We are excited
to announce that effective January 1, 2020 Dal-Bac Manufacturing and Dallas Bias Converting Solutions have merged.
Going forward the company will operate as Dal-Bac Manufacturing with Dallas
Bias Converting Solutions as a primary product line.
Dallas Bias has
been in business since 1958 and focuses on converting solutions for a range of
- Custom cutting, binding, folding and specialty services for
the apparel industry.
- Customized nametapes for all types of uniforms.
- Bindings for a wide variety of medical products
- Custom protective covers for boats, cars and recreational
- High visibility reflective trim options for safety apparel
company will provide a comprehensive suite of integrated services including our
existing flame lamination,
coatings, thermal fusing, die cutting, printing, and
slitting conversion capabilities. The addition of Dallas Bias will expand
our supplier network and add to our talented production and customer service
teams. Plus, the Dallas Bias warehouse in Central America will extend our international
is one of our primary services at Dal-Bac
Manufacturing. We use thermal fusing to bond thin flexible materials in
situations where it is not practical to utilize other laminating techniques. This
process is ideal for fusing materials like:
- Plastic films
The finished products have enhanced durability and performance that
stands up in a wide range of environmental extremes.
Selecting the correct adhesive is a critical part of any thermal fusing
project. Our engineering team works closely with our customers to gain a
complete understanding of the bond requirements in the finished product. This
can depend on where and when the adhesive will be fully activated. There are
three primary options:
- The project involves creating a finished product consisting
of one or multiple layers of materials bonded together for use in downstream production. In this case the adhesive is fully activated
creating the final composite product.
- The project requires that adhesive be added to a material
but not fully activated. The adhesive will be reactivated at a later production
stage to create bonds between the original material and other surfaces.
- The project does not
require any adhesive because of the nature of the materials being bonded
together. With some materials we can create a strong bond by using controlled
melting of one of the lamination materials. The melted material flows into the
other materials and creates an exceptionally strong bond while eliminating
adhesive application and cost.
the type of project, the keys to successful thermal fusing are carefully
controlling the temperature, dwell time, pressure and selecting the best
adhesive substrate. This requires a dedication to a manufacturing process that
is confirmed by our ISO 9001:2015 certification.
understands the importance of meeting your requirements and we strive to always
exceed customer expectations. That’s why we offer prototypes and samples to
demonstrate our expertise and allow for your internal testing.
Adhesives are commonly known as “peel and stick” adhesives, or
“sticky back tapes.” A typical PSA consists of a layer of adhesive
that is applied to a variety of substrates and then covered and protected by a
release paper or film that is removed to expose the adhesive. Pressure is then
used to secure the substrate to the target surface.
Common examples of pressure sensitive adhesives include:
- Duct tape
- Peel and stick labels
- Medical patches
- Athletic tape
- Automotive trim
- Safety labels
- Note pads
Some pressure sensitive adhesives are permanent like safety labels on
power equipment and some are removable like a Band-Aid. Both are applied with
pressure but require very different types of adhesive. The key to an effective
PSA is a complete understanding of the anchoring requirements for the adhesive
and the expected environmental conditions.
At Dal-Bac our
engineering teams work with our customers to make sure our anchorage solutions
will meet their expectations. This includes:
- Identifying and understanding the primary surface for the
adhesive (this is the surface of the substrate to which the adhesive is to be
- Identifying and understanding the target surface for the
adhesive (this is the surface to which the pressure sensitive adhesive product
is to be applied by the consumer)
- Understanding the customer’s duration of bond expectations:
permanent, repositionable or removable
- Defining the expected environmental conditions, both during
application of the adhesive and during it’s performance window
With this information we come up with the best adhesive options for
each specific application.
Get the benefit of our experience
Dal-Bac is an ISO 9001:2015 certified company. This means we are
dedicated to exceeding customer expectations and improving our processes to
create better customer value. In practice, this means we can put all of our
extensive pressure sensitive adhesive knowledge to work for you.
We work with both water-borne and solvent-based adhesives – with a
range of chemistries – and will select the one best suited for your product. If
additional anchoring power is needed we can utilize either Corona treating or a
double coated PSA. In addition, we have developed a proprietary, dual-adhesive technology
that allows us to boost the anchorage of PSA’s across a wide variety of
We take pride in creating the right “anchor” for all of our
PSA customers. We specialize in creating companion pressure sensitive products
for our customers’ primary product lines.
Consider Dal-Bac for your pressure sensitive needs, and let us show you
what we can do.
Company operates on a simple principle. We can only succeed by helping our
customers. That is why we directly state on our website that our goal is to
“help our customers reduce costs and increase yields.”
To live up to that goal we became an ISO 9001:2008 certified company
and updated to the most recent certification ISO: 9001:2015 in July
To become ISO certified a company must demonstrate:
- Ability to consistently provide products and services that
meet customer requirements and all applicable regulatory requirements
- Compliance with a Quality Management System that details
requirements for materials, products and services
- Use of a process-based approach that identifies
interactions between processes and discovers methods to improve results
We are one of the few ISO certified companies in our industry and are
proud to have set such a high standard for ourselves. It keeps us focused on
exceeding your expectations.
Dal-Bac has been providing soft goods converting solutions across a
wide range of industries since 1973. Our core service areas are:
- Coating Services: We apply both solvent and water-borne
coatings to an array of substrates including fabrics, films, foams and papers.
- Flame Lamination: We bond flexible foams and non-wovens
with our low-cost and eco-friendly process that can produce single-sided,
double-sided or multilayer laminations.
- Thermal Fusing: We use controlled
heat, pressure and dwell time to bind thin flexible materials in situations
where wet adhesives are not practical.
Beyond our core services we offer a range of specialty services
including die cutting, slitting and narrow-web screen-printing. In addition we
also support our customers with a complete engineering department and an
extensive supplier network.
engineers help you get the best outcome for your product by identifying the best
materials and process for it. They can help you come up with a new product,
solve a problem and develop prototypes as a proof of concept.
Network: We have long-term partnerships with suppliers and work closely with
them to develop and identify new and improved materials solutions.
What you end up
with is a company dedicated to helping you succeed. Please let us know if we
can help improve your process, lower your costs or help you launch a new
Dal-Bac manufacturing has a long
history of creating custom foam lamination solutions for a wide variety of
industries. Our approach is a bit different in that we specialize in creating
new solutions and processes in order to deliver exceptional value.
It all starts with our ISO 9001: 2015
certification. Achieving ISO certified status requires two key elements that
are central to our business:
- Demonstrated commitment to exceeding customer
- Dedication to continuous process and system
Both of these elements
are a key parts of our foam lamination services.
A key benefit that
Dal-Bac delivers is access to our extensive network of supplier partners. This
allows us to explore all the available composite options to make sure that we
get the foam lamination solution that is right for your business.
We pride ourselves on
working with our supplier network to come up with innovative solutions and
process improvements that improve the overall project yield for our customers.
This starts with our engineering team working with you to get a complete
understanding of your needs for the final product. From there we can shift our
focus to niceties that our customers may not have realized were available. This
includes looking at the specific features you require, including:
- Overall thickness of
the final composite
- Padding capability
- Flexibility and stretch
These features help our
engineering team focus in on the right materials for your project
- Foam materials
- Outer layer requirements
- Lamination process
Depending on the
project, we frequently share design and production prototypes at this stage to
insure that the finished product will be everything it is expected to be. Once
the prototype is approved we move on to actual production and immediately start
looking for ways to improve our process.
Our commitment to
quality and continuous improvement results in excellent value for our
customers. Please let us know if we could put our engineering team to work on a
project for you.
composites are efficient, reliable and deliver exceptional value. The core
process involves passing a substrate (primarily polyurethane foam) across an
open flame to create a thin tacky layer of melted polymer. This layer is then
brought into contact with another substrate under controlled pressure and
tension to create a cohesive bond between the layers. Flame Lamination can also
create multiple – layer composites including sandwiching a foam layer between
decorative or technical materials.
At Dal-Bac Manufacturing, Inc. we
utilize flame lamination to create custom composites for a wide array of
products and industries:
- Orthopedic padding
- Automotive interiors
- Thermal and
- Flexible Beverage
Insulating Laminates – (koozies)
- Intimate apparel
- Medical disposables
- Sports equipment
Our technical team works with our
customers to help determine:
- The best combination of materials to meet your
- The most efficient production process for your
We also help our customers with prototype
development and process testing.
As an ISO 9001: 2015 certified company,
our focus is on exceeding your expectations. Our specialty is creating
customized solutions for our customers using the expertise of our technical,
engineering, production and supply teams.
We are proponents for flame lamination
composites because they:
- Do not require adhesives, which lowers the
costs and makes the product easier to recycle.
- Have a faster throughput than other laminating techniques,
which improves efficiency and lowers costs.
- Can be used to create multi-layer composites
with a laminate on one side or both sides of the core material.
- Can be made from a wide variety of materials as
long as the core material is flame laminable.
- Can have variable thickness and in many cases
the bond between layers will add no appreciable thickness.
Please let us know if you are looking for either a straight forward or
custom lamination solution. Our team would be happy to tackle your project.
Dal-Bac Manufacturing offers a comprehensive suite of coating services utilized by a diverse range of industries. Our technical and engineering capabilities are keys to our success as they allow us to:
- Identify the best coating solution for specified substrates
- Customize the application process to meet specific performance requirements
- Create custom formulations to meet the unique requirements of a specific application
Production excellence and testing are critical parts of coating applications. Even the correct coating will not perform up to expectations if it is not applied within the required specifications. Testing during application and post application is necessary to confirm accurate application and deliver exceptional quality.
As an ISO 2001: 2015 certified company, Dal-Bac is committed to exceeding customer expectations. One of the requirements for ISO certification is a proven commitment to continuous improvement in terms of both process and product quality.
As a result of this commitment, Dal-Bac has just added a new Keyence sensor to our wet coating production capabilities. The new sensor:
- Is positioned above the web of wet coated material
- Utilizes reflective technology to measure the distance from the top of the coating to the bottom of the coating
- Provides a delta value between the top and bottom measurements that determines absolute coating thickness
- Measures coating thickness as thin as .0034″
The key benefits of our new Keyence sensor are:
- Ability to better control wet coating weights
- More accurate measurements leading to improved application performance
- Ability to apply and measure thinner layers of coating
- Real time readings for coating applications immediately downstream from liquid deposition
- Better process and quality control
The addition of the new sensor to our wet coating application process is simply a demonstration of our commitment to improve our ability to exceed customer expectations. Our goal continues to be to help our customers reduce costs and improve yields by continuously improving our processes.
Please contact us if you need a custom coating solution for one of your products.
Laminated fabric is most often thought of
as a composite material composed of two or more layers of fabric. At Dal-Bac, Manufacturing we define
laminated fabric as a composite composed of two or more layers – at least one
of which is a textile fabric.
For any type of laminated fabric
composite, the critical issue is making sure that the adhesive bond between the
layers will not degrade or deteriorate across the expected use conditions of
the finished product. This can require a variety of adhesive solutions
depending on the application:
- Adhesive can be applied using Thermal Fusing
- If one or more of the component
layers have the right properties Flame Lamination is a common solution
- Pressure sensitive adhesives are also used to create laminated
- Sometimes the solution requires using more than one adhesive
Let’s look at how we solved a specific
challenge for one of our athletic products customers. Our client created a fitness-training
device made of compressible foam to create resistance for developing strength
and muscle tone.
The device was shaped to fit the body and
they soon discovered that the foam surface was rough in texture and not
suitable for skin contact. They quickly decided to add pads to the device using
a plush knit nylon fabric with an antimicrobial treatment. However, when they could not find a way to get
the fabric to adhere to the foam – they called us.
created a custom laminated fabric for them. We began with a series of tests
that revealed that a dual adhesive approach would be required. We solved the
- Using a general purpose acrylic adhesive on the
foam side of the product
- Transfer coating a pressure sensitive adhesive
to a fabric adhesive film which was then fused to the back side of the fabric,
with the required second adhesive
- Die cutting the resulting composite to fit the
- Using a back slit liner to allow installers to
remove the release paper for installation.
The final result was a laminated fabric skin
contact pad that could not be removed without tearing the foam itself. Read
more about this project here.
We solved this particular problem in just
three weeks from start-to-finish. If you
have some adhesive challenges – we can help!
Healthcare is constantly adding new services, procedures, treatments
and requirements that require innovative medical fabric solutions. Medical
fabrics are found throughout the healthcare industry:
- Surgical masks and clothing
- Disposable padding and component materials
- Skin contact sensor materials
- Laminates for fluid collection pouches
- Padding composites and attachment systems for orthopedic
Like most healthcare issues there is always a concern about costs and
quality. This where working with a laminator and converter of soft goods like Dal-Bac Manufacturing Company, Inc.
can really pay off.
As an ISO 9001:2015 certified company Dal-Bac is committed to:
- Exceeding customer expectations
- Continuously improving our processes
- Reducing costs and improving yields for our customers
We use our experience with lamination, fusing and coatings techniques
to create innovative solutions for use in medical fabric
applications. Our in-house engineering team is accustomed to meeting very
specific technical requirements including:
- Padding capability
- Durability and strength
- Moisture wicking
- Moisture and air barriers
- Direct Skin contact
- Direct Skin contact adhesive
Our extensive experience, engineering expertise and supplier network
help us select the best medical fabric options for your application and use, or
create, an efficient production process that will reduce costs over time. A
selection of the materials we currently use includes:
- Hook-compatible loop knits
- Non-woven fabrics
- Anti-microbial fabrics
- Enhanced wicking fabrics
- Mesh fabrics
- Stretch knits
- Foam laminates
- Coatings for both barrier and permeable solutions
- Adhesives that are approved for skin contact
Our current medical fabric products include:
- Padding composites for orthopedic and orthotic appliances
- Hook and Loop solutions for orthopedic and orthotic devices
- Disposable surgical masks
- Skin contact sensor materials
- Laminates for fluid collection pouches
- Skin contact pressure sensitive adhesive products
We specialize in custom solutions and you can see our process at work
for orthopedic device here.
If you have a new challenge or are looking for a better solution for an
existing product, we invite you have a conversation with us!
How does thermal fusing get involved with laundry? Well, at Dal-Bac Manufacturing we love to solve problems and we learned that industrial and institutional laundry services had a critical need to be able to identify garments. This is especially true for industries that utilize uniforms.
The solution to the challenge seemed simple enough – place labels on the garments. However, the labels would need to meet some challenging requirements:
- Be available in a variety of sizes and colors
- Be printable using commonly available processes
- Be easy to apply
- Be machine washable – repeatedly
- Provide a surface that could be used to adhere to garments
This is where
our thermal fusing capabilities met laundry labels. We use thermal fusing to
bond thin, flexible materials in situations where it is not possible to use wet
adhesives. Our process is ideal for fusing materials like textiles, plastic
films, and paper into a finished product with enhanced durability and
controlling temperature, pressure and dwell time we create exceptionally strong
bonds between layers of fabrics, papers, foams and non-wovens that can stand up
to any environment extreme – like repeated trips through the laundry!
A key part of
our process is the ability to bond adhesive films to the surface of other
materials. These films can then be reactivated during processing to adhere to
another surface – such as a garment.
To solve the
laundry label challenge we created a line of garment labels under our Thermadata brand.
Our fabrication process involves:
- Using 100% polyester, durable twill fabric
- A number of high visibility colors
- Fusing a high -performance thermoplastic urethane (TPU) to
the fabric in bulk rolls
- Converting the bulk rolls to narrow rolls
- Cutting labels into a variety of sizes
- Finished labels on rolls available for downstream printing
The final result was a complete set of color-coded garment labels in a
variety of sizes that can be printed in their roll form, individually removed
from the roll and applied to garments using heat and pressure from simple
T-shirt presses. And the labels
absolutely withstand repeated laundry cycles!
If you have a challenge that requires innovative converting
capabilities, please contact us – we would welcome the opportunity to help.