Airlaid and nonwoven products with VAE

Vinyl Acetate Ethylene (VAE) copolymer emulsions are widely considered the gold standard for binding airlaid and nonwoven products. Whether it is for wet wipes, feminine hygiene products, medical drapes, or absorbent pads, VAE offers a unique combination of chemical and physical properties that other binders (like pure acrylics or older styrene-butadiene rubbers) struggle to match.

1. Inherent Softness and Flexibility

In personal care and hygiene products, the “hand feel” (how soft the material feels against the skin) is critical. The ethylene segment in the VAE polymer chain acts as an internal plasticizer. This means the binder is naturally soft and flexible without needing added, external chemical plasticizers. Because there are no external plasticizers, there is nothing that can migrate out of the product over time or irritate the skin.

2. Exceptional Health and Safety Profile

Because airlaid and nonwoven products are frequently in direct contact with human skin or sensitive areas, safety is paramount.

• VAE emulsions are water-based and typically have ultra-low Volatile Organic Compounds (VOCs).
• They are manufactured without formaldehyde and do not release formaldehyde during processing or use (unlike older binder technologies).
• They are generally odorless and highly skin-compatible, meeting strict regulatory standards for food contact and personal hygiene.

3. High Wet Strength and “Flushability”

Many nonwovens, particularly wet wipes, need to maintain their structural integrity while soaked in liquid (high wet strength). VAE binders provide excellent wet tensile strength. However, VAE can also be specifically formulated for “dispersibility.” This means the binder holds the wipe together while in the packaging, but quickly breaks down when subjected to the agitation and large water volumes of a toilet and sewer system, making it the go-to binder for flushable wipes.

4. Strong Adhesion to Mixed Fibers

Airlaid processes often mix different types of fibers to achieve the right bulk and absorbency—typically natural cellulose (fluff pulp) mixed with synthetic fibers like polyester (PET) or polypropylene (PP). VAE is highly polar, meaning it acts as an excellent bridge, adhering strongly to both hydrophilic (water-loving) natural fibers and hydrophobic (water-repelling) synthetic fibers.

5. Manufacturing Efficiency

From a production standpoint, VAE is very machine-friendly. It runs cleanly on high-speed airlaid and nonwoven production lines with minimal foaming or buildup on the equipment. It cures rapidly at relatively low temperatures, which saves energy and allows for faster production speeds compared to binders that require intense heat to cross-link.