1820 Evans Street N.E.
Conover, NC 28613
Based in Conover, NC, Polyester Fibers operates 22 nonwoven production lines at eight manufacturing sites in the U.S., offering a wide array of bonding, chemistry and fabrication capabilities. The company delivers its solutions to over 1500 customers in markets such as filtration, home furnishings, bedding, craft, seasonal and custom industrial applications.
Since the company’s inception in 1968—starting off as Cumulus Fibres—Polyester Fibers has seen its fair share of changeover between buyouts and acquisitions, which has ultimately led to its current success. Today, the company is comprised of five operating units including Tupelo Fibers, Cameo Fibers, Cumulus Fibres, Mountain Mist and Buffalo Batt.
Last year, a management buy-out of Polyester Fibers took place, and President and CEO Keith White and two partners now own the company. In its first year, the team has grown the business by over 18% year-over-year.
“The other two owners, Dean Cobb and Darren White, were on the executive management team of Polyester Fibers when it was previously owned by a venture capital firm,” White says. “They initiated a management buy-out in June 2014 at which time I was brought in as president and CEO. We purchased the company because it is well positioned in the key markets that it serves, has a loyal, long-time customer base and has a highly engaged and experienced labor force.”
Polyester Fibers’ web formation capabilities include airlaid, garneting and carding technologies, while bonding capabilities include thermal, mechanical entanglement, resin, soft and compound. Polyester Fibers uses a wide range and blend of fibers including natural, manmade, and synthetic fibers generated from virgin, semi-virgin or recycled materials, and it can fabricate materials into rolls, mattress pads, custom shaped cushion pads, strip rolls ranging from 1.5 inches and wider and vacuum packing.
Additionally, to extend the performance of its customers’ products, Polyester Fibers can apply specialty features to its materials including dry or wet tack, antimicrobial, fungal resistant, odor reducing additives, custom developed additives to improve MERV and dust holding, and high absorption additives for paint arrestor media.
Environmental sustainability is also a major part of the company’s manufacturing processes. “We are committed to minimizing environmental impacts by increasing our reliance on recycled materials and reducing wastes, emissions and energy consumption,” White says. Polyester Fibers does this by recycling edge trim, which dramatically takes waste out of landfills; partnering with suppliers that produce high quality fiber from recycled pre-industrial, post-industrial and post-consumer waste; implementing scrap buy-back programs with key customers to recycle their fiber scrap; and working with customers to minimize packaging materials that are often thrown away upon receipt. “This further reduces the waste stream while at the same time reducing the amount of space required for shipping which lowers the number of truckload deliveries required,” White explains, adding that the company recently replaced its tractors with higher efficiency vehicles, which improved overall fleet efficiencies while reducing CO2 emissions.
While half of the company’s business revolves around the air filtration market, with home furnishings/bedding and craft/seasonal following, Polyester Fibers is constantly exploring new markets. “We are currently in the process of conducting product research in the areas of hydroponics, acoustics, and residential building materials,” White reveals.
In the future, the company is also looking to expand its presence in the filtration and home furnishings/bedding markets either by adding new manufacturing lines or acquiring existing companies.