Densified Polyester Fiber Products

In addition to high-loft polyester products, we also custom-manufacture densified polyester fiber to meet the needs of a wide variety of customers. Our nonwoven fabrics can be compressed from a natural batt of 12 inches in thickness to a finished size of just a few inches, creating a very dense product. This densified polyester fiber can be used across many industries, often in place of foam. Applications include outdoor furniture, playpen mats, acoustical panels and much more. Contact us to find out how our densified fiber might solve a problem for your business.

Customized Products

Do you have special requests for your product? We are happy to customize your order. Below are some of the components that can be adjusted to meet your specific needs. Your sales representative can assist you in developing specifications for the material you need for a particular application.

Staple Polyester Composition:
Depending on the application and purpose we can use different types of white staple polyester: virgin, recycled, or reclaimed. Within these grades we can specify variations in color, fiber length, and related characteristics. For large programs we can manufacture with colored polyester.

Denier:
The denier of staple polyester is a unit of measurement for the thickness of the strands of fiber. Finer denier material has a softer feel. Coarser denier fibers are rougher and more abrasive. The majority of our products use a 15 denier staple polyester and a 4 denier bicomponent binder. However, we can manufacture materials using polyester that is as thin as 1.5 denier or as thick as 60 denier.

Bonding:
We bond our fiber primarily through the use of low-melt polyester, which is thermally activated when it passes through an oven. Needling also can be used to bond – either as a stand-alone process or in addition to thermal bonding. More detail on needling is provided below.

Weight:
In the high-loft non-woven industry, weight is normally measured by the number of ounces per square foot. Our typical range is from 0.25 ounce to 12.0 ounces.

Loft:
Our products have a standard loft (or thickness) based on common industry practices. A general rule for high-loft nonwovens is that each ounce per square foot corresponds to an inch of loft. So, a 1-ounce-per-square-foot product would be 1 inch thick. However, we have the ability to increase the loft slightly if you desire a product with more thickness. Similarly, we can decrease the loft to make a denser material.

Needling:
Most of our production lines have the capability to entangle fibers with a needle loom prior to thermal bonding. Needling provides additional rigidity and strength to the finished material. Variables in this process include the speed of the loom (how quickly it engages the material), the depth of the penetration, and the type of needle that is used. Needled fiber is significantly stronger than products bonded in other fashions.

Firmness:
Outside of densification and needling, the firmness of a fiber product is determined by the amount of bicomponent polyester included in the material, the oven temperature, and the amount of dwell-time in the oven. Over the years, our engineers have developed a standard that is the right balance between soft and firm for most customers. However, if your application requires additional rigidity (or increased softness), we can modify your product accordingly.