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Casati Flock&Fibers

The Flock Technology

Certified Innovation

How does the flock production works?

Discover how the flock creation process comes to life in our Renate facility, utilizing industrial machinery and specialized systems designed for grinding, cutting, dyeing, and activate the flock powder.

PHASE 1
Raw Material Procurement

Textile raw materials are selected based on the fiber type (vegetable, animal, synthetic, artificial) and its physical presentation (tow, staple, or textile scraps) for flock production.

PHASE 2
Grinding (staple and textile scraps)

Raw materials in the form of staple or textile scraps, not being continuous bundles, undergo grinding through industrial mills, resulting in flock powders with various granulometries.

PHASE 2
Cutting (tow)

Raw materials presented as tow (a continuous ribbon of multiple filaments joined) are cut using guillotine cutters, ensuring precise measurements for the subsequent process.

PHASE 3
Dyeing

Flock powders, whether from grinding or cutting, undergo the dyeing process in dedicated vats, meeting specific customer requests in terms of color and fiber fastness.

PHASE 4
Activation

In the dyeing vats, the flock undergoes activation through a chemical recipe, creating a "film" around the fiber and making it suitable for flocking machines.

PHASE 5
Drying

After the dyeing, activation, and centrifugation processes, the flock powder passes through dryers, where it is dried with hot air.

PHASE 6
Sieving

This procedure eliminates longer textile fibers that may be present within each individual production.

PHASE 7
Flock

The flock, properly bagged, is ready for shipment.

Quality Control

Casati Flock&Fibers is committed to monitoring and ensuring high product quality throughout all stages of the process through numerous tests.

01
FLOCK SHAPE TEST
Cutting Phase
  • Precision cutting control
02
VOLUMETRIC TEST
Grinding Phase
  • Micronage control of fibers
03
COLOR TEST
Dyeing Phase
  • Laboratory color control with the reference sample
04
COLOR TEST
Drying Phase
  • Possible final color correction
12
SCOTCH TEST
Sieving Phase
  • Verification of the presence of longer fibers (their presence would create craters in flocking)
05
"HAND" TEST
Final Test
  • Checking the "hand" of the flock, assessing the softness of the flock
06
MAHLO TEST
Drying Phase and Final Test
  • Checking the conductivity of the flock, the effectiveness of the flock's activation.
08
FLOCKING TEST
Final Test
  • Simulation of flocking to evaluate the workability of the flock in flocking plants.
09
DRY AND WET RUBBING FASTNESS
Final Test
  • Ensures that the flock does not release color when rubbed, both in wet and dry conditions.
10
WETTABILITY TEST
Final Test
  • Typically measured in a few seconds, determining the correct fiber penetration time into the adhesive used for flocking.
11
RISE TIME TEST
Final Test
  • The rise time simulates the duration it takes for the flock fibers to fall down from the net to the flocking surface.
07
SIFTABILITY TEST
Final Test
  • Verification to check if the flock fibers are separated from each other, to ensure good flowability for them to fall from the machine’s net in the right way.

INDUSTRIES

Flock is an extremely versatile semi-finished product, making it applicable across various industrial sectors. In the same industry, flock can be employed for highly technical purposes and simultaneously for more glamorous applications.

Tessile
TEXTILES
Flock
  • Velvet-effect flocked fabrics with total or partial flock prints for clothing and furnishings
  • Flock transfer for fabrics
  • Blankets
  • Curtains
  • Blackout curtains
  • Coated with filler
  • Coating with filler
Christmas gift boxes background 2022 12 16 11 12 02 utc 2
PACKAGING
Flock & Fibers
  • Flocked outer packaging
  • Flocked foam rubber
  • Packaging coatings with interior fibers
Carta
PAPER
Flock & Fibers
  • Flocked paper
  • Recycled paper created from textile waste
  • Decorative paper
  • Wallpaper
Design 2
DESIGN
Flock & Fibers
  • Flocked design objects for special effects
  • 3D printing with recycled fibers
Design
FURNITURE
Flock
  • Flocked fabrics for sofas or armchairs
  • Flocked furniture for special effects
  • Flocked wallpaper
  • Flocked doormats
Oggettistica
OBJECTS
Flock & Fibers
  • Flocked hangers
  • Flocked objects or toys
  • 3D printing with recycled fibers
Medicale
MEDICAL
Flock
  • Flocked swabs for medical analyses
Cosmetica
COSMETICS
Flock
  • Flocked applicators for lipstick 
  • Cosmetic sponges
  • Brushes
  • Flocked outer packaging for special effects
Alternativa edilizia
CONSTRUCTION
Fibers
  • Provide reinforcement and inhibit cracking
Isolanti
INSULATION
Flock & Fibers
  • Flocked sound-absorbing products 
  • Filler for sound insulation
  • Filler for thermal insulation
Cementi
CEMENT
Fibers
  • Fibrous concrete
  • Fibers increase tensile strength, impact resistance, deformability, crack resistance
Vernici
PAINTS
Fibers
  • Primers and finishes 
  • Decorative coatings and paints
  • Stabilizers for paints
Filtri
FILTERS
Fibers
  • Filter papers
  • Felts
  • Optimizes dimensional stability and porosity of the filter medium
Casa
HOME
Flock
  • Technical absorbent or abrasive articles
  • Sponges
  • Cloths
Automotive
AUTOMOTIVE
Flock
  • Flocked rubber profiles 
  • Flocked window seals 
  • Flocked glove box 
  • Door panels
  • Carpets
  • Flocked thread
  • Battery reinforcement Increased safety for brake pads
Modellistica
MODELLING
Flock & Fibers
  • Grass for dioramas
  • Sand for dioramas
  • Flocked objects
Vetrinista
SHOP DISPLAYS
Flock & Fibers
  • Flocked objects
  • Flock powder
Verde
GREEN AND PLANTS
Flock
  • Flocked flowers
  • Flocked branches
Natale
CHRISTMAS
Flock & Fibers
  • Fake natural snow
  • Snow-covered 
  • Christmas trees Snow-covered
  • Christmas objects 
  • Velvet-effect flocked Christmas baubles
Sicurezza
ANTI-COUNTERFEITING
Flock & Fibers
  • Banknotes
  • Passports
  • Certificates
  • Stamps
Plastica
PLASTIC
Flock & Fibers
  • Masterbatch from recycled fibers
  • Natural fiber fillers for bioplastics
  • Slip and heat regulation for thermosetting materials
Fabric textile material texture 2023 02 01 06 13 04 utc
TEXTILE RECYCLE
Flock & Fibers
  • Recycled flock for glamour applications
  • Recycled fibers for technical applications

APPLICATIONS

WHAT ARE THE APPLICATIONS OF FLOCK?

Explore the versatility of our flock, a semi-finished product adaptable to a wide range of industrial sectors. From technical contexts to glamourous ones, flock offers innovative solutions for every application.

HOW DO FLOCK APPLICATIONS TAKE PLACE?

Flock applications take place thanks to the flocking process, a technological production process through which flock powder is applied to a surface, flat or three-dimensional, previously covered with adhesive.

WHAT ABOUT TECHNICAL FIBERS?

The applications of technical fibers, on the other hand, do not involve the flocking process, since these are almost always used as fillers, and therefore inserted directly into the compounds.

Flock Tips
Did you know that flock
has sound-absorbing properties,
making it ideal for various
sound control applications?
If you work in the fashion industry,
you can contribute to circular economy
projects by creating your flock
from textile waste.
Did you know that cosmetic
applicator tips are made using flock?
Did you know that glove boxes in cars
are flocked for an elegant and soft touch on one side,
and to reduce noise and vibrations
from objects on the other?
Did you know that flock
can be used in paper as a filler
for structure or as a dye?
Did you know that technical fibers
are used in cement to provide
more structure to the material?
Did you know that paper
can contain ground fibers
from pre-consumer fashion waste?
Did you know that colored technical fibers
are integrated into money for
anti-counterfeiting purposes?
Did you know that flock
in concrete
prevents the formation of cracks?
Did you know that flock on a hanger
prevents clothes from slipping?
Did you know that a snow-covered
Christmas tree is made of flock?
REACH
OEKO TEX
GRS 125
141 Blatt rgb 120
CID DETOX
TUV sud
FSC 3002
REACH
OEKO TEX
GRS 125
141 Blatt rgb 120
CID DETOX
TUV sud
FSC 3002

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