Pressure Sensitive Adhesives – It is all about the “anchor!”

Pressure Sensitive 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:

  • Band-Aids
  • 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 coated)
  • 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 challenging substrates.

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.

Your Success is Our Business

Dal-Bac Manufacturing 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 of 2016.

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.

  • Engineering: Our 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.
  • Supplier 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 product.

Foam Lamination: Engineered for Success

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:

  1. Demonstrated commitment to exceeding customer expectations
  2. Dedication to continuous process and system improvement

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
  • Breathability
  • Durability
  • Comfort

These features help our engineering team focus in on the right materials for your project

  • Foam materials
    • Polyurethane
    • Polyethylene
    • Vinyl-nitrate sponges
    • EVA sponges
  • Outer layer requirements
    • Fabrics
    • Films
    • Non-wovens
    • Adhesives
  • Lamination process
    • Custom solution

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.

Flame Lamination Composites

Flame Lamination 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 acoustical insulation
  • Luggage
  • Flexible Beverage Insulating Laminates – (koozies)
  • Costumes
  • Intimate apparel
  • Medical disposables
  • Sports equipment
  • Packaging

Our technical team works with our customers to help determine:

  • The best combination of materials to meet your specific needs
  • The most efficient production process for your product

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.

Better Coatings with Better Measurement

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 Solutions

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 fabric
  • Sometimes the solution requires using more than one adhesive technique

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.

 We 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 problem by:

  • 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 required shape
  • 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!

Growing Need for Medical Fabrics

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 devices

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:

  • Absorbency
  • Padding capability
  • Durability and strength
  • Flexibility
  • Softness
  • Breathability
  • Moisture wicking
  • Moisture and air barriers
  • Direct Skin contact
  • Direct Skin contact adhesive
  • Biodegradability

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!

Thermal Fusing for Laundry Labels!

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 performance.

By carefully 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.

Foam Composites for All!

Dal-Bac Manufacturing has been creating foam composites for over 25 years. We use foams to add specific features to composites such as:

  • Bulk
  • Padding
  • Flexibility and Stretch
  • Breathability
  • Durability
  • Comfort

Our foam composites are used by our customers to make:

  • Orthopedic devices and braces
  • Soft interior surfaces for automotive products
  • Exterior covers for recreational equipment
  • Thermal insulation materials
  • Acoustical insulation materials
  • Die cut promotional products – “We’re #1!”
  • Beverage insulation products
  • Intimate apparel
  • Disposable medical padding and bandages
  • Safety equipment
  • Costumes
  • Protective helmets
  • Saddle pads
  • Gym mats
  • And many more….

We use two primary processes for creating foam composites:

  1. Flame 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.
  2. Thermal 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.

Solutions for Start Ups and New Ideas

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.
  • Intellectual Property: Your idea will be safe with us as a result of our privacy policy. Our goal is to help you make the new product!
  • 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.