Production Operator 1

Alkegen expands needlefelt capacity in Germany. €1.5 million investment extends production to heavy technical felts of up to 4,000gsm. 22nd September 2026 Innovation in Textiles Fulda, Germany Alkegen has invested approximately €1.5 million in new needlefelt equipment at its Fulda plant in Germany, increasing production speeds while extending the weight range of technical nonwovens the site can manufacture. At the centre of the investment is a new elliptical pre-needle loom installed on an existing needlepunching line. Alkegen says initial production results indicate an increase in line performance of around 20%, alongside a two-to-three percentage point improvement in yield and an estimated 15% reduction in energy consumption per kilogramme of fibre processed. Significantly, the equipment also allows Fulda to produce much heavier needlefelt constructions than previously possible, with weights now reaching approximately 4,000gsm. This opens up additional applications in the steel industry and other demanding industrial markets requiring high-basis-weight technical felts. The elliptical pre-needling process provides tighter control of web elongation in both the machine and cross directions, enabling more isotropic felt structures with more consistent properties. Alkegen also reports improved process stability and reduced downtime compared with the previous hydraulic equipment, including a lower risk of contamination from hydraulic oil leakage. Fulda manufactures needlepunched nonwovens from a wide range of staple fibres, including conventional polyester and polypropylene as well as higher-performance preox, polyimide, PTFE and aramid fibres. The upgraded line can accommodate different fibre types, lengths and constructions, allowing materials to be engineered for industrial filtration, fire protection, acoustics, construction and architecture, white goods and PPE, among other applications. Alkegen says its technical felt capabilities now address more than 100 end-use applications. The Fulda investment also strengthens Alkegen's needlefelt manufacturing capacity on either side of the Atlantic. Its other major facility in this area is in North Augusta, South Carolina, with both plants producing filter media and technical fabrics for international markets. "This is about giving our customers confidence that we will keep investing in the capability behind their supply," said Peter Keck, senior business development manager at Alkegen. "Technical felts are not a single-spec product. Customers need range, consistency and the ability to move with the market. The new pre-needle loom helps us run faster, waste less fibre and open weight and property windows we could not serve as well before." Alkegen views the investment as particularly relevant as manufacturers seek regional sources of technical nonwovens alongside increasingly tightly specified mechanical and environmental performance. "Our manufacturing sites at Fulda and in the US both pioneered membrane felt composites and now provide a diverse range of filter media and technical fabrics to customers around the world," added John Lewis, director of global sales at Alkegen. The installation and integration of the new equipment were carried out by Alkegen's operations, maintenance and engineering teams at Fulda. The plant is one of Alkegen's main European nonwovens manufacturing locations, alongside other operations in the UK, France, Germany and Czech Republic. Twitter Facebook LinkedIn Email Business intelligence for the fibre, textiles and apparel industries: technologies, innovations, markets, investments, trade policy, sourcing, strategy...

Alkegen, a specialty materials manufacturer, has entered into a Restructuring Support Agreement to eliminate approximately $3.1 billion of debt. The agreement has backing from 99% of first lien holders and a majority of second lien holders. The company has secured $315 million in new capital to support operations during restructuring. Upon completion, Alkegen expects to emerge with a stronger balance sheet and approximately $200 million in available liquidity. The restructuring will be implemented through a prepackaged chapter 11 process, expected to be filed in the United States Bankruptcy Court for the Northern District of Texas. Operations will continue as usual with no anticipated disruption for customers, suppliers, or partners. Alkegen plans approximately $70 million in capital improvements for 2026, with an additional $300 million anticipated through 2030.