From plant to performance – How Andritz builds the complete natural fiber processing value chain

As industries look for lower-impact materials, natural fibers are gaining wider acceptance across manufacturing sectors. Bast fibers such as hemp, flax and jute, along with coconut fiber (coir), are now widely used in automotive parts, insulation, construction materials, technical textiles and geotextiles. Their renewable nature and strong mechanical properties make them an attractive alternative for many industrial applications.

Turning these raw materials into consistent, high-quality products is not straightforward. Fiber length, moisture, impurities and natural variation all influence processing performance. Producing reliable industrial materials requires well-designed preparation systems before fibers even reach web formation.

This is where ANDRITZ has built its expertise. From bast fiber decortication to web forming with airlay and carding technologies, the company provides complete processing solutions that cover the full production chain.

Natural fibers continue to expand into industrial applications

Different natural fibers serve different markets because each offers unique physical characteristics.

Jute is valued for its strength, biodegradability and cost efficiency. It is widely used in geotextiles, erosion control fabrics, carpet backing and packaging materials.

Hemp offers high tensile strength, durability and good moisture resistance. These characteristics make it suitable for automotive interior components, technical composites, thermal insulation and construction materials.

Flax is known for its fine fibers and excellent stiffness-to-weight ratio. It is commonly used in premium textiles, lightweight automotive composites, furniture, thermal insulation and acoustic panels.

Coconut fibers, commonly known as coir, are naturally resistant to moisture and decay. They are widely used in mattresses, bedding products, horticulture, erosion control mats, brushes and cushioning materials.

Together, these fibers support a broad range of sustainable products, from industrial composite components to everyday consumer goods.

France’s long history with natural fibers

France has played a major role in natural fiber production and processing for centuries.

The country has long been recognised for producing high-quality flax, particularly in Normandy and Northern France, where some of the world’s finest linen fibers are still grown today for textile and technical applications.

French industry also has deep roots in hemp processing. Hemp was widely cultivated during the Middle Ages for ropes, sails and industrial textiles.

The country’s textile expertise also includes the historic silk industry centred around Lyon, which helped establish strong capabilities in fiber processing and textile engineering.

This long industrial heritage has created the foundation for France’s continued expertise in natural fiber processing and technical textiles.

Today, ANDRITZ continues that tradition through its three French locations, where decades of experience support the development of modern natural fiber processing technologies.

Complete natural fiber processing under one supplier

With more than 100 years of textile engineering experience, ANDRITZ provides industrial systems covering the complete production route from bast fiber decortication to finished nonwoven products.

Its portfolio combines fiber preparation with downstream airlay and carding technologies, allowing manufacturers to process natural fibers efficiently on an industrial scale.

Customers also have access to three technical centres in France, located in:

• Montbonnot
• Elbeuf
• Cours-la-Ville

These facilities allow customers to test various fibers and applications under production-like conditions before commercial investment.

Fiber preparation starts long before web formation

Natural fibers present several processing challenges.

Fiber length can vary considerably. Raw materials often contain dust, shives and other impurities. Moisture content also affects processing consistency.

Many equipment suppliers focus mainly on web formation. ANDRITZ addresses the earlier stages by integrating fiber preparation into the complete production line.

Its decortication, refining and cottonizing technologies are specifically developed for bast fibers. These systems are designed to:

• Open fibers gently
• Remove impurities efficiently
• Preserve fiber integrity
• Improve downstream processing for both carding and airlay applications

Preparing fibers properly at the beginning helps improve consistency throughout the entire manufacturing process.

Proven bast fiber processing performance

The ANDRITZ teXline bast fiber system combines dry cleaning, decortication and refining into a single processing solution.

For a typical hemp processing line, the system delivers approximately:

• 50% cleaned shives
• 25% cleaned refined fibers
• 15–20% dust
• Around 5% very short fibers

The process maintains high separation efficiency while preserving fiber quality.

The system is designed to process bast straw with controlled moisture levels between 12% and 16%, depending on the fiber type.

It can process both:

• Rectangular cut bales up to 50 cm in length
• Round uncut bales

The modular design allows production capacities to start at 1 tonne per hour, with expansion up to 2.5 tonnes per hour.

Standard industrial lines are available for straw throughputs of:

• 2.5 tonnes/hour
• 5 tonnes/hour
• 10 tonnes/hour

ANDRITZ also offers dedicated cottonizing technology developed from decades of flax cottonizing experience.

These systems operate between 0.1 and 1 tonne per hour, producing fibers suitable for:

• Spinning
• Nonwovens
• Hygiene products
• Specialty applications

The cottonizing process delivers consistent fiber quality while minimising remaining shive content.

Technical centres support process development

The three ANDRITZ technical centres in France allow customers to validate processing conditions before full-scale production.

The facilities support testing for:

• Bast fiber processing
• Decortication
• Airlay production
• Textile recycling
• Fiber preparation

This practical testing reduces uncertainty during project development and helps optimise processing parameters for different natural fibers.

From fiber preparation to value creation

Natural fiber properties often vary depending on harvest conditions and geographical origin.

Years of experience gained through the French technical centres allow ANDRITZ to deliver stable and repeatable fiber preparation, helping customers reduce production risks and quality fluctuations.

Once fibers are prepared, downstream airlay and carding technologies convert them into engineered webs with precise textile characteristics.

The systems are designed for natural fibers while remaining compatible with recycled and shoddy fibers when required.

Many manufacturers increasingly seek control over the complete production chain because better control of raw material preparation often leads to improved product quality and manufacturing consistency.

Local production also plays an important role.

Decortication facilities are typically located close to cultivation areas, such as hemp-growing regions. The prepared fibers can then move into nearby downstream manufacturing operations, supporting regional value creation throughout the production process.

Airlay technology for challenging natural fibers

ANDRITZ airlay production lines are designed to process:

• Short fibers
• Long fibers
• Recycled fibers
• Fragile natural fibers

The technology manages these different materials within one controlled process.

From blending through mat consolidation, the systems produce:

• Homogeneous fiber distribution
• High weight uniformity
• Consistent product performance

This is particularly valuable when processing natural raw materials that naturally exhibit greater variability than synthetic fibers.

Typical products range from 500 to 10,000 gsm, serving markets such as automotive components and insulation materials.

End-to-end systems for long-term production

When manufacturers invest in new production capacity, success depends on more than individual machines.

ANDRITZ provides complete process expertise across the entire natural fiber value chain—from decortication through fiber preparation, web forming, bonding and finishing.

As a single-source supplier, the company integrates every production stage into engineered systems designed around customer requirements.

Its technologies are developed, tested and validated through application-focused engineering, supported by technical centres and industrial installations worldwide.

With hundreds of installations operating across Europe, Asia, the Americas and emerging markets, ANDRITZ applies global processing experience to help manufacturers utilise natural, recycled and bio-based fibers in commercially viable production.

The result is a complete production approach that supports faster commissioning, higher equipment availability, consistent product quality and long-term operational competitiveness while enabling wider industrial use of sustainable fiber materials.