Contract and Toll Lamination: How to Develop a Custom Nonwoven Laminate

Nonwoven and film lamination rolls

Toll Lamination and Contract Manufacturing: What Is the Difference

When a brand or converter needs a laminated nonwoven that is not available off the shelf, there are two ways to work with a laminator. In toll lamination, you supply some or all of the materials, such as your own film, nonwoven or membrane, and we laminate them on our lines to your specification. You keep control of the raw materials, and we provide the process, the equipment and the know-how. In contract manufacturing, we source or produce the layers ourselves, laminate them and deliver the finished roll or even the finished product. This gives you a single supplier for the full structure.

At Felix Nonwovens in Eskişehir, Türkiye, we offer both through our contract and toll lamination service. Because we produce our own spunbond, SMS, meltblown and breathable film, many customers combine both models: they supply one special layer and we supply the rest.

Lamination Methods and When to Use Each

Hot-melt lamination: an adhesive is applied in a controlled pattern between the layers. It is flexible, works with many materials and keeps good breathability when the adhesive pattern is open. Common for hygiene backsheets, medical drape laminates and breathable structures.
Ultrasonic lamination: layers are bonded by ultrasonic energy at points or patterns, without adhesive. It gives a soft, clean bond and is suitable when adhesive is not wanted, for example in some medical and skin-contact products.
Calender lamination: heated rolls bond thermoplastic layers under pressure. It is fast and strong, and works well when layers are compatible, for example polypropylene to polypropylene.
Heat sealing: heat bonds layers along defined areas or edges. It is useful for sealed structures, pockets and finished goods.

The right method depends on the materials, the required bond strength, softness, breathability and the end use. We often trial more than one method before recommending a final process.

Typical Layers

Polypropylene spunbond (10 to 100 g/m²): strength and a textile feel.
SMS and SSMMS (10 to 100 g/m²): strength with built-in barrier.
Meltblown (10 to 100 g/m², including nano and ultra-nano grades): filtration and barrier.
Breathable film (12 to 20 g/m²): liquid-proof and vapour-permeable.
Barrier film: for full liquid barrier where breathability is not required.

Laminates can be produced in widths of 160, 320, 400 and 540 cm, with custom slitting to your roll widths.

Example Structures

Drape laminates: nonwoven and film laminates for surgical drapes, with absorbent and liquid-proof layers in the critical areas.
Textile backsheet: spunbond laminated to breathable film for diapers, adult incontinence and feminine hygiene products, with a soft, cloth-like outside.
Housewrap and roofing membranes: spunbond and breathable film laminates that keep water out of a building while letting vapour escape.
Sorbents: meltblown-based structures laminated with spunbond for strength and handling.
SFS gown fabric: spunbond/film/spunbond for fully reinforced surgical gowns.

From Brief to Trial: What Information We Need

A clear brief shortens development. When you contact us, please share:

The end product and the market it will be sold in.
The structure you have in mind, or the performance you need if the structure is open.
Target weights for each layer and the total weight.
Required properties, such as hydrostatic head, breathability, bond strength, softness or tensile strength.
Width, roll diameter, core size and any slitting needs.
Whether you will supply any materials (toll) or need us to supply all layers (contract).
Any standards the finished product must meet, for example EN 13795 for medical products.

With this information, we can propose a structure and method, run a lab or line trial and share samples for your own testing.

Testing and Quality

Our materials are OEKO-TEX certified. Laminates are checked for properties such as weight, bond strength, hydrostatic head and breathability, depending on the end use. Datasheets are available on request.

Private Label and Finished Goods

Lamination does not have to stop at the roll. We also produce medical finished goods such as surgical gowns and drapes, with drapes available sterile and non-sterile. Private label is available, so a laminate developed for you can reach the market as a finished product under your brand.

Have a laminate in mind? Send your brief to info@felixnonwovens.com or use our contact page, and our team will help you develop the right custom nonwoven laminate.