Hubei Gesalife Industry Co. Ltd., China, has successfully commissioned its first crosslapped configuration neXline spunlace production line from Austria-based ANDRITZ. Operational since late 2024, the line produces up to 1,000 kilograms per hour of spunlace roll goods, with crosslapper speeds of 130 meters per minute. The installation supports Gesalife’s expansion in wipes and hygiene product converting, aligning spunlace output with its existing capabilities. The company manufactures hygiene products, disposable medical
supplies and protective equipment.
Li Jun, chairman of Gesalife, said: “This new spunlace production line and the cooperation with Andritz marks a major leap forward for Gesalife. We look forward to leveraging this technology to support future innovation and growth.”
To expand its polypropylene fiber production Italy-based ALMA S.p.A., a floor coverings specialist, has installed a new nonwoven needling line from Germany-based Dilo Systems GmbH. The line serves ALMA’s markets in exhibition carpet, artificial grass, automotive interiors and domestic applications. The system includes DiloTemafa fiber blending and filtration system, DiloSpinnbau card feeding, state-of-the-art carding, high-speed crosslapping from DiloMachines, and 6-meter-wide needling with DI-LOOP for high-speed structuring, in addition to Industry 4.0 DI-Connect controls.
According to ALMA, the line has been installed and started up in a smooth, straightforward way, synchronizing DILO’s team with ALMA’s operating and maintenance department. The launch provided a quick start-up and full production capacity.
Continuous Composites (CCI), Coeur D’Alene, Idaho, has secured multi-million-dollar funding from the U.S. Air Force to advance high-temperature materials using its CF3D® technology. The first funding phase will establish baseline material properties for CF3D-produced components, while the second phase will expand to full-scale production and flight testing. CF3D enables automated manufacturing of continuous fiber composites in near-net shapes, offering precise control and scalability for high-performance applications.
According to CCI, by integrating advanced materials fiber steering and automated manufacturing, CF3D enables the production of lightweight, high-performance structures with unmatched precision and scalability.
England-based Nonwovenn has invested in its MediTech division, adding a new medical manufacturing suite at its headquarters location. The facility includes a Class 8 standard performing cleanroom and supports the company’s three-year plan to drive 14 percent annual growth through innovation, partnerships and expansion. Recent product developments include x-ray detectable materials for surgical safety, reinforced CMC hydrofiber for wound care, and a translucent dressing scaffold that enables incision site inspection without removal.
John Birkett, medical business director at Nonwovenn, said: “The investment reflects our commitment to quality, innovation and continuing to serve the evolving needs of our partners in the sector across the UK, Europe and Middle East.”
INDA’s annual Hygienix™ event will gather in Orlando for the 2025 edition.
TW Special Report
Hygienix™, an annual event focused on the absorbent hygiene products (AHP) industry organized by the Cary, N.C.-based Association of the Nonwoven Fabrics Industry (INDA), will be held in Orlando, Fla., November 17-20, 2025, at the Omni Orlando Championsgate hotel.
Hygienix brings conference sessions, workshops, tabletop exhibits and product showcases, networking, and the Hygienix Innovation Award™ together in a single event for industry leaders, innovators and professionals from the AHP industry.
First up, on November 17, are three workshops designed to provide hands-on learning and insights. James Robinson, principal, Absorbent Hygiene Insights LLC, is hosting a workshop titled “Fundamentals of Absorption Systems and Opportunities in Adult Incontinence.” Crown Abbey CEO Heidi Beatty will lead a workshop on “Innovations in Menstrual Care.” A third workshop named “Baby and Infant Care Market Dynamics” will be conducted by Natalia Richer, director of business development, Diaper Testing International.
Conference Topics
As of TW’s press time, INDA was still finalizing the speakers and the presentation titles for the conference. But, this year’s conference program will focus on key areas that are trending in the AHP industry:
Sustainability and Circularity — including biobased materials, natural fibers, packaging innovations, end-of-life solutions and safe operating limits;
Consumer and Market Insights — including private label product growth, regional market outlooks and skin health;
Product Innovation — including strategies to manage hurdles when bringing period care products to market; and
Regulations and Standards — including regulatory updates and testing methods.
In 2025, Hygienix offers participating companies two opportunities to share information, and demonstrate products and services to attendees who may be potential partners or future clients — tabletop exhibits; and fast-paced, five minute Lightning Talks. The talks will take place November 18 and 19 in the afternoon. INDA also is hosting extended networking with three receptions — the official welcome reception on November 17, as well as receptions and the chance to view the exhibits at the end of the day on November 18 and 19.
Innovation Awards
Finalists for the Hygienix Innovation Award will give presentations about their nominated products to event attendees on November 18. At the close of the event on November 20, the winner will be announced. As of TW’s press time, the finalists had not been determined, but the products always cover breakthrough ideas in technology and product solutions. Last year’s winner was HIRO Technologies, a start-up out of Austin, Texas, awarded for its biodegradable MycoDigestable™ Diapers.
“Having attended every Hygienix since its inception, what I always found valuable was the ability to connect with both my suppliers and customers at the same event,” said Dr. Matt O’Sickey, director of Education & Technical Affairs, INDA. “Having both my technical and commercial team members with me in those meetings allowed us to take quick decisions that accelerated programs and ultimately enhanced our speed to market, elevated our hit rate and improved our overall ROI. Now with INDA, I appreciate the efforts made to provide actionable market and technical content and facilitate the supply chain connectivity that was so critical for my success in the corporate world. Hygienix is an exhausting week in the very best possible way.”
For more information about Hygienix™ — including the full conference schedule, speakers and topics — please visit hygienix.org.
The 15th annual RISE® conference will bring industry and academia together in a forum for science, innovation and collaboration in engineered fabrics.
TW Special Report
The 15th RISE™ — Research Innovation & Science for Engineered Fabrics — conference is set to take place October 14-15, 2025. The two-day event, co-organized by the Cary, N.C.-based Association of the Nonwoven Fabrics Industry (INDA) and The Nonwovens Institute, will take place at the McKimmon Conference and Training Center on the NC State campus, Raleigh, N.C.
RISE focuses on emerging technologies and ideas with the aim of connecting innovations with real-world applications for professionals in the nonwoven/engineered fabrics industry.
Speakers included experienced industry, government and academic personnel.
While the event is created by a nonwovens organization, topics and focus areas stretch beyond nonwovens with a large focus on materials science. There definitely are reasons to attend for those who do not work exclusively in the nonwovens industry.
Key topics covered at RISE include:
Recycling methods, raw materials alternatives and circular economy;
Biobased/hybrid fibers and natu-ral-synthetic blends;
Innovations in coatings, additives and adhesives; and
Enzyme technology and the biodegradation processes. Speakers from Nova Institute,
Total Corbion, Fibroline, Gottlieb Binder, CJ Biopolymers, Bast Fibers, Keel Labs, Hills Inc. and INDA, among other companies are commit-ted to speak during this year’s event. Please visit the RISE website for the full conference lineup and schedule.
On Monday, October 13, a day ahead of the conference, there is a golf tournament starting at noon at the Lonnie Poole Golf Course on the NC State campus. The conference also is offering tours of NWI from 3-5 p.m. at the conclusion of the conference proceedings on October 15.
RISE® Innovation Award, Research Posters
Nominations have already concluded for the RISE® Innovation Award, which honors innovation in nonwovens that solve problems and meet unmet needs. The top three nominations as selected by an INDA Technical Advisory Board (TAB) will present their technologies during the RISE conference. The winner is determined by votes cast by TAB, the affiliated Conference Committee and attendees at RISE, with each group’s votes carrying equal weight. All votes are tallied during the conference and the winner is presented with the award before the end of RISE. Last year’s winner was Hempitecture Inc. for its PlantPanel™ product (See “From Hemp Farm To House Frame: The Hempitecture Story,” TW,, this issue).
An evening reception, to be held from 5-6 p.m. on October 14, will allow attendees to view current research work of graduate students who are enrolled in a variety of non-woven, textile and fiber programs as well as corporate research posters.
Pre-RISE® Webinar
On Thursday, October 2, INDA will host a preconference webinar on the topic “Enhancing Softness and Loft in Nonwoven Fabrics.” The presentation — featuring ExxonMobil Technology & Engineering Co.’s Dr. Paul E. Rollin Jr., senior principal scientist – Global Hygiene, and Thomas Cugnon, Hygiene Market Development Lead, Europe — will explore the role of ExxonMobil’s Vistamaxx™ performance polymers in softness including approaches to achieving a high-loft feel.
“What I’ve really come to enjoy about RISE is that it is one of the few places where you can find a blend of scalable academic and independent lab research side-by-side with fresh to the market industrial innovations,” said Dr. Matt O’Sickey, director of Education & Technical Affairs, INDA. “Observing how this mix fosters cross-pollination and synergies in the fiber, engineered fabrics, and nonwoven space is invigorating.”
Make plans to attend this year’s RISE conference and participate in this unique forum where research, innovation and commercialization really do intersect. The conference showcases what’s next, but also fosters collaboration and helps accelerate ideas.
For more information about RISE®, please visit riseconf.net.
The Advanced Textile Association’s (ATA’s) annual conference will take place in Indianapolis in November.
TW Special Report
The COVID pandemic halted the Advanced Textiles Association’s (ATA’s) plans to host its annual trade show in Indianapolis, Ind. The year 2020 was the association’s 100th anniversary and it was looking forward to a standout event to mark the occasion. While COVID had other ideas, ATA is excited to host the 2025 edition of the AT Expo at the Indiana Convention Center in downtown Indianapolis. Education sessions begin on November 4 and the show floor is open November 5-7, 2025.
What To Expect
The show will again be collocated with Messe Stuttgart’s Sun Shading Expo North America. According to ATA, the collocation of the events for these two complementary industries offers value in terms of connecting with customers, suppliers, end-product manufacturers, and industry counterparts, as well as providing growth opportunities. Attendees have access to both events including the combined show floor, show floor education and networking receptions. The only exceptions are AT Expo’s Emerging Technologies (ET) conference, which is only open to AT Expo registrants; and Sun Shading Expo classroom education, which is only open to Sun Shading Expo registrants.
The show floor will feature the ATA Hub, which is a great place to learn more about ATA or join a member division open meeting.
Education
For an add-on charge, attendees can arrive one day early to kick off their expo week at the ET Conference. On Tuesday, November 4, a full day of presentations will conclude with the ET Networking Reception from 5:30-6:30 p.m.
Topics will cover a variety of subjects from medical textiles and bio-materials to space innovations and artificial intelligence. A full lineup of speakers and topics is available on the AT Expo website.
Education continues on the show floor stage beginning Wednesday morning. These more informal, 30-minute sessions are designed to be interactive and digestible.
New In 2025
ATA has planned several new features for attendees at the upcoming expo. Networking Roundtables will allow fabricators and suppliers to engage in topic-driven and candid conversations. It’s free to attend these peer-to-peer sessions that will cover topics such as tariffs, workforce development and overcoming sales objections, among other topics.
ATA also will present a State of the Industry Update, which highlights findings from its annual State of the Industry survey. This session, to be held on the show floor, is open to all expo attendees. In addition to the economic outlook, growth markets and industry trends content, the presentation will include testimonials about ATA programming and how it helps support member success.
“Talking Textiles” — a daily live podcast — will be recorded on the show floor. According to ATA, visitors will be able to hear “textile leaders, innovators and changemakers” as they are interviewed on subjects such as trends, challenges and industry stories for the podcast. ATA will publish a full schedule of hosts and guests as the expo date draws closer.
Other Notable Events
Returning to AT Expo is the Marine Fabricators Association (MFA) Roadshow. Julie Tinsman from Strataglass, Jeff Newkirk from Precision Custom Canvas and Kyle Van Damme from Marine Tops Unlimited, will host sessions on marine fabric selection, traditional patterning techniques and U-Zips. The roadshow is free to attend, but registration is required to save a seat.
ATA is again giving women a chance to meet and network during the expo. On Friday, November 7, before the show floor opens, the Women’s Networking Walk will take place. Later the same morning, women also can participate in the Women’s Leadership Empowerment session. Under the title “Balancing Priorities for Success,” the session will impart advice and ideas on managing work and life while building a career.
Nighttime Social Events
To kick things off, the Professional Awning Manufacturers Association (PAMA), ATA Canada and the Fabric Structures Association (FSA) are hosting Pub Night at Pins Mechanical Tuesday, November 4, from 7-9 p.m. Members of PAMA, ATA Canada and FSA are welcome to connect with peers and network in a relaxed atmosphere. The event is sponsored by Herculite®, Trivantage® and Sunbrella®.
On Wednesday, November 5, AT Expo will host the official opening reception at 4 p.m. The reception is included with all registration types to give all participants the chance to mix and mingle to wrap up the first full day. The reception is sponsored by Herculite.
Attendees who opt to purchase a separate ticket during registration can move from the opening reception to Industry Night at 7 p.m., which this year will be held at the Slippery Noodle Inn in downtown Indianapolis. As always, live music will be provided by ATA member band Hangin’ by a Thread. Event sponsors are Herculite, Sunbrella, TVF and Weathermax®.
For more information about Advanced Textiles Expo — including the full conference schedule with speakers — as well as to register, please visit advancedtextiles expo.com.
Hempitecture’s HempWool® is a 90-percent hemp fiber batt insulation material designed to replace mineral wool and fiberglass in insulation applications. It can be installed in wood or metal framing systems.
Hempitecture is bringing natural fibers, hemp in particular, to the forefront of sustainable building design.
By Rachael S. Davis, Executive Editor
Not every textile entrepreneur begins their journey in the textile space. Some arrive by way of a completely different path — driven by a problem they can’t ignore and a vision for change. For Matthew “Mattie” Mead, co-founder and CEO of Jerome, Idaho-based Hempitecture Inc., that moment came while studying architecture, environmental science, and entrepreneurship at Hobart College in Geneva, New York.
As Mead became immersed in the world of sustainable design and materials, “I saw a big problem,” Mead said. “Buildings and their operations are responsible for nearly 40 percent of our carbon footprint. In seeking to understand how to solve that issue, I became enamored with the idea of using plant-based, sustainable fibers.”
He was inspired to use hemp as a carbon-storing, high-performance material, and what started as a vision, quickly became Mead’s mission.
Leveraging Hemp
In 2013, Mead co-founded Hempitecture — a company he touts as a “Public Benefit Corporation with a mission to benefit both people and planet through carbon capturing mate-rials.” Mead works with Co-Founder and Chief Innovation Officer Tommy Gibbons to develop Hempitecture’s biobased construction materials.
The company primarily uses decorticated and cleaned industrial hemp fiber to create its products, along with some cotton and thermoplastic fibers including polyethylene and polyester biocomponent bonding fibers. Depending on the use case, the company may also create products using polylactic acid (PLA) fibers.
“Hemp is our cornerstone because it’s fast-growing, regenerative, and has ideal insulation properties,” Mead said. “We like to consider it our carbon capturing engine behind our product portfolio. We blend the hemp with other fibers, depending on the performance characteristics we are seeking to achieve.”
Hempitecture’s facility is in Jerome, Idaho, in the heartland of agricultural industrial hemp fiber production.
Jerome, Idaho, was selected for the company’s headquarters and manufacturing location because it’s in the heartland of agricultural industrial hemp fiber production, according to Mead. “From a logistical standpoint, it’s centrally located to where hemp is grown, but our factory is located right on Interstate 84, allowing efficient distribution of our finished nonwovens,” Mead shared. “In Idaho, we’ve found great team members, we’ve received support from the Idaho Department of Commerce, and we’re proud to sup-port this agricultural opportunity in Idaho, an agriculturally aligned state.
“Agriculture is at the heart of what we do,” Mead emphasized. “By sourcing fibers like hemp from American farmers, we’re creating new markets for regenerative crops. We’re turning farms into supply chains and putting rural communities at the center of climate solutions.”
Hempitecture also operates five distribution centers around the country.
Hempitecture’s product portfolio includes PlantPanel™ — a continuous insulation panel made from biobased fibers for exterior or interior wall assemblies —as well as HempWool™ fiber batt insulation.
First Introduction: HempWool®
Hempitecture’s first innovation was HempWool®. This natural fiber batt insulation material contains hemp, but no wool as the name may suggest. The wool portion of the name arises from the fact that HempWool was designed to replace mineral wool and fiberglass products traditionally used in the construction business. HempWool comprises 90-percent hemp and 10-percent binder fiber.
“We initially collaborated with Europe-based OEMs and other manufacturers who had experience in natural fiber insulation and nonwovens,” Mead said. “That helped us under-stand the machinery and process requirements. With their support, we developed a unique configuration of nonwoven machinery with modifications so it can handle natural fibers like hemp, which behave differently than synthetic fibers.”
Eventually, Hempitecture brought the technology stateside and made it their own, modifying, improving, and ultimately scaling it into a domestic operation.
Hempitecture began development of HempWool in its production facility in 2022, and after working with academic and industry partners, launched the product for sale in the U.S. market.
HempWool currently is used primarily in residential construction, but Hempitecture is working on expanding its reach into other markets including industrial and commercial for wall, roof, and floor assemblies.
“Current capabilities include fiber opening and cleaning, fiber treatment, airlay and thermal bonding, and nonwoven cutting,” Mead shared. “We also can offer custom formulations for partners across industries and are always open to collaborating on nonwoven projects.”
Hempitecture is focused on healthier and more sustainable alternative construction materials for the whole building including insulation and acoustic products.
Whole Home Solutions
Once HempWool hit the market, Hempitecture looked for other areas where its natural fiber technology could make an impact. The company is building a portfolio of whole home thermal and acoustic insulation solutions, but is not limiting itself to building products.
“Manufacturing is about continuous improvement, and we continue to develop our manufacturing technologies and capabilities to advance our product portfolio,” Mead said. “While we started with HempWool, it’s an evolving product as we continue to advance our fiber compositions, our treatment technologies and our operational efficiency.”
PlantPanel™ — a continuous thermo-acoustic insulation panel made from biobased fibers for exterior or interior wall assemblies —and FiberFill™ — a blowable loose-fill insulation material ideal for retrofits and attics — became the next two products offered by Hempitecture. In addition, it offers a carpet underlay named FiberPad, and an eco-friendly building material called Hempcrete.
“We also entered the cold-chain packaging sector, developing a high-performing hemp-based liner for shipping food and pharmaceuticals,” Mead said. Hempitecture utilizes cotton shoddy fiber for the cold-chain packaging products, which helps divert landfill bound textiles into new materials.
“While hemp and building materials are our core focus, we also produce products for a variety of industries needing nonwoven materials using a range of different fibers,” Mead noted.
Hempitecture Advantage
According to Mead, Hempitecture’s products compete head-to-head on thermal performance. The company has completed ASTM C518 thermal testing, ASTM E84 testing and ISO-based lifecycle assessments to back up its claims. “From an R-value perspective, we’re competitive with mineral wool and fiberglass, but our product phase shift resistance is improved over these conventional products,” Mead noted. “Hemp fiber insulation has incredible phase shift resistance — storing heat and then releasing it as temperature shifts from hot to cool, reducing heating and cooling loads,” Mead said. “It’s also highly dimensionally stable so it won’t sag or slump over time.
“From an embodied carbon and health standpoint, we’re significantly better. We’re continually optimizing our products and we’re advancing our fire-resistance ratings to better align with commercial and industrial standards.”
HempWool®can be handled and cut without special tools or protective gear.
Mead notes however that there is a lot more to insulation than just R-value. In addition to making the grade on thermal performance, Hempitecture products offer other significant advantages. They are non-toxic, vapor open, carbon-storing and safe to touch. HempWool can be handled, cut and installed all without wearing gloves. Hemp also confers a natural mold- and pest-resistance.
Properties can be further enhanced with the company’s proprietary fiber fortification line that can increase fiber consistency, and improve flame and pest resistance. “We also
enhance our fibers with our fiber treatment technology, which is typically borate-based chemistries — a naturally occurring mineral with a long safety record,” Mead added.
In addition, Hempitecture products are landfill-safe and mostly biodegradable. “Unlike traditional insulation, which can persist for decades releasing harmful substances as it degrades, our materials break down safely,” Mead said. “Because our products are airlay thermal bonded, we do use small amounts of polymers, but are always monitoring the world of biobased bonding fibers.”
Wide-Scale Adoption
Response to Hempitecture products has been incredibly positive, especially among architects, builders and homeowners who prioritize health and sustainability. “The biggest hurdle is awareness, and people don’t always know that better alternatives exist,” Mead reflected. “We also face typical industry barriers like code compliance and cost competitiveness at scale.”
Mattie Mead (center) accepted the RISE® Innovation Award from the Association of the Nonwoven Fabrics Industry (INDA) for PlantPanel™.
In 2024, Hempitecture’s Plant-Panel received the Association of the Nonwoven Fabrics Industry’s RISE® Innovation Award. Being recognized by the nonwovens industry helped raise awareness for Hempitecture. “Winning the RISE Innovation Award put us on the radar of some major players in the nonwoven and building material industries,” Mead said. “It validated our work and opened doors for collaboration, funding and visibility in sectors we hadn’t yet tapped. We are excited about the opportunity to collaborate with mainstream players in the nonwovens and textiles industries to help custom build nonwoven solutions using our technology and capacity.”
A Better Future
The Hempitecture team is small, but growing. The company is eyeing an expansion in Tennessee that would be enabled in part by Department of Energy funding.
Mead considers material innovation, sustainability leadership and the company’s supply chain as its biggest strengths. “We partner with companies who produce fibers to our specification, which gives us flexibility and resilience,” Mead said. “Our team also brings together architectural knowledge, manufacturing experience and startup experience, which is a rare combination.
“Our culture is mission-driven, entrepreneurial, and rooted in the belief that materials can be a force for good,” Mead offered. “We value transparency, sustainability, health and performance, as well as American manufacturing.”
PlanetPanel™ X exterior rigid board thermo-acoustic insulation panels.
Long-term, Hempitecture envisions a world where natural fibers are a cornerstone of the built environment from walls to packaging and beyond. “We’re building a platform for biobased building materials,” Mead said. Our technology can be extended to new product categories including acoustic panels, molded composites and prefab building systems.”
Summing up, Mead said: “The materials we build with matter. They shape our health, our climate and our economy. I believe we have a responsibility, as well as a huge opportunity, to reimagine those materials for a better future.”
From an idea born in a college thesis to a growing company reshaping how buildings are made, Hempitecture has proven that natural fibers can compete with — and perhaps surpass — conventional materials. By pairing agricultural innovation with advanced manufacturing, the company is carving out new markets for regenerative crops while delivering healthier, more sustainable products for builders, homeowners, and industries beyond construction. As awareness grows and collaborations expand, Mead sees Hempitecture not just as a manufacturer, but as a catalyst for change — proof that the materials we choose can protect our planet, strengthen communities and inspire a better future.
Alternative or multipurpose PPE may feature a jacket with bi-wing back design for mobility, multiple pockets for tools and radios, and top-quality reflective trim while pants may include long zipper bottoms for easy boot entry, adjustable waist straps and even ample cargo storage.
Firefighter apparel is not a one-product-fits-all scenario —different emergencies may require different gear.
By Todd Herring
This summer’s wildland fire forecast — above normal potential from Texas and Oklahoma clear out to the Western slopes — is a reminder to men and women on the line that their personal protective equipment (PPE) gear must have the flexibility to go from manageable to lifesaving, often in minutes.
Modern firefighters are constantly toggling between structure protection, vehicle crashes, medical calls and many other types of emergencies. Yet for decades, gear strategy has typically called for structural turnouts for every call, whether a four-alarm blaze or an overheated transformer.
The problem is that turnouts are designed for high-heat fire suppression, not hours of movement in extreme outdoor heat, and that mismatch can take a special toll on the health and performance of wildland firefighters.
Shifting To Alternative PPE
National Fire Protection Association (NFPA) records leave no doubt that the number of structural fires has taken a steep dive over the last 40 years.1 Meanwhile, EMS responses have dramatically multi-plied — to 421 percent higher than before — and non-fire calls across the board are close to triple the old counts.
Wearing flashover-rated turnouts to handle a roadside crash in triple-digit heat, for instance, probably means hauling weight you don’t need, trapping heat you can’t shed and pushing your body toward the kind of overexertion that too often leads to heat stress.
The good news is that gear is get-ting smarter as materials are getting lighter without losing their protective edge. And maybe most importantly, departments are beginning to talk about “right gear for the right call” as a legitimate operational philosophy rather than a luxury.
Not Just A Nice-To-Have
Alternative PPE, or gear built specifically for nonstructural fire calls, has been around for years, but is still considered “optional” for many departments. The reality, however, is that it’s more like an insurance policy for both the firefighter’s body and the department’s budget.
On the health side, the case is straightforward in terms of lighter, more breathable gear that helps regulate core body temperature and reduce fatigue. When you lower the strain on the body, you preserve cognitive performance, decision-making and physical capacity over long shifts. And if that gear is kept separate from structural turnouts, it also reduces the amount of toxic contamination that firefighters carry back to the truck or station, as shown in studies such as one published in the International Journal of Hygiene and Environmental Health.2
On the financial side, alternative PPE keeps turnouts fresher for when they’re truly needed. It’s not unusual for departments to get years of additional service out of their most expensive gear by rotating in multi-purpose gear for the high-volume, low-heat calls.
The year 1980 brought more than 10 million calls to fire departments, almost 3 million of them structural fire runs. Flash-forward to 2023, and structural emergencies dipped to just 1.4 million while total calls including EMS, search and rescue and “other” soared to more than 42 million. New challenges demand new strategies for gear as NFPA data shows.
Science Under The Seams
The real leap forward has come from materials science. Looking at TECGEN® fiber from Medina, Ohio-based Fire-Dex LLC, for example, it’s easy to assume at first that it’s just another carbon fiber. But it’s not. Rather, the fiber comprises a viscoelastic core that is encased in a high-density carbon shell. This structure provides the thermal protection of carbon fiber without its biggest drawback — brittleness —making it far better suited for fabric blends that need to breathe and move with the body.
TECGEN first entered the fire service in 2008 as part of rescue gear, and by 2015, it became exclusive to the Fire-Dex brand. TECGEN51 — originally introduced in 2011 by the TEC-GEN team as TECGEN XTREME — was purpose-built as a single-layer fabric for nonstructural emergencies. Fire-Dex acquired the technology in 2015, and partnered with Spartanburg, S.C.-based Milliken & Company — a manufacturer recognized for its NFPA-compliant fabrics — who began producing the material under license to ensure a consistent, large-scale supply.
Dual-certified to NFPA 1951 — for technical rescue — and NFPA 1977 — for wildland performance — TECGEN51 delivers the abrasion resistance, thermal protection and breathability needed for everything from motor vehicle accidents to wildland-urban interface (WUI) operation, but without the weight and heat load of multiple heavier layers.
However, if the design doesn’t match the realities of the job, the best fabric in the world still doesn’t help achieve the goal. For alternative PPE, every detail must be scrutinized through the lens of movement, heat dissipation and hazard coverage, including:
Mobility — Bi-wing backs in jackets let shoulders move freely when climbing, hauling or carrying tools.
Debris Defense — Mandarin-style collars keep grit and embers out without adding the bulk of a traditional turnout collar.
Ease of Donning — Oversized pant legs with long zipper openings make it easy to quickly pull gear over boots.
Targeted Reinforcement —High-wear zones like knees and cuffs get abrasion-resistant overlays without adding weight across the entire garment.
Taken alone, these features don’t create a lot of buzz, but add them up, and they cut fatigue and help firefighters stay sharp when it matters most — and that’s worth getting excited about.
The Wildfire Connection
So, what does all this have to do with the looming wildfire season?Everything. Fighting fire in the WUI is a different game than a traditional structure fire. Firefighters are moving constantly, covering distance and working in full sun. The radiant heat from the fire is only part of the equation as the ambient temperature, gear insulation and exertion can all stack up fast.
Imagine running a marathon in full winter gear: runners will finish slower, heavier and hotter, of course. And that’s what turnouts can feel like in the WUI, and why alternative PPE is finding the firm middle ground with heat and abrasion protection, plus the comfort to last through the shift.
Departments that embrace a “gear match” philosophy by investing in PPE built for the actual risks of wildland firefighting — and a growing litany of non-fire scenarios — are going to have an edge going forward that will show up in firefighter endurance, incident outcomes, gear longevity and long-term health metrics.
Weather patterns, the topography or the fuel load cannot be controlled. But how the people running toward the fire line are equipped can be controlled. And in this new normal, that choice might be the single biggest factor in keeping them safe and ready for whatever comes next.
References:
1 NFPA Research; Fire Department Calls; accessed 8.12.25. https://www.nfpa.org/education-and-research/research/nfpa-research/fire-statistical-reports/fire-department-calls?l=58
2 Air pollution inside fire stations: State-of-the-art and future challenges; January 2024. https://www.science direct.com/science/article/pii/S1438463923001803?via%3Dihub
Editor’s Note: Todd Herring is vice president of Product Innovation and Strategy, Fire-Dex, Medina, Ohio.
Enka Bio Carrier, made from renewable resources, is a sustainable carrier material for green roofs on urban buildings.
Enka® Solutions technology has been meeting diverse needs since the late 1960s.
TW Special Report
Every once in a while, the textile industry throws a curve in a positive kind of way. Maybe walking through the aisles of a show or expo, or maybe thumbing through an industry related magazine, a product or technology genuinely causes an abrupt stop with a desire to investigate further, only to find that it now creates more wonder and curiosity. Thoughts of “what is that,” “what’s it used for,” “how did they actually manufacture it” and maybe even “how can it be used in some application” start pinging around. Freudenberg’s Enka® Solutions technology is one of those unique and versatile product lines that has the ability to create this type of reaction.
Best described as a 3D nonwoven matrix structure generated from extruded polymeric filaments, Enka Solutions’ technology has been generating conversations and fulfilling various application needs since its development in the late 1960s. “It is a unique product technology with a virtually endless range of possibilities,” offered Audrey Sanders, business manager for Enka America. “The flexibility this technology provides to designers and engineers enables the creation of solutions for use in rather diverse market segments.”
Enka Solutions’ products are being produced both as private label products and also to be sold direct to customers. Global manufacturing locations now include Asheville, N.C., Obernburg, Germany, and Changzhou, China. The list of market segments for this technology currently includes filtration, composites, building and construction, civil engineering, green roofing, and sports and recreation, with more segments and applications in development or under consideration on a daily basis.
Enka’s Path To Present Day
The Enka name and brand has a long and storied history globally as well as in the American textile industry. Enka is derived from the initials of the organization’s original founding company, the Netherlands-based firm Nederlandse Kunstzijdefabriek (N-K), which translates as Dutch Artificial Silk Factory, which was founded in 1911 in Arnhem.
The American Enka Co. was established in Candler, N.C., just outside of Asheville, in 1928, providing N-K a base to expand into the growing American textile industry. It began as a manufacturer of rayon yarn before transitioning into producing nylon 6 in the 1950s.
While N-K is no longer in business, the Enka name has carried on. After a succession of different corporate ownerships and name changes, Enka was acquired by Low and Bonar in the mid-2000s. The Germany-based Freudenberg Group then acquired the Low and Bonar assets in 2020 positioning the Enka products as a brand under the Freudenberg Performance Materials (FPM) segment. According to Sanders, who has been with the company for more than 17 years and is happy that they are now part of FPM, “Freudenberg provides us with the stability and direction to invigorate, grow and build upon these technologies along with the freedom to make a deeper dive into our existing product offerings while also exploring new opportunities.”
A variety of Enka® Solutions 3D nonwoven matrix products
A Highly Adaptable Technology
“It really is a highly engineerable and adaptable technology,” stated Lori Hascher, Enka Technology’s research and development manager. “We have the ability to alter most any parameter or characteristic in the material, including the mesh shape and structure, interaction of the extruded filaments, the polymer composition and physical characteristics as the application may require.” The 3D structures can be produced in thicknesses ranging from 1 millimeter (mm) — 1/32-inch — to more than 50 mm — approximately 2-inches — with void spaces of up to 95 percent. A selection of standard and customized shape profiles are available as the molds used in the 3D matrix manufacturing process are created in-house. Polymer options include polyamide, polypropylene and polyester with others always in consideration. “Numerous additives are available to improve parameters through the polymer compounders we work with,” Hascher added.
In addition, the manufacturing process allows for the inclusion of “skins” applied to the face, back or both surfaces of the 3D matrix. These skins can be in the form of a nonwoven material, woven or knit fabrics and/or membranes to impart even more characteristics or functionalities towards the application’s requirements.
EnkaSpacer is a high-performance flow medium for injection molding.
Diverse And Growing List Of Applications
Most 3D textile structures remain somewhat unique to the industry, but in general have gained acceptance in a number of technical and performance driven applications in countless facets of industry (See “3D Textiles: The Difference is Depth”, TW, July/August 2016). “It certainly can be challenging given the variety of applications this technology serves,” suggested Luca Quinones, product manager and inside sales. “One minute we’re speaking with a customer on soil stabilization and the next you might be discussing roof venting or spacer inclusion applications. It can make for interesting and varied conversations.”
There are several examples of Enka 3D matrix products and applications that may not generally be considered traditional textile applications.
Building and Construction:
— EnkaSonic is a family of products used as a cushioning layer installed between flooring — such as hardwoods, engineered wood flooring and tiles — and the sub-floor of the building, which is usually concrete. EnkaSonic’s formation acts as a cushioning layer for the flooring that also provides a level of sound control. According to Sanders, a new customer is currently using a variation of this product in a layered system being used to deaden the sometimes-annoying sounds coming from indoor and outdoor pickleball courts when in use.
Ventilation Systems:
— EnkaExFlo is a unique construction designed to fold over the peak or ridge of a roof structure and allowing for proper ventilation along the ridge without letting unwanted moisture from rain or blowing snow to enter the ceiling structure.
Water Management:
— Variations of the Enka technology can be used to improve water management from within or outside building structures to safely redirect and improve water drainage from roofs or areas subject to pooling.
Civil Engineering:
— Erosion Control applications make use of Enka Solutions products as a protective layer for soil stabilization on slopes and embankments, waterways and shorelines. It can also be used to protect riverbanks, spillways and drainage areas from erosion caused by waterflow. Given its high level of void space, the 3D products can also help to establish vegetation in these applications.
— EnkaDrain refers to a multi-functional material construction that provides a proven reliable alternative for earthwork drainage of embankments, dykes and slopes as well as for reinforced walls. Its high shear strength and pressure resistant design can help to minimize construction time and reduce the localized environmental impact.
Green and Blue Roofing Systems
— Variations of the 3D matrix, generally with skins applied to one or both sides can be incorporated into green and blue roofing systems as a carrier for vegetation as well as to facilitate water management and mimic natural hydrology aiding in plant growth, easy harvesting and installation in rather unlikely environments.
Other Applications: Composites Manufacturing:
— EnkaFusion and EnkaChannel are two products being used as aids for the manufacturing of molded composite parts using vacuum infusion and resin transfer molding processes. Both products are compatible with most commonly used resin systems. EnkaFusion is employed as a flow media that as the name implies encourages the quick and even spread of resin across the width and breadth of the part being molded resulting in more even and consistent infusion. While EnkaFusion is designed to spread the resin flow, EnkaChannel was created to specifically provide a channel for the resin to flow efficiently and more directly to specific targeted locations. It is available in two widths and generally used in conjunction with larger molded part sizes such as boat hulls and wind turbine blades.
EnkaChannel is a resin feeder that can provide high and constant flow rates. It’s available in two widths and is often used when making larger molded parts such as boat hulls and wind turbine blades.
Benefiting from the newly found stability as part of the Freudenberg Group, Sanders has been reevaluating the Enka business segments and market opportunities with a view towards the future. “We’ve learned from the building industry that it is really important to be developing and providing the precise tools for each business segment and its associated applications,” she said. “So, we’re working hard to add the right products into our portfolio. We want to be closer to the market and end user to make sure we’re developing the products optimized to meet those needs in North America and globally.”
Given the broad diversity of potential applications for this technology and continued interest in those that create more wonder and curiosity, there is sure to be no short-age of viable opportunities for Sanders and her group to pursue.
