Manufacturing Processes
The Enkev Group is a real manufacturing company. Sure, we do some trading but the real focus lies on the products that can be made with our 14 production lines. We can process coarse fibres like coir, hair and abaca, but we can also proces fine fibres like cashmere, wool and cotton.
Below you'll be able to learn which processes we run..
Spinning
In the world's most exclusive beds you’ll find layers of hand-layered curled and resilient horsehair. To make the hair curly and resilient ENKEV spins the fibres into ropes which are thereafter steamed to fix the curls. Either the ropes are sold as a product or they serve as the basic material for the subsequent treatment processes in our facilities.
- When the selected and washed fibres enter into our spinning lines they are straight.
- In the spinning machine we twist the fibres so that the shape of the fibres goes from straight to curly.
- These curls are then fixed by prolonged steaming.
- After this steam/heat treatment the fibres are ready for their function in the worlds most comfortable beds. In those beds they enhance the microclimate that leads to good sleep!
- These spun fibres are in many cases used as raw material in the other processes in our factories.
Needling
During the needling process, fibres are mechanically linked together onto a hessian or PP backing. This happens in a special needleloom. Sometimes we add a thin layer of natural latex. This enhances the binding of the fibres and the strength of the material. Needled coir and hair are produced in rolls and sheets.
- In the needling process the fibres are linked together by a special technique, normally onto a hessian or PP backing.
- A thin layer of latex may be applied for the enhanced binding of the fibres.
- Needled coir and hair are produced in rolls and sheets.
Needled sheets provide great microclimates, known for their sound-absorbing and heat-isolating properties. Needled products are suitable for insulation, mattresses, furniture, car seats, filters, packaging, and many more uses.
Rubberising
In the rubberising process, natural fibres are layered and form a loose fleece. Then we spray fully traceable (if needed: FSC-certified) natural latex onto the fleece. Little latex drops sit down on each place where fibres meet. When we subsequently heat the wet semifinished sheet, the latex converts into flexible and elastic natural rubber.
- Curled fibres are layered and form a loose sheet.
- We spray natural latex into the sheet.
- During pressing and heating we determine the thickness and the density of the material.
- Vulcanisation leads to a sheet that's resistant to sagging.
This process delivers fully natural and biodegradable sheets with a very open, thus ventilating, yet resilient structure. Each of our plants in Volendam (The Netherlands), Poland and the United Kingdom produces rubberised products locally and with its own specialities.
Fire Retandant versions of rubberized products are available!
Moulding
During this process, freshly rubberised natural fibres are pressed in custom and in-house made moulds and then vulcanised. The most widely used applications are seat cushions and armrests for furniture and/or car seats. There's space for sustainability in the moulding business. With our fully recyclable and biodegradable product line, we are helping to eliminate polluting PU foam from the moulding industry.
- The moulds are manufactured in-house according to the customer’s specifications.
- The freshly rubberised coir fibres are pressed in moulds and then vulcanised.
Non-woven Products
In Havivank and in Walotex we produce a full range of specialty non-wovens and fleeces for mattress industry, for horticulture and for thermnal insulation.
We are flexible and have a wide range of different fibres on stock. We can make unique blends of many different fibres.
Lately, our 'Eco' and Vegan products have been well received on the market.
The products come with Vegan and GOTS certificates. We produce mostly rolls.
Extrusion
In our extruders we create ventilating and resilient structures that are made of one recyclable material.
The 3D structures of fused monofilamentsform a spaghetti-like structure, which donates properties such as ventilation, elasticity, comfort.
Labyrinth is ready for multiple lifecycles. We can take the material back, shred it again and give it a new life.
Engineered for Sustainability.