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Flock is a textile powder that can transform a simple surface into a soft, velvety, and pleasant-to-touch coating. It is a versatile material used in sectors ranging from automotive to packaging, from fashion to design, and owes its qualities to a production process that is as technical as it is fascinating. Casati Flock & Fibers has been producing high-quality flock for decades, starting from raw textile fibers and turning them into a perfect powder ready for application.

It all starts with the choice of raw material.
Casati uses vegetable, animal, synthetic, or artificial fibers, which can come in different forms: continuous filaments (tow), staples, fabric scraps, or textile waste from the fashion industry. Depending on their nature, these fibers are processed using different techniques. Non-continuous materials are ground in industrial mills to obtain flock in fine powders with specific granulometries, while filaments are precisely cut using guillotine cutters. In both cases, the result is fibers reduced to tiny fragments, ready for the next steps.

The resulting flock can then be dyed. This is done in dedicated vats and follows precise color specifications requested by clients: uniformity, lightfastness, and washfastness are essential. After dyeing, the flock undergoes activation, a chemical treatment that imparts the physicochemical properties necessary for the flock to be introduced into the flocking process.

After dyeing and activation, the flock is centrifuged and dried with hot air to reach a defined moisture range, which is crucial for achieving high-performance flock. It is then sieved to remove any fibers that are too long and could compromise the final result. Only after a series of rigorous quality checks—evaluating cut uniformity, color, granulometry, conductivity, and hand feel—is the flock considered ready. Casati completes its work by packaging the product and delivering it to clients, who then handle the actual flocking application.

But how does this process work?
The most common method is electrostatic flocking. In practice, the surface to be coated—whether plastic, metal, fabric, paper, or other material—is first cleaned and covered with a specific adhesive. Then, thanks to the properties imparted during activation, the flock fibers align in the electrostatic field and move perpendicularly to the surface, embedding themselves into the adhesive to create a uniform coating. After application, the adhesive is dried or polymerized, permanently fixing the fibers. Excess particles are then removed using compressed air or suction, resulting in a smooth, homogeneous surface.

This is where Casati’s precision really makes a difference. Properly cut, dyed, and sieved flock allows clients to achieve flawless results without defects or inconsistencies. Electrostatic flocking requires fibers with specific sizes, adequate conductivity, and a loose hand feel—characteristics that only a carefully controlled production process can guarantee.

In this way, raw textile material—or even waste from fashion production—becomes a valuable and versatile material. Casati Flock & Fibers provides clients with a perfect product, leaving them to transform it into stunning, velvety, and durable surfaces. It’s an ideal collaboration: on one side, expertise in producing high-quality flock, and on the other, the application skills of the companies that use it in their products. This is how every flocked surface comes to life.

Casati Flock & Fibers, a company specializing in the production of certified textile powder from by-products, is investing nearly half a million euros to give new life to waste.

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The Renate-based company, famous for transforming waste into resources, is ready for another leap.

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Casati Flock & Fibers is focusing on recycling and energy and water savings: the Renate, Brianza-based company has launched a €460,000 plan—50% co-financed by the Lombardy Region (through the Ri.Circo.Lo. call for proposals, which draws on the European Regional Development Fund)—to increase its capacity to recover previously untreatable textile waste, as well as rethinking the entire production process to reduce electricity and water consumption.

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Flock can be found in a wide range of industries—from interior design to automotive, from luxury packaging to cosmetics. But how do you choose the right flock for a specific project? It’s not just a decorative detail: it’s a strategic decision that affects perception, durability, and the identity of the final product. In this guide, we explore the main criteria to consider when selecting flock: appearance, texture, resistance, application methods, and fiber differences.

What is flock?

Let’s start with the basics: flock is a textile powder made from cut or ground fibers, electrostatically activated to adhere to a surface. This process transforms natural, artificial, or synthetic fibers into soft, visually rich, and often surprising coatings. Flock can be applied to a variety of flat or three-dimensional surfaces, delivering top-level visual and functional results.

From an aesthetic standpoint, luster is one of the most striking features. Depending on the fiber type, flock can be glossy, semi-glossy, or ultra-matte. The surface can therefore be elegant and discreet or more vibrant and dynamic, depending on project needs. Color is also highly customizable—but it’s important to note that the final appearance depends on the fiber's nature. Mass-dyed synthetic fibers, for example, offer superior lightfastness and maintain vivid tones even after long exposure.

Another defining trait of flock is the variety of visual effects it can produce. There are trilobal flock fibers that reflect light brilliantly, or special blends of cuts and fibers that create iridescent, dense, and textured surfaces. Casati Flock&Fibers has developed particularly innovative solutions in this area, such as “Stars” or “Special Blend” flocks, used in automotive interiors, design objects, and artistic installations.

Texture and technical features

Texture is equally important and depends on the fiber length, its diameter (measured in Dtex), and the density of application. Very short flock feels dry and rough to the touch, while longer flock is softer and more enveloping. A thicker fiber results in a full, substantial touch, while ultra-fine fibers give a lighter, velvety feel. Density plays a key role too: higher concentrations create rich, compact surfaces, while lighter applications allow the base to show through, giving a more natural and tactile effect.

Beyond appearance and feel, technical performance is crucial. Abrasion resistance is essential for products subject to frequent handling or rubbing, such as car interiors, packaging, or accessories. Again, synthetic fibers tend to offer the best performance. For projects exposed to direct sunlight or UV rays, mass-dyed fibers are recommended to maintain color stability over time.

The functionality of flock

Flock also serves a protective function: it can absorb impact, prevent scratches, and even contribute to sound insulation. In the automotive industry, for example, it helps reduce internal mechanical noise. Post-flocking treatments are available to make surfaces water-repellent, antibacterial, flame-retardant, or resistant to oxidation, depending on project requirements.

From an application standpoint, flock can be used on plastic, paper, metal, wood, textiles, and three-dimensional objects. Electrostatic activation ensures uniform coverage even on complex geometries, making it suitable for many sectors. In interior design, for instance, it is used on walls, furniture, and decorative elements, offering a warm and inviting aesthetic. In automotive applications, flock is used both inside and out—as shown in the Velvet Car project, where Casati developed a tailored solution for this specific use. In packaging and accessories, flock adds a tactile quality that instantly conveys craftsmanship and attention to detail.

In conclusion

Choosing the right flock means combining aesthetics, tactility, technical performance, and sustainability. It’s a choice that should be made with full awareness of fiber characteristics, application methods, and desired outcomes. At Casati Flock&Fibers, every project is a chance to turn surfaces into experiences.
And the perfect flock? It does exist—you just have to imagine it.

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