Our capabilities include:

Custom development of materials

We produce nonwoven fabric in virtually any style you can imagine, with options for different types of polyester with varying degrees of denier, loft, thickness, density and more. Read more here.

Garnetting

Four of our five lines use a garnett to form the web. In this method, the fiber is pushed through a series of cylinders equipped with metal teeth, which produces a material where the fibers are at different angles. This randomization can be useful for many applications, including those where it is important for fluid to be able to transfer through the web.

Carding

One of our five lines uses a card to form the web. The carding process is similar to garnetting, but the fiber passes through more cylinders, which results in a web with fibers laid out in a flatter, straighter way, which is advantageous for some uses.

Thermal bonding

We bond by passing the web through an oven, where low-melt polyester is thermally activated, fusing the fibers. This creates additional strength in the web, which is essential in many products. We use only thermal bonding, which has environmental benefits over other types of bonding.

Densification

When a very densified product is required, we utilize one of our double-belt compression ovens. These ovens not only generate heat to melt the polyester, but also make it possible for operators to compress the fabric by adjusting the gap between the two belts. The web can be compressed from a natural depth of 12 inches to as little as a few inches, creating a very dense material.

Needling

Four of our five lines are equipped with needle looms, which can be used alone or in conjunction with thermal bonding to provide additional strength to fabric when needed for certain applications. The needles have barbs on them, which pull the fibers up and down, entangling them. Operators can adjust the type of needle, as well as the loom’s speed and level of penetration. Needling can be particularly helpful as a method of adding increased strength to a lightweight fabric.

Converting

Using our advanced computer numerical control (CNC) machines with computer-aided design technology, we can trim products to the size and precise shape clients need before shipping them from our facility. We also operate sheeters, slitters and similar equipment that enable us to cut rolls into smaller pieces. Read more here.

Wholesale packaging

We manufacture custom packaging materials for gift boxes, jewelry boxes, sunglasses and eyeglasses, breakable and delicate items, and e-commerce. Read more here.