Packaging Textiles

Packaging textiles include all textile packing material for industrial, agricultural and other goods.
The demand for packing material is directly proportional to economic growth, industrial
production and trade as goods are produced and then distributed both locally and internationally.
The growing (environmental) need for reusable packages and containers is opening new
opportunities for textile products in this market.

Sacks and bags made of traditional jute, cotton or natural fiber are gradually casting way for
modern synthetic fibers. These technical textiles, used in packaging and subsequent
transportation are called “PACKTECH.”

It is well known that these fabrics are ideal for many kinds of packaging. At one end,
PACKTECH includes heavyweight, dense woven fabrics (used for bags, sacks, flexible
intermediate bulk carriers and wrappings for textile bales and carpets) and on the other end, it
includes lightweight non wovens used as durable papers, tea bags and other food and industrial
product wrappings.

The use of textile materials in consumer packaging is exhibited in the following products:

 FIBC big bags (Flexible Intermediate Bulk Containers), for powdered and granular
materials.
 Laundry bags and other bulk packaging products.
 Sacks for storage etc.
 Twine and string for tying packages, etc (excludes agricultural applications)
 Non-paper tea bags and coffee filters.
 Food soaker pads.
 Net packaging for storing, packing, transporting, retailing foodstuffs, toys.
 Woven fiber strapping, lightweight mailbags.
 Soft luggage.


Coating and lamination techniques are used to impart properties to fabrics which are not
necessarily those naturally assumed by textile fabrics. Having widespread application across a
range of technical textiles sectors, they increase functionality and durability as well as value.
They can include; waterproofness, increased abrasion, stain, flame and UV resistance, retro-
Reflection or Fluorescence?, anti microbial or Phase Change Materials.

These functions can be imparted using a range of application methods, dictated by the materials
being processed and the required outcome, whether they are applied as a coating or laminate is
also determined by this criteria. The definition between the two is a technicality relating to the
application method, generally coatings are applied to a fabric in their preparatory state, often in
liquid form. Lamination requires the pre-preparation of a laminate membrane that is then applied
to the textile.

The application for coated and laminated textiles is widespread across a variety of technical
textile sectors, these include;

Sector Application/Role
Automotive and Aerospace Vehicle interiors- textiles often laminated onto interior
components such as door panels.
Medical and Hygiene Anti Bacterial Coatings
Waterproof breathable Hydrophilic? membranes
Construction and Engineering Tarpaulins, Bulk bags
Interiors Upholstery- Stain resistance, UV resistance
Technical Apparel and PPE? Waterproof Breathable Membranes, Phase Change Materials
Fluorescence?
Apparel Fashion, luggage and accessories- textured looks such as
high shine or ‘wet’ look, PVC/Faux leather
Sports and leisure Sail cloth, Bouncy castles

Coatings and laminates will interact differently with the fabric; this is due to the way in which
they affix to the textile surface. Figure A demonstrates how a coating covers the surface of the
fabric, as applied in liquid form, it is able to penetrate the fabric structure, filling the air pockets
and bridging the interstices. Figure B depicts how a laminate sits on the fabric surface, the fabric
retains its air pockets and the laminate has fewer points of contact.
 Figure A. Schematic of a coated textile

Figure B. Schematic of a laminated textile.

As with both lamination and coating the bonding mechanism is of importance. The bonding can
occur through the thermoplastic qualities of the coating or laminate, whereas it is heat set,
although this is not appropriate for all materials, so solvent or water-based adhesives are used.
The use of adhesives is a highly technical area, as gaining a strong yet flexible bond can be a
challenge.

Fabric pre-treatment prior to coating is important, particularly its stabilisation, as some coatings
bridge the interstices within the textile, and for the coating to remain functional this must remain
the case. Therefore ensuring a fabric is stabilised prior to coating limits the risk of movement
within the fabric structure which may impact on the coating or laminate applied.

The end product is sometimes referred to as a composite, as it is a composition of a textile and

non-textile component. Many of the mechanical properties are determined by the fabric, such as
tear strength, the coating largely determines the chemical properties, and the handle is often
determined by both.

It is not just technical applications which utilise coating and lamination technology, the fast
paced fashion market is constantly giving the technology new challenges with the need to create
innovative and visually interesting looks such as a high shine, futuristic finish, or imitation
animal skin.

COATING

The Textile Institutes defines a coated textile as;

“A material composed of two or more layers, at least one of which is a textile fabric and at least
one of which is a substantially continuous polymeric layer.”

Laminate ‘a material composed of two or more layers, at least one of which is a textile fabric,
bonded closely together by means of an added adhesive, or by the adhesive properties of one or
more of the component layers’

This Polymeric layer is applied in liquid form in a solvent or water base, which evaporates off to
leave the polymer behind, applied to one or both surfaces. Dependant upon the application
method the liquid may require thickening so it does not soak through the fabric, or an anti-
foaming agent to aid processing. The thickness of the coating, or amount of product applied is
controlled. Bonding occurs either through the drying process (evaporation) or through a curing
process, required to provoke crosslinking.

The term coating can apply to the adherence of a textile membrane to the fabric surface, or to a
coating of micro or nano particles that adhere to the fibre surface forming a ‘substantial’, but not
necessarily ‘continuous layer’. Figure 1 depicts what is traditionally viewed as a coated fabric;
the fabric is coated on one side, and would be visible to the naked eye and detectable by fabric
handle. Figure 2 displays a fabric coated with microencapsulated Phase Change Materials
(PCM’s), unlike a traditional coated fabric this would not be visible on the fabric surface as the
adherence is between micro sized particles and the fibre, not the fabric structure. This coating
technique is used to add agents such as microencapsulated ingredients containing; fragrances,
cosmetics, FR agents, Anti microbial agents, or materials such as; cyclodextrines, abrasion or
stain resistant materials, and UV blockers. As they are often at the micro or nano scale, they are
not visible by the naked eye, though adhesive agents or surfactants used in their application may
display a residue, but this is not ideal. Dependant upon the end requirements, coatings such as
those displayed in figure 2 they should have little if any impact on fabric handle.

Figure 1. Image from; http://www.walkandramble.co.uk/Glossary/GlossaryT.html Low Alpines,

Triplepoint fabric
Figure 2. Image shows PCM’s in a textile. From; International Journal of Clothing Science and
Technology http://www.emeraldinsight.com/journals.htm?articleid=1501621&show=html

The chemical formation of the coating is dictated by the end use. This formation may contain a
range of functional additives to improve the mechanical properties, increasing durability, fire
retardant or UV resistant properties. Table 1 outlines a range of properties imparted using
different coating chemicals.

Table 1. From; A review on coating and Lamination in Textiles; Processes and

Applications http://article.sapub.org/10.5923.j.ajps.20120203.04.html

In coatings, the melted, liquid version of the polymeric substance is sometimes used, for example
in calendering. If this is the case then the melt temperature (Tm) of the applied coating must be
outside of that which will be experienced during use. If this is not possible, it is more appropriate
to create a pre-prepared membrane, applied through a lamination technique.

Knife Coating (floating knife) or Direct Coating

In Knife Coating, as seen in Figure 3, the liquid coating is applied to the fabric while being run at
tension under a floating knife blade, the distance between the fabric and the knife blade
determines the thickness of the coating. The blade can be angled and have different profiles to
affect the coverage. For this process to be effective the liquid coating must be quite viscous in
order to prevent it soaking through the fabric, the coating is then dried or cured.

This technique is best used for Filament? yarns as the staple fibres in spun yarns can protrude on
the surface creating an un-even finish, but this is dependant upon the thickness of the applied
coating. For this type of coating to be most successful the weave structure has to be quite tight
and the fabric capable of being held taught.

Figure 3. Fung, W, 2002, Coated and Laminated Textiles, UK;Woodhead

Publishing;http://books.google.co.uk/books/about/Coated_and_Laminated_Textiles.html?id=U0
Rh-TrvMz4C

Direct Roll Coating

In this process coating liquid is rolled onto the fabric by a roller suspended in the coating
solution, often a blade is positioned close to the roller to ensure not too much coating solution is
applied.

Figure 4. Direct Roll Coating from;Sen, A K, 2008, Coated Textiles; Principles and
Applications, 2nd Edition, USA;Taylor and Francis.
 http://books.google.co.uk/books?id=4K7-
VM6T2A4C&printsec=frontcover#v=onepage&q&f=false

Pad-Dry-Cure

Also referred to as Padding?, this technique, widely regarded as a textile finishing technique, can
in fact be used to add a variety of coatings, but this usually refers to a fibre coating for the
application of micro or nano materials or chemical compositions.

As shown in figure 5, the fabric is submerged in the coating solution then the excess squeezed
out in the rollers, which dictates the pick-up percentage, the fabric is then dried and cured.

Figure 5. Image adapted from; http://www.kenencoregroup.com/aloevera-finish.html

Calender coating

Calender finishing involves the fabric passing through a set of heated rollers to singe off any
surface fibres and add lustre and smoothness. Calender coating is the same principle in which the
fabric passes through heated rollers, but through this process a coating is applied as demonstrated
in figure 6. This image demonstrates the simultaneous coating of both sides of the fabric with the
thickness of the coating determined by the width of the nip in-between the rollers, more rollers
used can provide a thinner coating.

Figure 6. Depicts calender coating. Image from; TPO coated PP fabrics and their applications
http://www.fibre2fashion.com/industry-article/pdffiles/16/1526.pdf
Hot melt extrusion coating

Hot melt extrusion coating is applied in the same process as calendering with the coating being
melted from granules fed to heated rollers which then nip the coating to the fabric. It is used to
produce un-supported films and these freshly produced films are added direct to fabric. Its uses
are mainly for Thermoplastic polymers such as Polyurethane, Polyolefin’s and PVC.

Foam Finishing

Foam finishing was developed as a more environmentally friendly version of the pad-dry-cure
system, as the chemical applied requires less product in weight, but equates to a high surface
area. Foam also ensures less wetting takes place, which requires less drying; furthermore waste is
reduced in terms of residual liquor. This technique is useful in coating heavy fabrics such as
carpets and can be used to effectively coat only one side.

LAMINATE

Laminated textiles consist of one or more layers of textile and component. The Textile Institute
defines a laminated or combined fabric as;

‘a material composed of two or more layers, at least one of which is a textile fabric,
bonded closely together by means of an added adhesive, or by the adhesive properties of
one or more of the component layers’

This adhesive is required to bond the fabric and component layers together. Creating a strong
bond, which will not deteriorate through conditions experienced in use such as movement and
laundering, is not the biggest challenged faced. Adhesives are often associated with making the
fabric too rigid and thus affecting the handle, which is often a negative characteristic, particularly
for applications in performance clothing where comfort is a requirement. Environmental
consideration has led towards more interest in hot melt adhesives, rather than solvent based
adhesive, or the use of flame adhesion. (ref
to http://article.sapub.org/10.5923.j.ajps.20120203.04.html )

Laminated fabrics are widely used in high performance apparel where fabrics are required to be
waterproof yet breathable. In this case a laminate membrane Laminates often consist of a non-
textile membrane sandwiched between 2 textiles, for example in the case of the micropourous
membrane Gore Tex.
 Figure 8. Gore Tex laminated fabric depicts the functions for the different layers. Image
from; Gore-tex?.co.uk/">www.Gore-tex?.co.uk

Usually the reverse or technical back of the fabric surface is laminated, so as to not affect the
look of the fabric, and in the case of the Hydrophilic? membranes, these are more effective worn
close to the body. As in the gore tex example, the membrane or laminate is often sandwiched
between two fabric layers. However this is not the case for fashion fabrics where the look is the
priority over function. Lamination is carried out on the fabric surface to produce some visually
interesting designs such as foil holograms or textures.

Lamination is widely used in garment manufacture where woven or non-woven fabrics are pre-
prepared with thermoset adhesive. These are then cut and applied to the fabric as part of the
manufacturing process to provide reinforcement, for example of a button hole, or to give shape
and stability, for example in a collar. These ‘fusible’s’ are applied under heat and pressure for a
specified time, to set the thermo adhesive.