The Evolution of TBV: KE Fibertec’s Journey from Innovation to Industry Standard

For over half a century, we have remained at the forefront of Textile Based Ventilation (TBV), pioneering a revolutionary approach to air distribution that offers a sustainable, flexible, and efficient alternative to traditional metal duct systems. The journey to TBV began with a simple vision: to create an air distribution system that not only meets functional needs but also contributes to a healthier, more sustainable environment. This article explores the history of our company, tracing the milestones that have led to the development of TBV and detailing why it has become the preferred choice for modern ventilation solutions.

The Origins of Textile Based Ventilation
So how did the concept of TBV come about? Surprisingly, the idea was first conceived in Danish slaughterhouses. Large spaces within these facilities required high-velocity air supply at freezing temperatures to maintain hygiene and operational standards. However, the intense cold drafts negatively impacted employee wellbeing, resulting in higher-than-average sick days. This sparked a growing belief that, while cold drafts and temperatures do not directly cause illnesses, they make the human body more vulnerable to common illnesses like the cold and flu. There are several theories as to why this might be the case - such as reduced nasal cavity temperatures that weaken antiviral defences or that rhinoviruses replicate faster at lower temperatures - but science has yet to offer a definitive answer. What is certain, however, is that well-designed ventilation with minimal drafts can significantly reduce infection rates.

Following the switch to textile ducts in Danish slaughterhouses, employee health markedly improved, with sick days decreasing drastically. This success marked the start of a new era in air distribution that emphasised health and comfort alongside functionality.

From Cotton Bags to Modern Materials: TBV’s Material Evolution
The first TBV solutions introduced in 1974 were simple "bags" made from cotton fabric. These textile ducts would inflate and gently diffuse air into spaces, offering a comfortable and consistent airflow. Over the years, as the concept proved successful, we experimented with other materials, focusing on improving cost-effectiveness, sustainability, and durability.

The next material advancement came with the use of polypropylene, a choice driven by both environmental and economic considerations. Polypropylene production has a lower environmental impact, generating no toxic waste or emissions, no fluorocarbons (a greenhouse gas), and no halogens (toxic chemicals). The shift to polypropylene made TBV even more sustainable while keeping costs manageable, positioning textile ducts as a viable alternative for a wider range of applications.

The final transition was to flame-retardant Trevira, a 100% polyester material that we still use today. Trevira is not only durable and cost-effective but is also fire-rated according to the OEKO-TEX Standard 100, ensuring safety in even the most demanding environments. With Trevira, we brought textile ducts up to modern standards, making TBV an attractive choice for commercial, industrial, and institutional spaces worldwide.

Innovations in Air Distribution Design
As we continued to innovate, it wasn’t only the materials that evolved but also the way air was distributed. Over the years, we introduced sophisticated orifice and nozzle systems, which allowed for even greater precision in airflow control and distribution. These innovations helped adapt TBV to increasingly diverse environments - from quiet office spaces to large sports arenas - where precise airflow and minimal noise were essential.

In addition, we developed the InTex monitoring system, which allows clients to assess and manage indoor air quality in real-time, ensuring the effectiveness of their TBV systems and promoting a healthier indoor environment. Another groundbreaking development was our CradleVent recycling programme, an initiative aimed at extending the lifecycle of textile ducts while reducing waste. CradleVent promotes a circular approach by taking used textile ducts and repurposing them, furthering our commitment to environmental sustainability.

Meeting the Environmental Challenges of the 1990s
During the 1990s, environmental concerns grew, and sustainable construction practices began to gain prominence. We recognised that traditional HVAC systems were energy-intensive and often failed to meet evolving environmental standards. Textile ducts, by contrast, required fewer resources to produce and could be designed to support energy-efficient airflow patterns, thus reducing the overall environmental impact of ventilation systems.

Customisation options also came into focus, with TBV systems tailored to specific architectural and operational needs. From colour matching to shape adaptations, our custom TBV systems blended seamlessly with building aesthetics while optimising airflow for different layouts. By the end of the decade, TBV had gained popularity across a range of applications, from commercial offices to sports arenas.

The 2000s and the Role of TBV in Sustainable Building Certifications
As the 2000s brought stricter indoor air quality and energy efficiency standards, we continued pushing the boundaries of TBV design and digital integration. Building Information Modelling (BIM) software enabled precise digital modelling of TBV designs, improving installation efficiency and ensuring regulatory compliance. Additionally, advanced airflow simulation software allowed us to refine TBV solutions further, enhancing their efficiency and adaptability for complex architectural projects.

In recent years, green building certifications like BREEAM, LEED, and WELL have become industry standards, and our TBV systems have emerged as an essential tool for achieving these certifications. With a low environmental footprint and reduced HVAC energy use, textile ducts support buildings aiming for high sustainability standards. Innovations like yarn dyeing and water-free transfer printing reduced water consumption by over 1 million litres annually, aligning with global trends in sustainable manufacturing and further lowering the environmental impact of TBV.

Advanced Technology and the Future of Textile Based Ventilation
Today, we continue to lead the industry in Textile Based Ventilation by embracing cutting-edge technology. Digital twinning and BIM integration allow clients to visualise TBV installations, assess airflow patterns, and streamline installation processes, all while ensuring the highest precision in air distribution. Additionally, sector-specific solutions like the Defrost Sock demonstrate our ability to meet specialised needs, such as reducing defrost times and saving energy in refrigerated environments.

Why Choose Textile Based Ventilation?
Unlike traditional metal ducts, TBV systems are lightweight, easy to install, and offer unparalleled flexibility. Textile ducts can be designed in various shapes, colours, and sizes, making them suitable for almost any architectural style or functional requirement. TBV provides quieter, more comfortable, and energy-efficient air distribution, significantly reducing energy costs and environmental impact.

Our Legacy and the Future of Sustainable Air Distribution
With decades of experience and an unwavering commitment to sustainable innovation, we have reshaped air distribution through TBV, establishing textile ducts as a viable alternative to traditional metal ductwork. Our journey from simple cotton “bags” to the advanced systems of today underscores the power of continuous improvement and adaptability to industry needs.

As we look to the future, our dedication to technological advancement and environmental responsibility promises even greater benefits for buildings, occupants, and the planet.