How Are Air-Laid Napkins Made?A person in a white dress shirt and black vest is folding white napkins

How Are Air-Laid Napkins Made?

Air-laid napkins are a type of high-quality disposable napkin that are known for their softness, absorbency, and cloth-like texture. They feel like heavy linen. Air-laid napkins are ideal for catered parties and weddings. They are perfect for restaurants that want the convenience of a disposable paper napkin but want the look and feel of cloth ones. Because air-laid napkins are disposable, there is no need to wash them at the end of the night. Like regular paper napkins, they can be composted in many regions.


Like traditional paper napkins, some air-laid napkins are made from wood pulp. They are produced using a different manufacturing process.

We provide a bit of insight below as to how air-laid napkins are made.

Fiber Preparation: The process starts with the preparation of fibers. Various types of fibers, such as cellulose, synthetic fibers, or a blend of both, are selected based on the desired characteristics of the final napkin. Ours are made from wood pulp (cellulose).

Fiber Opening: The selected fibers are opened and blended together using mechanical processes. This step ensures that the fibers are evenly dispersed and prepared for the next stage.

Air-Laying: In the air-laying process, the opened fibers are transported through a series of pipes. High-pressure air carries the fibers and deposits them onto a moving belt or web. The airflow creates a uniform distribution of fibers, forming a loosely structured sheet.

Bonding: To give the napkin strength and integrity, the loosely laid fibers need to be bonded together. Various bonding methods can be used, including thermal bonding or the application of adhesives. Thermal bonding involves passing the air-laid sheet through heated rollers, which melt and bond the fibers together. Adhesives can be applied to the fibers in a specific pattern or sprayed onto the sheet to bond the fibers.

Drying and Finishing: Once the bonding process is complete, the air-laid sheet goes through a drying process to remove any moisture. This can involve passing the sheet through heated drying ovens or using other methods to evaporate the moisture. After drying, the sheet is calendered to improve its smoothness and texture. (Calendering is a process that makes the material look less fibrous and spongy.)

Cutting and Folding: The dried and finished sheet is then cut into individual napkin-sized pieces. It can be cut into different shapes, such as square or rectangular. If desired, the napkins can undergo additional processing steps for embossing or printing designs. They can be pre-folded into sixths or eighths or left unfolded. Unfolded napkins are a great option for creating napkin origami.

Packaging: The final step involves packaging the air-laid napkins in appropriate quantities for distribution and sale. They are packaged in a way that maintains their cleanliness, hygiene, and presentation until they are ready to be used. Our air laid napkins are wrapped in a plastic covering, and then boxed.

The air-laid process allows for greater flexibility in terms of fiber selection and provides the napkins with superior softness and absorbency compared to traditional paper napkins. This makes them a popular choice for premium table settings and special occasions.