Union Industries


Location: Masserano, Italy

Sales: $81 million

Description: Key personnel
Matteo Moltrasio, vice president; Luigi Cassano, managing director; Alessandro Taramasso, commercial director

Plant
Masserano, Biella, Italy

ISO Status
ISO 9001:2000 since 1997 renewed in 2006

Process
Spunbonded, spunbonded-meltblown, carded thermal bonded

Trade name:
Spundouce

Market
Hygiene, wipes, medical, agriculture, industrial


sales were on the rise for Italian roll goods producer Union Industries. And, with a new line—the company’s fifth—set to come onstream within the fourth quarter of this year, this trend is only set to continue. In 2005, sales clocked in at €65 million due largely to the full utilization of a new Reicofil 4 SSS line, which began production in the fourth quarter of 2004, according to vice president Matteo Moltrasio.
 
The new line, which like the rest of Union Industries’ business mainly targets hygiene applications, joined four other production lines, a carded line built in 2000 and three other Reifenhauser lines, an SMS line installed in 1994 and upgraded in 2005 and two SSS lines, which Union Industries added in 2001 and 2004.
 
“We are quite specialized in lightweight materials so our core business is hygienic,” Mr. Moltrasio said. “This does not mean we won’t sell to other markets. Even today, we are involved in other markets, not quite as important as hygiene—agriculture market, medical, industrial applications and a little bit of filtration as well.”
 
Currently, about 90% of Union Industries 45,000-ton capacity is exported beyond Italy with main markets lying within Europe but other areas of interest including the Middle East and the Far East.
 
Because the bulk of its output is based on polypropylene and focused on the hygiene market, Union Industries, like many nonwovens producers in its position, has been challenged by pricing pressures and eroding markets.
 
“For sure, raw material prices have made earnings much more difficult than in the past,” said Mr. Moltrasio. “Also a lot of new capacity is coming on the market. The raw material prices are getting higher and higher and obviously our margins are very much reduced if we compare the margins we have today to the past.”
 
Also of interest to Union Industries is the wipes market, which it targets with material made on its carded thermal bonded line, established in 2000. This line can make materials with blends of polypropylene and other fibers such as cotton and viscose, making them ideal for wipes.
 
Union Industries has achieved success by concentrating on understanding the market needs and trying to serve them with the latest technologies available. “We try to innovate with some new technology and we are always focusing to keep a very high standard in terms of quality and in terms of service. Most importantly, we are able to grant the same high standard constantly.
Location: Masserano, Italy

Sales: $90 million

Description: Key Personnel
Matteo Moltrasio, vice president; Luigi Cassano, managing director; Alessandro Taramasso, commercial director

Plant
Masserano, Biella, Italy

ISO Status
ISO 9001:2000 since 1997; renewed in 2006

Processes
Spunbond, spunbond-meltblown, carded thermal bond

Brand Name
Spundouce

Major Markets
Hygiene, wipes, medical, agriculture, industrial


Sales in 2006 increased from €65 million to €72 million for Union Industries. The company attributes the increase to larger manufacturing volumes, partially adjusted prices and increased raw material costs. Thanks to increased production volumes, Union was able to rationalize and control certain costs.  Despite this, however, no profit growth was reported in 2006.
 
The latest line installed, a Reicofil 4 SSS system that came onstream at the end of 2006, brings the company’s total capacity to 60,000 tons per year, which mainly targets the global hygiene market. According to the company, the start-up of the line met expectations and production volume grew remarkably in the first months of 2007. This new line widens Union’s existing production capacity of spunbond (Reicofil.3 and Reicofil.4), spunbond-meltblown and carded thermal bond nonwovens.
 
“Union’s specialty is lightweight nonwovens, which are valued by the hygiene market,” explained vice president Matteo Moltrasio. “We are always concentrating on market needs and serving customers with the latest technologies, consistently granting very high standards in terms of quality and service. These are considered the key factors for a demanding market such as hygiene.”
 
Mr. Moltrasio  went on to say that the future is linked to development. “Therefore we are focusing on a constant commitment to improve our products and search for new ones, including specialties,” he said. “We are always watching and are attentive to signs from different world markets, including those outside of Europe.”
 
Currently, about 90% of Union Industries’ 60,000-ton capacity is exported outside of Italy with main markets lying within Europe. Other areas of interest include the Middle East and the Far East."
Location: MASSERANO, ITALY

Sales: $90 million

Description: Key Personnel
Matteo Moltrasio, vice president; Luigi Cassano, managing director; Alessandro Taramasso, commercial director

Plant
Masserano, Biella, Italy

ISO Status
ISO 9001:2000 since 1997; renewed in 2006

Processes
Spunbond, spunbond-meltblown, carded thermal bond

Brand Name
Spundouce

Major Markets
Hygiene, wipes, medical, agriculture, industrial

Italy’s Union Industries produces 60,000 tons of spunbond, spunmelt and carded thermal bonded nonwovens at its facility in Masserano. Its latest line, a Reicofil 4 SSS system came onstream at the end of 2006 and mainly targets the hygiene market. The new line widens Union’s existing production capacity of spunbond (Reicofil 4 and Reicofil 4) spunbond-meltblown and carded thermal bonded nonwovens.
 
According to company executives, Union’s specialty is lightweight nonwovens, which are valued by the hygiene markets. Other markets for the company include hygiene, wipes, medical, agriculture and industrial.
 
Approximately 90% of the company’s output is exported outside of Italy with main markets lying within Europe. Other interest areas include the Middle East and Far East.
Location: MASSERANO, ITALY


Sales: $143 Million


Description: Key Personnel
Matteo Moltrasio, vice president; Luigi Cassano, managing director; Alessandro Taramasso, commercial director

Plant
Masserano, Biella, Italy

ISO Status since 1997
ISO 9001:2008; renewed in 2009

Processes
Spunbond, spunbond-meltblown, carded thermal bond

Brand Name
Spundouce

Major Markets
Hygiene, wipes, medical, agriculture, industrial

Sales increased from $133 million to $143 million for Italian nonwovens producer Union Industries as the company’s production lines were better utilized.

The Masserano-based company is investing in a 5.2 meter Reicofil spunmelt line which will add 24,000 tons per year and bring its total throughput to 84,000 tons per year. The new line, featuring SSMMMS technology, is expected to start up during the third quarter of next year.

According to executives at the Masserano, Italy nonwovens producer, the decision to build a new line was driven by Union’s goal of supplying the hygiene and medical nonwovens market with high quality, ultra-lightweight nonwovens. While executives admit there is some overcapacity in the European hygiene market, they said they feel that investing in new technology will give Union Industries the necessary advantage to succeed.

“We believe that with this new asset we could offer the market an advanced generation of spunmelt material,” said vice president Matteo Moltrasio. “The goal is to obtain and give better performances and at the same time to give a savings to the market. Moreover, we assume we could explore other fields of application.

Currently 90% of Union Industries’ nonwovens output is exported outside of Italy, chiefly to Europe and the Middle East.

Union Industries’ most recent investment was a Reicofil 4 SSS system, a 4.2 meter that came onstream at the end of 2006, bringing the company’s total capacity to 60,000 tons per year. All of the company’s current spunbonded manufacturing assets are based on Reicofil technology.
Location: Masserano, Italy

Sales: $120 million

Description: Key Personnel
Matteo Moltrasio, vice president; Luigi Cassano, managing director; Alessandro Taramasso, commercial director

Plant
Masserano, Biella, Italy

Processes
Spunbond, spunmelt, carded thermal bonded

Brand names
Spundounce

Major Markets
Hygiene, wipes, medical, agriculture, industrial

Sales dropped slightly for Masserano, Italy-based Union Industries due to lower raw material prices, tougher market conditions and a weaker currency exchange rate but the company reported that its production lines operated continuously at high yields throughout the year. This trend has continued into 2010 and the company has been able to increase its prices as raw materials costs have begun to rise again.
Sales are expected to receive a further boost this year when the company finishes work on a new facility, dedicated to a brand new, state-of-the-art Reicofil spunmelt line which will add 24,000 tons per year to the operation, bringing its total output to 84,000 tons per year. The SSMMMS line is expected to begin production during the third quarter of 2010.
“We expect to allocate the additional volume generated within our core business, hygiene chiefly, yet we think we may have as well the opportunity to explore other fields of application,” said vice president Matteo Moltrasio.
Currently, all of Union Industries’ 60,000 tons of nonwovens are made using Reicofil technology which are largely targeted at the hygiene market however medical, wipes, industrial and agriculture are other interests.
According to executives, the decision to build the new line was driven by Union’s goal of supplying the hygiene and medical nonwovens markets with high quality, ultra-lightweight nonwovens. Union Industries’ latest investment—a 4.2-meter line—came onstream in late 2006
Masserano, Italy
2011 Nonwovens Sales: $184 million
 
Key Personnel: Matteo Moltrasio, vice president; Luigi Cassano, managing director; Alessandro Taramasso, commercial director
 
Plants: Masserano and Biella, Italy
 
Processes: Spunbond, spunmelt, carded, thermal bonded, apertured
 
Brands: Spundouce
 
Major Markets: Hygiene, wipes, medical, agricultural, industrial
 
Sales increased 25% to €132 million ($184 million) for Masserano, Italy-based Union Industries due mainly to the continued allocation of a new production line, which came on-stream as planned in the third quarter of 2010 and started making nonwovens mainly for hygiene applications during the fourth quarter, as well as increased raw material prices.
 
The new line, a state-of-the-art Reicofil spunmelt line, added 24,000 tons per year to Union’s operation, bringing its total output to 84,000 tons per year.
 
With the European nonwovens market seeing an overcapacity situation in many commoditized areas, Union has been focusing on adding specialty applications to its traditional products. “Union is focusing on specialties, aiming to bring innovative products to the market,” says Matteo Moltrasio, vice president, adding the company will evaluate a development plan in the early months of 2013, considering global nonwovens consumption.
 
In addition to growth, Union Industries has focused on improving the environmental footprint of its operation. In fact, one major goal achieved by the company from January 2011 is sourcing 100% of the energy consumed from renewable sources, Moltrasio adds.
Masserano, Italy
2012 Nonwovens Sales: $189 million
 
Key Personnel: Matteo Moltrasio, vice president; Luigi Cassano, managing director;
Alessandro Taramasso, commercial director
 
Plants: Masserano and Biella, Italy
 
Processes: Spunbond, spunmelt, carded, thermal bonded, apertured
Brands: Spundouce
 
Major Markets: Hygiene, medical, wipes, agricultural, industrial
 
Volumes rose 7% at Italy’s Union Industries in 2012 due to a better optimization and a full allocation of its production lines. The company has a production capacity of 84,000 tons of nonwovens in Masserano, Italy. Sales were reported at €142 million ($189 million).
 
With no new investment since 2010 when a 24,000-ton spunmelt line was added, Union has more recently been focusing on specialties and innovation in the face of a European market defi ned by overcapacity and reduced consumption, according to president Matteo Moltrasio. These efforts have been rewarded with the development of a new substrate featuring increased softness and texture for the hygiene market, where Union does about 80% of its business. The commercialization of the new material is starting now.
 
Other efforts have centered on new grades of apertured nonwovens for new applications, which became available in the second quarter of this year and the company is reporting more activity within the medical market.
 
“We have as well undertaken initiatives for the medical sector which we see more and more of interest,” Moltrasio says.
Union Industries
Masserano, Italy
2014 Nonwovens Sales: $176 million

Key Personnel

Matteo Moltrasio, president; Luigi Cassano, managing director; Alessandro Taramasso, commercial director 

Plants
Masserano, Italy, Radomsko Poland

Processes
Spunbond, spunmelt, carded, thermal bonded, apertured

Brands
Spundouce, Pillow
 
Union Industries’ first non-Italian line is set to come onstream in September 2015 in Poland, a move that should consolidate growth for the Italian company throughout Europe. The new line, which was announced in 2013, is a 3.2-meter wide Reicofil 4 SSMMS line that will bring Union’s total capacity to above 95,000 tons per year.

Executives said the new line should help Union grow in North, Central and Eastern Europe in the coming years. President Matteo Moltrasio says the company will evaluate the possibility of expanding outside of Europe after the Poland line comes onstream.

Currently, Union makes about 80,000 tons of nonwovens in Masserano, Italy, and in 2014 its sales were €145 million ($176 million).
Moltrasio says the sales, which were up in Euro terms but down when converted to U.S. dollars, were impacted by raw material pricing and as well as a strong focus on materials for hygiene and medical applications.

“We went into the direction of more customized products, which confirms Union’s ability to specialize,” Moltrasio says. “Hygiene remains our core business for which we are widening our portfolio range focusing on soft and ultra lightweight nonwovens.”
Masserano, Italy
2015 Nonwovens Sales: $162 million


Key Personnel
Matteo Moltrasio, president; Luigi Cassano, managing director; Alessandro Taramasso, commercial director

Plants
Masserano, Italy, Radomsko Poland

Processes
Spunmelt, spunbond,  carded, thermal bonded, apertured

Brands 
Spundouce, Pillow, Honeycomb


Sales increased slightly thanks to the start up of the Italian nonwovens producer’s first foreign investment—a 15,000-ton-per-year, 3.2-meter Reicofil 4s spunmelt/spunbond line that came onstream in Poland during the third quarter of 2015.

In 2015, sales increased from €145 million to €146.6 million and this figure is expected to climb as the Polish line achieves full utilization in 2016.

Looking ahead, Union is exploring further opportunities of investment either in Poland or other regions, consolidating its reputation among its customers and supporting growth, providing state-of-the-art technology and as always focusing on ultra lightweight nonwovens and special products.

In fact, the development of new specialties is another growth strategy for Union Industries. In 2015, the company introduced to the market a new product range of spunbond and spunmelt nonwovens that are softer and bulkier than the market standard, with unique engraving patterns, available either in Italy and Poland.
Masserano, Italy
2016 Nonwovens Sales: $170 million


Key Personnel
Matteo Moltrasio, president; Luigi Cassano, managing director; Alessandro Taramasso, commercial director

Plants
Masserano, Italy; Radamsko, Poland

Processes
Spunmelt, spunbond, carded, thermal bonded, apertured

Brands
Spundouce, Pillow, Honeycomb

The addition of new capacity at a new site in Poland as well as an increased focus on specialty products, helped drive Union Industries’ sales to $170 million in 2016. The company’s first foreign investment, in Radomsko, Poland, came onstream during the third quarter of 2015 and its full capacity of 12,000 reached sold out status during 2016. This led the Masserano, Italy-based nonwovens producer to announce plans, last year, for a second line at the site.

This new line, a Reicofil 4S bicomponent spunmelt line, will add 18,000 tons of capacity to the operation while also helping Union widen its focus on specialty products. It should be complete during the fourth quarter of 2017.

“After the latest additional capacity in Europe, including ours, we do not see room for any further investment in the area in the next years,” says Matteo Moltrasio, president. “We are considering initiatives in other geographical areas for our future.”
Masserano, Italy
2017 Nonwovens Sales: $176 million


Key Personnel
Matteo Moltrasio, president; Luigi Cassano, managing director; Alessandro Taramasso, commercial director; Gerardo Salvatore Menna, production director

Plants
Masserano, Italy; Radamsko, Poland

Processes
Spunmelt, spunbond, carded, thermal bonded, apertured

Brands
Spundouce, Pillow, Honeycomb


Sales increased to $176 million at Union Industries thanks to the initial contribution of its latest investment in Radamsko, Poland. The site’s second line came onstream during the last quarter of 2017, as planned, and is delivering novelty soft grades of nonwovens for hygiene applications, providing a new industry standard in nonwovens in terms of softness, comfort and performance.

Union established its first foreign operation in Poland in 2015 with a line capable of making 12,000 tons per year. This investment reached sold-out status in 2016 leading the Masserano, Italy-based company to announce plans for line number two at the site. The line, a Reicofil 4S bicomponent spunmelt line, added 18,000 tons to the operation and has increased Union’s focus on specialty products.

Looking forward, Union will continue to grow through investment in product innovation and expansion as it looks positively toward the future. The company also makes spunmelt and carded nonwovens at sites in Masserano and Biella, Italy.
Masserano, Italy
2018 Nonwovens Sales: $192 million


Key Personnel
Matteo Moltrasio, president; Alessandro Taramasso, commercial director; Gerardo Salvatore Menna, production director

Plants
Masserano, Italy; Radamsko, Poland

Processes
Spunmelt, spunbond, carded thermal bonded, carded air through bonded, apertured, printing

Brands
Spundouce, Pillow

Sales at Italy’s Union Industries increased slightly to $192 million in 2018 due to the partial allocation of the company’s second line in Radomsko, Poland, as well as an increase in volume for specialty nonwovens. Union’s second Polish line came onstream as planned in the last quarter of 2017 and is delivering novelty soft grades of nonwovens for hygiene applications.

“We keep seeing innovation in our future,” Matteo Moltrasio says. “We have consolidated the expertise and know-how in semi high loft technology and we see the product established as winning for specific applications.”

These developments in fact led Union, earlier this year, to decide to invest in a new line featuring carded air through bonded technology to expand Union’s offerings to the hygiene market.

“With this asset we believe we will be able to offer advanced and different range of products,” president Matteo Moltrasio says.

The new line is expected to be operational by early 2020, delivering customized super soft premium grades and new eco-sustainable fabrics for the hygiene market.

In other investment news, in the second quarter of 2019, Union began producing printed nonwovens using state-of-the-art technology.

As in past years, Union Industries continues to source and use renewable energy for the 100% of its consumption, partially produced within our group.
Masserano, Italy
2019 Nonwovens sales: $192 million


Key Personnel
Matteo Moltrasio, president; Alessandro Taramasso, commercial director; Gerardo Salvatore Menna, production director

Plants
Masserano, Italy; Radomsko, Poland

Processes
Spunmelt, spunbond, carded air through bonded, carded thermal bonded, apertured, 3-D embossing, printing 

Brands
Spundouce, Pillow

The full allocation of the second spun-melt asset in Radomsko, Poland as well as commercialization of printed nonwovens helped drive sales slightly higher at Union Industries. In addition to increasing the company’s nonwovens output in the region, it has allowed the company to deliver novelty soft grades of nonwovens for hygiene applications.

The focus on specialties and innovation led to the addition of an air through bonded line in Radomsko, Poland. The investment has allowed the company to deliver nonwovens for premium topsheet application of unprecedented softness and new eco-sustainable fabrics for the hygiene market.

Looking ahead, the company decided in December 2019 the investment in a Reicofil 5 bicomponent spunmelt line in Masserano, Italy. The new line is expected to begin production in the first half of next year.

In addition to investment, Union Industries remains committed to its sustainability efforts. This includes a conversion to using green energy for 100% of its consumption since year 2010 and the establishment of its own hydroelectric power plant.
Masserano, Italy
2020 Nonwovens Sales: $208 million


Key Personnel
Matteo Moltrasio, president; Alessandro Taramasso, commercial director; Gerardo Salvatore Menna, production director

Plants
Masserano, Italy; Radomsko, Poland

Processes
Spunmelt, spunbond, carded air through bonded, carded thermal bonded, apertured, 3-D embossing, printing 

Brands
Spundouce, Pillow

Union consolidated its position in the market during 2020, maintaining a good productivity level aligned to the previous year.

The nonwovens industry has been significantly impacted by Covid-19; during the year, mainly in the initial emergency phase, Union dedicated a small share of its production to this unexpected demand, without upsetting its position on the market. Union remained focused on hygiene, since it’s always been the company’s core business market.

Union Industries in parallel keeps up to its sustainability efforts, addressing development in sustainable and natural fibers/polymers while energy from renewable sources for its total consumption is in use since year 2010.
Masserano, Italy
2021 Nonwovens Sales: $260 million


Key Personnel
Matteo Moltrasio, president; Alessandro Taramasso, commercial director; Gerardo Salvatore Menna, production director

Plants
Masserano, Italy; Radomsko, Poland

Processes
Spunmelt, spunbond, carded air through bonded, carded thermal bonded, apertured, 3-D embossing, printing

Brands
Spundouce, Pillow

New investments, including an air through bonded line in Poland and a Reicofil 5 spunmelt line in Italy, helped increase Union Industries sales to $260 million in 2021, which was also severely marked by increased raw material prices and unprecedented energy cost spikes as well as shortages.

The company’s latest investments, an ATB line in Poland and a Reicofil 5 line, which came onstream in late 2021, have allowed the company, in addition to the existing assets, to continue to make both specialty and commodity materials for the hygiene market.

Union Industries also continues its sustainability efforts, addressing development in sustainable and natural fibers/polymers.

For Union Industries' 2020 top company profile, click here.
Masserano, Italy
2022 Nonwovens Sales: $226 million


Key Personnel
Matteo Moltrasio, president; Alessandro Taramasso, commercial director; Gerardo Salvatore Menna, production director

Plants
Masserano, Italy; Radomsko, Poland

Processes
Spunmelt, spunbond, carded air through bonded, carded thermal bonded, apertured, 3-D embossing, printing

Brands
Spundouce, Pillow

Raw material price decreases, reduced market demand and increased industrial costs led to a slight decrease in sales for Union Industries. The Masserano, Italy-based company reported sales of $226 million in 2022.

The company’s latest investments, an ATB line in Poland and a Reicofil 5 line, which came onstream in late 2021, have allowed the company to make both specialty and commodity materials for the hygiene market.

Notwithstanding the tough period, Union looks positively to the future and believes in the hygiene industry  and its customers, which it is willing to support in Europe and beyond.  “We keep on innovating and improving our products with a focus on softness, visual appearance and the use of sustainable natural raw materials,” says Matteo Moltrasio, president.

Within Union Industries’ key markets, the company offers the most advanced productive technologies to continue, as always, to propose and follow the more and more challenging market requirements of downgauging solutions.