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.
Dal-Bac Manufacturing has been creating foam composites for over 25 years. We use foams to add specific features to composites such as:
- Flexibility and Stretch
Our foam composites are used by our customers to make:
devices and braces
- Soft interior surfaces for automotive products
- Exterior covers for recreational equipment
- Acoustical insulation materials
- Die cut promotional products – “We’re #1!”
- Beverage insulation products
- Intimate apparel
- Disposable medical padding and bandages
- Safety equipment
- Protective helmets
- Saddle pads
- Gym mats
- And many more….
We use two primary processes for creating foam composites:
Lamination – involves passing foam over an open flame, which creates a thin
layer of melted polymer on the surface of the foam. A strong bond is then
formed when the secondary (substrate) is quickly brought into contact with the
tacky surface under controlled tension and pressure.
This process allows us to create double-sided composites where the foam is
sandwiched between a combination of decorative or technical materials. A key
benefit of flame lamination is that it eliminates the need for adhesive and the
risk of adhesive creep and bond failure.
Fusing – allows us to bond flexible materials in a continuous roll-to-roll
manner. By carefully controlling temperature, pressure and dwell, and selecting
the best adhesive solution, we create strong bonds between foams and target
materials to create bonds that stand up under any environmental extreme.
Regardless of the method we use for your project everything begins with
clearly understanding your needs. Many of our solutions include custom elements
and we prepare prototypes and samples along the way to make sure we are
exceeding your expectations.
As an ISO certified company achieving customer satisfaction is our
primary goal. Our mission is the help you reduce costs and improve yields. That
is good business for both of us.
Dal-Bac specializes in all types of foam lamination products and pressure sensitive adhesives. We also specialize in helping Start Up companies and existing customers bring new products and ideas to the market.
When you have a new idea what you really need is a partner that will work with you to realize your vision. We love to do that and have had great success helping launch new products and brands.
Our central business is primarily soft goods converting and we have a range of capabilities to help develop new products and solutions.
- Experience: Dal-Bac has been converting a variety of soft goods since 1973. We have particular expertise in all areas of foam lamination creating a wide variety of composite solutions.
- Engineering: Our engineers can help you realize your vision and then create the manufacturing process to realize it. We can help you develop totally unique composite or adhesive solutions to meet the needs of your new idea. This includes developing prototypes that are designed with real production needs in mind.
- Supplier Network: New ideas frequently need unique material solutions and our extensive supplier network lets us source anything you need.
- Processes: as an ISO 9001: 2015 certified company, process is a real priority for us. We can develop a completely new production process for your new product and then work to improve it and reduce your overall production costs.
- Value: A central premise at Dal-Bac is to help our customers reduce costs and improve yields. Our extensive knowledge about foam lamination products and pressure sensitive adhesive applications allows us to quickly plan for the right materials and leverage our existing manufacturing expertise.
- Shared investment: We recognize that product development can have significant costs. As a result we frequently work with Start Ups to reduce their costs by crediting some of the development cost against future sales.
If you are a Start Up company or just have a new idea requiring foam lamination, flexible laminated goods or pressure sensitive adhesives we would love to start a conversation.
Pressure Sensitive Adhesives, or “peel and stick” tapes are both loved and despised by consumers but often for the same reason! Take a tape that is used to secure a picture to the wall. The expectation is that the adhesive will securely hold that picture in place – pretty much forever = Love! However, what happens if you hang the picture in the wrong spot and then cannot get the adhesive off the picture or the wall = Hate!
Part of this is that consumers do not really understand the complexity and sophistication that is required to create a pressure sensitive adhesive that will measure up to expectations by sticking to two potentially different surfaces. Their expectation is that the adhesive is going to work and hold as expected, unless they decide to move it.
How Dal-Bac Gets it Right
Making sure our products can meet customer expectations is a core value at Dal-Bac. Our ISO 9001:2015 certification means that we are dedicated to:
- Exceeding our customers expectations
- Improving our processes to create better value for our customers
To achieve this we start by making sure that we completely understand what our customer needs their pressure sensitive adhesive to accomplish:
- How long is that picture expected to stay on the wall?
- What exactly are the surfaces to which the adhesive is expected to anchor?
- What environmental conditions will the adhesive encounter?
Our engineers and process teams use the answers to these questions to determine the best pressure sensitive adhesive solution for each customer application. This can involve:
- Defining the anchoring expectations
- Developing adhesive options
- Recognizing disparities between target and primary substrates
- Utilizing specialized production techniques
With our background in pressure sensitive adhesives, we can help make adhesive recommendations that bridge the gaps between what is desired and what is possible.
A Proprietary Process
Because we are committed to improving value in our internal processes, we are always looking for better and more efficient ways to produce exceptional results. As part of our extensive work with pressure sensitive adhesives, we have a developed a proprietary technique that can sometimes allow us to forego corona treating or the development of a double-sided solution. Both of these methods can require additional time and costs that may not be absolutely necessary.
By experimenting with alternate materials and approaches, we have worked out a means to boost the anchorage of our pressure sensitive adhesives to some problematic substrates. We can examine the serviceability of this process for challenging applications and determine if it adds value to your product.
Flame lamination is one of the core services at Dal-Bac Manufacturing. As an ISO 9001: 2015 certified company we take great pride in exceeding our customers expectations. Our goal is to help our customers reduce costs and improve yields.
Achieving our goals is simply all about helping you achieve yours. That is why we are well known for creating custom solutions to customer challenges. We use our array of services, including flame lamination, to find the most efficient and economical answer to specific challenges.
Flame lamination is at the center of many of our solutions for many very good reasons:
- Lower costs
- Highly efficient process
- An extensive array of available substrates can be used as long as the core material is flame laminable
- It does not require adhesive which make flame lamination an eco-friendly solution
- Composites can be created with multiple layers
- Variable thickness of the final composites up to a maximum of .75 inches
While we certainly do a lot of straightforward flame lamination production we really shine when our customers are not exactly sure what solution they need. In these cases our engineering and productions teams work closely with you to identify what you need and how to efficiently make it happen. Services we provide along the way include:
Helping identify the exact requirements for the final composite
- Determining the best combination of materials to meet your specific needs
- Developing the best production process to efficiently produce your product
- Assisting with materials sourcing from our partner network
- Prototype development
- Process testing
Our flame lamination experience covers a wide range of industries including:
- Orthopedic padding
- Automotive interiors
- Thermal and acoustical insulation
- Flexible Beverage Insulating Laminates – (koozies)
- Intimate apparel
- Medical disposables
- Sports equipment
We welcome challenges and are committed to exceeding your expectations. Please ask us if you need some specialized solutions to your converting challenges!