News

Latest News/Updates

Mar 2019

Insulated Packaging - A New Market Sector

At the beginning of 2017, John Cotton took the opportunity to expand its expertise into a new market area, where our traditional highloft nonwoven products found a natural fit. Having over 20 years’ experience producing loft insulation for housing, and technical expertise in fibres for thermal performance, the Nonwovens Division launched itself into the ‘insulated packaging’ market. The insulated packaging market traditionally uses polystyrene foam, or foil lined bubble wrap, both of which have limited recycling routes at the end of life. With the increasing concern over plastic waste ending up in landfill and our oceans, companies and the consumer are becoming more environmentally concerned about the disposal of packaging. The John Cotton Nonwovens Division has always had the environment at the forefront of its business philosophy. Founded on the recovery and upcycling of textile waste for over 100 years, we are experts in this field and have been producing natural and recycled synthetic materials for various industry sectors, including loft insulation for decades. With a growing trend in subscription box services, where insulated packaging is required in a large percentage of these cases, John Cotton Nonwovens Division saw a gap in the market where our products could provide the performance and protection needed, plus the ability to manufacture the whole product in one offering “outbidding the competition on price”. OUR CUSTOMERS ‘Hello Fresh’ Europe’s largest online meal kit delivery service, produces approx. 40,000 boxes a week for the UK alone, and was our first customer who gave us the chance to grow and establish ourselves in this new market sector. For Hello Fresh, we produce an insulated pouch where the fibre has originated from recycled polyester waste such as bottles. Hello Fresh market this fact on the recyclable polyethylene bag which surrounds the insulation, by telling the consumer the number of plastic bottles that have been recycled to make that pouch. Our other well-established customer in the market, ‘Mindful Chef’, who pride themselves on donating a meal to charity for every meal they sell, use our Cool Blue™ denim insulation. This product is made from the offcuts and waste produced during denim manufacturing. Every year we recycle just over 160 tonnes of denim offcuts by upcycling this pre-consumer waste into our Cool Blue™ insulated packaging. PERFORMANCE & SAFETY All our insulated packaging materials are tested in-situ and using a guarded hot plate to obtain an R-Value. Our onsite laboratory allows us to test our products inside a climate-controlled room that mimics the external ambient temperature. Our results show that our insulating material can maintain temperatures below the important 8° for up to 48 hours. At John Cotton we consider the safety of the product as paramount, that is why our insulated packaging is tested for fibre cleanliness using BS 1425: Part 1: 1991, in our in house UKAS accredited laboratory. The insulation is also tested by Smithers Pira, the World recognised authority for packaging, print and paper chain supply to certify it is compliant with BS EN 1186-3:2002 (suitability of materials in contact with food stuffs). INVESTMENT To help with the increasing demand of customers in this sector approaching John Cotton for products and to aid with the growing volume from our well-established customers Hello Fresh and Mindful Chef, John Cotton Nonwovens Division made an investment of £90K in an automated packaging line to improve efficiency and increase productivity. With the growth in subscription box services such as Hello Fresh and Mindful Chef set to rise to a £1 billion market by 2022 (according to Royal Mail), John Cotton Nonwovens are excited about the prospect this new market may bring to the business.

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Oct 2018

New Factory Opening in Szczawno Zdroj, Walbrzych, Poland.

On Wednesday 24th October 2018 John Cotton Europe had their grand opening of their new factory in Szczawno Zdroj/Walbrzych, Poland. Duvets, toppers and children’s mattresses will be made here which has generated 100 new jobs! The factory is a sizeable 130,000 square feet. In attendance for the grand opening where the Mayor of Szczawno and Mayor of Gluszyca along with John Cotton, Mark Cotton, Nicholas Manning and Paul Butterfield who had flown from the UK for this special event. Managing Director of John Cotton Europe, Michael Rudniak, said “This world class facility will provide a great platform for future growth for John Cotton Europe. This was a really challenging project which went extremely well. From being a retail macro outfit to being a very important well-equipped business unit is incredible in the time scale of 1 year”.

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Sep 2018

Bed Component Supplier of the Year - Runner Up

John Cotton Nonwovens achieved Runner Up for the Bed Component Supplier of the Year Award at the Bed Show in September 2018. We are immensely proud to have been recognised again for this category having won it twice before. We are going for another win next year!

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1.5k Investment

Jul 2018

£1.5 Million Investment in New Thermal Bonding Oven

In July 2018 John Cotton made a £1.5 million investment to upgrade our existing thermal bonding oven used on our unique carding line.

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Nov 2017

£90K Investment – Automated Packaging Line

Having successfully secured new business in the chilled packaging market, the Nonwovens Division were committed to improve our manufacturing capability to deliver value to our new customer base.

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Sep 2017

NBF Winner of Bed Component Supplier of the Year

John Cotton Group has won 'Bed Component Supplier of the Year 2017/2018'.

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