Hazle Township, Pa.—Forbo Flooring Systems held a ribbon-cutting ceremony here as it officially opened its first U.S.- based Flotex production facility.
Top executives from Europe joined the staff and sales team from North America to commemorate the launch of a facility that features digital print technology, with the goal of achieving expanded design capabilities, enhanced service levels and fast delivery times to its North American customers.
Forbo executives say the Flotex high-performance carpet is engineered to outperform traditional carpet with a unique, high-density flocked construction, providing healthy, cleanable, durable carpet with limitless design possibilities.
“Manufacturing can be a doubled-edge sword,” said Denny Darragh, vice president of Forbo’s North American operations. “Manufacturing brings incredible flexibility to the market, and it brings a cost and a commitment that has to be fulfilled; that’s our challenge. We’re taking on the future together.”
Just as he was about to cut the ribbon, Darragh told the audience, “We’re here to win; let the games begin.”
In its infancy Flotex will operate one eight-hour shift. Over time, the company said it expects to run round-the-clock with three shifts. “At full capacity, we will add roughly 50 jobs to the area in manufacturing and the support functions that go with manufacturing,” Darragh said. “I’m looking forward to being part of the solution to bring better-quality jobs to the area.”
Joining Darragh for the ceremony were dignitaries from corporate headquarters in Europe, including Johannes Huber, CEO, and Jean-Michel Wins, executive vice president, flooring systems.
“This is the first Forbo factory built outside of Europe, so that’s a really big thing,” Huber told the assembled Forbo team of roughly 100 people. “We want to build a company with long-term, sustainable growth based on innovation, a strong culture and people development. We want Flotex to be the benchmark.”
Wins added, “Until today we only had factories in Europe. Today is just the beginning of the story of being a significant presence in the U.S. market.”
Wins noted Flotex fits in well with Forbo’s unique approach to the market. “Forbo is good at selling niche, and Flotex is a niche product,” he said. “I don’t mind saying that because it takes special skill sets to do niche.”
Flotex comprises a solid vinyl reinforced base with a densely flocked surface of nylon 6.6 fibers that are anchored firmly into the base layer. The product is dimensionally stable and has the optics of a textile floor covering while being as functional, durable and easy to clean as resilient flooring. Moreover, the nylon fibers not only perform in sound absorption and comfort, they also capture allergens and fine dust from the air—all of which is released in any cleaning action in both dry and wet conditions. Through its construction Flotex is protected against mold and odors while keeping its appearance as the floor restores to mint condition after every cleaning action, the company said.
Flotex is printed, backed, cut and packaged in the U.S. Flotex Modular lines qualify for the Buy American Act and Build America, Buy America (BABA) Act.
Key elements of the production facility:
• The digital printer uses five colors but is designed with six color stations to allow for ink development trials without affecting production quality.
• A chemical reaction occurs between the pre-treatment formula, the ink and the nylon to ensure full penetration of the fiber. A solution is prepared offline and transferred to the print line.
•All water processed during printing is collected and treated to remove all chemicals, particulates and color before being released back to the township.
