Nylstar Opens North American Nylon Production Facility

Italy-based Nylstar has opened a state-of-the-art, $50-million production facility in Martinsville,
Va.The new plant can produce up to 50 million pounds per year of 15- to 200-denier nylon yarns.
Nylstar will manufacture many of its specialty Meryl® brand fully-oriented (FOY) and
partially-oriented yarns (POY) at the site
(See Quality Fabric Of The Month, TI, May 2001).Brand-new texturing and spinning machinery
for the plant was supplied by Germany-based Barmag AG. Nylstar sent 47 supervisors and line workers
to its French, Spanish and Italian locations to train on similar types of machines.At peak
operation, the 300,000-square-foot plant will employ 250 workers and operate 24 hours a day, seven
days a week.From having the most modern Barmag machines available, to training employees overseas,
to being CBI- and NAFTA-compliant, we set out for this plant to do one thing, and that is to
demonstrate to fabric and apparel manufacturers in the United States, Canada and Mexico that we are
committed to nylon in North America. In other words, were committed to their business like no other
yarn producer in the world, said Dina Dunn, vice president of marketing for Nylstars North American
operations, Greensboro, N.C.

November 2001

Berkshire Hathaway To Acquire Fruit Of The Loom39 S Apparel Business

CHICAGO and OMAHA, Neb., Nov. 1 /PRNewswire/ — Fruit of the Loom, Ltd.(OTC Bulletin Board: FTLAQ), Fruit of the Loom, Inc. (collectively the”Company”) and Berkshire Hathaway Inc. (brK.A, brK.B) announced that they andcertain of their respective subsidiaries have executed a definitive agreementtoday (the “Purchase Agreement”) for New FOL Inc., a Berkshire subsidiary, toacquire substantially all of the Company’s basic apparel business operationsat a purchase price of $835 million in cash, subject to adjustments. Thepurchase price is subject to significant reduction for certain liabilities aswell as adjustment upward or downward depending on working capital levels.New FOL will assume the ordinary course post-petition liabilities and certainspecified pre-petition liabilities of the business. Warren E. Buffett, Chairman of Berkshire Hathaway, said, “We’ve agreed tobuy Fruit of the Loom for two major reasons: the strength of the brand andthe managerial talent of John Holland.” John B. Holland, Chief Operating Officer of Fruit of the Loom, said,”Fruit is excited to become part of the Berkshire Hathaway family ofcompanies. Berkshire’s acquisition will complete the Company’s tremendousoperational turnaround and pave the way for emergence from Chapter 11.” The Company is currently operating as a debtor-in-possession pursuant toits Chapter 11 bankruptcy filing currently pending before the United StatesBankruptcy Court for the District of Delaware (the “Bankruptcy Court”). Ascontemplated by the Purchase Agreement, the Company will seek approval of theBankruptcy Court to conduct an auction whereby higher and better offers topurchase the business may be considered. The closing under the PurchaseAgreement will be effectuated pursuant to an amendment to, and confirmationof, the Company’s Joint Plan of Reorganization and is subject to completion ofthe auction, and other conditions set forth in the Purchase Agreement. Theproceeds from the sale will be distributed to creditors pursuant to theCompany’s plan of reorganization and under the oversight and procedures of theBankruptcy Court. The Company’s decision to enter into the Purchase Agreement is supportedby the Unofficial Secured Bank Steering Committee, the Steering Committee ofthe Informal Committee of Senior Secured Noteholders, and the OfficialCommittee of Unsecured Creditors of the Company. Fruit of the Loom and Berkshire presently expect the closing to occur inthe first quarter of 2002.SOURCE Fruit of the Loom, Ltd. and Berkshire Hathaway Inc.Copyright © 1996-2001 PR Newswire Association Inc.

India Aims At Global Role In Textiles

INDIA AIMS AT GLOBAL ROLE IN TEXTILESWith the ambitious theme Roadmap to Global Supremacy, the Textile Association of India is staging its 57th annual textile conference in the city of Chandigarh on Nov. 24-25. The venue is at the heart of the Northern Indian textile industry.Conference organizer Dr. Sanjay Gupta, of the National Institute of Fashion Technology in New Delhi, said the event would focus on the Indian industrys strengths — including its vast fiber base, abundant and low-cost skilled labor force, large and diversified textile infrastructure, huge (and growing) domestic market, and manufacturing flexibility.But among competitive weaknesses also being pinpointed were the “considerable lag in production technology,” slow pace of modernization, shortage of capital, lack of indigenous research and development, low productivity, inadequate training, and over dependence on cotton. “The elimination of quotas by Jan. 1, 2005, is further likely to generate intense worldwide competition, both in India and abroad,” Dr Gupta says. “An integrated strategy to increase the competitive strengths and remove the competitive weaknesses is an essential part, therefore, of any game plan to attain global supremacy.”November 2001

Rolling Out The Red Carpet

Rolling Out The Red Carpet
Carpet capital hosts three-day event presenting the latest in floor-covering
technologies.
 This years Carpet Technology Show® began its three-day market in Dalton,
Ga., on September 11. Devastated by the events of that day, the show continued as best it could
with the business at hand. Vendors displayed and promoted their machinery, equipment, services and
supplies. Attendees saw the latest in equipment, machinery and support for their businesses. Some
of the countries represented included the United Kingdom, Canada, Australia, Belgium and Japan.The
Dalton Floor Covering Marketing Association (DFCMA) produces and promotes the Carpet Technologies
Show. Wanda Ellis, executive director, was very upbeat about this years show despite the
difficulties caused by the tragedy of September 11. Normally, we attract about 3,000+ attendees,
and we were off about one-third, partly due to the fact that many who had planned to fly in on
Tuesday couldnt get here.Global Outlook 2001, an international forum, showcased six industry
experts from Europe, Japan, South America and the United States. The forum was an undertaking of
Dalton State College (DSC). According to Marilyn M. Helms, Sesquicentennial Endowed Chair and
director of DSCs Center for Applied Business Studies, DSC is taking a more active role in the
carpet industry. Exhibitor CommentsRieter ICBT Greensboro Inc., Greensboro, N.C. Chuck Crow,
product sales manager, said the firm is primarily involved in the twisting of carpet face yarns.
Machinery sales have been slow for the past six to eight months, but there are indications that
things are picking up. Last year saw false starts, and most believe we wont see anything
significant until the first of the year but given whats happened with the tragedy, all bets are
off. He continued, saying that changes would have to be significant for him to get excited. We need
to be selling more machines, and we feel this particular show is good for us, he said. Our machines
handle both two-for-one twisting on single-end filament, spun yarns; and direct cabling for bulk
continuous filamant (BCF) yarns. This is a twisting (direct cabler or two-for-one, depending on the
application) machine, he continued. This particular type of equipment has been in operation and
part of Rieter ICBTs product lines for five or six years.Zima Corp., Spartanburg, S.C. Bill
McAndrew, vice president, sales and marketing, explained that Zima is a sales agent for several
companies, including Kusters, IMTEC and Mitter. The firm handles sales, engineering service and
spare parts for all three companies. We have project managers to handle large projects for each one
of them, and service technicians, McAndrew said.Information was available for all product lines,
with emphasis on Kusters dyeing and finishing, and the combination of its Instacolor/Instatachem
and Quick Change Dye Applicator. Rotary screen printing equipment was available from Mitter, and
shearing equipment from IMTEC. It appeared some of the biggest interest was in the new Quick Change
Fluidyer. McAndrew noted that one of these machines is installed at each of Zimas major customers
facilities, and the company is working to install others.McAndrew felt that carpet is not as
import-sensitive as other textiles. The carpet industry will hold up better, in our opinion, than
the textile industry. The nonwovens industry and paper industry are basically like carpet, down a
bit but not as bad as textiles. We feel theres a huge future in the U.S. carpet industry. The
people here are as efficient as anywhere in the whole world. Theyve got the best machinery, the
best people and best carpet made right here in Dalton, he said.NICCA U.S.A. Inc., Fountain Inn,
S.C., was exhibiting with and representing Suminoe Textile Co. Ltd., Japan. The two companies enjoy
a strong supplier/manufacturer relationship. NICCA is a chemical manufacturer in Japan and the
United States, but Suminoe has no facilities in the States. Kazu Ikebata, R and D manager for
NICCA, explained, Suminoe is our biggest customer in Japan. Satoru Tanaka, general manager,
administrative services for NICCA, added, NICCA supplies a lot of chemicals to Suminoe in Japan and
represents them in the States. Suminoe has a great cleaning system that has been used in Japan for
about 10 years, but nobody in the United States has used it yet, so we are hoping to find buyers in
Dalton. Both feel Carpet Technologies is a good market for their products, but they had hoped to
see more people.Pierret, North American Division, Spartanburg Todd Cooper, sales and marketing
manager, stated he is an optimist. The market may be down now, but Im positive the future will see
things getting back to normal. Theres not a lot of money right now, and folks are holding the purse
strings tightly. We do understand because were doing that, too. Cooper talked about the firms
CT6020 cutting machine. Our equipment is very common in this industry. We have at least 15 or 20
companies in the Dalton area using our size-reduction equipment. Most are using recycled carpet
yarn in some form or other some cutting edge-trim and so forth. We also have an in-line tool cutter
that is made for cutting edge-trim.Cooper continued, In Europe, there are more government subsidies
for recycling. Here, its more common that customers, if they cant make a profit off of it, they
dont want to deal with it. Its something that we have, and the market is developing and growing for
us. Were continuing to push our products in this industry and feel confident well continue to grow
when the economy gets back on its feet.Belmont Machinery Inc., Mount Holly, N.C. Dean Smith, Jr.,
vice president, marketing, works from Belmonts sales office in Dalton. Smith was upbeat and said he
had seen a fair number of customers. The customers weve seen have been quality people in
purchasing. We like to see everybody, but we especially need to see the guys in charge of
purchasing. With the tragic events, a fog has been cast on everything, but its not anybodys fault
and we have had some fairly good traffic and activity. Were probably spending fewer dollars for
prospects here than anywhere else in the world. So it pleases me very much to exhibit.Belmont was
showing new winding equipment, which had been introduced at the American Textile Machinery
Exhibition-International (ATME-I) 2001. According to Smith, one of the units is in operation at the
Mohawk twisting plant in Calhoun, Ga. It appears to be attracting interest. We also have a
space-dyeing line and twisting machines, but winding is our core business, he said. Belmont has
introduced an automated package-handling system. What were trying to do is eliminate or reduce
labor in a winding operation, he explained.Saurer Textile Systems, Charlotte, N.C. Ted Street,
regional sales manager, noted, We see signs of the industry picking up, and Saurer has made some
good sales in the last two weeks. Saurer was showing videos of machinery how its set up and
maintained. There was also a display of spare parts and literature, plus some new items relating to
tension and gadgets that help run specialty yarns. The firms Volkmann CarpetTwister, a machine
range for twisted and cabled carpet-yarn production, appeared to attract a lot of interest.Eltex US
Inc., Greer, S.C. Peter Titcomb, district sales manager, also feels the market seems to be picking
up. Some of the spinning mills Ive called on are busy running seven days a week, 24 hours a day.
BCF seems to be holding steady. Air entangling is a little slack but will pick up later. Eltexs
equipment line includes warping, weaving, winding and other applications. The Eltex QTV Yarn Break
Detection System reacts to a yarn break in milliseconds. The number of ends to be monitored in the
creel are automatically detected and displayed by the QTV systems central unit. The Weft Yarn
Tension Monitor has created a small revolution in weaving technology and makes it possible to
significantly increase weaving efficiency, according to Titcomb.

 Van de Wiele, Belgium Arthur Phillips, president, and Gilbert Moulin, sales manager,
discussed Van de Wieles face-to-face carpet weaving machines, which Phillips said are mainly for
area rugs but also for wall-to-wall contract carpet. Several examples of carpets and rugs woven by
customers were shown. Our collection shows a trend toward better qualities by using better yarns,
such as wool, and finer densities, which means more pile knots per square meter or per square yard,
Phillips said. Moulin added, There are better and finer designs in high-end quality. Imports are
already successful, and now the American market is going forward. Wool has been successful at Shaw
Industries and Karastan. Both have a collection of carpets in wool.Van de Wiele will complete a
range of carpet weaving machines with another Axminster weaving machine. Moulin said it is under
development and will be running sometime about the middle of next year.Mahlo America Inc.,
Spartanburg The market has been fine for us, we had good meetings, but with the tragic events,
traffic has been slow, related Alan Lavore, sales and marketing manager. The main product were
displaying this week is our PCS-10, a pattern-control system in which we can use camera-based
technology to image the surface of the carpet and look for patterns within the carpet whether they
be structural or color, he said. The system detects distortions and repeats within the actual
pattern of a material. This is important because distorted carpet or fabric loses its value as a
usable finished product and gives rise to complaints.Mahlo also had on display some process
monitors and control systems for moisture monitoring, weight measurement and exhaust
humidity.American Superba Inc., Dalton Frank Walburger, president, and John Cornelison, regional
sales manager, were on hand to talk about the companys equipment. Superba developed the ARG/M for
computerized regulation of saturated-steam, pressurized, continuous heat-setting of carpet
yarns.Were also introducing the B401, which is the narrowest winder on the market. It is an upgrade
for the B400 introduced in 1999. It will be coming out soon. Were also introducing a MF3 Frieze
unit that will be coming out within the next two months. The show has been good for us. The traffic
weve had is high-quality traffic. Were happy with that, Walburger affirmed.Americhem Inc., Concord,
N.C. Americhem is a manufacturer of custom-color masterbatch for polypropylene, polyester, nylon
fiber and fibers used in floor covering and textile applications. Americhem can produce color for
anything that is solution-dyed. According to Paul Mrzlak, sales and marketing manager, Americhem is
known as a high-performance company in terms of lightfastness and spin performance of its products.
We pretty much service the floor-covering industry, and have for 15 years. Were a custom
manufacturer, with everything being designed specifically for customers, he said.Customers are in
25 countries worldwide. Mrzlak said that despite the slow economy, he sees positive signs that
things are turning around. Of course, with the tragic events, it could change things. Our total
commitment to innovation and quality will not be diminished, no matter what, he stated.A.B. Carter
Inc., Gastonia, N.C. An unusual and interesting product was being demonstrated by A.B. Carter. Its
Sliver-Join splicer was designed specifically to improve the consistency of the sliver-splicing
process at the ring-spinning frame, resulting in fewer ends down, reduced waste and lower
maintenance cost. This very different splicing technique also requires little training, allowing
new and inexperienced employees to quickly become skilled at producing consistent, high-quality
splices. Fred Rankin, vice president, Mill Devices Co., said the splicer has demonstrated superior
performance in major carpet spinning operations.Fi-Tech Inc., Richmond, Va. Weve seen old faces and
weve seen new faces here at the show, and generally speaking, we certainly like to see both. Its a
good show for us, said Keith Wise, spare parts manager, sales and marketing. Wise was especially
promoting the firms biggest item Euro-Spares, a source for European spare parts.Fi-Tech is a
technical service company and North American representative for European equipment manufacturers.
Offices are maintained in the United Kingdom, Germany and Italy, enabling speedy pricing and
availability, and other related services. Fi-Tech identifies and locates parts; works with
currency; arranges shipments; clears customs, tariffs and duties; and receives at its warehouse in
Richmond. The company also inspects for damage in transit and a very important service bills
customers in U.S. dollars.BTSR (Best Technologies StudyandResearch), Italy BTSR was represented
well by Scott Yates, general manager, PAF Sales LLC, Greensboro. PAF is the exclusive distributor
of BTSR yarn control systems. BTSR was showing different systems for the industry on-line
tension-monitoring and on-line twist-monitoring systems, and a smart clear system.Yates said the
firm is cycle-proof when it comes to the economy. We sell when other things are down (such as
apparel), and we have staples niche-market items such as fiberglass and carpet industry items.
Others areas include medical, hosiery, tire cord and things that are not your typical textile
market items. Were very optimistic and upbeat. We intend to continue carrying our products to the
industry. Our products can be contoured into anywhere. Find a yarn strand or fabric formation, and
were there.Lawson Hemphill Sales Inc., Spartanburg Richard Doyne, Industrial Sales Division, said,
Weve had interest in our principal accounts here at the show, and we will follow-up. Our lab
equipment has been observed and favorable comments received. The firm was promoting Colortronic, an
extrusion control unit. Doyne said the Colortronic can simplify line startup and job changeovers
and reduce scrap accumulation during string-up. In co-extrusion lines, it guarantees that all
extruders will run in layer ratio control.The TYT-EW electronic yarn tester offers a user-friendly
format that channels yarn-quality data via a network to a central database, enabling rapid and
precise performance analyses by production and quality-control management. The FST 3000 force
shrinkage tester increases flexibility to capture and transfer data to a companys computer system.
Test results can be stored and retrieved easily for analysis at any time.Textube Corp., Greer C.P.
(Butch) Moss, Jr., sales manager, said he always looks forward to this particular show because a
major segment of his business is the carpet industry. On opening day, we had tragic events that
changed the overall schedule, but the traffic has still been pretty good for us, and weve seen a
lot of customers, said Moss.Textube had many products for the carpet industry spinning tubes,
twisting products, finish winder combs and others. The company carries a full product line in
plastic as well. Moss, like many others, talked about the effects of the slow economy. It has been
a slow economy, but we hear about new housing starts and the trickle-down effect, which takes a
while to get to us as a carrier. It seems the younger generation is having a preference for
hardwood flooring as opposed to carpeting. That could change too! A lot of people in this country
have carpet in their homes and just might use it an extra year or few months longer rather than
replacing it. But I do feel theres still a bright side of business.  

Freudenberg Nonwovens Group, Durham, N.C. According to Jean Skinner, marketing, the firm has
been, for a long time, incorporating post-industrial recycled content into its product up to 12
percent. This year we have the capability of adding up to 50-percent post-consumer recycled
content. Weve had a lot of customers asking for this, so weve used a lot of capital investment to
be able to incorporate that amount of recycled content into the product. And were the only backing
company in the world that can offer up to 50-percent post-consumer recycled content in the primary
backing. Freudenberg has 17 plants producing nonwovens in 12 countries worldwide.A new breakthrough
primary carpet backing has already begun to show phenomenal results, noted Skinner. This product,
Lutradur type 059, delivers improved face appearance, tighter backstitch, better pile-holding
capabilities, improved mending properties, reduced noise at tufting, and minimized bow and
skew.Currently the firm is investing $40-million to increase the capacity of its spunbond plant in
Durham. Production is scheduled to begin during the first quarter 2002. Freudenberg will be the
largest producer of polyester spunbond for its primary market segments: automotive carpet backings;
interior soft trim; carpet tile backings; and broadloom backings, according to
Skinner.International Baler Corp., Jacksonville, Fla. Jerry Wise, sales manager, talked about his
firms products. The auto-tie balers have many features and are engineered for maximum performance.
The equipment meets tough standards due to its hydraulically operated wire inserters for safer,
more dependable operation and more uniform ties; variable bale length control and automatic
tensioning control cylinders for tighter bales and ease of operation; electronic eye sensors for
trouble-free operation in the automatic start cycle; components for minimum down time, ease of
maintenance; reliability; plus much more. There are 16 Auto-Tie models.The industry in general will
pick up through 2005, and after that we should cross our fingers and hope that China wont ruin us,
Wise said. Why 2005 Because thats when all the quotas come off products coming into the states. The
carpet industry as a whole should be fine up to that point. After that, all bets are off.EPIC
Enterprises Inc., Southern Pines, N.C. Epic is a replacement parts company for the carpet industry
and fine count. Product lines shown included twisting and heat-setting. Claude Crisp, director of
sales, said Epic has been in business for 23 years. The firm handles replacement parts for Verdol
and Volkmann two-for-one and cabling equipment; replacement parts for Superba Heatset, Signal
Equipment, and Suessen Heatset; ring assembly cleaning and rebuilding; and EPI-Mark yarn and fabric
markers.Our EPI-Mark has many non-fluorescing colors and is cold-water-soluble. It does not melt,
contains no wax and easily cleans with no mess. Our EPI-Mark crayons are rapidly replacing chalk
markers for cotton, carpet, wool, worsted and man-made yarns and fabrics, Crisp said. 

Williams Sales Inc., Nashville, Tenn. This was Williams Sales first time to exhibit. Were
excited about this industry, said Dan Williams, vice president. Were showing a flex strap machine
by Felins that wraps stretch film around a roll of rug. Most have been doing this by hand, which
can cause problems such as carpel tunnel. The stretch film is held by front and rear grippers below
the bed of the machine, the product to be wrapped or banded is placed into position, and the foot
switch is depressed. When the required number of selected wraps has been made, the stretch film is
automatically cut and sealed. The procedure works especially well on smaller rugs, such as 5-by-7s,
play rugs. And, according to Williams, its a cost-saving alternative to using a rigid poly plastic
strapping-type machine. He said it usually pays for itself in less than a year. The Felins machine
is made in the United States.New Binders Group, Miamisburg, Ohio New Binders Group manufactured the
first bobbinless, portable carpet-binding machine. Most carpet-binding machines are made from
modified home sewing machines, but New Binders Durabind is a stronger and faster heavier-duty
industrial machine, according to Bruce Dellert, vice president, sales and marketing. It is designed
to increase productivity and efficiency, is economical and simple to operate, and adapts to
carpeting of all grades and backings, among other benefits. It is portable and can be taken to job
sites.Dellert stated, This is our first time at the Carpet Technologies Show, and we are somewhat
disappointed with attendance, but with the tragedy in our country, we understand many could not get
here. However, were looking forward to the next show in two years and to selling more machines. The
Durabind machine is made in Hudson, Ohio.Electric Systems Integrator, LLC (ESI), (an NSC Groupe
Company), Chattanooga, Tenn. Bill Gains, sales engineer, said the trade show has been somewhat busy
in his area, but he would like to see more participation from the carpet industry. Theyve done a
good job with the show here, but we need more support from the carpet industry, because thats what
were here for. ESI was showing an ABB600, which features Allen Bradley, Reliance, Siemens and
Yaskawa drives networked via remote 1/0 on Profibus and Device Net.According to Gains, the
simulated nonwoven line utilizes soft PLC (Programmable Logic Controller) technology based on
Wonder Ware. It has an in-touch and in-control platform, which is somewhat unique in the industry,
he noted.CYG, Santa Monica, Calif. CYG is an investment firm that handles mergers, acquisitions and
financial data. Greg Yorkison was on hand promoting one of CYGs clients, Syndesis Inc.,
manufacturers of Syndecrete®, a lightweight, hard-surface application that incorporates carpet
waste such as the latex backing and polypropylene tape. The product can be utilized for multiple
applications including floor covering, table tops, counter tops, wall panels, and bathroom
fixtures. The product can go indoors and outdoors. This is a multi faceted, very flexible product,
said Yorkison.IRO Inc., Charlotte IRO handles a full range of yarn-feeding devices and yarn-tension
controls, according to Thomas Hansen, president. The firm provides tension control for all types
and counts of yarns. By controlling tension and yarn feeding, it will increase production and
improve quality. The firm showed a full range of yarn guides, ceramic tensions and stop motions, as
well as its latest electronic yarn-tension meter and yarn-speed and rate meter.Day International
Inc., Greenville, S.C. Day International manufactures and sells rubber cots and aprons to assist
carpet manufacturers in creating top-quality carpet yarn. Day was exhibiting two brands of cots and
aprons, DAYtex® and Accotex®, to cover a wide range of applications and machinery. According to
Bill Howle, director of technical services, Day also provides top-quality rolls for Superba
machines, as well as balloon rolls and clearer covers for carpet yarn spinning machines. Another
product being shown was roll covering for tufting machinery.Day has been serving the textile and
carpet industry since 1938. Howle said he enjoyed being at the show and appreciated the opportunity
of exhibiting to an enthusiastic crowd of carpet mill personnel.

November 2001

New Book Highlights Cotton Fibers Impact On U S Economy

New Book HighlightsCotton Fibers’ Impact On U.S. EconomyCottons Renaissance A Study in Market Innovation, a new book by George David Smith and Timothy C. Jacobson published by Cambridge University Press, is now available from booksellers. The book tells the story of the struggle by U.S. cotton growers to grow, compete and survive for more than two centuries through a series of challenges to their markets. The book also traces the rise of Cotton Incorporated, Cary, N.C., from its establishment in 1968.In 1960, cottons share of the U.S. textile fiber market was 63 percent; by 1973, that share had fallen to an all-time low of 33 percent. Today, cotton holds a 60-percent share of the U.S. market.The authors were given full access to our records and reports, said Hugh Malone, vice president of administration, Cotton Incorporated. We let them see everything. Otherwise its merely an ego piece, and we werent interested in that.For more information, contact Thomas Pendleton, Cotton Incorporated, (212) 413-8316.November 2001

Fasturn Initiates Operations Network For Apparel Trade

Fasturn Inc., Los Angeles, has launched its Operations Network (OPN) to enable apparel retailers
and manufacturers to facilitate and streamline supply-chain management. The OPN software solution
combines advanced process management techniques with electronic communications for any business
function.Fasturn developed OPN after identifying the primary challenges that have led to industry
profits being reduced by one-half to two-thirds over the last several years. The company visited
key countries in the apparel sourcing chain and interviewed apparel retailers, manufacturers and
suppliers. Upon defining the problems and causes, the company collaborated with Accenture, PwC,
KPMG and Kurt Salmon Associates on various projects to determine the aspects of an effective
solution.The industrys supply chains are complex, multi-layered and subject to change with each new
season and style, according to Fasturn. Not surprisingly in an industry that has focused primarily
on design, promotion and site selection to gain market share, the problem was found on the
operational side of the business, said William Seagrave, CEO. Our Operations Network was designed
to help solve these challenges.By using the Internet and other such technologies, OPN users can
plan and view the entire supply chain for each style to be ordered. Internet use eliminates the
need by each supplier for investment, an advantage that Fasturn claims is particularly important in
light of the number of suppliers in the chain and the frequency with which they change.OPN features
include: coordination of schedules and tasks; two approaches management by exception and management
by key criteria; proactive monitoring of activities; and executing the supply plan.

November 2001

DuPont Teflon Unveils Let Life Happen Concept

The Wilmington, Del.-based DuPont Teflon® business has introduced Let Life Happen, a new lifestyle
concept for its Teflon fabric-protection products. DuPont wants to add value to garments and make
consumers feel comfortable eating spaghetti or allowing the kids to jump on the sofa.The concept
will be introduced globally in 2002 with an advertising print campaign, a new retail hangtag design
and a comprehensive set of promotional materials. The use of advertising in the Yellow Pages next
to listings for pizza or mechanics, for example, is an idea that will be implemented.We are
committed to raising awareness and interest in garments and home fashions which are enhanced with
stain protection, bringing value to both our trade customers and consumers, said Teresa Kleinhans,
global textiles manager, DuPont Teflon.

November 2001

GretagMacbeth GE Launch CCM Programs

CCM Silver, CCM Gold and CCM Platinum are three new corporate color management (CCM) programs
launched jointly by Switzerland-based GretagMacbeth and General Electric (GE) ColorXpressSM
Services, Pittsfield, Mass.The programs are designed to help customers reduce costs and
time-to-market issues by collaborating with industry experts to manage and improve color
communications throughout the supply chain.Key elements offered by the CCM programs include:
standards development; standards ordering and distribution via a customized Web page;
pre-production and production part auditing; color consulting, training and education; controlled
lighting and measurement devices; Root Cause and Corrective Action (RCCA) consulting, a GE Six
Sigma program; and monthly reporting and communication to the supply chain. Customers may also
select items a carte to create specific programs to fulfill general needs.

November 2001

Safe And Sound

Safe And Sound
Reeves Brothers, LINQ Industrial Fabrics and Hexcel Schwebel produce textile products for
safety and performance-related applications.
 

Globalization. Diversification. Innovation. Specialization. Important words all, especially
for the future of the U.S. textile industry. While still a neophyte to the concept of a world
marketplace, the U.S. textile industry is making inroads and nowhere is this more evident than in
the arena of technical and industrial fabrics.Technical fabrics create a wide range of
opportunities for textile manufacturers and capitalize on the U.S. industrys ability to make
high-quality fabrics to the most exacting specifications.From geotextiles to armor, from aerospace
fabrics to automotive airbags, from filters to truck covers, U.S. companies have few peers in this
growing segment of textile production. Reeves Brothers Diversifies Into High-Tech
MarketsReeves Brothers Inc., Spartanburg, S.C., is known for the production of its famed Vulcan®
brand of printing blankets, but the Engineered Fabrics Division of the company has diversified into
high-tech markets that maximize its production capabilities. Among the many fabrics woven and
coated with specialized treatments at the companys facilities in Spartanburg and in Rutherfordton,
N.C., is a material for the escape slides in commercial aircraft.These slides, obviously, must be
manufactured to very stringent safety requirements because of the safety factors involved, said Tom
Layton, director of sales and business development, Reeves Air Safety group. The slides are
manufactured from multiple fabrics that work together to form a single product. Flooring fabrics
are mounted to a tubing material that can inflate and stay inflated for a specific amount of time.
The base fabric for the slide is a multiple-denier nylon substrate woven using Dornier rapier looms
at the companys Spartanburg plant. A special urethane coating is applied at another Spartanburg
facility.The escape slides are manufactured to very exacting specifications, Layton said. They must
meet certain deployment standards that is, they must deploy in the same fashion every time,
maintaining specific distance from parts of the aircrafts structure. Additionally, the fabric must
have strength and elongation properties, and the coating must be able to maintain specific pressure
for a given time.Special attention is given as well to abrasion resistance and non-conductive
properties. Obviously, the most likely use of an evacuation slide is in an emergency, and it cannot
be the source of sparks that could ignite fuel, Layton said.Reeves is the leading supplier of
urethane-coated fabrics for the aerospace industry, according to Layton. The company supplies both
Boeing, the worlds largest manufacturer of commercial aircraft, and Airbus Industrie, the European
consortium that is the worlds other major manufacturer of jetliners.Reeves urethane-coated fabrics
are also used for other aviation applications including life rafts, life vests, fuel cells, deicers
and acoustical insulation. Automotive Airbags

In addition to being the largest supplier of fabrics for certain aviation applications,
Reeves Brothers is also among the worlds largest suppliers of automotive airbag fabrics.Reeves
pioneered engineered, coated airbag fabrics and is the leading supplier in the North American
market, Layton said. As in aviation, quality and reliability are critical in the deployment of
airbags, he said. Reeves vertically integrated weaving and coating operations give the company the
ability to meticulously control all quality standards and ensure that all products are manufactured
to the most rigorous standards, he said.The company offers products used for driver-side airbags,
passenger-side airbags and side-impact airbags, and is working on a new, one-piece, woven
side-curtain airbag that would protect during a rollover event.In the event of a side impact, the
rollover curtain would deploy and remain inflated for the duration of the roll. The curtain covers
from the A-pillar to the C-pillar, meaning that both windows are covered during a roll. The product
has been designed initially for vans and sport utility vehicles, but, Layton said, it will
eventually be available for all cars.No doubt, automotive and aerospace applications are associated
with the glamour side of technical and industrial fabrics. But there is a more basic side one that
involves interaction with the day-to-day lives of nearly everyone.Frank Hannas, director of sales
and business development for the Engineered Fabrics group, said the company is a market leader in
the mechanical rubber-parts industry and supplies fabrics for gas meters, gaskets, diaphragms and
seals.For example, we make a rubber-coated nylon fabric that measures gas in gas meters. It used to
be that leather was used in the bellows in these meters, but we developed a fabric specifically
designed to replace the leather. It is now used in 98 percent of the meters in place today. Gas
meters are guaranteed for 30 years and, to this point, there has never been a failure of Reeves
fabric in one, said Hannas.A coated silk fabric from Reeves goes into the diaphragm of two-stroke
gasoline engines, such as those used in chain saws and weed eaters. And for military applications,
Reeves has developed a rubber-coated fabric for hovercraft skirts. This is a heavy-weight nylon
fabric coated with rubber that can be used as a replacement for skirts on Navy craft, Hannas
said. Military ApplicationsAdditionally, the company at the request of the military is
developing a fabric for flexible fuel tanks. These tanks are bladders that have capacities from
10,000 to 50,000 gallons. The objective is for the military to be able to drop the fuel tanks from
an airplane and enable helicopters in the field to land and refuel.Previously, fabrics tended to
disintegrate in the desert heat. Reeves is working on a rubber-coated fabric that withstands both
the impact of being dropped from an airplane and the heat inherent in a desert operation. This same
material must also be able to withstand extreme cold environments.Yet another military application
from the company is a rapid air decelerator product that would slow down missiles fired from
helicopters and enable the craft to get clear of the damage area. The fabric is earmarked for
anti-personnel/tank missiles and those that would be used to destroy runways.Other fabrics by
Reeves include those for dock seals, oil booms, truck tarps and rafts. Polyproylene From
LINQWhile companies such as Reeves concentrate on developing coated fabrics for technical
applications in automotives, aerospace and material handling, other companies, such as LINQ
Industrial Fabrics Inc., Summerville, S.C., focus efforts on polypropylene fabrics for geotextiles
and flexible bulk containers.Formerly a division of Exxon Chemical Co., LINQ is a global supplier
of woven and nonwoven polypropylene-based fabrics for a wide variety of textile applications.The
companys woven geotextiles feature a combination of high tensile strength and water flow. The
fabrics have been used in projects ranging from parking lot stabilization to retaining walls. LINQ
also offers a line of nonwoven geotextiles that provide high tensile strength and superior
hydraulic properties. StabilizationThe company used its GTF 200 woven geotextile, for example,
to stabilize the Miami Dolphins football stadium parking lot. Improvement was needed to meet the
increased demand for parking at the stadium. A field was selected to serve as an additional parking
area near the stadium. The original field consisted of unstable muck soils, from 6 to 20 feet deep,
which had to be stabilized to support suitable fill material. The expensive alternative, said Jay
Wilson, Technical Services Engineer at LINQ Industrial Fabrics Inc., was to excavate all of the
unstable soil and replace it with suitable fill. 

LINQs GTF 200, a high-survivability, general-use woven geotextile, was placed directly over
the soft subgrade and then covered with sandfill. The muck soil was covered with 25,000 square
yards of GTF 200. The geotextile was covered with 3 to 4 feet of fill, which was graded and
compacted. Grass was planted to complete the project. After six years, the parking lot is in
excellent shape, so plans were delayed to pave the lot.The contractor specified GTF 200 be used for
stabilization. This fabric meets the separation specifications in many states, as well as Class 3
separation requirements set by the American Association of State Highway and Transportation
Officials. Floodwall SolutionsLINQ also supplies fabrics used in floodwalls. In Kentucky, the
Environmental Protection Agency (EPA) proposed a concrete structure to protect a waste site from
floodwaters up to the 100-year storm elevation. The waste site is 300 feet from a nearby river. The
compressible subsoils made this concrete approach unfeasible. A second approach was a compacted
clay structure; however, with a maximum wall height of 38 feet and a minimum top width of 14 feet,
the required side slopes would make the base so wide that it would encroach on adjacent properties
and take up valuable landfill capacity.To overcome these problems, an engineer proposed a
geotextile-reinforced wall with near-vertical sides. This wall would also be compliant to
accommodate any settlement due to the compressible subsoils. There were some concerns because this
was to be a permanent structure, and the EPA had never installed this type of geotextile wall
before. Said Wilson: There was a substantial amount of coordination between LINQ and the designing
engineer to make sure the right geotextile was used in this application. LINQ has a full-time civil
engineer on staff to aid in all design applications and answer any questions concerning
installation, as well as helping get the right geotextile for the job.Using acceptable geotextile
design methodology, the engineer developed a double-sided structure consisting of layers of
permeable backfill reinforced with LINQ geotextiles. Each layer of geotextile was folded over and
secured beneath the next layer of backfill. The bottom 12 feet of the wall has 12-inch nominal
backfill layers reinforced with LINQ GTF 375N. The upper layers are 18 inches thick, reinforced
with LINQ GTF 300.The GTF 375N is a stronger fabric than the GTF 300 and was required to support
the weight of the higher layers. The final design called for an impermeable geomembrane and a
toe-drain system to be installed on the landfill side. The entire structure would be covered with a
puncture-resistant, nonwoven geotextile to protect the reinforcing fabric against physical damage
and ultraviolet degradation.The 1,735-foot-long wall, finished more than 10 years ago, is still
stable and meets all design objectives.LINQs manufacturing plant in Summerville is capable of
manufacturing up to 200 million square yards of fabric per year. Filling A NicheWhat each of
these companies Reeves and LINQ share in common is a flair for innovation, of meeting specialized
demands in markets in which few other companies have either the desire or the expertise to compete.
As evidenced by the developments of fabrics with significantly enhanced properties Reeves fuel
tanks, for example, or LINQs GTF 200 this commitment is paying off in enhanced sales and greater
market share. Hexcel Schwebel Weaves For PerformanceIn the world of high-performance fabrics,
DuPonts Kevlar® brand enjoys perhaps the widest name recognition among the general population no
doubt because of its association with lightweight body armor for law enforcement and military
applications.Kevlar was developed in 1965 by DuPont research scientists who were looking to create
a fiber with exceptional strength, but which was also lightweight and flexible. It is an organic
fiber in the aromatic polyamide family, also known as aramid. General features include high tensile
strength at low weight; high modulus (structural rigidity); high chemical resistance; high
toughness; high cut resistance; low elongation to break; low electrical conductivity; low thermal
shrinkage; excellent dimensional stability; and self-extinguishing flame resistance.Kevlar is five
times stronger than steel, weight for weight. It provides excellent impact resistance and is one of
the lightest structural fibers available. The product is commercially available in a multitude of
fiber physical property balances for specific end-use performance benefits. Originally available as
either Kevlar 29 for ballistic applications or Kevlar 49 for structural applications, today Kevlar
technology is available with physical properties developed to deliver enhanced performance in a
myriad of targeted end-uses. Examples of this are stab and puncture resistance, enhanced products
for body armor, improved military fragmentation technology, performance increases in cut-resistant
and cyclical motion (fatigue) applications, and improved products for structural and aerospace
needs.

Despite the fact that Kevlar is used in a host of applications today, there was a point at
which DuPont was unsure exactly what it would do with the product. The fiber was originally
developed for use in automobile tires, but the emergence of a cheaper polyester alternative waylaid
that end-use. DuPont began to look for other applications for the product, and one of the companies
DuPont turned to for assistance was Hexcel Schwebel in Anderson, S.C.We were the first weaver in
the United States to weave Kevlar fabric for DuPont, said Ken Langford, marketing manager, Hexcel
Schwebel. We started weaving fabric specified for use in soft body armor in 1972.Today, Hexcel
Schwebel continues to weave Kevlar for a variety of applications, including ballistic protection,
safety apparel, recreation and aerospace.The company gets filament and a small amount of spun yarn
from DuPont and performs ring twisting and cable twisting in-house. The yarn is woven into fabric
on Sulzer rapier looms and is finished at the Anderson plant. We do scouring, water-repellent
treatment and some coatings here in Anderson, said John Leatham, North American sales manager,
ballistics.Because of Kevlars end-uses, the product must be handled with extreme care during
fabrication, Leatham said. Our challenge is to protect the properties of Kevlar as they exist when
the yarn comes in. It has to be handled very gently. Tension, abrasion, exposure to thermal cycles
all of those can impact the strength and performance of the fiber. We want to limit that impact
throughout the process and provide the opportunity to have a product that performs very well.As a
result, Hexcel Schwebel has improved each process preparation, weaving and finishing in order to
provide delicate handling of the fiber.We measure the properties of the product when it first comes
in, Leatham said, and then extract strands throughout the process to measure loss. Because of the
applications of Kevlar, our customers need process integrity, so we provide a substantial amount of
quality control testing on a lot-to-lot basis.Hexcel Schwebel keeps meticulous records of each
process so that traceability is never an issue. We begin with the certification we receive from
DuPont and then do our own random testing of incoming product, Leatham said. Then we have
traceability throughout our system from the bobbin to the finished roll. We can tell by roll number
everything that has happened to the product from the moment it comes in until the moment it leaves
the plant.In addition to Kevlar, Hexcel Schwebel produces a number of other high-performance
fabrics for various applications. The companys biggest market is fiberglass. Hexcel Schwebel weaves
fabrics for electronic, filtration and composites, as well as for general industrial use.
November 2001

National Acquires Glen Raven39 S Open-End-Package Dyeing Business

National Spinning Co., Inc., a leading US-based supplier of yarns, and Glen Raven Yarn Co., LLC confirmed today the acquisition, effective November 12, 2001, by National Spinning of Glen Ravens open-end spinning and package-dyeing business, including two plants located in Alamance County, North Carolina. The former Glen Raven plants, which will immediately be integrated into Nationals operations, will become known as the Alamance Spinning Plant and Alamance Dyeing Plant of National Spinning. Over 200 associates will be added to Nationals base of 1,600 owner-associates.The added capacity will enhance National Spinnings ability to service its customers. Commenting on the acquisition, Jim Chesnutt, president and CEO of National, stated, “Despite being in an environment that has not favored domestic textile producers, National is fortunate to be in a position to expand its core business. Chesnutt added, “This move will emphasize our commitment to US-based manufacturing and North American/Caribbean markets. We will continue to support our customers with the highest quality products and service, to assure their success in difficult markets.”Brookwood Associates Inc., investment bankers, of Charlotte, NC assistedNational Spinning with this transaction.National Spinning Co., Inc., an employee-owned company, was founded in 1921. In addition to the Alamance plants, National operates plants in Beulaville, Warsaw, Washington, and Whiteville, North Carolina, and LaFayette, Georgia. National and its Caron International subsidiary provide high-quality natural and dyed yarns for apparel, home furnishings, industrial goods, hosiery, automotive fabrics, and home-crafting. Glen Raven, Inc. is a highly diversified textile marketing, sales, and manufacturing company producing yarn and fabric for the awning, marine, casual furniture, industrial fabrics, apparel fabrics, and automotive fabric markets, through various subsidiaries, with manufacturing facilities in North America and Europe. The company is headquartered in Glen Raven, NC.

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