Where a 180gsm fleece relief blanket fits
180gsm polyester fleece disaster relief blankets sit in the light-to-medium emergency category. They are not heavy winter relief blankets, wool-rich camp blankets, or quilted thermal blankets. At 180gsm, the fabric is usually warp or weft knitted polyester fleece, brushed on one or both sides, then cut and overlocked. Common finished sizes are 130 x 170 cm, 140 x 190 cm, 150 x 200 cm, and sometimes 160 x 220 cm. Finished unit weight depends more on size than the headline GSM. A 150 x 200 cm blanket at true 180gsm contains about 540 g of fabric before overlock yarn, care label, cutting tolerance and finishing variation. A realistic finished unit normally lands around 560-620 g if the size is held correctly.
The strength of this construction is speed, price, low cube, fast drying and simple field distribution. The weak points are limited thermal insulation, edge durability if the overlock is underspecified, pile flattening under compression, and buyer disputes when GSM, size and unit weight are not linked in the PO. Do not write 180gsm into a cold-weather shelter tender unless users will also receive additional bedding. For colder deployments, a buyer should evaluate 220-300gsm polar fleece, quilted polyester, sherpa-backed fleece, or wool-rich blankets. Related FIELDLOOM references include 250gsm polar fleece emergency blankets, quilted polyester travel blanket construction, and wool-blend blanket construction, but the procurement logic is different: relief bales prioritise count accuracy, repeatable unit weight, pack strength and fast loading.
Fabric specification: GSM, yarn, brushing and shrinkage
A workable mill specification is 100% polyester fleece, 180gsm nominal, with finished GSM tolerance of ±5% measured after conditioning. For a tender, write 171-189gsm finished fabric weight instead of only “180gsm”. That gives the inspector a measurable acceptance band. Some suppliers will quote ±8% or ±10% to reduce yarn and finishing risk; the price may look better, but bale-to-bale handfeel variation becomes visible. For relief distribution, that inconsistency becomes a complaint even when colour and nominal size match.
Most 180gsm fleece in this category uses polyester filament yarn in the broad 75D-150D range. Finer yarn can give a softer surface, but if knit density is too open it can pill faster and lose body after washing. Coarser yarn is usually more stable and cheaper, but it feels harsher. For bulk relief work, we prioritise even knitting, controlled brushing, low lint and stable dimensions over a luxury handfeel. Modest pile height after brushing and shearing is commonly around 1.5-2.5 mm. Over-brushing makes the blanket look fuller at shipment but can increase fibre shedding, pilling and packed-volume variation.
Dimensional stability should be written plainly. A practical requirement is shrinkage after washing not worse than -5% length and -5% width under ISO 6330 domestic washing, with measurement by ISO 5077. If an agency or buyer supplies its own wash cycle, follow that exact method. Colour fastness to washing can be requested under ISO 105-C06, often grade 3-4 or better for shade change and staining on multifibre. For dark navy, red or black, add ISO 105-X12 rubbing fastness: dry grade 3-4 and wet grade 2-3 are practical targets, with wet crocking on deep shades the harder result. Pilling can be checked under ISO 12945-2; a realistic relief-grade target is often grade 3 or better after the agreed cycle count. For children’s or family programmes, chemical restrictions should be reviewed separately; do not assume basic polyester fleece automatically satisfies every destination rule. For broader buyer context, see blanket quality control inspection and blanket care and washing guidance.
Overlocked edges: low cost, high failure risk if underspecified
Overlock is the right edge finish for most low-cost relief blankets because it is fast, flexible and uses little added material. The tender still needs numbers. We suggest: four-side overlocked edge; 3-thread or 4-thread polyester sewing yarn; stitch density 3-4 stitches per cm; seam bite 4-6 mm; no open seam longer than 10 mm; no broken thread at corners; thread colour matching or buyer-approved contrast. A 4-thread overlock usually gives better edge security than a light 3-thread stitch, but it adds sewing time and yarn. On a high-volume 180gsm programme, that small sewing difference can become a meaningful cost line.
The common failures are predictable. A dull cutting blade leaves loose fibres before sewing. A narrow seam bite ladders after handling. Poor corner turning leaves thread tails that catch during bale packing. Excessive stitch tension curls the edge; loose tension creates loops that snag. A weak edge is the first defect field staff and recipients notice, even when the fabric GSM is correct.
There is a cost trade-off. Moving from 3-thread to 4-thread overlock may add only a few cents per piece in many China FOB quotations, but it reduces edge-unravelling risk on heavy handling. Increasing stitch density improves security but slows output. Using wider seam bite protects the cut edge but slightly reduces apparent finished size if cutting allowance is not adjusted. For a higher-value stadium or retail throw, whipped stitch may look better; see 230gsm fleece blankets with whipped stitch edges. For relief bales, a well-controlled overlock is normally the efficient choice.
Unit weight tolerance and PO wording
Unit weight control is where many blanket tenders become disputed. A buyer orders 180gsm, the supplier ships blankets that look thin, and both sides argue because the PO did not define whether tolerance applies to fabric GSM, finished blanket weight, finished size or bale average. Write all three when the order matters. Example: finished fabric 180gsm ±5%; finished size 150 x 200 cm ±3%; finished unit weight target 580 g with tolerance ±7%, excluding polybag and outer bale wrapper. The exact target must be calculated from the approved sample, size and edge construction, not copied from another tender.
For a 150 x 200 cm blanket, theoretical fabric weight at 180gsm is 540 g. Add overlock yarn, label and process variation, then adjust for actual finished size. If the factory cuts 148 x 196 cm instead of 150 x 200 cm, area falls from 3.00 m² to 2.90 m², removing about 18 g before any GSM reduction. A blanket can therefore pass a loose unit-weight check while failing size, or pass size while failing GSM. Inspection should record dimensions and weight on the same sampled units.
A practical PO line can read: “Blanket, 100% polyester fleece, finished fabric 180gsm ±5% by ISO 3801 or buyer-approved equivalent, finished size 150 x 200 cm ±3%, four-side overlock, navy blue, individual finished blanket weight not less than 540 g, lot average 580 g ±5%, excluding polybag and outer bale wrap.” Some buyers set only a minimum unit weight. That protects against under-supply, but may push factories to add cheaper bulk through finishing rather than better fabric. A lot-average target plus individual minimum is more balanced.
Small tolerance choices affect money and rejection risk. Tightening GSM from ±8% to ±5% can raise fabric-control cost because the mill must manage knitting, dyeing and finishing loss more carefully. Tightening size tolerance from ±5% to ±3% reduces under-size disputes but increases cutting and inspection discipline. A 2-3 cm shortfall on both length and width saves real fabric over tens of thousands of units, so it must be policed. Overly tight tolerances without price allowance invite failed inspections or renegotiation. Align the price, inspection method and acceptance bands before deposit.
Bale packing specification: count, dimensions and loading
Relief blankets are often bale packed because agencies and kit assemblers buy by container, not by shelf display. For 150 x 200 cm at about 0.58 kg finished blanket weight, common bale counts are 20, 25, 30 or 50 pieces. A 25-piece bale gives roughly 14.5 kg net blanket weight before polybags, PP wrapper and straps; gross weight commonly falls around 15.5-17.5 kg depending on film and compression. A 50-piece bale may reach 30-35 kg gross and can be too heavy for manual cross-docking. If the destination warehouse lacks pallet trucks, keep gross bale weight under roughly 25-30 kg unless the tender specifies otherwise.
A complete bale line should cover fold, count, compression, wrapper, straps, dimensions and marks. Example: 25 blankets per bale, folded uniformly, mechanically compressed by hydraulic press, wrapped in outer PP woven bag of approximately 90-120gsm or buyer-approved equivalent, 2-3 external PP straps of about 12-16 mm width, no metal strapping, bale label on two long sides, barcode if required, and count verified before compression. If individual hygiene is required, add one clear LDPE or recycled-content polybag per blanket, commonly 25-35 micron, with suffocation warning where destination rules require it. Individual bags add cost, plastic and cube, but reduce soiling and speed kit assembly.
Indicative compressed bale dimensions for 25 pieces of 150 x 200 cm 180gsm fleece are often around 58 x 42 x 38 cm to 65 x 45 x 45 cm, depending on fold pattern, pile recovery and polybagging. A 30-piece bale may sit around 65 x 45 x 45 cm to 70 x 50 x 50 cm. These are planning ranges, not guarantees; the approved pre-production bale should define the actual target. For container planning, a 40HQ may carry roughly 1,700-2,300 compressed 25-piece bales if floor-loaded efficiently, equal to about 42,500-57,500 blankets, but real loading depends on bale dimensions, container condition, carton mix, fumigation-free pallets if used, and destination unloading rules. Palletising improves warehouse handling but reduces blanket count per container.
Bale-count decisions change unit economics. A 20-piece bale is easier to lift and inspect, but uses more outer wrap and straps per blanket. A 50-piece bale reduces packaging cost per unit and may improve cube, but increases manual-handling risk, count-dispute risk and damage concentration if one bale gets wet. We normally recommend 25 or 30 pieces for 150 x 200 cm relief fleece unless the tender already fixes the count. Ask for a bale mock-up before bulk packing and include top, side, label and loaded-container photos in the pre-shipment photo set.
Compression, moisture and contamination controls
Compression saves CBM but introduces crease, odour and moisture risk. Brushed polyester does not absorb much water, but compressed bales trap humidity if blankets are packed warm, stored near wet floors or loaded into a sweating container. If a moisture meter is used, agree the method and substrate because readings on polyester can vary; as a practical factory control, reject visibly damp goods and investigate any bale or blanket reading materially above the approved dry baseline. Many buyers set an internal caution band around 8-10% on textile moisture meters, but the number is only useful if the same meter and method are used consistently.
Warehouse controls matter. Finished blankets should cool and equilibrate before compression, not be packed immediately after high-temperature finishing. Bales should be stored off the floor, away from exterior walls, chemical odours, food, oil, mouldy cartons and direct rain exposure. For ocean freight through humid lanes, use clean dry containers, inspect roof and door seals, photograph the empty container, and consider container desiccant according to route duration and season. Bale wrappers may need small venting or breathable woven PP rather than fully sealed plastic if condensation is a known risk; the buyer must balance venting against dust and splash protection.
Inspection should include odour and contamination criteria. Reject mildew smell, fuel or solvent odour, visible mould, insect contamination, oil stains, mud, rust transfer, hair, sharp debris and mixed-colour contamination. Compressed fleece often has temporary creases; that is different from permanent heat-set crushing, wet compression marks or dirty fold lines. If recovery appearance is important, open a compressed bale from the pilot run after 48-72 hours and after longer storage if timing allows. Vacuum compression should not be used for basic relief fleece unless the buyer accepts the recovery appearance; FIELDLOOM discusses compression trade-offs in vacuum-compressed mink blanket costing.
Inspection plan and AQL table
For relief tenders, inspection should combine quantity check, workmanship inspection, measurement, unit weight check, bale integrity and document review. A common third-party approach is ANSI/ASQ Z1.4 or ISO 2859-1 single sampling, normal inspection, general inspection level II for workmanship, with special inspection levels for measurements depending on lot size and buyer risk. Do not leave AQL as a single number without defect definitions; a critical safety defect is not equivalent to a loose thread.
A practical AQL framework for fleece relief blankets is: critical defects AQL 0 or not allowed; major defects AQL 2.5; minor defects AQL 4.0. Some humanitarian buyers tighten major to AQL 1.5 for repeat tenders or dark colours with high crocking risk. Sample size code letters and accept/reject numbers should be taken from the agreed ISO 2859-1 or ANSI/ASQ Z1.4 table after final lot quantity is known. For measurements and unit weight, many buyers check a smaller sub-sample, for example 13-32 pieces per lot or per colour, but this must be written before inspection.
Inspection should open bales across the lot, not only the top row. Select samples from different bale numbers, pallet positions if palletised, and production dates if more than one batch is included. Record blanket size, unit weight, visual defects, edge seam defects and label accuracy on the same sample sheet. For destructive GSM tests, use retained fabric or extra blankets approved for cutting. Related inspection structure is covered in AQL 2.5 fleece blanket inspection checklist and blanket quality control inspection.
UN-agency-style tender wording without overclaiming
Many buyers say “UN spec” when they mean a disciplined humanitarian tender format. Unless the tender document names a specific agency specification and the supplier has been assessed against that exact document, do not claim the blanket is UN approved. A safer phrase is “UN-agency-style procurement format” or “humanitarian tender specification format”. The technical file should be executable by procurement, inspection and logistics teams without relying on broad claims.
Typical parameters include fibre composition, finished GSM and tolerance, finished size and tolerance, colour reference, edge finish, unit weight target, label content, bale count, bale dimensions, gross and net weight, bale marks, AQL plan, test methods, Incoterms, shipment window and document package. Tender labels often require item description, size, fibre composition, country of origin, manufacturer or supplier identification, care symbols or written care instructions, and lot or batch number. Some programmes require no retail branding, no promotional logos, and specific donor or project wording on bale marks; confirm before printing anything.
A sample bale mark can read: “RELIEF BLANKET / 100% POLYESTER FLEECE / 150 x 200 CM / NAVY / 25 PCS / PO NO. ___ / LOT NO. ___ / BALE NO. ___ OF ___ / NET WT ___ KG / GROSS WT ___ KG / MADE IN CHINA / KEEP DRY.” If barcode or QR traceability is needed, specify data fields and label durability. Marks should appear on at least two sides of the bale and remain legible after compression, strapping and normal handling. Do not put agency logos, donor marks or regulated symbols on packaging without written artwork approval.
Labels, documents and pre-shipment evidence
Care labels should be simple and consistent with actual test performance. Typical content: fibre composition “100% polyester”; finished size; country of origin; supplier or manufacturer identification if required; lot or batch number; care instructions such as machine wash warm or cold, do not bleach, tumble dry low or line dry, do not iron pile if that is the buyer’s instruction; and any required language versions. If the buyer needs ISO care symbols, define them in artwork approval. Do not claim antimicrobial, flame retardant, recycled content or special chemical performance unless it is specified, tested and documented.
The packing list should match physical bale marks. Minimum fields: PO number, item code, colour, finished size, pieces per bale, total bales, total pieces, bale number range, net weight, gross weight, total CBM, container number if loaded, seal number, production lot number and country of origin. Commercial invoice, packing list, bill of lading or sea waybill, certificate of origin if needed, and test reports should be aligned before shipment. If Incoterms are used, write the year, for example FOB Ningbo Incoterms 2020 or CIF destination port Incoterms 2020, and define who pays inspection, port charges, destination clearance and inland delivery. FIELDLOOM’s freight notes on EXW versus FOB Ningbo cost items and CIF costing and palletisation are useful for comparing tender price bases.
Pre-shipment photos should not be cosmetic only. Ask for approved sample, bulk fabric roll label, inline cutting, overlock close-up, care label, individual polybag if used, open bale before compression, compressed bale with marks, gross weight on scale, bale dimensions with tape, moisture or warehouse condition evidence if required, empty container interior, container loading pattern, container seal and final door-close photo. Photos do not replace inspection, but they catch many avoidable logistics disputes before the goods leave the mill.
Cost and trade-off guidance for buyers
The cheapest quote is often cheap because tolerances are loose. A wider GSM tolerance lowers mill risk and may lower price, but it increases buyer risk: thin units, inconsistent bales and inspection disputes. A tighter size tolerance protects coverage and prevents silent fabric saving, but it requires better cutting control. A 150 x 200 cm blanket reduced by only 3 cm in both directions loses about 0.10 m² of area; at 180gsm that is roughly 18 g of fabric. Across 50,000 pieces, that is close to 900 kg of fabric difference before edge yarn. That is why size must be measured, not assumed.
Edge finish is another controlled cost. A 3-thread overlock is cheaper and adequate for many low-risk programmes if stitch density and seam bite are controlled. A 4-thread overlock improves security and appearance under rough handling. If the blankets will be repacked into family kits, dragged across warehouse floors or repeatedly handled by volunteers, the 4-thread option often costs less than post-shipment complaints. If they are single-distribution emergency items in sealed bales, a well-made 3-thread overlock may be acceptable.
Bale count changes both logistics and claims risk. More pieces per bale reduce outer packaging cost per unit and may improve floor-loaded container cube, but each bale becomes heavier, harder to inspect and more damaging if wet. Fewer pieces per bale improve manual handling and count checks, but increase PP bag, strap and label cost. For 150 x 200 cm 180gsm fleece, 25 or 30 pieces per bale is usually a balanced starting point. Ask suppliers to quote the same bale count, wrapper and Incoterm; otherwise unit prices are not comparable.
Individual polybags should be a deliberate choice. They add plastic cost and may increase CBM, but protect against dust, speed distribution and reduce contamination claims. If the destination programme will open bales and distribute loose blankets immediately, no individual polybag may be acceptable. If blankets enter hygiene kits or multi-item cartons, individual polybags usually reduce handling damage. For broader sourcing context, see promotional stadium throw sourcing and custom blanket lead times and shipping.
Recommended specification checklist
A strong 180gsm fleece relief blanket specification should be short enough for a tender table and detailed enough for inspection. Include: 100% polyester fleece; finished GSM 180 ±5% by ISO 3801 or approved equivalent; finished size such as 150 x 200 cm ±3%; finished unit weight target and individual minimum; colour reference; four-side overlock with 3-thread or 4-thread construction; stitch density 3-4 stitches per cm; seam bite 4-6 mm; care label content; bale count; bale wrapper; strap type; bale marks; AQL plan; test methods; document package; and Incoterms.
A realistic test set for a basic relief fleece can include GSM by ISO 3801, dimensional change by ISO 6330 and ISO 5077, colour fastness to washing by ISO 105-C06, rubbing fastness by ISO 105-X12 for dark colours, pilling by ISO 12945-2, fibre composition by the buyer’s nominated method, and visual inspection under agreed AQL. If flammability, children’s chemical requirements, recycled-content claims or restricted-substance rules apply, specify them separately. Do not let the supplier infer requirements from vague phrases such as “export standard”.
For FIELDLOOM production, we prefer to confirm a pre-production sample, then a packed bale mock-up, before bulk cutting. The sample approves handfeel, colour, size, edge and label. The bale mock-up approves fold, compression, count, dimensions, gross weight, PP outer bag, straps and marks. Those two approvals prevent most tender disputes because the inspector can compare bulk goods against physical references rather than marketing language.
Frequently asked
Is a 180gsm fleece blanket warm enough for disaster relief? It is suitable for warm climates, temporary shelter, hygiene kits and budget-sensitive distributions. It is not a heavy winter blanket. For cold-weather use, buyers should consider 220-300gsm fleece, quilted polyester, sherpa-backed fleece or wool-rich constructions and accept higher cube and cost.
What finished weight should a 150 x 200 cm 180gsm fleece blanket have? The fabric area is 3.00 m², so true 180gsm fabric gives about 540 g before overlock yarn, label and process variation. A practical finished unit may be around 560-620 g, but the PO should define a lot average and an individual minimum based on the approved sample.
How many blankets should go in one relief bale? For 150 x 200 cm 180gsm fleece, 25 or 30 pieces per bale is often balanced. A 25-piece bale may be around 15.5-17.5 kg gross depending on packaging. A 50-piece bale reduces packaging per unit but can exceed comfortable manual-handling weight and increases damage concentration if a bale gets wet.
What AQL should be used for fleece relief blankets? A common framework is critical defects not allowed, major defects AQL 2.5 and minor defects AQL 4.0, using ISO 2859-1 or ANSI/ASQ Z1.4 sampling after lot quantity is known. Measurements, unit weight and bale count should have separate written sub-sample rules or 100% checks where the buyer requires them.
Can a supplier say the blanket is UN approved? Not unless a specific agency specification, approval route and documentation apply. Most buyers should use “UN-agency-style tender format” or similar wording, then list measurable parameters such as GSM, size, label content, bale marks, AQL, test methods and documents.
Should each relief blanket be individually polybagged? Use individual polybags when hygiene, kit assembly or dust protection matters. Typical LDPE film is around 25-35 micron, subject to buyer and destination rules. Skipping individual bags lowers plastic use, cost and sometimes cube, but increases soiling and handling risk after bales are opened.
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