Expandable graphite-based carrier material expands to 40 to 60 times its volume in the event of fire Flame-retardant textiles have long faced the same dilemma: the higher the level of protection, the greater the compromise in comfort, weight and breathability. This is especially important for workwear and protective clothing worn for long hours, where comfort is crucial to wearer acceptance and satisfaction. At Techtextil 2026 in Frankfurt, Swiss company Textilcolor AG will unveil pyroshell™, an innovative flame-retardant technology designed to tackle this challenge. Protection is provided by a graphite-based functional layer integrated into the textile structure, which doubles the reaction time before burns occur while significantly enhancing comfort. The material does not release any toxic fumes and offers textile manufacturers entirely new opportunities to design and produce protective and functional garments. It is also durable enough to withstand up to 50 industrial washes.
“With pyroshell™, we are presenting a flame-retardant technology at Techtextil for the first time that combines safety with comfort,” says Detlef Fischer, CEO of Textilcolor AG. “It provides protection in critical situations without compromising comfort in everyday wear.”
Thin expandable graphite layer delivers high flame protection
The demands on modern protective textiles are continuously increasing. In addition to regulatory requirements, ergonomics, breathability and low weight play a central role. Traditional flame-retardant solutions often rely on inherently flame-resistant specialty fibres or additional chemical treatments, which can make garments heavy, stiff and uncomfortable. Modern solutions such as pyroshell™ provide high levels of protection without compromising comfort, making them suitable for a wide range of applications – from police, security and special forces to energy companies and industrial workers in high-risk environments such as oil, gas or high-voltage networks. Conventional flame-protection garments often have two major drawbacks: they can release harmful fumes when exposed to heat and are typically heavy, stiff or uncomfortable in everyday use. This creates a trade-off between maximum flame protection and wearability. Pyroshell™ was developed to address this challenge, offering reliable safety while maintaining comfort.
Pyroshell™ doubles the reaction time before burns occur
It consists of a flexible expandable graphite layer combined with a thin, non-melting and non-combustible carrier layer, which serves as a stable protective base. This component is integrated as a separate layer between textile fabrics without restricting comfort or freedom of movement. A key differentiator is that it can be applied to a wide variety of fabrics, including polyamide, polyester, Cordura-like materials, and stretch textiles. The technology allows for a lower overall weight while providing greater design flexibility.
In everyday use, the intermediate pyroshell™ layer remains dormant, giving garments the feel of standard workwear or outdoor clothing. It responds only when exposed to heat or flames exceeding 180 °C, and if the outer textile layer is damaged, it activates to provide protective performance. The embedded expandable graphite rapidly swells to 40 to 60 times its original volume, forming a stable protective barrier that effectively shields the wearer from heat and flames. It prevents further burning and stops molten material from dripping onto the skin. Tests have shown that pyroshell™ doubles the reaction time before burns occur compared with conventional materials, offering a significant safety advantage for the wearer. As a reactive safety solution, the protection is virtually invisible in everyday wear, yet permanently present and activates precisely when needed. It remains reliable even after 50 industrial washes.
Maximum protection without compromising comfort or freedom of movement
A key advantage of pyroshell™ is its combination of high protective performance and comfort. The material contains no halogen- or phosphorus-based chemicals, ensuring that no toxic fumes are released in the event of fire. At the same time, the fabric remains lightweight, flexible and breathable, a crucial factor for comfort and acceptance during daily use. Depending on the fabric construction or material combination of the end product, pyroshell™ meets European standards for protective clothing against heat, flames and thermal hazards, as well as requirements for limited flame spread. The material is also suitable for protection against electric arcs, making it ideal for applications in high-voltage environments. Additional protective properties, such as electrostatic dissipation or chemical splash resistance, can also be integrated. pyroshell™ can be tailored to different applications and combined with other functional technologies. Manufacturers benefit from design flexibility and the ability to develop protective solutions based on common synthetic fabrics.
Under the motto “Specialty Chemicals Designed for You,” we will be presenting pyroshell™ to a broad professional audience for the first time at Techtextil in Frankfurt. This expands our product range with a forward-looking solution for integrated flame protection and opens up new application areas in protective and functional clothing,” says Fischer. pyroshell™ complements the other brand technologies on display at the trade fair stand: coolcolors reduces heat build-up in textiles under sunlight, improving thermal comfort and UV protection. Dry³ ensures rapid drying and effective moisture management. enerG uses a titanium mineral matrix to selectively reflect the body’s far-infrared energy, and RepelPro provides eco-friendly, PFC-free water and dirt repellency for weather-resistant textiles.
