FREQUENTLY ASKED QUESTIONS
AIRLAID & NONWOVEN MANUFACTURING
Custom nonwoven manufacturing is the process of producing engineered fiber materials to meet specific product applications, performance targets, and dimensional requirements rather than relying on an off-the-shelf material.
Green Fox Manufacturing uses airlay technology to form natural, cellulose-based, and other compatible fibers into nonwoven mats, pads, panels, and other custom formats. In the airlay process, fibers are dispersed in a controlled airstream, deposited into a uniform web, and consolidated through an appropriate bonding method to create the finished material.
Depending on the application, materials can tailored around fiber type, fiber blend, basis weight, thickness, density, strength, loft, stiffness, surface characteristics, and finished dimensions.
Airlaid nonwoven manufacturing is a process that uses airflow to distribute fibers into a uniform web, which is then formed into a finished nonwoven material. Unlike traditional textile manufacturing, airlaid technology can process a wide range of natural, cellulose, and recycled fibers into products like mats, pads, and panels.
Green Fox Manufacturing uses Cormatex airlaid technology to process hemp, flax, cellulose, cotton, wood fiber, and custom fiber blends. This flexible process allows us to develop nonwoven materials around application specific requirements such as fiber blend, basis weight, thickness, density, strength, stiffness, and finished dimensions.
Green Fox Manufacturing works with natural fibers like hemp and flax as well as cellulose, cotton, wood fiber, recycled fibers, and custom fiber blends. Our team can help evaluate different fiber combinations to determine the best fit for your application.
Airlaid nonwoven manufacturing offers flexibility in how fibers are combined and formed into finished products. Depending on the application and material formulation, airlaid nonwoven materials can be engineered for specific fiber blend, basis weight, thickness, density, strength, loft, stiffness, and other performance requirements. The process can also accommodate a broad range of natural, cellulose, recycled, and blended fibers.
MATERIALS
Yes. Hemp fiber is one of Green Fox Manufacturing's core materials. We process hemp fiber into custom nonwoven materials for applications including acoustics, animal care, erosion control, insulation, and other specialty products.
Yes. Green Fox Manufacturing offers co-manufacturing or toll processing partnerships for qualified customer-supplied fibers and other raw materials.
PRODUCTS & APPLICATIONS
Airlaid nonwoven materials can be engineered into acoustic panels, animal-care and nesting products, erosion-control mats, horticultural products, insulation, packaging materials, and specialty industrial components.
Hemp nonwovens can be used across a variety of applications where natural fiber materials are well suited to the product’s performance requirements. Green Fox Manufacturing works with hemp fiber for applications including acoustic panels, animal care products, erosion control blankets, insulation, packaging, and other specialty applications.
MANUFACTURING SERVICES
Yes. Green Fox Manufacturing can manufacture to partner-defined product specifications, designs, and performance requirements.
For established products, we can work from existing specifications and designs to produce consistent, repeatable materials or finished goods. We can also collaborate with product teams to evaluate materials, manufacturing requirements, and process parameters.
No. You don’t need a finished product design to start a conversation with Green Fox Manufacturing. We work with partners at different stages of development, from early-stage concepts and material ideas to established products with defined specifications. If you are still determining the right material or manufacturing approach, we can help evaluate the application, material requirements, and potential path to production. For established products, we can manufacture to your existing specifications through a co-manufacturing or toll-processing relationship.
The primary difference is who owns the product design and materials, and what role Green Fox Manufacturing plays in developing and producing the product.
OEM manufacturing is a fit for partners who want Green Fox Manufacturing to produce our existing manufactured products under the partner’s brand, including white-label or private-label arrangements. Depending on the project, product options, packaging, labeling, and other requirements may be customized.
Co-manufacturing is typically used when a partner has an established product design or specification and needs a manufacturing partner. Green Fox can provide raw material sourcing, production, quality control, and conversion to finished goods based on the partner’s requirements.
Toll processing is designed for partners who want to retain control of their raw materials and product specifications. The customer supplies the materials, while Green Fox provides the equipment, labor, processing, and conversion services.
At Green Fox Manufacturing, toll processing can include using our airlaid nonwoven equipment, labor, process expertise, quality controls, and converting capabilities to process customer-supplied fiber materials according to established specifications. The customer retains ownership and rights to their product, materials, and specifications while leveraging specialized manufacturing equipment.
GETTING STARTED
Minimum order quantities are project dependent. Run sizes can vary based on the fiber, product specifications, production requirements, and stage of the project. Green Fox Manufacturing evaluates each project individually to determine the appropriate production scale and manufacturing approach.
First, tell us about your application, industry, material needs, and production goals. From there, we’ll help determine whether OEM, co-manufacturing, or toll processing is the right fit for your project.
Together, we’ll review the required materials, processes, product specifications, and production requirements to assess manufacturing fit. Once the scope and fit are aligned, we’ll outline the appropriate next steps toward pilot work and production.