There are many types of laminates in the returnable packaging market. If you are packaging parts with Class-A surfaces, or parts can’t have any scratching or marring, you will need some kind of laminateon your dividers. Some of the most used laminates are Spun Bond, Tyvek, and Evolon. Some of the new laminates that hit the market recently are Suede Microfiber and Brushed Nylon.
These new laminates give an even higher level of protection for the parts being shipped, however, there is one big problem that arises – the top edge of the dividers. You can have the best laminate inside the dividers but the potential of scratching the parts during the load/unloading process is high. When plastic is cut to make the divider panels, it can leave a very sharp edge. Not only can this damage the parts but can also scratch the hand of the packaging associate – it can be a real “cuticle killer” when you reach into the cell to grab the part.
Click any image below to learn more.
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Spuntex
Common Names: Spuntex, Spunguard, PP Woven material
Description: Spuntex is a soft, pliable, non-abrasive fabric that can be laminated to most of our materials like plastic corrugated and HDPE. We can apply to 1 or 2 sides and use our rolled-edge technology. Spuntex meets most class-A surface protection requirements. Spuntex is environmentally friendly.
Uses: We use spuntex to laminate our plastic corrugated either 1 or 2 sides and/or our rolled edge products. "Spun" is used to protect many surfaces including Class A, painted, and leathered surfaces. We use spuntex on our divider, pads, carton and tote liners, and bag systems.
Physical Properties: Spuntex is 100% polypropylene spun material available in 2 - 2.5 oz. fabric weight with a thickness of appx .062" thick. The colors available are Blue, which is our stock color, but Black and Gray are available in minimum quantity.
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Brown Suede
Common Names: Suede, Brushed Suede, Faux Suede
Description: Suede laminated to PP sheets or used as separators is another solution for parts that need additional abrasion protection for their class A packaging application.This Suede material is great for protection between parts and/or layers of parts.
Uses: We use Suede to laminate our plastic corrugated on either 1 or 2 sides, rolled edge products, and sewn bags & separators.Suede fabric is used to protect many surfaces including Class A and painted parts that need a softer surface.We can use Brush Nylon on our divider, pads, carton and tote liners, and bag systems.
Physical Properties: Suede is a 100% polyester faux suede material that usually comes in a Brown (Toffee) color.
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Tyvek
Common Names: Tyvek
Description: Tyvek is a woven material that has a slick, non-abrasive, and smooth surface. Parts slide on Tyvek unlike other laminates that have a rougher surface that can scratch or mar product surfaces.
Uses: We use Tyvek to laminate our plastic corrugated either 1 or 2 sides and/or our rolled edge products. Tyvek is used to protect many surfaces including Class A, painted, and leathered surfaces. We use Tyvek on our divider, pads, carton and tote liners, and bag systems.
Physical Properties: Tyvek is made from 100% polyethylene fibers that are spun weaved together making a surface that is Non-linting, Non-dusting, and mildew-proof.Tyvek® brand materials are inherently water resistant, inert to most organic and inorganic chemicals, and stand up to mishandling/abuse. Tyvek is available in White.
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Evolon
Common Names: Evolon, Evalon
Description: Evolon microfilament textiles are adapted for packaging sensitive parts. It has an extremely soft and smooth surface that avoids micro-scratches or texture transfer. Evolon is extremely strong and does not scratch or fray under normal conditions.
Uses: We use Evolon to laminate our plastic corrugated either 1 or 2 sides and/or our rolled edge products. Evolon is used to protect many surfaces including Class A, painted, or clear lenses that cannot have any dust or particulate from common laminates. We can use Evolon on our divider, pads, carton and tote liners, and bag systems.
Physical Properties: Evolon is a non-woven microfiber that is made up of endless bi-component filaments, uniformly laid on a belt, then simultaneously split into microfilaments and entangled using high-pressure water jets. Evolon is fiber, lint, and scratch-free. Available in gray.
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Brush Nylon
Common Names: Brush Nylon, Brushed Fabric, Polyester Fabric
Description: Brush Nylon polyester laminated to PP sheets is another solution for parts that need additional abrasion protection for their class A packaging application. This brushed fabric is great for metal parts and painted surfaces.
Uses: We use Brush Nylon to laminate our plastic corrugated on either 1 or 2 sides and/or our rolled edge products. Brushed fabric is used to protect many surfaces including Class A and painted parts that need a softer surface. We can use Brush Nylon on our divider, pads, carton and tote liners, and bag systems.
Physical Properties: Brush Nylon is a polyester-based textile that is made of filament yarn with a warp knit. The common weight of Brush Nylon is 6oz. Color available - Blue
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XLPE Foam
Common Names: XLPE laminate, Volara, Foam Lamination, Crosslinked Foam Lamination
Description: Crosslinked (XLPE) foam laminated to our plastic corrugated is just another option to provide a combination of abrasion protection and extra cushioning protection for class A packaging applications.
Uses: We use XLPE to laminate to our plastic corrugated either 1 or 2 sides. Crosslinked foam is used to protect many surfaces including Class A, painted, and give cushioning protection. We can use XLPE on our divider, pads, carton and tote liners, and bag systems.
Physical Properties: Our XLPE / Crosslinked Polyolefin foam laminate has a density of 2# for 1/8" and 1/4" and a density of 4# with thicknesses of 1/16" and 1/18". The standard color for XLPE laminate is Black.
Our Rolled Edge Method: What steps can be taken to make the top edge soft and smooth?
1.) Panels can be folded in half with the laminate on the outside. This provides a nice edge. The problem is, you are using double the material and the plastic tends to bow - making your cells a little smaller.
2.) Laminates can be sewn to the top edge of the divider. This can be a very expensive solution. It does provide a soft, smooth edge, and for some applications, this can be a good thing. A problem that seems to come up is the lip the laminate gives on the top edge. When it’s sewn there is extra laminate next to the stitch. Parts can have the potential to get caught on the lip.
3.) The final and best solution is the rolled laminate over the top edge. There are not too many places that know how to do this process or have the equipment to make this type of edge. In this type of edge, the laminate is continued from inside the cell over the top edge and into the next cell. No lip to catch your parts, no bowing of the cells, and the price isn’t much more than just a standard lamination. There are only a couple of packaging suppliers that know this process
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