Freudenberg Performance Materials
Weinheim, Germany
www.freudenberg.com
2014 Nonwovens Sales: $1.54 billion
Freudenberg Nonwovens: $825.2 million
Freudenberg Politex Nonwovens: $269.8 million
Freudenberg Filtration Technologies $451 billion
Key Personnel
Bruce Olson, CEO; René Wollert, CFO; Frank Heislitz, CTO, Richard Shaw, COO
Plants
Weinheim, Germany; Neuenburg, Germany; Kaiserslautern, Germany; Greetland, UK; Swindon, UK; Littleborough, U.K.; Colmar, France; Barcelona, Spain; Nizhiniy, Novgorod, Russia; Sant´ Omero, Italy; Cossato, Italy; Novedrate, Italy; Pisticci, Italy; Hong Kong, China; Suzhou, China; Nantong, China; Chennai, India; Pyungtaek, South Korea; Yang Mei, Taiwan; Tayuan, Taiwan; San Martin/Buenos Aires, Argentina; Durham, NC, U.S.; Jacarei, Brazil; Cape Town, South Africa
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotives industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needle punched, thermal bond, chemical bond, water entanglement
Brands
Celestia, Comfortemp, Evolon, Lutradur, Lutrasil, SoundTex, Vildona, Viledon, Vilene, Vilmed, Vlieseline, Marelli & Berta Major
Markets
Automotive interiors, apparel, energy, geotextiles, building interiors, medical, hygiene and special applications.
A new name and a new structure were among the top headlines for Freudenberg, which ranks number two on the list of top manufacturers this year after being edged out by Avintiv. At the start of the year, its parent company merged Freudenberg Nonwovens with its roofing and construction outfit Freudenberg Politex Nonwovens to create Freudenberg Performance Materials. The combined company now reports sales of €905 million and supplies materials in various markets and applications including automotive interiors, apparel, building materials, hygiene, medical, shoe components and specialties.
“Many products from former Freudenberg Nonwovens and Freudenberg Politex Nonwovens are very similar concerning their production and their application,” says CEO Bruce Olson. “Therefore we can use synergies along the entire value chain, for example concerning the material expertise.”
At Techtextil in Germany this year, Olson discussed the new company. On the one hand, he says, it is a very young company—due to its January launch—but at the same time, the company is looking back on “a long and successful history” developed by the previous groups.
“Together, we believe we are headed to an even brighter and more successful future,” Olson says.
The new business group will continue to be driven by the same set of values and guiding principles, he explains, and while nonwovens is a core technology platform for the company, the creation of Freudenberg Performance Materials will strengthen nonwovens further as a core technology platform.
“But our vision does not stop there,” he continues. “The name Performance Materials stands for more than just the name of a new business group. It represents a new strategic orientation and a mandate from our shareholders and hopefully from our customers to look beyond nonwovens in providing customers with solutions they need to remain successful and profitable.”
On the same day Freudenberg Performance Materials began operations, it also acquired 100% ownership of Polymer Health Technology, Wales, U.K., a leading supplier of polyurethane foams for advanced wound care applications.
With the acquisition of Polymer Health Technology, Freudenberg Performance Materials is able to offer its globally active customers additional innovative solutions for modern wound management. The hydrophilic polyurethane foam systems from Polymer Health Technology absorb wound exudate, creating an ideal environment for healing the wound and protecting it from drying out.
Freudenberg’s woundcare business in general has been earmarked a strong growth area in which different material groups—all supporting the healing process—are used. “Our substrates for advanced wound care dressings are used in the treatment of complex hard-to-heal wounds, e.g. diabetic foot, leg and pressure ulcers,” Olson says. “The nonwovens and foams designed by Freudenberg offer numerous constructions and raw material options to provide customized and innovative product solutions in advance wound care: hydroactive nonwovens, high absorbing nonwovens, hydrophilic foams and other tailor made solutions. One of the latest nonwoven developments with a thickness of two millimeters can even absorb wound exudates of up to 25 times of its own weight.”
Another important division for Freudenberg Performance Materials is its spunlaid business which primarily serves the automotives, construction and bedding markets, which has assets serving this business on three continents—North America, Europe and Asia.
“Freudenberg Performance Materials has an excellent position in the spunlaid business. All three markets show specific opportunities for growth,” Olson says. “The customer base in our core segments is becoming more globalized, which drives us to ensure that we offer the same product range worldwide. The tiles sub-segment (construction market) shows the highest growth rates globally. “
In January 2014, Freudenberg announced a plan to upgrade its spunlaid operations in Durham, NC and Kaiserslautern, Germany. According to the company, the projects—both line enhancements—will improve product quality, allowing them to make nonwovens with high quality and improved performance. In Durham, three spunlaid lines were retrofitted with advanced production technology, while in Kaiserslautern an existing pilot line, which provides a good platform for product development at the planning level was upgraded. This project led to improvements in the quality of the product’s physical properties, allowing the business group to proactively serve the needs of its customers. “We continue to evaluate options for capacity expansions globally. If we realize an investment, it will be in next generation technology,” Olson adds.
Freudenberg’s spunlaid facility in Taiwan was not affected by the project. This site received a new line in 2012 to help increase the company’s profile in Asia.
Another important growth market for Freudenberg is Evolon, its microfilament nonwoven material, which was developed more than a decade ago but continues to evolve.
“Thanks to microfilaments which are around 100 times thinner than a human hair, Evolon’s worldwide patented technology provides outstanding lint-free, anti-scratch cleaning performance,” Olson says. “Furthermore, endless microfilaments make Evolon strong and mechanically stable. The isotropic fabric provides extended durability starting from lightweight wipes and frequent wash resistance for heavier weights.”
In May, Freudenberg launched Evolon 3D. This three-dimensional version of the material features increased surface volume and has become more refined, paving the way for other possible applications. Evolon 3D preserves the high performance of original Evolon, while increasing its bulkiness and volume and by taking on a feel and a look that are even more like fabric, according to Freudenberg. Like the original Evolon, Evolon 3D can be washed again and again without losing its structure. It can be kept white or dyed various colors. Transfer printing multiplies the possibilities for design and personalization and also produces very good results on Evolon 3D, according to company literature.
The applications are many and varied. In the ultralight category (as low as 30gsm), the 3D structure reinforces the uniformity of the microfilaments and increases ease of handling, making it possible to supply 3D microfilament wipes, which are 1.5 to 2 times lighter than the lightweight wipes traditionally obtained using competing processes. In addition, in its 100gsm version, Evolon 3D enables a new generation of sports towels to be produced that are just as ultra-compact, lightweight and effective but with a traditional fabric look that consumers know well.
Lastly, designers can use Evolon 3D in decoration, where Evolon is already valued for its matte look, lightness, ease of handling and its acoustical properties.
In keeping with Evolon’s clean production—free of solvents and chemical binders and with a minimum of production stages—the Evolon 3D structure is achieved without post-treatment and without the addition of chemicals.
In 2014, Freudenberg’s Interlinings Division recorded moderate growth in Europe, benefiting from market recovery in southern Europe, in particular Italy and Spain. Sales of woven, knit and nonwoven interlinings in the industrial apparel segment rose while a project known as the menswear initiative resulted in increased sales of woven and knit products.
A series of product innovations contributed to growth in the year under review. The main growth drivers were elastic interlinings and innovative paddings as a substitute for down as well as optimized product positioning in key markets.
In 2015, the Interlinings Division has returned to operating as a global division, bringing together all regions. The creation of this global management team has allowed Freudenberg Nonwovens to serve its customers in the global apparel industry more effectively and efficiently, according to Olson.
“The apparel business is truly global and business between regions is closely interlinking,” he says. “With its long established global presence, it was the next logical step for Freudenberg Apparel to evolve into a global division.”
Olson adds that the new organizational structure will enable the company to fully exploit the synergies between operational and strategic structures. The goal is to drive growth in the apparel market segment by engaging with customers at a global level.
“The global apparel market is growing in line with GDP. Apparel is a competitive business but Freudenberg has a strong position in most core markets,” Olson adds. “With its customized product and service packages, global network and broad product range globally available, Freudenberg Apparel is well positioned to serve the specific customer demands and further strengthen its global marketshare.”
In July 2014, Freudenberg expanded its interlinings business through the acquisition of the Hänsel brand from Hänsel Textil in Iserlohn, Germany. As a leading global manufacturer of highly-developed textiles, Hänsel has allowed Freudenberg to offer additional sophisticated interlining solutions. Hänsel offers numerous special interlinings for manufacturers of ladies and men’s outer garments, childrenswear and sports clothing. Products include genuine horsehair canvas, multi-zone interlinings or extremely light wovens and knits.
“The Hänsel brand stands for quality and innovation. With the textile interlinings used throughout the fashion industry, we are extending our comprehensive portfolio and our know-how in the field of knitted fabrics in a future-oriented manner,” Olson adds.
In new product news, Freudenberg has developed the world’s first nonwoven interlining made from 100% biodegradable polyester fiber, which made it the first company to be issued with a certificate for the biodegradation of a PES interlining by the German Hohenstein Institute, an accredited test laboratory.
ECO 123 degrades twice as fast as a standard polyester interlining. In an alkaline composting environment, degradation would already be completed in approximately six to nine months. The lightweight nonwoven interlining has good resistance to washing and drycleaning and is suitable for ironing.
Freudenberg Politex Nonwovens
In January 2015, Freudenberg Politex Nonwovens—the Freudenberg´s roofing and construction specialist, which makes polyester-based nonwovens using both staple and spunbonded technology—merged with company’s nonwovens business group to become Freudenberg Performance Materials.
Recent developments from this arm of the company include an expansion of its product range through the addition of innovative special products for roofing materials and the construction industry. Central to these developments were the modification of two production lines in Pisticci, Italy.
One of these lines now makes fiberglass-reinforced spunbonded nonwovens for flat roof applications and the other can manufacture nonwoven roofing reinforcements for pitched slate roofs. Freudenberg Politex also operations production sites in Spain, Russia and Georgia.
Freudenberg Filtration Technologies
Freudenberg Filtration Technologies reported sustained growth in 2014 with sales increasing to €373.1 million. The business group made good progress in profitability on the back of the higher sales volume, increased productivity at plants, systematic costs, inventory and receivables management as well as continuous improvement programs.
In 2014, good sales growth in Europe and China contrasted with developments in South America, Australia and South Africa which were characterized by challenging economic factors. In industry filtration, Freudenberg Filtration Technologies further expanded its business with Viledone filter elements and service contracts. Furthermore, the group won and concluded key major orders for system solutions. Projects included complete air filtration systems for offshore oil platforms in Brazil, filtration systems for a hospital in Spain and several project orders for efficient resource-saving wastewater treatment in the U.K. food and beverage industry.
Demand for micronAir cabin air filters, which are sold as original equipment in new vehicles and on the aftermarket, increased in all regions, with appreciable growth in China, North America and Europe. In response to this increased demand, the group has commissioned a new logistics center at its Kaiserslautern, Germany site. The newly created close proximity of production and logistics is one contributory factor in meeting customers’ growing demands regarding product availability and delivery flexibility.
In 2014, Freudenberg Filtration Technologies acquired the industrial activated carbon corrosion protection business of U.S.-based MeadWestvaco Corporation. The air purification product portfolio comprises activated carbon pellets, Honeycomb modules, which include the innovative Versacomb technology and system solutions. These new products complement the company’s existing range of quality gas phase filtration solutions.
www.freudenberg.com
2014 Nonwovens Sales: $1.54 billion
Freudenberg Nonwovens: $825.2 million
Freudenberg Politex Nonwovens: $269.8 million
Freudenberg Filtration Technologies $451 billion
Key Personnel
Bruce Olson, CEO; René Wollert, CFO; Frank Heislitz, CTO, Richard Shaw, COO
Plants
Weinheim, Germany; Neuenburg, Germany; Kaiserslautern, Germany; Greetland, UK; Swindon, UK; Littleborough, U.K.; Colmar, France; Barcelona, Spain; Nizhiniy, Novgorod, Russia; Sant´ Omero, Italy; Cossato, Italy; Novedrate, Italy; Pisticci, Italy; Hong Kong, China; Suzhou, China; Nantong, China; Chennai, India; Pyungtaek, South Korea; Yang Mei, Taiwan; Tayuan, Taiwan; San Martin/Buenos Aires, Argentina; Durham, NC, U.S.; Jacarei, Brazil; Cape Town, South Africa
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotives industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needle punched, thermal bond, chemical bond, water entanglement
Brands
Celestia, Comfortemp, Evolon, Lutradur, Lutrasil, SoundTex, Vildona, Viledon, Vilene, Vilmed, Vlieseline, Marelli & Berta Major
Markets
Automotive interiors, apparel, energy, geotextiles, building interiors, medical, hygiene and special applications.
A new name and a new structure were among the top headlines for Freudenberg, which ranks number two on the list of top manufacturers this year after being edged out by Avintiv. At the start of the year, its parent company merged Freudenberg Nonwovens with its roofing and construction outfit Freudenberg Politex Nonwovens to create Freudenberg Performance Materials. The combined company now reports sales of €905 million and supplies materials in various markets and applications including automotive interiors, apparel, building materials, hygiene, medical, shoe components and specialties.
“Many products from former Freudenberg Nonwovens and Freudenberg Politex Nonwovens are very similar concerning their production and their application,” says CEO Bruce Olson. “Therefore we can use synergies along the entire value chain, for example concerning the material expertise.”
At Techtextil in Germany this year, Olson discussed the new company. On the one hand, he says, it is a very young company—due to its January launch—but at the same time, the company is looking back on “a long and successful history” developed by the previous groups.
“Together, we believe we are headed to an even brighter and more successful future,” Olson says.
The new business group will continue to be driven by the same set of values and guiding principles, he explains, and while nonwovens is a core technology platform for the company, the creation of Freudenberg Performance Materials will strengthen nonwovens further as a core technology platform.
“But our vision does not stop there,” he continues. “The name Performance Materials stands for more than just the name of a new business group. It represents a new strategic orientation and a mandate from our shareholders and hopefully from our customers to look beyond nonwovens in providing customers with solutions they need to remain successful and profitable.”
On the same day Freudenberg Performance Materials began operations, it also acquired 100% ownership of Polymer Health Technology, Wales, U.K., a leading supplier of polyurethane foams for advanced wound care applications.
With the acquisition of Polymer Health Technology, Freudenberg Performance Materials is able to offer its globally active customers additional innovative solutions for modern wound management. The hydrophilic polyurethane foam systems from Polymer Health Technology absorb wound exudate, creating an ideal environment for healing the wound and protecting it from drying out.
Freudenberg’s woundcare business in general has been earmarked a strong growth area in which different material groups—all supporting the healing process—are used. “Our substrates for advanced wound care dressings are used in the treatment of complex hard-to-heal wounds, e.g. diabetic foot, leg and pressure ulcers,” Olson says. “The nonwovens and foams designed by Freudenberg offer numerous constructions and raw material options to provide customized and innovative product solutions in advance wound care: hydroactive nonwovens, high absorbing nonwovens, hydrophilic foams and other tailor made solutions. One of the latest nonwoven developments with a thickness of two millimeters can even absorb wound exudates of up to 25 times of its own weight.”
Another important division for Freudenberg Performance Materials is its spunlaid business which primarily serves the automotives, construction and bedding markets, which has assets serving this business on three continents—North America, Europe and Asia.
“Freudenberg Performance Materials has an excellent position in the spunlaid business. All three markets show specific opportunities for growth,” Olson says. “The customer base in our core segments is becoming more globalized, which drives us to ensure that we offer the same product range worldwide. The tiles sub-segment (construction market) shows the highest growth rates globally. “
In January 2014, Freudenberg announced a plan to upgrade its spunlaid operations in Durham, NC and Kaiserslautern, Germany. According to the company, the projects—both line enhancements—will improve product quality, allowing them to make nonwovens with high quality and improved performance. In Durham, three spunlaid lines were retrofitted with advanced production technology, while in Kaiserslautern an existing pilot line, which provides a good platform for product development at the planning level was upgraded. This project led to improvements in the quality of the product’s physical properties, allowing the business group to proactively serve the needs of its customers. “We continue to evaluate options for capacity expansions globally. If we realize an investment, it will be in next generation technology,” Olson adds.
Freudenberg’s spunlaid facility in Taiwan was not affected by the project. This site received a new line in 2012 to help increase the company’s profile in Asia.
Another important growth market for Freudenberg is Evolon, its microfilament nonwoven material, which was developed more than a decade ago but continues to evolve.
“Thanks to microfilaments which are around 100 times thinner than a human hair, Evolon’s worldwide patented technology provides outstanding lint-free, anti-scratch cleaning performance,” Olson says. “Furthermore, endless microfilaments make Evolon strong and mechanically stable. The isotropic fabric provides extended durability starting from lightweight wipes and frequent wash resistance for heavier weights.”
In May, Freudenberg launched Evolon 3D. This three-dimensional version of the material features increased surface volume and has become more refined, paving the way for other possible applications. Evolon 3D preserves the high performance of original Evolon, while increasing its bulkiness and volume and by taking on a feel and a look that are even more like fabric, according to Freudenberg. Like the original Evolon, Evolon 3D can be washed again and again without losing its structure. It can be kept white or dyed various colors. Transfer printing multiplies the possibilities for design and personalization and also produces very good results on Evolon 3D, according to company literature.
The applications are many and varied. In the ultralight category (as low as 30gsm), the 3D structure reinforces the uniformity of the microfilaments and increases ease of handling, making it possible to supply 3D microfilament wipes, which are 1.5 to 2 times lighter than the lightweight wipes traditionally obtained using competing processes. In addition, in its 100gsm version, Evolon 3D enables a new generation of sports towels to be produced that are just as ultra-compact, lightweight and effective but with a traditional fabric look that consumers know well.
Lastly, designers can use Evolon 3D in decoration, where Evolon is already valued for its matte look, lightness, ease of handling and its acoustical properties.
In keeping with Evolon’s clean production—free of solvents and chemical binders and with a minimum of production stages—the Evolon 3D structure is achieved without post-treatment and without the addition of chemicals.
In 2014, Freudenberg’s Interlinings Division recorded moderate growth in Europe, benefiting from market recovery in southern Europe, in particular Italy and Spain. Sales of woven, knit and nonwoven interlinings in the industrial apparel segment rose while a project known as the menswear initiative resulted in increased sales of woven and knit products.
A series of product innovations contributed to growth in the year under review. The main growth drivers were elastic interlinings and innovative paddings as a substitute for down as well as optimized product positioning in key markets.
In 2015, the Interlinings Division has returned to operating as a global division, bringing together all regions. The creation of this global management team has allowed Freudenberg Nonwovens to serve its customers in the global apparel industry more effectively and efficiently, according to Olson.
“The apparel business is truly global and business between regions is closely interlinking,” he says. “With its long established global presence, it was the next logical step for Freudenberg Apparel to evolve into a global division.”
Olson adds that the new organizational structure will enable the company to fully exploit the synergies between operational and strategic structures. The goal is to drive growth in the apparel market segment by engaging with customers at a global level.
“The global apparel market is growing in line with GDP. Apparel is a competitive business but Freudenberg has a strong position in most core markets,” Olson adds. “With its customized product and service packages, global network and broad product range globally available, Freudenberg Apparel is well positioned to serve the specific customer demands and further strengthen its global marketshare.”
In July 2014, Freudenberg expanded its interlinings business through the acquisition of the Hänsel brand from Hänsel Textil in Iserlohn, Germany. As a leading global manufacturer of highly-developed textiles, Hänsel has allowed Freudenberg to offer additional sophisticated interlining solutions. Hänsel offers numerous special interlinings for manufacturers of ladies and men’s outer garments, childrenswear and sports clothing. Products include genuine horsehair canvas, multi-zone interlinings or extremely light wovens and knits.
“The Hänsel brand stands for quality and innovation. With the textile interlinings used throughout the fashion industry, we are extending our comprehensive portfolio and our know-how in the field of knitted fabrics in a future-oriented manner,” Olson adds.
In new product news, Freudenberg has developed the world’s first nonwoven interlining made from 100% biodegradable polyester fiber, which made it the first company to be issued with a certificate for the biodegradation of a PES interlining by the German Hohenstein Institute, an accredited test laboratory.
ECO 123 degrades twice as fast as a standard polyester interlining. In an alkaline composting environment, degradation would already be completed in approximately six to nine months. The lightweight nonwoven interlining has good resistance to washing and drycleaning and is suitable for ironing.
Freudenberg Politex Nonwovens
In January 2015, Freudenberg Politex Nonwovens—the Freudenberg´s roofing and construction specialist, which makes polyester-based nonwovens using both staple and spunbonded technology—merged with company’s nonwovens business group to become Freudenberg Performance Materials.
Recent developments from this arm of the company include an expansion of its product range through the addition of innovative special products for roofing materials and the construction industry. Central to these developments were the modification of two production lines in Pisticci, Italy.
One of these lines now makes fiberglass-reinforced spunbonded nonwovens for flat roof applications and the other can manufacture nonwoven roofing reinforcements for pitched slate roofs. Freudenberg Politex also operations production sites in Spain, Russia and Georgia.
Freudenberg Filtration Technologies
Freudenberg Filtration Technologies reported sustained growth in 2014 with sales increasing to €373.1 million. The business group made good progress in profitability on the back of the higher sales volume, increased productivity at plants, systematic costs, inventory and receivables management as well as continuous improvement programs.
In 2014, good sales growth in Europe and China contrasted with developments in South America, Australia and South Africa which were characterized by challenging economic factors. In industry filtration, Freudenberg Filtration Technologies further expanded its business with Viledone filter elements and service contracts. Furthermore, the group won and concluded key major orders for system solutions. Projects included complete air filtration systems for offshore oil platforms in Brazil, filtration systems for a hospital in Spain and several project orders for efficient resource-saving wastewater treatment in the U.K. food and beverage industry.
Demand for micronAir cabin air filters, which are sold as original equipment in new vehicles and on the aftermarket, increased in all regions, with appreciable growth in China, North America and Europe. In response to this increased demand, the group has commissioned a new logistics center at its Kaiserslautern, Germany site. The newly created close proximity of production and logistics is one contributory factor in meeting customers’ growing demands regarding product availability and delivery flexibility.
In 2014, Freudenberg Filtration Technologies acquired the industrial activated carbon corrosion protection business of U.S.-based MeadWestvaco Corporation. The air purification product portfolio comprises activated carbon pellets, Honeycomb modules, which include the innovative Versacomb technology and system solutions. These new products complement the company’s existing range of quality gas phase filtration solutions.
Weinheim, Germany
www.freudenberg-pm.com
2015 Nonwovens Sales: $1.7 billion
Key Personnel
Bruce Olson, CEO; René Wollert, CFO; Frank Heislitz, CTO, Richard Shaw, COO
Plants
Weinheim, Germany; Neuenburg, Germany; Kaiserslautern, Germany; Greetland, U.K.; Swindon, U.K.; Littleborough, U.K.; Colmar, France; Barcelona, Spain; Nizhiniy, Novgorod, Russia; Sant´ Omero, Italy; Cossato, Italy; Novedrate, Italy; Pisticci, Italy; Hong Kong, China; Suzhou, China; Nantong, China; Chennai, India; Pyungtaek, South Korea; Yang Mei, Taiwan; Tayuan, Taiwan; San Martin/Buenos Aires, Argentina; Durham, NC; Jacarei, Brazil; Cape Town, South Africa
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotives industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunched, thermal bond, chemical bond, water entanglement
Brands
Celestia, Comfortemp, Evolon, Lutradur, Lutrasil, SoundTex, Vildona, Viledon, Vilene, Vilmed, Vlieseline, Marelli & Berta
Major Markets
Automotive interiors, apparel, energy, geotextiles, building interiors, medical, hygiene and special applications
Beginning in 2015, Freudenberg began operating through a new model combining its nonwovens business with its roofing and construction outfit, Freudenberg Politex. The merged businesses are now known as Freudenberg Performance Materials. By combining these two formerly independent companies, Freudenberg Performance Materials can leverage technological and material synergies more intensively, create more efficient processes and pool knowledge. In its first year, the group established a new organizational structure for the global Apparel and Building Materials Divisions well as the regional Business Units of Europe, North America, South America and the Asia/Pacific.
Freudenberg Performance Materials is a leading global supplier of innovative solutions for a broad range of applications such as automotive interiors, apparel, building materials, filtration, hygiene, medical, shoe components and specialties. The company has more than 25 manufacturing sites in 14 countries.
The company’s apparel business, which includes both woven and nonwoven technologies, has reported appreciable sales growth thanks largely to the acquisition of the Hansel brand from Hansel Textil in Iserlohn, Germany. The acquisition has allowed Freudenberg to offer sophisticated interlining solutions in ladies and men’s outer garments, childrenswear and sportswear. In June 2016, Freudenberg added to these offerings through the investment of a stretchable interlinings line in Weinheim, Germany. Freudenberg relocated all of the Hansel operations from Iserlohn to its Weinheim headquarters in 2015.
In 2015, the apparel business was strong in the Asian countries of Vietnam and Bangladesh but growth was subdued in China and challenges were felt in Southern Europe, due to the Russia-Ukraine conflict.
Meanwhile, the Building Materials segment was recognized with several awards. In Taiwan, the Interface Group presented Freudenberg Far Eastern Spunweb, based in Taoyuan, Taiwan, with its Supplier Gold Award.
In China, the city of Nantong recognized Freudenberg & Vilene Interlinings (Nantong) Co. Ltd., Nantong, China, as a “Green Company” for the thirteenth time.
On the manufacturing front, this division continued its intensive efforts to improve manufacturing process efficiency and progressed with the phased transition of production lines to manufacture high quality glass fiber reinforced spunlaids with a view to offering sustainable solutions to construction industry customers worldwide.
Additionally, special products, such as solutions for steep gabled roofs, were added to upgrade the product range. By converting the production lines in Pisticci, Italy, and Colmar, France, Freudenberg Performance Materials can offer customized solutions for underlays.
The business group also consolidated its position as the world market leader for polyester nonwovens for roofing applications by expanding its range of high-quality products, know-how in both spunlaid and staple fiber technology and close ties with global customers. Furthermore, Freudenberg Performance Materials built on existing achievements in sustainable and efficient resource management, for example reducing CO2 emissions in staple fiber production at Novedrate, Italy, by 4%.
In 2015, Freudenberg & Vilene Nonwovens (Suzhou) Co. Ltd., Suzhou, China, invested in a new state-of-the-art production line for automotive headliners at the Suzhou facility in Eastern China. Start of production was scheduled for summer 2016. The company began marketing printed headliners in 2010 and is currently the only headliner manufacturer with in-house printing capabilities.
In the U.S., Freudenberg’s Durham, NC site is adding spinning capabilities to provide more uniformity in a number of markets including automotives, carpets and geotextiles. This $6 million investment is known as Freudenberg’s PA2 line.
In other investment news, in September Freudenberg added a €3 million pilot plant at its Kaiserslautern, Germany site to develop and test new processing technologies.
“We are producing spunlaids with the patented technology developed by us, a technology with significant advantages compared to competing technologies,” says Michael Ehret, head of operations regional business unit Europe and site manager in Kaiserslautern. The benefits include tailor-made products, consistent quality and higher productivity.
“With the new pilot plant, we are able to open up completely new application fields and to develop new innovative products for individual customer needs,” says Dr. Volker Röhring, manager process development. The plant is operated with the existing workforce.
In January 2015, Freudenberg’s medical business received a boost through the acquisition of Polymer Health Technology, a Wales, U.K.-based supplier of polyurethane foams for advanced wound care applications. This has allowed the company to offer its customers additional innovative solutions for modern wound management. The hydrophilic polyurethane foam systems from Polymer Health Technology absorb wound exudate, creating an ideal environment for healing the wound and protecting it from drying out.
Since the acquisition, Freudenberg has been working closely with customers to intensify the research and development of foam-based solutions. Its first successes include customized, antimicrobial polyurethane foam systems for medium to strong extruded wounds such as decubitus and second degree burns. The antimicrobial effect contributes to reducing the bacterial load in infected wounds. It also acts as a barrier in wounds with high and renewed risk of infection. In the future, the company will also offer standardized solutions for a wide range of applications.
Another source of new products and new market opportunities is Evolon, Freudenberg’s microfilament nonwoven material, which was developed more than a decade ago but continues to evolve.
In 2016, Freudenberg showcased Evolon’s usage in the high tech wiping markets. While the material has been used as a heavyweight, high-tech cleaning cloth for years, recent developments have allowed Freudenberg to combine the benefits of microfilaments and the convenience of disposable items to develop its range of lightweight wipe substrates. Evolon wipes offer exceptional cleaning performance in their category thanks to the fineness and density of the microfilaments. Dry or pre-impregnated, Evolon lightweight wipes are set for highly demanding applications requiring the best surface preservation, and are currently being qualified by the automotive and aerospace industries. These Evolon lightweight wipes give Freudenberg the opportunity to consolidate its position in the industrial cleaning segment.
Beyond wipes, Evolon’s evolution has allowed it to be used in a microfiber towel that can absorb four times its weight in large-scale graphics and in automotives applications where it aids in sound control. Evolon is currently used in General Motors’ Malibu automobile as a dashboard and full floor system to absorb sounds.
Additionally, the three-dimensional version of Evolon features increased surface volume and has become more refined, paving the way for a number of applications.
In corporate news, in August 2015, Freudenberg’s parent company purchased a 75% stake in Japan Vilene, one of Japan’s largest nonwovens manufacturers. Toray Industries will own the other 25% share in the company. Japan Vilene continues to operate as an independent company but Freudenberg, as the largest shareholder of the company, can make
Freudenberg Filtration Technology
Freudenberg Filtration Technology is also operating under a new structure. In January 2015, the group split into two global divisions—Automotive Filters and Industrial Filtration—while the existing Water Solutions global segment remained in operation.
Within automotives, demand from OEMs and the aftermarket for automotive filters developed very well, particularly in North America, with Freudenberg Filtration Technologies also reporting increased sales in Europe. The downturn in sales with key accounts in the Chinese automotive market could not be offset by the business group’s success in the non-branded aftermarket. The market environment in South America, particularly Brazil, was also challenging.
The Chinese filtration team won a major order from Zhejiang Geely Automobile Parts & Components Stock Co., Ltd., Hangzhou, China, to develop and supply engine intake air systems for a new platform for compact vehicles from the Volvo brand. This is the largest single order Freudenberg has won so far for the engine intake air filtration business in China.
In Weinheim, Freudenberg Filtration Technologies automated its pocket filter production lines—these filters are used in various industrial applications such as the food industry, in gas turbines or in paint shops, and invested in new machinery for cartridge filters for dust removal applications.
Within its Industrial Filtration Division, Freudenberg Filtration Technologies set up a new global market segment structure and improving global project management amidst generally volatile, extremely challenging market conditions.
Sales of filters for air purifiers and other household appliances in China and Korea decreased as a result of altered consumer behavior, more intense competition and changes in the purchasing patterns of key customers. The mining industry in Australia stagnated.
The market environment in South America also continues to be extremely challenging. In Europe there is strong demand fluctuation in many segments, and this calls for high flexibility in production and throughout the entire supply chain.
Freudenberg Filtration Technologies’ engineering business developed well despite a somewhat subdued investment climate for the maintenance, conversion and expansion of filtration systems. The business group built 12 ultra-modern filter houses for gas turbines on three offshore platforms operated by a Brazilian oil company off the South American coast.
The key benefit for the customer is reliably high filtration performance in continuous operation. Despite extremely high flow rates and extreme environmental conditions, Freudenberg air filters have a long service life.
Expansion of engineering business lines up with Freudenberg Filtration Technologies’ strategic goal to evolve from a supplier of high quality filtration products into a competence partner for complete, energy-efficient filtration solutions.
www.freudenberg-pm.com
2015 Nonwovens Sales: $1.7 billion
Key Personnel
Bruce Olson, CEO; René Wollert, CFO; Frank Heislitz, CTO, Richard Shaw, COO
Plants
Weinheim, Germany; Neuenburg, Germany; Kaiserslautern, Germany; Greetland, U.K.; Swindon, U.K.; Littleborough, U.K.; Colmar, France; Barcelona, Spain; Nizhiniy, Novgorod, Russia; Sant´ Omero, Italy; Cossato, Italy; Novedrate, Italy; Pisticci, Italy; Hong Kong, China; Suzhou, China; Nantong, China; Chennai, India; Pyungtaek, South Korea; Yang Mei, Taiwan; Tayuan, Taiwan; San Martin/Buenos Aires, Argentina; Durham, NC; Jacarei, Brazil; Cape Town, South Africa
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotives industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunched, thermal bond, chemical bond, water entanglement
Brands
Celestia, Comfortemp, Evolon, Lutradur, Lutrasil, SoundTex, Vildona, Viledon, Vilene, Vilmed, Vlieseline, Marelli & Berta
Major Markets
Automotive interiors, apparel, energy, geotextiles, building interiors, medical, hygiene and special applications
Beginning in 2015, Freudenberg began operating through a new model combining its nonwovens business with its roofing and construction outfit, Freudenberg Politex. The merged businesses are now known as Freudenberg Performance Materials. By combining these two formerly independent companies, Freudenberg Performance Materials can leverage technological and material synergies more intensively, create more efficient processes and pool knowledge. In its first year, the group established a new organizational structure for the global Apparel and Building Materials Divisions well as the regional Business Units of Europe, North America, South America and the Asia/Pacific.
Freudenberg Performance Materials is a leading global supplier of innovative solutions for a broad range of applications such as automotive interiors, apparel, building materials, filtration, hygiene, medical, shoe components and specialties. The company has more than 25 manufacturing sites in 14 countries.
The company’s apparel business, which includes both woven and nonwoven technologies, has reported appreciable sales growth thanks largely to the acquisition of the Hansel brand from Hansel Textil in Iserlohn, Germany. The acquisition has allowed Freudenberg to offer sophisticated interlining solutions in ladies and men’s outer garments, childrenswear and sportswear. In June 2016, Freudenberg added to these offerings through the investment of a stretchable interlinings line in Weinheim, Germany. Freudenberg relocated all of the Hansel operations from Iserlohn to its Weinheim headquarters in 2015.
In 2015, the apparel business was strong in the Asian countries of Vietnam and Bangladesh but growth was subdued in China and challenges were felt in Southern Europe, due to the Russia-Ukraine conflict.
Meanwhile, the Building Materials segment was recognized with several awards. In Taiwan, the Interface Group presented Freudenberg Far Eastern Spunweb, based in Taoyuan, Taiwan, with its Supplier Gold Award.
In China, the city of Nantong recognized Freudenberg & Vilene Interlinings (Nantong) Co. Ltd., Nantong, China, as a “Green Company” for the thirteenth time.
On the manufacturing front, this division continued its intensive efforts to improve manufacturing process efficiency and progressed with the phased transition of production lines to manufacture high quality glass fiber reinforced spunlaids with a view to offering sustainable solutions to construction industry customers worldwide.
Additionally, special products, such as solutions for steep gabled roofs, were added to upgrade the product range. By converting the production lines in Pisticci, Italy, and Colmar, France, Freudenberg Performance Materials can offer customized solutions for underlays.
The business group also consolidated its position as the world market leader for polyester nonwovens for roofing applications by expanding its range of high-quality products, know-how in both spunlaid and staple fiber technology and close ties with global customers. Furthermore, Freudenberg Performance Materials built on existing achievements in sustainable and efficient resource management, for example reducing CO2 emissions in staple fiber production at Novedrate, Italy, by 4%.
In 2015, Freudenberg & Vilene Nonwovens (Suzhou) Co. Ltd., Suzhou, China, invested in a new state-of-the-art production line for automotive headliners at the Suzhou facility in Eastern China. Start of production was scheduled for summer 2016. The company began marketing printed headliners in 2010 and is currently the only headliner manufacturer with in-house printing capabilities.
In the U.S., Freudenberg’s Durham, NC site is adding spinning capabilities to provide more uniformity in a number of markets including automotives, carpets and geotextiles. This $6 million investment is known as Freudenberg’s PA2 line.
In other investment news, in September Freudenberg added a €3 million pilot plant at its Kaiserslautern, Germany site to develop and test new processing technologies.
“We are producing spunlaids with the patented technology developed by us, a technology with significant advantages compared to competing technologies,” says Michael Ehret, head of operations regional business unit Europe and site manager in Kaiserslautern. The benefits include tailor-made products, consistent quality and higher productivity.
“With the new pilot plant, we are able to open up completely new application fields and to develop new innovative products for individual customer needs,” says Dr. Volker Röhring, manager process development. The plant is operated with the existing workforce.
In January 2015, Freudenberg’s medical business received a boost through the acquisition of Polymer Health Technology, a Wales, U.K.-based supplier of polyurethane foams for advanced wound care applications. This has allowed the company to offer its customers additional innovative solutions for modern wound management. The hydrophilic polyurethane foam systems from Polymer Health Technology absorb wound exudate, creating an ideal environment for healing the wound and protecting it from drying out.
Since the acquisition, Freudenberg has been working closely with customers to intensify the research and development of foam-based solutions. Its first successes include customized, antimicrobial polyurethane foam systems for medium to strong extruded wounds such as decubitus and second degree burns. The antimicrobial effect contributes to reducing the bacterial load in infected wounds. It also acts as a barrier in wounds with high and renewed risk of infection. In the future, the company will also offer standardized solutions for a wide range of applications.
Another source of new products and new market opportunities is Evolon, Freudenberg’s microfilament nonwoven material, which was developed more than a decade ago but continues to evolve.
In 2016, Freudenberg showcased Evolon’s usage in the high tech wiping markets. While the material has been used as a heavyweight, high-tech cleaning cloth for years, recent developments have allowed Freudenberg to combine the benefits of microfilaments and the convenience of disposable items to develop its range of lightweight wipe substrates. Evolon wipes offer exceptional cleaning performance in their category thanks to the fineness and density of the microfilaments. Dry or pre-impregnated, Evolon lightweight wipes are set for highly demanding applications requiring the best surface preservation, and are currently being qualified by the automotive and aerospace industries. These Evolon lightweight wipes give Freudenberg the opportunity to consolidate its position in the industrial cleaning segment.
Beyond wipes, Evolon’s evolution has allowed it to be used in a microfiber towel that can absorb four times its weight in large-scale graphics and in automotives applications where it aids in sound control. Evolon is currently used in General Motors’ Malibu automobile as a dashboard and full floor system to absorb sounds.
Additionally, the three-dimensional version of Evolon features increased surface volume and has become more refined, paving the way for a number of applications.
In corporate news, in August 2015, Freudenberg’s parent company purchased a 75% stake in Japan Vilene, one of Japan’s largest nonwovens manufacturers. Toray Industries will own the other 25% share in the company. Japan Vilene continues to operate as an independent company but Freudenberg, as the largest shareholder of the company, can make
Freudenberg Filtration Technology
Freudenberg Filtration Technology is also operating under a new structure. In January 2015, the group split into two global divisions—Automotive Filters and Industrial Filtration—while the existing Water Solutions global segment remained in operation.
Within automotives, demand from OEMs and the aftermarket for automotive filters developed very well, particularly in North America, with Freudenberg Filtration Technologies also reporting increased sales in Europe. The downturn in sales with key accounts in the Chinese automotive market could not be offset by the business group’s success in the non-branded aftermarket. The market environment in South America, particularly Brazil, was also challenging.
The Chinese filtration team won a major order from Zhejiang Geely Automobile Parts & Components Stock Co., Ltd., Hangzhou, China, to develop and supply engine intake air systems for a new platform for compact vehicles from the Volvo brand. This is the largest single order Freudenberg has won so far for the engine intake air filtration business in China.
In Weinheim, Freudenberg Filtration Technologies automated its pocket filter production lines—these filters are used in various industrial applications such as the food industry, in gas turbines or in paint shops, and invested in new machinery for cartridge filters for dust removal applications.
Within its Industrial Filtration Division, Freudenberg Filtration Technologies set up a new global market segment structure and improving global project management amidst generally volatile, extremely challenging market conditions.
Sales of filters for air purifiers and other household appliances in China and Korea decreased as a result of altered consumer behavior, more intense competition and changes in the purchasing patterns of key customers. The mining industry in Australia stagnated.
The market environment in South America also continues to be extremely challenging. In Europe there is strong demand fluctuation in many segments, and this calls for high flexibility in production and throughout the entire supply chain.
Freudenberg Filtration Technologies’ engineering business developed well despite a somewhat subdued investment climate for the maintenance, conversion and expansion of filtration systems. The business group built 12 ultra-modern filter houses for gas turbines on three offshore platforms operated by a Brazilian oil company off the South American coast.
The key benefit for the customer is reliably high filtration performance in continuous operation. Despite extremely high flow rates and extreme environmental conditions, Freudenberg air filters have a long service life.
Expansion of engineering business lines up with Freudenberg Filtration Technologies’ strategic goal to evolve from a supplier of high quality filtration products into a competence partner for complete, energy-efficient filtration solutions.
Weinheim, Germany
www.freudenberg-pm.com
2016 Nonwovens Sales: $1.7 billion
Key Personnel
Bruce Olson, CEO; René Wollert, CFO; Frank Heislitz, CTO; Richard Shaw, COO
Plants
Weinheim, Germany; Neuenburg, Germany; Kaiserslautern, Germany; Greetland, UK; Swindon, UK; Littleborough, Wales, UK; Colmar, France; Barcelona, Spain; Nizhiniy, Novgorod, Russia; Sant´ Omero, Italy; Cossato, Italy; Novedrate, Italy; Pisticci, Italy; Suzhou, China; Nantong, China; Chennai, India; Pyungtaek, South Korea; Yang Mei, Taiwan; Tayuan, Taiwan; San Martin/Buenos Aires, Argentina; Durham, NC; Jacarei, Brazil; Cape Town, South Africa, Macon, GA
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotive industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunch, thermal bond, chemical bond, water entanglement
Brands
Comfortemp, Evolon, SoundTex, Vlieseline
Major Markets
Automotive, apparel, building materials, medical, hygiene and special applications, shoe and leather goods
Two years after combining its nonwovens-related businesses—the nonwovens group and its Politex construction operation—the company now known as Freudenberg Performance Materials continues to capitalize on synergies between the businesses, which include 25 sites in 14 countries.
“The combination of Freudenberg’s nonwovens business with its Politex construction-related businesses has allowed the company to leverage technology and materials synergies effectively, further optimizing processes and pooling knowledge,” explains CEO and president Bruce Olson.
To remain competitive long term, Freudenberg has taken steps to improve its flexibility to respond to changing market conditions and customer demands. In Weinheim, Germany, the company decided to outsource its warehousing and logistics operations at a lower cost and reduce head counts. “The production model at Weinheim is also introducing a more flexible and modern staffing model,” Olson adds.
Meanwhile, in South America, Freudenberg responded to difficult conditions by launching a major restructuring of its hygiene operations and making the production of its sites in Buenos Aires, Argentina, and Jacarei, Brazil, fully dedicated to the hygiene market. In addition, these sites keep on serving customers in the apparel and shoe businesses.
“We are a niche player in hygiene with acquisition and distribution layer material for diapers and feminine hygiene, yet what we did was very successful,” Olson adds. “The turnaround in our South America hygiene business was a significant contributor to profit growth in the Performance Materials business.”
In addition to restructuring, Freudenberg has continued to grow its business through investment. Freudenberg is preparing to start up a new glass reinforced spunbond line, which is based on new in-house technology for glass reinforced nonwovens in Macon, GA. The new line, which represents a new technology for Freudenberg, will supplement output from three staple fiber lines already located in Macon. Olson says some of the technology used so far will likely be shuttered to make room for the more advanced technology, which will roll out to Europe in the future—where Freudenberg has similar sites in Italy, France and Russia.
Meanwhile, in Freudenberg’s tuft spunbond polyester business, the PA2 line, has been upgraded in Durham, NC. Calling the upgrade a “fairly significant investment,” Olson says the improvements will make the substrates more uniform impacting the tufting performance of materials for carpet backing, automotives, carpet tiles and shoe component markets.
“We are working on the next generation of spinning technology that gives even more uniformity,” he adds.
Once this next generation technology is fully refined, investment in Taiwan, where Freudenberg operates a two-line site in Tayuan, will surely follow.
“This investment should have been made earlier but we wanted to invest with the best processing technology available and we are waiting for our new spinning technology to be fully developed,” Olson says.
In Europe, Freudenberg has not made any major investments in new technology but has made some improvements to its technological offerings. In Weinheim, there are new pilot facilities for coating and impregnating that are focused on the long term development of lithium ion and fuel cell battery components, markets that the company hopes will represent a significant part of its business in the next five years.
Another area that represents Freudenberg’s excellence in innovation is Evolon, its continuous filament microfiber technology that has been under development for the past 15 years. These materials are currently made on one line in Colmar, France, which was debottlenecked three years ago to increase capacity by 50%. At the same time, Freudenberg continues to develop the process technology to allow it to make smaller and smaller microfibers to open new doors for Evolon.
The use of microfilament technologies in Evolon has allowed the material to act as technical and eco-friendly solutions in pillows, duvets, sleeping bags and other quilted products filled with feathers and down.
Thanks to its structure of closely entangled super-microfilaments, which are up to 200 times thinner than a human hair and weigh less than 130gsm, this Evolon variant is a high density cover fabric which prevents any loss of filling from even the finest layer of down. The textile also makes it possible to mask dark feathers or those that are a little too thick and prickly.
Evolon is known for being a natural physical barrier against dust mite allergens. As a result, Evolon also filters residual dust from feathers and down which could escape from the pillow or duvet. This improves bedding hygiene considerably. “Evolon is an example of how you can develop a unique process, patent it and then go out and find new applications for the material,” Olson says.
While acquisition has also been a past growth strategy for Freudenberg, the company has not made a major one since January 2015 when it purchased Polymer Health Technology, a Wales, U.K.-based supplier of polyurethane foams for advanced wound care applications, allowing the company to serve a market it had already supplied with nonwovens with foam. “When we chose to name our merged business Performance Materials, it was a signal to everyone that we want to solve problems with products, not just nonwovens,” Olson says. “But, we are looking for these nonwoven adjacent products only where we already have a strong position and advanced wound care is definitely an area that fits the bill.”
This strategy was also implemented in the company’s interlinings business when Freudenberg purchased Hansel, a German-based manufacturer of knitted interlinings in 2015. This acquisition allowed Freudenberg to offer sophisticated interlining solutions in ladies and men’s outer garments, childrenswear and sportswear. In 2016, Freudenberg added to these offerings through an investment of a stretchable interlinings line in Weinheim, Germany, where Freudenberg relocated the Hansel operation following the acquisition.
“A lot of these adjacent businesses are still in the niche state,” Olson says, “but, they should pay off in the next 10-15 years.”
www.freudenberg-pm.com
2016 Nonwovens Sales: $1.7 billion
Key Personnel
Bruce Olson, CEO; René Wollert, CFO; Frank Heislitz, CTO; Richard Shaw, COO
Plants
Weinheim, Germany; Neuenburg, Germany; Kaiserslautern, Germany; Greetland, UK; Swindon, UK; Littleborough, Wales, UK; Colmar, France; Barcelona, Spain; Nizhiniy, Novgorod, Russia; Sant´ Omero, Italy; Cossato, Italy; Novedrate, Italy; Pisticci, Italy; Suzhou, China; Nantong, China; Chennai, India; Pyungtaek, South Korea; Yang Mei, Taiwan; Tayuan, Taiwan; San Martin/Buenos Aires, Argentina; Durham, NC; Jacarei, Brazil; Cape Town, South Africa, Macon, GA
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotive industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunch, thermal bond, chemical bond, water entanglement
Brands
Comfortemp, Evolon, SoundTex, Vlieseline
Major Markets
Automotive, apparel, building materials, medical, hygiene and special applications, shoe and leather goods
Two years after combining its nonwovens-related businesses—the nonwovens group and its Politex construction operation—the company now known as Freudenberg Performance Materials continues to capitalize on synergies between the businesses, which include 25 sites in 14 countries.
“The combination of Freudenberg’s nonwovens business with its Politex construction-related businesses has allowed the company to leverage technology and materials synergies effectively, further optimizing processes and pooling knowledge,” explains CEO and president Bruce Olson.
To remain competitive long term, Freudenberg has taken steps to improve its flexibility to respond to changing market conditions and customer demands. In Weinheim, Germany, the company decided to outsource its warehousing and logistics operations at a lower cost and reduce head counts. “The production model at Weinheim is also introducing a more flexible and modern staffing model,” Olson adds.
Meanwhile, in South America, Freudenberg responded to difficult conditions by launching a major restructuring of its hygiene operations and making the production of its sites in Buenos Aires, Argentina, and Jacarei, Brazil, fully dedicated to the hygiene market. In addition, these sites keep on serving customers in the apparel and shoe businesses.
“We are a niche player in hygiene with acquisition and distribution layer material for diapers and feminine hygiene, yet what we did was very successful,” Olson adds. “The turnaround in our South America hygiene business was a significant contributor to profit growth in the Performance Materials business.”
In addition to restructuring, Freudenberg has continued to grow its business through investment. Freudenberg is preparing to start up a new glass reinforced spunbond line, which is based on new in-house technology for glass reinforced nonwovens in Macon, GA. The new line, which represents a new technology for Freudenberg, will supplement output from three staple fiber lines already located in Macon. Olson says some of the technology used so far will likely be shuttered to make room for the more advanced technology, which will roll out to Europe in the future—where Freudenberg has similar sites in Italy, France and Russia.
Meanwhile, in Freudenberg’s tuft spunbond polyester business, the PA2 line, has been upgraded in Durham, NC. Calling the upgrade a “fairly significant investment,” Olson says the improvements will make the substrates more uniform impacting the tufting performance of materials for carpet backing, automotives, carpet tiles and shoe component markets.
“We are working on the next generation of spinning technology that gives even more uniformity,” he adds.
Once this next generation technology is fully refined, investment in Taiwan, where Freudenberg operates a two-line site in Tayuan, will surely follow.
“This investment should have been made earlier but we wanted to invest with the best processing technology available and we are waiting for our new spinning technology to be fully developed,” Olson says.
In Europe, Freudenberg has not made any major investments in new technology but has made some improvements to its technological offerings. In Weinheim, there are new pilot facilities for coating and impregnating that are focused on the long term development of lithium ion and fuel cell battery components, markets that the company hopes will represent a significant part of its business in the next five years.
Another area that represents Freudenberg’s excellence in innovation is Evolon, its continuous filament microfiber technology that has been under development for the past 15 years. These materials are currently made on one line in Colmar, France, which was debottlenecked three years ago to increase capacity by 50%. At the same time, Freudenberg continues to develop the process technology to allow it to make smaller and smaller microfibers to open new doors for Evolon.
The use of microfilament technologies in Evolon has allowed the material to act as technical and eco-friendly solutions in pillows, duvets, sleeping bags and other quilted products filled with feathers and down.
Thanks to its structure of closely entangled super-microfilaments, which are up to 200 times thinner than a human hair and weigh less than 130gsm, this Evolon variant is a high density cover fabric which prevents any loss of filling from even the finest layer of down. The textile also makes it possible to mask dark feathers or those that are a little too thick and prickly.
Evolon is known for being a natural physical barrier against dust mite allergens. As a result, Evolon also filters residual dust from feathers and down which could escape from the pillow or duvet. This improves bedding hygiene considerably. “Evolon is an example of how you can develop a unique process, patent it and then go out and find new applications for the material,” Olson says.
While acquisition has also been a past growth strategy for Freudenberg, the company has not made a major one since January 2015 when it purchased Polymer Health Technology, a Wales, U.K.-based supplier of polyurethane foams for advanced wound care applications, allowing the company to serve a market it had already supplied with nonwovens with foam. “When we chose to name our merged business Performance Materials, it was a signal to everyone that we want to solve problems with products, not just nonwovens,” Olson says. “But, we are looking for these nonwoven adjacent products only where we already have a strong position and advanced wound care is definitely an area that fits the bill.”
This strategy was also implemented in the company’s interlinings business when Freudenberg purchased Hansel, a German-based manufacturer of knitted interlinings in 2015. This acquisition allowed Freudenberg to offer sophisticated interlining solutions in ladies and men’s outer garments, childrenswear and sportswear. In 2016, Freudenberg added to these offerings through an investment of a stretchable interlinings line in Weinheim, Germany, where Freudenberg relocated the Hansel operation following the acquisition.
“A lot of these adjacent businesses are still in the niche state,” Olson says, “but, they should pay off in the next 10-15 years.”
Weinheim, Germany
www.freudenberg-pm.com
2017 Nonwovens Sales: $2.1 billion
(including sales from Freudenberg Performance Materials,
Freudenberg Filtration Technologies and Japan Vilene)
Key Personnel
Frank Heislitz, CEO; Thomas Herr, CFO; John McNabb, COO
Plants
Weinheim, Germany; Neuenburg, Germany; Kaiserslautern, Germany; Greetland, U.K.; Swindon, U.K.; Littleborough, Wales, U.K.; Colmar, France; Barcelona, Spain; Nizhiniy, Novgorod, Russia; Sant´ Omero, Italy; Cossato, Italy; Novedrate, Italy; Pisticci, Italy; Suzhou, China; Nantong, China; Chennai, India; Pyungtaek, South Korea; Yang Mei, Taiwan; Tayuan, Taiwan; San Martin/Buenos Aires, Argentina; Durham, NC; Jacarei, Brazil; Cape Town, South Africa; Macon, GA
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotive industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunch, thermal bond, chemical bond, water entanglement
Brands
Comfortemp, Evolon, SoundTex, Vlieseline, Terbond, Texbond
Major Markets
Automotive, apparel, construction, building interiors, energy, medical, hygiene and special applications, shoe and leather goods
Nonwovens sales at Freudenberg Group, including contributions from the Performance Materials division, Filtration Technologies and Japan Vilene, reached €1.909 billion ($2.1 billion) in 2017. According to executives the year was mostly positive despite weakened demand in some markets and regions. Highlights include growth in medical and special applications like Freudenberg’s microfilament Evolon technology, a strong first half for the European construction market and growth in the apparel markets of China and India.
Challenges included slower than expected growth in hygiene and shoe components in South America, due to macroeconomic factors.
In fact, conditions in Argentina deteriorated to the point where Freudenberg decided to shutter its hygiene production operations at Villa Zagala at the end of the second quarter. Production of materials made at the site, which exclusively target the hygiene market, has been transferred to Freudenberg’s plant in Jacarei, Brazil.
“This decision was necessitated by the joint effects of market characteristics over recent years in combination with structural conditions in Argentina that have been unfavorable for this type of business,” CEO Frank Heislitz says. “We continue to serve our clients in the usual way from a modern facility with a highly efficient production system as part of our strategy of asset consolidation. Other Freudenberg Group companies and the shoe and interlinings divisions belonging to Freudenberg Performance Materials have and will continue their operations as usual.”
The closure of the hygiene production was not the first measure Freudenberg made to secure itself against difficult conditions in Argentina. In 2016, the company launched a major restructuring of its hygiene operations, where it is a niche player making acquisition and distribution layer materials for diapers and feminine hygiene items. This effort initially was successful and executives said the initial turnaround in South America was a major contributor to profit growth in the division in 2016.
In other restructuring efforts, Freudenberg has taken steps to improve its flexibility to respond to changing market conditions and customer demands. In Weinheim, Germany, the company decided to outsource its warehousing and logistics operations to increase flexibility.
“Restructuring in Weinheim has allowed external partners to handle logistics better than we can. More agile production allows us to react more quickly,” says Heislitz.
Amidst these efforts, Freudenberg continues to enlarge the scope of its business through investment. In March 2018, the company announced it would add a production line in Tayuan Tao-Yuan, Taiwan. Expansion of this capacity will allow the company to meet growing demand in the traditional automotive and carpet markets in Asia. The investment will add about 11,000 metric tons to Freudenberg’s Taiwan capacity. It is expected to be complete by 2020.
“The expansion of our capabilities underscores our long-term commitment to Asia. We want to continue to support our customers in the automotive and carpet markets with innovative and sustainable solutions that will help them grow,” Heislitz says.
Freudenberg currently supplies Asia with primary and secondary carrier materials for automotive carpet moldings and inlay mats, as well as dry running mats, carpets and carpet tiles. The high-performance materials are easy to form and thus contribute to economical processing. In addition, their high dimensional stability ensures a precise fit and they are extremely durable.
This capacity expansion will also enable Freudenberg to develop the company’s regional position.
“Asia is a very important market for us as a global player. Through our technologically leading solutions, we want to continue to grow with our customers in this region and at the same time make a significant technological contribution to their success,” says Lin Gow Ming, president of Freudenberg Far Eastern Spunweb Co. Ltd.
“Our process technology and spinning technology is constantly being improved to meet customer requirements,” Heislitz says. “With the new line we can further reduce weights, which is particularly in demand in automotives and carpet tiles, without sacrificing tufting performance.”
In addition to the Taiwan site, Freudenberg operates a spunbond operation in Durham, NC, where it has recently upgraded a PA2 line, allowing it to make more uniform substrates impacting the tufting performance of materials for carpet backing, automotives, carpet tiles and shoe components markets.
“Upgrading the new line was a logical step,” Heislitz says. “We improve the line to bring the latest technology to meet customer demand for light-weight carpet tiles and carpet backing.”
Meanwhile, in Freudenberg’s construction business, the company completed work on a new line in Macon, GA in mid-2017. The new line, which represents a new technology for Freudenberg, will allow the company to offer glass reinforced polyester spunbond nonwovens to satisfy demand in the roofing markets. The line, which is supplementing output from three staple fiber lines already located in Macon, was originally going to replace existing capacity but strong market conditions kept all four lines up and running.
Other areas of strength for Freudenberg’s nonwovens business include filtration, interiors and medical, particularly in advanced wound care, which is a growing market for Freudenberg.
“A big factor in the medical market is the aging populations. Growth is being driven by things like diabetes and obesity,” Heislitz says. “It’s not just wound care because that is a commodity.”
In 2015, Freudenberg expanded into foam technology through the acquisition of Polymer Health Technology, a Wales, U.K.-based supplier of polyurethane foams for advanced wound care applications, allowing it to broaden its offerings to the market. Freudenberg is now working on merging its nonwovens expertise with these new capabilities in the foam market to develop valued added products for this market.
Freudenberg’s strategy was the same when it acquired Hansel, a German-based manufacturer of knitted interlinings in 2015. While Hansel did not participate in nonwovens, its expertise in adjacent markets helped Freudenberg expand its offerings in the apparel segments.
Another market growing in importance is battery separators. As this market shifts its preference from nickel to lithium ion, Freudenberg already provides a solution to create value with its ceramic-coated polyester materials. “We already had out first customers in 2017 and this has gotten us through the learning curve,” Heislitz says. “Even for other applications and demands Freudenberg offers its fuel cell technology, which is becoming a very significant business for us.”
Meanwhile, in November 2017, Freudenberg introduced Evolon New Generation, which builds on the success of its unique Evolon microfilament technology first introduced in 1999. Evolon New Generation is made from super-microfilaments that are half the thickness and twice the density of those used in the original Evolon, opening up entirely new applications in the fields of bedding, technical packaging and many others.
Executives says the technical possibilities of Evolon New Generation are enormous. ”It was time to do something new in Evolon,” Heislitz says. “In some applications we were facing higher customer demands and the new technology addresses this. We have not fully utilized the full potential of [this] new Evolon.”
www.freudenberg-pm.com
2017 Nonwovens Sales: $2.1 billion
(including sales from Freudenberg Performance Materials,
Freudenberg Filtration Technologies and Japan Vilene)
Key Personnel
Frank Heislitz, CEO; Thomas Herr, CFO; John McNabb, COO
Plants
Weinheim, Germany; Neuenburg, Germany; Kaiserslautern, Germany; Greetland, U.K.; Swindon, U.K.; Littleborough, Wales, U.K.; Colmar, France; Barcelona, Spain; Nizhiniy, Novgorod, Russia; Sant´ Omero, Italy; Cossato, Italy; Novedrate, Italy; Pisticci, Italy; Suzhou, China; Nantong, China; Chennai, India; Pyungtaek, South Korea; Yang Mei, Taiwan; Tayuan, Taiwan; San Martin/Buenos Aires, Argentina; Durham, NC; Jacarei, Brazil; Cape Town, South Africa; Macon, GA
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotive industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunch, thermal bond, chemical bond, water entanglement
Brands
Comfortemp, Evolon, SoundTex, Vlieseline, Terbond, Texbond
Major Markets
Automotive, apparel, construction, building interiors, energy, medical, hygiene and special applications, shoe and leather goods
Nonwovens sales at Freudenberg Group, including contributions from the Performance Materials division, Filtration Technologies and Japan Vilene, reached €1.909 billion ($2.1 billion) in 2017. According to executives the year was mostly positive despite weakened demand in some markets and regions. Highlights include growth in medical and special applications like Freudenberg’s microfilament Evolon technology, a strong first half for the European construction market and growth in the apparel markets of China and India.
Challenges included slower than expected growth in hygiene and shoe components in South America, due to macroeconomic factors.
In fact, conditions in Argentina deteriorated to the point where Freudenberg decided to shutter its hygiene production operations at Villa Zagala at the end of the second quarter. Production of materials made at the site, which exclusively target the hygiene market, has been transferred to Freudenberg’s plant in Jacarei, Brazil.
“This decision was necessitated by the joint effects of market characteristics over recent years in combination with structural conditions in Argentina that have been unfavorable for this type of business,” CEO Frank Heislitz says. “We continue to serve our clients in the usual way from a modern facility with a highly efficient production system as part of our strategy of asset consolidation. Other Freudenberg Group companies and the shoe and interlinings divisions belonging to Freudenberg Performance Materials have and will continue their operations as usual.”
The closure of the hygiene production was not the first measure Freudenberg made to secure itself against difficult conditions in Argentina. In 2016, the company launched a major restructuring of its hygiene operations, where it is a niche player making acquisition and distribution layer materials for diapers and feminine hygiene items. This effort initially was successful and executives said the initial turnaround in South America was a major contributor to profit growth in the division in 2016.
In other restructuring efforts, Freudenberg has taken steps to improve its flexibility to respond to changing market conditions and customer demands. In Weinheim, Germany, the company decided to outsource its warehousing and logistics operations to increase flexibility.
“Restructuring in Weinheim has allowed external partners to handle logistics better than we can. More agile production allows us to react more quickly,” says Heislitz.
Amidst these efforts, Freudenberg continues to enlarge the scope of its business through investment. In March 2018, the company announced it would add a production line in Tayuan Tao-Yuan, Taiwan. Expansion of this capacity will allow the company to meet growing demand in the traditional automotive and carpet markets in Asia. The investment will add about 11,000 metric tons to Freudenberg’s Taiwan capacity. It is expected to be complete by 2020.
“The expansion of our capabilities underscores our long-term commitment to Asia. We want to continue to support our customers in the automotive and carpet markets with innovative and sustainable solutions that will help them grow,” Heislitz says.
Freudenberg currently supplies Asia with primary and secondary carrier materials for automotive carpet moldings and inlay mats, as well as dry running mats, carpets and carpet tiles. The high-performance materials are easy to form and thus contribute to economical processing. In addition, their high dimensional stability ensures a precise fit and they are extremely durable.
This capacity expansion will also enable Freudenberg to develop the company’s regional position.
“Asia is a very important market for us as a global player. Through our technologically leading solutions, we want to continue to grow with our customers in this region and at the same time make a significant technological contribution to their success,” says Lin Gow Ming, president of Freudenberg Far Eastern Spunweb Co. Ltd.
“Our process technology and spinning technology is constantly being improved to meet customer requirements,” Heislitz says. “With the new line we can further reduce weights, which is particularly in demand in automotives and carpet tiles, without sacrificing tufting performance.”
In addition to the Taiwan site, Freudenberg operates a spunbond operation in Durham, NC, where it has recently upgraded a PA2 line, allowing it to make more uniform substrates impacting the tufting performance of materials for carpet backing, automotives, carpet tiles and shoe components markets.
“Upgrading the new line was a logical step,” Heislitz says. “We improve the line to bring the latest technology to meet customer demand for light-weight carpet tiles and carpet backing.”
Meanwhile, in Freudenberg’s construction business, the company completed work on a new line in Macon, GA in mid-2017. The new line, which represents a new technology for Freudenberg, will allow the company to offer glass reinforced polyester spunbond nonwovens to satisfy demand in the roofing markets. The line, which is supplementing output from three staple fiber lines already located in Macon, was originally going to replace existing capacity but strong market conditions kept all four lines up and running.
Other areas of strength for Freudenberg’s nonwovens business include filtration, interiors and medical, particularly in advanced wound care, which is a growing market for Freudenberg.
“A big factor in the medical market is the aging populations. Growth is being driven by things like diabetes and obesity,” Heislitz says. “It’s not just wound care because that is a commodity.”
In 2015, Freudenberg expanded into foam technology through the acquisition of Polymer Health Technology, a Wales, U.K.-based supplier of polyurethane foams for advanced wound care applications, allowing it to broaden its offerings to the market. Freudenberg is now working on merging its nonwovens expertise with these new capabilities in the foam market to develop valued added products for this market.
Freudenberg’s strategy was the same when it acquired Hansel, a German-based manufacturer of knitted interlinings in 2015. While Hansel did not participate in nonwovens, its expertise in adjacent markets helped Freudenberg expand its offerings in the apparel segments.
Another market growing in importance is battery separators. As this market shifts its preference from nickel to lithium ion, Freudenberg already provides a solution to create value with its ceramic-coated polyester materials. “We already had out first customers in 2017 and this has gotten us through the learning curve,” Heislitz says. “Even for other applications and demands Freudenberg offers its fuel cell technology, which is becoming a very significant business for us.”
Meanwhile, in November 2017, Freudenberg introduced Evolon New Generation, which builds on the success of its unique Evolon microfilament technology first introduced in 1999. Evolon New Generation is made from super-microfilaments that are half the thickness and twice the density of those used in the original Evolon, opening up entirely new applications in the fields of bedding, technical packaging and many others.
Executives says the technical possibilities of Evolon New Generation are enormous. ”It was time to do something new in Evolon,” Heislitz says. “In some applications we were facing higher customer demands and the new technology addresses this. We have not fully utilized the full potential of [this] new Evolon.”
Weinheim, Germany
www.freudenberg-pm.com
2018 Nonwovens Sales: $2.1 billion
(including sales from Freudenberg Performance Materials,
Freudenberg Filtration Technologies and Japan Vilene)
Key Personnel
Frank Heislitz, CEO; Thomas Herr, CFO; John McNabb, COO
Plants
Weinheim, Germany; Neuenburg, Germany; Kaiserslautern, Germany; Greetland, U.K.; Swindon, U.K.; Littleborough, Wales, U.K.; Colmar, France; Barcelona, Spain; Nizhiniy, Novgorod, Russia; Sant´ Omero, Italy; Cossato, Italy; Novedrate, Italy; Pisticci, Italy; Suzhou, China; Nantong, China; Chennai, India; Pyungtaek, South Korea; Yang Mei, Taiwan; Tayuan, Taiwan; San Martin/Buenos Aires, Argentina; Durham, NC; Jacarei, Brazil; Cape Town, South Africa; Macon, GA
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotive industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunch, thermal bond, chemical bond, water entanglement
Brands
Comfortemp, Evolon, SoundTex, Vlieseline, Terbond, Texbond
Major Markets
Automotive, apparel, construction, building interiors, energy, medical, hygiene and special applications, shoe and leather goods
As it celebrates the 20th anniversary of its unique Evolon microfilament technology, finishes up work on its latest Tufts line in Taipei, Taiwan, and lets the ink dry on its latest filtration-related acquisition, Freudenberg is a company that wears many hats in the nonwovens industry. The company’s nonwovens-related businesses fall within three of its major divisions, Freudenberg Performance Materials, Freudenberg Filtration Technologies and Japan Vilene. Together, the three divisions reported sales of about $2.1 billion in 2018.
The largest division, Performance Materials, which was created through a marriage of the nonwovens business and Texbond, Freudenberg’s construction-related entity, in 2014, reported a challenging year in 2018. Sales were impacted by negative exchange rates and profits were hit with rising raw material prices.
The division’s largest recent investment is a new headliner line in Suzhou, China. The line which was officially complete in March, enables the company to meet the increasing demand for high-quality car headliners in China and South-East Asia.
With the new production line, Freudenberg will increase its annual production of technical textiles in Suzhou by around eight million square meters per year. Customers will particularly benefit from higher quality of the next generation headliner products. “This investment underscores our long-term commitment to Asia. We want to continue to support our customers in the automotive market with innovative and sustainable solutions that will help them grow,” comments Dr. Frank Heislitz, CEO of Freudenberg Performance Materials.
Freudenberg & Vilene Company headliners are based on nonwovens and can be finished in various ways to provide additional functionality. Apart from excellent surface appearance with good abrasion resistance, outstanding acoustic properties and improved stain resistance, these products contribute to higher comfort in the car interior as well as marked reduction in vehicle weight when combined with other vehicle components. In addition, the company also uses a proportion of recycled products in the manufacture of its products. In this way, Freudenberg helps its customers to reduce their environmental footprint.
In Asia and China, Freudenberg & Vilene Company enjoys long-standing relationships with Asian OEMs, where it holds a leading position in the market. A cornerstone of this success has been the ability to create numerous headliner innovations.
Meanwhile, in Taiwan, in March 2018, Freudenberg said it would add a production line at its Tufts facility in Tayuan Tao-Yuan. Expansion of this capacity will allow the company to meet growing demand in the traditional automotive and carpet markets in Asia. The investment will add about 11,000 metric tons to Freudenberg’s Taiwan capacity. It is expected to be complete by 2020.
“The new line features the most advanced spinning technology available which means a more uniform product,” says chief technology officer John McNabb. “Once this technology proves itself, we will roll it out to our existing spunbond lines.”
Outside of Taiwan, Freudenberg operates a spunbond facility in Durham, NC, where it continuously upgrades its lines to improve uniformity and improve tufting performance of materials targeting carpet, backing, automotives, carpet tiles and shoe components.
Elsewhere in the U.S., Freudenberg’s construction facility in Macon, GA, was expanded with a new line in mid-2017. The new line featured new technology for Freudenberg allowing it to offer glass reinforced polyester spunbond nonwovens to satisfy demand in the roofing markets. Following the completion of one of these lines, Freudenberg shut down an existing staple fiber in Macon.
Meanwhile, in South America, August 2018 saw the end of production at Freudenberg’s Villa Zagala, Argentina, facility amidst economic challenges in the region. Production of materials at the site, which is located near Buenos Aires, have been transferred to Freudenberg’s plant in Jacarei, Brazil. The move impacts Freudenberg’s hygiene business, where it is a niche player supplying acquisition and distribution materials for diapers and feminine hygiene products.
“This decision was necessitated by the joint effects of market characteristics over recent years in combination with structural conditions in Argentina that have been unfavorable for this type of business,” executives say. “We continue to serve our clients in the usual way from a modern facility with a highly efficient production system as part of our strategy of asset consolidation. Other Freudenberg Group companies and the shoe and interlinings divisions belonging to Freudenberg Performance Materials have and will continue their operations as usual.”
The closure was not the first measure Freudenberg made to secure itself against difficult conditions in Argentina. In 2016, the company launched a major restructuring of its hygiene operations, making its facility there fully dedicated to the hygiene market. This effort was initially successful and executives said the initial turnaround in South America was a major contributor to profit growth in the division in 2016.
Admittedly a niche player in the hygiene market, Freudenberg also shut down a hygiene-related site in Greetland, U.K., in late 2018 after a major customer decided to go in a different direction. “The line was very customized and it couldn’t be retrofitted,” McNabb says. “For us, hygiene is a niche area, we don’t compete globally.”
Within the company’s filtration business, Freudenberg Filtration Technologies announced it would purchase Apollo Air Cleaner Co. in China in December 2018. With approximately 1000 employees and €96 million in sales, Apollo is a leading supplier of air and water filtration products in China. The acquisition strengthens Freudenberg’s position in China’s rapidly growing filtration market, which is growing strong thanks to stricter regulations and increased environmental awareness.
“Apollo is a great fit for Freudenberg,” says Andreas Kreuter, CEO of Freudenberg Filtration Technologies. “It is an innovative technology company that complements our own portfolio of filtration solutions for indoor air and water purification.”
The company also has first class production expertise and excellent networks in the industry. The product solutions of Apollo keep air or drinking water free of (ultra) fine particles, dangerous gases, odors and microorganisms and protect health. At its production site in Shunde, China, the company has established high standards for product quality, process efficiency and workplace safety, and is certified to ISO 9001, ISO 14001 and TS 16949.
Apollo will continue as a joint venture between Freudenberg (major shareholder) and the current sole proprietor Apollo Trading Group, Japan, under the name Freudenberg Apollo Filtration Technologies. Freudenberg Filtration Technologies intends to bring its current consumer filtration business into the joint venture.
Looking at the overall division, Freudenberg Filtration Technologies continued on its sustainable, profitable growth path in 2018 despite a challenging market environment. Within the industrial filtration business, a focus on selected market segments as well as strong demand for filters for air purifiers in China had a positive impact. Meanwhile, the automotive filtration business—both for new vehicles and replacement parts was strong with sales growing in Europe and North America.
Freudenberg has responded to this demand with investments in new cabin air filter lines in Kaiserlautern, Germany as well as a production plant for high resistance air filters in China. Additionally, the group completed an extensive expansion at its factory in Potvorice, Slovakia, making the automotives and industrial filters site one of the group’s largest and most modern factories.
Back to Freudenberg’s nonwoven roll goods business, the company continues to find new application areas for Evolon, its continuous filament technology which his celebrating its 20th anniversary this year. Last year, Evolon released a new generation of the technology using super microfilaments that are half the thickness and twice the density of those used in original Evolon substrates. This opened up new application areas like bedding, technical packaging and many others.
“We have found that the new generation technology has allowed us to enter many new applications,” McNabb says. “It seems the more we work on the technology, the more applications we uncover.”
Another interesting technology targeting new applications is Comfortemp fiber ball, the world’s first padding made from fiber balls. It is ideal for use in sports garments as well as in the fashion segment where it offers optimal breathability, is supersoft and fluff and there’s no fiber migration. Freudenberg’s latest offering in this technology is made from 80% recycled fibers, providing a eco version in down fill replacement.
www.freudenberg-pm.com
2018 Nonwovens Sales: $2.1 billion
(including sales from Freudenberg Performance Materials,
Freudenberg Filtration Technologies and Japan Vilene)
Key Personnel
Frank Heislitz, CEO; Thomas Herr, CFO; John McNabb, COO
Plants
Weinheim, Germany; Neuenburg, Germany; Kaiserslautern, Germany; Greetland, U.K.; Swindon, U.K.; Littleborough, Wales, U.K.; Colmar, France; Barcelona, Spain; Nizhiniy, Novgorod, Russia; Sant´ Omero, Italy; Cossato, Italy; Novedrate, Italy; Pisticci, Italy; Suzhou, China; Nantong, China; Chennai, India; Pyungtaek, South Korea; Yang Mei, Taiwan; Tayuan, Taiwan; San Martin/Buenos Aires, Argentina; Durham, NC; Jacarei, Brazil; Cape Town, South Africa; Macon, GA
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotive industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunch, thermal bond, chemical bond, water entanglement
Brands
Comfortemp, Evolon, SoundTex, Vlieseline, Terbond, Texbond
Major Markets
Automotive, apparel, construction, building interiors, energy, medical, hygiene and special applications, shoe and leather goods
As it celebrates the 20th anniversary of its unique Evolon microfilament technology, finishes up work on its latest Tufts line in Taipei, Taiwan, and lets the ink dry on its latest filtration-related acquisition, Freudenberg is a company that wears many hats in the nonwovens industry. The company’s nonwovens-related businesses fall within three of its major divisions, Freudenberg Performance Materials, Freudenberg Filtration Technologies and Japan Vilene. Together, the three divisions reported sales of about $2.1 billion in 2018.
The largest division, Performance Materials, which was created through a marriage of the nonwovens business and Texbond, Freudenberg’s construction-related entity, in 2014, reported a challenging year in 2018. Sales were impacted by negative exchange rates and profits were hit with rising raw material prices.
The division’s largest recent investment is a new headliner line in Suzhou, China. The line which was officially complete in March, enables the company to meet the increasing demand for high-quality car headliners in China and South-East Asia.
With the new production line, Freudenberg will increase its annual production of technical textiles in Suzhou by around eight million square meters per year. Customers will particularly benefit from higher quality of the next generation headliner products. “This investment underscores our long-term commitment to Asia. We want to continue to support our customers in the automotive market with innovative and sustainable solutions that will help them grow,” comments Dr. Frank Heislitz, CEO of Freudenberg Performance Materials.
Freudenberg & Vilene Company headliners are based on nonwovens and can be finished in various ways to provide additional functionality. Apart from excellent surface appearance with good abrasion resistance, outstanding acoustic properties and improved stain resistance, these products contribute to higher comfort in the car interior as well as marked reduction in vehicle weight when combined with other vehicle components. In addition, the company also uses a proportion of recycled products in the manufacture of its products. In this way, Freudenberg helps its customers to reduce their environmental footprint.
In Asia and China, Freudenberg & Vilene Company enjoys long-standing relationships with Asian OEMs, where it holds a leading position in the market. A cornerstone of this success has been the ability to create numerous headliner innovations.
Meanwhile, in Taiwan, in March 2018, Freudenberg said it would add a production line at its Tufts facility in Tayuan Tao-Yuan. Expansion of this capacity will allow the company to meet growing demand in the traditional automotive and carpet markets in Asia. The investment will add about 11,000 metric tons to Freudenberg’s Taiwan capacity. It is expected to be complete by 2020.
“The new line features the most advanced spinning technology available which means a more uniform product,” says chief technology officer John McNabb. “Once this technology proves itself, we will roll it out to our existing spunbond lines.”
Outside of Taiwan, Freudenberg operates a spunbond facility in Durham, NC, where it continuously upgrades its lines to improve uniformity and improve tufting performance of materials targeting carpet, backing, automotives, carpet tiles and shoe components.
Elsewhere in the U.S., Freudenberg’s construction facility in Macon, GA, was expanded with a new line in mid-2017. The new line featured new technology for Freudenberg allowing it to offer glass reinforced polyester spunbond nonwovens to satisfy demand in the roofing markets. Following the completion of one of these lines, Freudenberg shut down an existing staple fiber in Macon.
Meanwhile, in South America, August 2018 saw the end of production at Freudenberg’s Villa Zagala, Argentina, facility amidst economic challenges in the region. Production of materials at the site, which is located near Buenos Aires, have been transferred to Freudenberg’s plant in Jacarei, Brazil. The move impacts Freudenberg’s hygiene business, where it is a niche player supplying acquisition and distribution materials for diapers and feminine hygiene products.
“This decision was necessitated by the joint effects of market characteristics over recent years in combination with structural conditions in Argentina that have been unfavorable for this type of business,” executives say. “We continue to serve our clients in the usual way from a modern facility with a highly efficient production system as part of our strategy of asset consolidation. Other Freudenberg Group companies and the shoe and interlinings divisions belonging to Freudenberg Performance Materials have and will continue their operations as usual.”
The closure was not the first measure Freudenberg made to secure itself against difficult conditions in Argentina. In 2016, the company launched a major restructuring of its hygiene operations, making its facility there fully dedicated to the hygiene market. This effort was initially successful and executives said the initial turnaround in South America was a major contributor to profit growth in the division in 2016.
Admittedly a niche player in the hygiene market, Freudenberg also shut down a hygiene-related site in Greetland, U.K., in late 2018 after a major customer decided to go in a different direction. “The line was very customized and it couldn’t be retrofitted,” McNabb says. “For us, hygiene is a niche area, we don’t compete globally.”
Within the company’s filtration business, Freudenberg Filtration Technologies announced it would purchase Apollo Air Cleaner Co. in China in December 2018. With approximately 1000 employees and €96 million in sales, Apollo is a leading supplier of air and water filtration products in China. The acquisition strengthens Freudenberg’s position in China’s rapidly growing filtration market, which is growing strong thanks to stricter regulations and increased environmental awareness.
“Apollo is a great fit for Freudenberg,” says Andreas Kreuter, CEO of Freudenberg Filtration Technologies. “It is an innovative technology company that complements our own portfolio of filtration solutions for indoor air and water purification.”
The company also has first class production expertise and excellent networks in the industry. The product solutions of Apollo keep air or drinking water free of (ultra) fine particles, dangerous gases, odors and microorganisms and protect health. At its production site in Shunde, China, the company has established high standards for product quality, process efficiency and workplace safety, and is certified to ISO 9001, ISO 14001 and TS 16949.
Apollo will continue as a joint venture between Freudenberg (major shareholder) and the current sole proprietor Apollo Trading Group, Japan, under the name Freudenberg Apollo Filtration Technologies. Freudenberg Filtration Technologies intends to bring its current consumer filtration business into the joint venture.
Looking at the overall division, Freudenberg Filtration Technologies continued on its sustainable, profitable growth path in 2018 despite a challenging market environment. Within the industrial filtration business, a focus on selected market segments as well as strong demand for filters for air purifiers in China had a positive impact. Meanwhile, the automotive filtration business—both for new vehicles and replacement parts was strong with sales growing in Europe and North America.
Freudenberg has responded to this demand with investments in new cabin air filter lines in Kaiserlautern, Germany as well as a production plant for high resistance air filters in China. Additionally, the group completed an extensive expansion at its factory in Potvorice, Slovakia, making the automotives and industrial filters site one of the group’s largest and most modern factories.
Back to Freudenberg’s nonwoven roll goods business, the company continues to find new application areas for Evolon, its continuous filament technology which his celebrating its 20th anniversary this year. Last year, Evolon released a new generation of the technology using super microfilaments that are half the thickness and twice the density of those used in original Evolon substrates. This opened up new application areas like bedding, technical packaging and many others.
“We have found that the new generation technology has allowed us to enter many new applications,” McNabb says. “It seems the more we work on the technology, the more applications we uncover.”
Another interesting technology targeting new applications is Comfortemp fiber ball, the world’s first padding made from fiber balls. It is ideal for use in sports garments as well as in the fashion segment where it offers optimal breathability, is supersoft and fluff and there’s no fiber migration. Freudenberg’s latest offering in this technology is made from 80% recycled fibers, providing a eco version in down fill replacement.
Weinheim, Germany
www.freudenberg-pm.com
2021 Nonwovens Sales: $2.85 billion
(including Freudenberg Performance Materials, Freudenberg Filtration Technologies and Japane Vilene
Key Personnel
Frank Heislitz, CEO; Thomas Herr, CFO; John McNabb, COO
Plants
Africa: 1; Asia: 7; The Americas: 4; Europe: 21
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotive industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunch, thermal bond, chemical bond, water entanglement
Brands
Comfortemp, Colback, Colbonddrain, Enka Solutions, Dr!pstop, Evolon, Lutradur, SoundTex, Vlieseline, Terbond, Texbond, Mehler Texnologies
Major Markets
Automotive, apparel, building interiors, building materials, energy, filter media, healthcare, and special applications, shoe and leather goods
Sales increased nearly 30% for Freudenberg Performance Materials in 2021, thanks largely to the full integration of two acquisitions—Low & Bonar and Filc—as well as market recovery in most of its key segments. Together, Low & Bonar and Filc, which joined the company in 2020, represented about one-third of total sales for the business unit. Sales for the unit reached €1.32 billion last year.
In addition to the expanding sales, both acquisitions fill technology gaps in Freudenberg’s nonwovens business, according to CEO Frank Heislitz.
Low & Bonar has a proprietary two-step spunbond process solution, which is adjacent to the company’s existing spunbond technology. It allows Freudenberg to be more flexible and individually tailor products to customer specifications. Through this, the company has expanded its broad product range, particularly in construction, building interiors and automotives, while also targeting new application areas. The acquisition also added production facilities in North America, Europe and Asia.
Freudenberg has proven its confidence in the strength of Low & Bonar’s Enka brand with the construction of a new line to produce EnkaMat products in Changzhou, China. Output from the new line will serve demand for the erosion protection/landfill, green roofs and acoustic segments in the Asia-Pacific region. Production is expected to begin in the first quarter of next year.
Meanwhile, the acquisition of Filc earlier in the year, has made Freudenberg stronger in needlepunch technology, broadens its product lineup in roofing and construction and makes it more competitive in automotive. In March 2021, Freudenberg announced it would add a new needlepunch line at its Slovenia production location to meet high demand and to reinforce Filc’s strong market position in the construction market.
“The new line supports Filc’s history of investment and it is allowing us to broaden our offerings,” says Heislitz. “Also, its proprietary design offers high quality and efficient production.”
Within its existing businesses, in early 2021, Freudenberg completed work on a meltblown production line in Kaiserslautern, Germany, which can make base material for FFP1, FFP2 and FFP3 face masks. While the line was initially intended to meet unprecedented demand for face mask materials, Heislitz says the new line is also meet long-term demand for high performance filtration and automotive applications.
Within its apparel business, Freudenberg has made a number of adjustments in response to changes in the European market. Earlier this year, the company began the construction of a competence center for finishing and coating base material for the apparel industry at its site in Sant’Omero, Italy. The site will house two lines formerly located in Weinheim, Germany, as well as a third from an Argentinean operation that was shuttered and disassembled a few years ago.
The company’s interlining base materials business meanwhile will be headquartered in Weinheim, Germany, where the company will continue to develop know-how for the market.
The restructuring will allow customers to enjoy many advantages such as more flexible solutions, faster lead times and swifter delivery. At the same time, they could continue to benefit from the “product originating in Europe” designation.
Even as it adjusts its manufacturing assets to meet the changing needs of traditional apparel markets, Freudenberg has increased its focus on other areas of the apparel market like high performance outdoor items and sportswear. Its comfortemp Lyocell padding, which meets all requirements for high performance thermal insulation for sports and outdoor padding, is the first fully biodegradable padding made from sustainably produced cellulose. In 2020, Freudenberg expanded capacity of its comfortemp technology with a new line in Suzhou, China.
In Nantong, Freudenberg has established an Apparel Technical Solution Center – Asia at its Nantong factory to expand its innovation capabilities. With floor space of 900 square meters, the new center offers unparalleled technical expertise and innovations to apparel customers from nearly all apparel segments in Asia and around the world.
Elsewhere in Asia, Freudenberg completed work on its latest spunlaid investment in Taiwan, the site’s third, in 2021. This new line is the first to feature Freudenberg’s latest spunlaid technology which enhances filament distribution for increased material uniformity, which in turn provides customers with ease of processing the nonwovens for a variety of applications.
In other investment news, Freudenberg is expanding its gas diffusion layer capacity with a €28 million investment in Weinheim, Germany. The investment, which will expand the company’s role in fuel cell technology, follows a €10 million investment two years ago.
“We have been looking at what we can contribute to fuel cell technology for 20 years,” Heislitz says. “But we have seen a lot of traction in this category for the past five years.”
Currently, fuel cell technology is prominent in long haul trucks and fork lifts and other commercial vehicles but experts expect it will expand into passenger vehicles once the infrastructure is in place.
“This will for sure become a global business with the European Union taking a leading role,” Heislitz says. “Already, most major automotive manufacturers have made strong commitments to the technology.”
Earlier this year, Freudenberg introduced battery pack liquid absorbers, which are core elements of mobile and stationary lithium-ion energy storage systems. These absorbers make battery systems safer by capturing and storing unwanted liquids inside the packs quickly and reliably. With adjustable absorption capacity and geometries, battery pack liquid absorbers ensure long-lasting battery packs.
Freudenberg’s Battery Pack Liquid Absorbers are absorbent nonwoven pads endowed with fast liquid take-up and high retention capacity. Even in an emergency, leaking coolants are quickly absorbed and reliably retained.
As one of the biggest recyclers in Europe, Freudenberg continues to focus on way to incorporate PCR and PIR materials into its nonwoven materials. In early 2022, the company introduced a version of its Evolon high performance, continuous filament material using an average of 70% recycled polyester, which the company makes by recycling post-consumer PET bottles in-house. Evolon RE is available for various applications, including high-tech wiping and technical packaging, in weights currently ranging from 80-300g/sqm.
The use of recycled materials in the demanding production of Evolon textiles without sacrificing product performance underlines Freudenberg’s technological know-how, as Heislitz explains: “We have more than 20 years of experience with Evolon technology. Our technical teams are real experts in this demanding process, and it is thanks to their knowledge that we were able to overcome the challenge of integrating recycled PET from post-consumer bottles into our products.”
www.freudenberg-pm.com
2021 Nonwovens Sales: $2.85 billion
(including Freudenberg Performance Materials, Freudenberg Filtration Technologies and Japane Vilene
Key Personnel
Frank Heislitz, CEO; Thomas Herr, CFO; John McNabb, COO
Plants
Africa: 1; Asia: 7; The Americas: 4; Europe: 21
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotive industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunch, thermal bond, chemical bond, water entanglement
Brands
Comfortemp, Colback, Colbonddrain, Enka Solutions, Dr!pstop, Evolon, Lutradur, SoundTex, Vlieseline, Terbond, Texbond, Mehler Texnologies
Major Markets
Automotive, apparel, building interiors, building materials, energy, filter media, healthcare, and special applications, shoe and leather goods
Sales increased nearly 30% for Freudenberg Performance Materials in 2021, thanks largely to the full integration of two acquisitions—Low & Bonar and Filc—as well as market recovery in most of its key segments. Together, Low & Bonar and Filc, which joined the company in 2020, represented about one-third of total sales for the business unit. Sales for the unit reached €1.32 billion last year.
In addition to the expanding sales, both acquisitions fill technology gaps in Freudenberg’s nonwovens business, according to CEO Frank Heislitz.
Low & Bonar has a proprietary two-step spunbond process solution, which is adjacent to the company’s existing spunbond technology. It allows Freudenberg to be more flexible and individually tailor products to customer specifications. Through this, the company has expanded its broad product range, particularly in construction, building interiors and automotives, while also targeting new application areas. The acquisition also added production facilities in North America, Europe and Asia.
Freudenberg has proven its confidence in the strength of Low & Bonar’s Enka brand with the construction of a new line to produce EnkaMat products in Changzhou, China. Output from the new line will serve demand for the erosion protection/landfill, green roofs and acoustic segments in the Asia-Pacific region. Production is expected to begin in the first quarter of next year.
Meanwhile, the acquisition of Filc earlier in the year, has made Freudenberg stronger in needlepunch technology, broadens its product lineup in roofing and construction and makes it more competitive in automotive. In March 2021, Freudenberg announced it would add a new needlepunch line at its Slovenia production location to meet high demand and to reinforce Filc’s strong market position in the construction market.
“The new line supports Filc’s history of investment and it is allowing us to broaden our offerings,” says Heislitz. “Also, its proprietary design offers high quality and efficient production.”
Within its existing businesses, in early 2021, Freudenberg completed work on a meltblown production line in Kaiserslautern, Germany, which can make base material for FFP1, FFP2 and FFP3 face masks. While the line was initially intended to meet unprecedented demand for face mask materials, Heislitz says the new line is also meet long-term demand for high performance filtration and automotive applications.
Within its apparel business, Freudenberg has made a number of adjustments in response to changes in the European market. Earlier this year, the company began the construction of a competence center for finishing and coating base material for the apparel industry at its site in Sant’Omero, Italy. The site will house two lines formerly located in Weinheim, Germany, as well as a third from an Argentinean operation that was shuttered and disassembled a few years ago.
The company’s interlining base materials business meanwhile will be headquartered in Weinheim, Germany, where the company will continue to develop know-how for the market.
The restructuring will allow customers to enjoy many advantages such as more flexible solutions, faster lead times and swifter delivery. At the same time, they could continue to benefit from the “product originating in Europe” designation.
Even as it adjusts its manufacturing assets to meet the changing needs of traditional apparel markets, Freudenberg has increased its focus on other areas of the apparel market like high performance outdoor items and sportswear. Its comfortemp Lyocell padding, which meets all requirements for high performance thermal insulation for sports and outdoor padding, is the first fully biodegradable padding made from sustainably produced cellulose. In 2020, Freudenberg expanded capacity of its comfortemp technology with a new line in Suzhou, China.
In Nantong, Freudenberg has established an Apparel Technical Solution Center – Asia at its Nantong factory to expand its innovation capabilities. With floor space of 900 square meters, the new center offers unparalleled technical expertise and innovations to apparel customers from nearly all apparel segments in Asia and around the world.
Committed to bringing enhanced technical support and services tailored to customers’ needs, the dedicated Apparel Technical Solution Center – Asia (ATSC) is equipped with cutting-edge technology. This includes a wide variety of fusing and bonding machines, laser and ultrasonic cutters, specialized sewing machines for sportswear applications, fiber filling machines for insulation applications and washing and dry cleaning machines that meet GB and AATCC standards.
The ATSC offers unparalleled technical know-how to help customers design complex apparel solutions. In particular, it furthers Freudenberg’s dedication to joint innovations with sportswear customers and to finding technical solutions for performance applications.
Elsewhere in Asia, Freudenberg completed work on its latest spunlaid investment in Taiwan, the site’s third, in 2021. This new line is the first to feature Freudenberg’s latest spunlaid technology which enhances filament distribution for increased material uniformity, which in turn provides customers with ease of processing the nonwovens for a variety of applications.
In other investment news, Freudenberg is expanding its gas diffusion layer capacity with a €28 million investment in Weinheim, Germany. The investment, which will expand the company’s role in fuel cell technology, follows a €10 million investment two years ago.
“We have been looking at what we can contribute to fuel cell technology for 20 years,” Heislitz says. “But we have seen a lot of traction in this category for the past five years.”
Currently, fuel cell technology is prominent in long haul trucks and fork lifts and other commercial vehicles but experts expect it will expand into passenger vehicles once the infrastructure is in place.
“This will for sure become a global business with the European Union taking a leading role,” Heislitz says. “Already, most major automotive manufacturers have made strong commitments to the technology.”
Earlier this year, Freudenberg introduced battery pack liquid absorbers, which are core elements of mobile and stationary lithium-ion energy storage systems. These absorbers make battery systems safer by capturing and storing unwanted liquids inside the packs quickly and reliably. With adjustable absorption capacity and geometries, battery pack liquid absorbers ensure long-lasting battery packs.
Freudenberg’s Battery Pack Liquid Absorbers are absorbent nonwoven pads endowed with fast liquid take-up and high retention capacity. Even in an emergency, leaking coolants are quickly absorbed and reliably retained.
As one of the biggest recyclers in Europe, Freudenberg continues to focus on way to incorporate PCR and PIR materials into its nonwoven materials. In early 2022, the company introduced a version of its Evolon high performance, continuous filament material using an average of 70% recycled polyester, which the company makes by recycling post-consumer PET bottles in-house. Evolon RE is available for various applications, including high-tech wiping and technical packaging, in weights currently ranging from 80-300g/sqm.
The use of recycled materials in the demanding production of Evolon textiles without sacrificing product performance underlines Freudenberg’s technological know-how, as Heislitz explains: “We have more than 20 years of experience with Evolon technology. Our technical teams are real experts in this demanding process, and it is thanks to their knowledge that we were able to overcome the challenge of integrating recycled PET from post-consumer bottles into our products.”
Weinheim, Germany
www.freudenberg-pm.com
2022 Nonwovens Sales: $2.9 billion
Performance Materials: $1.65 billion
Filtration Technologies: $712 million
Japan Vilene: $538 million
Key Personnel
Frank Heislitz, CEO; Thomas Herr, CFO; John McNabb, COO
Plants
Africa: 1; Asia: 7; The Americas: 4; Europe: 21
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotive industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunch, thermal bond, chemical bond, water entanglement
Brands
Comfortemp, Colback, Colbonddrain, Enka Solutions, Dr!pstop, Evolon, Lutradur, SoundTex, Vlieseline, Terbond, Texbond, Mehler Texnologies, Filtura
Major Markets
Automotive, apparel, building interiors, building materials, energy, filter media, healthcare, special applications, shoe and leather goods
Reporting strong topline growth in 2022 was Freudenberg Performance Materials. A combination of rebounds in its core markets and the results of previous acquisitions and investments led to more than double-digit top line growth during the year. Earnings, however, were impacted by a number of factors including the European energy crisis, the war in Ukraine and supply chain disruptions at the beginning of the year.
“Things have been much more difficult,” says Frank Heislitz, CEO of Freudenberg Performance Materials. “I have never seen such a situation in my professional life with so many challenges coming all at once.”
During the first half of the year, growth was driven by strong recovery following Covid, particularly in the building construction, filtration and apparel markets. However, toward the end of the year, consumer concerns over inflation and other economic factors contributed to a slowdown in certain markets.
“If you look into the market segments with consumer spending like apparel and construction, these have been challenged by high inflation and other uncertainties,” Heislitz says. “I would say these conditions are global. For sure, there is a lot of competition but the challenges are more being driven by slower demand.”
One area that has remained strong is medical, which typically is resilient against any crisis. In recent years, Freudenberg has focused on its advanced wound care business, which is primarily served from its two U.K. facilities.
“We continue to launch interesting new products so maybe we are stronger than the market,” Heislitz adds.
Products include an elastic variant of its flexible superabsorbers for modern wound dressings. These superabsorbers increase the comfort level for patients as well as enabling longer wear time, thus reducing the frequency of dressing changes. Using a new technology to manufacture the elastic superabsorbers, Freudenberg does not perforate or slit the material, thus achieving a high degree of consistent elasticity. Furthermore, the technology used by Freudenberg bonds the superabsorbent fibers more uniformly with the material, thus enhancing the integrity of this layer in the wound dressing.
Additionally, the M 1714 wound pad component is an example of a sustainable solution that simultaneously delivers on performance. The dressing consists of bio-based fibers and exhibits a smooth wound contact layer. M 1714 has been evaluated for industrial compostability and conforms to ISO 13432. This enables certification of the product biodegradability.
Another bright spot lies in gas diffusion layers for fuel cell technology, a market with high growth dynamics. Particularly in Europe and Asia, the market is growing in commercial vehicles and heavy truck areas. To better serve this market, Freudenberg is adding gas diffusion layer capacity in Weinheim, Germany through a €28 million investment, marking the second investment in this technology this decade. Freudenberg invested €10 million in new capacity, also in Weinheim, in 2020.
“Right now, it’s more on the commercial side,” Heislitz says. “The market for fuel cell passenger cars will pick up later. For now this doesn’t matter because all suppliers are busy industrializing their processes. This will help to make fuel cell technology more attractive for passenger cars.”
In other investment news, Freudenberg has completed work on a new needlepunch line at the Slovenian facility acquired from Filc, in response to increased demand. Additionally, Freudenberg completed work on a new EnkaMat production line at its Changzhou, China site. The investment increases capacity and complements existing EnkaMat sites in Obernburg, Germany and Asheville, NC.
The EnkaMat technology are three-dimensional Matrixes that prevent restriction. Investment in China will allow Freudenberg to develop the local market. “These are the types of materials that are difficult to slit because they are too bulky and they contain too much air.,” Heislitz adds.
Both of these investments build on recent acquisitions at Freudenberg. The company acquired Filc in early 2021, an action that has not only made the company stronger in needlepunch technology but also broadened its product lineup in roofing and construction and made it more competitive in automotives. Meanwhile, the EnkaMat and Colback technologies were acquired from Low & Bonar. Enka is a polymer 3D entangled mat made of specific polymers that are thermally bonded where the filament meet. It provides efficient erosion protection. Colback is a two-step spunbond process solution that is adjacent to the company’s existing spunbond technology, known as Tufts. It allows Freudenberg to be more flexible and individually tailor products to customer specifications.
Within its apparel business, Freudenberg has made a number of adjustments in response to global market dynamics. In early 2022, the company began the construction of a competence center for finishing and coating base material for the apparel industry at its site in Sant’Omero, Italy. The site, which houses two lines formerly located in Weinheim, Germany, as well as a third from a shuttered Argentinean site, officially opened in May.
Customers are now benefitting from faster and more flexible order processing of products originating in Europe. The Freudenberg team in Sant’Omero has over 35 years of expertise in the manufacture of high-quality interlinings for menswear: base materials produced at the site are finished and coated to customers’ specifications. With the new competence center, the facility is now focusing on coating and finishing all nonwoven, woven and weft apparel interlinings in Freudenberg’s portfolio.
Prior to this investment, the bulk of interlinings were coated and finished in Weinheim, Germany, which will continue to be Freudenberg’s headquarters for the production of interlining base materials.
Meanwhile in Asia, Freudenberg has established an Apparel Technical Solution Center – Asia at its Nantong factory to expand its innovation capabilities. With floor space of 900 square meters, the new center offers unparalleled technical expertise and innovations to apparel customers from nearly all apparel segments in Asia and around the world.
Recent innovations within the apparel segment include 37xx PES—a revolutionary range of interlinings that offer the classic feel of cotton with the modern features of enhanced durability, increased yields and low-temperature fusing. With a 100% PES base and special finish, these OEKO-TEX STANDARD 100 Class I certified products open new possibilities for the business and smart casual segments, which is supplied from the ATSC. Additionally, earlier this year Freudenberg expanded its Super Elastic Interlinings range with the introduction of the apparel industry’s first 100% recycled thermoplastic elastomers (rTPE) base content interlining series. In recognition of the growing use of elastic interlinings in apparel and building on the principles of Freudenberg Performance Materials´ Apparel’s House of Sustainability, these new products speak to Freudenberg’s ongoing dedication to high-quality and sustainable solutions, with responsible products in every season.
Freudenberg Performance Materials’ Apparel’s House of Sustainability is a major initiative designed to assist customers in enhancing the sustainability of their garment products and building towards a more sustainable future. Offering the latest innovations and solutions from its House of Sustainability that combine functional and environmental benefits, Freudenberg supports sustainable garments for people and the planet through all manufacturing seasons.
“Apparel continues to be an important market. It is one of our biggest divisions and we believe with the combination of optimizing the production footprint and new innovations in the market—particularly in the outdoor market—we believe that business will remain an important element,” says Heislitz.
Even as it adjusts its manufacturing assets to meet the changing needs of traditional apparel markets, Freudenberg has increased its focus on other areas of the apparel market like high performance outdoor items and sportswear. Its comfortemp Lyocell padding, which meets all requirements for high performance thermal insulation for sports and outdoor padding, is the first fully biodegradable padding made from sustainably produced cellulose. In 2020, Freudenberg expanded capacity of its comfortemp technology with a new line in Suzhou, China.
Within filtration, the company’s transition into a filter media supplier to external customers has influenced the creation of a new brand name that encompasses its full product range. Earlier this year, Freudenberg announced Filtura, a new brand for its filter media products replacing the Colback, Enka solutions, Evolon, Karbofil and Lutradur media brands. Filtura is expected to bring greater clarity to the filter media market and enable Freudenberg Performance Materials to extend its position in this market.
“The new brand reflects Freudenberg Performance Materials’ new position as a filter media supplier to the external world of Freudenberg, which occurred following the dual acquisitions of Low and Bonar and Filc,” Heislitz says. “In the past we mainly supplied Freudenberg Filtration Technologies but now we have a lot of external customers. We want to strengthen it by also building up a new brand in the market.”
Another important launch at Freudenberg this year was the introduction of its next generation range of sustainable carpet backing products for the flooring industry. Next generation sustainable backings support customers in their transition towards producing more sustainable carpets. The range is introduced as Colback ECO and Lutradur ECO and is part of the Freudenberg portfolio of high-performance spunbond nonwoven technical textiles.
www.freudenberg-pm.com
2022 Nonwovens Sales: $2.9 billion
Performance Materials: $1.65 billion
Filtration Technologies: $712 million
Japan Vilene: $538 million
Key Personnel
Frank Heislitz, CEO; Thomas Herr, CFO; John McNabb, COO
Plants
Africa: 1; Asia: 7; The Americas: 4; Europe: 21
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotive industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunch, thermal bond, chemical bond, water entanglement
Brands
Comfortemp, Colback, Colbonddrain, Enka Solutions, Dr!pstop, Evolon, Lutradur, SoundTex, Vlieseline, Terbond, Texbond, Mehler Texnologies, Filtura
Major Markets
Automotive, apparel, building interiors, building materials, energy, filter media, healthcare, special applications, shoe and leather goods
Reporting strong topline growth in 2022 was Freudenberg Performance Materials. A combination of rebounds in its core markets and the results of previous acquisitions and investments led to more than double-digit top line growth during the year. Earnings, however, were impacted by a number of factors including the European energy crisis, the war in Ukraine and supply chain disruptions at the beginning of the year.
“Things have been much more difficult,” says Frank Heislitz, CEO of Freudenberg Performance Materials. “I have never seen such a situation in my professional life with so many challenges coming all at once.”
During the first half of the year, growth was driven by strong recovery following Covid, particularly in the building construction, filtration and apparel markets. However, toward the end of the year, consumer concerns over inflation and other economic factors contributed to a slowdown in certain markets.
“If you look into the market segments with consumer spending like apparel and construction, these have been challenged by high inflation and other uncertainties,” Heislitz says. “I would say these conditions are global. For sure, there is a lot of competition but the challenges are more being driven by slower demand.”
One area that has remained strong is medical, which typically is resilient against any crisis. In recent years, Freudenberg has focused on its advanced wound care business, which is primarily served from its two U.K. facilities.
“We continue to launch interesting new products so maybe we are stronger than the market,” Heislitz adds.
Products include an elastic variant of its flexible superabsorbers for modern wound dressings. These superabsorbers increase the comfort level for patients as well as enabling longer wear time, thus reducing the frequency of dressing changes. Using a new technology to manufacture the elastic superabsorbers, Freudenberg does not perforate or slit the material, thus achieving a high degree of consistent elasticity. Furthermore, the technology used by Freudenberg bonds the superabsorbent fibers more uniformly with the material, thus enhancing the integrity of this layer in the wound dressing.
Additionally, the M 1714 wound pad component is an example of a sustainable solution that simultaneously delivers on performance. The dressing consists of bio-based fibers and exhibits a smooth wound contact layer. M 1714 has been evaluated for industrial compostability and conforms to ISO 13432. This enables certification of the product biodegradability.
Another bright spot lies in gas diffusion layers for fuel cell technology, a market with high growth dynamics. Particularly in Europe and Asia, the market is growing in commercial vehicles and heavy truck areas. To better serve this market, Freudenberg is adding gas diffusion layer capacity in Weinheim, Germany through a €28 million investment, marking the second investment in this technology this decade. Freudenberg invested €10 million in new capacity, also in Weinheim, in 2020.
“Right now, it’s more on the commercial side,” Heislitz says. “The market for fuel cell passenger cars will pick up later. For now this doesn’t matter because all suppliers are busy industrializing their processes. This will help to make fuel cell technology more attractive for passenger cars.”
In other investment news, Freudenberg has completed work on a new needlepunch line at the Slovenian facility acquired from Filc, in response to increased demand. Additionally, Freudenberg completed work on a new EnkaMat production line at its Changzhou, China site. The investment increases capacity and complements existing EnkaMat sites in Obernburg, Germany and Asheville, NC.
The EnkaMat technology are three-dimensional Matrixes that prevent restriction. Investment in China will allow Freudenberg to develop the local market. “These are the types of materials that are difficult to slit because they are too bulky and they contain too much air.,” Heislitz adds.
Both of these investments build on recent acquisitions at Freudenberg. The company acquired Filc in early 2021, an action that has not only made the company stronger in needlepunch technology but also broadened its product lineup in roofing and construction and made it more competitive in automotives. Meanwhile, the EnkaMat and Colback technologies were acquired from Low & Bonar. Enka is a polymer 3D entangled mat made of specific polymers that are thermally bonded where the filament meet. It provides efficient erosion protection. Colback is a two-step spunbond process solution that is adjacent to the company’s existing spunbond technology, known as Tufts. It allows Freudenberg to be more flexible and individually tailor products to customer specifications.
Within its apparel business, Freudenberg has made a number of adjustments in response to global market dynamics. In early 2022, the company began the construction of a competence center for finishing and coating base material for the apparel industry at its site in Sant’Omero, Italy. The site, which houses two lines formerly located in Weinheim, Germany, as well as a third from a shuttered Argentinean site, officially opened in May.
Customers are now benefitting from faster and more flexible order processing of products originating in Europe. The Freudenberg team in Sant’Omero has over 35 years of expertise in the manufacture of high-quality interlinings for menswear: base materials produced at the site are finished and coated to customers’ specifications. With the new competence center, the facility is now focusing on coating and finishing all nonwoven, woven and weft apparel interlinings in Freudenberg’s portfolio.
Prior to this investment, the bulk of interlinings were coated and finished in Weinheim, Germany, which will continue to be Freudenberg’s headquarters for the production of interlining base materials.
Meanwhile in Asia, Freudenberg has established an Apparel Technical Solution Center – Asia at its Nantong factory to expand its innovation capabilities. With floor space of 900 square meters, the new center offers unparalleled technical expertise and innovations to apparel customers from nearly all apparel segments in Asia and around the world.
Recent innovations within the apparel segment include 37xx PES—a revolutionary range of interlinings that offer the classic feel of cotton with the modern features of enhanced durability, increased yields and low-temperature fusing. With a 100% PES base and special finish, these OEKO-TEX STANDARD 100 Class I certified products open new possibilities for the business and smart casual segments, which is supplied from the ATSC. Additionally, earlier this year Freudenberg expanded its Super Elastic Interlinings range with the introduction of the apparel industry’s first 100% recycled thermoplastic elastomers (rTPE) base content interlining series. In recognition of the growing use of elastic interlinings in apparel and building on the principles of Freudenberg Performance Materials´ Apparel’s House of Sustainability, these new products speak to Freudenberg’s ongoing dedication to high-quality and sustainable solutions, with responsible products in every season.
Freudenberg Performance Materials’ Apparel’s House of Sustainability is a major initiative designed to assist customers in enhancing the sustainability of their garment products and building towards a more sustainable future. Offering the latest innovations and solutions from its House of Sustainability that combine functional and environmental benefits, Freudenberg supports sustainable garments for people and the planet through all manufacturing seasons.
“Apparel continues to be an important market. It is one of our biggest divisions and we believe with the combination of optimizing the production footprint and new innovations in the market—particularly in the outdoor market—we believe that business will remain an important element,” says Heislitz.
Even as it adjusts its manufacturing assets to meet the changing needs of traditional apparel markets, Freudenberg has increased its focus on other areas of the apparel market like high performance outdoor items and sportswear. Its comfortemp Lyocell padding, which meets all requirements for high performance thermal insulation for sports and outdoor padding, is the first fully biodegradable padding made from sustainably produced cellulose. In 2020, Freudenberg expanded capacity of its comfortemp technology with a new line in Suzhou, China.
Within filtration, the company’s transition into a filter media supplier to external customers has influenced the creation of a new brand name that encompasses its full product range. Earlier this year, Freudenberg announced Filtura, a new brand for its filter media products replacing the Colback, Enka solutions, Evolon, Karbofil and Lutradur media brands. Filtura is expected to bring greater clarity to the filter media market and enable Freudenberg Performance Materials to extend its position in this market.
“The new brand reflects Freudenberg Performance Materials’ new position as a filter media supplier to the external world of Freudenberg, which occurred following the dual acquisitions of Low and Bonar and Filc,” Heislitz says. “In the past we mainly supplied Freudenberg Filtration Technologies but now we have a lot of external customers. We want to strengthen it by also building up a new brand in the market.”
Another important launch at Freudenberg this year was the introduction of its next generation range of sustainable carpet backing products for the flooring industry. Next generation sustainable backings support customers in their transition towards producing more sustainable carpets. The range is introduced as Colback ECO and Lutradur ECO and is part of the Freudenberg portfolio of high-performance spunbond nonwoven technical textiles.
Weinheim, Germany
2023 Nonwovens Sales: $2.75 billion
Freudenberg Performance Materials $1.57 billion
Freudenberg Filtration Technologies $677 million
Japan Vilene $511 million
Key Personnel
Andreas Raps, CEO; Marco Altherr, CFO; John McNabb, CTO
Plants
Africa: 1; Asia: 7; The Americas: 4; Europe: 21
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotive industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunch, thermal bond, chemical bond, water entanglement
Brands
Comfortemp, Colback, Colbonddrain, Enka Solutions, Dr!pstop, Enka Solutions, Evolon, Lutradur, SoundTex, Vlieseline, Terbond, Texbond, Mehler Texnologies, Filtura, Filc
Major Markets
Automotive, apparel, building interiors, building materials, energy, filter media, healthcare, special applications, shoe and leather goods
“Challenging” was the word executives used to describe Freudenberg Performance Materials’ business environment in 2023 and 2024. These challenges existed in most of the company’s core markets but were felt particularly strongly in the building materials segment.
“We have seen more lowlights than highlights in our business environment—geopolitical risks are leading to uncertainty and global inflation and interest rates are not in our favor,” says Andreas Raps, CEO. “We are active in building and construction, and we see a lot of rigid behavior in these markets—an unwillingness to invest in new buildings and projects that are on hold.”
However, some highlights were seen in the company’s healthcare operations as well as its Asian-based apparel business, where the company recently invested in a new facility dedicated to manufacturing its comfortemp waddings material in Vietnam.
“I would say we consider 2024 a transitional year so I don’t see a lot of silver linings on the horizon right now,” Raps adds. “We hope we will have a better 2025. We are using this time to make house cleaning activities, cost structure, technology set up to be prepared for the next set up.”
Freudenberg employees celebrate the grand opening of a comfortemp site in Vietnam.
Because of its involvement in a far-reaching range of markets, Freudenberg is typically resilient in times of crisis. This downturn has been felt differently, however, because it’s a challenging time for the nonwovens industry in general.
Within the fuel cell technology market, where Freudenberg invested a reported €28 million in new capacity in Weinheim, Germany, last year, demand is not yet meeting expectations. However, executives remain bullish about the long-term prospects of this market.
“The gas diffusion layer is considered a future-oriented business,” Raps says. “Currently, the markets are down, and optimism is diminished, but we see it as an investment in the long-term future. We believe that businesses such as new energy models, battery separators, and fuel cells are the technologies of the future.”
Primarily targeting industrial applications like forklifts, the technology tends to be more expensive than oil and gas technology, and the willingness to pay more for cleaner energy is not yet widespread. Looking ahead, Freudenberg will focus on achieving economies of scale to improve its cost structure.
In other investment news, last year, Freudenberg expanded its EnkaMat technology with a new line in Changzhou, China. Completed in July 2023, the new line increased capacity and complemented existing EnkaMat sites in Obernburg, Germany, and Asheville, NC. The EnkaMat technology is used to create three-dimensional matrices that prevent restriction.
“With this new investment, we can support our customers locally and the good thing about Enka is we see a lot of synergies with a lot of our technologies and processes,” Raps says. “We are working to combine these technologies.”
In India, Freudenberg is on track to start production on a new interlinings line in Chennai, India, which will allow it to produce a wider range of materials, especially focused on polyester, at the end of 2025.
Also in Asia, in July Freudenberg held an opening ceremony in Vietnam for its brand new comfortemp thermal insulation facility. This facility, located in Long Thanh District, will expand the Asian reach of comfortemp, Freudenberg’s renowned high-performance thermal insulation material, designed to elevate fashion and sportswear apparel.
The Vietnamese facility is equipped to produce sustainable thermal insulations, providing customers with options that align with their sustainable garment production initiatives and goals. This additional new factory extends Freudenberg Apparel’s thermal insulation production across key Asian markets, including the Chinese mainland and South Korea. It also significantly strengthens Freudenberg Apparel’s global production capabilities and supply network.
Freudenberg already manufactures comfortemp at sites in China and Europe.
“The new line can make fully recyclable materials which is very positive,” Raps says. “We are convinced this is not a trend but a requirement in the future. We want to be a first mover and set the pace for this kind of development.”
In addition to comfortemp, Freudenberg has made several steps to improve its apparel business in recent years. In 2023, the company established a 900-square-meter Asian-based Apparel Technical Solution Center at its Nantong, China, factory to offer technical expertise and innovations to apparel customers from nearly all apparel segments in Asia and around the world.
In May 2023, Freudenberg completed work on a competence center for finishing and coating base materials for the apparel industry at its site in Sant’Omero, Italy. The site now accommodates two lines, which were relocated from Weinheim, Germany, as well as a third transferred from a closed Argentinean site.
Customers are currently benefitting from quicker and more flexible order processing of products originating in Europe. The Freudenberg team in Sant’Omero has a rich history of expertise in manufacturing high-quality interlinings for menswear, with base materials produced at the site being finished and coated according to customers’ specifications.
With the new competence center, the facility is now focused on coating and finishing all nonwoven, woven and weft apparel interlinings in Freudenberg’s portfolio. The Weinheim, Germany, site now serves as Freudenberg’s headquarters for the production of interlining base materials.
Freudenberg’s healthcare sector is thriving due to factors such as population growth and the aging population in many of its core markets. The company has made significant investments in two facilities in the U.K. that have allowed it to expand the scope of its advanced wound care business, offering high-performance nonwovens and polyurethane foams. One of the company’s more interesting recent product introductions is an elastic variant of its flexible superabsorbers for modern wound dressings. These superabsorbers enhance patient comfort and allow for longer wear time, reducing the need for frequent dressing changes.
In new product news, Freudenberg has developed a 100% synthetic wetlaid nonwoven product line in Germany. The new materials can be made from various types of polymer-based fibers, including ultra-fine micro-fibers and are designed for use in filtration applications and other industrial uses. This product line complements the company’s wide range of wetlaid nonwoven capabilities. Freudenberg can also incorporate glass fibers, viscose and cellulose into this substrate.
Throughout all of its business areas, sustainability continues to be an important component of Freudenberg’s success. This began decades ago when the company was among the first in the world to use recycled PET from water bottles and continues today through process improvements and new product launches.
“We think of sustainability in terms of handprint and footprint,” Raps says. “The handprint is the product that we hand over to our customers and the footprint is our internal efforts like the consumption of energy.”
Recent new products that offer a more sustainable option to its customers include a needlepunched material that can replace a nonwoven/glass fiber hybrid product in automotive applications. Eliminating the glass fiber materials makes the product recyclable, and Raps says customers are very excited about this product.
“Sustainability is a key pillar, and we strongly believe it will be a game changer,” he says. Freudenberg, with its R&D power and its technologies, is the first mover to offer more sustainable solutions, he says, adding that Freudenberg’s broad technology allows it to combine products and processes, no matter what the customers’ demand is. “I think the headline for the next three years is that we will continue to capitalize on this more,” Raps adds.
2023 Nonwovens Sales: $2.75 billion
Freudenberg Performance Materials $1.57 billion
Freudenberg Filtration Technologies $677 million
Japan Vilene $511 million
Key Personnel
Andreas Raps, CEO; Marco Altherr, CFO; John McNabb, CTO
Plants
Africa: 1; Asia: 7; The Americas: 4; Europe: 21
ISO Status
All locations are ISO 9001 and ISO 14001 certified; locations serving the automotive industry are TS 16469 certified; all sites are OHSAS 18001 certified
Processes
Drylaid staple fiber, wetlaid, spunbond, meltblown, needlepunch, thermal bond, chemical bond, water entanglement
Brands
Comfortemp, Colback, Colbonddrain, Enka Solutions, Dr!pstop, Enka Solutions, Evolon, Lutradur, SoundTex, Vlieseline, Terbond, Texbond, Mehler Texnologies, Filtura, Filc
Major Markets
Automotive, apparel, building interiors, building materials, energy, filter media, healthcare, special applications, shoe and leather goods
“Challenging” was the word executives used to describe Freudenberg Performance Materials’ business environment in 2023 and 2024. These challenges existed in most of the company’s core markets but were felt particularly strongly in the building materials segment.
“We have seen more lowlights than highlights in our business environment—geopolitical risks are leading to uncertainty and global inflation and interest rates are not in our favor,” says Andreas Raps, CEO. “We are active in building and construction, and we see a lot of rigid behavior in these markets—an unwillingness to invest in new buildings and projects that are on hold.”
However, some highlights were seen in the company’s healthcare operations as well as its Asian-based apparel business, where the company recently invested in a new facility dedicated to manufacturing its comfortemp waddings material in Vietnam.
“I would say we consider 2024 a transitional year so I don’t see a lot of silver linings on the horizon right now,” Raps adds. “We hope we will have a better 2025. We are using this time to make house cleaning activities, cost structure, technology set up to be prepared for the next set up.”
Freudenberg employees celebrate the grand opening of a comfortemp site in Vietnam.
Because of its involvement in a far-reaching range of markets, Freudenberg is typically resilient in times of crisis. This downturn has been felt differently, however, because it’s a challenging time for the nonwovens industry in general.
Within the fuel cell technology market, where Freudenberg invested a reported €28 million in new capacity in Weinheim, Germany, last year, demand is not yet meeting expectations. However, executives remain bullish about the long-term prospects of this market.
“The gas diffusion layer is considered a future-oriented business,” Raps says. “Currently, the markets are down, and optimism is diminished, but we see it as an investment in the long-term future. We believe that businesses such as new energy models, battery separators, and fuel cells are the technologies of the future.”
Primarily targeting industrial applications like forklifts, the technology tends to be more expensive than oil and gas technology, and the willingness to pay more for cleaner energy is not yet widespread. Looking ahead, Freudenberg will focus on achieving economies of scale to improve its cost structure.
In other investment news, last year, Freudenberg expanded its EnkaMat technology with a new line in Changzhou, China. Completed in July 2023, the new line increased capacity and complemented existing EnkaMat sites in Obernburg, Germany, and Asheville, NC. The EnkaMat technology is used to create three-dimensional matrices that prevent restriction.
“With this new investment, we can support our customers locally and the good thing about Enka is we see a lot of synergies with a lot of our technologies and processes,” Raps says. “We are working to combine these technologies.”
In India, Freudenberg is on track to start production on a new interlinings line in Chennai, India, which will allow it to produce a wider range of materials, especially focused on polyester, at the end of 2025.
Also in Asia, in July Freudenberg held an opening ceremony in Vietnam for its brand new comfortemp thermal insulation facility. This facility, located in Long Thanh District, will expand the Asian reach of comfortemp, Freudenberg’s renowned high-performance thermal insulation material, designed to elevate fashion and sportswear apparel.
The Vietnamese facility is equipped to produce sustainable thermal insulations, providing customers with options that align with their sustainable garment production initiatives and goals. This additional new factory extends Freudenberg Apparel’s thermal insulation production across key Asian markets, including the Chinese mainland and South Korea. It also significantly strengthens Freudenberg Apparel’s global production capabilities and supply network.
Freudenberg already manufactures comfortemp at sites in China and Europe.
“The new line can make fully recyclable materials which is very positive,” Raps says. “We are convinced this is not a trend but a requirement in the future. We want to be a first mover and set the pace for this kind of development.”
In addition to comfortemp, Freudenberg has made several steps to improve its apparel business in recent years. In 2023, the company established a 900-square-meter Asian-based Apparel Technical Solution Center at its Nantong, China, factory to offer technical expertise and innovations to apparel customers from nearly all apparel segments in Asia and around the world.
In May 2023, Freudenberg completed work on a competence center for finishing and coating base materials for the apparel industry at its site in Sant’Omero, Italy. The site now accommodates two lines, which were relocated from Weinheim, Germany, as well as a third transferred from a closed Argentinean site.
Customers are currently benefitting from quicker and more flexible order processing of products originating in Europe. The Freudenberg team in Sant’Omero has a rich history of expertise in manufacturing high-quality interlinings for menswear, with base materials produced at the site being finished and coated according to customers’ specifications.
With the new competence center, the facility is now focused on coating and finishing all nonwoven, woven and weft apparel interlinings in Freudenberg’s portfolio. The Weinheim, Germany, site now serves as Freudenberg’s headquarters for the production of interlining base materials.
Freudenberg’s healthcare sector is thriving due to factors such as population growth and the aging population in many of its core markets. The company has made significant investments in two facilities in the U.K. that have allowed it to expand the scope of its advanced wound care business, offering high-performance nonwovens and polyurethane foams. One of the company’s more interesting recent product introductions is an elastic variant of its flexible superabsorbers for modern wound dressings. These superabsorbers enhance patient comfort and allow for longer wear time, reducing the need for frequent dressing changes.
In new product news, Freudenberg has developed a 100% synthetic wetlaid nonwoven product line in Germany. The new materials can be made from various types of polymer-based fibers, including ultra-fine micro-fibers and are designed for use in filtration applications and other industrial uses. This product line complements the company’s wide range of wetlaid nonwoven capabilities. Freudenberg can also incorporate glass fibers, viscose and cellulose into this substrate.
Throughout all of its business areas, sustainability continues to be an important component of Freudenberg’s success. This began decades ago when the company was among the first in the world to use recycled PET from water bottles and continues today through process improvements and new product launches.
“We think of sustainability in terms of handprint and footprint,” Raps says. “The handprint is the product that we hand over to our customers and the footprint is our internal efforts like the consumption of energy.”
Recent new products that offer a more sustainable option to its customers include a needlepunched material that can replace a nonwoven/glass fiber hybrid product in automotive applications. Eliminating the glass fiber materials makes the product recyclable, and Raps says customers are very excited about this product.
“Sustainability is a key pillar, and we strongly believe it will be a game changer,” he says. Freudenberg, with its R&D power and its technologies, is the first mover to offer more sustainable solutions, he says, adding that Freudenberg’s broad technology allows it to combine products and processes, no matter what the customers’ demand is. “I think the headline for the next three years is that we will continue to capitalize on this more,” Raps adds.