Microfiber Synthetic Leather Manufacturing Process
The manufacturing process of microfiber synthetic leather begins with the selection of raw materials like polyester, polyurethane and other chemicals. Polyester fibers are melted and extruded into long filaments of 5–15 denier thickness. These filaments are then cut into staple fibers of 1–3 inches length. The staple fibers are carded and combed to remove any impurities and align the fibers. After this, the fibers are spun into yarns using various spinning processes like ring spinning.

The yarns are then woven or knitted into fabric backings using various weaving and knitting techniques like flat weaving, circular knitting etc. The fabric backing provides strength and durability to the final synthetic leather. A layer of polyurethane is then applied on the fabric backing by roll coating, dip coating or spraying. The coated fabric is then cured and dried under controlled conditions. The finished microfiber synthetic leather has grain-like appearance and texture like real leather.

Properties and Applications of Microfiber Synthetic Leather

Microfiber Synthetic Leather mimics the appearance and texture of real leather very closely yet it is more durable, stain resistant and affordable than genuine leather. Some key properties of microfiber synthetic leather are:

- Lightweight yet Strong - It is 75-80% lighter than real leather but has high tensile strength similar to real leather.

- Breathability - The microfiber fabric allows air circulation making the final product breathable.

- Water Resistance - The PU coating makes it highly water resistant and easy to clean. Stains and moisture does not affect it easily.

- Abrasion Resistance - The microfiber material has high durability and abrasion resistance lasting long years of use.

- Low Maintenance - Minimal care is required as dirt and stains can be easily wiped off with a damp cloth.

- Affordability - Its manufacturing process utilizes less resources and energy making the overall cost lower than real leather goods.

Due to the above properties, microfiber synthetic leather has applications in various industries like automotive, furniture, footwear, accessories and clothing. It is widely used in car seat covers, upholstery, jackets, bags, belts and shoes among others. The textured finishing mimics real leather closely satisfying customer demand at affordable rates.

Environmental and Sustainability Advantages

The production process of microfiber synthetic leather has certain environmental advantages compared to genuine leather manufacturing:

- No Animal Slaughter: No animals are killed during its production making it an ethical option for vegans and environment conscious consumers.

- Lesser Resource Intensive: The synthetic material requires fewer resources to produce than leather which needs livestock breeding, animal feed and their waste disposal.

- Less Water Usage: Leather tanning is a highly water intensive process while synthetic leather uses a fraction of water during its manufacturing.

- Lower Carbon Emissions: The synthetic materials have lower embedded carbon compared to cattle rearing contributing less greenhouse gases.

- Recyclable: Post-consumer microfiber synthetic leather scraps can be recycled back into the production process while real leather waste is difficult to reuse.

- More Durable: It lasts longer than real leather reducing resource consumption over time due to its high strength and abrasion resistance properties.

These sustainability benefits have made microfiber synthetic leather a viable replacement for real leather in applications aiming to reduce their environmental footprint. Many footwear and fashion brands are opting for faux leather in their products.

Quality Standards and Certifications

With increasing demand, many international standards and certifications have come up to ensure quality and safety of microfiber synthetic leather. Some commonly referred standards are:

- ISO 17228 (Leather) for physical and mechanical properties.

- ISO 25178 (Geometry) for surface quality specifications.

- REACH (Registration, Evaluation, Authorisation and Restriction of Chemicals) for limiting hazardous chemicals usage.

- OEKO-TEX Standad 100 for restricting harmful dyes and finishes.

- Global Recycled Standard for recycled content verification.

- Eco Passport by OEKO-TEX for chemical management in supply chains.

Certification to these quality and sustainability standards gives consumers assurance about the manufacturing processes and material contents. It also helps microfiber synthetic leather gain more acceptability as an ethical alternative to real leather goods.

Get More Insights on Microfiber Synthetic Leather