Innovation through collaboration and investigating Airlay technology

The project expanded expertise and developed methods for the mechanical processing of textile fibers for future investment, together with companies related to the value chain. Vilikkala used the project to build a value chain for new production. The project is part of a green transition investment that enables the further processing of waste textile fibers and bio-based fibers in Finland using airlay. The project has been supported through EU rural development funding (business support).

The project was implemented in Italy in March 11-14, 2025, with 6 people from five different organizations. Three companies were also involved without a representative from the raw materials or chemistry department. There were a total of 4 fiber materials to be tested, and in addition, there were two fusible binder fibers in the tests. The research organization was represented in the project by Sini Ilmonen, a special expert at Turku University of Applied Sciences (pictured left), and Jari Toivonen, who is responsible for product development, was the representative of Vilikkala (pictured right). This project has been the starting point for mutual cooperation between the companies and broader research in cooperation with Turku University of Applied Sciences.

The main research focus was recycled fibers

Fiber opening means opening textiles back into fibers, which also removes all hard parts such as buttons, zippers and buckles. Fibers can be utilized in many ways as raw materials for new materials, depending on, among other things, what the fibers consist of and how the process related to them is designed. A large part of textiles, such as workwear, is made of mixed fibers, meaning they contain both synthetic fibers (PES, PP, PA, etc.) and natural fibers, such as cotton and wool. Mixed fibers refer to the need for technical properties for the garment, such as durability, moisture wicking and breathability. Vilikkala's goal as a company is to produce new materials, especially from mixed fibers.

Airlay carding is a technology especially suitable for recycled materials

Mixed fibers are particularly suitable for airlay carding, which allows the production of so-called nonwoven fiber materials, i.e. felt or sheets, in the line. Airlay carding is a versatile production tool, for which there are several manufacturers in Europe. These also have major differences in the production for which the line is to be adapted. Airlay carding is also a suitable method for products made from hemp fibers, i.e. long and irregular fibers. Short fibers, such as cellulose fibers, are usually produced using a technology called airlaid. This project also included tests with so-called short fibers, from which sheets were successfully made. In addition to recycled textile fibers, the tests also included so-called new softwood cellulose fibers.

The project investigated the technology of the production line manufacturer

Vilikkala is investigating the construction of an airlay carding line, as it is a good continuation of its current production line. The company produces felt by heat treating wadding and coats and laminates felt materials. During 2025, the company will expand its related services with a CNC automated textile and felt cutting line. Vilikkala’s textile lamination line is a special opportunity to process recycled materials for Finnish industry and produce circular economy services based on the customer’s own textile resource. The production replaces virgin materials with raw material made from local end-of-life textiles. Vilikkala is one of the companies that will potentially provide services related to the EU Waste Framework Directive’s Textile Producer Responsibility (EPR) system, which will enter into force in late 2027.

This project has been supported by EU rural development funding.

Vilikkala is located in Salon Haliko. The company specializes in felt products. The company is part of Rester Oy's network utilizing recycled textile fibers. Textile lamination and cutting, as well as felt production from discarded textile fibers are Vilikkala's special expertise. Textile circular economy services and life cycle design include the use of discarded textiles, such as workwear, as raw materials for new products for the company's own use. vilikkala.fi

For more information, please contact Jari Toivonen at 050-5772675.