Flock. Our Future has a history.

David Capdevila, born in 1971 in Barcelona, studied Industrial Engineering in The Polytechnic University of Catalonia, where he achieved his specialization in Business Organization. Afterwards he continued his training with several postgraduate degrees in Quality Management (FUPC) and integrated management of quality, environment and safety (ICT). In 2009 he pursued an MBA executive program in IESE.

He is currently the CEO and shareholder of Velutex Flock, leading company in Flock Manufacturing. He has developed his entire career in Velutex, starting in 1994 implementing a Quality Management System according to ISO 9001 standards. He has developed different roles within the company where he has been Safety, Environment & Quality Responsible, Facility Manager, Plant Manager, Technical Manager and finally CEO.

· Introduction

The reading that we are going to present to you is not intended to be a complete history of the Flock in Euro- pe, but rather a short narration of the origins and development of the Flock technology, with the contribution of data, photographs and certain considerations. Our goal is to help new generations to know a little better the origins of the activity in which we all work and try to foresee the future together.

In this sense, the title of this reading OUR FUTURE HAS A HISTORY illustrates our intention.

This year‘s celebration of Velutex Flock 75th anniversary gives us a certain authority to be able to make an incomplete, but honest, summary that helps to have an optimistic hope about the future of the Flock.

· The original idea

We must place ourselves in the middle of the last century to witness the beginning of the development of an industrial idea that led to the origin of a textile product, which was soon known by the name of FLOCK.

We allow ourselves to speak first about the beginning of the new concept in Spain.

My grandfather Mr. Francisco Capdevila owned in the 1940’s a mechanical workshop dedicated to the construc- tion of machines for the wool & sheep leather industry (Talleres Capdevila).

During the manufacturing process of these sheepskins, there is a shearing  phase  that   involves  trimming the length of the wool to a certain extent, with rotary rolling machines, which produces a vast waste of wool fiber to be discarded.

Wool skin photograph (Wikipedia)

In times of great scarcity of everything, it was not logical to through away short wool fibres and Mr. Capdevila started seeking for a second life to this material. What we now all call as Closing the Loop.

These wool residues turned into textile powder, to be able to use it as a coating and ennoblement of paper. A new textile product had been born. It was the origin of the flock of wool and velvety paper.

It was 1947 when Mr Capdevila and  his wife Ms. Pallarés have founded the company: Industrias Pallarés.

Velutex Flock- Industrias Pallarés first logo and  colourcard

In a historical era of great difficulties, it is quite true that necessity makes ideas and imagination flow.

In the same period in France, the company Michel & Marchal  began to do trials with cotton waste, thus achie- ving what would become the cotton flock.

Soon, both Industrias Pallarés in Spain and Michel et Marchal in France, carried out positive tests to obtain Viscose Rayon Flock, using residues and different available presentations of this fiber.

The development of the flock industry in England started manufacturing flock by grinding waste textiles for fillers. John Peel & Son used tobacco cutting machines which they were guillotine machines and cut onto a wooden circular roller. They started cutting waste denim for fillers and viscose rayon tow for flock.

A following step was sieving the fibers using agricultural machines normally used to separate grain from stalks etc. Later the flock companies introduced dyeing, and other specific technologies.

Subsequently, several companies producing Flock of these fibres appeared in Switzerland and later in Italy.

We are in the 50‘s and the Flock and Flocking Industry is developing with Cotton Flock and Rayon Viscose, being used to flock paper, fabrics, some plastics and handicrafts. Many investments were done to develop the product

During that period the flocking was obtained by vibration and fulling/batage, on surfaces previously glued with very primary adhesives.

The tests carried out to obtain electrostatic generators, which could create an electric field during the fall of the flock, was really a great step in the development of flocking. On the late 60’s the companies began to study the possibility of making a generator, but the high voltage components were practically non-existent.

Mr. Riccardo Levi (AIGLE) explained to us the difficulties to find solutions during that period:

“I address myself to high voltage transformers on which to build multi-stage multipliers: rectifiers and capaci- tors were needed. The only rectifier available was the 1B3 thermionic  valve  used  in  the  of  the  cathode  ray tubes of primordial black and white televisions. After many tests, I solved the problem by making the coils with insulated cables, further insulated in polyethylene pipes, putting the high voltage apparatus in a Bakeli- te box and drowning everything in melted paraffin. The new electrostatic generator TE1 was sold to Mr. Contu we are on 1970, a craftsman who produced air filters for cars with flocked and pleated metal mesh.”

An Electrostatic Generator Mod. TE1 (Still  working,  owned  by  M/S  Qual- plast)

Other companies also started developing technology for the flock machines application (Eloflock, Arno H. Wirt, Maag Flock, Schnier, etc.). The greatest spread occurred when appearing the roll-to-roll systems as well as the de- velopments of control testing apparatus designed by Mr. U. Maag, which were essential for the normalization, and parametrization of flock charac- teristics.

With these technical developments, electrostatic flocking was already defi- ned and it started to be well known worldwide. In Europe, the flock industry spread rapidly throughout France, Spain, Switzerland, Italy, Germany, the UK, Netherlands and the rest of the countries.

Chronologically, the 1960s saw the beginning of the Polyamide Flock and in the mid-1970s the Polyester Flock started to be produced.

· The development of the Flocking Industry

In summary, 6 major actors are recognized in the flocking industry:

· Fiber Producers

· Flock Manufacturers

· Adhesive manufacturers

· Flocking Plant Builders

· Manufacturer of flocked products and articles

· Flocked products users

It is curious how textile fashion trends have exponentially advanced the use of flocking technology.For  example,  the trend in 1980’s to make stockings with flocked designs (butterflies, fish, polka dots, puppets,  etc)  which made many companies start flocking and buy relevant quantity of flocking machines.

In the USA the general use of flocked blankets also in the 80’s originated the creation of a new type of com- panies and experts in the flocking field.

Example of some 80’s & 90’s Flock applications

Later, flock was introduced in more technical applications such as profiles and glove boxes for the automotive industry and since then a large number of flocking of very specific products, which are well known today.

The extraordinary development of adhesives, based on the various types of resins and compositions, where important chemical companies as Kiwo and CHT among others invested in Flock adhesive technology, as well as the very important progress in flocking facilities, have made possible the progressive increase of the quality level of flocked products.

Later, flock was introduced in more technical applications such as profiles and glove boxes for the automotive industry and since then a large number of flocking of very specific products, which are well known today.

The extraordinary development of adhesives, based on the various types of resins and compositions, where important chemical companies as Kiwo and CHT among others invested in Flock adhesive technology, as well as the very important progress in flocking facilities, have made possible the progressive increase of the quality level of flocked products.

· The awareness & promotion

In the 1970s, in view of the development of the activity in the world of Flock, the meetings of the different protagonists and experts  began in Germany, which led to:

· Symposiums about Flock.

· The creation of the Verband Flock Industry Europe.

· Workshops, Flock School, magazines, Exhibitions, etc.

The Rosenheim Symposium in 1975 with great international attendance was a before and after in the world of Flock. Organized by Joachim Müller, Alma mater, and his team of the early Flock activity, it was a success of participants and presentations.

Photographs from Flock symposium’s and Exhibitions

From then until today, the succession of Symposiums, Workshops, meetings, etc. have greatly advanced the world of Flock, which today is a consolidated and recognized technique in multitudes of industrial activities.

Flock magazines and about Technical Fibres were extremely interesting for the cohesion of the world of the Flock.

Examples of several magazines and documents related with Flock Technical information

We must remember that all the Flock Symposiums have been held in Germany except three:

Saint Petersburg (Russia) – year 1996

In Como (Italy) – year 2013

and the current Symposium 2022 in Barcelona.

In America, the AFA association performs a role similar than the FAoE, but perhaps they have another approach more dynamic and personalized, orientated to the cooperation between companies more than a technical debate. On the other hand, it is rather restrictive in terms of links and approaches with other countries. As a suggestion, we believe it could be and interesting option to start developing FAoE –AFA synergies together.

· Current situation in Europe

Many different  key actors  have  passed during the 75 years of history of the Flock industry in Europe. Manufacturers of fibers, producers of Flock, adhesives, flocked products, etc.

Some of these companies as for example Hug Flock (Switzer- land), Dr. Platte (Germany), CEFSA (Spain), Insodec (France), AlphaFlock  (UK),  Reo  Flock  (Germany),  Le  Flockage  (France), Tinto Flock (Italy), Flock and Fasern (Germany); and others have been left behind. We want to point out that each one had relevant contributions in the world of Flock.

Other companies have overcome all the challenges and they have adapted to the different needs of the mar- ket. Indeed, they are currently the main references in the flocking sector. We must thank all of them their efforts and their hard work to launch this sector and help to lead our current state of the art.

Currently, despite the Covid-19 worldwide crisis, the world of flocking is very active in many areas. We can realize a continuous emergence of new applications and technologies, while more classical applications are disappearing.

Flocking continuous being a very active and creative technology, which provides solutions to multiple technical aspects.

The main difficulty we are facing is the lack of awareness about this technology by the young decision-makers (plastic engineers in automotive industry, packaging & textile designers, product developers in industry, etc).

An adverse publicity,  where some industrial fields see the flocked product as old-fashion and flocking process as difficult, dirty or unsustainable technology, can lead to a loss of business in the flocking sector in the coming years if we do not manage to change this view and approach about flocking products together. Those  of  us present at this symposium have  the responsibility to unify efforts in this area.

Nowadays, flock application is a relevant technology used in the automotive, technical textiles, paper, cosmetics, packaging, decoration, upholstery & medical sectors, but new ideas are ap- pearing every day.

Examples of different Flock applications by Velutex

The introduction of sustainability as a present and future feature enhances the value of recycled polyester, Rayon viscose and cotton fibres, better positioned than conventional polyamide fibres for this approach. Poly- amide fibres that respond to ecological demands will be also broadly available in the market in a short time, together with other new options of materials already under trials.

We must insist on achieving sustainability as a norm that it is an imperative of our time.

It is curious and surprising that the flock had its origin in the use of textile waste, with the objective of not throwing away any material due to an economic need, and now, 75 years later, we are in practically the same situation. Now our planet does not admit more waste.

We have gone from an economic need to an ecological need.

The price issue has also a determining role. Flock powder has become a commodity for most of its standard uses; therefore, its price must be much adjusted to the products and demands. We are convinced that we are witnessing a notable change regarding the different fibres to manufacture flock in order to make the product more competitive for some applications.

Nevertheless, we also want to highlight the importance of maintaining a balance in the economic margins of all the actors in the Flock world.

In this sense, globalization is an opportunity but also a threat. Europe has been from the beginning the magni- ficent engine and the origin of the innovation in the flock industry. It does not make sense to change now our objective to compete with some markets that look only for the cheapest price, without properly considering quality and service. In our opinion, it is not the way to continue and plan the near future. Otherwise, it would be the process towards self-destruction of our European industry.

· 2030‘s Flock Future Perspective

As explained in the previous pages, lately we have experienced a change in the type of queries related to the flock and also in the kind of professionals seeking opportunities in this sector.

From our perspective of flock manufacturer, we can see a continuous emergence of new applications and tech- nologies while applications that are more classical are reducing their consumption due to different reasons, some of them explained by other attendants during this symposium.

We would like to share with you some of the new trends detected in the market in order to work together in the 2030’s Perspectives for Flock.

It is a matter of fact, that companies working on SOUNDPROOFING and NOISE REDUCTION are looking for flocked solutions as an efficient and light weight alternative. Panelling of buildings, electric car interiors & aeronautics are an example about that.

SURFACE protection & haptics have been very well recognized properties of a flocked piece since many years ago. Nowadays, with the exponential incorporation of 3D pieces in different sectors (railway and naval inter- ior design, for example), it is necessary to find a solution to the dull and unpleasant surface of a 3D piece in contact with the final user skin. Flocked pieces are the best solution to that handicap and some builders have already realized this fact. This can be a huge market for flocking companies that can adapt their technology and products.

COVID-19 brought also opportunities to the Medical Flock manufacturers. Flock swabs have been used for fo- rensic uses and sample collection for many years. However, the recent need to take millions of testing samples for COVID-19 detections, has given the opportunity to a wide public (scientists, doctors, pharmacists, etc.) to know that swabs made with polyamide flock lead to an innocuous media that  experience better extractions/

sampling than other materials (ex. cotton swabs). That will bring new opportunities in medical & dental parts and equipment for the coming years.

New characteristics in the new generation of fibres and the resulting flock material with properties such as bacteriostatic, anti-virus, photocatalytic, etc can help in all type of uses where such a property is needed. It is an example the flocked panels in shops, where the flock has an Air-cleaning effect helping on the removal of bacteria/virus within the air of the shop. There are already trials made by an automotive brand in the USA, with such technology in areas with skin contact.

New projects related with shock-impact reduction, sealing force at extreme temperature, vibration dam-

pening, etc are sourced and tried at daily bases and surely new types of products will come to light in the

coming years. Nevertheless, if there is a common thread for all new items are the tags: SUSTAINABILITY, NEW POLYMERS, TECHNICAL TEXTILES.

We do invite the flock-related industry to have solutions for the 2030’s Flocking needs by using recycled and recyclable materials, having biodegradable adhesives and fibres, and launching closing the loop programs in our manufacturing facilities.

· Conclusion

We must recognize that the years 2020 and 2021, with the Covid-19 pandemic economical and social situation, have been very difficult period for the European industry and in particular for the Flock Industry. Despite the complexity to manage the shortage of raw materials, energy, transport difficulties, etc, we are all getting ahead with new projects and new challenges. In any case, we must remember a famous phrase:

"A calm sea has never made good sailors. "

We firmly believe that this year 2022 the situation will normalize. Velutex Flock therefore want to send a message of optimism and hope for our future. We all, as current major players in the European & Worldwide Flock industry would need to learn from our History and try to work closely to develop new products, promote the especial characteristics of the flock and apply flock to the new uses and applications. The European Flock Association and its Associates have been always very important to impulse, promote and give awareness about this niche product and we expect this will continue happening.

Thank you very much.

With this we end this reading. Now as planned in the Symposium program, we are pleased to offer all attendees a dinner to celebrate the 75th anniversary of the founding of our company, Velutex Flock.

· Abstract

· Flock. Our Future has a History.

We will analyse the recent and possibly future applications in the flock industry from a historical perspective. Since the development of an strong flock industry in Europe, starting during the 40’s last century, different major players in France, Spain, Germany, Switzerland,  Italy, UK, etc have strongly impulsed the awareness of technical solutions in sectors such as Automotive, Packaging, Textiles and many new applications in Industry. Research and Development of machinery, fibres, adhesives and also a close cooperation with technological centres and certifying agencies lead to a Golden Age of the Flocking Business at the end of XX Century. During the presentation, we will share some treasured documents from that period.

The European Flock Association and its Associates have been always very important to impulse, promote and give awareness about this niche product. Now, after a Global Pandemic situation that we are still living, new challenges and opportunities in Flocking Business are appearing. We would like to bring an optimistic and futuristic perspective to the attendants to this symposium in order to work together in the 2030’s Future for Flock.

This article is reprinted with permission from the European Flocking Association. Unauthorized secondary distribution is prohibited