For packaging engineers, puncture resistant packaging starts with analog design. You don’t need a vendor who just looks at your digital files. You need a design and manufacturing partner who loads and unloads sample parts into rack bags. Part drawings contain important information, but going hands-on and off-line will reveal problems like point loading.

Hold-True, a Made in the USA manufacturer of sewn fabric dunnage, specializes in analog design. For puncture resistant packaging, we know that choosing the right base material is important. As this article explains, however, you’ll also need to follow four key design guidelines for protective panels, structural members, bonding, and fabrics.

Protective Panels

Protective panels that are made of high-density polyethylene (HDPE) provide protection against point loading and abrasion. Hold-True sews HDPE panels onto parts bags and can recommend the right sheet thickness to use for your application. With steel sun visors and other parts that have sharp metal corners, it’s important to avoid using HDPE sheets that are too light. Otherwise, the plastic can crinkle or bend. If additional support is required, structural members offer a solution.

Structural Members

CON-Pearl® is a structural plastic that’s both strong and lightweight. Unlike Pcorr, a type of corrugated plastic sheeting that’s used with sewn fabric dunnage, CON-Pearl® provides strength in every direction. Depending on the application, Hold-True may recommend using sheets of CON-Pearl® in thicknesses of 3/8” or 1/16”. Thicker sheets aren’t necessarily better, however. If a plastic sheet is too thick, parts like a cabinet with attachment points may dig through.

Bonding

As some packaging engineers have learned the hard way, it’s difficult to bond HDPE to CON-Pearl® with regular glues. Most bonding agents that adhere to one substrate won’t stick to the other. Even plastic glues don’t work well because the two substrate materials are so dissimilar on a molecular level. That’s why Hold-True uses a specialized glue to achieve strong, reliable bonds. This bonding agent costs more than regular glues, but provides a strong return on investment (ROI).

Fabric

Finally, Hold-True can incorporate thin pieces of fabric into your fabric dunnage design to support parts loading and unloading. Design houses that only look at digital files can tell you how much a part weighs, but they lack the application knowledge to support ease-of-use for assembly line workers.

Puncture Resistant Packaging from Hold-True

Would you like to learn more about puncture resistant packaging? Do you have questions about reusable packaging materials or costs? To learn more about how Hold-True uses analog design to create sewn fabric solutions that are puncture-resistant, contact us.

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Brushed Tricot Basics

Brushing is a finishing process raises the fibers in fabrics. When tricot fabric is brushed, the material acquires a distinctive look and feel. The front of the fabric has vertical ribs, but the back has horizontal ribs. This appearance is a function of how the manufacturing processes stretches long parallel threads and then loops the adjacent threads around these parallel threads.

Brushed fabrics have a softer feel because raising a nap produces a fuzzy or down surface. Tricot fabrics that are brushed are also easy-to-produce and relatively inexpensive. These reusable packaging materials offer good elasticity and resist creasing, too. Typically, brushed tricot fabrics are made of synthetic fibers such as nylon or polyester. Natural fibers such as cotton can be used, but they’re usually blended with synthetic fibers that impart material properties.

Brushed Tricot Costs

Brushed tricot fabrics are soft and cost-effective, but these reusable packaging materials may also require frequent cleaning. Ultimately, the same finishing process that imparts their softer feel also makes them a “dirt magnet”. During the brushing process, hair-like fibers are pulled so that they stick out. In turn, these hairs tend to pick up more dirt. Brushed tricot fabrics are permeable and support cleaning, but packaging engineers should include cleaning costs in their total cost of ownership (TCO) calculations.

Learn More About Reusable Packaging Materials

Do you have questions about brushed tricot and other reusable packaging materials? Hold-True provides sewn fabric solutions for the automotive, heavy truck, power sports, and aerospace industries. In addition to expert sewing, we offer design assistance and help with material selection. To learn how we can help you, contact us.

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Rack Bag Design for Sewn, Reusable Fabric Dunnage

Rack bag design isn’t just about pocket size or material selection. It’s not just about computer aided design (CAD) software either.

Fabric Dunnage: How Dirty Rack Bags Muddy Your Costs

Fabric dunnage that’s cheaper may seem like a bargain, but there’s more to consider than just the purchase price. Dirty rack bags can muddy your true costs.

Work-in-Process Bags: Why the Pockets Sag on WIP Bags

Work-in-process bags are used for kitting and sequencing parts for assembly-line production. Learn how to design better pockets for WIP bags.

Three Ways to Cut Your Sewn Fabric Dunnage Costs

Sewn fabric dunnage costs are about more than just the purchase price of rack bags. Learn how to reduce your packaging costs and ensure rack bag ROI.

Fabric Dunnage Suppliers: Cost Isn’t the Only Consideration

Cost isn’t the only consideration with fabric dunnage suppliers. Hold-True explains what sourcing managers need to look for in reusable packaging partner.

Made in USA Fabric Dunnage

Made in USA fabric dunnage from Hold-True is about American know-how and a commitment to meeting your needs.

Sewn Fabric Dunnage: Four Reasons Why Rack Bag Seams Fail

Sewn fabric dunnage that fails can cost you time and money. Rack bag seams tear for many reasons, but there are four that relate to threads and stitching.

Fabric Dunnage Costs and Thread Selection

Fabric dunnage costs and thread selection are related. Lower-cost threads may seem like a bargain, but using a thread that’s too thin (and too weak) can cause rack bag seams to fail.

How to Design Fabric-Resistant Fabric Dunnage

Designing puncture-resistant fabric dunnage means following some basic guidelines for protective panels, structural members, bonding, and fabric. Learn what they are.

Fabric Dunnage Materials: Laminated Fabrics vs. Coated Fabrics

Laminated fabrics for sewn fabric dunnage are composite materials with a layered structure. Two of more materials are bonded together to impart benefits.

Fabric Dunnage Materials: Coated Fabrics vs. Laminated Fabrics

Coated fabrics are fabric dunnage materials that consist of a woven or non-woven cloth with a specialized coating. Woven coated fabrics are in rack bags.

Brushed Tricot Fabric for Reusable Packaging

Brushed tricot fabric for reusable packaging is a soft liner-material that can be used with Class A surfaces such as chrome parts or faux wood panels.

How to Choose Plastic Doors for Fabric Dunnage

Plastic doors for fabric dunnage need to protect parts and withstand the environment. Here’s what packaging engineers need to consider.

Custom Tyvek for Reusable Packaging Strengthens Fabric Dunnage

Custom Tyvek for reusable packaging (sewn fabric dunnage) combines the advantages of Tyvek with a reinforcing scrim and easy-to-clean surface.

Rack Bag ROI: Calculate Your True Dunnage Costs

What are your dunnage costs? If you don’t know what you’re really paying for sewn fabric dunnage, you might be spending too much on packaging.

Automotive Rack Bags: Advantages and Applications

Automotive rack bags provide important advantages over automated dunnage that’s made of corrugated cardboard, plastic, and all metal.

How to Get the Automotive Dunnage That You Need

Do you enjoy a good story? Then kick back, relax, and learn how Patrick the packaging engineer got the automotive dunnage that he needed.

Velcro Straps for Sewn Fabric Dunnage

Velcro straps are used to secure loads in sewn fabric dunnage. Velcro is easier to open and close than cams, buckles, zippers, or other hardware.

Sewn Fabric Dunnage: Seven Solutions to Packaging Problems

The benefits of sewn fabric dunnage are clear. Yet there are also seven challenges that require expert packaging solutions.

Reusable Packaging Design: Seven Common Challenges

With reusable packaging design, there are seven common challenges to avoid. Do you know they are? Read this article to find out.

Capital Planning for Returnable Dunnage

Capital planning for returnable dunnage can help you reduce your packaging costs over the long haul. Hold-True explains what capital planners need to know.

Reusable Packaging: A Buyer’s Guide for Capital Planners

Get the buyer’s guide that capital planners need for reusable packaging. Learn which questions to ask and which assumptions to question.

Reusable Packaging: How CFOs Make Better Budget Decisions

With reusable packaging, chief financial officers (CFOs) need to meet three challenges: changing the mindset, filling the vacuum, finding the right partner.

Returnable Packaging Basics: Digital vs. Analog Design

For packaging engineers, a sound knowledge of returnable packaging basics begins with digital vs. analog design. How well do you understand the difference?

Class A Surfaces and Reusable Packaging Materials

Class A surfaces need to be handled with care. To prevent scratching, a reusable packaging material like brushed tricot fabric is used.

What Will Be the Top Reusable Packaging Posts of 2018?

The new year isn’t even here yet, but you’ll find the top reusable packaging posts of 2018 here at Hold-True. In the meantime, contact us for more information about sewn fabric dunnage for the automotive, heavy truck, power sports, and aerospace industries.

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Evaluating Reusable Packaging Materials

Typically, brushed tricot fabrics are made of synthetic fibers such as nylon or polyester. Natural fibers such as cotton can be used, but they’re usually blended with synthetic fibers that impart specific properties. For sewn fabric dunnage, tricot or napped fabrics can be laminated to vinyl for reinforcement. Laminated fabrics can provide greater tensile strength than plain fabric alone, but they tend to act as separate materials and can de-laminate. Coated fabrics made of tricot materials are available.

Brushed tricot fabrics are soft and cost-effective, but these reusable packaging materials may also require frequent cleaning. Ultimately, the same finishing process that imparts their softer feel also makes them a “dirt magnet”. During the brushing process, hair-like fibers are pulled so that they stick out. In turn, these hairs tend to pick up more dirt. Brushed tricot fabrics are permeable and support cleaning, but packaging designers should include cleaning costs in their total cost of ownership (TCO) calculations.

Brushed Tricot Fabric and Class A Surfaces

Tricot fabrics that are brushed are easy-to-produce and relatively inexpensive. These reusable packaging materials also offer good elasticity and resist creasing. When tricot fabric is brushed, the material acquires a distinctive look and feel. The front of the fabric has vertical ribs, but the back has horizontal ribs. This novel appearance is a function of how the manufacturing processes stretches long parallel threads and then loops the adjacent threads around these parallel threads.

Brushing is a finishing process that uses brushes or other abrading devices to raise the fibers in fabrics like tricot. Raising a nap produces a fuzzy or downy surface, which is why brushed fabrics have a softer feel. This novelty texture is a good choice for Class A surfaces, a term that’s used in automotive design to describe high-quality surfaces that fit together. If parts with Class A surfaces become scratched, assemblers may reject them because even shallow grooves can affect part fit and function.

How to Protect Class A Surfaces

Do you have questions about brushed tricot materials for reusable packaging? Are you looking for a Made in the USA dunnage from a company that provides design assistance, help with material selection, and expert sewing capabilities? Hold-True offers sewn solutions that add value to the supply chain in industries like automotive, heavy truck, power sports, and aerospace. To learn how we can help you, contact us at our facility in Mansfield, Ohio (USA).

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What Is Velcro?

VELCRO® brand is a registered trademark of a company called Velcro BVBA, but the term “Velcro” is used generically to refer to hook-and-loop fasteners. Not all hook-and-loop fasteners are made by Velcro BVBA, however, and more than one type of VELCRO® brand strap is available. For example, some straps provide greater elasticity. Others support both indoor and outdoor use.

Dunnage Design Decisions

For designers of sewn fabric dunnage, deciding whether to use Velcro straps isn’t a simple yes-or-no decision. Packaging engineers need to understand the complete application environment in order to choose the best strap material.  Design considerations include peel strength, the use of batting, and the number of times (cycles) that the Velcro will be opened and closed.

Strap Material

Velcro straps can be made of nylon or polypropylene. Nylon is fine for general-purpose use, but this synthetic polymer can’t withstand prolonged exposure to ultraviolet (UV) light from the sun. Polypropylene looks like nylon, but has better sunlight and moisture resistance. For sewn fabric dunnage that’s stored in outdoor environments, Velcro straps made of polypropylene are a better choice.

Peel Strength

Peel strength is the average load required to separate bonded materials where the angle of separation is 180°. In layman’s terms, peel strength testing measures bond strength. With sewn fabric dunnage, designers need to specify a Velcro strap that’s strong enough to stay together but not too difficult to pull apart. Otherwise, loads can loosen the straps, or workers may struggle to separate the Velcro.

Batting

Some Velcro straps can adhere to the batting that’s used with headliners, door panels, and other packaged parts. This is a problem for personnel who need to slide parts in and out of automotive rack bags during loading and unloading. Damage to part surfaces can occur, too. Velcro straps that won’t stick to batting are available, but they’re more expensive. Yet in the long run, these straps can reduce your true costs.

Number of Cycles

Finally, design engineers need to consider the number of times that workers will open and close the Velcro straps. This number can vary considerably, and may require the use of a high-cycle material. It’s also important to remember that Velcro tends to lose “stickiness” toward the end of its useful life. A longer-lasting strap may cost more, but can save you money by preventing damage to high-value parts.

Which Velcro Straps Do You Need?

Hold-True is a Made in the USA manufacturer of sewn fabric dunnage that can help you to select the right Velcro strap for your rack bag application. We recommend UV-resistant polypropylene for the strap material and offer a choice of Velcro based on the number of cycles that you need. Our experienced team is ready to talk to you about batting and peel strength, too. To get started, contact us.

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For example, automotive racks bags are recyclable, collapsible, and stackable. By contrast, other types of automotive dunnage generate significant waste, take longer to setup, and require more space for fewer parts. Automotive rack bags also reduce inbound product damage while lowering the number of strapped parts. Sewn fabric dunnage weighs less than all-steel racks and some types of corrugated cardboard, too. In addition to saving you time and money, reusable rack bags reduce the size of your carbon footprint.

Automotive Rack Bags vs. Other Automotive Dunnage

Cardboard packaging consists of corrugated boxes and plastic dividers. Because these materials are expensive and the packaging is custom-made, companis are reluctant to discard this dunnage even when it’s damaged. When cardboard packaging reaches the end of its useful life, however, workers need to separate the cardboard boxes from the plastic dividers. Disposal is a messy, labor-intensive process that generates significant waste. Corrugated cardboard takes time to setup and can be heavy, too.

Plastic tubs and totes are relatively expensive. Some products collapse to save space, but other plastic dunnage does not. Plus, plastic tubs can require more room for the same number of parts. Some plastics are susceptible to cracking, too. Plastic totes are often used with smaller-sized parts, but putting a large number of totes on a pallet requires careful tracking. Disposing of plastic totes generates waste, and the foam inserts need to be separated from the tote itself.

All-steel racks are used with doors, windshields, engines, and other large parts. To protect surfaces such as windshield glass, custom-molded foam blocks are used. Other types of surfaces can be wrapped in plastic, but all of this expendable dunnage won’t help your sustainability initiatives. Automotive rack bags can integrate with metal racks and provide a reusable, recyclable alternative. With proper design and testing, sewn fabric dunnage can even accommodate large parts such as the crowns on heavy trucks.

Made in the USA Rack Bags

Would you like to learn more about automotive rack bags for your shipping, packaging, and assembly application? Hold-True, a Made in the USA manufacturer of sewn fabric dunnage, is ready to help. To get started, contact us.

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Advantages and Disadvantages of Tyvek

Tyvek is strong, lightweight, opaque, and dimensionally stable. Large Tyvek sheets are used as house-wrap in building and construction, but this protective material’s properties also make it a good choice for reusable packaging. Because Tyvek can be cut easily with knives and scissors, however, increasing its durability is important when puncture-resistance is required.

By using custom Tyvek that’s reinforced, packaging engineers can design rack bags where small cuts won’t cause big problems. Dunnage that lasts longer provides a stronger return on investment (ROI), but the benefits don’t end in the Finance Department. Parts bags that stay in the field and out of the shop are an asset for the people who assemble your company’s products.

Tyvek vs. Brushed Tricot

Strength, durability, and tear-resistance are important, but you also need reusable packaging that’s easy-to-clean for reduced maintenance costs. Packaging designers can choose brushed tricot for Class A surfaces, but the brushing process makes this fabric a “dirt magnet” that requires frequent cleaning. Tyvek surfaces can get dirty, but they’re easy to wipe clean with a rag when they do.

Unlike brushed tricot, Tyvek won’t retain moisture and doesn’t need to be dried out from exposure to rain or dew. So if your rack bags are stored outdoors in the elements, Tyvek is a smart choice. That’s why in addition to sewn fabric dunnage, Tyvek is often used with car covers and cargo covers. Standard Tyvek imparts many desirable properties, but custom Tyvek may be what you need for work-in-process bags.

Custom Tyvek and Fabric Dunnage from Hold-True

Hold-True, a Made in the USA manufacturer of reusable fabric dunnage, sources custom Tyvek that can strengthen your packaging designs. We also take a hands-on-approach to prototyping. With our cut-and-sew capabilities, we can create prototype WIP bags that fit your metal racks. We can then load and upload sample parts to identify single-point loading and reduce the risk of puncture.

With our strong supplier network, Hold-True can source the custom Tyvek that you need in lower minimum order quantities (MOQs) than you might expect. Tyvek is a commodity buy, but the composite material that we use is specialized and uses adhesive lamination to build a multi-layer structure. For a strong, reinforced, and easy-to-clean rack bag material, ask Hold-True.

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Dunnage Door Materials: PVC vs. PE

Plastic doors that are made of polyvinyl chloride (PVC) are used commonly with reusable packaging. PVC is strong and lightweight, but this thermoplastic won’t withstand prolonged exposure to sunlight and is prone to stress-cracking. That’s not just a problem if you need to store rack bags outdoors where the sun’s ultraviolet rays (UV) can yellow the plastic. UV-induced brittleness is also an issue since dunnage doors experience flexing whenever they’re opened and closed. Warehouses and assembly lines can also subject weakened plastics to puncturing and cracking from impacts.

Plastic doors that are made of polyethylene (PE) provide an attractive alternative to PVC. Different forms of PE are available, but this packaging material combines impact strength with rigidity. Importantly, PE plastic can also resist prolonged exposure to sunlight. When clear plastic doors begin to yellow, it’s difficult for workers to see through them. PE can maintain its optical clarity, a fact that workers like when they need to find parts quickly and don’t want to waste time opening and closing doors. PE plastic can also withstand frigid temperatures, something that companies in cold-weather climates appreciate.

Door Attachment Methods: Sewing vs. Velcro

Traditionally, suppliers of fabric dunnage have sewn plastic doors to rack bags. Sewn solutions are strong and reliable, but plastic doors that tear away from a rack bag need to be repaired. For example, if a forklift driver accidentally hits some returnable packaging that’s empty and left hanging, a plastic door may become detached and wind up on the floor. Even if the plastic door isn’t cracked, the rack bag must come out of service so that the door can be re-sewn to the rack bag.

Velcro provides an alternative method of attachment that eliminates the need for industrial sewing. When the ends are attached properly, Velcro won’t detach during normal operations such as the repeated opening and closing of doors. If a plastic door is detached accidentally, such as from the impact of a forklift, it’s easy to re-attach the door right on the shop floor. As long as the plastic isn’t damaged, workers can get the rack bag back in-service without ever removing the fabric dunnage from facility.

Ask Hold-True about Plastic Doors for Fabric Dunnage

Do you have questions about reusable packaging or fabric dunnage materials? Hold-True is a Made in the USA manufacturer of sewn fabric solutions that’s ready to help. Ask us about how we attach PE doors with Velcro for rack bags that provide a strong return on investment (ROI). To get started, contact us.

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How Brushed Tricot Fabrics Are Made

Brushing is a finishing process that uses brushes or other abrading devices to raise the fibers in fabrics like tricot. Raising a nap produces a fuzzy or downy surface, which is why brushed fabrics have a softer feel. This novelty texture is a good choice for Class A surfaces, a term that’s used in automotive design to describe high-quality surfaces that fit together. If parts with Class A surfaces become scratched, assemblers may reject them because even shallow grooves can affect part fit and function.

Tricot fabrics that are brushed are easy-to-produce and relatively inexpensive. These reusable packaging materials also offer good elasticity and resist creasing. When tricot fabric is brushed, the material acquires a distinctive look and feel. The front of the fabric has vertical ribs, but the back has horizontal ribs. This novel appearance is a function of how the manufacturing processes stretches long parallel threads and then loops the adjacent threads around these parallel threads.

Typically, brushed tricot fabrics are made of synthetic fibers such as nylon or polyester. Natural fibers such as cotton can be used, but they’re usually blended with synthetic fibers that impart particular properties. For sewn fabric dunnage, tricot or napped fabrics can be laminated to vinyl for reinforcement. Laminated fabrics can provide greater tensile strength than plain fabric alone, but they tend to act as separate materials and can de-laminate. Coated fabrics made of tricot materials are available.

Is Brushed Tricot Fabric Right for Your Application?

Brushed tricot fabrics are soft and cost-effective, but these fabric dunnage materials may also require frequent cleaning. Ultimately, the same finishing process that imparts their softer feel also makes them a “dirt magnet”. During the brushing process, hair-like fibers are pulled so that they stick out. In turn, these hairs tend to pick up more dirt. Brushed tricot fabrics are permeable and support cleaning, but rack bag designers should include cleaning costs in their total cost of ownership (TCO) calculations.

Do you have questions about brushed tricot materials for reusable packaging? Are you looking for a Made in the USA dunnage from a company that provides design assistance, help with material selection, and expert sewing capabilities? Hold-True offers sewn solutions that add value to the supply chain in industries like automotive, heavy truck, power sports, and aerospace. To learn how we can help you, contact us at our facility in Mansfield, Ohio (USA).

The post Brushed Tricot Fabric for Reusable Packaging appeared first on Hold-True.

In Part 1 of this series, Hold-True examined laminated fabrics for rack bags and described the advantages and disadvantages of these fabric dunnage materials. In Part 2, we’ll take a look at coated fabrics and consider both their strengths and their weaknesses. By understanding all of your requirements, you can select rack bag materials that support not just your packaging, shipping, and assembly application, but also your organization’s need for a strong return on investment (ROI).

What are Coated Fabrics?

Coated fabrics are woven or non-woven cloth with a specialized coating that’s applied to the surface of the material, or saturated into the material’s bulk. The coating is usually a polymer or elastomer that imparts particular properties, such as resistance to water, mildew, or sunlight. Coatings that increase puncture-resistance or that help make rack bags easier-to-clean are also used. Typically, these coatings are applied to the base fabric in a viscous or syrup-like form.

Natural Fibers and Synthetic Fibers

With coated fabrics, the base material may contain either natural or synthetic fibers. Natural fibers such as cotton can be recycled, but they absorb moisture and are less durable. Synthetic fibers such as polypropylene (PP) combine strength and durability with weather resistance and ease-of-cleaning. Coatings for fabrics also include polyvinyl chloride (PVC), high density polyethylene (PE), and low density polyethylene (PE). PVC resists water, but still promotes mold or mildew growth.

Advantages of Coated Fabrics

Coatings can reduce the tensile strength of fibers, but the advantages of coated fabrics outweigh their disadvantages – especially when compared to laminated fabrics. For example, coated materials tend to weigh less per square yard. They won’t de-laminate either. With coated fabrics, the coating and the base fabric tend to act as a single material. With laminated fabrics, each of the constituent materials must work well together, yet each layer tends to act as a separate material.

How to Increase Coated Fabric Strength

To address concerns about how coatings reduce tensile strength, Hold-True can source coated fabrics with a scrim for reinforcement. This strong but lightweight mesh or netting increases a coated fabric’s resistance to tearing under tension. Scrim also increases resistance to tongue or tab tear from ripping. Hold-True can also manufacture your parts bags with ripstop materials, woven fabrics that use a special reinforcement technique.

Learn More about Fabric Dunnage Materials

At Hold-True, our primary coated fabric is a woven material that provides durability and supports rack bag manufacturing. Woven strips of HDPE that are coated with LDPE are a great choice for sewn, reusable packaging that needs to withstand the elements and provide a strong ROI. For more information about choosing fabric dunnage, contact Hold-True at our facility in Mansfield, Ohio (USA)

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