Dallas, TX
www.alkegen.com
2024 Nonwovens Sales: $750 million

Key Personnel
John Dandolph, president and chief executive officer

Plants
Rochester, NH; Green Island, NY; Lancaster, PA; Fulton, NY; Hoosick Falls, NY; Beaver Falls, NY; Marshalltown, IA; Altenkirchen, Germany; Heerlen, The Netherlands; North Augusta, SC; Bethune, SC; Rawtenstall, U.K.; Bury U.K.; Stoke-on-Trent, U.K.; Wuxi, China; Yixing, China; Shanghai, China; Quebec, Canada; Fulda, Germany; Meinerzhagen, Germany; Saint Rivalain, France

Brands
AppLY Mat, Biotherm, CRS Wrap, Cryo-Lite, LydAir MG, LydAir MB, LydAir SC, LydAir GP, LyPore Defender, LyPore MB, LyPore SC, LyPore XL, Lytherm, ManniGlas, Select-A-Seal, dBCore, dBLyte, ZeroClearance, Fiberlox, Checkstatic, Microfelt, Pleatlox, Ultratech, Powertech, Powerlox, Microcap, Duotech

Major Markets
Specialty insulation, sealing, high-efficiency air and liquid filtration media and automotive

The latest news from Alkegen, a manufacturer of nonwovens for technical applications, is the full-scale commercial production of its proprietary fiber-enhanced aerogel insulation for electric vehicle (EV) battery fire protection. Announced in June, this  launch strategically expands Alkegen’s product portfolio for the EV market, delivering a comprehensive portfolio of advanced thermal and electrical insulation materials for original equipment manufacturers (OEMs). The addition of aerogels to its offering allows Alkegen to provide OEMs with end-to-end insulation solutions optimized for performance, design flexibility and scalable production.

“We’ve taken a platform that’s already proven itself in the industrial space and scaled it for one of the fastest-growing markets in the world—EV battery safety,” says Alkegen CEO John Dandolph. “Automakers no longer have to rely on a single supplier in North America for this mission-critical solution.”

At the heart of this expansion is AlkeGel, Alkegen’s next-generation, high performance fiber-aerogel composite, engineered to meet OEM demand for ultra-thin, safe and easy-to-install thermal runaway protection for lithium-ion battery systems. Unlike traditional aerogels, AlkeGel is low-dust, eliminating the need for full encapsulation and allowing for simpler and more cost-effective part designs that integrate more easily into space-constrained EV battery packs.

“Automakers need reliable, scalable partners. With AlkeGel, they now have a superior choice,” says Chad Cannan, CTO. “AlkeGel has proven to be significantly less dusty than traditional aerogel insulations—making it easier to convert, safer to handle and more adaptable to complex part geometries.”

This launch came a few months after Jaguar Land Rover (JLR) selected Alkegen’s new range of anti-thermal propagation products to bring the ultimate in thermal protection to its next generation electric vehicles. Alkegen is now playing a vital role in supporting JLR’s design process and assisting in material selection for anti-thermal propagation management within the battery pack.

The new product line introduces a range of flexible advanced solutions that provide multiple levels of protection throughout the battery. The versatility of these products allows for seamless integration into diverse applications within battery design, showcasing its adaptability across different electric vehicle models. Production for the new product line is aligning with the timeline for integration into JLR’s future EV programs.

“We are delighted to partner with JLR in championing its ambitious Reimagine strategy and our shared goal to create a more sustainable world,” says Alkegen’s Battery Group president Gaetan Borgers. “We look forward to collaborating with both JLR and its tiered suppliers to deliver both superior thermal protection and unmatched flexibility to its product design.”

Alkegen has provided thermal management, sustainability and driver safety solutions to major car OEMs for decades. Alkegen continues to build a broad portfolio of battery material technologies to improve lithium-based battery pack safety while helping to extend battery life and accelerate charging time.

In 2023, Alkegen, which was formed a year earlier after Unifrax’s acquisition of Lydall, divested its Thermal Acoustical Solutions (TAS) business unit, which manufactures high-performance acoustical and thermal management insulation components for the automotive and transportation industries. The divestiture aligns with Alkegen’s long-term strategy to advance its growing portfolio of specialty materials dedicated to sustainability and human health.

“This divestiture allows us to focus all of Alkegen’s resources on our primary goal: advancing our unique platform of specialty materials that meaningfully help the world breathe easier, live greener and go further than ever before,” says Dandolph.
The TAS included locations in Hamptonville, NC; Yadkinville, NC; St. Nazaire, France; Meinerzhagen, Germany; and Taicang, China.

After this divestment, the company has continued to focus on its high-performance filtration business. In October 2022, Alkegen increased its total micro-fine glass fiber (MFGF) manufacturing capacity by 30% by adding eight lines in Bahrain and 22 lines to its facility in Summerville, SC. The company also plans to improve its MFGF capacity operations in China, including doubling its current rotary capacity in the region.

Additionally, the company launched a number of new High Efficiency Filtration (HEF) products last year including one for air, one for liquid, one for molecular applications. The launch represented the first wave of advanced materials developed and released under our new Alkegen filtration product development team. Its combine Lydall’s well-known filtration and manufacturing expertise with Unifrax’s proven, rapid innovation capabilities.

Other new products include TriboStatiX, a new air filtration media that is a MERV 13 high-performance pleat media manufactured on a new best-in-class asset, and LyPore, a new line of meltblown liquid filtration media, which is designed to meet the most critical application requirements while providing high filtration efficiency, low-pressure drop and excellent dirt holding capacity.

Prior to being acquired by Unifrx, Lydall had invested approximately $40 million in meltblown nonwoven assets in New Hampshire and France in response to increased demand for face mask material as well as long-term demand for filtration applications.
These lines currently support the wider need for improved air quality beyond Covid-19; the company’s innovation team is focused on developing new carbon-based, high-efficiency media for hospitals, airplanes, restaurants, office buildings and other public spaces.

Plants: Rochester, NH; Green Island, NY; Lancaster, PA; Fulton, NY; Hoosick Falls, NY; Beaver Falls, NY; Marshalltown, IA; Altenkirchen, Germany; Heerlen, The Netherlands; North Augusta, SC; Bethune, SC; Rawtenstall, U.K.; Bury U.K.; Stoke-on-Trent, U.K.; Wuxi, China; Yixing, China; Shanghai, China; Quebec, Canada; Fulda, Germany; Meinerzhagen, Germany; Saint Rivalain, France
Brands: AppLY Mat, Biotherm, CRS Wrap, Cryo-Lite, LydAir MG, LydAir MB, LydAir SC, LydAir GP, LyPore Defender, LyPore MB, LyPore SC, LyPore XL, Lytherm, ManniGlas, Select-A-Seal, dBCore, dBLyte, ZeroClearance, Fiberlox, Checkstatic, Microfelt, Pleatlox, Ultratech, Powertech, Powerlox, Microcap, Duotech
Major Markets: Specialty insulation, sealing, high-efficiency air and liquid filtration media and automotive

Alkegen continues to reinforce its position as the world’s most sought-after specialty materials platform dedicated to sustainability and human health. Its internal sustainability program has been rebranded as SEEDS, which stands for Safety, Environmental, Engagement, Diversity of Social.

One of Alkegen’s key goals in establishing SEEDs was to evaluate its ESG focus to the rigor of its health and safety program by combining ESG pillars with “Safety” in the SEEDS acronym. Alkegen’s safety program has a well-established focus and operational cadence that it is leveraging for ESG oversight and management. Secondly, Alkegen made significant progress in bolstering its supply chain and sustainable procurement policies and practices to integrate ESG requirements.

In 2023, Alkegen divested its Thermal Acoustical Solutions (TAS) business unit, which manufactures high-performance acoustical and thermal management insulation components for the automotive and transportation industries. The divestiture aligns with Alkegen’s long-term strategy to advance its growing portfolio of specialty materials dedicated to sustainability and human health.

“This divestiture allows us to focus all of Alkegen’s resources on our primary goal: advancing our unique platform of specialty materials that meaningfully help the world breathe easier, live greener and go further than ever before,” says John Dandolph, Alkegen’s president and CEO.

Alkegen originally acquired TAS as part of its acquisition of Lydall, Inc. in October 2021. The sale included locations in Hamptonville, NC; Yadkinville, NC; St. Nazaire, France; Meinerzhagen, Germany; and Taicang, China.

Amidst this divestment, the company continues to focus on its high-performance filtration business. In October 2022, Alkegen, announced it would increase its total micro-fine glass fiber (MFGF) manufacturing capacity by 30% by adding eight lines in Bahrain and 22 lines to its facility in Summerville, SC. The company also plans to improve its MFGF capacity operations in China, including doubling its current rotary capacity in the region.

“Our advanced micro-fine glass fibers are critical components in many of the world’s most innovative products, from medical devices to battery packs for electric vehicles,” says Dandolph. “These latest investments reflect Alkegen’s ongoing commitment to our partners in the fiber technology space, increasing supply in anticipation of future demand as we continue to develop compelling new specialty applications for these advanced glass fiber chemistries.”

Additionally, the company launched a number of new High Efficiency Filtration (HEF) products last year. These are the first new filtration products launched under the Alkegen brand name since the merger of Lydall and Unifrax in October 2021.

“This trio of HEF media—one for air, one for liquid, one for molecular applications—represents the first wave of advanced materials developed and released under our new Alkegen filtration product development team. These launches combine Lydall’s well-known filtration and manufacturing expertise with Unifrax’s proven, rapid innovation capabilities,” says Paul Vallis, president of the Filtration & Catalysis Group.

Other new products include TriboStatiX, a new air filtration media that is a MERV 13 high-performance pleat media manufactured on a new best-in-class asset, and LyPore, a new line of meltblown liquid filtration media, which is designed to meet the most critical application requirements while providing high filtration efficiency, low-pressure drop and excellent dirt holding capacity.

Alkegen was formed in 2022 following the combination of two high performance specialty materials companies, Unifrax and Lydall, one of the world’s largest producers for nonwovens for high-performance filtration and acoustical applications, in late 2021. Prior to the acquisition, Unifrax was already a leading global provider of high-performance specialty materials focused on thermal management, specialty filtration, battery materials, emission control and fire protection applications.

In the months leading up to the acquisition, Lydall invested approximately $40 million in meltblown nonwoven assets in response to increased demand for face mask material as well as long-term demand for filtration applications. The company added two meltblown lines in Rochester, NH, and one in Saint-Rivalain, France.

These lines currently support the wider need for improved air quality beyond Covid-19; the company’s innovation team is focused on developing new carbon-based, high-efficiency media for hospitals, airplanes, restaurants, office buildings and other public spaces.

Plants: Rochester, NH; Saint Rivalain, France; Green Island, NY; Lancaster, PA; Fulton, NY; Hoosick Falls, NY; Beaver Falls, NY; Marshalltown, IA; Altenkirchen, Germany; Heerlen, The Netherlands; Hamptonville, NC; Yadkinville, NC; North Augusta, SC; Bethune, SC; Rawtenstall, U.K.; Bury U.K.; Stoke-on-Trent, U.K.; Wuxi, China; Yixing, China; Taicang, China; Shanghai, China; Quebec, Canada; Fulda, Germany; Meinerzhagen, Germany; St. Nazaire, France
Brands: AppLY Mat, Biotherm, CRS Wrap, Cryo-Lite, LydAir MG, LydAir MB, LydAir SC, LydAir GP, LyPore Defender, LyPore MB, LyPore SC, LyPore XL, Lytherm, ManniGlas, Select-A-Seal, dBCore, dBLyte, ZeroClearance, Fiberlox, Checkstatic, Microfelt, Pleatlox, Ultratech, Powertech, Powerlox, Microcap, Duotech
Major Markets: Specialty insulation, sealing, high-efficiency air and liquid filtration media and automotive

Earlier this year, Alkegen announced it would divest its Thermal Acoustical Solutions (TAS) business unit, which manufactures high performance acoustical and thermal management insulation components for the automotive and transportation industries. The divestiture aligns with Alkegen’s long-term strategy to advance its growing portfolio of specialty materials dedicated to sustainability and human health.

“This divestiture allows us to focus all of Alkegen’s resources on our primary goal: advancing our unique platform of specialty materials that meaningfully help the world breathe easier, live greener and go further than ever before,” says John Dandolph, Alkegen’s president and CEO. “We’re excited for the future and the new opportunities this creates for both Alkegen and the TAS business as it moves forward with Regent.”

Alkegen originally acquired TAS as part of its acquisition of Lydall, Inc. in October 2021. The sale includes locations in Hamptonville, NC; Yadkinville, NC; St. Nazaire, France; Meinerzhagen, Germany; and Taicang, China.

Amidst this divestment, the company continues to focus on its high performance filtration business. In October 2022, Alkegen, announced it would increase its total micro-fine glass fiber (MFGF) manufacturing capacity by 30% by adding eight lines in Bahrain and 22 lines to its facility in Summerville, SC. The company also plans to improve its MFGF capacity operations in China, including doubling its current rotary capacity in the region.

“Our advanced micro-fine glass fibers are critical components in many of the world’s most innovative products, from medical devices to battery packs for electric vehicles,” says Dandolph. “These latest investments reflect Alkegen’s ongoing commitment to our partners in the fiber technology space, increasing supply in anticipation of future demand as we continue to develop compelling new specialty applications for these advanced glass fiber chemistries.”

“Our MFGF expansion in Bahrain, Summerville, SC and Songyuan, China, keeps Alkegen positioned globally as the best option for customers that value quality and security of supply,” says Chris McPhillips, general manager of MFGF, Alkegen. “The addition of over 30 manufacturing lines will not only help alleviate some of the supply chain strains we’ve seen over the first half of the year, they will ensure that Alkegen continues to address growing demand for MFGF in rapidly-growing industry sectors like batteries, high end air and liquid filtration, and medical testing Medim.”

Additionally, the company launched a number of new High Efficiency Filtration (HEF) products its last year. These are the first new filtration products launched under the Alkegen brand name since the merger of Lydall and Unifrax in October 2021.

“This trio of HEF media—one for air, one for liquid, one for molecular applications—represents the first wave of advanced materials developed and released under our new Alkegen filtration product development team. These launches combine Lydall’s well-known filtration and manufacturing expertise with Unifrax’s proven, rapid innovation capabilities,” says Paul Vallis, president of the Filtration & Catalysis Group. “This is the first of many innovations we expect to deliver as our portfolio evolves to meet the continuous demand for ever-higher efficiency and reduced energy consumption.”

TriboStatiX is the brand name for Alkegen’s new air filtration media that is a MERV 13 high performance pleat media manufactured on a new best-in-class asset. The media provides lower initial resistance, reducing the amount of energy required in the HVAC unit and lowering overall operating costs. TriboStatiX improves indoor air quality through consistent filtration performance and high dirt holding capacity, providing longer service life and reduced energy demand.

Meanwhile, LyPore is Alkegen’s new line of meltblown liquid filtration media, which is designed to meet the most critical application requirements, while providing high filtration efficiency, low-pressure drop and excellent dirt holding capacity. Alkegen’s new molecular filtration media, LydAir GP, offer superior performance with expanded capabilities. State-of-the-art manufacturing facilitates exceptional uniformity and layering of a wide range of functional adsorbents including activated carbon and ion exchange resins. Additionally particulate filter media can be laminated in line providing a combination media for both molecular and particle filtration. LydAir GP offers 20%-30% better performance per specific gram of media, which results in higher efficiency and product performance that can be engineered to meet specific application demands.

Alkegen was formed in 2022 following the combination of two high performance specialty materials companies, Unifrax and Lydall, one of the world’s largest producers for nonwovens for high performance filtration and acoustical applications, in late 2021. Prior to the acquisition, Unifrax was already a leading global provider of high-performance specialty materials focused on thermal management, specialty filtration, battery materials, emission control and fire protection applications.

In the months leading up to the acquisition, Lydall invested approximately $40 million in meltblown nonwoven assets in response to increased demand for face mask material as well as long-term demand for filtration applications. The company added two meltblown lines in Rochester, NH, and one in Saint-Rivalain, France.

These lines currently support the wider need for improved air quality beyond Covid-19, the company’s innovation team is focused on developing new carbon-based, high-efficiency media for hospitals, airplanes, restaurants, office buildings and other public spaces.

Plants: Rochester, NH; Saint Rivalain, France; Green Island, NY; Lancaster, PA; Fulton, NY; Hoosick Falls, NY; Beaver Falls, NY; Marshalltown, IA; Altenkirchen, Germany; Heerlen, The Netherlands; Hamptonville, NC; Yadkinville, NC; North Augusta, SC; Bethune, SC; Rawtenstall, U.K.; Bury U.K.; Stoke-on-Trent, U.K.; Wuxi, China; Yixing, China; Taicang, China; Shanghai, China; Quebec, Canada; Fulda, Germany; Meinerzhagen, Germany; St. Nazaire, France
Brands: AppLY Mat, Biotherm, CRS Wrap, Cryo-Lite, LydAir MG, LydAir MB, LydAir SC, LydAir GP, LyPore Defender, LyPore MB, LyPore SC, LyPore XL, Lytherm, ManniGlas, Select-A-Seal, dBCore, dBLyte, ZeroClearance, Fiberlox, Checkstatic, Microfelt, Pleatlox, Ultratech, Powertech, Powerlox, Microcap, Duotech
Major Markets: Specialty insulation, sealing, high-efficiency air and liquid filtration media and automotive

Combining the businesses of two high performance specialty material specialists—Unifrax and Lydall, Alkegen announced its new corporate name in January 2022 to better reflect the scope of the newly merged companies. Based in Dallas, TX, Alkegen brings together two of the world’s leading specialty materials platforms and represents a new chapter for a unified, innovation-driven company.

Alkegen is well positioned to be the specialty materials leader serving mission-critical systems that the world is focused on for the future, including battery technologies, electric vehicles, filtration media, and specialty insulation materials that enable customers to reduce fossil fuel consumption, save energy and live greener.

The name Alkegen is a modern adaptation of two words that are central to the company’s identity and mission. “Alke” is derived from the word “Alchemy,” which evokes transformational innovation and breakthroughs in what is possible. “Gen” is a shortened form of “Next Generation” and speaks to Alkegen’s focus on human health and a sustainable future. The green Alkegen “arc” in the logo represents collaboration, connectivity and a horizon signifying the global nature of the company and its constant innovation and forward progress.

John Dandolph, president and chief executive officer of Alkegen, explains, “Our new name helps define this global platform with differentiated, sustainability-focused advanced materials. Customers will come to know Alkegen as a brand that helps the planet breathe easier, live greener and go further than ever before. Alkegen is an exceptional specialty materials platform that we believe is unrivaled in the world today.”

The company formerly known as Unifrax purchased Lydall, one of the world’s largest producers of nonwovens for high performance filtration and acoustical applications, in late 2021. Prior to the acquisition, Unifrax was already a leading global provider of high-performance specialty materials focused on thermal management, specialty filtration, battery materials, emission control and fire protection applications backed by Clearlake Capital Group. Lydall reportedly caught Unifrax’s attention because it is well positioned to capitalize on growth in clean air filtration and electric vehicle adoption, among many other attractive markets.

In the months leading up to the acquisition, Lydall invested approximately $40 million in meltblown nonwoven assets in response to increased demand for face mask material as well as long-term demand for filtration applications. The company added two meltblown lines in Rochester, NH, and one in Saint-Rivalain, France.

The installation of these two new production lines made Alkegen’s New Hampshire facility the largest site for meltblown filtration media production in the U.S. and a center of excellence for advanced filtration media innovation. To support the wider need for improved air quality beyond Covid-19, the company’s innovation team is focused on developing new carbon-based, high-efficiency media for MERV-, HEPA- and ULPA-grade filters for hospitals, airplanes, restaurants, office buildings and other public spaces.

In June 2022, Alkegen made another significant acquisition, obtaining a controlling ownership interest in Luyang Energy-Saving Materials Co. Ltd., a Chinese producer of energy-saving materials in the fields of ceramic fibers, soluble fibers, alumina fibers and other high temperature insulating materials. The company has partnered with Alkegen since 2015.

Last month, Alkegen announced it would add 30 micro-fine glass fiber lines to support growing battery and filtration demand worldwide. The investments will increase its total micro-fine glass fiber (MFGF) manufacturing capacity by 30%.

“Our advanced micro-fine glass fibers are critical components in many of the world’s most innovative products, from medical devices to battery packs for electric vehicles,” says Dandolph. “These latest investments reflect Alkegen’s ongoing commitment to our partners in the fiber technology space, increasing supply in anticipation of future demand as we continue to develop compelling new specialty applications for these advanced glass fiber chemistries.”

Alkegen plans to accelerate enhanced MFGF capacity by adding a total of eight manufacturing lines in its facility in Bahrain and 22 lines to its U.S.-based facility located in Summerville, SC. The company also plans to expand and improve MFGF capacity and operations in China, including doubling its current rotary capacity in the region