Production

Raw Materials

The Importance of the Right Blend

The primary fiber types used in nonwoven fabric production today, along with several fibers still under development, are:

Natural Fibers

  • Flax (LI)
  • Hemp (HA)
  • Kenaf (KE)
  • Cotton (CO)
  • Virgin Wool (WO)

Synthetic Fibers

  • Polypropylene (PP)
  • Polyester (PES, including bicomponent fibers)
  • SEAQUAL® FIBER (SEAQUAL® MARINE PLASTIC)
  • Polyacrylonitrile (PAN)
  • Polyethylene (PE)
  • Polyamide (PA)
  • Viscose (CV)
  • Glass Fibers (GF)

Technology

Our Production Process is —
simply put — astonishingly straightforward.

Nonwoven Formation

The formation of nonwovens primarily occurs through the mechanical carding process using tufting technology. For volumetric products, the aerodynamic method of airlay technology can also be applied.


Nonwoven Consolidation

The consolidation into nonwoven fabric is primarily achieved through needling or thermobonding technology. During this consolidation process, needle-punched or thermally bonded nonwovens can be combined into multilayer constructions.

Additionally, other mechanical, thermal, or chemical consolidation methods can be employed (e.g., calendering, thermo-fixing, impregnating).

Double Belt Press

Our Double Belt Press —
Offering Even More Flexibility

Thanks to our continuous press, we are able to further process our proven nonwovens into (pre-) consolidated fiber composite materials. This allows us to deliver the desired composite properties in the form of tailored fiber boards.

For many of our customers, this means: One processing step is eliminated—saving valuable time and energy! At the same time, we also create entirely new application possibilities.

We process both nonwovens made from synthetic fibers and blends with natural fibers and glass fibers. All of this is possible in either single or multilayer constructions (sandwich structures) and in combination with other materials.

The panels can be produced in sizes of up to 2,150 mm x 3,000 mm. The product can be calibrated to a maximum density of 0.7 g/cm³. As always, your individual requirements for the product are crucial.

Equipment

Upon Request, We Offer the Following Post-Treatment Processes for Our Surface Products:

  • Additional Nonwoven Strengthening
    through mechanical, thermal, and chemical consolidation
  • Coating / Laminating
    to create various multi-layer constructions with, for example, (spun) nonwovens, fabrics, (foam) films, etc.
  • Impregnation
    as full immersion impregnation (dipping) and one- or double-sided foam padding with various dispersions

  • Coating
    through sprinkling, spraying, or dabbing various media
  • Self-Adhesive Treatment
    with PSA hotmelts or acrylic dispersions
  • Other Post-Treatment Processes
    (mechanical / thermal / chemical) to enhance or supplement specific properties, such as calendering, thermo-fixing, hydro-/oleophobic treatment, as well as antistatic, flame-retardant, or antimicrobial finishes, etc.

Confectioning

The Right Sizes and Quantities for Every Application

  • Roll goods can be produced with a maximum web width of six meters.
  • Longitudinal cutting allows for customizable widths to meet varying requirements.

Part Manufacturing

  • 12 punching machines with a work width of up to 2.20 meters deliver rectangular or custom contour cuts.
  • Semi-automated assembly processes enable the three-dimensional construction of various stamped parts.

Cutter

  • We offer bespoke solutions for prototypes and production runs of up to 500 parts, catering to foundational development, small series, and spare part requirements.
  • Our proprietary scanning system enables the digitization of templates and sample components, ensuring swift delivery of the initial contour parts.

Research
and
Development

Fundamental Development

Research and Development

We owe much to our curiosity! Without the challenges of ever-evolving product requirements and application areas, we wouldn’t be the competent and reliable partner we are today—driving innovative ideas and solutions forward.

Our close collaboration with research institutes and the motivation of every team member are the driving forces behind our continuous developments and tailored concepts at Polyvlies.

Application Technology

Certificates

QM / QS

When It Comes to the Quality of Our Products, We Leave Nothing to Chance.

That’s why we implement a comprehensive quality policy, fully realized through an integrated quality management system. We not only meet the standard requirements of ISO 9001 but also fulfill a wide range of individual customer demands.

With substantial investments in state-of-the-art production facilities, Polyvlies is well-positioned for the future. This ensures optimal processing of various raw materials into high-quality end products. All product characteristics are meticulously monitored in our fully-equipped in-house testing laboratory under reproducible conditions.

The result: Technical nonwovens of the highest quality and maximum reliability for our customers!

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Environment and Energy

In response to emerging regulatory mandates, an increasing awareness of corporate environmental impacts, and the persistent rise in energy costs, it is prudent to systematically assess and enhance our environmental performance.

At Polyvlies, environmental stewardship is a cornerstone of our corporate ethos. We are steadfastly committed to the ongoing evaluation and advancement of our environmental performance. Furthermore, we endeavor to minimize our ecological footprint to the greatest extent possible. Our objective is to safeguard the environment—particularly our vital natural resources, energy consumption, and materials—while striving to elevate efficiency through a process of continuous improvement.

In 2014, Polyvlies commenced the implementation of an environmental management system, receiving the ÖKOPROFIT® environmental certification from the Steinfurt district in 2016, alongside certification under EN ISO 14001:2015. In 2015, our facilities in Bevergern and Sachsen achieved certification in accordance with DIN EN ISO 50001:2018.

Download:

ISO-14001-2015
pdf (108 Kb)
ISO-50001-2018
pdf (376 Kb)
Energiepolitik
pdf (518 Kb)

Certificates

Verified quality

We take pride in our commitment to excellence; our production facilities and processes undergo regular certification by independent inspection authorities to ensure the highest standards.


For your convenience, we have provided the latest certification documents for your review.

Certificates USA: