Our Weaving Mill
Euro Air operates its very own weaving mill in Vejen, Denmark. It is the only weaving facility in the world designed solely for the production of textile ducting. You might say that makes us the world’s top experts in wrapping threads around air!
Our testing methods and quality control procedures set a benchmark for international standards, and we proudly celebrate the exceptional and consistent quality of our products.
The entire textile production process is strictly monitored from start to finish and our raw yarn is rigorously inspected before, during and after production to guarantee optimal weaving tolerances.
All this attention to detail has resulted in quality control standards comparable to those in the automotive industry, with an average of just 1.5 defects per 100 running metres of textile. This is partly thanks to the incredible quality of our raw yarns, which are carefully selected from just a handful of boutique European suppliers.
The quality of these raw materials is amplified by our unique production software and heat-set stabilizing machinery. We’ve had years to perfect our craft, since 1991 in fact, and are constantly investing in new and improved ways to futureproof our products.
Entry Control (Raw Materials)
In the entry control phase our yarn's colour, shrinkage, and oil content is carefully checked.
Our weaving mill won’t allow a colour difference of any more than 1 ΔE.
The normal shrinkage rate of standard polyester or TCS is from 8-12 %, but we won’t accept any yarn with a shrinkage rate of more than 5 %. This is to ensure that the permeability of our textiles remains static and standardized throughout the production process, from the weaving loom all the way to the finished product and beyond. That means you’ll never have to worry about shrinkage from washing cycle to washing cycle.
The normal amount of spinning oil is between 3.5-7% added in the spinning process. But once again we impose a far stricter oil content limit of just 1%. This ensures that any remaining oil will be evaporated off in the heat setting of the finished product without altering our textile’s permeability.
We control the permeability of our finished product through a number of strict production parameters. The most important aspect is the amount of weft insertions per cm².
Here’s an example:
20 threads / cm²= Tight
15 threads / cm²= Middle
10 threads / cm²= Open
Our weaving mills are able to control weft insertions by 0.1/ cm² and our heat-setting machine is used to remove any variations once the weaving is done. This ensures that our textiles will retain their precise permeability throughout their entire lifecycle, wash after wash, year after year.
After heat setting, our textiles are sent off for inspection, where a set of human eyes susses out any defects or irregularities. The product’s permeability is given one last check and, if everything looks good, is finally approved.
We measure the textile’s permeability with a portable handheld testing device, which provides precise measurements from the entire width of the textile (between 50-70 measure points all across the width).
Whenever a textile’s permeability falls beyond our approved range, the entire roll is destroyed and begun anew.
Each roll contains a barcode with 11 identifying marks. These specify the textile’s:
- Air permeability
- Length in metres and m²
- Loom number
- Lot number of yarn
- Date of production
This gives us full traceability on every roll we produce - from cradle to grave.
Entry control (Duct Production)
Before forming the textile roll into the final duct we once again check that its permeability, colour and strength are up to par.
Since the introduction of the DFC product line in 2010, we’ve been leveraging hyper-precise laser cutting technology to produce our textile ducting solutions. Our Directional Flow Control (DFC) baffles are made with laser-cut perforations to ensure the total accuracy and effectiveness of our finished products.
Our 3 DFC Systems (Comfort, Induction, and Long Throw) are first engineered in our patented TBV Designer software, where laser parameters are automatically generated to secure the correct placement of every baffle and perforation.
There is a nearly endless number of combinations between textile permeability rates and the number of DFC laser perforations on any given duct, allowing us to design a fully optimized solution for virtually any air distribution challenge.
Read about the advantages of using our new DFC technology here.
This is a TCS polyester material made of TREVIRA CS fibres woven in our very own weaving mill in Vejen, Denmark. The material is woven in a twill weave consisting of heavy-duty, twisted staple fibres to ensure the largest possible fabric surface and a high dust holding capacity. This allows for greater air filtration and longer washing intervals. Read more here.
This is a polyester material made of High Tenacity Filament fibres woven in our very own weaving mill in Vejen, Denmark. The DFC-HT material is woven in a plain weave consisting of heavy-duty “High Tenacity Fibres” to create a strong, even and wear-resistant textile surface. The DFC-HT material has been approved for cleanroom applications, ISO class 4 acc. to ISO 14644-1. Read more here.
The DFC-0 is a non-permeable material that is highly colour compatible and treated with a dirt-and water-repellent finish for enhanced longevity. The material doesn’t contain PVC, halogens, silicone or other harmful substances. Read more here.
This TCS polyester material is woven in a twill weave consisting of heavy-duty, twisted staple fibres to ensure the largest possible fabric surface and a high dust holding capacity. The steel fibres provide additional antistatic properties. ANTISTATIC TCS is DIN 54345 (2x - 105 ohm/cm) approved. Read more here.
The Nomex material is woven with NM 60/2 yarns, it is exceptionally flame resistant and will neither melt, drip nor combust in air. Nomex is woven in a twill weave using staple fibres to ensure the largest possible fabric surface. It is designed to perform optimally in a wide range of temperatures, from -45°C to 120°C. Read more here.
For Euro Air, environmental sustainability is more than just a buzzword. We provide the world’s only Cradle to Cradle* certified textile duct, CradleSox. Every stitch and fiber of our textile solution is engineered with environmental impact reduction in mind. We’re committed to conserving resources, reducing our carbon footprint, and recycling our raw materials—all in the name of a better climate, indoors and out. CradleSox is the perfect green product for schools, offices, laboratories and other comfort area requiring a healthy indoor climate.
* Cradle to Cradle Certification was developed by Dr. Michael Braungart and William McDonough as a means of recognizing safer, more sustainable products made for the circular economy. Cradle to Cradle certification encourages manufacturers to carefully consider each material that goes into a product, as well as every resource used in the production process. Cradle to Cradle certified products aspire to be 100% recyclable.
Read more in the brochure