Known for their durability, versatility and cost-effectiveness, needlepunch nonwovens have become an essential material in products for a wide range of industries. One of the key advantages needlepunching has over other technologies is its wide range of uses—from filtration and construction materials to automotive and hygiene applications. As demand for sustainable and high-performance materials continues to grow, manufacturers are also exploring innovative ways to optimize production processes and minimize environmental impact. 

According to Phil Mango, nonwovens consultant, Smithers, automotive, filtration and geotextiles are major applications for needlepunch, although there are several other end uses. “Historically, needlepunch has had lower throughput and been restricted to heavier weight (>70-80 gsm) nonwovens,” he says. “Newer process equipment now is targeting faster lines and lower-base-weight products. While the end-use markets may stay the same, lighter-weight sub-segments are now available to needlepunch.”

Even though investment has slowed recently due to economic issues globally, Mango says investment in faster, wider (lower production cost) lines has increased.

In October, Bondex announced a major investment in its Trenton, SC, facility, with the installation of a new needlepunch line and expanded production capacity. This enhancement will allow the company to better serve the growing demand for U.S.-made products across sectors such as filtration, automotive, laundry felts, and other emerging markets.

The new needlepunch line, supplied by DiloGroup of Germany, enables Bondex to produce nonwovens over 4.5 meters wide, including scrim-supported and fiber-supported materials ideal for filtration and composite structures. 

Bondex president Brian Little says the investment in the new line was driven by a strategic commitment to innovation, market demand and expanding the company’s capabilities to better serve its customers. “As highlighted in our recent expansion announcement, we are focused on strengthening our position in the high-performance nonwovens sector,” he explains. “The growing need for advanced materials, coupled with increasing demand for domestic production, made this investment a logical next step. Additionally, our customers are seeking customized solutions with enhanced durability, functionality and sustainability—areas where our technology and expertise give us a distinct advantage.”

This expansion significantly enhances Bondex’s production capabilities by incorporating state-of-the-art needlepunch technology that allows for greater precision, consistency and efficiency. It also provides increased flexibility in fiber selection and processing, which means Bondex can better serve a broader range of industries, from industrial filtration to advanced composites. “Ultimately, this investment strengthens our ability to meet customer needs with shorter lead times and higher quality standards,” he says.

Several factors are fueling the demand for U.S.-made needlepunch products. “Supply chain disruptions over the past few years have highlighted the importance of reliable, domestic manufacturing,” Little says. “Customers are looking for suppliers who can offer stability, reduced lead times and consistent quality—all of which Bondex is committed to providing. Additionally, there’s a strong push toward sustainability and compliance with U.S. manufacturing standards, which align with our commitment to responsible production practices. Our domestic capabilities allow us to respond quickly to market needs while ensuring the highest level of technical support and innovation for our customers.”

As Bondex moves forward with its U.S. production expansion, Freudenberg Performance Materials is also strengthening its position in the North American market. The company is expanding its production capacity in the U.S. this year to better serve the local market, although specific details on the expansion plans and timeline have not yet been disclosed.

A significant trend in the industry is the growing demand for sustainable products, particularly those made from recycled materials or designed to be easily recyclable at the end of their lifecycle. According to Anže Manfreda, SVP of the Automotive & Condensation Solutions Division at Freudenberg, more and more customers are requiring Environmental Product Declarations (EPD) and similar certifications. However, he points out that the availability of high-quality recycled fiber is under pressure due to demand from other industries.

Freudenberg’s needlepunch products primarily serve the automotive, construction and filtration markets. These sectors have experienced distinct market cycles recently. “The automotive segment is in decline as vehicle production in Europe has fallen from its pre-Covid peak, and the company’s business is following this trend,” says Manfreda.

On the other hand, some markets are relatively stable, although affected by overcapacity and high energy prices in Europe. The filter media market is also down from its pre-Covid peak, but stable, he adds.

In Europe, two key challenges stand out: the shortage of skilled labor and high energy costs. The way forward is further automation and digitalization and better use of big data to optimize all aspects of the operating processes, he explains. “The needlepunch market should continue to grow—despite the current volatile situation—if we are able to effectively respond to increasing sustainability challenges.”

Meanwhile, new needlepunch lines are being commissioned in Italy and Belgium. In Italy, O.R.V. Manufacturing S.p.A. is set to add a large needlepunched and thermobonded polyester media line, supplied by Trützschler Nonwovens and Texnology S.r.l. The collaboration among these family-owned companies aims to establish one of Europe’s largest multi-purpose production lines. For over 75 years, O.R.V. Manufacturing has been producing nonwoven products for various applications, including clothing, furnishings, coating supports, filtration, thermal-acoustic insulations and a variety of different products for the automotive sector.

“With Trützschler Nonwovens and Texnology, we are pleased to have found two partners with whom we can realize this major project based on the shared values of a family-owned business,” says Gabriele Zanella, CEO of O.R.V. Manufacturing.

In Belgium, Sioen Technical Felts is expanding its production capabilities with a complete needlepunch line at its Liège facility. The Andritz-supplied equipment will allow Sioen to produce fabrics of more than 3500 gsm in a single step, using different types of fibers (recycled PET, OxPan, bicomponent) and finenesses. Normally two or three layers have to be needled off-line in a second step to achieve such a fabric weight. The single-step process results in a higher quality end product by minimizing the risk of delamination, i.e. the separation of layers during use. It also increases productivity by reducing the need for fabric handling.  

Autefa Solutions Focuses on Sustainability

According to André Imhof, CEO of Autefa Solutions Austria, card-crosslapped needlepunch lines remain the most widely used and popular process for nonwovens worldwide.

The main growth markets for needlepunch machines are currently the filter market, the geotextile sector, recycling and sustainability, he says. The filter market is showing the first signs of recovery, indicating an increasing demand for high-performance and efficient filtration solutions. The geotextile market remains stable and in high demand, driven by its essential role in construction and infrastructure projects. With its durability and strength, geotextile continues to be a key material, especially as emerging markets expand with new roads and buildings. In addition, the agricultural sector continues to grow, further boosting demand for geotextile products. “It is fair to say that the broad application base and relatively low investment costs make needlepunching technology attractive to customers,” says Imhof.

One of the major growth drivers for needlepunch is recycling and sustainability. “The ability to process a wide range of fibers without the addition of binding fibers is a key advantage of needlepunching machines and supports the industry’s shift to more environmentally friendly production methods,” he says. “The automotive industry is also increasingly adapting to sustainable concepts. The focus is shifting to the use of recycled filling materials that can be needlepunched into a sandwich structure between two layers. This development shows that the needlepunched nonwovens market will benefit in the long term from the growing importance of sustainable production processes.”

Autefa Solutions has a deep history in the industry, incorporating the expertise of the former Autefa in Friedberg, Bavaria, Germany, Fehrer in Linz, Austria, FOR and OCTIR in Biella, Italy, and Strahm Hi-Tex in Switzerland.

Autefa’s Stylus NL and Stylus Variliptic high-performance needlepunch machines are characterized by their exceptionally long service life and high precision. Meanwhile, Fehrer needlepunch machines are widely used throughout the world and enjoy an excellent reputation for reliability and performance, Imhof says.

While many companies are still reluctant to invest in full production lines or completely new equipment due to economic conditions or low demand, he says upgrades and retrofits remain very popular. “Our customers are increasingly investing in upgrades and retrofits, including electrical, software and mechanical enhancements, to keep their machines up to date.”

For older machines, the company launched the Autefa Classic Club, which is aimed at companies that have been using Fehrer needlepunch machines for 20, 30 or 40 years. “We offer machine-specific upgrades, retrofits and spare parts to extend the life and efficiency of these machines. The trend towards machine modernization continues to grow,” Imhof says.

As customers inquire about sustainable production processes, Autefa can provide complete needlepunch lines, including airlay machines, which enable the processing of pure fiber blends without the need for binding fibers. “The industry is increasingly moving towards greater recyclability and away from thermobonding with binder fibers, reinforcing the need for environmentally friendly and flexible production solutions,” he states.

One of the biggest challenges in the needlepunch market is the increasing competition from low-cost machines, which has intensified the competitive landscape. “While these machines may seem attractive at first glance, they cannot match the performance, durability and quality of high-end solutions,” Imhof says.

Another crucial factor is the shift in material usage. The industry is moving away from plastic towards recyclable alternatives, which is changing the requirements for production processes and machine concepts. “It is also essential to demonstrate to customers that replacing old machines is not just a cost factor but a strategic investment in quality,” he says. “Continuous improvement of production equipment is the key to maintaining market competitiveness in the long term.”

Trützschler Nonwovens Offers Flexibility

From machinery specialist Trützschler Nonwovens’ point of view, the current state of the needlepunch market reflects the broader global uncertainty. “Many manufacturers are postponing investment decisions, carefully evaluating future-proof technologies, and designing complex production lines to stay ahead of market trends,” says Jutta Stehr, head of marketing, Trützschler Nonwovens. “However, there are regions and applications showing a more optimistic outlook.”

In the coming years, the company expects technical textiles to remain a growth market. “Needlepunched nonwovens play a key role in producing geotextiles, automotive textiles and diverse filter media. Additionally, specialized applications—where nonwovens replace conventional materials—are driving above-average growth rates,” she adds.

According to the company, needlepunched nonwovens are currently in high demand in various industry sectors. GDP growth, industrial growth and ongoing regulations are all drivers for technical nonwovens growth.

Sustainability is a major driver in various markets. “As industries seek environmentally friendly alternatives, technical textiles are gaining traction due to their efficiency and adaptability,” says Stehr.

Trützschler also sees strong regional growth opportunities. “With trade barriers and tariffs becoming more influential, we expect nonwovens manufacturers are expanding internationally to stay close to their customers. This is also fostering the development of regional nonwoven industries, as high import duties influence ‘make or buy’ decisions,” she explains.

Currently, the aftermarket segment is more active than new machinery investments. Many producers are delaying large-scale projects until economic uncertainties stabilize and investment conditions improve. Since existing lines are running at full capacity, manufacturers are increasingly requesting spare parts, service contracts and solutions to extend machine uptime and expand production capacity.

“Looking ahead, we see a strong trend toward flexible production lines,” says Stehr. “A broad product window allows manufacturers to quickly respond to new market demands. As product diversity increases and batch sizes decrease, flexibility becomes a key competitive advantage. The ability to rapidly switch production settings is crucial for success in this evolving market.”

A key innovation from Trützschler is the X-Series with the NC-X and NCT-X nonwoven cards, which significantly improve accessibility and raw material efficiency compared to their predecessors. The carding and web-forming sections are divided into smaller units mounted on rails, allowing a single operator to separate them for easy access across the entire working width. This reduces daily cleaning time by up to 20 minutes, enabling over 100 additional operating hours annually.

Another feature is the edge suction system on the doffer, which recycles fibers from the web edges back into the process, reducing fiber consumption by up to 2.5% while maintaining quality.

For lightweight nonwovens, such as hygiene top sheets or automotive textiles, the NC-X offers a 5+5 worker/stripper configuration, enhancing carding and blending performance through an expanded carding area.

“Our recipe for modern needlepunching systems combines flexible production line concepts with efficient, highly configurable machines,” says Stehr. “Since the end product determines the system configuration, we deliberately avoid standard setups. Together with our customers and partners, such as Texnology srl for the needlepunching section, we develop tailored solutions that perfectly reflect the product, customer circumstances and specific requirements.”

DiloGroup Remains Optimistic

German machinery expert DiloGroup is seeing nonwoven producers continue to invest in new machinery and upgrades to enhance their production processes, although the pace has slowed due to some unfavorable political conditions and the ongoing war in Ukraine. These investments are aimed at improving efficiency, product quality and sustainability, with a focus on reducing downtime and simplifying cleaning processes, according to Johann Philipp Dilo, CEO of Dilo. The company is also seeing more decisions to completely retrofit older machines or production lines to modernize the degree of automation and effective operation.

The largest sectors driving demand for needlepunched nonwovens include automotive linings, such as technical felts for noise and thermal insulation and protection. Other key sectors are geotextiles, upholstery, mattress and bedding felts, floor and wall coverings, office partitions, roofing, synthetic leather, filtration (both wet and dry), industrial and household wipes, and technical felts with various specialties. These sectors represent some of the larger markets for needlepunched nonwovens, Dilo says.

Factors contributing to further growth are largely tied to ongoing innovations in needled nonwoven technologies. “Here, we see a great potential for needled light weights below 100 g/sqm for many sectors like hygiene, medical, cosmetical as well as shoe and garment linings,” he adds.

At the same time, other contributing factors to growth include the low energy consumption of the needling process, excellent recyclability, high-speed needling and effective use of raw materials, the degree of automation of the process and the high numbers of throughput rate and the versatility in hundreds of specific segments. This includes fine to coarse fiber, low weights to very high weights and lately, additive manufacturing by adding additional fiber mass at controlled areas which contributes to the reduction of the overall mass and fiber consumption. “All these factors together create a long-term growth potential,” Dilo explains.

In addition to continuous improvements in speed, recent innovations from Dilo have allowed the company to improve the CV value, reduce fiber consumption and lower energy consumption for the production of lightweight nonwovens.

Specifically, this involves the IsoFeed system which can be installed after the feeder and can target thin spots in the fiber mat with an additional measuring system, resulting in an improved CV value of approximately 5%. Additionally, the 3D Lofter can be used to spread additional fiber material before needling, to apply fibers to deep-drawing parts, helping to prevent thin spots in areas of strain concentration.

In the area of energy savings, with MicroPunch, Dilo can produce lightweight nonwovens, saving approximately 75% of energy compared to conventional production methods for lightweight materials. No water and gas are required and at the same time, there is less fiber loss.

Andritz: Navigating Economic Uncertainty with Innovation

Guillaume Julien, global sales director Engineered Textile – Airlay, Needlepunch & Bast Fibers at machinery specialist Andritz, highlights the versatility of needlepunch technology across a wide range of sectors, including geotextiles, flooring, automotive, filtration, synthetic leather, roofing, insulation, sound absorption, bedding, aircraft carbon brakes and ceramics, in addition to numerous niche markets. “This variety of applications and markets always offers different dynamics from one period to the next, each segment having its own distinct cycle,” he explains. “Global economic peaks and troughs as a machine manufacturer or roll-good producer are thus very much balanced when compared to single-segment industry players, resulting in less barriers to investment because of a lower risk approach.”

Despite global uncertainties, Julien notes that needlepunch saw rapid recovery in Northern America, Europe and Asia after the initial slowdown in 2020, just after the Covid outbreak, with growth continuing through Q3 2023. However, 2024 presented challenges, mainly in comparison to previous extremely good years in the needlepunch market, due to factors like economic uncertainty and geopolitical tensions, including the war in Ukraine, and the consequent lower number of investment decisions due to raw material inflation in Western countries, as well as global elections.

“It is interesting to note that from a long-term equipment manufacturer perspective, we often noticed that end-users who invested at a rather uncertain time usually gained a competitive edge over rivals in the end,” Julien says.

Looking forward, Andritz remains optimistic, expecting positive trends in 2025, and believes the global market should keep growing in the years to come, whether in terms of additional capacity from new complete lines or existing line improvements via single equipment sales. Anticipating continuous growth in the years to come, in June 2024, Andritz decided to build and inaugurate a new 2,000-square-meter needlelooms’ workshop in Elbeuf, France, to increase its production capacity to ensure timely deliveries in peak periods.

In addition to well-known Western markets, growth is anticipated in regions like the Middle East, Central Asia and the Far East, with Andritz’s hubs in France, India and China supporting local demand. The Russian market, for which Andritz had a predominant position for needlepunch until the conflict with Ukraine started in 2022, is still inaccessible due to sanctions linked to the situation, Julien explains.

From one market to the next, needlepunch demand is seen as very heterogeneous, he points out. Andritz is now able to demonstrate the needlepunch process for solutions ranging from light weights (from 30 gsm) up to heavy weights (4,200 gsm), expanding the range of action for needlepunch applications when compared to the (recent) past.

Geotextiles continue to be a major driver, fueled by global infrastructure demands and GDP growth. Andritz’s ProWin patented technology for web weight regulation is a key asset that enables end-users to enjoy lower ownership costs, thus enhancing their long-term market competitiveness.

Although the automotive market is not at its peak for several reasons, which vary from one geographical area to the other, Julien says new capacities are being installed by Andritz each year, particularly in wheel arch-liners in the U.S. and visual surface aspect nonwovens in Europe thanks to the ongoing development of needle patterns for aesthetics. Needlepunch for airlay production, which is also one of Andritz’s web forming technologies, linked to sound absorption and insulation, is also significant. Moreover, velour needlelooms for the automotive and shoe industries complete the picture, notably with strong demand from Asia.


Andritz also sees strong demand in Asia for filtration, synthetic leather and stitch-bonding, with significant market activity expected in 2025. The upcoming ITMA Asia and SINCE fairs in 2025 are expected to further stimulate regional projects for 2026, he says.

The processing of natural and mineral fibers, as well as recycled (shoddy) fibers, is increasingly attracting interest from the needlepunch market, with more mature volumes thus requiring more sophisticated needlepunch lines, which include dedusting and wiring cleaning systems. “This allows maintenance time to be minimized and the final quality of needlepunch products to be optimized,” Julien says. “Andritz can then process 100% recycled fibers in its needlepunch solutions, supporting eco-friendly production without compromising quality.”

In terms of innovation, Andritz’s ProWin system represents a significant advancement in web weight evenness control combining the company’s technologies for optimal fiber weight profiling and enhancing production efficiency. One of its key advantages is its ability to optimize CV% figures, leading to raw material savings of up to 7% annually, delivering a rapid return on investment.

Beyond material savings, ProWin integrates an Autopilot assistant, minimizing the level of instantaneous acceleration, resulting in the same battforming equipment being able to run faster with less mechanical stress (and a more optimized product regularity). “This leads to smart parameter controls, as the line settings for battforming parameters will be self-adjusting, and production quality will be optimized and less dependent on operator qualification,” Julien says.