The manufacturing process of Nonwoven Wet Wipes consists of several processes, including carding, hydroentangling, and thermal bonding. The focus of these processes is on water absorption and softness. The most common fibers used in wet wipes are cellulose and polypropylene. One nonwoven product made of a single synthetic fiber, however, is an industrial wipe. Its characteristics differ from those of a consumer wipe.

The production of nonwoven wet wipes has been associated with many challenges, including preservation and health risk. The high water content and large surface area can create a breeding ground for microorganisms. Biofilms can also create extracellular polymers that facilitate the attachment of microorganisms to surfaces. Biofilm-associated microorganisms are less susceptible to antimicrobial agents. The new process can eliminate many of these challenges and lead to better-quality products.

The underlying mechanisms for the problems associated with nonwoven wet wipes have been studied extensively. Using microbiological and physicochemical tools, the study uncovered interactions between nonwoven fabric constituents and preservatives. The results rationalized the relationship between these interactions and antimicrobial efficacy. The study results revealed that viscose hydrophilic nonwovens are an ideal carrier for contamination and an intrinsic source of food for microorganisms, while cellulosic materials are conducive to microbial colonization.

During the laundering of nonwoven products, a significant amount of microfibers is released into the atmosphere. This process simulates the generation of microfibers during use by shaking nonwoven materials. Researchers found that a wet wipe can generate anywhere from 0-35 microfibers per square centimeter. Depending on its characteristics, however, the number of microfibers generated is greater in some nonwoven products than in others.