By IND HEMP | Technical Fiber Insights Series | IDEA® 2025 Preview

As industries demand higher-performing and more sustainable materials, the nonwovens sector is turning to innovative processes that unlock the potential of natural fibers. Airlay thermobonding is one such process—offering a cleaner, greener, and more flexible method to create high-loft nonwovens from inputs like industrial hemp. 

This advanced manufacturing technique is making waves in insulation, automotive interiors, and packaging. At IND HEMP, we’re helping lead the way by supplying high-quality hemp fiber for these next-gen applications. Let’s dive into what airlay thermobonding is, how it works, and why it’s changing the game—especially when paired with hemp. 

What Is Airlay Thermobonding? 

Airlay thermobonding is a two-part process: 

1. Airlay Web Formation: Instead of carding fibers, an airlay machine uses airflow to randomly deposit fiber tufts onto a conveyor. The result is a fluffy, uniform batt with high loft and isotropic (multi-directional) strength—ideal for applications requiring insulation, cushioning, or sound dampening. 

2. Thermal Bonding: A small percentage of binder fiber (like PLA or PET) is added. The batt passes through a thermal oven where this binder melts and fuses the structure without compressing it, preserving thickness and breathability. 

This process excels at handling irregular or coarse natural fibers, making it perfectly suited for hemp. It also avoids chemical adhesives, enabling clean, VOC-free production—an asset for indoor air quality and sustainability certifications. 

Why Hemp + Airlay? 

At IND HEMP, we’ve found that hemp and airlay thermobonding are a natural match. Here’s why: 

• Gentle on Coarse Fibers: Hemp’s long bast fibers are stiff and challenging for traditional carding, but airlay machines handle them with ease. Our decorticated fiber flows cleanly through airlay systems with minimal breakage. 

• Superior Insulation & Acoustic Control: Hemp fiber naturally holds air and resists heat transfer. Combined with airlay’s high-loft structure, the result is a batt with excellent R-value (~3.7/inch) and sound-dampening properties. 

• Clean and Safe: Unlike fiberglass or chemically bonded mats, airlaid hemp insulation doesn’t itch, off-gas, or require gloves to install. Using bio-based binder fibers makes the product safer and 100% non-toxic. 

• Carbon-Negative Material: Hemp absorbs significant CO₂ during growth, and airlay processes preserve that benefit by minimizing energy use, water, and waste. The final product sequesters more carbon than it emits—a powerful ESG value-add. 

Real-World Impact: Hempitecture & HempWool® 

A leading case study of this technology is our partnership with Hempitecture, a sustainable building materials innovator. Their flagship product, HempWool®, is a batt insulation made of 90% hemp fiber supplied by IND HEMP. It’s produced using a custom airlay thermobonding line installed at their Idaho facility. 

This product: 

• Achieves high thermal and acoustic performance 

• Is safe to handle with no VOCs or formaldehyde 

• Was recognized with the 2024 RISE Innovation Award by INDA 

Together, IND HEMP and Hempitecture have built a scalable, traceable supply chain—connecting U.S. farmers to sustainable construction projects across the country. It’s a model of how natural fiber and modern manufacturing can merge to create solutions that are both high-performance and environmentally sound. 

Use Cases: Expanding Industry Applications 

🛠 Construction: From wall insulation to acoustic ceiling panels, airlaid hemp batts meet or exceed performance standards—while promoting healthier, greener buildings. 

🚗 Automotive: Hemp-based felts are molded into headliners, door panels, and trunk liners. Airlay enables lightweight, impact-resistant mats that reduce noise and lower vehicle weight. 

📦 Sustainable Packaging: Thick hemp batts replace foam or plastic in protective packaging, offering shock absorption and thermal insulation—especially useful in cold-chain logistics. 

🌬 Filtration: Lofted hemp nonwovens act as coarse filters or absorbent pads, with future potential in hybrid HVAC and oil spill filtration solutions. 

From upholstery to erosion control, the versatility of airlaid hemp is expanding rapidly—and we’re excited to help partners develop customized solutions for each use case. 

IND HEMP at IDEA® 2025: Let’s Build the Future Together 

As we gear up for IDEA® 2025, IND HEMP is showcasing our leadership in supplying industrial-scale, high-quality hemp fiber for natural nonwovens. We’re not just a supplier—we’re a strategic partner, helping OEMs optimize formulations, ensure fiber consistency, and co-create next-gen sustainable products. 

What sets us apart: 

• Controlled farm-to-fiber supply chain 

• Custom fiber prep for airlay, carding, or needle punch 

• Proven partnerships (like Hempitecture) 

• Support for carbon accounting and ESG goals 

We invite manufacturers, brands, and R&D teams to visit us at IDEA® 2025 and explore how hemp fiber can power your next innovation in nonwovens. 

Ready to innovate with hemp? 📩 Contact us at www.indhemp.com to request technical specs, fiber samples, or schedule a discovery call. 

IG: @indhemp 

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