In industries where precision matters, quality assurance in nonwoven felts is essential. At Bouckaert Industrial Textiles (BIT), we understand that our high-performance nonwoven felts are often used in mission-critical applications, from automotive heat shields to oil and gas pipeline insulation. Quality is central to everything we do. Through stringent testing, real-time monitoring, and customized solutions, we ensure each roll of felt meets the highest industry standards. Our clients rely on our products, and we’re committed to delivering consistency and reliability. Let’s explore how BIT maintains its commitment to nonwoven felts quality assurance across every product and customer need.
Adherence to Industry Standards: Quality Built on ASTM Guidelines
At BIT, we closely follow recognized industry standards. Our manufacturing processes for nonwoven felts adhere to ASTM guidelines, which ensure that our products meet precise specifications for thickness, strength, and durability. Our clients can count on us to consistently provide a high-quality service.
By following ASTM guidelines, BIT meets and often exceeds the expectations of clients in high-performance industries like automotive, aerospace, and oil & gas. This commitment to standards ensures that each product performs reliably, even in demanding environments with heat, stress, and harsh conditions. Our adherence to these benchmarks guarantees product consistency.
The Rigorous Testing Behind Every Product
Nonwoven felts quality assurance at BIT doesn’t just happen. It’s the result of deliberate and systematic testing to avoid any variables that might compromise product performance. Our approach is multifaceted, comprehensive, and leaves no detail overlooked.
For every roll of nonwoven felt we produce, we perform regular quality checks, including:
Thickness Testing: We measure thickness to meet customer specifications. Whether used for vehicle insulation or pipeline systems, thickness consistency is critical.
Weight Consistency: The weight of our felts indicates density and durability. In applications like heat shields, any weight variations can affect insulation and structural integrity.
Surface Quality: We inspect each roll’s surface to ensure it’s free of defects. Precision is essential, especially in aerospace industries.
These tests are part of our larger commitment to quality assurance in nonwoven felts. Every batch undergoes multiple testing rounds to ensure it meets or even exceeds, client expectations. We use state-of-the-art equipment like Ames gauges, Guston Bacon gauges, and Instron machines to achieve the highest accuracy in each test.
Custom Solutions for Client-Specific Quality Requirements: A Case Study in Precision
At BIT, we know that one-size-fits-all approaches don’t work in high-performance industries. That’s why we tailor our quality control processes for each client. Our work with a major oil and gas pipeline insulation manufacturer demonstrates this approach.
This customer uses our nonwoven felts as a substrate for their aerogel-based insulation. It’s a specialized application where any variation in thickness or weight creates issues. If the felt is too thick or too thin, it affects the aerogel application, leading to waste. In industries like oil and gas, inefficiencies are not just inconvenient—they’re costly.
To address this, BIT developed a custom quality control and reporting process for this client. We implemented a system that measures thickness and weight every 50 yards. This data is entered into our quality reporting software. If measurements deviate from nominal values, the system alerts supervisors, allowing us to correct issues immediately.
This real-time quality assurance process lets our client adjust their machinery based on each roll’s specific thickness and weight data. In the first year of working with BIT, this client saved over $300,000 in yield losses. The savings came from our ability to maintain consistent quality.
This example shows how BIT goes beyond standard practices to meet each customer’s unique quality needs. By customizing our processes, we help clients achieve efficiency and reduce waste.
The Role of Technology in Quality Assurance
At BIT, we rely on advanced technology to monitor and test our products throughout the manufacturing process. Key tools in our quality assurance arsenal include:
Ames Gauges and Guston Bacon Gauges: These gauges measure felt thickness. We choose the gauge type based on product density to ensure precise readings.
Durometer Tests: These tests assess the hardness and flexibility of our felts, confirming that they meet mechanical requirements for applications like thermal insulation.
Deflection Testing: This test evaluates felt resilience under pressure, simulating real-world stresses. The ability to withstand pressure is crucial in applications such as automotive heat shields and industrial pipelines.
Instron Machines: Instron machines allow us to perform multiple mechanical tests, including tensile strength and elongation, which ensure our products’ durability in high-stress environments.
Through this technology, BIT maintains real-time quality assurance. We catch issues early in the process, ensuring each product meets our standards before reaching the customer.
Sustainability Through Quality: Efficient Processes That Reduce Waste
At BIT, we believe that sustainability and quality are linked. By making products right the first time, we reduce waste and increase efficiency. High-quality production means fewer defective products, less rework, and a streamlined manufacturing process. These benefits translate to lower energy consumption and reduced material waste.
Quality products also mean longer-lasting performance for our customers. This reduces the need for replacements and repairs, saving both time and money. Reducing the environmental impact of production and shipping also aligns with our commitment to eco-friendly solutions. As sustainability becomes more critical, BIT’s focus on quality supports eco-friendly industrial practices.
Conclusion: BIT’s Uncompromising Commitment to Nonwoven Felts Quality Assurance
At BIT, quality is more than just a buzzword. It’s the foundation of everything we do. From our adherence to ASTM standards to our use of advanced technology and customized solutions, we ensure that every product that leaves our facility meets the highest standards. Whether we’re producing nonwoven felts for automotive heat shields, aerospace insulation, or oil and gas pipelines, our commitment to quality ensures that our clients receive reliable materials.
Through proactive testing, real-time tracking, and efficiency, BIT continues to lead in high-performance nonwoven felts. As industries evolve and demand more from their materials, BIT stands ready to meet those challenges with the same dedication to quality that has defined our success.
Restaurants, bars, cafes, hotels; we leave the comfort of our homes to indulge in these spaces.
COVID-19 restrictions have eased and the long-desired opportunity to frequent our forgotten social lives is now present. Properly designed noise control measures in your public spaces can make a difference between a returning customer and a bad Yelp review in these post pandemic times.
Sound: A Health Risk
We cannot escape noise. Our daily lives are inundated with a variety of sounds from the landscapers outside our homes to the swirling conversations surrounding us at the bar.
The most serious potential risks to our health are:
hearing loss
hearing impairment
tinnitus
But the most pervasive effects trigger issues with our physiological health.
Fact: Sound levels above 85 dB are considered harmful. Exposure to sound levels at or above 120 dB can cause immediate damage.
Sound disrupts our sleep, concentration, heightens our stressors by releasing cortisol, elevates blood pressure and heart rate…
And, to put it simply, too much sound is annoying. We don’t see noise or feel it, so we write off issues as non-noise induced. But for the average guest, noisy spaces make for uncomfortable environments.
Why So Noisy?
The number one complaint when dining out is poor service. The second is noise.
So when did the hospitality industry become so noisy? And why?
The trending upward levels of noise may have started in the mid-1990s with well known chef Mario Batali when he began playing the music in the kitchen and dining area. Now it has become commonplace to amp up the volume to create a “buzz” that draws people in.
It has also become a tactic for quicker turnaround. Research has shown that restaurant and bar owners use excessive levels of noise because it pushes patrons to eat faster thereby leaving sooner.
All five of our senses influence our perceived reality of not only places, but the food and drinks we consume. But further scientific research has shown evidence that noise interferes with our sense of taste. Because noise is a distractive nuisance, it becomes easy to mess with the senses.
Other purposeful choices in décor amplify noise. Modern design trends are the greatest conductors of sound. Gone are the days of plush booths and tablecloths; elements of style that helped dampen noisy spaces. Substituted with glass tables and bare floors, sound now bounces around freely with little absorption opportunities.
Where to Look for Acoustic Problems
To understand sound, it is good to know the basics of how sound travels.
Sound is vibrational energy. There is direct sound which travels directly from the source to the receiving end (for example, you and your partner talking over breakfast in your apartment). And then there is reflected sound. Reflected sound is direct sound bouncing off walls, floors and other mediums. The reflected sound is what gives us reverberations or echo. And why sound becomes exasperated in most spaces.
Think of a disco ball except with loud music, kitchen sounds, employees working, and the rolling conversations all overlap and bounce off one another making for, “Say that again” and “I can’t hear you” staple quotes of the night.
Sound treatment can be expensive. Hiring acoustic engineers and sound consultants can drive up the price. And altering your already designed interior can create issues for an already established institution.
There are simple ways to addressing noise issues without mind blowing renovations. First, taking inventory of intentional noise practices (as we mentioned, loud music) coupled with the décor of your space will help you pinpoint where sound is amplified.
Keep in mind the materials in your space (hard materials like steel or glass are non-absorbing) and the landscape of your interior. A cheap alternative to testing for room acoustics is a simple clap test. In your space, clap your hands together and wait to hear for the initial “slap” followed by its echo. The longer the sound continues, the more reverberation time your room holds. It’s an easy way to hear for where your acoustical problems lie.
Balancing Noise Levels with Acoustic Treatment
Thankfully, acousticissues in your space are not a unique problem. And most acoustic insulation solutions do not have to take away from the defined aesthetic of your brand.
The addition of acoustic panels improves sound quality by reducing the amount of reflected sound. Materials like PET (recycled polyester) absorb sound waves, dampening the sound by transferring the vibrational energy into kinetic energy, or heat. And they come in a variety of forms. Placing your acoustic panels accordingly (and relative to your space and its dimensions), you can effectively mitigate noise.
What Types of Acoustic Panels are Best for You?
Sound is the main issue. Turning off the music won’t change sound traveling. To find the right acoustic treatment, you need to take these things in to consideration:
Dimensions of your space (high ceilings, etc.)
Furniture materials, flooring, windows, doors
Noise absorbing material and “dead” space
Keep in mind the tone of your space. Acoustic panels do not have to dull the vibe; with so many options and designs, you can enhance without compromise.
Here are some acoustic solutions that can fit in to your space.
Acoustic Panels and Art
Acoustic panels can be any size and shape, placed in a variety of configurations at designated reflections points. In this scenario, less can be more, enhancing walls with modern visuals.
Acoustic panels can also double as artwork. Stock photos or custom images can be printed onto any size panel to give you a piece of artwork that works as your sound dampening tool. And in our post-COVID world, you can utilize acoustic panels as custom dividers (movable or fixed) for designated areas that will buffer sound and maintain safety regulations. They can also act like booths without the bulky nature.
Ceiling Baffles and Clouds
To better your bar and restaurant guests’ experience, hanging acoustic solutions can mitigate noise in a non-conspicuous manner. Or conspicuous: they are perfect examples of how to create artistic focal points in your space. Depending on shape and size, they are effective at tuning out unwanted noise in greater ranges of angles.
Plus, they can double as lighting fixtures, creating a two for one in your space’s décor.
Absorbent Furniture
One product, multiple functions. Sound absorbing furniture works well for physical comfort and sound buffering. In modern and sleek establishments, complimenting stark lines with plush furniture in lobby and rest areas soften trending contemporary styles and invite your patron so stay.
You Don’t Need to Reinvent the Wheel for Sound Management
Rendering your space acoustically “healthy” for patrons (and employees) can be easy without re-designing.
At BIT, we manufacture our Poly-Sonic Acoustic panel line to meet any acoustical need. Our panels are 100% polyester, free of any fiberglass or VOC, and customizable for all specialized products. From rolled good to hanging baffles, our partially recycled acoustic panels create top quality finished products.
Most consumers think of manufacturing as nothing more than a long line of automated machines creating thousands of copies of the same product every day. We can thank the TV show How It’s Made for this assumption. But what is custom manufacturing?
In reality, manufacturing companies come in many different shapes and sizes.
In many cases, companies are looking for more than just a copy-and-paste product. Their needs may not be met by any mass-produced product currently on the market. Or they are looking to get an edge over competitors through a new and unique product.
This is why custom manufacturers exist. One of the main purposes of a custom manufacturer is to create a product specifically designed for each customer. We should know because we have been a custom manufacturer of nonwoven felt fabric for more than 30 years!
What Does Custom Manufacturing Mean?
Custom manufacturing is the process of designing, engineering, and manufacturing products with unique specifications for each customer. The size of orders can vary from small, one-off batches to large, mass-production runs.
The main difference between mass-produced products and custom-manufactured products is that with a custom manufacturer, you can expect to work with them through every step of the process.
This will usually begin with a meeting to discuss your needs and requirements. If they believe that your needs are within their abilities, then the design process can start.
Depending on the complexity of the product, the design phase can take between a few hours or a few months. But this step is crucial to making sure that the testing phase flows smoothly.
Once you are satisfied with the design and specifications of the proposed product, then single-batch production and testing can begin. This stage will most likely include multiple rounds to ensure that the finished product meets your needs.
Upon approval of a single product, larger batches can begin to be produced. At this point, the process will be similar to that of an off-the-shelf manufacturing company because they will have pinpointed the best way to manufacture your product.
Advantages of Custom Manufacturing
Exact Specifications
Off-the-shelf product manufacturers will often give you a variety of options. Their offerings are usually based on research into their industry’s needs. This model works well for the majority of buyers, but it leaves out a significant number of people who need slightly altered specifications for a specific reason like performance or price.
Custom manufacturers will ensure that your needs are met in terms of design, dimensions, performance, price, or any other specifications.
If you require a product that cannot be purchased from any other seller currently on the market, then you may be in the right position to start searching for a custom manufacturer.
Unique Product
A common issue companies run into is finding three or four different products that each satisfy 75% of their needs.
For example, Product A will meet all of the specifications, but it is too expensive. Product B will be suitably priced, but it is missing an important specification. And Product C will meet all specifications and pricing requirements, but the distributors aren’t reliable enough and you have heard poor things from colleagues who have worked with them.
Working with a custom manufacturer can solve each of these issues by bringing the best aspects of each product into a new, unique product specifically for your business.
Lower Cost
Many people hear about a custom product and immediately think, “Wow, that must be expensive.” But when it comes to custom manufacturing, this is usually not true.
One of the main goals of a custom manufacturer is to meet all the customer’s requirements and this includes price.
If you go to a custom manufacturer and tell them that everything on the market is above your budget, then they are going to work with you to design a product that you can afford.
For example, a customer approached us back in 2012 with a problem: they were buying an off-the-shelf product from one of our competitors but it wasn’t exactly what they needed and the price was too high. We began a round of research and development to help them solve this issue.
Soon, we had developed a product that met every one of their specifications.
But, it came in at 17% more expensive than the off-the-shelf product. However, because the product was developed to fit their exact needs, they were able to reduce the labor involved in modifying the previous off-the-shelf product. This reduction in labor ended up saving the company 8% per yard compared to the old product.
Today, that company has increased their stock value by more than 16x since we began working with them. And it’s safe to say that our ability to help them cut costs and reduce margins was a factor in their growth.
Work Directly with Engineers
Certain industries require more than a simple 3D model to create a product. Many customers want to know that your products follow legal guidelines and requirements such as:
Quality
Functionality
Usability
Reliability
Safety
Packaging
Working directly with engineers will ensure that your product is designed to pass certifications. This level of communication with engineers is only offered through custom manufacturers.
Disadvantages of Custom Manufacturing
Custom manufacturing has many benefits. But it’s important to consider the disadvantages of custom manufacturing as well.
Longer Lead Times
The main benefit of mass-produced products is that they are sitting in a warehouse ready to be shipped out. Custom products don’t offer this same luxury.
Depending on the type of product, you may need to wait weeks, months, or even years for a product to be fully designed, developed, manufactured, and ready for shipping.
It’s important to keep in mind the fact that unique products require a long-term commitment. While it may take longer to start receiving your products, you can be assured that the longer timeframe will be worth it in the end.
Higher Costs (But Not Always!)
Custom manufacturers don’t have the luxury of walking into the factory, turning on a machine, and watching the products start rolling out.
Custom products are often produced in smaller batches. These smaller quantities mean that, between batches, the machines have to be reset and cleaned.
Smaller order quantities also mean that manufacturers can’t buy materials in bulk with the guarantee that they will be used any time soon.
Some months, certain products will be produced that require a specific material. Other months, that same material won’t be used at all.
So, the cost of the manufacturer having to use the additional time to reset machines between batches, buy smaller quantities of raw materials, and spend more time on product design and development is often passed down to the customer.
However, keep in mind that custom products don’t always mean higher costs. In many cases, the product you’re searching for doesn’t even exist on the market so there is no real way to compare costs.
Another reason why higher costs may not be applicable is if your company requires very large quantities of products. One of the main reasons for a higher cost is smaller batches, so if you are looking to be supplied with millions of the same product over multiple years then you may end up paying the same amount or less when compared to an off-the-shelf product.
Considerable Communication
Being able to go to a manufacturer’s website, add something to your cart, pay for it, and have it shipped directly to you is a great advantage. This experience is much different than what you can expect from a custom manufacturer.
You need to expect extensive communication between you and the manufacturer if you want a product developed. This may include meetings, factory visits, product testing, note-taking, and more.
Companies that cannot commit time to a potentially lengthy development process should consider using an off-the-shelf product.
Finding the Right Custom Manufacturer
What to Look For
Finding the right manufacturer to help you develop a new product can be tricky. But this shouldn’t scare you away.
Like working with any other business, it’s important to look around and compare your options. Depending on your industry, there may be 5 companies able to work with you or 500.
You should begin by gathering all your requirements before reaching out to potential manufacturers. This will save both parties time as you will be able to filter through company’s that cannot satisfy your needs before contacting them.
But, once you do begin to speak with companies and compare your options, you need to look out for the right signals. This can be done by asking a series of important questions.
Questions You Should Ask
Once you are in contact with a few companies that you believe could help you develop the right product, it’s important to ask the right questions.
Some basic questions include:
How long have you been in business?
This will tell you if they are a long-standing company you can trust.
How do you differentiate your company from others?
Find out what they do differently from the other companies you’re considering.
Have you manufactured products like what I’m looking for before?
While it’s likely that they haven’t manufactured your exact specifications before, you need to ensure that this is a space they’re comfortable in.
What does your custom design process look like?
Understanding the exact design process a company uses will help you to understand if working together will be an easy, beneficial process.
What issues do you see as a challenge to what we are hoping to achieve?
Many products will be smooth sailing from start to finish. But others will take difficulty if they are unlike anything currently on the market. You need to ensure the company is honest with you about the troubles that may arise with your project.
How long can I expect before production?
If you are in a time crunch, then this may be a very important factor to you. However, don’t let a long development time scare you away. It may be that they have a solid process in place for getting things right the first time.
What do your previous customers have to say?
Customer reviews are a great way to get feedback on what it is like working with a company. Keep an eye out for comments on customer service because it’s important that whichever company you choose is a pleasure to work with.
Can you send me a product you’ve manufactured before that is similar to what I’m looking for?
It’s always important to be able to get examples of previous work before deciding to work with someone. While they may talk the talk, receiving a product and being able to decide if it’s the quality you’re looking for is the only way to determine if they can walk the walk.
Questions They Should Ask
Asking the right questions is always important. But you should also expect to be asked important questions. If a manufacturer fails to ask you these questions, then that may raise a red flag:
What is the end goal of your product?
A good manufacturer will understand the different applications of their products. Finding out the end goal of your product may help them give you better recommendations.
What are the most important design aspects?
All design aspects are not equal. And they vary significantly between customers. So, a company must figure out what is important to you so that they can design a product accordingly.
What is your expected/required timeframe?
Manufacturers all work at different speeds depending on their process. They should be upfront and honest with you when estimating the time a project will take.
Conclusion
Whether you decide to work with a custom manufacturer or buy an off-the-shelf product, you need to make the decision that is best for your business. And, in many cases, the only option you have is to have a unique product developed for you.
It can be very daunting trying to choose the right manufacturer for your business. A wrong choice can potentially mean the loss of millions of dollars. So, take your time and weigh all your options.
Bouckaert Industrial Textiles has been a custom manufacturer of nonwoven felt fabric since 1988. And we have learned a lot over the years. But one of the main things we have discovered is that custom manufacturing is a people business. We are selling custom solutions to each customer. But more than that, we are selling the satisfaction of knowing your company has a unique product that will beat your competitors and help you position yourself as a leader in the industry.
The American economy would not be what it is today without outsourced manufacturing. But is it essential to the health of our industries?
What was once a cost-effective solution is now facing problems. Emerging regulation standards, longer lead times, rising shipping costs, and quality control issues are plaguing the global manufacturing industry. Whether you work with domestic manufacturers or not, sourcing decisions should be backed by careful analysis to avoid costly repercussions. Here is why staying in America can alleviate most issues concerning supplier relationships.
Keeping Manufacturing in America
Buying local is more than a transactional act of patriotism. And although the upfront cost may be higher, its best to remember that cheaper does not always mean better. In fact, according to a recent Thomasnet.com survey of manufactured goods buyers (given the current post-covid economy), over 83% of companies are looking to re-shore their supply chain within the next 3 to 6 months.
Here are the benefits of using a domestic manufacturer.
Higher Labor and Manufacturing Standards
Labor costs were the initial reason for the major trend in outsourcing that began in the later 1970s. Up until 2011, America witnessed millions of jobs move overseas to China. Today, we see a moving wage gap shrinkage between America and its foreign competitors every day (with global wages increasing by 20% year after year).
When addressing the issue of labor costs, you must consider the whole picture. High employee turnover associated with low labor wage costs typically results in low productivity. On paper, it looks mathematically sound to partner with an international manufacturer who makes a product for $4 an hour vs $20+ domestically. But the money saved will be tested by production rate issues associated with low labor costs. Not to mention the hassle of dealing with poor currency exchange rates.
In the United States, employers comply with the Fair Labor Standards Act (FLSA) enacted in 1938 as a federal guideline for reasonable working wages and conditions. As a business, protecting your brand by working with morally compliant manufacturers benefits your company’s reputation (and your conscience).
“On-shoring” is making an economic comeback with a newfound desire for locally sourced goods. At BIT, we carefully manufacture our industrial grade felt for industrial application according to SAE and ASTM mandated standards. We guarantee quality control, provide samples, and welcome plant visits (all facilitated by transparent communication without any time-zones to maneuver).
Supplier Relationship Opportunities
Fostering a long-distance relationship with your manufacturer can be tricky; differing time zones and language barriers can lead to costly communication issues. Proximity to your supplier reaps the benefits of quick response times, so if there is an issue, it can be addressed with little to no repercussions. You also have the personal touch of meeting face to face with your supplier, giving you the firsthand opportunity to oversee the facility and operations.
Building a rapport with your manufacturer can lead to growing business opportunities. Recently, we were able to produce and color match our Poly-Sonic acoustic panel felt for our sound abatement customer located on the west coast. From a plant visit, their supply chain team witnessed our production line firsthand. This key insight provided them with a new line of upholstered materials to match their current acoustic panel line.
Shorter Lead Times with Lower Shipping Costs
More companies have begun “re-shoring” jobs in the past ten years due (in part) to unreliable international shipping costs. Less than 1% of goods travel by air to the United States. 99% of the rest of all goods arrive here by container. It can take anywhere from 2 weeks to 2 months for product arrival by boat. If shipping wasn’t costly enough, COVID had only exasperated prices with considerable surges in container freight rates at the height of the pandemic. Just as we believed business was normalizing, incidents like the Suez Canal in March prompted a new price surge re-emphasizing the uncontrollable nature of overseas shipping. If that does not complicate things enough, extra add-ons to your overall cost include local tariffs, customs and duty taxes.
The cost of transporting goods from the point of sale ultimately adds up to time. Can you meet the demand of your customers with the given supply of your manufacturer within a proposed time-period? Unlike labor wage costs, quantifying international shipping can be tricky and lead to missed ship dates or, worse, missing inventory. There is little to no control over maritime trade. And without the proper regulations in place, it might as well be impossible to know when your shipment will arrive in adequate condition. Economic/geopolitical disruptions, competition with foreign markets, and weak currency further complicate getting your product to its end destination.
Domestic manufacturers can (potentially) bypass long lead times without the hassle of unwanted shipping costs, proving to be the most economical choice.
Tight Quality Control
Most companies partake in low-cost country resourcing to take advantage of available and cheap resources. With the added bonus of a low wage cost. But cut-down on operational expenses is easily disrupted by supply chain mishaps and unforeseen foreign barriers (geographical and political). As those are issues out of your control, the lack of quality control on product specs and regulations is slowly becoming a dangerous risk.
Knowing what could go wrong before it goes wrong should be detailed in advance to then formulate quality processes and policies relevant to your company. Minimizing overhead costs is appealing but can result in lower-quality materials managed by inexperienced workers leaving you with a not-so-great product.
This is not to say that every overseas manufacturer is a poor-quality choice. In recent years, international manufacturers have elevated production to mimic the standards and expertise of western principles. But most companies still fall short of properly executed quality policies and plans. With little to no insight into the production’s facility, relying on foreign companies to regulate in the name of your brand is risky. Good questions to ask yourself before engaging in business with any manufacturer (domestic or not) are:
Have they made this product before and under these regulations?
Not only have they produced them, but can they produce in mass production?
Are they able to ship to you on time?
Do they allow company quality checks?
We have worked with a handful of customers who have received acoustic panels from Chinese manufacturers with failure to test the finished product. Acoustic panels must pass a surface flammability test, testing both surface flame spread and smoke development (expressed as Flame Spread Index and Smoke Developed Index). You can read about our acoustic panel line with relative technical documentation here on our website.
To recertify the proper testing, the company chose to re-test the acoustic panels in-house upon arrival. Unfortunately for these clients, the quality control tests they were promised were never met, leaving the supplier and buyer at loggerheads over quality. After 3 months and threatened legal action, the refund from the supplier could not make up for robbed time and potential of a ruined reputation.
Diminish Risk with a Domestic Manufacturer
Like anything in life, you get what you pay for. And what you pay for has everything to do with overall product quality; from the sourced raw materials to the expertise of employees to the operational standards of the factory.
Localizing your choice of manufacturer places control back into your hands. And with a supply chain in sight, you can guarantee your company’s credibility all while promoting the local economy.
Interested in finding out if Bouckaert Industrial Textiles can help you re-shore your non-woven supply chain like we have so many others? Contact us today!
One of the hottest trends in office furniture and interior design is the rise of polyester (PET) acoustic panels. The use of these panels is growing significantly in markets such as construction, retrofits of existing offices, and other commercial and public spaces.
Over the past 3 years, polyester acoustic panels have seen a massive upsurge in demand. This is due, primarily, to their flexibility in color, form, and ease of use when compared to traditional fiberglass acoustic panels. Fiberglass panels can cause irritation and air contamination due to the chemicals they sometimes contain in their binders.
The industry has quickly adopted these panels whether being used as desk dividers, light fixtures, hanging sound baffles, wall-mounted art, or any number of other uses. But what exactly are polyester acoustic panels? How are they made? What should you look for in a quality product or a vendor? We answer all of these questions and more.
How are polyester acoustic panels made?
To understand the challenges that arise on the quality front, you first have to understand how polyester acoustic panels are made.
1. Define the desired outcome
The process to create a finished acoustical panel starts with determining what characteristics we want the finished panel to have. We can affect acoustical curves (NRC), stiffness, surface texture, or color by changing the fiber material or size, product density or thickness, or manufacturing processing of our finished panels. Each variable lets us dial in the ideal finished characteristics. Our standard Poly-Sonic panels are comprised of recycled polyester fiber and special lower melting point polyester fiber.
2. Manufacture the needle punch felt
Next, we start the manufacturing process. Every polyester acoustic panel starts out life as a nonwoven, needle punch felt. This felt is similar to the felt kids make craft projects out of, but much thicker and denser!
We begin by taking raw fiber and turning it into a “web”. We then build density and surface characteristics by adding batts and needling the material together. The repeated needling that the felt receives is one of the keys to creating a stiff panel while maintaining a super smooth-surfaced panel. From this process, we create a “master roll” of felt. For a more detailed description of how needle punch felt is made, check out this link.
3. Heat-setting
The felt moves to the heat-setting machinery following the creation of the master roll. This could be a mold for 3d shaped panels or some form of flat pressing system. This process changes the material from a roll of flexible felt to a stiff polyester acoustic panel.
When heat hits the polyester fibers, they melt and flow like a liquid thermo-plastic. Fibers like these are specially designed to have a low melt point. As this material cools, it turns back into plastic but is now spread throughout the felt, attached to all the fiber around it, and (with the assistance of the needling) creates the stiffness of the finished acoustic panel.
The heat-setting process is one of the most difficult to perfect. This is because the material will shrink three-dimensionally while being heated. And any imperfections in needling will create very obvious surface defects.
4. Cutting
The final manufacturing step is to cut the panels to their final dimensions or shape. Most architects and interior designers need tolerances of +/- 1/8th of an inch. Some elaborate designs require tighter than +/-1/16th of an inch. This would normally favor a die-cutting process but in many cases, the variety of shapes and rectangular dimensions needed would make this cost-prohibitive. Only with extremely precise cutting tools such as CNC machinery using oscillating blades, lasers, or waterjet cutting can near-perfect acoustical panels be cut every time.
What quality attributes should you look for when assessing polyester acoustic panels?
There are several factors to consider when determining whether a polyester acoustic panel is of top quality.
Uniformity
Is the first panel just like all the others and, also as important, is each individual polyester acoustic panel consistent within itself?
One of the key giveaways of an inconsistent process is that one panel does not look like the next. When dealing with large-scale projects, even minor consistency problems can stand out when looking from panel to panel or from one section of a panel to another. Unfortunately, due to the nature of the panel manufacturing process, it is impossible for panels to be exactly identical, but the closer they are, the better.
Blending
The distribution of colors in a panel is one of the first things to stand out. Many panels have a “heathered” look to them. This comes from blending two or more colors of fiber together. Do you see clumps color? Or is everything evenly spread out?
Thickness
Another one of the most noticeable attributes comes when comparing the thickness of different panels. When placing panels next to each other on a wall or in a line of desk dividers, check to see if the panels are of different thicknesses.
The thickness of each acoustic panel is one of the major drivers of its acoustical absorption capability. Thicker is better!
Stiffness
Many applications for acoustic panels, such as desk dividers, require very stiff panels. Make sure to check if the panels stiff enough for your use. Is each panel consistently stiff? This could be from one corner to another or from one surface side to another.
Many manufacturers struggle with getting enough heat all the way through the panels to fully activate the low-melt fiber. This is especially true on thicker panels. Often, an inferior panel will have a softer center and two harder surface faces when you look at the panel from the side. When this happens, the panels tend to not hold mounting bolts or hardware as well and also tend to collapse and bend easily when held from only one side. This usually destroys the panel by creating unwanted wrinkles on the surface.
Acoustic Certifications (ASTM C423)
Polyester acoustic panels have many uses, but as the name implies, “acoustic” tends to be the key attribute for many applications. All panels should have an NRC value, and most “standard” specifications will.
Where this gets tricky is when comparing panels from different vendors that look the same but have vastly different ASTM C423 results. Logic says that the higher number is better, right? Well, not quite…
There are different variations of the ASTM C423 test. These range from “A” mount where the acoustic panel is placed directly against a cement floor (and will have a lower NRC number) to “E Mount” where the panel is suspended several inches in the air (and the NRC number will be higher). It isn’t wrong for a vendor to use “E” mount test data, but make sure you compare apples to apples when comparing!
As a secondary note for ASTM C423 testing that produces an NRC value, keep in mind that NRC is an average of performance at different frequencies. If you have specific acoustical profiles or sound frequencies that you need to target, then make sure you look at the charts to compare performance at your specific frequency.
The acoustical curve of BIT’s Poly-Sonic 45 (9mm thick) acoustical panel using ASTM 423 A-mount. Note the different absorption coefficients at different frequencies. NRC: 0.30
Flame and Smoke Certifications (ASTM E84)
The ASTM E84 certification uses a combination of a flame spread and smoke generation test. It is one of the most important certifications for applications that are considered “building materials”. Depending on your application, you may not require this certification, but most suppliers will have their acoustic panels tested to this specification.
There are several results possible all resulting from the flame spread portion of the test. The generally accepted standard is “Class A” and, if your application requires this test then be sure to look for this.
One word of caution here, not all ASTM E84 tests or testing labs are equal. Many of our customers are wary of using unknown foreign laboratory results for good reason. We have heard some horror stories about vendor-provided laboratory results looking good but when independently tested their panels fail miserably.
Due to the moral values and legal penalties involved in failing this test, most of our customers will conduct their own testing using a US certified lab. We recommend that you do the same if you do not personally know the lab that conducted the testing.
What to look for in a vendor
Now that we have reviewed the critical parts of a quality panel, it is easier to identify what to look for (and what we strive to be!) in a vendor as well. For many customers, being able to provide a consistent, high-quality panel is paramount and all-encompassing. Other normal vendor characteristics to inquire about are minimum order quantities, lead times, and, of course, price. However, there are a few other factors to consider that not every PET acoustic panel vendor can provide.
First is the ability to customize. The market is becoming flooded with 9mm thick panels that look, feel, and perform pretty similarly. But your company might require a distinct acoustical performance curve, custom color options, or different thicknesses. Finding a supplier who can work with you to provide the exact product you need isn’t always needed, but be sure to review your requirements and make sure the company you are working with can handle them.
Another often overlooked aspect of vendor capability is someone you can build a relationship with. Maybe you are in a bind and need an order shipped early. Or you are stuck with a whole truckload of panels after a customer backed out of a deal. Is your vendor willing to take them back no questions asked? Finding a company that you can work with is often worth paying a bit more when they save you headaches down the road!
Bouckaert Industrial Textiles tries to meet all of our customer’s needs from minimum order quantities, to lead time, to price, to customization and relationship. Our Poly-Sonic polyester acoustic panels are designed and manufactured entirely in the USA.
Have questions or want to learn more about us? Contact us today!
