INNEGRA™ Fiber: Amplified Performance

Solution-dyed INNEGRA™ increases the possible end-uses for the fiber.

Marketed under the tagline, “The Social Fiber,” INNEGRA™ works best when combined with other fibers to enhance and elevate product performance.

TW Special Report

Fibers for highly technical applications are subjected to demands where often failure is not an option. Over the years, fibers have been engineered to meet stringent technical specifications whether it be for aerospace, energy, medical, filtration, construction or automotive applications, as well as protective gear. Fibers are pushed to be lighter, stronger and perform better — all at the lowest cost.

A newer high-tech fiber on the market is INNEGRA™, a high modulus polypropylene (HMPP) fiber available from Colfax, N.C.-based Quantum™ Materials LLC (see sidebar). Innegra may be used on its own in a high-tech application. However, the most interesting thing about Innegra is that the fiber performs at its best when it is blended with other fiber types.

Recognizing this attribute, Quantum coined the phrase “The Social Fiber” to describe the unique benefits of Innegra and its ability to “play well” with other fiber types. “We like to say it performs best when it is combined with other materials where they can bring out the best in each other,” said Jen Hanna, director of Innegra sales, Quantum Materials.

“While it cannot carry a load like carbon, it can protect those structural fibers and provide something carbon cannot. It’s the Swiss army knife of fibers, packing a lot of versatility into a lightweight package.”

Beginnings

For a newer fiber, Innegra has a pretty involved origin story. Originally created between 2004 and 2008 in Greenville, S.C., the fiber was first introduced to the market in 2009 by Innegrity LLC. Initially produced in Greenville and Germany at facilities where the capabilities existed, the technology was acquired in 2011 by CCH, which changed its name to Innegra Technologies. In 2014, 100 percent of the production was moved to Quantum’s production facilities, and in 2023, Quantum purchased Innegra Technologies outright.

While Quantum did not play a role in the fiber’s initial creation, the company has worked to improve the manufacturing process to in turn improve the fiber quality since it began manufacturing the fiber in 2014.

What Makes Innegra Unique?

Innegra has some unique and in some cases, unexplained, properties that set it apart from other technical fibers. The fiber is manufactured using a melt spun process with quench, followed by a high draw. The finished fiber is highly crystalline and porous, which results in an ultralightweight fiber with high modulus. In fact, the fiber is the lightest synthetic fiber that is commercially available.

Innegra also has a unique surface structure and cross section that feature micro voids and nanofiber bridges (See Figure 1). It is suspected that these nanofiber bridges act as shock absorbers of a sort, although this has yet to be tested and verified.

Figure 1: INNEGRA™’s surface structure and cross section, featuring nano bridges and micro voids, contribute to the fiber’s unique properties.

According to Quantum, other inherent characteristics of the fiber include excellent dielectric properties, low creep, density and elongation; high sonic velocity; and cold temperature stability.

Innegra also is hydrophobic — therefore performance is not impacted by moisture or water — and is chemically inert. When subjected to more than 25 different chemicals — including acids, bases and organic solvents, as well as hydraulic fluids and oils, among other chemicals — test results showed either no effect on the breaking strength of the fiber or only a slight effect, where Quantum defines no effect as less than 10 percent and slight as between 10 and 20 percent.

Innegra has a double melt point between 162 and 164°C with the melt onset occurring above 150°C, or approximately 302°F. The fiber’s unique characteristics remain intact and continue to perform up to 150°C.

The fiber properties compared to those of a regular PP fiber are shown in Table 1.

Table 1

Enhance, Amplify & Elevate

When hybridized with other fibers, Innegra enhances performance. “As a material that works best with other fibers, Innegra truly is an enhancer or amplifier to a product as a whole, elevating performance when combined with other materials,” Hanna reinforced.

The fiber:

  • Is Tough and Durable — It can prevent fracture propagation or catastrophic failure because it is ductile and has the ability to dissipate energy;
  • Dampens Vibration — Innegra dissipates energy helping to reduce vibration for enhanced protection or performance;
  • Is Flexible — The fiber maintains excellent flex fatigue and does not break after many cycles of bending and flexing;
  • Maintains Shape — It exhibits excellent shape retention after long-term use and its low creep and recoil reduction extends a product’s lifespan;
  • Is Fusible — Innegra maintains performance characteristics when fused and compacted into solid shapes;
  • Is Impact Resistant — The fiber will quickly dissipate a tremendous amount of energy in high impact applications; and
  • Is Ductile — Innegra is pliable, not brittle — even in cold temperatures — and does not lose toughness when deformed during application.

Applications

Innegra is found in a wide variety of applications including military ropes, puncture resistant insoles for firefighter boots and military jungle boots, webbing, ballistic fabrics, and lacrosse and other sports netting.

However, Innegra is used most widely in composite applications where it supports high modulus fibers to increase toughness, durability and damping, while also reducing weight. Such applications include sporting goods, automotive applications, radomes, luggage and prosthetics.

For example, Innegra is combined with carbon fiber to produce tennis racquets where it reduces weight, improves impact resistance and reduces vibration. When blended with carbon and basalt fiber in hockey goalie masks, Innegra reduces the weight and vibration, and increases impact resistance. Blends comprised of Innegra, glass basalt and carbon fiber reduce weight, increase damage tolerance and increase impact resistance when used in canoes and kayaks. Innegra also can be combined with aramids and ceramic fibers in ballistic applications for weight reduction, energy dissipation, and chemical resistance, among other benefits.

It also can be combined with natural fibers. “Hybridizing Innegra with natural fibers is another area to explore that could prove to be beneficial,” Hanna mused.

“Innegra can be used in an effort to reduce over engineering,” Hanna said. “Sometimes, when products are designed, extra layers are factored in for safety as an insurance policy. Instead of overengineering with heavier or more costly materials, Innegra may be used to provide increased durability and protection without the added weight or extra cost.”
Brands currently using Innegra fiber include East Coast Dyes (ECD) for lacrosse mesh, Head, Bauer, Shi-mano, Swift Canoe, Nova Craft and Allied Cycle.

Fly Bag

A Germany-based university also researched using Innegra fiber as a component in a fly bag — a textile bag designed to mitigate the risk of a blast from bomb located in passenger luggage stored in the cargo area of an airplane. The bag was designed to absorb shockwaves, contain fragments of the explosion and contain the fire. “The design was proven to perform,” Hanna said.

High Value, High Performance

Innegra also offers excellent value per pound of fiber, according to the company. Compared to other high-performance fibers on the market, Innegra is competitive in price. “Innegra is a specialty fiber that aims to bring higher performance,” Hanna said. “With higher performing fibers, price tends to increase. However, keep in mind when talking per pound pricing, Innegra is 60-percent lighter than glass, 50-percent lighter than carbon and 40-percent lighter than aramids. A pound of Innegra goes a long way!”

Looking Ahead

“Quantum Materials is committed to pushing the boundaries of innovation,” Hanna noted. “As we expand into emerging markets, like composites, we continue to focus on developing advanced materials and high-performance solutions that address the most challenging technical demands.”

Quantum has more recently added solution-dyed Innegra to its portfolio, which offers greater customization options to customers. “Often times Innegra is used in the laminate where you cannot see it after production,” Hanna said. “However, there are many applications where it is visible and the solution-dyed expanded the options beyond natural or black.”

Quantum also offers a variety of coated Innegra yarns to meet the demands of different applications from ultraviolet to weather resistance and beyond. In addition, the company has experimented with a glow-in-the-dark version that needs some fine tuning, but will be developed further if a good-fit application is discovered.

Hanna also noted that a new product, PROTECC, is positioned to enter the thermoplastic market this year. Protecc is a blend of Innegra and the company’s proprietary Quantum Fusion Technology. “Protecc comes in two versions, coated Innegra or Innegra hybridized fabrics, or fabrics combined with a low melt adhesive yarn.” Hanna explained. “Combined with the low melt adhesive yarn, Protecc can be processed using heat and pressure — which shortens cycle times and improves efficiencies — to create high-performing durable parts.

“Today, Innegra is used in a variety of markets including sporting goods, transportation, radomes, military, protective, industrial applications,” Hanna said. “The potential is really untapped between thermoplastic composites and textiles. These are two areas we are just beginning to explore.”

The company will participate in trade shows such as JEC World, Techtextil North America and CAMX to build awareness for the fiber and its unique opportunities.

Quantum’s continuous development of Innegra positions the company at the forefront of advanced material innovation. The Innegra journey has just begun, and the potential is as limitless as the products Quantum aims to transform.

Quantum Materials LLC: Pursuing The Undiscovered

Originally established as a manufacturer of high-performance elastomeric-based suspension fabrics, Colfax, N.C.-based Quantum Materials LLC is today a vertically integrated manufacturer with the ability to convert resin into finished fabrics all under one roof. Its 150,000-square-foot facility supports three core areas of Quantum’s business — Quantum Suspension Fabrics, Quantum Technical & Industrial Yarns and Textiles, and INNEGRA™.

Quantum processes polyester, nylon, polypropylene, copolyester, and recycled and biobased materials.

Yarn capabilities include mono- and multifilament yarn extrusion, fully drawn yarn, yarn coating, air-jet texturing and twisting. The company also has the ability to impart a variety of additives and offers a variety of fiber cross-section options.

In weaving, Quantum has warping capacity, and can produce 2- and 4-way stretch fabrics, as well as bonded and non-bonded stretch wovens.

The Quantum Difference

The company prides itself on quick turn production cycles and research and development. It has in-house designers on staff and also dedicated resources for new product development initiatives. Quantum’s smaller team of approximately dedicated 90 employees is agile and adaptable, as well as focused on technical excellence, operational efficiency and rapid customer response.

The company has been a trusted supplier to global companies for more than 30 years, and Quantum continues to leverage its technical expertise to overcome complex challenges while delivering high-performance solutions.

2025 Quarterly Issue I

 

IACMI Celebrates Decade Of Innovation, Economic Growth & Strengthening U.S. Advanced Manufacturing

IACMI’s Impact: Collaborative efforts are tackling the industry’s toughest challenges.

Established by the Department of Energy in 2015, the Institute for Advanced Composites Manufacturing Innovation® (IACMI) has emerged as a leader in advanced composites and workforce solutions, bolstering American manufacturing and national defense.

TW Special Report

The Institute for Advanced Composites Manufacturing Innovation® (IACMI), also known as IACMI–The Composites Institute®, recently celebrated a decade of revitalizing American manufacturing and strengthening the nation’s defense industrial base. Established by the Department of Energy (DOE), IACMI was announced as the fifth of now 18 Manufacturing USA® institutes on January 9, 2015. The Advanced Functional Fabrics of America (AFFOA) is also a Manufacturing USA institute.

The institute comprises more than 170 members — including those from industry, universities, national laboratories and government agencies — that work together to accelerate the development and adoption of advanced composites and innovative manufacturing technologies. Its collaborative work through public-private partnerships drives domestic production capacity, strengthens U.S. manufacturing competitiveness and elevates domestic job creation.

IACMI is managed by the Collaborative Composites Solutions Corp. (CCS), a not-for-profit organization established by the University of Tennessee Research Foundation. IACMI is supported by the U.S. Department of Energy’s Advanced Materials and Manufacturing Technologies Office, and the U.S. Department of Defense (DoD) Industrial Base and Sustainment (IBAS) Program from the Innovation and Capability and Modernization (ICAM) office, as well as key state and industry partners.

IACMI Impact

For 10 years, IACMI has played a pivotal role in America’s reindustrialization, aiming to secure its position as a global leader in manufacturing innovation and workforce development. Reshoring initiatives have been key to bolstering U.S. economic and national security. Through multiple national workforce programs sponsored by DOE and the DoD, IACMI has been inspiring, educating, and training a skilled workforce to help address the projected 4.6 million open manufacturing jobs in the coming decade.

IACMI’s impact for economic growth has been clear in four primary ways:

  • Public-Private Collaborations — Convening more than 170 members and 4,500 professionals from industry, academia, and federal labs to tackle the composites industry’s toughest challenges in automotive, aerospace, wind, infrastructure and the circular economy.
  • Technical Innovation — Connecting more than 90 of its members to conduct 60-plus industry-led R&D projects that helped commercialize dozens of products; advance the Technology Readiness Level (TRL) of numerous technologies; and create hundreds of design, engineering, and manufacturing jobs.
  • Workforce Development —Catalyzing IACMI, Americas Cutting Edge (ACE), and Metallurgical Engineering Trades Apprenticeships & Learning (METAL) programs to enable:
    • More than 100 internships with industry collaboration resulting in 100-percent placement in industry jobs or higher education;
    • 18,300-plus STEM outreach engagements;
    • More than 12,400 trained online across 50 states in CNC machining;
    • 5,100-plus trained in-person in composites, CNC, metrology, and metallurgy; and
    • 40 machine tool training centers in 14 states.
  • Leveraging Resources — Providing open access to more than $400 million in scale up facilities across eight states has led to an additional $220 million-plus for companies, universities, national labs and workforce initiatives.

“For 10 years, IACMI has harnessed the power of public-private partner-ships to improve products, processes, and people’s lives through composites innovation and workforce solutions that secure America as a global leader in advanced manufacturing,” said Chad Duty, IACMI’s CEO. “With steadfast investment and support from industry and government partners, notably DOE and DoD, IACMI has empowered domestic manufacturers to accelerate design and commercialization, fostering a more reliable, secure, and competitive U.S. economy.”

IACMI’s Impact: Open access to facilities led to additional funding for initiatives.

Shared Infrastructure, Investments

Since 2015, IACMI, the DOE, and state economic development organizations have invested in a shared infrastructure that collectively delivers a breadth and scale of open-access advanced composites manufacturing R&D capabilities that stand unmatched in the U.S. These facility and infrastructure investments have been led by IACMI’s core innovation partners in Colorado, Indiana, Michigan, Ohio and Tennessee. Today, these capabilities uniquely position IACMI to build on past achievements, de-risk future research, and accelerate onshoring efforts in the United States.

Examples of state-of-the-art scale-up facilities include:

  • Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL), Oak Ridge, Tenn.;
  • Carbon Fiber Technology Facility (CFTF) at ORNL;
  • Fibers and Composites Manufacturing Facility (FCMF) at University of Tennessee, Knoxville, Tenn.;
  • Laboratory for Systems Integrity and Reliability (LASIR) at Vanderbilt University, Nashville, Tenn;
  • The Composites Laboratory at the University of Dayton Research Institute, Dayton, Ohio;
  • The Composites Manufacturing & Simulation Center (CMSC) at Purdue University, West Lafayette, Ind.;
  • The IACMI Scale-Up Research Facility (SuRF) in Detroit; and
  • The Composites Manufacturing Education and Technology Facility (CoMET) at National Renewable Energy Laboratory (NREL), Applewood, Colo.

IACMI has leveraged these facilities to undertake transformational R&D, in nation-critical industries including energy, transportation, aerospace, and infrastructure & construction. An IACMI-sponsored project team helped Volkswagen (VW) of America redesign and validate a composite liftgate for SUVs, reducing the weight by 35 percent and lowering its recurring cost by 9 percent compared with steel. Technological advances from this research are now being used across multiple VW platforms, including the new VW ID Buzz EV.

The scaling, manufacture and testing of novel thermoplastic wind turbine blades that are recyclable and lower in cost has also been demonstrated. Further research in automating finishing processes for wind blades aims to reshore wind manufacturing jobs. Simulation and modeling work to develop a virtual twin for additive manufacturing is revolutionizing the production of tooling.

Today, these capabilities uniquely position IACMI to build on past achievements, de-risk future research, and accelerate onshoring efforts in the United States. Duty predicts, “Over the next few years, IACMI and its partners will leverage their full-scale facilities and equipment and significantly expand programs. IACMI will continue to convene, connect, and catalyze the U.S. composites community by attracting startups and small enterprises while creating opportunities with large companies, national labs, and universities. Our ecosystem of innovation is ready to advance American manufacturing.”

To learn more about IACMI, visit IACMI.org.

2025 Quarterly Issue I

Cleaner Composite Fibers Recycling With DEECOM

Jen Hill receives the award from Ben Fletcher (left), COO of Make UK, and Dan Hulme, head
of sales from category sponsor Inspired, at the London awards ceremony. (Image courtesy of Make UK)

Longworth and Cygnet Texkimp are partnering to commercialize DEECOM reclamation technology for the composites industry.

By Adrian Wilson

During a recent ceremony held in London, England-based B&M Longworth claimed the Make UK National Award in the Energy and Sustainability category for its development of DEECOM technology.

Longworth has a long history in the manufacture and supply of specialized cleaning and waste-reduction technologies for the polymer and coating industries and its DEECOM system exploits pressurized steam in a process called pressolysis to successfully separate and reclaim fibers and polymers from composite parts for reuse.

Enabling true circularity for materials, DEECOM completely eliminates the need for traditional dirty processes involving solvents, chemicals, burning or mechanical grinding.

Pressure Swings

Using a combination of compression and decompression cycles or “pressure swings,” it can gently remove a range of resins from composite fibers, effectively reversing the bond between the fiber and the matrix. The process takes place in a pressure vessel filled with super-heated steam.

Depending on the polymer type, temperatures above 200°C (392°F) will melt or soften the polymer and a degree of hydrolysis will occur. When at pressure, the steam penetrates fissures in the polymer where it condenses, before it boils on decompression, causing an instant physical fracturing of the polymer chain and carrying away monomers and oligomers along with polymer fragments from the outer faces.

Since the process interacts with the resins, it can reclaim the format, length and structure of fibers from post-industrial or end-of-life waste composites, whether cured or uncured.

“The pressolysis process enables the high-yield reclamation of high-quality, clean, reusable fibers that are free from residues and have a retained length and properties akin to virgin materials,” explained B&M Longworth Director Jen Hill.

Emphasizing Project

Longworth and its partners in the Emphasizing Project — EMS-Chemie, Ford Motor Company, Gen2plank, Gestamp, TWI and the Brunel Composites Centre at Brunel University in London — have already received the JEC World 2024 Innovation Award in the Circularity and Recycling category.

This has focused on the reclamation of materials from end-of-life wind blades, their resizing and subsequent remanufacture into mass production car parts.

This resized material is based on DEECOM-recovered glass fibers that are treated with various chemistries to retain performance properties.

“The aim is to find several use cases for the reclaimed and/or resized material, and for the industry to gain access to a brand new, low impact advanced material at a low cost,” Hill said.

Cygnet Texkimp

The technology is now being commercialized for the composites industry in a partnership between Longworth and England-based Cygnet Texkimp. A first DEECOM reclamation unit has recently been installed at the Henry Royce Institute in Manchester.

Royce is bringing together nine leading institutes in a pioneering R&D program to fully investigate and commercialize new applications for reclaimed fibers.

Founded in 1974, Cygnet Texkimp, is a supplier of advanced handling and processing machinery to the advanced fibers and composites markets, with 80 percent of its machines exported to more than 30 countries. In particular, the company is a supplier of creels for unwinding high value composite fibers and tire cord at constant tension and at optimal speed into a range of down-stream processes including weaving, prepregging, coating and beaming.

“It’s a time of unprecedented growth for our company because in addition to DEECOM we are also busy with projects for the UK’s National Composites Centre and the Advanced Manufacturing Research Centre,” said Cygnet’s international sales manager Josh Ingham. “We currently have a healthy order book, especially in creels for aerospace industry suppliers, but we’re also excited about the new opportunities we believe DEECOM will open up for us.”

Both Longworth and Cygnet are members of the British Textile Machinery Association (BTMA).

Editor’s Note: Adrian Wilson is an England-based analyst and writer specializing in the technical textiles, nonwovens and composites industries. He is the owner of AWOL Media.

2025 Quarterly Issue I

Medical Textiles With Infection Prevention

Dispersion of AGXX particles (Image courtesy of DITF)

DITF and Heraeus are researching AGXX antimicrobial technology for use in medical textiles.

TW Special Report

In collaboration with the Germany-based Heraeus Group, the German Institutes of Textile and Fiber Research (DITF) is developing fibers and textiles with a novel infection protection system. The basis is an antimicrobial mechanism of action licensed from Heraeus and marketed under the name AGXX. The goal of the collaboration is to optimally integrate the AGXX technology into textile finishes and coatings and to incorporate it into fiber-spinnable polymers to provide medical textiles with highly effective and long-lasting protection against microbial infections.

Novel Action Mechanism

AGXX technology is based on an entirely new mechanism of action. It uses a catalytic redox reaction initiated by metallic AGXX particles consisting of silver and ruthenium. In interaction with humidity, reactive oxygen species such as peroxides are formed. These are oxygen-containing molecules with very high reactivity. They effectively kill microorganisms such as bacteria, fungi and algae and are equally effective against viruses.

The special feature of this mechanism of action is that the AGXX particles are not reduced and do not release any active ingredients. In established antimicrobial systems based on the release of silver ions, the release of active ingredients has become a problem: the release of the silver ion concentration is difficult to control and many of the established systems do not meet the requirements of the European Chemicals Agency (ECHA). Such systems will disappear from the market in the medium term and must be replaced by alternatives.

In addition to permanent efficacy, the AGXX technology offers a particularly broad spectrum of protection against pathogens and prevents the formation of resistance.
Heraeus AGXX technology is used in various industries; and in general, the particles can easily be incorporated into various materials. However, textiles used in the medical sector are subject to more stringent requirements. The resistance of the antimicrobial protection mechanism must be high, as contaminated textiles can be a source of transmission of pathogens over a long period of time. Modification of the textile material, either by surface treatment— finishing or coating — or by incorporation of AGXX into filament yarns, should not adversely affect the physiology of the garment. This is because a reduction in textile proper-ties is unlikely to be accepted by the wearers of the textiles.

The goal of the collaboration is not only to determine the optimal concentration of AGXX particles to provide the best possible protection against infection without compromising the mechanical properties of the textiles, but to also determine techni-al prerequisites for the development of suitable textile finishes and the compounding of polymer melts.

The resulting textile samples were tested for antimicrobial and antiviral activity in DITF’s laboratories where finishes and coatings for polyester and nylon fabrics showed convincing results. Compounding AGXX in the nylon 6 polymer melt enabled the production of filament fibers with consistently good fiber strength values.

The determination of textile mechanical parameters such as abrasion resistance, air permeability and dimensional change as a function of number of wash cycles is still in progress. However, it is becoming apparent that textiles modified with AGXX are consistently effective without having an excessive impact on the nature of the textile.
The results of the research are an important contribution to reducing the risk of infection from medical workwear. They form the basis for future industrial production of textiles for durable and reliable protection against infection.

2025 Quarterly Volume I

Konica Minolta Launches CM-3700A Plus

Konica Minolta, Japan, has launched the CM-3700A Plus, its latest spectrophotometer designed for industries requiring high-precision color measurement, including textiles and plastics, among others. Building on the success of the CM-3700A, the new model offers unmatched accuracy with an inter-instrument agreement of ΔE*ab 0.08 or less, ensuring consistent color data across global supply chains. Key features include a built-in camera viewfinder for improved sample positioning, simultaneous SCI and SCE measurements that cut measurement time in half, and environmental sensors for tempera-ture and humidity monitoring. The device is also compatible with SpectraMagic™ NX2 software for advanced data management and supply chain communication.

2025 Quarterly Issue I

Shein Increases Use Of Cool Transfer Denim Printing

Singapore-based SHEIN increased its use of Cool Transfer Denim Printing by 90 percent in 2024, producing approximately 380,000 denim pieces with this resource-efficient technology, up from 200,000 in 2023. This innovation, developed in partnership with NTX®, reduces water usage by 70.5 percent compared to traditional denim methods —according to Bureau Veritas in October 2023 — saving more than 10,000 metric tons of water in 2024.

Cool Transfer Denim Printing uses reactive ink to digitally print designs onto transfer film, which is then applied to white denim fabric, replicating faded finishes without harmful chemicals like chlorine.

2025 Quarterly Issue I

X- Rite Introduces Judge LED Light Booth

X- Rite Inc., Grand Rapids, Mich., has launched the Judge LED light booth for precise visual color evaluation, designed to support industries transitioning from fluorescent to energy-efficient LED lighting. This new light booth, featuring seven distinct light sources, ensures color consistency across supply chains in sectors like textiles, automotive, and packaging, addressing the challenges posed by differing spectral power distributions between fluorescent and LED lights. Key features include instant warm-up, stabilized illuminants, energy efficiency, and compliance with ISO, ASTM, AATCC, and BSI standards. It also integrates with digital workflows, allowing comparison between physical samples and digital material twins.

“Our custom-designed LEDs are optimized to offer the best SPD match for legacy fluorescent tubes, including U30, U35, CWF and TL84, ensuring a seamless integration into color workflows,”said Albert S. Laforet, director of Strategic Projects, X-Rite.

2025 Quarterly Issue I

Techtextil Launches New Dyes & Chemicals Area

For the first time, Techtextil Frankfurt 2026 will feature Textile Chemicals & Dyes as a separate product area, highlighting their growing importance in the global textile industry. This new segment will create a central hub for suppliers and users, fostering collaboration and streamlining communication across the value chain. Collocated with Fibers & Yarns and Performance Apparel Textiles, the setup aims to enhance industry synergies and accelerate solution development.

“Textile Chemicals & Dyes are becoming increasingly important for the production of technical and performance textiles,” said Sabine Scharrer, director, Brand Management, Technical Textiles & Textile Processing, Germany-based Messe Frankfurt. “At Techtextil, we will bring the players even closer together in future. In this way, we enable dialogue, comparability, and raise even more awareness for this promising sector.”

2025 Quarterly Issue I

Fibroline & Navis TubeTex Open State-Of-The-Art Innovation Lab

A ribbon-cutting ceremony was held to officially open the new Fibroline USA Innovation Lab housed at the Navis TubeTex facility in Lexington, N.C.

Fibroline USA Innovation Lab introduces cutting-edge dry powder impregnation technology to North American market.

By Jim Kaufmann, Contributing Editor

An advanced dry impregnation processing technology was formally introduced into the North American markets with a ribbon cutting ceremony held at Navis TubeTex in Lexington, N.C., The event marked the grand opening of the Fibroline USA Innovation Lab, which is the result of a strategic partnership between France-based Fibroline and finishing machinery manufacturer Navis TubeTex.

The new state-of-the-art innovation center showcases Fibroline’s cutting-edge technologies, and provides access for potential customers to conduct scalable trials for existing and developing applications in a wide array of market segments. According to Jerome Ville, Fibroline’s CEO, “This partnership with Navis Tube-Tex and the opening of this Innovation Center will help us to more effectively introduce and promote our unique technology’s capabilities to the North American markets.”

A Partnership In The Making

Fibroline was founded in 2003 focused on developing and engineering solutions for the global textile industry. The company owns more than 50 technology and application patents. Its dry powder impregnation technology evolved from these efforts, and since 2016, Fibroline has focused on creating strongly diversified, technology-driven applications.

Fibroline’s facility in France features a pilot unit for scaling up trials.

It has a research and development facility in France, which includes pilot lines for sampling and prototyping units for larger scale evaluations. Fibroline’s flexible business model focuses on developing performance-based applications and technologies that may be patented and subsequently licensed to interested companies on a royalty basis. The company employs manufacturing partners to produce full turnkey solutions in Europe, and now, given the partnership with Navis TubeTex, in North America as well.

In early 2024, Navis TubeTex entered into a manufacturing partnership with Fibroline after it was introduced to the Fibroline technology by Dr. Sanjay Patel, an advanced materials and process expert who consults for Navis TubeTex.

“I just felt this would be a good opportunity to introduce Fibroline’s technology to North America and open up new markets,” offered Dr. Patel. William Motchar, president and CEO of Navis TubeTex, saw the possibilities and extended an invitation to Fibroline to establish the Innovation Lab at the Navis TubeTex facility in Lexington.

“We anticipate the innovation center will become a hub for collaboration and ingenuity where we can assist our customers to explore, test and foster creative solutions to meet ever evolving market demands,” Motchar said.

The new innovation lab resides in an 800-square-foot segment of the Navis TubeTex building with room to expand, where the company will also effectively manufacture and sell the Fibroline inspired equipment to North America customers. In addition, Navis TubeTex will provide machine engineering expertise as well as installation and after sales services.

The Technology

Fibroline’s eco-friendly in-line technology is identified as a dry impregnation process, but the flexibility of the line along with its system of modular pieces that can be switched in or out depending on needs, offer up greater possibilities for both flexible and ridged composite materials. The best way to view this technology from a textile perspective is as a methodology to provide value-added performance attributes to potentially any textile material type to meet a wide selection of application needs.

Illustration showing the principle behind the Fibroline dry powder impregnation technology.

In general terms, the dry impregnation begins with a powder “chemistry” that can be one specific powder, or possibly a mix of different chemistries related to the intended application. The powder chemistry is distributed onto the surface of the material to be impregnated using conventional powder processing means. As the powder-coated material passes through the machine, electrodes positioned above and below create alternating electric fields that evenly position the powder throughout the thickness of the material while fixing it to the fibers.

One limitation of this technology is that carbon fiber and other conductive materials cannot be treated because of the electric fields employed during the process. However, most any other man-made or natural material may be processed using the Fibroline technology.

It should also be noted that by controlling the current, dwell time and other machine settings, a gradient distribution of the powder may be made. For example, powder can be applied just on the surface of the material or located at specific levels throughout the thickness, including covering all fibers through the thickness. This technique allows for many unique possibilities in the impregnated structure, including surface treatments, fully encapsulated fibers, partially coated layers, thru the thickness powder coatings, consolidated thermoplastic composites, both flexible and rigid composites, to name just some of the possible configurations.

Low Energy, Solvent Free Processing

According to Fibroline, energy consumption during processing is very low compared to traditional systems. There is no rise in the temperature of the material during the impregnation process. In addition, there is no residual build-up of static electricity in the material at the end of the impregnation treatment, which makes it possible to process heat-sensitive chemistries. Also, Fibroline’s process does not require the use of any consumables. The impregnated material can then be fully cured separately or in-line using heat and pressure or whatever other means the application may require.

This process does not require the use of solvents or any drying steps, and therefore the types of powders employed have very few limits. Thermoplastics, thermosets, medical additives, flame retardants, absorbents, and numerous other types of chemistries can be utilized. It’s possible to process powders from 5 microns to 500 microns in size. Single or multiple chemistries can be applied during the same process. Theoretically, any powder or combination of powders can be applied. For example, a medical powder — a vitamin or pharmaceutical perhaps — could be combined with a biodegradable binder to create a time release platform or other chemistries. Colors may be employed together to produce multiple characteristics on the same material. Of course, there are sure to be limitations, but untold possibilities exist with this type of technology.

A variety of “porous structures” can be processed using the Fibroline dry impregnation process. These include nonwovens and foams along with most variations of woven and knit textiles as well as technical yarns, fiber roving, tapes, and assorted composite materials.

There currently are three different impregnation technologies to choose from depending on the intended applications. The “D-Preg” technology is more of a traditional inline process intended for large industrial applications. The “S-Preg” technology is designed for applications requiring lower powder content and a high level of accuracy in powder distribution. The “Y-Preg” system has been developed specifically for processing yarn and unidirectional tapes and does allow for the processing of multiple bobbins in parallel.

The equipment installed at the Navis TubeTex innovation lab is in concert with the D-Preg technology, but downscaled and designed primarily for technology demonstrations.

Product and application development, chemistries evaluations, proof of concept or feasibility trials are also within the capabilities of this equipment. Larger product development and pilot validation trials can be performed at Fibroline’s R&D facility in France.

Open house visitors were given a demonstration by Fibroline’s Sofien Bouzouita of the static lab unit, which can be used for preliminary trials.

The Markets And Applications

As suggested previously, the number of existing and potential applications for this technology is truly mind-boggling. During an introductory presentation and tour of the new innovation center, a variety of products and possibilities were discussed. Dr. Sofien Bouzouita, Fibroline’s Innovation manager highlighted examples of current applications including Ethizia™, a hemostatic sealing patch from Johnson and Johnson; wound dressings from Smith and Nephew; technology licensed to Depestele, Europe’s leading flax producer, for unidirectional tapes made from flax fiber; and automotive headliner technology licensed to foam manufacturer Howa Tramico that will be available in 2026.

Fibroline’s dry powder impregnation technology may be used for a wide variety of applications across a diverse group of markets.

Other applications in development with partners include rubber reinforcements to improve tire manufacturing and longevity, active air and water filtration systems, as well as active filtration systems designed for protection against chemical, biological, radiological and nuclear malicious-use agents. In addition, flame retardancy, thermal insulation and composites markets continue to find opportunities for this technology, not to mention all the others yet to be discovered.

Ultimately, given the nearly end-less combinations of chemistries, substrates or materials impregnated, and the modular combinations of the processing technology, the beauty of this system is truly in the eyes and creative minds of its beholder. The employees and consultants at both Navis TubeTex and Fibroline are certainly willing and able to initiate the various conversations necessary to validate this technology and the numerous technologies that may follow. Here’s to its bright future!

2025 Quarterly Issue I

Color Accuracy, Supply Chain Certification Are Keys To A Strong Brand

Datacolor provides light booths that can simulate a variety of lighting conditions for color assessment.

Getting color right the first time reduces waste, saves time and offers value to customers.

By Basto Wong

To improve the value they provide to their customers, some industry-leading brands and major retail chains now require their suppliers to follow tighter quality and sustainability guidelines. These include mandates to use color specification and quality control (QC) technologies throughout their supply chains.

Companies hope to achieve multiple goals by specifying these technologies. First, they reduce the environmental impact caused by waste-producing color mistakes that can occur during manufacturing. In addition, they help provide universal color consistency — a benefit at every stage of the supply chain and to customers as well.

Although many brands have been utilizing color management technology in their own facilities for years, these requirements are now being extended to current and would-be suppliers. The reasons are well justified. Color management systems can help reduce waste, save time, provide consistent color QC across multiple locations, and improve communication between brands and their suppliers.

Implementing the necessary hardware and software tools isn’t enough, however. To ensure supply chain consistency and transparency, many vendors are also being required to prove they can meet color standards by participating in a color management verification program.

Verifying The Supply Chain

Quality-conscious brands take color consistency seriously. To ensure that their suppliers’ color programs and processes meet specified standards, many are increasingly turning to verification and certification processes. Experts recommend that each supplier be assessed by a third-party authority such as Data-color Certify, a color assessment and lab audit program that also provides training services.

The auditor will check for conditions within the manufacturing process that can affect color quality, such as:

  • Operator expertise, skill, knowledge, and ability to use color management software and technology properly;
  • Overall equipment performance, condition and calibration; and
  • Humidity, temperature and other environmental factors.

Assessments typically involve a combination of off-site and on-site inspections designed to ensure that the supplier is qualified and capable of meeting a brand’s color quality expectations. Inspections should ideally be performed annually to ensure that proper color develop-mental procedures are followed consistently over time.

Achieving Objectives

By implementing regular color management assessments like this across their supply chains, brands can achieve multiple goals, including:

  • Reducing the overall number of lab dips or samples;
  • Reducing or eliminating shipments of physical color samples for approval;
  • Easing the environmental impact of repeat production by minimizing color matching and formulation errors;
  • Increasing speed to market;
  • Verifying the color capabilities of suppliers;
  • Empowering vendors to make decisions locally, eliminating delays waiting for guidance — especially from customers in distant time zones; and
  • Ensuring consistent quality for end customers.

Benefits Of A Color Program

Although verification is typically required by brands or retailers, suppliers are often the primary beneficiaries when it comes to cost savings. For those in the apparel sector, for example, color approval processes that used to involve as many as six lab dip submissions can potentially be streamlined to only one or two. Those kinds of savings add up quickly because a single lab dip can cost more than $100. Lab dip samples also must be ferried back and forth between brands and suppliers, incurring additional costs and creating unnecessary carbon emissions. The savings in time, money and resources from these two benefits alone can easily justify the effort of verifying a color program, both for brands and suppliers.

Certification can empower qualified suppliers in other ways. Being able to self-approve samples that meet measurable specifications delivers increased production efficiency and opportunities to optimize the color developmental process. Suppliers can also reach more brands by showcasing their capabilities. A universal accreditation program is especially advantageous, because a single annual certification can satisfy the requirements of multiple brands.

Suppliers often become validated in response to mandates from their customers, but they can also benefit by seeking certification proactively. Certified suppliers are automatically more attractive to brands because they’ve already proven their color management capabilities; the brand doesn’t have to worry about training or lag time. In addition, some certification providers maintain databases that brands can search when looking for suppliers to work with.

Brands benefit from the capability to respond to market demands faster, with the confidence that color quality from all their suppliers will meet their expectations.
Implementation across an entire supply chain can shave several weeks off color developmental and production processes while providing greater transparency. In cases where the same color is being utilized by multiple suppliers, brands can expect much greater consistency and fewer rejections. Partnership with a third-party validation authority also eliminates the time, administrative and travel costs needed to send knowledgeable team members overseas to certify suppliers.

Color consistency within the every stage of the supply chain is critical to a brand’s success.

Improving Supply Chain Sustainability

In addition to improving the consistency and quality of products, partnership with a verification service can help support more sustainable supply chains. Wasted time, money, labor, materials and resources are significant issues for all industries. Minimizing the unnecessary carbon emissions associated with shipping samples or transporting team members across continents are also relevant concerns.

Getting color right the first time is the best way to reduce all of these things. This commitment to sustainability aligns with broader corporate responsibility goals established by many organizations, whether for their own sake or in response to regulations.

What To Look For In A Color Certification Partner

An expert verification service can help a company achieve more ambitious color formulation, measurement and QC goals. Here are some key factors to consider when evaluating potential partners.

Start by looking for a vendor that also makes high-quality measurement tools themselves, rather than relying on hardware from a third party. Its instruments should be capable of adhering to the industry’s tightest color tolerance ranges and have high inter-instrument agreement. With proper usage, good instruments can prevent suppliers from accidentally shipping products with off shades.

It’s important to also make sure instruments have 100-percent backward compatibility. This will ensure that any valuable color data curated over the years won’t be lost because of incompatibility with newer instruments when it’s time to upgrade.

In addition to trusted and reliable products, look for a partner with an even more valuable asset — people. Hardware and software should be supported by experts who have experience working in the industries they serve — ideally, for many years. This will ensure that they’re not only proficient in their company’s products and services, but have a deep under-standing of your industry’s unique needs and challenges.

Finally, make sure any investment in a solution is backed by a global team capable of providing guidance every step of the way, from choosing the right solutions through final installation and continued support thereafter. A partner should have a dedicated local sup-port team that speaks regional languages and is ready to help should problems arise.

Elements of a Complete Color Solution

Many well-known brands utilize color management technologies to bring end-to-end color solutions to their supply chains. Common packages include:

  • Spectrophotometers: High-precision benchtop instruments used for close-tolerance color measurement, ensuring uniform assessment of materials across
    the supply chain.
  • Performance monitoring: A predictive measurement monitoring system that assists with the calibration of spectrophotometers and correlates to master instruments to ensure performance meets a brand’s requirements.
  • Formulation software: Amplifies the accuracy of color development, improving QC and productivity. This can significantly reduce the need for physical matches and improve first-shot match rates, shortening formulation time.
  • QC software: Enables objective analysis, reporting, communication and visualization of accurate color results.
  • Industry-specific applications: Specialized software is available to meet the unique needs of certain industries, including textiles, apparel, home furnishings, paint and coatings, plastics, and other applications.
  • Light booths: Viewing stations that simulate a variety of lighting conditions, including daylight, common light sources used in retail stores, typical home and office lighting, LED, ultraviolet, and more. This enables visual color assessments of inks, paints, plastics, textiles, paper, colorants and other materials. Calibrated light booths across the supply chain promote consistency in color decisions by ensuring that everyone evaluating samples views them under similar lighting conditions.
  • Operator training: Remote or hands-on instruction provided by experts fluent in the operator’s local language.

 

Editor’s Note: Basto Wong is the Service Project manager and head of Assessments at Lawrenceville, N.J.-based Datacolor.

2025 Quarterly Issue I

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