45+ years experience in nonwoven textiles.
Rontex America, Inc., has operated since 1970 manufacturing needled nonwoven textiles for a variety of end uses and industries, including automotive OEM and aftermarket, marine and other transportation. Needlefelted products include thermal bonded carpet and structured carpet.
What We Do
The first stage of our production process is the procurement of our staple fibers. We have strong relationships with suppliers all over the world which allow us to source a wide variety of fibers at worldwide competitive pricing.
In some cases, we will need to perform a small prototype or preproduction trial to obtain a color or appearance approval, or in the case of a technical fabric, evaluate physical properties. This is easily done with our complete small scale prototype equipment.
Once the product aesthetic and physical requirements have been determined, the next stage is the blending of the fibers. With our in house blending and opening equipment we can process runs ranging from small runs to truckload quantities with great precision and accuracy.
The next operation is the key to the needle punch nonwoven process – the actual carding and needling operation. Here the blended fiber is carded into a web, crosslaid to build the proper mass, and mechanically entangled using thousands of barbed needles to achieve the correct density and surface finish. Typical products produced by Rontex will vary in mass from 4 to 30 oz. /yd², and a thickness of 0.080” to 0.250”.
In some cases this is the final production operation. In other cases, a surface finishing operation is required to raise a pile surface, impart a linear pattern of pile loops, or create a geometric pattern. Rontex has full complement of unique machines to offer a wide variety of eye-catching effects.
Thermal bonding can be performed with any of the Rontex products. Thermal bonding is used to increase dimensional stability, reduce elongation, and improve abrasion resistance. Generally this involves incorporating a low melt fiber at the blending stage which is then activated by the application of heat. Rontex can use either through air bonding or direct contact heating methods for activation, the choice is determined by the desired appearance and physical properties required. Thickness calibration and slitting of products in widths as low as 9 inches can be accommodated in this operation.
Rontex actively engages outside sources at our customers request to provide other finishing operations such as extrusion coatings, singeing, or adhesive lamination which allow the production process to include operations not available under our own roof.