Improving margin in nonwoven production is often approached through pricing or cost-cutting. But in practice, the biggest gains come from something more fundamental; delivering the same customer outcome with less waste, less variability, and less complexity without increasing risk.

In this article, we outline a practical 5-step roadmap to improve margin.

Step 1: Increase Saleable Output 

Profit is lost whenever you make material that cannot be shipped.

Focus on:

• Reject reduction: identify the three biggest defect types and remove their causes (web non-uniformity, bonding instability, winding damage, contamination).
• Faster grade changes: improve start-up efficiencies with standard machine settings and fast checks.
• Less unplanned stoppage: treat critical components (dies/nozzles/rolls/filters) as measurement tools, when condition drifts, defects rise.

Step 2: Reduce Material Usage 

Many products carry “extra grams” because specifications are not tied tightly to real use conditions. By defining measurable outcomes and designing smarter structures, weight can be reduced without sacrificing function.

Focus on:

• Clearly defining the customer outcomes in measurable tests: for example, filtration efficiency and pressure drop, fluid uptake and rewet, abrasion resistance. 
• Reducing mass with structure, not hope: use layered designs so more expensive fibres or chemistry sit only where they are needed to work.
• Mapping the safe operating window: run controlled trials so you know where performance drops sharply and set limits before scale-up.

Step 3: Rebalance Raw Materials 

Raw materials cost money twice; once when you buy them, and again when their variability creates scrap, claims, or over-processing.

Focus on:

• Blend optimisation: adjust fibre types and ratios to hit performance at minimum cost.
• Remove “nice-to-have” chemicals: keep only what measurably improves processing, performance, or durability.
• Control variability at the gate: set acceptance limits for incoming material properties so the process stays stable.

These efficiencies directly reduce operational risk and shrink the environmental footprint of processing.

Step 4: Reduce Energy and Utilities 

Energy is often used to compensate for instability. Improve process control to reduce the need for excess energy. 

Focus on:

• Drying and heating: recover heat, control exhaust humidity, balance airflow, and avoid overheating. 
• Water and filtration systems: keep filtration and nozzle condition high so you don’t need higher pressure to get the same effect.
• Compressed air: fix leaks and lower pressure where possible, small changes have large cost effects.

Step 5: Simplify the Product Range 

Every additional product variant increases complexity, testing burden, inventory, and opportunities for error.

Focus on:

• Building platform families: create a small number of base materials, then add features only where customers pay for them.
• Eliminating low-value variants: keep differences only when they deliver a measurable customer outcome.
• Pricing for performance: where function is proven, sell the outcome delivered, not the material used.

The common thread across all five steps can be summarised as follows: optimise for customer outcome and remove everything else that doesn’t contribute.

However, this isn’t about trying to tackle everything at once. The most effective approach is to start with yield, capture the quick wins, and then improve step-by-step from there.

When approaching margin improvement, the key question is: where are you seeing the biggest margin losses today, materials, waste, or complexity?

Let’s Continue the Conversation

Contact us to discuss how this approach could apply to your manufacturing operation and customer requirements.

Contact NIRI via email or phone +44 (0)113 350 3829.

In our previous article, we highlighted how lightweighting, monolayer constructions, and mono-component solutions are gaining traction as manufacturers pursue performance with less material use and improved recyclability. Now, we want to address a challenge, and opportunity, which sits at the heart of sustainable manufacturing: energy and resource efficiency.

For nonwoven and textile manufacturers, energy is a critical input that shapes competitiveness, environmental impact, and long-term resilience. The industry remains energy intensive throughout its process chain, from fibre preparation to bonding and finishing. Improving energy efficiency is no longer optional to future-proof operations in a climate-constrained world. 

1. Resource Efficiency: More Than Just Cost Cutting

Lightweighting and mono-component materials are not just sustainability buzzwords; they are strategic levers for resource efficiency. By reducing material consumption while maintaining or enhancing performance, manufacturers cut embodied energy upstream and lower the operational energy tied to processing heavier, more complex constructions. 

Why it matters:

• Fewer material types mean fewer process steps, fewer energy-intensive bonds, and fewer chemical inputs.
• Lighter materials often require less thermal and mechanical energy to process.
• Mono-component systems simplify recycling and reduce energy costs during end-of-life handling.

2. Low-Energy Production & Bonding Technologies

Manufacturers are increasingly adopting bonding technologies that reduce both energy and water use:

• Thermal bonding with optimised heat profiles and active cooling control.
• Airlaid and hydroentanglement processes that reduce reliance on high-energy drying stages. 

These approaches do not just save energy, they reduce water usage and emissions too, driving multi-dimensional efficiency.

3. Water & Dyeing: A Big Piece of the Efficiency Puzzle

Wet processing remains one of the most energy and water-intensive phases of textile production. But strategic interventions can make a big difference:

• Sustainable dyeing techniques such as digital printing and low-impact dyes reduce both water and energy per batch. 
• Heat recovery systems reuse energy from process exhaust streams to pre-heat water or air, cutting net energy demand.
• Process automation and real-time monitoring help eliminate over-processing, another unseen drain on resources.

These efficiencies directly reduce operational risk and shrink the environmental footprint of processing.

4. Supply Chain & Process Optimisation: Immediate and Long-Term Gains

Strategic analysis of process capability and manufacturing workflows can identify bottlenecks and energy hotspots. By rethinking layout, sequence, and resource scheduling, companies can significantly reduce peak loads and wasteful energy spikes.

Examples include:

• Energy audits to benchmark performance and pinpoint opportunities.
• Smart controls and sensors to shut down idle equipment and optimise heating/cooling cycles. 
• Data-driven manufacturing optimisation using emerging AI tools to balance efficiency and output.

This is where the dual benefits of immediate savings and long-term resilience converge, smarter processes make operations leaner and more adaptive.

5. Renewables, Low-Carbon Energy Integration & Science-Based Targets – Why 2026 is a Pivotal Year for Action

Energy efficiency improvements inside the factory are critical but they are only part of the decarbonisation equation. Increasingly, manufacturers are aligning operational strategy with structured frameworks such as the Science Based Targets initiative (SBTi).

SBTi provides companies with a clear methodology to set greenhouse gas reduction targets aligned with climate science and the goals of the Paris Agreement. For textile and nonwoven manufacturers, this typically means:

• Reducing Scope 1 emissions (direct emissions from owned or controlled sources)
• Cutting Scope 2 emissions (indirect emissions from purchased electricity, heating, cooling)
• Addressing Scope 3 emissions (all other indirect emissions across the value chain), which is often the largest proportion of emissions, including raw materials, logistics, and end-of-life impacts

While more than 11,000 companies and financial institutions have already set science-based targets or committed to doing so, SBTi is currently developing an updated Corporate Net Zero Standard, V2.  Incorporating new technical standards, this will include incentivisation for companies taking early, voluntary action to remove emissions.  From 1^st January 2028, all companies will need to use this new Net Zero Standard – those that act now will gain competitive advantage.

ISO: The International Organisation for Standardisation is currently reviewing the first internationally recognised Net Zero Standard, ISO 14060.  This will set out the requirements for how organisations can demonstrate targets and delivery on these, showing credible and verifiable progress, aligned with the Paris Agreement, and guarding against greenwashing.  It will ensure a consistent, internationally agreed approach to carbon accounting.  It is anticipated that this Standard will be published mid to late 2026.  Companies acting now to align with ISO 14060 will be better prepared to meet disclosure requirements, particularly when working across multiple territories and jurisdictions.

The implications are significant. Energy strategy is no longer about efficiency, it becomes part of a company’s formal decarbonisation roadmap which is increasingly scrutinised by customers, investors, and regulators.

Practical steps include:

• Transitioning to renewable electricity through on-site solar, wind, or power purchase agreements (PPAs)
• Electrifying thermal processes where feasible, supported by industrial heat pumps and electric boilers
• Implementing heat recovery and energy cascading across production stages
• Collaborating with suppliers to reduce embodied carbon in raw materials

For many organisations, Scope 3 reduction, particularly in polymer and fibre sourcing, is now the defining challenge. This is where material optimisation, lightweighting, and mono-component design become powerful levers, reducing both raw material intensity and upstream emissions.

Conclusion: Efficiency as a Competitive Advantage

Nonwoven and textile manufacturing operate in a global environment of rising energy prices, tightening climate regulation, and increasingly conscious customers. With material optimisation, low-energy technologies, water reduction, and supply chain optimisation, manufacturers can turn energy challenges into strategic advantage.

Meeting sustainability goals doesn’t mean accepting lower performance or higher costs. Rather, it means re-thinking how we use energy and materials and in doing so, unlocking value across the entire value chain.

At NIRI, we see these challenges every day across nonwovens and technical textiles. Energy efficiency, material optimisation, and supply chain resilience are rarely solved by a single intervention, they sit at the intersection of product design, process capability, and manufacturing reality.

Our work supports manufacturers across:

• Product development, including lightweighting strategies, mono-component and monolayer constructions, and performance-led material selection
• Manufacturing and process optimisation, helping identify energy hotspots, reduce waste, and improve process capability
• Supply chain and sourcing support, ensuring materials and processes are not only technically sound, but scalable, resilient, and commercially viable

By taking a holistic view from concept through to industrialisation we help clients reduce energy and resource intensity while protecting performance, margins, and long-term competitiveness.

Let’s Continue the Conversation

If you’re exploring ways to reduce energy use, improve resource efficiency, or build long-term manufacturing resilience, we’d be happy to talk.

Contact us to discuss how NIRI can support your product development, manufacturing optimisation, or supply chain strategy. Efficiency isn’t just about doing less – it’s about doing things better.

Contact NIRI via email or phone +44 (0)113 350 3829.

2025 was a milestone year for NIRI as we proudly marked 20 years of supporting commercial innovation across nonwovens, textiles, and advanced materials. As a group it was important that we took a moment to reflect on our history, the partnerships, expertise, and problem-solving that have shaped our journey. Now, as we turn our focus to 2026, the pace of change shows no sign of slowing.

As we enter 2026, the nonwovens and textiles industries face another defining year. Sustainability targets are tightening, regulatory obligations are accelerating, and cost pressures remain a constant challenge. Yet with these pressures come significant opportunities – for innovation, efficiency, and competitive diversification.

At NIRI, we see 2026 as a year where technical excellence, regulatory readiness, and smart supply-chain decisions will be critical to success and we are ready to support customers through these challenges.

Cost and Energy Efficiency: Doing More with Less

Cost saving remains a priority across manufacturing sectors, but in 2026 it is increasingly linked to resource efficiency and energy reduction rather than simple cost-cutting. Lightweighting, monolayer constructions, and mono-component solutions are gaining momentum as manufacturers look to reduce raw material use while maintaining performance.

Alongside material optimisation, low-energy production and bonding technologies, reduced water usage, and waste minimisation are becoming essential tools for maintaining margins. Supply chain optimisation, through process capability analysis, manufacturing optimisation, and improved material selection, can deliver both immediate savings and long-term resilience 

NIRI’s Supply Chain & Manufacturing Support services are designed to help companies identify inefficiencies, optimise processes, and support measurable progress toward cost and energy reduction goals.

Net Zero and Science-Based Targets

Net zero commitments and Science Based Targets initiative (SBTi) alignment are now moving from ambition to execution. In 2026, companies will be expected to demonstrate credible plans backed by data—covering Scope 1, 2, and increasingly Scope 3 emissions.

Process optimisation, energy-efficient manufacturing routes, and material substitution all play a role. Independent technical assessment and life-cycle thinking can help businesses make decisions that are both environmentally and commercially sound.

Materials Innovation: Biobased and Recycled Solutions

The adoption of biobased materials and the rapid development of fibre and textile recycling technologies, including mechanical, thermal, enzymatic and chemical, continue to reshape product design. While these technologies offer clear sustainability benefits, they also introduce technical, performance, funding/ investment, and regulatory challenges.

Balancing recyclability, functionality, and compliance requires robust testing, validation, and expert guidance. NIRI supports companies across the innovation lifecycle, from early-stage material evaluation through to scale-up and market readiness.

Regulatory Readiness: From PFAS to Textile Waste

Regulatory change will be one of the most significant drivers of activity in 2026.

One major development is the EU restriction of PFHxA and related substances under Regulation (EU) 2024/2462. From 10 October 2026, products placed on the market must not exceed:

• 25 ppb for the sum of PFHxA and its salts, or
• 1000 ppb for the sum of PFHxA-related substances

Ban on Plastic Containing Wipes

In the UK, the upcoming ban on plastic-containing wet wipes adds further urgency. Scotland is expected to implement the ban around April 2026, Wales from December 2026, and the UK-wide ban comes into force in May 2027—impacting baby wipes, cosmetic wipes, and household cleaning wipes sold both in-store and online 

Navigating this evolving regulatory landscape requires not only awareness, but proactive planning, organisation, technical validation, and clear documentation.

Industry Events: INDEX26 and Techtextil

Key industry events in 2026 will play a vital role in shaping the year ahead. For example, INDEX26 will showcase the latest innovations, sustainability solutions, and regulatory developments in nonwovens, while Techtextil will be a focal point for technical textiles and advanced material applications.

These events offer valuable opportunities to explore emerging technologies, share best practice, develop collaboration and partnerships and understand how the industry is responding to global challenges.

How NIRI Can Support Business in 2026

As companies prepare for the year ahead, NIRI’s commercial and technical expertise can support organisations across product development, application diversification, manufacturing optimisation, sustainability strategy, and regulatory compliance.

Our comprehensive suite of services is tailored to help accelerate the development and commercialisation of new products. With our extensive pilot facilities and state-of-the-art analytical laboratories, we fast-track innovation from concept to commercialisation, helping you to de-risk in-house R&D, allocate resources effectively and meet the demands of an increasingly complex market.

2003: Chris Fowler and Professor Stephen Russell meet – and immediately saw the potential for collaboration
Steve was then – and still is today – one of the leading minds in nonwovens and technical textile engineering.  At this time, he led a nonwovens research group at the University of Leeds.  Chris, with a background in running innovative medical technology companies, was looking for an investment opportunity – a business where he could make a major contribution, and ideally one based in Yorkshire.

2004: a spin-out is negotiated
The University of Leeds, where Steve’s research group was based, were looking to spin-out and commercialise cutting-edge innovation and product development capabilities from this world-class textile expertise, with the help of a commercially minded investor.  Chris and Steve’s skillsets aligned in a compelling case for the birth of NIRI.

2005: NIRI Limited is formed
The company is established, with Chris as Managing Director and Steve as Technical Director, combining the commercial acumen with the technical rigour that remain very much the core values of NIRI to this day.

2007 – 2014: expansion, facilities, and people – and a £1 million turnover
From the outset, NIRI knew that world-class consultancy is only possible with world-class talent – the driven individuals that make up a team passionate about technical textile development for real-world, commercial product development.  And it is testament to this approach that the company’s first recruit, Dr. Matthew Tipper, is now NIRI’s CEO.

To provide the best possible service to clients, NIRI started out with an investment-led philosophy, with a clear focus on the facilities and equipment needed to ensure both the opportunity to experiment with technical textile development  – the cutting-edge commercial research that has always underpinned NIRI’s offering – and to facilitate the speed to market necessary for optimum return on investment for clients.

NIRI achieved a first licence deal for a new textile product within four years of spin-out.  And 2013 marked a £1 million-plus turnover from commercial consultancy.

2015 – 2017: success leads to funding – and further expansion
Growth in NIRI technologies was supported by several grant awards and significant investor funding.  10 years on from the company’s formation, NIRI’s commercial success led to expansion with new premises – now off the University campus and into an 11,000 ft² facility.  And this investment and expansion incorporated a range of new equipment to help develop, test and manufacture better-performing products for NIRI’s expanding client base.

A laboratory-scale electrospinner meant NIRI could respond to the growing use of nanofibres for clients across a wide range of sectors, for small-scale investigation prior to scaling up to larger sample sizes.  A flatbed hydroentanglement pilot line was installed in the new premises, with the flexibility to allow for fabric structure and properties to be tailored to specified requirements.  A new Scanning Electron Microscope (SEM) provided an additional tool for understanding how manufacturing conditions affect the microstructure of nonwovens, and integrated image analysis software meant that NIRI could quantify fibre dimensions, pore size and other structural features more effectively. And investment in a new liquid extrusion capillary flow porometer helped NIRI’s clients quantify the through-pore diameters present in a nonwoven structure. 

Recognising and anticipating the growth in the hygiene sector, NIRI invested in bespoke testing equipment, including liquid strike through time and re-wet. Additional testing equipment included a fluff pulp specific volume and absorption tester, to balance wet strength and user comfort alongside biodegradability and dispersibility, all aimed at helping clients enhance existing products, with cost-reduction and quality improvement, and to help identify and evaluate new markets.

2018 – 2022: company changes, awards, investment and independence
Having moved from university premises in the previous year, one of NIRI’s Technologies was sold in 2018, and NIRI continued global expansion and consultancy, to turn ideas into products and sales more rapidly. The company’s collaborative approach to innovation saw a win with The Engineer C2I (Collaborate to Innovate) Award for the Sanguis universal plasma technology, in partnership with NHS Blood and Transplant and Macopharma.  And the Surfaceskins antibacterial door-push and -pull product received the 2019 Innovation Award at the Research, Innovation & Science for Engineered Fabrics (RISE®) Conference.

Major investments over these four years included:

• A new V-Lap machine to help clients develop applications for 3D vertically lapped nonwoven fabrics.
• A new airlaid system capable of prototyping pilot-scale samples containing high proportions of wood pulp and other very short fibres, to support clients in the hygiene and medical sectors. 
• Upgrade to the latest meltblown technology – an investment particularly relevant for clients’ R&D, pilot projects, sampling and prototyping, and proof of concept testing, for enhanced functionality and the rapid development of innovative and commercially-viable products.
• Bespoke-engineered spray bonding capability, to enable products to meet current and future regulatory demands, and to help investigate and develop better-performing products with improved functionality.

Alongside this investment, NIRI expanded their team and expertise, with more than 20 additional staff joining the company in 2021, alone – including principal scientists, senior innovation engineers, and technicians.  With project delivery doubling, NIRI achieved full independence in 2022, following a buy-out from the University. NIRI’s consultancy continued to have impact during this period, and work on one dual-AI net technology has been proven to reduce malaria cases and has recently been calculated as saving more than 24,000 lives.

2023 – a landmark year with the opening of Innovation House
Following 2022’s year of growth, NIRI relocated to new headquarters in Leeds with a £1.2 million investment, more than doubling the size of the facilities, with seven new laboratories and significantly increased R&D capabilities designed in close collaboration with NIRI’s textile engineers and material scientists.

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As part of a three-year strategy for growth, much of the new equipment at Innovation House is bespoke to NIRI, with new labs designed to foster the expansion of NIRI’s functional chemistry, formulation, and polymer engineering capability. This was coupled with the expansion of NIRI’s US presence, and further investment in NIRI’s 40-strong team.

Unveiling a plaque to commemorate the opening of Innovation House, the Rt. Hon. Hilary Ben, MP for Leeds Central, highlighted the pivotal role NIRI play in the development of sustainable, commercially driven nonwoven innovation,

“You are helping to design the future… Creating products that are genuinely biodegradable, will not add to the problems of the planet, that will help us to solve climate change – you couldn’t be doing a more important job.”

2023 onwards – and looking to the future of textile innovation
NIRI’s investment continues apace: with ongoing investment into biopolymer processing and development; investment in R&D focused on high performance PFAS replacement, and further investment this year in polymerisation facilities.

2025 sees the launch of a new initiative, an innovation hub dedicated to supporting scientific companies grow their ideas into commercial realities.  The Technology & Innovation Hub enables companies to co-locate alongside NIRI’s state-of-the-art facilities – with access to fully-equipped laboratories, private meeting rooms, and office suites – with support services and access to NIRI’s commercialisation expertise through bespoke support packages designed to help start-ups and scale-ups accelerate their innovations into commercially-viable technologies.

The company remains committed to its original commercially driven ethos and, in the current economic climate, helping clients reduce costs and improve efficiency is at the heart of development and innovation.

Chris Fowler reflects on NIRI’s growth and ambitions over the last twenty years, “Our evolution has been a great learning experience and having successfully innovated many novel products across many sectors I am proud of the positive impact the NIRI team has made for our clients, end users and the planet.

I feel our mission to develop cost effective, novel products, which deliver high performance and help protect the planet is even more relevant today than when we started out over 20 years ago.”

Steve Russell adds, “It’s been exciting to be part of NIRI’s 20-year evolution, from small University-spinout to an internationally recognised commercial innovation Company. It’s been a pleasure to work with so many different companies over the years, to deliver meaningful product improvements, and to witness the real-world impact, first hand”.

And Matt Tipper, from the perspective of NIRI’s first recruit to his current position as the company’s CEO, considers NIRI’s future, “After 20 years NIRI continues to build on the founding vision of combining scientific excellence with industry knowledge to help the polymer, textile and nonwoven industry develop new products, solve industrial problems and generate new business.

“Looking to the future, the industry faces a radical change with new regulations, sustainability requirements, cost challenges, social responsibilities and the transition to a circular economy. NIRI is at the forefront of these material challenges and continues to help our clients meet existing and emerging business needs.”

Advanced Materials. Smarter Protection. Proven Results.

NIRI is an established polymer, fibre, nonwoven and product development consultancy with deep expertise in protective textiles. Over the past 20 years, we have worked with industry leaders to develop innovative products that meet the most demanding performance and regulatory requirements. 

Expertise that Drives Innovation

At NIRI, we help to create next-generation products which enhance user safety and performance. Our expertise spans the entire product development lifecycle from initial proof-of-concept and prototyping to small-scale manufacturing and product validation. We also work across all nonwoven and technical textile market sectors. 

We combine scientific acumen with extensive commercial experience, ensuring our solutions are not only technically sophisticated but also commercially viable and easily scalable.

Technological advancements in materials science can improve the effectiveness and usability of protective textiles and equipment. In recent years demand for innovation has been driven by many factors, including:

• An increase in asymmetric warfare and non-conventional tactics including increasing threat of CBRN incidents. 
• Growing emphasis on emergency preparedness and response capabilities boosts the demand for reliable protective apparel and equipment. 
• Stricter international safety and regulatory standards driving the need for the development of new materials and structures.  

NIRI remains dedicated to creating new materials and products that meet both current and future needs of protective textiles.  As a result, we have identified key areas for development and improvement:

• Advanced Filtration Technologies: NIRI leverages its expertise in filtration technologies to develop materials that provide superior protection against liquid chemicals and airborne particles. This includes the use of next-gen chemistries, nanofibres and advanced composite structures to filter out harmful substances effectively.
• Lightweight and Ergonomic Design: We focus on creating protective apparel that is lightweight and ergonomically designed, enhancing user comfort and mobility, whilst reducing material cost. By integrating advanced materials and design techniques, we ensure that protective products do not compromise on safety enabling increased operation field time whilst reducing wearer thermal burden.
• Rapid Detection and Response: NIRI can help businesses in developing smart materials and integrated sensor technologies that enable rapid detection and response to serious threats. These innovations allow for immediate identification of hazardous agents and prompt protective measures.
• Multi-Threat Protection: NIRI can enhance materials that provide multi-threat protection, addressing a range of liquid chemical hazards in a range of environments. Products can be designed to offer comprehensive protection in various high-risk scenarios, ensuring the safety of users in diverse environments.
• Durable and Long-Lasting: Our focus extends to creating durable and long-lasting protection. NIRI employs advanced material treatments and composites that resist wear and degradation, ensuring prolonged use in harsh environments without compromising on safety and effectiveness.
• Market Saturation: Differentiating products in a crowded field requires new approaches to problem-solving, as well as awareness of developments in adjacent fields of product development.
• Circularity and Developing Sustainable Solutions: Modifying and revising product architectures to improve their design and compliance with circular economy principles and ensure compliance with emerging regulations while maintaining high performance.

PFAS Legislation is Coming: How Manufacturers Can Innovate and Thrive

As industries strive to become more sustainable, manufacturers face mounting pressure to address a critical challenge: replacing per- and polyfluoroalkyl substances (PFAS).

PFAS are employed for their durability and repellence, making them essential across many protective textile industries, including medical and healthcare, first responder garments, defence and CBRN protection. However, pressure to replace PFAS is growing because these substances are generally known to be toxic, persist in the environment and cause widespread contamination. In addition, research has revealed alarming health risks, including elevated cholesterol levels, pregnancy-induced hypertension, reduced vaccine efficacy, and links to kidney and testicular cancers.

But, PFAS represent a very large chemical family of substances, and they are not all equal in terms of persistence, bioaccumulation and toxicity. Their environmental and health risks are governed by the molecular chain length, functional groups and stability. 

Nonetheless, significant legislative developments are now driving the urgency to replace PFAS, as a result of emerging research. Because of the large number of PFAS compounds, restrictions are focussing on targeted PFAS groups, as opposed to isolated compounds. The Environmental Protection Agency (EPA) and the European Union’s REACH regulations are set to impose severe restrictions on PFAS usage. Amendments to the Stockholm Convention have expanded the list of restricted PFAS, with subsequent effects across international markets. 

Derogations for PFAS usage are likely to be limited and temporary, so businesses across nonwoven and technical textile industries must act now to remain compliant or risk severe penalties and product restrictions. As regulatory pressures increase, protective industries are being called to innovate and address growing consumer demand for safer, more sustainable products. 

Understanding the chemical nature of PFAS and regulatory focus is also vital to the development of new products and applications. Partnering with external expertise can help to navigate these challenges with greater confidence. 

Companies that fail to adapt to such upcoming restrictions may find themselves quickly outpaced by competitors who embrace innovation. The call to replace PFAS is not just a requirement, it’s an urgent mandate that will shape the future of protective apparel and equipment. 

Now is the time for businesses to invest in research and developmentdemonstrate their commitment environmental strategies and position themselves as leaders in sustainability and innovation.

PFAS Alternatives: How the Nonwoven Industry Can Respond

The search for direct PFAS replacements has been ongoing for years and is particularly challenging. PFAS have traditionally delivered exceptional alcohol and fluid resistance due to their unique molecular structure. However, PFAS alternatives often struggle to deliver the same level of performance, as they lack the low surface energy given by carbon-fluoride bonds, which is key to robust liquid chemical resistance – a critical requirement for protective textiles.

Repellence to liquid chemicals is crucial to maintain effective protection against pathogen-laden fluids and chemical exposure in extremely hazardous settings. 

Therefore, this challenge demands innovative approaches. The nonwovens and technical textiles industries need a multifaceted strategy to address PFAS replacement, including:

1. Address Over-Specification: Many products are designed to meet performance standards that exceed actual requirements, leading to the overuse of PFAS. Reviewing these specifications can help decrease reliance on these chemicals.
2. Develop Different PFAS Replacement Strategies: No single solution currently exists for replacing PFAS. However, innovative fabric design, intelligent material selection, and surface functionalisation offer promising pathways forward. At NIRI, we have applied these strategies to develop next-generation PFAS-free products, using a combination of lightweight and breathable high-surface area nonwoven structures with durable woven layer. 
3. Ideate Alternative Coatings and Surface Treatments for Oil, Water and Stain Repellency: utilising expertise in polymerisation and coating technologies, NIRI is developing a PFAS-free polymer, in addition to design and replacement strategies. Polymer properties can be engineered and coatings can be produced without the use of harsh solvents.

Collaboration and Innovation are Key to Success

As leaders in material innovation, NIRI has expertise in developing high performance barrier and filtration technologies, composite structures, PFAS-free alternatives and supporting clients through regulatory transitions. Our fully equipped laboratory includes analytical tools which are essential for understanding the chemical properties of polymers. 

We understand the importance of bringing innovative products to market quickly and efficiently. Our comprehensive suite of services are tailored to help you accelerate the development and commercialisation of your products:

Product Development
From ideation to market-ready products, we provide end-to-end support to turn cutting-edge ideas into successful products. Our services include concept prototyping, performance benchmarking, and disruptive technology creation.

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Market and Application Development
We offer strategic advice, market insights, and competitor evaluations to help you make informed decisions and reduce the risk of failure. Our tailored reports and strategic guidance enable you to stay ahead of the competition and capitalise on new opportunities.

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Supply Chain and Manufacturing Support
Our services ensure excellence in every aspect of your production line, from raw material sourcing to quality control. We help you build reliable supply chains, optimise manufacturing processes, and develop robust quality control protocols.

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With our extensive pilot facilities and state-of-the-art analytical laboratories, we fast-track innovation from concept to commercialisation – helping you to de-risk in-house R&D and allocate resources effectively. If you’re looking to enhance protection or accelerate innovation, we’d love to discuss how NIRI can help.

Economic headwinds in traditional textile and related markets are being faced by many businesses. To combat this, uncertainty can be turned into opportunity through targeted product innovation and diversification into new application areas. The medical sector can be reasonably resilient during economic downturns, providing attractive opportunities for technical innovators with an awareness of the needs of patients and healthcare providers, the regulatory landscape and the performance limitations of existing products. 

Current Challenges for Manufacturers

Globally, textile and related businesses are contending with inflationary pressures, geopolitical tensions, and shifting consumer behaviour. The uncertainty in some supply chains, coupled with rising material and energy costs, has disrupted traditional business models. Tightening environmental regulation is a further challenge in some markets, affecting the ways products need to be designed, manufactured and quantitatively measured. At the same time, the medical sector is providing pockets of resilience with numerous healthcare products and medical devices now relying on the properties of fibres and engineered textile materials to perform.

Opportunities in the Medical Market

Despite continued economic uncertainty, the medical sector stands out as a robust and largely recession-proof market. Products incorporating textile materials for supporting healthcare and hygiene as well as non-implantable, implantable and extracorporeal medical devices are enabling patient outcomes and reduced morbidity to be achieved in a variety of healthcare settings, whilst delivering attractive margins and costs-in-use. Preventative treatments, diagnostics, remote patient monitoring, wearable technology and products for personalised healthcare are just some of the areas where textile materials are finding new applications to improve patient outcomes, both in medical and community settings. Changes in regulation also open new avenues for innovating, creating new products to deal with performance deficits in currently available products. Although not previously a major driver of innovation in this sector, sustainability concerns and the reliance on single-use plastics for hygiene and infection control has become an area of development.  

Diversifying into the medical sector comes with a unique set of challenges and they vary depending on the country involved, and the specific way in which its healthcare system operates. Product classifications, costs, margins and regulatory compliance are naturally of major importance, but so too is understanding the needs of healthcare professionals and patients, if new products are to provide real-world benefits. When faced with this opportunity, collaboration with external innovation specialists can be valuable, improving targeting, de-risking in-house R&D and accelerating progress towards the creation of competitive products.  Access to the necessary prototyping facilities, testing and structure-property modelling can significantly reduce the timescale between concept and scale-up, reducing commercial risk.

How NIRI Can Support Market Diversification

At NIRI, we understand that entering new markets involves more than just producing a high-quality product. 

As experts in fibrous materials development, the NIRI team has proven experience in medical textile product development, such as transdermal drug delivery systems, pharmaceutical filtration, advanced wound care, blood filtration and medical packaging. NIRI’s R&D services enable rapid prototyping and are tailored to meet the unique demands of the medical sector. NIRI provides bespoke market insights, awareness of medical market trends, a route to GMP compliant textile production, and knowledge of regulatory requirements and standards. Leveraging this understanding means that we can effectively communicate the unique benefits of a product and support go-to-market strategies. 

With a proven track record of helping manufacturers diversify into medical applications, NIRI provides customised, confidential and strategic product development, which de-risks market entry and accelerates time-to-market all under complete confidentiality.

NIRI’s Application Development Process

Targeting Compelling Use Cases: The first step in market diversification is understanding where potential products fit. NIRI conducts in-depth analysis to identify medical applications suited to your existing materials, manufacturing capabilities and expertise. By evaluating market trends, regulatory requirements, economics and growth potential, we identify the most promising opportunities and provide the strategic support to explore them efficiently. 

Product Prototyping and Manufacturing: NIRI manufactures lab-scale prototypes with quantitative performance specifications aligned with medical industry standards. Small-scale fibre and fabric manufacturing lines can be configured for GMP production, depending on requirements, e.g. for clinical trials or pre-production prototyping. We focus on producing scalable products that are cost effective, commercially viable and reliable and have the industry connections to create new supply chains.

Testing and Benchmarking: NIRI rigorously evaluates product performance in relation to existing benchmarks and competitive products.Our rapid evaluation and testing service reduces the gap between concept and prototype, helping to demonstrate a product’s unique advantages to stakeholders.

Value Proposition Development: A strong value proposition is critical when entering the medical market. NIRI works to define a product’s most relevant attributes and value, relevant to the perspectives of both customers and investors. 

Samples and Quantitative Specifications: Whether to support discussions with potential customers, investors, or industry partners, relevant physical samples are essential for showcasing a product’s potential. 

Seizing Opportunities in the Medical Sector 

The medical sector offers opportunities for businesses seeking to innovate and grow during times of uncertainty, but targeted innovation and expert support is essential. Companies can leverage NIRI’s confidential development services, to navigate these opportunities with confidence and diversify into exciting new markets.

Working with NIRI enables companies not only to move much more swiftly, but also strategically, complementing your existing expertise and knowledge base to increase your competitiveness and range of product offerings. Don’t miss the opportunity to diversify and transform your innovation process. 

Contact NIRI today to explore how we can help you to identify new opportunities in the medical sector.

NIRI is advancing polymer science to support textile and material innovation. With a unique combination of expertise, state-of-the-art facilities, and industry-focused processes, our polymer capabilities enable partners to confidently go from molecular design to next-generation textile product.

Expertise that Drives Innovation: Dr Bryan Kaushiva

Central to NIRI’s polymer innovation capability is Dr Bryan Kaushiva, an Innovation Scientist with expertise across polyamides, polyesters, polyolefins, and emerging biopolymers. His background includes technical leadership roles in papermaking, polyurethane processing, and polyamide manufacturing, where he led the development and scale-up of new polymeric materials.

Much of Dr Kaushiva’s work has focused on sustainability, including the commercialisation of polymers made from renewable or recycled inputs and bio-derived intermediates. His depth of experience supports NIRI’s mission to accelerate innovation through a detailed understanding of polymer structure and function.

Advanced Facilities for Rapid End-to-End Polymer Development

NIRI’s laboratory and pilot facilities support polymer research and development from gram-scale synthesis through to fibre production and performance testing. 

At the synthesis stage, our high-pressure polymerisation reactor allows for precise control of reaction conditions, whilst our micro-reactor with capacities as small as 5 grams is ideal for exploratory chemistry and screening when material availability is limited. These unique tools also enable rapid formulation adjustments and facilitate early decision-making.

Our solid-phase polymerisation system allows for the controlled increase of molecular weight after initial polymerisation. Compounding then enables masterbatch production and the incorporation of any functional additives. Our pelletising capabilities help to prepare feedstock for spinning, while desiccant drying ensures resin conditioning prior to melt processing allowing us to evaluate fibre performance and application viability quickly and efficiently. 

Our fully equipped textile and polymer chemistry lab includes analytical tools which are essential for understanding thermal and chemical properties, such as Fourier Transform Infrared Spectroscopy (FTIR), Differential Scanning Calorimetry (DSC), and Thermogravimetric Analysis (TGA). Our extensive testing facilities also enable us to evaluate the performance of polymers, fibres, nonwovens, and finished products.

Driving the Future of Polymer Innovation

With growing regulatory and consumer pressure to reduce dependency on fossil-based inputs, industries are increasingly focused on developing bio-based and biodegradable polymers. NIRI has been utilising its polymerisation capabilities to advance innovation in areas including using renewable intermediates and fermentation-derived monomers. 

Furthermore, fibre-to-fibre recycling is becoming essential to circularity in the textile sector. Our ability to analyse, reprocess and restore recycled polymers is increasingly important to advancing circular textile systems. 

Meanwhile, sectors requiring enhanced performance can benefit from tailoring polymer blends to meet functional demands, whether it’s temperature resistance, bio-inertness, or flame retardancy.

By coupling material science with practical application development, and fostering collaborative innovation, NIRI de-risks and accelerates innovation through tailored consultancy to complement business growth.

Get in Touch

Need support with polymer development? NIRI’s experts and facilities are here to help. 

Contact us to discuss your polymer technologies and project goals. 

Biomaterials in the Medical Sector

With an evolving healthcare sector, ageing population and growing incidence of chronic conditions there are opportunities to process biomaterials into advanced fibres and fabrics, including nonwovens and coated substrates for use in medical products. Biomaterials, many with multifunctional properties, play a crucial role in providing diagnostic or therapeutic capabilities in contact with biological tissues and organs, with the ultimate aim of improving patient outcomes.

Advanced drug delivery, scaffolds for tissue regeneration, wound care, stents and other implantable devices are among various fibre and fabric based applications. Modified biomaterial formulations, as well as processing methods, are now being explored to manufacture new medical product formats, suitable for a variety of clinical needs. 

The Role of Biomaterials in Fibrous Medical Products 

Certain biomaterials have well established compatibility with existing fibre spinning and textile processing methods, while others are incorporated within mixed polymer formations as components for fibres, or coatings. Certain inorganic compounds can be converted into fibres and fabrics directly, or incorporated within fibres as dispersed nanoparticles.

More commonly, natural biopolymers and synthetic polymers are used as materials for making fibres and filaments (alone, or as additives in commixed polymer formulations), fabrics and porous coatings, as follows: 

• Polysaccharides: e.g., alginates, cellulose including carboxymethyl cellulose (CMC), regenerated cellulose, chitosan, pectin, hyaluronan and dextrin. 
• Polypeptides: e.g., collagen, gelatin, fibrin and various forms of silk. 
• Synthetic polymers: e.g., aliphatic polyesters and copolyesters (including PLA, PGA, PLGA, PCL, PHAs and PHBs), polyanhydrides, polyolefins (including PE, HDPE and UHMWPE, PP), PVOH, polyamides, polycarbonates and polyurethanes. 

Each material formulation is selected based on physical properties, economics, regulatory requirements and compatibility with the appropriate fibre or textile manufacturing platform with specific medical needs depending on the application. 

Challenges and Opportunities in Developing Biomaterials using Textile Processes

Despite the promise of new biomaterials, significant hurdles can be encountered in their development for clinical use. Biomaterials can be challenging to process and manufacture into fibres and fabrics at different scales, often requiring specialist techniques, process modifications and expertise. This can increase development costs and time to market. Meeting regulatory requirements also demands careful planning, good manufacturing practice and validation. Limited infrastructure can be a significant challenge, as many organisations lack the facilities to conduct efficient end-to-end biomaterial development.  

Biocompatibility can be investigated in laboratory settings, but the safety and performance for extended periods of time must also be addressed. Careful consideration and materials selection must be employed.

Materials such as alginate and collagen are sensitive to processing conditions such as temperature, pH, and ionic strength, and over-processing can denature proteins, or alter the molecular structure, affecting material functionality and performance.  

Controlling moisture levels of highly hydrophilic biomaterials during processing is also challenging, but critical to maintaining their structural integrity and performance in the final application.  

Many biopolymers used in medical applications also lack inherent mechanical strength, requiring reinforcement through blending or cross-linking to achieve a balance between flexibility and durability.

Beyond electrospinning to produce nanofibrous webs from polymer solutions or melts, (i.e. products in the form of ‘mats’ and ‘meshes’ and sometimes yarns), developers frequently overlook other highly versatile fibre spinning and fabric forming methods that have the capacity to produce better performing products. This includes wet, dry, dry-wet and gel spinning of biomaterials into continuous filaments, or staple fibres and melt spinning (for thermoplastic polymers). A large variety of fabric forming techniques can then follow, depending on the final products’ required structure-property relationships, and high reproducibility and speed of production are possible. Drylaid, wetlaid and spunlaid nonwovens, followed by appropriate web bonding can enable three-dimensional, porous fabrics to be made very cost effectively from biomaterials than can be challenging to make using other processes.  

NIRI can help to address these challenges by providing access to a comprehensive suite of services, including material innovation, pilot-scale fibre and fabric manufacturing, and performance validation, all under one roof. 

Innovations in Material Processing

In addition to fibre and fabric manufacturing, textile substrates and the materials from which they are made can also be modified. Functionalisation is a key area of innovation. By modifying biomaterials at the molecular level, as well as at the fibre and fabric levels, it is possible to enhance physical properties and therefore performance, tailoring materials to meet precise clinical needs.  

How NIRI Supports Biomaterials Innovation 

NIRI provides a holistic approach to the development of fibres, filaments, fabrics, films and coatings containing biomaterials, ensuring a smooth transition from research to market-ready products:

• End-to-End Prototyping: From polymer formulation, fibres, filaments, films and coatings, to fully formed products, NIRI offers comprehensive prototyping capabilities to bring ideas to life quickly and efficiently.  
  Polymer engineering and compounding.  
  – Fibre and filament extrusion – melt-spinning (mono and multi-filament), bicomponent spinning, wet-spinning, dry-wet spinning and electrospinning. 
  – Spunmelt nonwovens – meltblowing and spunbond.  
  – Staple fibre production, fibre crimping and cutting. 
  – Drylaid and wetlaid nonwovens, including short (<10 mm) and long staple fibre. 
  – Web bonding (chemical, mechanical and thermal).  
  – Coating, laminating, particle incorporation and fabric functionalisation  
• Analytical Capabilities: We provide performance validation and benchmarking for medical products.  
• Customised development: NIRI’s collaborative R&D approach aligns processes with client goals, optimising biomaterial performance for specific applications. 

The Future of Biomaterials in Medicine 

Developments in biomaterials processing provide an exciting frontier for innovation. In addition to biomaterials formulation, alternative methods of processing biomaterials into finished textile formats, provides a basis to improve diagnostic and therapeutic devices that meet regulatory demands and redefine patient care standards.  

NIRI bridges the gap between concept and commercialisation, supporting clients at every stage of the biomaterial development process. From material innovation to commercialisation, we provide the expertise and resources needed to create high-performing, sustainable medical products. 

Contact us today to explore how we can help you innovate your medical technologies. 

Jack Eaton brings extensive experience in commercial strategy and business development. As CCO, Jack will work closely with clients to understand their challenges and help translate scientific innovation into commercially viable products. In his role, Jack leads NIRI’s commercial development, managing key client relationships, overseeing marketing activity, guiding the expansion of service offerings to better meet evolving industry needs.

Jack spent seven years at NIRI earlier in his career in consultancy and technical management and returns with broad commercial and industry experience in coatings, pigments and polymer processing. His appointment reflects NIRI’s focus on combining technical expertise with commercial impact to deliver value to our clients.

Our clients will benefit from Jack’s ability to connect market insight with technical capability, helping to shape collaborative innovation projects that move from idea to market.

Dr Clement Denis, an expert in advanced materials and nonwoven technologies, steps into the role of CTO, where he will oversee NIRI’s research and development strategy and project delivery. In his six years at NIRI, Clement has played a pivotal role in developing novel materials and processes, guiding innovation projects across sectors including medical, hygiene, filtration, and sustainable packaging. With a PhD in Materials Chemistry and a strong background in applied science, Clement combines technical rigour with an entrepreneurial mindset.

These strategic appointments reflect NIRI’s commitment to enhancing both its commercial and technical capabilities, reinforcing its position as a trusted partner in the global nonwovens industry.

We also take this opportunity to thank Dr Ross Ward, who has moved on to pursue a new opportunity, and to wish Dr Richard Allen all the very best in his retirement.

The medical industry is rapidly evolving in multiple markets, shaped by techno logical innovation, regulatory changes, and shifts in demand. Businesses can address the resulting opportunities by developing highly competitive new products and position themselves as market leaders.

The Need for Innovation in the Medical Sector

The global healthcare industry is under pressure to improve patient outcomes while delivering economic and environmental sustainability. Medical and healthcare products have to meet stringent performance requirements, as well as appropriate price points, providing value to healthcare providers, whether patient care is delivered in hospital or community settings.

Additionally, sections of the industry are not immune to the pressures of environmental regulation, meaning that the polymer and fibre composition of products, fabric structure, modes of use, and full life cycle impacts of finished products are being more carefully considered. Concerns about waste, and also the lack of circularity, are now influencing healthcare innovation, particularly where waste accruals associated with single use products and device components are known to be significant burdens. Manufacturers also face increasing pressure in some parts of the industry to reduce reliance on single-use plastics and adopt alternative materials, creating functional, but also reusable or recyclable products, with circular economy principles in mind. Meanwhile, evolving chemical, product and environmental regulations – including the ban on per- and polyfluoroalkyl substances (PFAS) – challenge manufacturers to find alternatives to traditionally used materials.

Compounding these challenges is the saturated nature of some markets. Businesses must differentiate their products by innovating to address clearly defined unmet needs while delivering benefits to patients and healthcare provides such reduced morbidity, nursing time and risks of infection. Failure to innovate risks stagnation in a field where product performance requirements and regulatory landscapes are continually evolving.

Challenges in Developing Next-Generation Products

While the importance of innovation is clear, several hurdles stand in the way of next-generation product development for medical devices and healthcare products:

• Performance Criteria: Increasingly challenging performance criteria need to be addressed without compromising compatibility with installed manufacturing infrastructure. The practical integration of new materials science as well as digital and diagnostic components are just a few examples.
• Sustainability Goals: Balancing performance, cost and evidence-based environmental benefits, particularly from a full life cycle perspective, remains a major challenge.
• Legislative Pressures: Evolving regulations, including bans on harmful substances like PFAS are presenting major challenges as simple material-switching is often insufficient to address the resulting performance gap.
• Patient-Centred Design: The ageing population and the issue of long-term care of chronic conditions presents opportunities to improve product design, reduce patient morbidity and reduce overall healthcare delivery costs.
• Market Saturation: Differentiating products in a crowded field requires new approaches to problem-solving, as well as awareness of developments in adjacent fields of product development outside the medical sector.

Addressing these challenges requires detailed market awareness, technical expertise, market insights and access to diverse manufacturing supply chains. 

Emphasising Human-Centred Design 

The importance of human-centred design in the medical sector cannot be overstated. Technical performance is of course critical to the utility of the product, but ease of use and compliance with the requirements and experiences of healthcare providers and patients also influence outcomes. 

For instance, new products with integrated diagnostic devices may provide inconsistent results leading to inaccurate interpretation by users, PPE may have excellent barrier performance in use, but be a source of infection during removal, and advanced wound dressings that accelerate healing, may still require multiple dressing changes with significant nursing time and costs per week.

Medical products should therefore perform effectively but also with users in mind. Coupled with this are the effects on cost in use, overall healthcare outcomes and waste.

Why NIRI is Uniquely Positioned to Lead Innovation

NIRI’s expertise in ideation and product development offers medical companies a distinct advantage. With a unique approach to problem-solving and detailed overview of both current and emerging trends, NIRI draws insights from cross-sector experiences to develop innovative product improvements tailored to the medical sector.

Key areas where NIRI has supported ideation and product development include:

• Infection Control: Developing new approaches to breaking the chain of infection, for example by integrating antimicrobial chemistry within fibrous devices and developing new approaches to combatting neglected tropical diseases (NTDs) such as malaria.
• Advanced Woundcare: Designing and manufacturing fibrous woundcare and surgical components to improve fluid management and enhance tissue repair and regeneration. 
• Patient Dignity & Wellbeing: Creating products to reduce patient morbidity through improved performance, including odour control for ostomy and continence management.
• Filtration and Separation: Developing new approaches for removing unwanted components in biological liquids such as antibodies, e.g. in donated blood, to provide universal plasma.
• Diagnostics: Integrating physical and electronic functions within industrially scalable medical and healthcare devices to enable early, or remote detection of a change in state.
• Advancing Circularity: Modifying and revising product architectures to improve their design and compliance with circular economy principles, extending their time in use, opportunities for reuse or recycling, and improving their compatibility with end-of-life waste management options beyond incineration.
• Developing PFAS-Free Solutions: Ensuring compliance with emerging regulations while maintaining high performance.

By leveraging our comprehensive knowledge of materials and nonwoven science, pilot manufacturing facilities and industry knowledge, NIRI provides a confidential service to help companies innovate and position their products for success.

NIRI’s Approach to Ideation and Product Development

NIRI ensures that every stage of product development is optimised to deliver the highest value.

We facilitate ideation workshops with individual companies internationally on a confidential basis, to identify unmet needs and generate creative options for new product development. Supported by a comprehensive pilot manufacturing facility, we have experience of processing natural, regenerated and synthetic fibres into finished fabrics and prototype products, enabling subsequent scale-up via larger manufacturing supply chains. NIRI will identify the best materials to balance functionality, cost, and sustainability as well as test and validate prototype products to ensure they meet required standards and benchmark performance against existing market leading products.  Consideration of the existing competitive landscape, impending legislative developments and other intellectual property is an integral part of our approach, to ensure products remain relevant, competitive and compliant with future market demands.

Driving the Future of Medical Innovation

Ideation and next-generation product development are essential for businesses aiming to lead in the medical sector. By fostering innovation, addressing emerging challenges, and incorporating sustainable practices, companies can position themselves to stay ahead of the market. 

Contact NIRI today to explore how we can help you innovate in the medical sector.

Article by:
Jack Eaton, Chief Commercial Officer