers) in materials such as insulation and geotextiles (used for erosion control)
    • Fiber-based packaging such as cardboard and molded pulp use high amounts of recycled fibers

  • What is the difference between mechanical and chemical fiber recycling?

    Mechanical recycling uses a process such as shredding or opening to mechanically separate fibers for reuse.  Chemical fiber recycling uses chemical processes to break down materials into their molecular building blocks to be re-made into high quality fibrous materials

  • How many times can fibers be recycled?

    Some fibers can be recycled indefinitely (especially chemically recycled materials), while others must be blended with virgin material or downcycled due to degradation that occurs during recycling

  • What products can be made from recycled fibers?

    Many products are made with recycled fibers including.  Some of the most common include:

    • Apparel
    • Home textiles such as carpet and bedding
    • Insulation
    • Geotextiles for soil erosion control
    • Automotive upholstery
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Airlay Machines

Airlay

What Is Airlay? A Complete Guide to the Nonwoven Process

The Random Airlaid Process is a dry-laid nonwoven technology that uses airflow to randomly deposit individual fibers into a uniform web structure. Unlike carded or spunbond nonwovens, The Airlaid process achieves true isotropic orientation, which enhances strength, durability, and dimensional stability.

Introduction to Airlay Technology

Airlay, also known as the dry-laid process, is a nonwoven textile manufacturing method where loose fibers are dispersed in an airstream and deposited onto a forming belt to create a web. Unlike wet-laid or spunbond processes, Airlay does not require water or extrusion, making it ideal for blending natural and recycled fibers. This unique Airlay technology supports sustainable textile solutions and offers high versatility across multiple applications.

The Airlaid process while running at a slower production speed makes a stronger bond with the fibers than a carding machine. Carded fiber pad has a tendency to delaminate or come apart in layers while a random Airlaid fiber pad holds a more consistent and stronger pad and can achieve a higher loft.

How Airlay Nonwovens Are Made

  1. Fiber Preparation

  • Fibers are selected based on the desired properties (e.g. pulp, viscose, cotton, polyester).
  • Commonly used: wood pulp, natural fibers, recycled fibers, and binder fibers (like bi-component fibers).

  1. Fiber Opening

  • Fibers are opened and separated into individual or small fiber clusters using deflakers or fiberizers.
  • The goal is to create a loose, fluffy mix of fibers.

  1. Fiber Air Suspension (Air laying)

  • The opened fibers are entrained in a high-speed airstream.
  • This air stream carries the fibers through a duct or chamber toward a forming screen or belt.
Airlay Machines

  1. Web Formation

  • The fibers are pulled out of the airstream onto a perforated conveyor belt or rotating drum using vacuum suction from below.
  • This forms a loose, randomly oriented web on the surface.
  • The thickness and density can be controlled by adjusting air speed, fiber feed, and vacuum pressure.

  1. Web Bonding

After the web is formed, it must be bonded to gain strength. There are several bonding methods:

a) Thermal Bonding

  • Uses bi-component fibers (e.g., fibers with a low-melting sheath) or thermoplastic binders.
  • Web is passed through heated rollers or an oven, melting the binders to bond fibers.

b) Latex Bonding (Chemical)

  • A liquid binder (latex) is sprayed or printed onto the web.
  • Followed by drying to cure and bond the structure.

c) Hydrogen Bonding (for pulp-based Airlaid)

  • Uses mechanical compression and moisture to form hydrogen bonds between cellulosic fibers.
  • Typically used in toilet paper or napkins.

d) Needle Punching or Hydroentanglement (less common in pure Airlaid, sometimes hybridized)

  1. Drying & Curing (if chemical bonding used)

  • A drying oven removes moisture and cures any chemical binders applied.

  1. Finishing

  • The bonded web may go through processes like calendaring, cutting, molded, embossing, perforating, or lamination.
  • Final products are rolled or sheeted for shipment.

Airlay excels in using reclaimed textile waste, cotton, wool, hemp, kenaf, Jote, and synthetic scraps, making it an eco-friendly fabric solution.

Machines Rando

Key Properties of Airlay Materials

Loft and bulk

Rando equipment supports lofts up to 10” and width up to 124”

Insulation capabilities

Effective for both thermal insulation and acoustic performance.

High recovery and resilience

The structure springs back after compression.

Applications of Airlay Nonwovens

Automotive interiors (acoustic insulation, trunk liners)

Used in trunk liners, acoustic dampening panels, and seat padding.

Home insulation materials

Wall and roof insulation panels with strong thermal performance.

Filtration media

Airlaid material makes excellent filter media.

Bedding and mattress padding

Comfortable and breathable layers in mattresses.

Benefits of the Airlay Process

Allows incorporation of high-recycled content

Airlaid equipment allows you to use not only recycled content but by adding a refiberizer you can run your own scrap back through the equipment after it has been bonded.  

Highly customizable GSM and thickness

You are able to get a more consistent product with tighter tolerances using an Airlaid machine instead of carding equipment.

Innovations in Airlay Technology

High Loft Condenser

Versatility: make webs from ½” to 10” with no changeover, and runs a wide variety of natural and synthetic fibers

Web quality: The High Loft Condenser makes an isotropic web in a single pass, eliminating cards and cross lappers

Vertical Pre Opener

This new machine is designed to allow fiber to be fed vertically and pre-opened with a feed roll, main cylinder and brush roll. Rando rolls are wired vs. the competitors pinned rolls. Wired rolls are more cost effective to manufacture and require less servicing by the customer. Robustly built, the Vertical Pre-Opener is manufactured in standard widths from 36” to 100”. The vertical design creates a smaller footprint than earlier designed pre-openers that fed horizontally, thus running cleaner with gravity and constant vacuum pressure.

Conclusion

Airlay represents a powerful and sustainable method for producing versatile, high-performance nonwovens. With its flexibility in fiber sourcing, bonding, and structure, it is rapidly expanding across automotive, construction, and eco-friendly packaging sectors.

Frequently Asked Questions

What is the Airlay process used for?
Airlay is used to manufacture insulation, acoustic padding, filtration media, and sustainable packaging.
What materials can be used in Airlay nonwovens?
Natural fibers, synthetic scraps, reclaimed textiles, and recycled blends including vinyl fiber, polyester, nylon, stainless steel, rayon, and carbon.
Are Airlay fabrics environmentally friendly?
Yes, especially when made with recycled or natural materials and dry-laid processing.
What’s the difference between carded and Airlay webs?
Carded webs are fiber-aligned using mechanical rollers, while Airlay uses air currents for deposition.
How does Airlay improve thermal insulation performance?
Its lofted, layered structure traps air and resists heat transfer effectively.
What industries benefit most from Airlay nonwovens?
Automotive, construction, bedding, filtration, and sustainable packaging.
Is Airlay suitable for acoustic insulation?
Absolutely. Its porous, dense structure absorbs sound and reduces vibration.
Can Airlay materials be made from 100% recycled fibers?
Yes, depending on bonding technique and fiber quality.
What is the GSM range typically supported in Airlay fabrics?
Airlay fabrics can range widely from 15 GSM to over 5,000 GSM+, depending on the application.

Rando Airlaid Technology: High-Performance Nonwoven Solutions for Filtration, Hygiene & Insulation

Rando Airlaid® technology is an advanced nonwoven manufacturing process that delivers high-loft, isotropic, and uniform fiber webs ideal for demanding applications such as air filtration, medical wipes, thermal insulation, automotive acoustics, and hygiene products. Developed by Rando Machine Corporation, this airlay method ensures superior fiber distribution, performance consistency, and design flexibility.

Rando Machine
100 Rawson Road, Suite 230
Victor, New York 14564 USA
646.817.4218
www.randomachine.com

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