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Kenactiv Innovations launches new line of nonwoven mats

04 May '13

2 min read

Kenactiv Innovations Inc announced the launch of a line of nonwoven mats ("felts") designed in consultation with BASF Corporation, makers of Acrodur resins, for compatibility and performance in natural fiber composites using the VOC-free, water-based acrylics. These products can replace injection-molded plastics and other materials at significantly reduced weights and no reduction in strength, and with a significantly improved environmental profile.

Kenactiv, a leading manufacturer of natural fiber and nonwoven products for composites and other applications, and BASF began collaborating in early 2012. The companies agreed to work together to develop a custom natural fiber substrate product specifically matched to Acrodur resins and optimized for existing and emerging manufacturing technologies. Importantly, the Acrodur and Kenactiv solutions can present a drop-in solution without the need for high new capital investment and can be processed using most conventional machinery.

"Increasingly, manufacturers are realizing not just the sustainability benefits of these state-of -the-art composite solutions, but also the performance value and process cost reductions they can achieve," said Christopher E. Galvin, Chairman, President and CEO of Kenactiv. "These products yield composites that have a significantly higher strength-to-weight ratio than fiberglass, are less abrasive to machinery, and provide excellent acoustic insulation."

In addition to an extremely favorable environmental profile, kenaf has particular suitability to these types of applications due to its higher inherent thermal tolerance, low specific gravity, and unparalleled absorptive capacity among natural materials. Kenactiv's proprietary treatment for water resistance enhances the fiber's resin interface, and innovative processing methodologies yield higher structural integrity and add tensile strength to the mats.

"While Acrodur can be used with a variety of natural and synthetic substrates, we found our manufacturing customers were most eager to maximize Acrodur's performance and sustainability value by pairing it with natural fiber substrates, but wanted a drop-in solution," said Henning Karbstein, in charge of New Business Development for Acrodur in North America. "While BASF works with all partners for this technology, we like to see that Kenactiv's solutions provide both the compatibility with Acrodur and supply chain solutions manufacturers in North America require - including the plan to use soon natural fibers grown and processed in the region."

Acrodur is an eco-friendly water-based acrylic resin with excellent bonding performance, completely formaldehyde-free, and free of potentially hazardous cross linker chemistry. It produces highly durable results with excellent chemical resistance and bio-stability.

Kenactiv Innovations