280gsm RPET Fleece Blankets in RF-Welded EVA Zip Cases

280gsm recycled polyester fleece blanket folded inside a clear RF-welded EVA zip case on a factory inspection table with weld seams, zipper and measuring tools visible

Where cost actually moves on this pack-out

For this article, the commercial assumptions are: FOB Ningbo, blanket size 127 x 152 cm, plain dyed 280gsm finished RPET fleece, 4-side overlock edge, one-colour paper insert, clear zip case with 0.20-0.22 mm RF-weldable EVA or EVA-blend film, 5# nylon coil zipper, 12 pcs per export carton, no embroidery, no retail gift box. Under those assumptions, workable FOB ranges are often around US$4.10-4.90 at 1,000 pcs, US$3.65-4.35 at 3,000 pcs, and US$3.35-4.00 at 5,000 pcs. Add roughly US$0.12-0.28 for a simple one-position embroidery, or around US$0.05-0.12 for a printed paper belly band if the case insert is reduced. If the case film goes from 0.20 mm to 0.25 mm, the case line typically rises more than the blanket sewing line, and carton count often drops before material cost becomes the main issue.

A useful FOB cost split at 3,000 pcs under the same assumptions is often: blanket fabric and finishing 46-56%, cut-sew and edge finishing 10-15%, decoration 0-8%, case film, zipper and RF conversion 14-22%, insert and labels 2-4%, export carton and packing 2-4%, QA/overhead 6-10%. That split changes quickly if the case geometry is custom or the blanket is oversized. On low-ticket promotional programmes, freight and case bulk can erase the savings from a cheaper zipper or lighter insert.

Be precise on area math. Moving from 120 x 150 cm to 127 x 152 cm increases fabric face area from 18,000 cm2 to 19,304 cm2, about 7.2% more face area. Buyers should not apply that 7.2% directly to total FOB. Actual fleece consumption also depends on cutting yield, seam allowance, selvage loss if relevant, nap direction, and whether the size increase forces a larger folded case or lower carton density. On fleece, the fabric delta is real, but the commercial effect is wider than fabric only because packed volume usually increases with it.

MOQ economics are not only about unit count. They are driven by case geometry and decoration method. A standard rectangular RF case using an existing weld die may stay commercially reasonable from 1,000 pcs. A new case outline, hang-hole shape, rounded radius change, or printed film can push the practical MOQ nearer 3,000 pcs because die cost, line set-up loss, and approval rounds do not amortise well below that level. Embroidery usually becomes more stable from roughly 1,500-2,000 pcs upward because run efficiency improves; a simple paper insert change can stay viable at 1,000 pcs; custom moulded zip pullers or printed film usually need a higher break-even, often nearer 5,000 pcs.

For adjacent sourcing decisions, see fleece weight throw blanket program, picnic blanket MOQ pricing 2026, and custom blanket lead times shipping.

Blanket construction: lock the basis before sampling

Do not buy this as only '280gsm RPET fleece blanket'. State whether 280gsm refers to finished fabric basis weight before cutting, or finished blanket basis after sewing. For fleece, the cleaner commercial spec is usually: finished fabric basis weight 280gsm plus or minus 5% measured on conditioned bulk fabric, then separately define finished blanket piece-weight acceptance by approved size and edge construction. That avoids the common dispute where the mill supplies fabric close to nominal GSM but the sewn blanket ships light because cutting yield, brushing loss, or size drift changed the final piece weight.

A buyer-side construction block should freeze at least: finished size 127 x 152 cm plus or minus 2 cm after sewing; finished fabric basis weight 280gsm plus or minus 5% after finishing; fibre content label wording; pile description such as one-side brushed polar fleece; edge finish such as 4-thread overlock in matching thread; care label content; fold sequence; packed-case target dimensions; and approved reference sample code. If you prefer piece-weight control, add a nominal finished blanket weight based on approved sample and agree the shipment acceptance method in writing.

Testing on the blanket should cover substance and serviceability, not only handfeel. For laundering, use ISO 6330 for the domestic wash procedure and ISO 5077 for dimensional change. For colourfastness to washing, use ISO 105-C06. For rubbing on dark shades or printed areas, use ISO 105-X12. If the blanket is exposed in store windows, vehicles, or events, add ISO 105-B02 for light fastness. For pilling, align the method and grade before bulk approval; buyers often use the framework discussed in anti-pilling test requirements for 240gsm polar fleece blankets.

Clarify recycled content properly. Fibre-content verification confirms polyester composition; it does not verify recycled percentage. A fibre lab can tell you that the blanket is polyester or blended polyester, but not whether 50% or 100% of that polyester came from recycled feedstock. If the claim is recycled polyester content, you need a certified chain-of-custody path such as GRS or RCS, or another defensible claim-substantiation route, in addition to normal fibre-content testing. Buyers should keep those two checks separate in the PO and artwork approval.

Buyer acceptance checklist for blanket and case

Convert acceptance language into a shipment checklist. A practical final inspection basis is ANSI/ASQ Z1.4 single sampling, General Inspection Level II, with AQL 2.5 for major defects and 4.0 for minor defects unless your programme requires tighter. For a narrower QC framework on soft promotional blankets, see AQL 2.5 inspection checklist for 200gsm coral fleece promotional blanket.

Suggested acceptance checklist for the blanket: finished size 127 x 152 cm, tolerance plus or minus 2 cm after conditioning; edge sewing even with no skipped stitches over 25 mm; no holes, oil marks, panel shading, or obvious nap-direction mismatch within one blanket; average finished blanket weight from 10 conditioned pieces not below PO nominal; no individual blanket more than 5% under approved sample weight; no more than 1 piece in the inspected sample more than 3% under nominal if the average still passes. Conditioning before weighing should be at roughly 20 plus or minus 2 degrees C and 65 plus or minus 4% RH for about 24 hours where practical, or at minimum long enough for consistent comparative weighing if the inspection site is not a full laboratory.

Suggested acceptance checklist for the packed case: packed fold size tolerance plus or minus 10 mm in length and width, plus or minus 8 mm in thickness versus approved sample; case outer dimensions per approved drawing; zipper runs smoothly for three open-close cycles with no chain burst or stop failure; weld width within approved range, for example 8 mm nominal with no point below 6 mm at controlled inspection points; no split welds, severe whitening, sharp flash, trapped contamination, or gross waviness at the zipper insertion zone. Check packed dimensions after a defined compression period, not immediately after hand packing only. A workable method is 12-24 hours after packing, then measure before carton loading and again on retained cartons after at least 24 hours of stacked compression.

Add pack-out controls because they become claim points later: carton pack 12 pcs exactly as specified; carton gross weight not exceeding the buyer limit, often 12-16 kg for this type depending on market; case-packed dimensions within approved carton fit; export carton dimensions within plus or minus 2 cm of approved spec; shipping marks, barcode, and country-of-origin labels match the approved pack sheet. These are not minor admin details. If the case grows 8-10 mm in thickness, the carton count can fail before the blanket itself does.

Case material: specify the film, sealing method and compatibility

'EVA case' is too vague for a PO. Suppliers often use EVA loosely for a vinyl-free soft film family that may include pure EVA or EVA-blend formulations. Appearance can look similar while weld response, odour, whitening, cold-flex behaviour, and compliance paperwork differ. The quote and PO should state the supplier-declared film description, nominal gauge, sealing method, zipper type, and whether the film is intended for RF welding, thermal heat sealing, or both.

Do not assume RF compatibility is universal across all EVA-type films. RF welding relies on dielectric heating response; some soft films sold commercially as EVA-type package film weld well under RF, while others are better suited to heat sealing or impulse sealing and give a narrower process window under RF. If the supplier says 'RF-welded EVA', ask for the exact film code or at least supplier-declared formulation family and confirmation that the approved bulk film is the same as the sample film. Otherwise a factory can switch to a cheaper film that still looks clear but behaves differently at the fold and zipper insertion zones.

For this pack format, a commercially common film range is around 0.18-0.25 mm. Around 0.20-0.22 mm is usually the balance point for promotional packs. Below about 0.18 mm, whitening at fold lines, corner stress marks and panel distortion after carton compression become more likely. At around 0.25 mm, the case body looks better and holds shape better, but zipper closing force rises and carton density usually drops. Gauge must therefore sit inside both a packaging spec and a logistics spec.

Zipper build should be explicit. For flatter folds, a 3# nylon coil zipper can be adequate. For a 280gsm blanket in a fitted clear case, a 5# nylon coil zipper is typically safer, especially if the opening spans the long side. Specify zipper size, tape material, slider type, top and bottom stop method, end insertion geometry, and puller finish. Missing zipper size in a quotation is a practical risk because the visual difference is modest but the service difference is not. For a sewn pouch contrast, see specifying 180gsm microfleece travel blankets with nylon carry pouches.

RF weld construction and transport durability

RF welding suits many EVA-type soft films because it gives a continuous sealed edge without needle holes, but the seam only works if the geometry is controlled. Freeze weld width, weld path, corner radius, zipper insertion geometry, and vent allowance on the approved PP sample. For a case in this size band, weld width around 6-10 mm is common; 8 mm nominal is a practical target. Narrow decorative welds look cleaner on line drawings but leave less process window and lower peel margin.

Testing should include the case as a case, not only material swatches. Ask the supplier to declare its internal weld test method, strip width, sample orientation, and pass criterion, then add shipment-level performance checks. A practical buyer matrix can include: weld integrity visual check on 100% in-line; weld peel or seam force control on factory retains to an agreed internal method; zipper retention and stop retention check by repeated open-close cycles; handle or hanging feature retention if present; packed-case compression hold; and filled-case drop test. For drop and compression, ISTA-style protocols are useful as a framework even if the buyer does not require a formal certification report.

Two predictable field failures deserve explicit controls. First, fold-line whitening after low-temperature transport and carton compression. Second, zipper-end breakout where the chain ends or tape edges sit too close to the weld. Buyers should request retained packed samples from pilot run and inspect them after at least one compression cycle, not only fresh off line. Odour is another real issue with clear soft-film packaging. Add an odour assessment against the approved sample after 24 hours sealed storage and again after opening. This can stay as a comparative organoleptic check if no formal market protocol is required, but it should be written into approval notes.

Soft packaging also needs restricted-substance paperwork. The blanket and the case are different substrates and should not share one generic statement. The blanket packet should cover material declaration, fibre content claim basis, REACH/SVHC statement where relevant, and dye or colorant restriction statement if claimed. The case packet should cover film material declaration, zipper material declaration, REACH/SVHC statement, and any market-specific packaging compliance evidence requested by the buyer. If the programme carries azo-free or similar claims, the claim must match the actual scope of testing and artwork language.

RPET claim chain: what document to request and when

Document timing needs to be written into the order. Before PP sample approval, request the current scope certificate for the exact certified facility that will knit, dye, cut, sew or pack the claimed product, and confirm that the product category and process are within scope. If certified logo use is planned on the hangtag, insert or carton, logo approval should be completed before artwork release for bulk print. Before booking shipment, the supplier should confirm in writing that the booking quantity and product description align with the certified claim route and the certifier's transaction-certificate workflow.

At or immediately before document release, the shipment-specific transaction certificate should be available if the programme is sold with a certified recycled-content claim that requires it under the chosen scheme and market presentation. Do not release certified swing tags or printed claim inserts on trust alone. The shipping invoice, packing list, product description, claim wording and, where relevant, TC details should reconcile. If the certifier issues the TC shortly after shipment rather than before vessel departure, write that timing into the PO and hold the claim-sensitive document release until the agreed evidence point is met.

If the supplier is not offering a certified claim and instead uses a general RPET statement, request the exact label language before artwork approval, plus an internal material declaration and normal fibre-content verification route. That does not substantiate recycled percentage by itself. Buyers should avoid mixing generic recycled wording with certified logos. That is where packaging artwork becomes misleading even when the blanket fibre is polyester. The related workflow is discussed in GRS transaction certificate workflow for 250gsm RPET sherpa throws and global recycled standard logo approval for 300gsm RPET raschel blanket.

EU import structure: DDP vs DAP vs FOB decision table

The quote must show more than a freight term. For EU shipments, ask the supplier to state the Incoterm, named place, who is importer of record, whether VAT is included or excluded, who bears post-entry customs audit risk, and which documents are included in the quoted service. Without that, a 'DDP EU' quote can still leave the buyer exposed on VAT registration, EPR or packaging obligations, or post-clearance document gaps.

Decision table for buyer control: DDP named place: seller typically arranges carriage and acts through its customs structure or appointed importer solution; VAT treatment must be written clearly because DDP does not by itself guarantee who funds or recovers VAT in every structure; post-entry audit risk should be stated, especially if a third-party importer is used; the quote should show customs duty status, VAT status, destination delivery scope, and document responsibilities. DAP named place: seller delivers to named destination but buyer or buyer's agent usually handles import clearance, duties, VAT, and importer obligations; post-entry audit risk mainly sits with the buyer-side importer; quote should state export charge, main freight assumptions and destination delivery assumptions only. FOB Ningbo: seller clears export and loads on vessel; buyer controls freight, insurance, import clearance, duties, VAT and post-entry customs risk; quote should state FOB port, carton and CBM assumptions, cargo ready window, and any booking cut-off constraints.

For many promotional blanket orders into the EU, FOB is cleaner if the buyer already has a stable forwarder and importer structure. DDP can work for smaller buyers or one-off campaigns, but only if the seller states who the importer of record is and how VAT is handled. DAP is often a halfway house where the freight is managed by the seller but customs control stays with the buyer. Ask those questions before confirming the PO, not after the shipment is on water. For broader shipping context, see DDP UK costing for 260gsm brushed polar fleece blankets with printed belly bands and EXW vs FOB Ningbo for 160gsm airline fleece blanket tenders cost items.

Carton density and size-change logistics

Packed-case size affects freight faster than many buyers expect. A numeric example: if a 127 x 152 cm blanket in a 0.20 mm case folds to about 38 x 30 x 7 cm, a master carton holding 12 pcs may land around 62 x 40 x 46 cm, or roughly 0.114 m3. That gives about 105 cartons per 12 m3, subject to pallet pattern and container loading constraints. If the blanket size increases and the packed thickness rises from 7 cm to 8 cm, the carton might move closer to 62 x 40 x 52 cm, or about 0.129 m3. At the same 12 pcs, cartons per cubic metre fall by roughly 11-12%. The blanket did not only get bigger; the freight density got worse.

This is why packed dimensions belong in the commercial spec. If the case geometry is fixed, the factory may over-compress the blanket to hit carton count, which increases fold whitening and zipper stress. If the case is enlarged to protect the product, freight cost per unit rises. Buyers should ask for carton plan approval based on actual folded retained samples, not only CAD estimates. For programmes where freight sensitivity is high, approve two things together: the folded case size and the units-per-carton plan.

Sample buyer-side specification block

A practical PO clause set can read like this: Product: RPET fleece blanket packed in clear RF-welded EVA or EVA-blend zip case. Blanket: finished size 127 x 152 cm plus or minus 2 cm after sewing; finished fabric basis weight 280gsm plus or minus 5%, measured on conditioned bulk fabric; fibre claim and label wording as approved artwork only; edge finish 4-thread overlock, matching colour; colour and handfeel equal to approved PP sample. Finished blanket piece weight: shipment average of 10 inspected pieces not below approved nominal; no individual inspected piece more than 5% under approved nominal weight. Case: supplier-declared RF-weldable vinyl-free EVA or EVA-blend film, nominal 0.20-0.22 mm; 5# nylon coil zipper; weld width 8 mm nominal, no point below 6 mm at controlled check points; packed fold size per approved sample plus or minus 10 mm length and width, plus or minus 8 mm thickness. Pack-out: 12 pcs per export carton, carton dimensions and gross weight per approved pack sheet.

Add testing and document clauses: Blanket tests to ISO 6330, ISO 5077, ISO 105-C06 and ISO 105-X12 as applicable to shade and decoration. Case performance checks to include zipper retention, weld integrity, packed-case compression retention and drop resistance against approved internal test plan. Recycled claim: scope certificate before PP approval; logo approval before claim artwork release; transaction certificate available at agreed document-release point. Compliance packet to be issued separately for blanket and case, including material declaration and REACH/SVHC statement. Final inspection basis: ANSI/ASQ Z1.4, General Level II, AQL 2.5 major / 4.0 minor unless otherwise stated in PO. This level of wording is not elegant, but it prevents most of the predictable arguments.

Frequently asked

What does '280gsm' need to mean on this product? State it explicitly. The cleaner commercial approach is usually 280gsm as finished fabric basis weight before cutting, measured on conditioned bulk fabric, then a separate finished blanket piece-weight acceptance rule by approved size and edge finish. If you write only '280gsm blanket', supplier and buyer can measure different things and both claim compliance.

Does fibre-content testing prove the blanket is recycled polyester? No. Fibre-content testing can verify polyester composition or blend ratio, but it does not prove recycled percentage. Recycled-content claims need a certified chain-of-custody route such as GRS or RCS, or another substantiated claim path, in addition to normal fibre-composition verification.

Is RF-welded EVA always the right case construction? Not automatically. Many EVA-type soft films can work well in RF welding, but some formulations have a narrower RF process window or are better suited to heat sealing. Buyers should confirm the exact film family, nominal gauge, and approved sealing method rather than assuming all clear 'EVA' films behave the same.

What are reasonable MOQ breakpoints for this pack-out? A standard existing-die rectangular case with simple insert artwork can stay viable from around 1,000 pcs. A custom weld die or more complex case geometry often makes better economic sense from around 3,000 pcs. Printed film, custom zip pullers, or more involved case tooling often look more rational from around 5,000 pcs, depending on size and decoration.

What inspection method should be written into the PO? For many promotional programmes, ANSI/ASQ Z1.4 single sampling, General Inspection Level II, AQL 2.5 major and 4.0 minor is a workable baseline. Also specify conditioning before weight checks, how many blankets are averaged, and whether packed dimensions are checked after a defined compression period. Without those details, inspectors can reach different conclusions on the same lot.

What should the compliance packet include for blanket and case? Separate the two. For the blanket: material declaration, fibre claim basis, REACH/SVHC statement where requested, and dye or colorant restriction statement if claimed. For the case: film material declaration, zipper material declaration, REACH/SVHC statement, and any market-specific packaging compliance evidence requested by the buyer. One generic declaration for the whole set is usually too loose.

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280gsm RPET fleece blanket with RF-welded EVA zip case