At Main, we believe in an open innovation model that involves the entire value chain: from raw material suppliers to customers, all the way to end applications.
This approach has guided us on a sustainability journey that began in 2008, with the goal of developing increasingly efficient air-laid nonwoven materials with a lower environmental impact.
From material research to compostable solutions
Among the early developments, we introduced air-laid materials made with short bicomponent fibers based on PLA (polylactic acid), a plant-based polymer derived from renewable sources such as corn, sugarcane, and sugar beet.
In the initial stages, these fibers featured a high denier, which limited some of their performance. Over time, thanks to technological advancements by suppliers, it became possible to improve their characteristics through a significant reduction in denier, thereby enhancing resilience and overall performance.
At the same time, we expanded our research toward sustainable alternatives for all the main components of the materials:
- fibers
- binders
- superabsorbent materials
- additives such as surfactants
with the goal of progressively reducing dependence on fossil-based raw materials.
Main Bio Web platform
From this journey, Main Bio Web was born—a platform of compostable air-laid nonwoven materials designed for absorbent applications.
The platform includes solutions for:
- acquisition and distribution layers (ADL)
- absorbent layers without superabsorbent materials
- absorbent layers with naturally derived superabsorbent components
- integrated solutions that combine multiple functions into a single material
The goal is to offer sustainable and technically reliable alternatives for a wide range of applications.
Technical innovation in air-laid materials
Air-laid nonwoven structures enable a uniform fiber distribution and high porosity—key factors that enhance fluid management and material stability.
The use of CoPLA/PLA bicomponent fibers allows to:
- ensure cohesion through thermal bonding
- maintain structural integrity even under stress
- control capillarity and absorption rate
The integration of biodegradable binders also makes it possible to meet specific market requirements and recognized environmental standards.
Performance control
Material performance is controlled through precise design parameters, including:
- basis weight
- ratio between cellulose fibers and CoPLA/PLA fibers
- content of superabsorbent materials
- binder concentration
These elements make it possible to optimize:
- absorption capacity
- fluid distribution
- penetration rate
- reduction of liquid rewet under load
An integrated design approach
Material development is approached as a system.
Unlike traditional products, where each layer performs a separate function, the approach adopted in air-laid nonwoven materials enables the integration of multiple functions within a single engineered substrate.
This leads to:
- reduced structural complexity
- thinner and lighter materials
- greater design flexibility
- faster development times
Absorbency, distribution, softness, and integrity are designed in a coordinated way, as interdependent properties.
Towards a new generation of materials
The evolution of air-laid nonwoven materials is increasingly tied to the ability to combine technical performance and sustainability.
Work on processes, materials, and product architecture represents a key step in meeting the needs of a rapidly evolving industry.
