KRYSTALFLEX® films are a flagship safety‑glazing technology, manufactured in‑house by Huntsman’s thermoplastic polyurethane (TPU) elastomers team at the corporation’s Ringwood, Illinois facility. Tom Baird, Site Manager at Ringwood, explains more about the plant’s manufacturing capabilities, and the processes and people involved in making this innovative interlayer laminating film solution.
Can you describe Huntsman’s Ringwood facility and what is made on-site?
Huntsman’s Ringwood manufacturing plant is a long-established hub for TPU production, with roots stretching back to the 1960s. Located around an hour’s drive from Chicago, the plant produces advanced materials including KRYSTALFLEX® TPU resins for safety glazing film applications. These grades are manufactured alongside KRYSTALGRAN® aliphatic-based resins for optical and non-optical applications such as display screens traffic signs, graphics and surface protection films.
When did the production of KRYSTALFLEX® TPU start at Ringwood?
KRYSTALFLEX® TPU production started at Ringwood around the millennium, when the technology was transferred from a Massachusetts facility. The move consolidated the production of KRYSTALFLEX® TPU under one roof, as part of Huntsman’s long-term TPU strategy. Today the site is as a key manufacturing center within Huntsman’s global polyurethanes business; with investments and upgrades made to the facility’s production capabilities in recent years.
Does a dedicated team handle the production of KRYSTALFLEX® TPU?
From a production perspective there are a mix of employees and contractors at Ringwood – with many focusing primarily on the manufacture of aliphatic TPU, which includes optical grades for KRYSTALFLEX® TPU film applications. The site operates 24/7 with 12‑hour rotating shifts. Operators are cross‑trained and flexible, allowing the site to adapt quickly and easily to the changing demands of customers, while maintaining the very highest quality and safety standards. For KRYSTALFLEX® TPU we also have dedicated process engineering; quality; and commercial and technical service teams – who work closely with many of the world’s leading safety glazing customers. This mix of expertise ensures just the right blend of deep manufacturing know-how alongside exceptional customer sales and technical support.
Can you give an overview of the production process?
The KRYSTALFLEX® TPU production process is broadly made up of three core stages:
What about film testing? Where does that take place?
Film testing takes place on site at Ringwood but also extensively at our R&D center in Derry, New Hampshire. Plus, our film‑Extrusion partners also run tests after the resin is converted into films.
KRYSTALFLEX® TPU films are growing in popularity and Ringwood has been operating for a long time. Does the site have the capabilities and the capacity to support future growth?
Absolutely. At Ringwood we have scalable capacity for resin production and agile batch‑based processes enabling customization and the creation of tailor-made formulations for customers. Recent investments on site have focused on process control and safety improvements – including the installation of advanced feeder systems. We’ve also enhanced our testing capabilities – including haze measurement and application-relevant testing to match customer requirements. These changes mean the site is well positioned to support future growth in the Americas, but also in Europe and in APAC – where there are significant opportunities.
What about sustainability and waste reduction efforts in the production of KRYSTALFLEX® TPU? Are there specific processes in place at Ringwood to ensure the manufacture of resins is as environmentally friendly as possible?
TPU is an inherently recyclable form of polyurethane chemistry. Unlike thermoset materials, it can be melted down and reprocessed multiple times without fundamentally changing its chemical structure. At Ringwood, we utilize closed-loop practices, which means any waste in the KRYSTALFLEX® TPU production process is minimized – with most production scrap recycled back into the process. As a result, very little waste leaves the facility.
Where are current KRYSTALFLEX® TPU innovation efforts focused?
KRYSTALFLEX® TPU films are a flagship product for the Ringwood team and the business is in a strong market position, with the portfolio widely regarded as a leading technology in the field. However, but we don’t take that for granted. Everyone that works at Ringwood takes great pride in the history of KRYSTALFLEX® TPU films and in knowing that their work supports a wide range of applications – from train and aircraft windows; to bullet‑resistant and armored glazing for military and high-security vehicles. With that pride, comes a passion for innovating and staying one step ahead of market requirements. The KRYSTALFLEX® TPU team is continuously innovating – driven by interactions with customers. Obviously, we can’t be too specific when talking about current innovation efforts – but suffice to say we are focused on developing advanced material solutions with improved performance characteristics that can meet the strict quality and safety requirements needed in target markets from transportation to architecture and building safety.
For more information about KRYSTALFLEX® TPU or to discuss its use in a specific application, please email Elastomers_Americas@Huntsman.com.
Disclaimer
While all the information in this publication is to the best of our knowledge and belief accurate at the date of publication, NOTHING HEREIN IS TO BE CONSTRUCTED AS A WARRANTY, EXPRESS OR OTHERWISE. Huntsman warrants only that its products meet the agreed specifications. Typical properties, where stated, are to be considered as representative of current production and should not be treated as specifications. In all cases, it is the responsibility of the user to determine the applicability of such information and the suitability of any product for its own particular purpose. The sale of products referred to in this publication is subject to the general terms and conditions of sale of Huntsman International LLC or of its affiliated companies.
KRYSTALFLEX® is a registered trademark of Huntsman International LLC or an affiliate thereof in one or more, but not all, countries. © 2026. Huntsman Corporation or an affiliate thereof. All rights reserved.
