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From field to sustainable products Integrated bast fiber and airlay processes for advanced applications

In a world increasingly focused on sustainability, natural fibers are stepping into the spotlight. Bast fibers such as hemp, jute, and flax are no longer niche, they are becoming essential in automotive, construction, and technical nonwoven applications

Their appeal lies in sustainability, but their variability in length, cleanliness, and moisture content demands advanced processing solutions. ANDRITZ has combined decades of expertise with innovative bast fiber processes and airlay technology to deliver a complete, integrated approach for natural nonwovens and technical textiles – all under one roof.

The bast fiber process – from straw to high-performance fibers

ANDRITZ bast fiber processes enable a sustainable journey from agricultural straw to high-performance fibers. Processing begins with dry cleaning, decortication, and refining, removing hard foreign objects to reduce fire risk and extend equipment life. Compared to conventional lines, this approach optimizes yield and quality while handling retted or unretted hemp, flax, jute, and other bast straws in rectangular or round bales. Capacities typically range from 1 ton/hour to 10 tons/hour, with straw humidity maintained at 12–16% for process stability.

For technical textiles, cottonizing shortens and softens fibers, making them suitable for spinning and technical applications. This integrated process minimizes waste and supports eco-friendly production by bridging agriculture and advanced technology.

The airlay technology – From high performance fibers to technical nonwovens

ANDRITZ airlay technology allows manufacturers to process a wide range of fibers, from virgin, recycled fibers to non-fiber particles such as foam, shredder paper, and straw. It ensures uniform fiber distribution and excellent product consistency. The airlay fiber mat can be bonded by needling, thermobonding and/or hydroentanglement depending on customer needs. This makes it ideal for a wide range of applications.

When it comes to bast fibers, the airlay technology offers significant advantages. The process handles natural fibers gently, preserving their inherent strength and sustainability benefits. When combined with thermobonding or resin impregnation, the process enables lightweight composites and high-performance acoustic & thermal insulation. Its versatility perfectly complements the ANDRITZ bast fiber process, unlocking sustainable solutions for automotive, construction, and technical applications. Thus, manufacturers achieve superior material properties while embracing natural fibers for a greener future.

Industry proven and trusted solution

Global leaders in nonwoven and technical textile production, such as Ekolution, prove these performances. Ekolution has successfully integrated ANDRITZ technologies into their operations to manufacture sustainable, high-performance building materials. Their achievements highlight the powerful synergy between bast fibers and airlay technology, a combination that meets both technical and environmental demands.

In addition, ANDRITZ's technologies are gaining the confidence of prominent players in the geotextile sector, substituting Geosynthetics with 100% bast fibers based raw materials. Notably, two European manufacturers have chosen to implement ANDRITZ solutions processing hemp from the field to Geotextiles roll goods in their operations, with production set to commence next year. It highlights ANDRITZ reputation for reliability and innovation in sustainable nonwoven and technical textile production.

Alexandre Butte, Vice President Engineered Textiles at ANDRITZ, states: “Natural fibers are an essential part of the future of nonwovens. The ANDRITZ one-stop-shop approach for bast fibers and airlay technology is a vertically integrated solution designed to deliver complete, sustainable production lines from raw material to finished nonwoven products. ANDRITZ brings longstanding expertise and innovation to every step of the process.”

Conclusion: Nature and technology in perfect alignment

As industries accelerate toward greener solutions, bast fibers offer a compelling alternative to synthetics – provided they are processed with precision and in a streamlined value chain, offering competitive bio-based end products. ANDRITZ’s integrated approach, from fiber preparation to airlay process, ensures that sustainability, competitiveness and performance can go hand in hand.