A Commitment That Endures

In 1899, Thomas M. Barnhardt founded a manufacturing company producing layered cotton batting for furniture, horse collars, buggy seats, quilts, and comforters. By 1914, the company designed and produced the first cotton filters for rayon fiber manufacturing.

As northern furniture companies relocated south to access abundant hardwoods, upholstery fabrics, and labor, Barnhardt became a key supplier of cotton batting for cushions and upholstered furniture.

Carolina Absorbent Cotton Company was established to distribute surgical dressings and related products. During this period, we also developed a chemical treatment process to make cotton flame-resistant for use in furniture, mattresses, and insulation.

During World War II, the company focused on manufacturing surgical dressings for military use. In 1947, we acquired Richmond Dental Cotton Company, relocating it from Niagara Falls, New York, to Charlotte to continue producing cotton products for dentistry.

We expanded our operations by constructing a new plant and executive offices on the original site. During this period, we began processing polyester fibers to manufacture polyester batting, primarily used for furniture cushioning.

We expanded our presence in the furniture industry by opening High Point Cushion in 1963. In 1964, we acquired the foam division of Essex Wire in Mount Airy, North Carolina, forming North Carolina Foam Industries (NCFI). NCFI foam has since been used in furniture cushions produced at our cushion branch. In 1967, we opened the Hickory Cushion Division in Hickory, North Carolina, and began manufacturing rigid polyurethane foam systems.

New Facilities and Expansions: The company opened Charlotte Cushion, a new cushion fabricating division. In 1981, a new bleachery was completed, and by 1984, it was expanded by 33%. In 1985, a fourth cushion facility was established in Ocala, Florida. Hickory Cushion Division moved into a new fabricating facility on Tate Boulevard in Hickory in 1988. Additionally, NCFI underwent several facility expansions and acquired Dalton Foam in Dalton, Georgia, to manufacture rebonded foam for carpet underlay.

Diversification into Beauty Products: In the 1980s, Barnhardt introduced Carolina Beauti-Products, offering 100% cotton coil to professional spas and salons. This division evolved into Intrinsics in 1999, expanding its product range to include various cotton-based items for the beauty industry.

The 21st century ushered in a series of acquisitions. In 2005, we acquired the pharmaceutical coil business of US Cotton, LLC, and expanded our NCFI rigid foam operations to Utah. In 2007, we acquired Fiberweb’s cotton bleachery in Colrain, MA, establishing us as the leader in global purified cotton capacity. In 2010, we acquired Kinston Fibers’ cotton mote cleaning operation to further strengthen our raw material supply.

Barnhardt remains a privately held family business, now managed by the fourth generation. Our headquarters are still located on the original site where the company was founded in 1900. We currently own and operate five manufacturing facilities across the United States. As we look to new opportunities for growth, we remain dedicated to the core values of integrity and honesty that have guided us since our inception.