Roaches has introduced Fortis, a new high-speed infra-red yarn bonding and coating system designed to overcome the long-standing limitations of traditional horizontal yarn coating processes and deliver higher precision, lower waste and greater operational flexibility for modern textile manufacturing.
Yarn and thread coating is a critical process across multiple textile applications, where fibres are treated with chemicals, dyes, finishes and bonding agents to achieve specific performance, handling or end-use characteristics. However, conventional horizontal coating systems have long been associated with a range of process inefficiencies, including uneven chemical distribution, inconsistent product quality and limited control over critical operating parameters.
According to Roaches, one of the most persistent problems in horizontal coating systems is the effect of gravity on coating uniformity. In traditional layouts, coating substances can accumulate on one side of the yarn during processing, resulting in inconsistent application, variable product quality and unnecessary chemical waste. These challenges are often compounded by fluctuating yarn tension, restricted speed and temperature control, and inefficient use of factory floor space.
Fortis developed to solve long-standing coating challenges
To address these issues, Roaches has developed Fortis, a high-speed infra-red (IR) yarn bonding and coating system that rethinks the coating process from the ground up. Unlike conventional horizontal machines, Fortis uses a vertical configuration, changing both the physical layout of the system and the way yarn is processed during coating and bonding.
The machine is built as a compact upright structure in the form of an arch, allowing yarn to pass vertically through the system while also enabling operators to move freely through the machine footprint. This design significantly reduces floor space requirements while creating a more controlled processing environment aimed at delivering more even, efficient and repeatable yarn coating.
Precision control at the core of the Fortis system
Roaches has positioned Fortis as a technology-driven coating platform with a strong focus on process control. The system offers a range of tightly managed operating parameters intended to improve coating consistency and production efficiency. These include:
- High-accuracy chemical dosing of up to four solutions
- High-speed throughput of up to 600 metres per minute
- Precision yarn tension control
- Exact control of infra-red power output
The ability to fine-tune these variables to extremely tight tolerances makes Fortis suitable not only for production-scale manufacturing but also for research and development environments, where repeatability, adaptability and process experimentation are essential.
Built for space efficiency and modern manufacturing flexibility
Beyond coating precision, Fortis has been engineered to respond to broader production challenges faced by textile manufacturers. Its compact vertical footprint allows mills and processing facilities to reduce the space needed for yarn coating operations compared with conventional horizontal systems, helping optimise plant layouts and improve equipment density within production sites.
The machine has also been designed with modular scalability, enabling manufacturers to configure the system for different capacity requirements, from specialised technical applications to larger high-throughput operations. Roaches notes that the system can also be integrated with existing winding technology already in use on production floors, allowing users to retain the nuances of their current winding setup while upgrading to the performance and process benefits of Fortis.
Supports multi-stage chemical application with low waste
A major feature of the Fortis platform is its ability to support multiple application stages within a single process. The system can apply up to four different chemicals sequentially to a single yarn, enabling more complex treatment combinations without sacrificing efficiency.
This multi-pass capability opens up opportunities for manufacturers working with technical, functional or performance yarns that require layered coatings, specialised bonding or multiple finish applications. At the same time, the system has been designed for ultra-low chemical wastage, supporting both cost savings and sustainability targets by reducing material losses during processing.
From bespoke customer solution to commercial product
The development of Fortis began as a bespoke engineering project for a customer seeking a more modern and precise yarn coating and bonding solution. Roaches worked closely with the client to design a system tailored to their operational needs and process requirements.
Following successful implementation, the company further refined and expanded the technology, leading to the commercialisation of Fortis as a market-ready solution for a wider range of textile manufacturers. Roaches says the system is already installed and operating in facilities in the UK and international markets, where it has demonstrated its ability to improve efficiency, consistency and control in yarn coating and bonding applications.
A modern alternative to traditional yarn coating systems
With growing demand for higher-quality yarn processing, reduced waste, better energy efficiency and more adaptable manufacturing systems, technologies such as Fortis reflect the textile industry’s shift towards smarter, more controlled production environments.
For manufacturers looking to improve coating uniformity, reduce chemical waste, optimise production space and introduce more flexible process capabilities, Roaches’ Fortis system offers a modern alternative to traditional horizontal yarn coating methods, combining precision engineering with scalable industrial performance.