From Wet-Laid to Air-Laid: A Step Change in Filtration Performance and Scalability

A leading HVAC filtration manufacturer significantly improved dust-holding capacity, pressure-drop stability, and production efficiency after upgrading from traditional wet-laid paper media to advanced Air-laid Filter Media in its high-efficiency air filter products. Air-laid technology forms nonwoven webs by dispersing fibers in air rather than water, enabling precise control over fiber orientation, basis weight, porosity, and layer structure. This results in highly uniform media with excellent permeability, consistent filtration efficiency, and strong mechanical integrity.

Compared with wet-laid cellulose papers, air-laid filter media offer higher bulk, improved depth-loading performance, lower initial pressure drop, and greater design flexibility. The ability to integrate synthetic fibers, meltblown layers, and functional additives makes air-laid media particularly well suited for HVAC, industrial dust collection, cabin air filtration, and high-performance consumer air-cleaning applications.

The above case highlights how Air-laid Filter Media enable next-generation filtration performance and manufacturing scalability. QY Research has recently published a comprehensive market study on this important filtration materials segment. Key findings are summarized below.

https://www.qyresearch.com/reports/5536416/air-laid-filter-media

Core Market Data

Global market size: USD 2.1 billion
CAGR (2024-2030): 5.3%
Average price: USD 8400 per ton
Annual production: 250 kilotons
Gross margin: 27%
Production capacity: 340 kilotons

List of Main Players

Freudenberg (Germany)
Hollingsworth & Vose (USA)
Glatfelter (USA)
Magnera (USA)
SharpCell (Finland)
McAirlaid's (Germany)
Domtar (USA)
Asahi Kasei (Japan)
Suominen (Finland)
Fitesa (Brazil)
Avgol Industries (Israel)
Pegas Nonwovens (Czech)
Jacob Holm (Switzerland)
Favourite Fab (India)
Kino Cloth (Japan)
Tech Absorbents (UK)
Gessner Filtration (Germany)
Berry Global (USA)
Ahlstrom-Munksjö (Finland)
Johns Manville (USA)

1. By Fiber Grade

High-permeability Grade
Medium-permeability Grade
Low-permeability Grade

2. By Filtration Structure

Ultralight (25-60 gsm)
Standard (60-120 gsm)
Heavy-duty (120-200 gsm)

3. By Application

HVAC System
Automotive
Industrial
Healthcare
Electronic
Food & Beverage

Case Study for Bidding

Time: March 2024
Supplier: Ahlstrom
Buyer: Global HVAC Filter Manufacturer (USA)
Product: Multi-Layer Air-laid Filter Media (Low ΔP, High Dust-Holding Capacity)
Quantity: 6,800 tons
Contract Value: USD 72 million
Delivery Timeline: January 2025

Detailed Application Scenario

The HVAC filter manufacturer integrated Ahlstrom's multi-layer air-laid filter media into residential and commercial air-filter products. The high-loft structure and controlled pore distribution allowed particulate matter to be captured throughout the media depth rather than only on the surface, significantly increasing dust-holding capacity while maintaining a low pressure drop. This translated into longer filter service life and improved energy efficiency in HVAC systems.

The air-laid media also demonstrated excellent pleatability and mechanical strength, enabling high-speed automated filter assembly with minimal breakage. Optional functional layers-such as activated carbon and antimicrobial additives-were incorporated to address odors and microbial growth. The project illustrated how air-laid filter media deliver performance consistency, manufacturing flexibility, and enhanced lifecycle value across modern air-filtration applications.

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This release was published on openPR.