Sound Insulation and Carpet Backing Nonwoven Line
Acoustic felt and carpet substrate on one integrated, in-house-built line.
Two of the highest-volume nonwoven parts in a car are the floor carpet and the acoustic package: dash insulation, floor underlay, wheel-arch and trunk liners. They share the same production DNA. A sound insulation nonwoven line and a carpet backing line are close cousins, both heavy, both needle-punched or bonded, and both judged on weight consistency and how they perform once molded into the vehicle. KSG builds both, and often the same line serves both product families with a recipe change.
Carpet backing
Automotive floor carpet is usually a face material laminated or tufted onto a nonwoven backing that carries the structure. That backing is where carpet backing nonwoven machinery earns its keep: it has to hold a consistent weight and thickness so the finished carpet molds to the floor pan without thin spots or bunching. We build the backing line around a well-controlled card web and a profiled cross lapper, then consolidate with needle punching for the loft and recovery the part needs.
For velour-style and dilour face fabrics we use the velour needle loom, the same equipment behind our automotive velour line, which structures the surface into the fine, dense pile those parts call for. The rest of the line, opening through lapping, is shared with the backing product, so a plant can run both without a second setup.
Acoustic and sound insulation felt
Acoustic parts do their job through mass and airflow resistance, so a sound insulation nonwoven line is really about hitting a target weight and density reliably. Heavier felts, often 800 to 1,500 g/m² and sometimes more, get built up on the cross lapper and consolidated by needle punching, with the fiber blend chosen for the absorption and the thermal behavior the part needs in the vehicle.
Where a part will be molded, we bond it with heat as well, using the same dryer and heating-roll approach as our thermal bonding work so the felt holds its shape in the tool. Recycled and shoddy fiber is common in this segment, and our opening and blending line is set up to handle reclaimed feedstock without choking the card, which keeps material cost down on high-volume acoustic parts.
Because acoustic felt is heavy, the line runs slower than a light-trim line and the material handling matters more. We size the winders, cutters, and takeoff around the actual part weight so the back end keeps up with the card and the crew is not fighting the roll.
One line, two product families
The reason we point automotive customers at a single line for carpet and acoustics is simple economics. The opening line, carding machine, and cross lapper are shared; only the consolidation and finishing settings change. That means one installation, one crew to train, and one supplier to call, which is how KSG has delivered these plants across more than forty countries.
We handle the layout so both product families fit the floor space and the material flow makes sense, then install and commission the line with our own engineers on site. Trial runs against the customer's weight and acoustic targets happen before handover, so the plant starts making saleable parts quickly.
From molded acoustic felt to tufted-carpet backing, KSG Group can design, build, and install the complete line as one partner, from the opening section to the needle looms and finishing. Send us your part weights and volumes and we will propose a line that covers both your carpet and sound-insulation work.
Ready to integrate the Automotive Interiors?
Contact our sales engineers to discuss integration, custom configurations, and pricing for your facility.