News
Fibre: The secret behind smarter soft furnishings!
Fibre fillings are driving a new era in upholstery as their use as a high-performance alternative to PU foam becomes more prevalent.
There are several reasons why fibre is gaining traction:
Comfort & Support
Fibre offers a soft, plush feel that’s perfect for creating that sought-after “sink-in” sensation in cushions and sofas. It also provides excellent support and rebound, ensuring furniture holds its shape and comfort over time.
Natural Breathability
Fibre allows for better air circulation, which helps prevent heat buildup and contributes to a more comfortable sitting experience.
Inherently Flame Resistant
One of the major advantages of fibre fillings is their natural flame resistance. This means there’s no need for additional flame-retardant chemicals.
Hypoallergenic Properties
Fibre’s hypoallergenic nature makes it is ideal for those with allergies.
Recyclability
Fibre is completely recyclable at the end of its life and can often be found in products such as carpet underlay.
The fibre used in our sprung sofa cushion, the PeakPocket™, is made from recycled plastic bottles and goes some way towards combatting the eight million tonnes of plastic waste that fill our oceans every year.
So far this year, we have repurposed more than 400,000 bottles through our use of innovative fibre fillings, and this number is increasing daily.
- To find out more, get in touch sales@peakconverters.co.uk
We’ve been crowned the BFA’s Excellence in Sustainability award-winner!
We are delighted to announce that we have been awarded the Excellence in Sustainability Award by the British Furniture Association!
This award recognises exemplary work from a BFA member in working towards a more sustainable future.
From installing LED lighting across our factory, to upgrading our production machinery as part of our drive to reduce energy consumption and installing solar panels on our factory roof which will generate sufficient power to run our entire production facility, we are making big strides forward.
We’re also partnering with suppliers who give us access to more environmentally friendly foam and fibre materials than ever before and have recently launched our new fully recyclable spring sofa cushion, the PeakPocket™
Well done to our entire team on this fantastic achievement.
Reflecting on 2024’s Highlights and Embracing Innovation for 2025
As we step into 2025, January offers the perfect opportunity to reflect on our successes from 2024 and outline our goals for the year ahead.
The furniture market faced its share of challenges last year, particularly during a slower summer period. However, we saw robust demand in other sectors, including automotive, sports equipment, and industrial applications. Despite the fluctuations, our commitment to innovation and quality remained steadfast.
Key Achievements in 2024
- Progressing with Our IIOT Initiative
- We made significant strides in our Industrial Internet of Things (IIOT) project. A key milestone was the launch of an extensive machine refurbishment program, targeting every piece of equipment in our factory. These upgrades aim to enhance efficiency and future-proof our operations.
- Enhancing Upholstery Production
- To meet growing customer demand, we implemented major upgrades to our upholstery line. These improvements increased throughput for upholstery kits, ensuring our lead times remain among the most competitive in the industry.
- Exhibiting at the Furniture Component Expo
- Spring marked an exciting first for us as we participated in the Furniture Component Expo in Telford. The exhibition, which looks set to grow into an important industry event, provided an excellent platform to connect with existing customers and forge new partnerships. It also gave us a good insight into the ways furniture manufacturing may be changing in the future.
- Innovating through partnerships
- In collaboration with Wade Springs, we developed an eco-friendly sprung sofa cushion that is fully recyclable at the end of its life. This project reflected our ongoing dedication to developing practical, environmentally friendly, solutions without compromising on quality or performance.
- Investing in Renewable Energy
- Sustainability took centre stage in the Autumn with the installation of solar panels enabling us to generate enough energy to power our entire factory. This investment underlines our commitment to reducing our environmental footprint.
Looking Ahead to 2025
As we move into 2025, we’re focused on solidifying our position as the go-to partner for innovative, high-performance, eco-friendly foam and fibre solutions.
New Partnerships
- We’ve joined forces with Think Group (formerly Texfelt), a leader in resilient fibres and sustainable non-wovens. This partnership will allow us to offer more innovative and environmentally friendly fibre solutions to our customers.
IIOT Phase 2
- Building on the success of our IIOT initiative, Phase 2 will focus on monitoring and reducing energy consumption across the factory. This effort will further drive our energy conservation commitment and help to boost operational efficiency.
Returning to the Furniture Component Expo
- We’re thrilled to be participating in the Furniture Component Expo (19th/20th March) once again. The event promises new opportunities to connect with industry leaders and showcase our latest innovations.
Commitment to Excellence
- Our dedication to outstanding customer service remains unwavering. We aim to maintain competitive lead times and exceed customer expectations through strong long-term relationships and by adopting an innovative approach. Additionally, we’re continuing to invest in our workforce by implementing a multi-skilling program to enhance employee development.
2025 promises to be an exciting year for all of us at Peak Converters.
Investing for a Sustainable Future
We are delighted to announce that this month will see the start of our solar energy project, which will involve the installation of 500 solar panels on our factory roof.
The sizeable installation will generate sufficient energy to power our entire factory and will take 60 days from project inception to completion, with the installation of the panels anticipated to be completed within two weeks.
Solar energy is a clean, renewable source that produces zero emissions. Our project is equivalent to avoiding 54 tons of CO2 output – comparable to planting 10,318 trees over the lifetime of the system.
111% of our energy will be generated from solar with surplus going back into the national grid, so that any excess electricity can be stored for later use, further reducing our carbon footprint.
This investment demonstrates our dedication to reducing our environmental impact and brings us closer to achieving our long-term goal of becoming a net-zero converter. We are leading by example by ensuring a brighter, greener future.
STRIVING FOR A GREENER FUTURE
As one of the UK's largest foam and fibre converters, we convert around 1000 tonnes of foam and 250 tonnes of fibre every year. We are the UK’s leading supplier of upholstery kits to the trade and produce around two million kit components every year. These are assembled and supplied as upholstery kits or cushions to some of the largest furniture, caravan, and mobile home manufacturers in the UK.
We also manufacture components for hundreds of other applications, from car sponges to pipeline pigs.
As part of our commitment to moving towards net zero and improving our environmental impact, we have introduced several continuous improvement initiatives throughout our design and manufacturing process to minimise foam and fibre waste during production, including a fully integrated, automated nesting system.
By its very nature, conversion is about minimising waste to get as much product as possible out of every block of foam or sheet of fibre. We are enormously proud to say that waste foam and fibre never ends up in landfill directly from their factory. In fact, there are several outlets through which waste product (trim) is managed, including sending it back to the foam manufacturers where it is repurposed into reconstituted foam. Reconstituted foam can be used in applications such as gym mats, underlay or upholstery. In addition, the company also creates its own crumb for use in applications such as cushions and soft play bags.
Good stock management is critical to minimising waste with every foam block or fibre sheet, as well as part blocks, being tracked so it can be used for sampling and small part runs. Our reputation for handling trim well, and keeping it exceptionally clean, has seen us become preferred supplier to several fibre manufacturers as it’s use has become more mainstream over the last few years.
So where does the future lie?
Says MD Mike “We have seen many manufacturers switch from foam to fibre over the last 5 years following chemical shortages in the foam industry and an increased demand for more environmentally friendly raw materials. I expect this shift will continue as fibre manufacturers improve their products and create materials which offer similar comfort and longevity to foam. Having said that, I don't think foam will completely disappear. Foam manufacturers are working hard to remove chemicals and create more recyclable products and we are well placed to help them test the applications for those.”
Furniture Component Expo Show Roundup
We were delighted to take part in the inaugural Furniture Component Expo in April. The event proved to be a busy couple of days for our team who enjoyed meeting with existing customers as well as new contacts.
Our focus for the show was on our upholstery kits and cushions, with the stand featuring a selection of our innovative foam and fibre fillings. The stand also incorporated a live link to the factory, which proved an interesting talking point for visitors!
Says sales director, John Davies “The exhibition gave us a good insight into the ways furniture manufacturing may be changing. The general opinion was that it had been a good show and everyone I spoke to said they would be doing it again next year. I believe it could grow into an important industry event.”
Farewell to Maggie!
At the end of April we said farewell to Maggie Brooks-Kinder who retired after 23 years' of service.
Maggie is a local resident of our beautiful Derbyshire Dales town, Wirksworth and was a valued member of our Cushion Line Team.
Maggie has seen many changes during her time with us and has always approached them with enthusiasm and support.
She is also well known for her delicious cheese scones which she makes for our annual MacMillan bake sale!
We thank Maggie for her service and hope she enjoys spending more time with her children and grandchildren.
We wish her all the best and hope that she will pop in to see us from time to time.
Welcoming 2024 with enthusiasm and LOTS of plans at Peak Converters!
Happy New Year! It is hard to believe we are well into January already. Time really does fly.
At Peak Converters we are looking forward to the year ahead and wanted to give you a sneak peek into some of the developments on the horizon.
Investing in excellence: Modernising our facilities
We are continuing to invest in modernising and upgrading our plant and facilities to deliver the absolute best in service for our customers, whilst also making our environment inviting and comfortable for our employees.
To that end we are embarking on a refurbishment programme of our staff facilities which will include new kitchens, flooring, paintwork, and general modernisation to help us make Peak Converters a great environment to work in, helping us attract new talent into the business and to continue to grow our Peak Converters family.
Green Initiatives: Moving towards net zero.
On the back of our upgrade to LED lighting right across our factory in 2023, which slashed our lighting energy consumption by 59%, we are continuing our journey towards net zero manufacturing and are committed to improving our environmental impact. In the spring we’ll be installing solar panels, which will further help to move us towards our goal.
Upholstery kits and cushions: Expanding our supply.
Having sold more upholstery kits and cushions than ever before in 2023, we remain ready to meet the needs of customers up and down the UK for upholstery kits on very short lead times.
Save the Date: Our exhibition debut!
Finally, we are looking forward to attending our very first exhibition! You’ll be able to find us at the Furniture Component Expo in Telford on 24/25th April. We are looking forward to taking part in this inaugural event and showcasing our products.
Here's wishing you all a fantastic 2024!
Fundraising for Macmillan
At the end of September we hosted a Macmillan Coffee Morning for our employees.
Everyone came together to enjoy coffee and cake and our HR Manager Kathryn was rushed off her feet serving up the delicious treats. As you can imagine there weren't many left at the end of the day!
Together we are very proud to have raised £257.50 for this wonderful charity and we had lots of fun in the process!
Your upholstery kits are in safe hands with us!
We are proud to be the UK’s leading supplier of upholstery kits to the trade and have produced millions of kits and cushions for some of the largest furniture, caravan, and mobile home manufacturers in the UK.
Whether you are upholstering a sofa, stool, chair, or headboard, our 80 strong team has a wealth of knowledge, and our factory is fully equipped to deal with both standard and complex, small- or large-scale batch runs, with incredibly competitive lead times, including a one-week turnaround on upholstery kits.
Upholstery kits can save upholsterers time and effort by providing all the necessary materials in one package and typically include; foam padding, which comes in various thicknesses and densities, giving shape and comfort to the piece; cushioning material that is placed between the foam and the outer fabric, which helps to smooth out any irregularities, and gives the upholstery a more polished appearance; bespoke accessories such as tape or dipryl can also be included.
Says managing director Mike Crowshaw “Upholstery kits really are our bread and butter. We despatch several thousand kits to clients up and down the UK every month. Our job is to keep the furniture makers in production and our kits can be uniquely tailored to the requirements of each customer. We pride ourselves on our quick turnaround time, and the high quality of our kits. Our return rate is a fraction of a percent.
“We appreciate that upholstered furniture is a key investment for many and are proud of the part we play in helping upholsterers to create something special for the consumer.”
Peak Converters celebrate Pride month
During the month of June we participated in Pride celebrations, which culminated in our coffee morning last Thursday, where all employees were invited to join us to celebrate diversity and inclusion across our workforce.
Our theme was simple ‘Everyone is welcome here’.
Special thanks to Derbyshire business ProjectD for providing customised doughnuts for our event. We're sure you’ll agree they look delicious. Our driver Richie, certainly enjoyed his!
Why fibre makes a great alternative to foam for upholstered furniture
Fibre has been used as a filling material by the furniture industry for many years now, primarily for wrapping cushions made from foam cores to give a softer feel. During the pandemic its usage became more mainstream with fibre now being more widely used by upholstered furniture manufacturers for frame wrapping.
This was partly driven by foam shortages within the supply chain, which meant that the industry had to seek alternatives during a time when the demand for upholstered furniture was increasing. As a result, fibre gained popularity.
Fibre fillings are generally made from polyester fibres and provide good levels of comfort. Fibre offers a soft feel and can be particularly suitable where a ‘sink-in’ sensation is required. It also has good hypoallergenic properties. Fibre adds a luxurious touch to furniture, making it comfortable and inviting.
Fibre fillings have gained popularity in recent years due to their affordability and eco-friendly nature. Some are now made from fully recycled materials, with fibre being a completely recyclable product at the end of its life.
Please get in touch if you would like to find out more about our fibre products.
Why foam continues to be the filling of choice for upholstered furniture manufacturers
Foam fillings have been widely used in upholstery for decades and have long been the go-to material known for their exceptional comfort and support.
Here we examine why foam has stood the test of time as the filling of choice for upholstered furniture manufacturers, and we look at what the future holds for the foam manufacturing industry.
Foam
Foam fillings are highly durable, designed to be long-lasting, and have an ability to retain shape, even with regular use. Foam is resistant to sagging, deformation and loss of support over time, meaning that for upholstery manufacturers the product maintains its original look and feel for an extended period, giving enhanced durability. It also comes in a variety of densities and firmness levels, allowing the furniture manufacturer to choose the right one for each product and specific need, or desired USP for your product. High density foams, due to their structure, also have excellent anti-allergen properties.
Despite its many proven benefits, the main draw-back associated with foam usage is its environmental credentials. Foam is made by mixing chemicals and expanding agents and until very recently it has been difficult to recycle end of life foam products. Many foam products can be repurposed at the end of their life into materials such as insulation, soundproofing, and even mulch. However, if sent to landfill, foam can take a long time to decompose.
The foam industry has been working very hard to find a solution to this issue. Earlier this year it was announced that foam manufacturers have successfully produced the first flexible foam sample from fully recycled polyol, along with the technology to chemically recycle these products and convert polyurethane into a high-quality recycled material. This is great news for our industry and the circular economy.
At Peak Converters we have several exciting, ongoing projects aimed at supplying more eco-friendly products using both foam and foam replacement fibres and look forward to sharing details of these later in the year.
For more information please contact our sales team
Peak Converters celebrates International Women’s Day
Earlier this month we celebrated International Women’s Day in recognition of the contribution of our female colleagues who make up some 40% of our 80 strong workforce.
We are extremely proud to celebrate our female colleagues, half of whom work on a part-time, flexible, basis. We are also proud to champion the role of women in manufacturing where female employees average only around 15-20% of workers.
Peak Converters launches innovation programme that will see it reduce lead times and increase capacity
We are proud to have been converting foam and fibre products from our site in Wirksworth, Derbyshire for over 50-years. Having rebranded our company at the start of 2022, the focus for 2023 is on transformation.
We are underway with a number of initiatives which will benefit our customers as we strive to reduce lead times and increase capacity.
One such initiative involves using Industrial Internet of Things (IIOT) to integrate monitoring hardware with our in-house software to track energy usage and machine efficiency in real-time. The project will be ongoing over the next 12 months with the end goal of ensuring the efficiency of our plant is maximised.
IIOT, otherwise known as industry 4.0 or the ‘industrial internet’ involves the connected use of machines, sensors and devices in industrial applications. There are hundreds of IIOT compatible sensors available to measure current, temperature, humidity, voltage, water levels… you name it. Our focus will be on improving our environmental impact by using sensors to monitor and identify areas of increased energy consumption in our factory. We will also be using sensors to measure and trouble-shoot machine efficiency.
Managing Director Mike Crowshaw states ‘Offering competitive, short lead times and being able to respond quickly is a key selling point for us at Peak Converters and we are always striving to do more for our customers. I’m really excited about this innovative project which will allow us to improve our environmental impact as well as increase capacity for our customers.’
