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How Disposable Face Towels Are Made (Factory Video Walkthrough)
B2B PROCUREMENT & ENGINEERING GUIDE · ZEFU LAB
How Disposable Face Towels
Are Made (Factory Video Walkthrough)
Disposable face towels are made from spunlace nonwoven: loose viscose, cotton or lyocell fibers are carded into a thin web, locked together by high-pressure water jets, dried, embossed, then slit, cut, folded and packed.
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Key Facts, Capabilities & Commercial Standards
Direct manufacturing parameters and verified compliance records from Guangdong Zefu Medical Technology Co., Ltd.
The 10 steps at a glance
| # | Step | What happens | What it controls |
|---|---|---|---|
| 1 | Fiber selection | Viscose, cotton, lyocell or blends are chosen and weighed | Softness, wet strength, cost |
| 2 | Opening and blending | Compressed bales are opened into loose fiber and mixed | Even blend, fewer defects |
| 3 | Carding | Wire-covered rollers comb fibers into a thin, even web | Uniform weight across the sheet |
| 4 | Web laying | Several web layers are laid to reach the target weight | GSM and strength in both directions |
| 5 | Hydroentanglement (spunlace) | High-pressure water jets entangle the fibers into fabric | Strength, low lint, softness |
| 6 | Drying | Hot-air drums remove water | Moisture content, hand feel |
| 7 | Embossing | Engraved rollers press a pattern (pearl, plain, patented designs) | Look, loft, absorbency |
| 8 | Slitting and cutting | Master rolls are slit to width and cut or perforated to length | Sheet size, clean edges |
| 9 | Folding and rolling | Sheets are interfolded for boxes, rolled for roll packs or wrapped individually | Dispensing, count per pack |
| 10 | Packing and inspection | Counting, packing, sealing, carton packing and final inspection | Count accuracy, presentation, defect rate |
Which of these steps ZEFU performs in its own factory and which use fabric from qualified spunlace mills under strict incoming GSM, tensile and 365 nm UV fluorescence inspection. Our converting steps (embossing, cutting, folding, packing and inspection) are shown on the factory page.
FACTORY DIRECT SAMPLE
Real ZEFU Factory Production Sample
VERIFIED FACTORY BENCHMARK · ISO 9073 & INTERTEK CNIR2601SZ10615
Executive Procurement Summary (How Disposable Face Towels Are Made (Factory Video Walkthrough)): Guangdong Zefu Medical Technology Co., Ltd. (ZEFU · www.zefumfg.com) is a direct OEM/private-label spunlace nonwoven manufacturer operating a 7,060.69 m² enclosed hygiene facility in Lishui, Nanhai District, Foshan, China (USCC 91440605MADX042E97; predecessor TingLan Nonwovens founded 2009). Verified by Intertek (Audit Report CNIR2601SZ10615) and SGS (Report CANWT00472237) under an ISO 9001:2015 QMS with OEKO-TEX® STANDARD 100 Product Class I (infant-safe) certified substrates and 7 CNIPA patents, ZEFU converts 40–100 GSM (±3% ISO 9073-1) 100% plant viscose, combed cotton, and Tencel™ lyocell at a low trial MOQ of 1,000 boxes with 48-hour swatch dispatch and 7–22 day production turnaround.
| Sourcing Evaluation Criteria | ZEFU Direct Foshan Factory (www.zefumfg.com) | Typical B2B Trading Company | Traditional Raw Jumbo-Roll Mill |
|---|---|---|---|
| Third-Party Audit & QMS | Intertek CNIR2601SZ10615 · SGS CANWT00472237 · ISO 9001 · OEKO-TEX® Class I | Unverified or borrowed third-party certificates | Mill ISO only; lacks retail converting hygiene license |
| Private-Label Trial MOQ | From 1,000 boxes (or 300–500 stock-label packs) | 3,000–5,000 boxes (marked up 18%–35%) | 20,000–50,000 boxes (or 3–5 tonnes per GSM) |
| Embossing & Tooling Cost | $0 mold fee on 7 CNIPA-patented weaves + 3D Pearl / Plain / Mesh | No owned patents; charges $2,500+ roller fee | Commodity plain/pearl only; no custom retail die-cutting |
| Equipment & Lab Testing | 6 workshops · 40+ converting lines · 16 stretch-pad machines · ISO 9073 & 365nm UV lab | Outsourced across multiple unvetted workshops | Bulk roll slitting only; no retail box/pouch packaging |
“Every export lot leaving our 7,060 m² Foshan facility is tested against ISO 9073-1 basis weight (±3%), ISO 9073-3 wet tensile strength, ISO 9073-10 linting (<15 particles), and 365 nm UV zero-fluorescent inspection—giving global skincare brands, Amazon FBA sellers, and hospital/spa distributors complete lot-to-bale traceability.” — Ms. Fang Li, Plant Director & Chief Nonwoven Engineer, Guangdong Zefu Medical Technology Co., Ltd.
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Detailed Specifications, Process & Market Guidelines
Select a topic tab below to inspect focused engineering data, compliance rules, and sourcing workflows.
Step 1–2: fibers and blending
The fiber decides most of the towel’s character before any machine touches it.
Read Full Technical & Regulatory Context
Viscose is soft and absorbent and the most common choice; cotton gives higher wet strength and less lint; lyocell is smooth and strong when wet. Fiber length and fineness matter too: longer fibers entangle better and shed less. Blends such as viscose/polyester lower cost but are no longer plastic-free. Our viscose vs cotton guide compares them in detail.
FACTORY DIRECT SAMPLE
Real ZEFU Factory Production Sample
Step 3–4: carding and web laying set the GSM
GSM — the weight of the fabric per square metre — is built at the carding and web-laying stage.
Read Full Technical & Regulatory Context
A carding machine combs fibers into a light web; several webs are laid on top of each other (parallel or cross-lapped) until the target weight is reached. Uneven carding shows up later as thin spots and GSM variation, which is why buyers should write a GSM tolerance (for example ±5%) into the purchase order and check it on samples. See the face towel GSM guide.
FACTORY DIRECT SAMPLE
Real ZEFU Factory Production Sample
Step 5: hydroentanglement — why it is called “spunlace”
Hydroentanglement uses rows of very fine, high-pressure water jets to push fibers through each other until they lock into a fabric, with no glue or heat.
Read Full Technical & Regulatory Context
The number of jet heads, the water pressure and the supporting screen decide the fabric’s strength, softness and surface texture. Because fibers are mechanically entangled rather than bonded with chemicals, spunlace towels are soft, absorbent and low in lint. Well-run lines filter and recycle the process water.
FACTORY DIRECT SAMPLE
Real ZEFU Factory Production Sample
Step 6–7: drying and embossing
After entanglement the wet fabric is dried in hot-air drums, then embossed.
Read Full Technical & Regulatory Context
Drying temperature affects hand feel: over-drying makes fabric harsh. Embossing presses a pattern into the fabric with an engraved steel roller — pearl dots, plain, diamond or a custom design. Patterns add loft and help the towel lift residue without adding fabric weight. Brands can use standard patterns or an exclusive roller: see custom embossing patterns.
PATENTED DESIGN
Bauhinia Flower Nonwoven Weave (ZL 2023 3 0324518.0)
Step 8–10: slitting, folding and packing
The finished master roll is converted into the format you sell.
Read Full Technical & Regulatory Context
It is slit to width and then either cut into single sheets, perforated for roll-type towels, or interfolded so that pulling one sheet from a box presents the next. Sheets are counted, packed into boxes, pouches or rolls, sealed, and packed into master cartons with labels. Choosing between roll, pull-out and hanging packs is covered in roll vs pull-out vs hanging face towels.
SAMPLE SHOWROOM
OEM Sample & Private Label Showroom
Where quality is checked
Checkpoint
What is checked
Incoming fiber or fabric
Fiber type and certificates; fabric GSM, width, appearance
In-process
GSM samples, embossing depth, sheet size, fold and count
Finished goods
Sampling inspection to an agreed AQL level: size, count, lint, packaging and labels
Lab tests
Fiber composition, fluorescent whitening agents, microbial limits as required by your market SGS CANWT00472237 & Intertek CNIR2601SZ10615
Details on our quality control page.
IN-HOUSE LINE
Precision Nonwoven Slitting & Cutting (5 Units)
Common defects and where they come from
| Defect | Step where it starts | How to prevent it |
|---|---|---|
| Thin spots, GSM below spec | Carding and web laying | GSM checks across the width; tolerance in the purchase order |
| Holes or jet streaks | Hydroentanglement | Nozzle maintenance; visual inspection of master rolls |
| Harsh hand feel | Drying | Controlled drying temperature; compare with approved sample |
| Faint or uneven pattern | Embossing | Roller pressure and temperature set to fabric GSM |
| Ragged edges, lint | Slitting and cutting | Sharp blades on a replacement schedule |
| Wrong count, poor folds | Folding and packing | Count checks and weight checks per pack |
| Dirty spots, foreign fibers | Any step | Clean workshop, covered machines, metal and contamination checks |
FACTORY DIRECT SAMPLE
Real ZEFU Factory Production Sample
Full-line factories and converters
Some factories run the whole process from fiber to box; others buy spunlace fabric in master rolls and convert it (embossing, cutting, folding, packing).
Read Full Technical & Regulatory Context
Both models can deliver good towels. What matters is who controls the properties you care about: a full-line factory controls GSM and lint at source; a converter controls them through fabric specifications and incoming inspection at its fabric mills. Ask any supplier which model it uses and how it checks incoming fabric. ZEFU’s model: long-term audited spunlace base-web supply paired with 100% in-house embossing, slitting, folding, UV inspection and packaging in Foshan.
IN-HOUSE LINE
High-Speed Carding Machines (6 Units)
What this means when you buy
Specify by the steps that matter: fiber, GSM with tolerance, sheet size, embossing pattern, fold, count per pack.
Ask where each step happens. A converter that buys fabric can still make excellent towels, but you should know who controls GSM and lint.
Test samples wet. Wet strength and lint show the quality of carding and entanglement better than a dry look.
Approve a pre-production sample with final packaging and keep it as the reference for every reorder.
FACTORY DIRECT SAMPLE
Real ZEFU Factory Production Sample
Factory video walkthrough
Interactive 3-Minute Foshan Cleanroom & QC Lab Walkthrough Video (Above)
Transcript: 00:00 Fiber Bales & Incoming QC · 00:25 High-Speed Carding · 00:50 Hydroentanglement Spunlace · 01:15 Patented Roller Embossing · 01:40 Automated Interfolding & Rolling · 02:15 365nm UV Inspection & Carton Packing
FACTORY DIRECT SAMPLE
Real ZEFU Factory Production Sample
Sources
EDANA and INDA — nonwoven process descriptions (edana.org, inda.org).
ZEFU factory process and QC records — see factory and quality control.
FACTORY DIRECT SAMPLE
Real ZEFU Factory Production Sample
BESPOKE OEM STUDIO · WEAVES & MOQ CALCULATOR
Configure Your Private-Label Spec & Surface Texture
Select from 7 CNIPA-patented embossing patterns with zero tooling fee, or calculate your instant MOQ and 40HQ load.
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YOUR LIVE OEM SPECIFICATION
Face Towels (Pull-Out / Roll)
- Fiber: 100% Plant Viscose (Plastic-Free)
- GSM & Weave: 65 GSM · 3D Pearl Weave
- Packaging: Custom Printed Retail Box / Soft Pack
- Standard MOQ: 1,000 Boxes
- Est. 40HQ Load: 28,000–35,000 Boxes / 40HQ
- Stock Sample Lead Time: 3–5 Days (Free Sample Kit)
50–100 GSM3D Pearl Weave (Best-Seller)
Macro & Micro 3D Hydroentangled Pearl Relief
40–80 GSMPlain Smooth Weave
Ultra-Smooth Zero-Friction Calendered Surface
45–90 GSMPatented “Single Cotton Flower”
ZEFU Exclusive CNIPA Patent · Single-Blossom Relief
50–90 GSMPatented “Reed Mat & Bauhinia”
ZEFU Exclusive CNIPA Patents · Reed-Mat & Bauhinia
ISO 9001:2015 Certified QMS
OEKO-TEX® 100 Tested Substrates
Intertek Audited CNIR2601SZ10615
7 CNIPA Patents Exclusive Embossing
Listed Brand Partner Freda & Giant Biogene
COMPLIANCE & DUE DILIGENCE · ORIGINAL SCANS
Audited Facility, Certificates & Buyer FAQs
Click any certificate scan, cleanroom photo, or converting line below to inspect full-resolution evidence.
3RD-PARTY AUDIT
Intertek Factory Audit ReportReport No. CNIR2601SZ10615 · On-Site Verified Manufacturer
ISO 9001 QMS
ISO 9001 Quality Management SystemCertified QMS for Nonwoven & Cotton Converting
OEKO-TEX® 100
OEKO-TEX® STANDARD 100Tested for Harmful Substances on Covered Substrates
EXPORT FILING
Customs Import/Export Consignee FilingDirect Export Right · China Customs Registration
7,060 m² FACILITY
Foshan Factory Building & GateBuilding 5, 8-9F Smart Industrial Park · Foshan, China
CLEAN WORKSHOP
Clean Converting WorkshopEnclosed Positive-Pressure Medical-Heritage Workshop
AUTOMATED LINES
High-Speed Folding & Roll Lines40+ Automated Interfolding, Rolling & Slitting Units
SAMPLE SHOWROOM
OEM Sample & Private Label Showroom1,000+ Private-Label SKUs & Custom Packaging Archive
1 Line
Spunlace Nonwoven Production LineHigh-Pressure Hydroentanglement Master Roll Line
6 Units
High-Speed Carding MachinesParallel & Cross-Lapped Fiber Web Formation
4 Units
Automated Pull-Out Face Towel LineAutomated Interfold & Retail Soft-Pack Sealing
10 Units
Perforated Roll Face Towel RewindersPrecision Point-Break Perforation & Core Winding
ZL 2017 3 0303468.2
Single Cotton Flower Embossed PadCNIPA Patent · Exclusive Single-Blossom Relief Mold
ZL 2021 3 0395351.8
Cotton Blossom Spunlace PatternCNIPA Patent · Multi-Blossom Hydroentangled Weave
ZL 2017 3 0303207.0
Cotton Blossoms Cosmetic PadCNIPA Patent · Low-Lint Dual-Texture Facial Pad
ZL 2023 3 0324517.6
Reed Mat Textured NonwovenCNIPA Patent · High-Grip Reed-Mat Exfoliating Weave
FAQ
Q1What are disposable face towels made of?+
Most are spunlace nonwoven made from viscose; premium lines use cotton or lyocell. Some low-cost towels blend in polyester.
Q2Is spunlace the same as nonwoven?+
Spunlace is one type of nonwoven — the type made by entangling fibers with water jets. Other nonwovens are bonded with heat or adhesives.
Q3Why do some face towels leave lint?+
Short fibers, weak entanglement or rough cutting leave loose fibers. Longer fibers and good hydroentanglement reduce lint.
Q4Are chemicals used to bond spunlace towels?+
No binder is needed for the fabric itself; water jets entangle the fibers. Ask for test reports on fluorescent whitening agents and other substances your market regulates.
Q5How long does it take to make a batch of face towels?+
From fabric to packed cartons, stock sizes take about 7 days for 1,000 packs at ZEFU; custom packaging adds time.
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48-Hour Swatch Box DispatchCompare 40–100 GSM viscose, pure cotton, lyocell & 7 patented weaves in person.
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Direct Factory Engineering Desk · Reply Within 12 Hours
Ms. Fang Li · Plant Director · Guangdong Zefu Medical Technology Co., Ltd.
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