Laminate Options
There are many types of laminates in the returnable packaging market. If you are packaging parts with Class-A surfaces or parts that can’t have any scratching or marring, you will need some kind of laminate on your dividers. Popular laminates include Spun Bond, Tyvek, and Evolon, along with new additions like Suede Microfiber and Brushed Nylon.
While laminates protect surfaces, sharp edges on dividers can still pose risks during loading and unloading. Our innovative rolled-edge method ensures smooth edges for maximum safety and part protection.
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. It meets most Class-A surface protection requirements and is environmentally friendly.
Uses: Spuntex is used to laminate plastic corrugated (1 or 2 sides) and rolled-edge products. It is ideal for protecting Class A, painted, and leathered surfaces. Applications include dividers, pads, carton liners, tote liners, and bag systems.
Physical Properties: Spuntex is a 100% polypropylene spun material, available in 2-2.5 oz. fabric weight, with a thickness of approximately 0.062". Available colors: Blue (stock), Black, and Gray (minimum quantity required).
Brown Suede
Common Names: Suede, Brushed Suede, Faux Suede
Description: Brown Suede laminated to PP sheets offers abrasion protection for Class-A packaging applications. It’s great for protecting surfaces between parts or layers of parts.
Uses: Brown Suede is used to laminate plastic corrugated (1 or 2 sides), rolled-edge products, and sewn bags or separators. It protects Class-A and painted parts that require softer surfaces.
Physical Properties: This 100% polyester faux suede material is typically available in Brown (Toffee).
Tyvek
Common Names: Tyvek
Description: Tyvek is a woven material with a slick, non-abrasive surface, allowing parts to slide without damage. It is non-linting, non-dusting, and mildew-proof.
Uses: Tyvek is laminated to plastic corrugated (1 or 2 sides) and rolled-edge products, protecting Class-A, painted, and leathered surfaces.
Physical Properties: Made from 100% polyethylene fibers, Tyvek is inherently water-resistant and chemically inert. Available in White.
Evolon
Common Names: Evolon, Evalon
Description: Evolon microfilament textiles offer a soft, smooth surface that avoids micro-scratches or texture transfer. It is extremely strong and scratch-resistant.
Uses: Evolon laminates plastic corrugated (1 or 2 sides) and rolled-edge products, ideal for sensitive parts like Class-A surfaces or clear lenses.
Physical Properties: Made of bi-component filaments, Evolon is lint- and scratch-free. Available in Gray.
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
Evolon
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
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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.
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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.
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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
