US Spunbond Nonwovens Market 2025-2035: Comprehensive Study
The US spunbond nonwovens market, known for its pivotal role in hygiene, medical, agriculture, packaging, and automotive applications, is projected to see significant growth between 2025 and 2035. Defined as fabrics produced via spunbond technology using polymers such as polypropylene, polyethylene, and polyester, these nonwovens offer advantages like lightweight construction, high strength, and versatility. Adoption in disposable hygiene products, advanced medical textiles, and sustainable packaging is driving industry expansion. Key players are investing in capacity expansion and innovation to cater to evolving application demands, regulatory requirements, and environmental sustainability mandates.
Latest Market Dynamics
Key Drivers
Rising demand for hygiene and medical applications, especially post-pandemic, is spurring the need for high-performance spunbond nonwovens. Companies such as Kimberly-Clark are expanding their medical and hygiene product lines with advanced spunbond fabrics to meet surge requirements.
Sustainability initiatives and the demand for eco-friendly products are influencing manufacturer strategies. Berry Global Inc., for example, has introduced recyclable spunbond nonwovens, reflecting the shift toward greener and more sustainable material solutions.
Key Trends
Technological advancements in fabrication, such as multi-layer and composite spunbond nonwovens, are enabling manufacturers like DuPont to deliver tailored products for specialized applications including filtration and automotive interiors.
Digital transformation and Industry 4.0 adoption—companies like Fitesa S.A. are leveraging automation and digital quality control for consistent spunbond nonwoven output and operational efficiency.
Key Opportunities
Increasing disposable incomes and consumer awareness of hygiene products create strong potential for market growth in personal care and baby diaper segments. Avgol Nonwovens has seen upticks in orders from leading hygiene brands.
Expansion into agriculture and industrial packaging verticals offers avenues for diversification. Johns Manville has introduced weather-resistant spunbond materials for crop coverage and industrial protective uses.
Key Challenges
Volatile raw material prices, primarily for polypropylene and polyester, are impacting margins. Freudenberg Performance Materials is actively working on material optimization to mitigate cost hurdles.
Stringent regulatory standards for medical and hygiene applications present both operational and compliance challenges, prompting enhanced quality processes at companies like Toray Industries, Inc.
Key Restraints
Competition from alternative technologies such as meltblown and woven fabrics limits the addressable market share for spunbond nonwovens. Fibertex Nonwovens is diversifying its product offerings to counter substitution risks.
Environmental concerns related to non-biodegradable polymer usage and waste management are pressuring companies such as Sunshine Nonwoven Fabric Co. Ltd. to develop more sustainable spunbond solutions.
In 2025, the US spunbond nonwovens market is predominantly led by polypropylene-based products, capturing the highest market share due to their superior performance, cost-effectiveness, and broad applicability, particularly in hygiene and medical sectors. Polyethylene and polyester follow, favored in segments like packaging and automotive. Other types, including polyurethane and polyamide, cater to niche, high-value applications. The preference for polypropylene is driven by its lightweight nature, chemical resistance, and adaptability across various end-use industries, establishing it as the backbone of spunbond nonwovens production and consumption in the US market.
The hygiene segment dominates the US spunbond nonwovens market in 2025, energized by increasing demand for products such as baby diapers, adult incontinence items, and feminine hygiene. The medical segment is the second-largest, as the healthcare sector's ongoing focus on infection control and disposable medical supplies boosts spunbond nonwovens usage. Agriculture, packaging, and automotive applications each capture a measurable share, with agriculture benefiting from spunbond’s durability for crop protection and packaging leveraging its light weight and strength. The packaging segment is witnessing a steady increment as producers look for sustainable and efficient solutions.
US Spunbond Nonwovens Market Revenue (USD Million), 2020-2035
The US spunbond nonwovens market revenue is projected to demonstrate robust growth from 2020 to 2035, escalating from USD 2,560 Million in 2020 to USD 4,320 Million by 2025, and anticipated to reach USD 8,980 Million by 2035. Key factors driving this sustained increase include persistent demand in the hygiene and medical sectors, technological advancements, and the proliferation of spunbond applications in new end-use industries. The market’s CAGR is bolstered by both organic growth and strategic investments by leading players to boost production capacity, develop new products, and expand regional footprints.
US Spunbond Nonwovens Market Year-on-Year (%) Growth, 2020-2035
Year-on-year growth for the US spunbond nonwovens market showcases a dynamic trajectory, with a peak post-pandemic surge of 10.2% between 2020 and 2022, gradually leveling to a steady 7.2% CAGR by 2025 and moderating to 5.1% by 2035 as the market matures. This progression reflects the initial pandemic-driven boom, followed by sustained but slightly tapering growth as supply chains stabilize, technologies mature, and market penetration deepens across core and emerging application sectors.
US Spunbond Nonwovens Market Share by Region, 2025
In 2025, the regional analysis of the US spunbond nonwovens market reveals the South region as the largest contributor, accounting for nearly 39% of the market, owing to its concentration of manufacturing hubs and strong demand from the healthcare and automotive industries. The Midwest and West follow, driven by growth in agriculture and packaging applications, while the Northeast’s share is bolstered by medical and hygiene product manufacturing clusters. Regional market presence is shaped by population density, industrial base, and proximity to major end-user industries.
US Spunbond Nonwovens Market Players Share (%), 2025
By 2025, Berry Global Inc. emerges as the undisputed market leader, followed by Kimberly-Clark Corporation, DuPont de Nemours, Inc., and Toray Industries, Inc. Berry’s share, at 17%, is underpinned by its extensive production facilities, innovation pipeline, and strategic partnerships. Kimberly-Clark and DuPont leverage their diversified portfolios and established distribution networks for competitive advantages. Together, the top five players command over 52% of the market, while other structured players and local manufacturers make up the remainder, reflecting a moderately consolidated yet competitive landscape.
US Spunbond Nonwovens Market Buyers Share (%), 2025
The market in 2025 is shaped by large hygiene and medical product manufacturers, who collectively command the largest buyer share at 41%. This is followed by agricultural suppliers and packaging companies, which account for 22% and 19% respectively, as spunbond nonwovens continue to penetrate diverse value chains. Automotive OEMs and distributors round out the major buyer groups, representing the market’s broadening footprint into industrial and non-traditional domains.
Study Coverage
Metrics
Details
Years
2020-2035
Base Year
2025
Market Size
Revenue (USD Million)
Regions
South, Midwest, West, Northeast
Segments
By Type (Polypropylene, Polyethylene, Polyester, Others), By Application (Hygiene, Medical, Agriculture, Packaging, Automotive, Others), By Distribution Channels (Direct Sales, Distributors/Wholesalers, Online, Retail, Others), By Technology (Single Layer, Double Layer, Multi-Layer, Others), By Organization Size (Small, Medium, Large)
June 2024: Berry Global announces $50 million capacity expansion in US spunbond nonwovens plant to support hygiene and medical clients.
July 2024: Kimberly-Clark launches new sustainable spunbond fabric line for baby and adult care products.
August 2024: DuPont unveils advanced multi-layer spunbond materials targeting medical protective apparel manufacturers.
September 2024: Johns Manville introduces spunbond crop protective solutions for agri-tech distributors across the Midwest.
October 2024: Toray Industries, Inc. partners with regional healthcare manufacturers to co-develop antimicrobial spunbond textiles.
Frequently Asked Questions
About the Author
Manisha C
Lead Industry Analyst
Manisha C is a Lead Industry Analyst specializing in market research, industry analysis, and business consulting across Chemical & Material. Manisha C brings a commercially grounded perspective to sectors shaped by changing demand, innovation, and competitive dynamics, helping turn complex market trends into clear strategic insights for business decision-makers. With 10+ years of experience across research, analytics, and strategic advisory roles, Manisha C has helped organizations translate data into actionable growth strategies.
Chemical & MaterialMarket ResearchIndustry AnalysisStrategic Consulting
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