京都パイル繊維工業 Product Lineup

When using a sheet with flocking, air can get trapped between the sheet and the surface during application, leading to bubbles and wrinkles that detract from its appearance. This issue can be resolved if the sheet is made from a material that allows air to pass through, but the process of applying the binder (adhesive) to the sheet tends to block the air passage holes. As a temporary measure, we had been making small holes with a needle in the sheet after flocking, but this did not achieve 100% customer satisfaction. Therefore, we improved the binder to ensure that the sheet's inherent breathability is not compromised. After two years of development, we successfully created a binder that maintains breathability even after it has cured! Since using this binder for flocking, we have received positive feedback from customers stating that no bubbles have formed.

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Sometimes, we receive requests asking, "Is there a way to add some variation or movement, as just doing a regular flocking is not interesting enough?" By using our custom processing equipment, we can apply pressure to the pile after flocking to flatten it, allowing us to create changes on the surface. Additionally, using glossy piles or piles with a triangular cross-section can alter the appearance. Moreover, there are various ways to create changes, not just by flattening the pile, but also through processes like rubbing, washing, and tumbling. By combining these methods, we can achieve a variety of expressions and textures.

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The request was for "flocking on fabric for bottoms," so naturally, we had to ensure strength against wear and tear. However, since the fabric was made of cotton, which easily absorbs moisture, even when applying the binder (adhesive), the fabric quickly soaked it up, making it difficult to achieve the necessary adhesion strength during the flocking process. The client is a well-known brand in America, and while confirming the strength they required, we conducted multiple developments and tests of the binder (adhesive). During the dyeing process after flocking, we faced various issues such as shedding of the flocked pile, dye unevenness, and fabric shrinkage, but we resolved each one and successfully commercialized the product after six months! The client's product has become a tremendous hit, and they were very pleased.

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I received a request to use flocking on the belt part of women's lingerie bras to make it softer to the touch. Typically, binders (adhesives) contain formaldehyde, but since this would be used on parts that come into direct contact with the skin, it was necessary to reduce the content to less than one-tenth for safety reasons. Therefore, I started the development of the binder. This job was a request from the United States, so to carefully assess the impact on the skin, I conducted a patch test on 100 individuals in the U.S. (applying small pieces to the skin for a certain period to investigate any effects). I often thought along the way that it might not work out as I hoped, as the results were not coming as expected. However, by continuing to challenge myself without giving up, I was able to confirm safety successfully, and in the end, I received the official order contract! This was a significant project that took a year and a half from the initial request to the final order. Due to the many difficulties, I was able to build a very deep trust relationship with the dyeing factories, trading companies, and buyers involved in this work.

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We received an inquiry from a sportswear manufacturer who wanted to create golf apparel using flocking. At that time, there was almost no track record of flocking on sportswear. Therefore, we started by discussing the types and colors of the pile and began by creating test samples. However, since this was our first attempt, significant issues arose with the initial test samples. The fabric was made of nylon, which is typical for sportswear and has a smooth surface, causing the attached pile to easily detach. It was at a level that could not be commercialized, and the customer suggested, "Shall we give up this time?" but I requested another chance to try again. Our laboratory staff and production manager worked on enhancing the adhesion strength. We tested various types of binders (adhesives) with different adhesion strengths and paid attention to viscosity to ensure that the fabric did not become stiff and uncomfortable during intense movement. As a result, we were able to achieve the durability that met the customer's requirements! The customer was pleased, and subsequently, we received repeat orders for the product.

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Our company mainly manufactures short fibers called "pile," using primary raw materials such as rayon, nylon, polyester, acrylic, and cotton. The length of the fibers can be adjusted in 0.1mm increments, such as 0.6mm or 1.5mm. We also offer a wide variety of color samples for dyeing. We accurately cut thin threads made of nylon and rayon into short lengths, dye them, process them into pile, and deliver them in bags. 【Manufacturing Process】 1. Raw yarn 2. Cutting 3. Dyeing 4. Drying 5. Sorting 6. Product shipment *For more details, please download the PDF or feel free to contact us.

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We offer a "flocking process" where we apply adhesive (binder) to the fabric entrusted to us by our customers, sandwich it between a pile supply machine and electrodes, and utilize static attraction to implant the pile vertically. Taking into account the fabric's characteristics such as elasticity and water repellency, we work closely with our customers in advance to create solutions that enhance patterns and designs to meet their requests. Please feel free to consult us if you have any inquiries. 【Applications】 ■ Clothing ■ Kotatsu covers ■ Mahjong tables ■ Inner lining of lenses *For more details, please download the PDF or feel free to contact us.

• Processing Contract
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