JANESVILLE PRODUCTS

CUSTOM - DESIGNED - ACOUSTICAL and THERMAL - INSULATION

Just one example of how we applied our in-house technical capabilities to innovative problem solving is the development of molded fiber technology.

Janesville's core automotive business consists of carpet padding as well as acoustical and thermal interior trim products.

An automotive customer, who utilizes large quantities of our acoustical and thermal carpet padding, asked us if we could develop a new product which would reduce installation time, improve fit and finish, be completely recyclable and environmentally safe.

Janesville's research and development professionals had been working on a number of new product concepts and new manufacturing systems for many years prior to this customer's request. Now, it was time to put that research to work.

A project director was named and a group formed which consisted of representatives of research and development, engineering, quality assurance, marketing and manufacturing.

Each area of expertise contributed to development of the new product and process.

R&D had been exploring use of compassion molding techniques, utilized in other industries, on the company's nonwoven fibers. This manufacturing technique appeared to offer the best method for developing a new product to meet customer requirements.

Each team member was assigned tasks, which would result in measuring feasibility of the proposed new system.

R&D developed and tested a number of fiber blends searching for the right combination to produce a superior acoustical material, which could be compression, molded. The result was a new formulation, which also had the added benefit of eliminating use of thermalset phenolic resins, containing phenyl formaldehyde, a welcomed environmental benefit.

The Engineering team established the product specifications for the new product. In addition, a search was begun for molding equipment, which could reproduce the product to exact specifications on an assembly line basis.

The Quality Assurance team developed new methods for inprocess control, thus assuring repeatable, high quality production. They also conceived, designed and built new test fixtures for both inplant and laboratory testing of the product in production.

Manufacturing team members developed new methods of testing incoming raw materials needed for the new product. Blending of raw materials to new formulations required more sophisticated handling thus a new training program was developed and instituted for all plant employees involved with the new manufacturing process.

Granada hotelsSamples of the new molded product were presented to the customer by Janesville's Marketing team, on time and within cost parameters. It was enthusiastically received.

Product specifications were further refined in accordance with customer requirements and a validation testing program was instituted.

After further customer quality audits and inplant reviews, Janesville's first molded fiber product was accepted for standard use.

Today, other Janesville customers are specifying and using custom molded, nonwoven, fiber products in their applications.

Environmentally safe, easy to handle, completely recyclable, with carefully engineered acoustical and thermal properties, Janesville's molded fiber products are ideal for a great many applications at an attractive cost to the user.

Our dedicated employees stand ready to provide excellent service and quality products for your application.

The basic raw material used in the manufacturing of our products consists of producer grade and reprocessed synthetic fibers such as nylon and polyester.

five star hotel in BlackpoolBy blending these, and other fibers, in a variety of formulations and applying various surface treatments, each end product will feature characteristics required by our customers.

Fibers are bound to each other via mechanical entanglement utilizing a highspeed needle punch loom. No bonding agents are used.

The fiber blanket, in its original form, can be manufactured to width and thickness required by customer specification. Acoustical and thermal performance, tensile strength, dimensional stability and other characteristics required by the end product is controlled during the manufacturing process.

Additional surface treatments and value-added items such as sizing, reheatable adhesives, polyethylene films, robotically applied pressure sensitive adhesives with release media, can also be specified to meet customer requirements.

In applications where customers require enhanced acoustical performance, Janesville can supply a full range of asphalt based barrier materials in sheet form or as fiber and barrier composites.

Molded fiber products provide the design engineer with greater latitude in designing acoustical insulators, which possess variable thickness, densities and surface conformance to mating shapes, thus improving fit and finish and ease of installation.

Molded fiber products are manufactured in a wide range of weights, densities and shapes. For review of additional molded fiber capabilities, Janesville is staffed with highly qualified sales engineers eager to assist customers in identification and specification of the appropriate material for their particular application.

Janesville's in-house, nationally accredited quality assurance laboratory is staffed by ASQCGent Hotels qualified and trained engineers.

All incoming raw materials is inspected and tested to assure that it meets our high quality standards and is free of contamination.

As active members of ASTM, SAE, and American Society of Quality Control, we consider ourselves in the forefront of quality innovation for our industry. The many quality awards and quality supplier designations we have: received recognizes our unparalleled expertise.

Yes, we are extremely aware of how our products affect the environment as well as those persons who handle, install and live with them on a daily basis.

Our basic product ingredient is a recycled fiber, which is thoroughly tested before use to ensure it contains no harmful material. Janesville's finished products are all 100% recyclable after there useful, life and all trim material generated during manufacturing are recycled our plants.

In addition, we are continually monitoring our manufacturing processes to assure meeting and exceeding all local state and federal environmental regulations.