320gsm polyester fleece sleeping bag liners folded with two-way zipper tape and size graded patterns on a cutting table

Start with construction, not only GSM

A 320gsm liner is a removable warmth layer for car camping, caravan beds, scout programmes, rental fleets and outdoor retail add-ons. It is not a hostel sheet and it is not a filled sleeping bag. The first sourcing question is construction: one folded panel with one long side seam, two body panels sewn together, tapered mummy shape, or a blanket-style liner that opens flat.

The fabric calculation needs care. A 75 x 210cm rectangle has a face area of 1.575m². At 320gsm, that single face area weighs about 0.504kg before waste. That is only correct if the liner is made from one folded panel where the fold creates the second side, or if the quoted area already represents the full cut area. A two-panel rectangular liner normally needs about 3.15m² of fleece before seam allowance and marker loss, or about 1.01kg of fleece at 320gsm. A blanket-style open-flat liner with binding, zipper facing and pockets can be higher again.

For costing, separate finished area from cut consumption. A practical Standard 75 x 210cm folded-panel liner may consume roughly 1.1–1.4 linear metres on 155–165cm usable fleece after seam allowance, roll-end loss, shade defects and marker efficiency. A two-panel construction may consume roughly twice that unless the fabric width allows nesting. Wide and tapered patterns change the marker yield. Ask the factory to show consumption by marker, not only by finished size.

Define the sales route in the RFQ because it changes the product. A value camping liner can use a plain polybag, one barcode and carton-level assortment. A rental fleet needs stronger wash labels, stitch durability and no fragile retail pouch. An e-commerce SKU needs drop-test-resistant inner packing, scannable barcode position and low carton damage risk. A private-label outdoor shop usually needs cleaner shade grouping, retail pouch artwork, hangtag control and more detailed final inspection.

If the liner must zip open into a blanket, decide that before sample cutting. A full L-shaped two-way zipper on adult sizes usually adds about 180–260cm of zipper, two end stops or a separating end depending on design, extra slider handling and more sewing operations. A short side opening is cheaper and less failure-prone, but it cannot honestly be marketed as an open-flat camp blanket. For adjacent fleece weight decisions, see fleece weight throw blanket programmes.

Copy-ready RFQ specification

A buyer RFQ should remove guesswork before sampling. The table below is the level of detail we prefer before quoting FOB Ningbo or FOB Shanghai. Some tolerances are buyer-recommended targets; others depend on fabric route, dye lot and finishing stability, so they should be confirmed at sample approval and written into the purchase order.

Do not ask three factories to quote only "320gsm fleece liner with zip" and expect comparable prices. Zipper length, usable fabric width, marker efficiency, pouch construction, colour matching and carton cube can move cost more than the visible fleece GSM.

Control the fleece before negotiating zipper cost

Many zipper complaints start with the fleece. Loose pile sheds into the coil teeth. Over-brushed pile gets caught by the slider. A relaxed knit can grow after cutting and make the zipper line ripple. For a 320gsm liner, a medium-pile polar fleece is usually safer than very high-pile plush. Common production routes may use polyester microdenier yarns such as 150D/288F or similar, but the PO should control measurable outcomes rather than locking a yarn route the buyer cannot verify.

Roll relaxation is not optional on heavier knit fleece. After brushing, shearing, dyeing and compacting, rolls can hold tension. If fabric is cut immediately after unrolling, panels may recover unevenly and the zipper line can wave. A practical factory control is to relax rolls on the cutting floor for 12–24 hours, longer in cold or humid conditions, then record roll number, shade group and usable width on the cutting ticket.

Useful controls are ISO 3801 for mass per unit area, ISO 5077 for dimensional change after washing, ISO 12945-2 for pilling, ISO 105-C06 for wash fastness and ISO 105-X12 for rubbing fastness. For camping retail, a practical fabric target is 320gsm ±5%, pilling grade around 3–4 after the agreed ISO 12945-2 cycle count, wash shrinkage within about ±3% after one or three domestic 30°C washes, and no objectionable odour. Tumble dry should not be assumed; if the care label allows tumble drying, test the exact condition.

Dark fleece needs tighter shade control. Mixed shade bands inside one SKU are common when rolls from different dye lots are cut into the same size bundle. Use roll-by-roll shade grouping, mark roll numbers on cutting tickets and avoid mixing obvious A/B shade groups in one liner panel or one carton assortment. For navy, black, burgundy and forest green, dry rubbing around grade 4 and wet rubbing around grade 3–4 under ISO 105-X12 is a common target range, but saturated colours may need buyer approval of a realistic limit.

Needle and seam choice matter because polar fleece is a knit. A ballpoint or light ballpoint needle, often around Nm 75/11 to 90/14 depending on thread and seam thickness, reduces yarn cutting compared with a sharp needle. Tex 27–40 polyester thread is common for retail liners. Check skipped stitches at the foot corner where layers build up, and check seam appearance after washing because presser-foot stretch can appear only after relaxation.

Write claims separately from material specs. A general spec can say 100% polyester fleece. A recycled-content claim, GRS claim, OEKO-TEX claim or restricted-substance claim is brand- and supply-chain-specific and needs document scope review before artwork is printed. Do not place certification logos on swing tags unless the certificate, product class, facility scope and transaction documents support the exact product. For buyer-side claim checks, see textile certifications explained for buyers.

Choose the zipper configuration by use case

For 320gsm fleece liners, nylon coil zipper is usually preferred because it bends around a foot corner better than moulded tooth zipper and feels softer against the body. #5 coil is the safer default for full-length L-shaped openings, rental use and wide sizes. #3 coil can work for short side openings or low-weight travel liners, but it is easier to jam with fleece pile and gives less tolerance for rough handling. Do not select #3 only to save a few cents if the liner is marketed for frequent camping use.

Use short side openings when the product is a budget liner, hostel liner or simple caravan accessory and only needs easier entry. A 70–120cm side opening can reduce zipper length, sewing time and jamming risk. Use a full L-shaped zipper when the liner is sold as both liner and camp blanket. Use #5 coil when the zipper runs around the foot corner, the width is 80cm or above, the customer may wear boots near the liner, or rental laundering is expected. Use two-way sliders when foot ventilation is a selling point or the user must open from inside and outside.

Anti-snag design is a construction package. Specify anti-snag zipper guard or tape, pile kept out of the stitch line, facing width usually around 18–25mm, slider garage at top, bartacks at zipper ends and a reinforced foot-corner turn. Woven anti-snag tape gives cleaner slider travel. Folded self-fabric facing has a warmer appearance but can roll into the slider after washing if it is too narrow or too soft.

Cost impact is not only trim price. Compared with a short #3 side zipper, a full L-shaped #5 zipper can add roughly 1.0–1.8m of zipper length, extra slider cost, more corner sewing time, more bartacks and more inspection points. A two-way slider set is commonly a small but visible trim upcharge versus one slider, and it doubles the number of slider functions to check. A separate zipper pouch adds fabric or shell material, cord or zipper, label placement, packing labour and carton cube.

Test the sample by use, not only by appearance. Run the slider 20–30 cycles before wash and again after wash for development screening. For a stronger claim, define a recognised zipper test: BS 3084 can be used for zipper strength characteristics such as lateral strength, slider locking and top/bottom stop strength, while ASTM D2061 covers zipper strength test methods in markets that reference ASTM. Seam strength around zipper and foot-corner reinforcement can be checked by ASTM D5034 where the construction allows a suitable specimen. State the method, specimen position and acceptance value; do not leave zipper strength as a marketing sentence.

Grade sizes from fit and shrinkage

Retailers often ask for one universal liner, but consumers compare it with sleeping-bag sizes. A practical rectangular range is Standard around 75 x 210cm, Wide around 85 x 220cm and Compact or Kids around 70 x 180cm. A tapered adult liner may be around 80cm at shoulder, 55cm at foot and 220cm long. These are not fixed standards; they should match the sleeping bags, camp beds or caravan beds in the buyer’s range.

Each size needs marker planning, cutting bundles, size labels, barcode data and carton rules. A Standard-only order is simple. Two colours in Standard and Wide becomes four SKUs. Three colours in three sizes becomes nine SKUs before packaging variants. For every SKU, state finished size, shape, zipper side, zipper length, label size code, barcode, carton assortment and tolerance. Avoid vague lines such as adult size or large size.

Shrinkage allowance belongs in the pattern. If the fleece loses 2% in length after wash, a 210cm liner can shorten by about 4.2cm. For polar fleece, a realistic retail target is often within ±3% after one or three 30°C domestic washes if fabric has been stabilised. Coral fleece or high-pile plush routes may behave differently, and tumble drying can increase dimensional change. Approve both pre-wash finished size and post-wash acceptable range using the same wash and drying method from sample to bulk.

Pile direction must be fixed by panel. If one side panel is cut with pile running down and the other up, the liner can show a two-tone effect under store lighting even from the same roll. Add arrows on paper patterns, cutting markers and inspection boards. This is especially visible on charcoal, olive, burgundy and any brushed fleece with a directional nap.

For measurement, define the method: liner laid flat on a smooth table, zipper closed, no stretching, length measured from top edge to foot seam, width measured at the chest or widest point, and tolerance applied to finished goods before washing unless the PO states otherwise. A buyer-recommended finished-size tolerance is often ±2cm on length and ±1.5cm on width for rectangular adult liners. Factories may ask for wider tolerances on very soft fleece, curved mummy shapes or compressed packing; agree this before bulk cutting, not during final inspection.

Size grading affects zipper length. If Standard uses a 210cm L-shaped zipper route and Wide uses 220cm length plus wider foot turn, the zipper cannot always be shared. A shared zipper colour may be possible, but zipper length and stop position may differ by size. For mixed-size orders, approve each size sample instead of scaling the first sample on paper only.

MOQ is driven by colour, trim and packing

MOQ for 320gsm fleece liners is not one number. It changes by fabric colour, zipper colour, size assortment, packaging version and documentation route. A factory can sometimes make a low-MOQ trial when the buyer accepts available fleece colours, stock black zipper tape, one size and plain packing. A private-label programme with custom dyed fleece, custom zipper tape, retail pouch and recycled-content documentation is a different production job.

Fabric colour is usually the largest MOQ driver. Piece-dyed polyester fleece may require a dye-lot minimum that depends on mill route and colour depth. As a practical quoting range, stock colours may be possible from a few hundred pieces if fabric is available; custom colours often need roughly 500–1,000 pieces per colour or more for stable dyeing and cutting efficiency. Very dark or saturated colours may need larger lots because lab dip correction and shade grouping create more unusable edge cases.

Zipper colour can quietly raise MOQ. Stock black, dark grey and sometimes navy zipper tape are easiest. A custom tape dyed to match fleece may require its own trim MOQ and lead time, and the colour can still look different because zipper tape is woven and the fleece is brushed. If exact tone matching matters, approve zipper tape beside bulk fleece under D65 and TL84, not as a separate trim swatch.

Size assortment reduces efficiency. One colour in one size is the cleanest plan. A launch with three sizes and two colours divides fabric, zipper and labels into six SKUs. If the order is small, keep one common carton quantity per size or pack one size per carton. Mixed-size cartons can work for club-store bundles, but they need locked assortment rules and barcode scan control.

Private-label packaging changes MOQ because bags, inserts, hangtags, cartons and barcode labels all have minimums. A plain recycled-content polybag or belly band is easier than a printed zipper pouch. A sewn fabric pouch looks premium but adds cutting, sewing, label placement and cube. If the pouch fabric must match the liner, include pouch fabric in the same dye lot plan.

Recycled-content requirements add documentation cost and scheduling risk. If the buyer needs a certified recycled claim, confirm scope certificate, product category, transaction certificate workflow and claim wording before PO. Do not assume that using recycled yarn automatically permits a logo claim. For recycled fleece sourcing questions, see RPET polar fleece blanket documentation for buyers.

Carton cube can change the landed cost

A 320gsm fleece liner is bulky. FOB unit price can look acceptable while landed cost suffers because the carton count per container is poor. This is especially true when the liner has a full L-shaped zipper, self-fabric pouch or loose retail fold that traps air. Ask for packed carton dimensions at quotation stage, then verify them on the pre-production sample pack.

Example only: a Standard 75 x 210cm folded-panel liner with #5 L-shaped zipper and polybag may have a finished unit weight around 0.8–1.1kg depending on construction and zipper length. If packed 10 pieces per export carton at 60 x 40 x 45cm, carton volume is 0.108m³. With a net weight around 9.5kg and gross weight around 10.5–11.5kg, each piece carries about 0.0108m³ before palletisation. A retail zipper pouch could push the carton to 60 x 45 x 55cm, or 0.1485m³, even if the FOB unit price changes only slightly.

That cube increase matters for CIF, DDP and e-commerce replenishment. At 10 pieces per carton, moving from 0.108m³ to 0.1485m³ adds about 0.004m³ per piece. On a 5,000-piece order, that is roughly 20m³ extra cargo. Freight rates move, so do not convert this into a fixed dollar claim; use it as a warning to cost packaging and fold method before PO.

Oversized liners also affect warehouse handling. A Wide 85 x 220cm two-panel liner may need 8 pieces per carton instead of 10 to avoid over-compression or carton bulging. Carton bulge causes barcode scuffing, stacking damage and inaccurate measured volume at the forwarder. If vacuum compression is used, run recovery checks after 7–14 days packed and one wash cycle, because pile flattening can become a consumer complaint.

For FOB-to-landed-cost planning, request carton length, width, height, net weight, gross weight, pieces per carton, cartons per SKU, pallet plan if applicable, and whether measurements are before or after carton settling. The packing list should use the same dimensions as the approved carton sample. If the factory changes fold method after inspection to save space, zipper waviness and crease marks may appear in store.

For broader freight planning on blanket programmes, see custom blanket lead times and shipping.

Barcode, assortment and carton controls

Mixed-size fleece liners fail retail receiving when the carton label, inner polybag barcode and actual size do not match. This is preventable with a barcode control plan. The factory should receive a locked barcode file showing SKU, size, colour, barcode number, label artwork revision and carton mark text. Do not send barcodes in separate emails without a revision trail.

Use scan checks at three points: after label printing, during packing and during final inspection. A basic control is to scan the inner barcode and carton barcode against the packing list before carton sealing. For mixed-size cartons, scan every unit until the packing team proves stability; for repeat runs with one size per carton, scan a defined sample from each carton or every carton label plus random inner units.

Inner-carton segregation helps. If a carton must contain Standard and Wide sizes, use inner polybags with clear size windows or colour-coded size stickers, and place sizes in fixed layers. The carton label should state assortment such as "STD 6 pcs + WIDE 4 pcs" rather than only "10 pcs". If e-commerce fulfilment needs each unit scannable, do not hide the barcode under the fold or inside the pouch.

Carton labels should include PO number, style number, SKU, colour, size or assortment, barcode where required, quantity, carton number, N.W., G.W., carton dimensions and destination marks if required. If the buyer uses GS1 labels, UCC/EAN-128 or SSCC rules, provide exact label format before mass printing. Factories should not improvise retail-compliance labels at packing stage.

Final random inspection should verify barcode readability and data accuracy, not only label presence. Inspectors should scan selected units, compare to the approved barcode list, check carton count, open mixed cartons, confirm size labels, and record any wrong barcode as at least a major defect because it can trigger chargebacks or rejected receiving.

Inspection criteria that should be written into the PO

Use ANSI/ASQ Z1.4 or ISO 2859-1 sampling if the buyer requires AQL inspection. A common retail setting is General Inspection Level II with AQL 2.5 for major defects and AQL 4.0 for minor defects, but the buyer can tighten this for launch orders, club-store delivery or e-commerce. Critical defects should be zero tolerance, especially safety hazards such as broken sharp zipper parts or contamination.

Major defects should include wrong size outside tolerance, wrong barcode or label, shade mismatch between panels, mixed dye lots in one visible panel, zipper jamming that prevents normal opening, slider missing or reversed, pile trapped in the coil causing repeated blockage, open seam, skipped stitches over a defined length such as more than 3 consecutive stitches or repeated skips, broken bartack, dirty marks larger than the agreed limit, strong chemical or mildew odour, and carton assortment errors.

Minor defects can include small thread ends, slight but acceptable shade variation within the approved range, minor pile crush that recovers after airing, small washable marks below the agreed size limit, slightly uneven folding, small label skew within tolerance and non-functional stitch waviness that does not affect use. Define limits visually on an approved defect board because fleece hides and reveals defects depending on pile direction.

Zipper inspection needs its own line on the checklist. Open and close the full zipper route on sampled pieces, check both sliders on two-way designs, inspect the foot-corner turn, confirm top garage coverage, check for sharp tape ends and pull gently at bartacks. For development, 20–30 manual cycles can screen poor construction. For a lab-backed claim, specify BS 3084 or ASTM D2061 test items and acceptance values agreed with the lab and zipper supplier.

Measurement inspection should cover length, width, zipper route length where critical, label placement, pouch size and carton dimensions. Fabric inspection should include GSM by ISO 3801 on retained bulk fabric or cut panels, pilling by ISO 12945-2 if required, wash dimensional change by ISO 5077, wash fastness by ISO 105-C06 and rubbing fastness by ISO 105-X12. For a general QC framework, see blanket quality control inspection.

Cost drivers buyers often miss

Zipper length is visible, but it is not the only cost driver. Usable fleece width can change the marker. A 160cm nominal fleece may have 155cm usable width after selvedge and shade-edge exclusion; a 75cm folded pattern can fit well, while an 85cm wide pattern may waste fabric or require a different construction. Ask for marker efficiency and usable width, not just fabric price per kilogram.

Dye-lot minimums affect small programmes. A custom colour that looks simple on a mood board may require a larger dye lot than the PO quantity supports. If the buyer splits the order into several sizes, the factory may have leftover fabric in one size and shortage in another. This is why size ratio and cutting plan should be confirmed before dyeing bulk fabric.

Anti-pilling finish can change handfeel and cost. A soft heavily brushed fleece may feel better in showroom samples but pill faster in use. A tighter anti-pilling finish may feel slightly drier but perform better after washing. Approve the handfeel and pilling target together; do not approve the softest sample and then ask for high pilling performance without a construction change.

Pouch type changes labour and cube. A plain polybag is cheapest and lowest bulk. A drawstring stuff sack is better for camping use but adds cutting and cord work. A zipper pouch looks retail-ready but can double zipper quality concerns and increase carton volume. A self-fabric pouch made from 320gsm fleece is bulky; a 190T polyester pouch is lighter but changes the perceived value.

Certification documentation takes time. Recycled-content claims may require supplier scope certificates, input yarn documents, transaction certificates and artwork claim approval. Restricted-substance testing or retailer compliance testing may require sealed samples from bulk. Build this into the lead time instead of treating it as a packing-stage file request.

Retail carton cube is a cost driver for the buyer even when it is invisible in the factory FOB. Large cartons may reduce labour but hurt container loading and store backroom handling. Small cartons can improve handling but increase carton material and label work. Choose the carton around the buyer’s distribution route, not only the factory’s packing convenience.

Sampling gates before bulk production

Use one prototype to settle shape and zipper logic, then a pre-production sample to lock fabric, shade, labels and packing. The prototype can be in available colour if timing is tight, but it should still use the intended zipper type and opening route. Do not approve zipper behaviour from a short mock-up when bulk will use a long L-shaped opening around the foot corner.

The pre-production sample should be made from bulk-like fabric weight, approved zipper tape, correct labels, correct barcode, agreed pouch or polybag and export carton mock-up if carton cube matters. Keep one sealed sample at the factory and one with the buyer. If the buyer changes size, pouch or zipper after PP approval, restart the affected checks.

A practical sample checklist includes finished weight, fabric GSM, measurement before wash, zipper operation, pile direction, shade under D65/TL84, label wording, barcode scan, packing fold, carton dimensions, wash shrinkage, pilling assessment and odour after sealed packing. For custom colour, keep the lab dip, bulk roll head-end swatch and approved PP sample together.

For lead time planning, allow time for lab dip, trim sourcing, sample sewing, wash testing, packaging artwork, barcode approval and final inspection booking. A simple stock-colour trial may move quickly. A custom colour, custom zipper tape, printed pouch and recycled documentation route needs a longer calendar and fewer last-minute artwork changes.

PO wording that prevents disputes

The purchase order should state the approved sample reference, construction, finished size and tolerance, GSM tolerance, zipper type, zipper length or route, slider count, anti-snag guard, label artwork revision, barcode file revision, packing method, carton quantity, carton marks, Incoterms, inspection standard and required tests. If the buyer expects a maximum carton cube, write it into the PO.

Clarify buyer-recommended versus factory-dependent tolerances. Buyer-recommended targets may include finished-size tolerance, barcode scan pass, carton label format and AQL classification. Factory-dependent items include achievable shrinkage, pilling grade, shade grouping and zipper pull strength after the exact construction is tested. These must be confirmed through sample and lab results before being treated as contractual pass/fail values.

For shade, use wording such as "bulk to match approved lab dip within commercially acceptable tolerance; no obvious shade difference between panels of one unit; no mixed A/B shade groups in one carton unless approved." For pilling, state ISO 12945-2 method details, cycle count and minimum grade. For shrinkage, state ISO 5077 wash and drying conditions. For zipper, state BS 3084 or ASTM D2061 test items if a lab claim is required, plus factory functional cycling during inspection.

For care labels, align claims with tested performance. If the liner is machine washable at 30°C, test wash shrinkage, seam appearance, pilling and zipper function at that condition. If tumble drying is not tested, do not place tumble-dry approval on the care label. ISO 3758 symbols can be used where markets expect symbol-based care labelling, but local language and retailer rules may still apply.

A complete spec does not make the product expensive by itself. It prevents the factory from quoting an easier product than the buyer expects. The best cost saving is often a clean SKU plan: one or two sizes, stock zipper colour, stable fabric colour, realistic packaging and carton cube verified before the order is placed.

Frequently asked

What is a realistic MOQ for a 320gsm fleece sleeping-bag liner? For stock fleece colour, stock black zipper and one size, a few hundred pieces may be possible if fabric is available. For custom dyed fleece, custom zipper tape, several sizes or private-label pouch packing, plan roughly 500–1,000 pieces per colour or more, depending on dye-lot minimums and trim availability.

Is #3 zipper strong enough for a fleece liner? #3 nylon coil can work for short side openings on budget liners, but #5 coil is safer for full L-shaped openings, wide sizes, two-way sliders and rental or scout use. The heavier 320gsm pile gives less margin for slider snagging.

What fabric tolerance should buyers specify? A practical starting point is 320gsm ±5% by ISO 3801, finished-size tolerance around ±2cm on length and ±1.5cm on width for rectangular adult liners, and wash shrinkage within about ±3% under the agreed ISO 5077 wash condition. Confirm these against the approved fabric route before bulk.

How should zipper strength be tested? For lab-backed zipper claims, specify recognised methods such as BS 3084 or ASTM D2061 and name the exact characteristics to test, such as lateral strength, slider locking and stop strength. For seams around the zipper, ASTM D5034 can be used where the specimen can be prepared correctly.

Why does carton cube matter for fleece liners? A 320gsm liner is bulky. For example, 10 pieces in a 60 x 40 x 45cm carton equals 0.108m³, while a pouch-packed version at 60 x 45 x 55cm equals 0.1485m³. On large orders, that difference can materially change freight, warehouse and landed-cost assumptions.

What defects should be treated as major in final inspection? Major defects should include wrong size, wrong barcode, visible shade mismatch, zipper jamming, missing or reversed slider, pile trapped in the coil, open seam, repeated skipped stitches, broken bartack, strong odour, dirty marks above the agreed limit and incorrect carton assortment.

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