Top 5 Edge Finishes for 240gsm RPET Fleece Airline Blankets

Stacked 240gsm RPET fleece airline blankets beside sample edge swatches showing overlock, blanket stitch, binding, ultrasonic, and heat-cut finishes in a mill QC setting

Start With the Three Decisions That Matter

For airline blankets, the first question is service life. A blanket intended for one sector plus disposal needs a different edge from a blanket that will be collected, laundered, and reissued 10-30 times in a managed programme. The same 240gsm RPET fleece body fabric can pass or fail depending on edge construction, thread selection, and how aggressively it is folded and compressed.

The second question is handling. If the blanket is packed in a slim polybag or amenity kit, the edge must stay flat and not telegraph through the fold. If it is bulk-stacked for turnaround catering, snag resistance matters more. The third question is proof. For reusable programmes, buyers should ask for a defined test plan around ISO 12945-2 for pilling of the fabric body, ISO 6330 for domestic laundering procedures where washing is expected, and edge-specific strength checks that are named precisely in the PO. If you mean fabric tensile strength, cite ASTM D5034; if you mean seam strength, specify the seam construction and the test method used for that seam; if you mean edge opening or pull-out, define a buyer pull test with a measured force and failure limit. Do not let the factory quote a finish before the use case is fixed in writing.

What 240gsm RPET Fleece Demands from an Edge

At around 240gsm, RPET fleece sits in the practical middle ground for amenity programmes: warm enough to feel substantial, light enough to keep freight and pack size under control. Typical construction uses brushed polyester fleece made from recycled polyester staple, often with a pile face that is soft but not especially edge-stable. Raw-cut fleece can shed fibre and curl, so edge choice has more impact here than on a woven shell. A short pile, around 0.8-1.5 mm, is easier to finish cleanly than a lofty double-brushed fleece.

A useful PO line is: 240gsm RPET fleece, 100% recycled polyester content as claimed by supplier, face brushed, pile height stated, colour-fastness target stated against named method, anti-pilling target stated against named method, finished size and tolerance stated separately. If recycled-content traceability matters, define the claim route before sampling. For chain-of-custody, ask whether the factory will supply transaction-level evidence, lot traceability, and recycled-content declaration language that matches the buying route. For GRS or similar claims, the documentation package should be defined before bulk approval, not after shipment. For visual acceptance, use a sealed PPS or sealed master and tie it to the intended edge sample. For inspection, AQL should be buyer-defined and defect-class specific. A common starting point is something like AQL 2.5 for major visual defects, with tighter limits for critical functional defects such as open edge, broken stitches, exposed raw edge, or contamination.

How the Five Methods Compare

Use this as a procurement ranking, not a style guide.

Overlock: lowest complexity, moderate cost, good baseline fray control. Best when price and throughput matter more than premium presentation.

Blanket stitch: cleaner visual profile than plain overlock, but more dependent on operator control and thread choice. Better for passenger-facing programmes where the blanket is seen and handled but not sold at retail. Use this term only if the sample actually shows the stitch path you want, because mills sometimes use it loosely.

Binding: best edge security and easiest visual inspection. Highest bulk and usually the highest sewing cost. Strongest choice for repeat laundering or rough handling.

Ultrasonic: low thread use and clean appearance on the right substrate, but highly dependent on fleece structure and binder response. Works on some polyester-rich constructions, fails badly on others.

Heat-cut: the lightest-looking edge and sometimes the cheapest in operation, but only suitable on controlled polyester-rich constructions with low loft and stable edge geometry. Poor fit for plush, lofty, or heavily brushed fleece if the blanket must survive repeated reuse.

Overlock: The Baseline Benchmark

Overlock is the default for many airline blanket programmes because it balances cost, speed, and acceptable edge control. A 3-thread overlock can be acceptable for one-way or very low-reuse programmes only if the blanket is a stable polyester fleece, the pile is modest, the perimeter is not exposed to abrasion from straps or hooks, and the programme does not include aggressive laundering. For reusable service, a 4-thread overlock is the safer default. A practical stitch density range is about 3.5-5.0 stitches/cm, with thread commonly in textured polyester or core-spun polyester depending on the required handfeel and abrasion resistance.

Specify the overedge width, stitch density, thread ticket, corner treatment, and acceptable waviness after pressing. For a 240gsm fleece blanket, a narrow, stable overlock usually performs better than a wide decorative edge because excessive thread mass can make the perimeter stiff and prone to curl. Typical failure modes are knife misalignment, thread tension imbalance, edge tunnelling, and skipped stitches at corners. Buyer acceptance should include no skipped stitches in the sample master, edge opening not exceeding a buyer-defined limit after folding and pull, raw edge exposure no more than 1-2 mm at any point, and corner lay-flat within an agreed tolerance. If laundering is in scope, request samples washed under ISO 6330 and check edge opening, curl, and pilling around the stitch line against the sealed master.

Blanket Stitch: Cleaner Look, Narrower Margin

Blanket stitch is used when the buyer wants a more finished appearance than a plain serge without the cost and bulk of a full binding. In sourcing language, be precise about the construction: many mills use the term for a blanket-style overcast or whip-like wrap around the cut edge, while some buyers mean a decorative overcast line with visible loops. Those are not identical. The edge coverage, thread consumption, and durability differ, and the spec should say which one is required. If you need the actual loop path to be consistent across factories, attach a photo sample to the PO and call out loop height, spacing, and whether the stitch pierces the body fabric or only wraps the edge.

It can work well on RPET fleece if the operator keeps the wrap tight and consistent around corners. The thread should fully cover the cut edge; partial coverage looks neat on day one and turns into fibre escape after handling or washing. This method has less process forgiveness than overlock. If the thread is too fine, it can disappear into the pile and lose edge control. If it is too coarse or too tight, the perimeter becomes hard and locally stiff. For airline use, ask for a sample that has been folded and unfolded at least 20-30 times, then inspect the corners and curved transitions. Acceptance criteria should name maximum loop slippage, no visible gap greater than 1-2 mm, no skipped wraps at corners, and no hard puckering that prevents flat packing. Blanket stitch is a presentation choice first and a durability choice second.

Binding: Highest Security, Highest Bulk

Binding is the conservative choice when the blanket must survive repeated handling and laundering. A woven or tricot binding encloses the raw edge and makes inspection straightforward, but it adds bulk and sewing time. On a 240gsm fleece blanket, a narrow binding often lands in the 12-18mm finished width range, but that is only meaningful if the tape type and fold geometry are stated. Narrower tricot or polyester binding can keep pack bulk down; wider woven tape can hide edge irregularities but increases stiffness. If binding is specified, define the tape material, cut width before folding, finished width, fold style, stitch class, and corner construction on the PO. For example, a 25-30mm cut tape may finish near 12-15mm depending on double-fold geometry, while a different fold pattern of the same tape can finish wider and stiffer.

From a sourcing angle, binding usually consumes the most labour because the operator has to control feed, align the fold, manage the corners, and keep the stitch line straight through the full perimeter. Thread consumption is also higher than a simple overlock because there is a second visible construction line or a denser stitch path. That extra material and sewing time often buys better yield in service: fewer open edges, clearer QC, and lower rejection risk after laundering. The main failure modes are corner bulk, binding twist, seam grin at the fold, and differential shrinkage if the tape and blanket body are not matched for wash response. For reusable airlines, ask for a wash trial under ISO 6330 plus a post-wash inspection for corner distortion, seam slippage, and packability.

Ultrasonic and Heat-Cut: Only on the Right Substrate

Ultrasonic can reduce thread use and give a clean perimeter, but it is not a universal solution for RPET fleece. It is most viable when the fabric is predominantly polyester, the pile is short and even, the edge area is low-loft, and the fleece contains enough thermoplastic binder response for localized fusion. As a working guideline, it is more plausible on smooth 100% polyester fleece than on bulky brushed or mixed-fibre constructions. Pre-trials are mandatory, but the approval step should be concrete: submit one sample for peel resistance, one for repeated flex or fold cycling, and one for laundering if reuse is intended. Define an accept/reject limit for edge fracture, shine, hardening, and fuzzing. A sealed edge that turns brittle after folding is a failure, even if it looks clean off the machine. Ultrasonic and heat-cut are both substrate-sensitive, and both can fail when the fleece has too much loft, too much brushing, or the wrong binder system for clean edge response.

Heat-cut is only suitable on polyester-rich synthetics with controlled edge geometry and relatively low loft. It works by trimming and sealing in one pass, which can reduce labour and keep the edge flat. For a fleece blanket, heat-cut is most plausible when the fabric is low-pile, the polyester content is effectively 100%, the edge is not subject to heavy laundering, and the programme accepts a more utilitarian handfeel. It is a poor fit for plush or high-loft fleece, especially when the blanket must be reused often or survive hot laundering. Ask the supplier to state the minimum material conditions: polyester content range, pile height, and the handling limits after sealing. Acceptance should cover no exposed raw fibre exceeding a small, buyer-defined threshold, no brittle edge cracking after fold cycling, and no visible heat glaze outside the edge line.

Make the Acceptance Criteria Measurable

Finish selection becomes actionable only when the buyer writes thresholds that QC can check without interpretation. For overlock and blanket stitch, define stitch density in stitches/cm, thread ticket or Tex, edge width, maximum skipped stitches per blanket, corner quality, and allowed raw edge visibility. For binding, define finished width, fold geometry, stitch class, permissible corner bulk, and whether mitred or rounded corners are allowed. For ultrasonic and heat-cut, define edge continuity, crack or split tolerance after flexing, appearance change after laundering, and whether slight edge stiffening is acceptable.

Use the right test for the right claim. Fabric tensile strength belongs to body fabric verification, not edge finish approval. If the supplier quotes seam or edge strength, ask how the specimen was cut and loaded, because a blanket edge is not the same thing as a woven seam. For reusable airline blankets, a practical inspection block for RFQ or PPS approval is: no open edge longer than 3mm, no visible stitch omission at corners, no loose thread tail longer than 10mm, no raw fibre escape beyond 2mm on any edge section, no unacceptable curl that prevents the blanket from folding to pack spec, and no obvious contrast between PPS and bulk production at arm’s length. For visual language, separate measured tolerance from appearance language: corner lay-flat is an inspection criterion, while waviness should be written as a dimensional tolerance or a straight-edge deviation limit. Add a fold-and-unfold check if the blanket will be compressed in amenity packaging.

How To Write the PO

Write the finish as a manufacturing spec, not a marketing term. Example: 240gsm RPET fleece blanket, 100% recycled polyester claimed by supplier, size 120x150cm +/- 2cm, edge finish 4-thread overlock, 4.0-4.5 stitches/cm, polyester thread Tex 27-40, corner finish matched, no raw edge exposure over 2mm, no skipped stitches, AQL 2.5 major and 1.0 critical, PPS sealed against photo sample, post-launder appearance to remain acceptable after 5 cycles under ISO 6330. If you want blanket stitch, binding, ultrasonic, or heat-cut, state the exact construction and attach the approved swatch.

For buying teams, the simplest way to avoid disagreement is to lock three things before bulk: the edge photo, the inspection checklist, and the wash or handling test. That gives the mill a target it can build to and gives procurement a basis for comparing mills on the same terms, not on different interpretations of the same phrase.

Decision Matrix

Finish	Reuse cycle	Pack bulk	Appearance	Process risk	Best use case
Overlock	1-20 cycles	Low	Utility	Low	Economy amenity, controlled turnover, price-sensitive tenders
Blanket stitch	1-15 cycles	Low to medium	Cleaner than plain serge	Medium	Passenger-facing amenity where the edge is visible but cost still matters
Binding	10-30+ cycles	Medium to high	Best-defined edge	Medium to high	Reusable programmes, rough handling, stronger inspection control
Ultrasonic	1-10 cycles	Very low	Very clean if substrate suits	High	Low-bulk programmes on stable polyester fleece with proven trials
Heat-cut	1-5 cycles	Very low	Minimalist	High	Single-use or low-reuse polyester-rich blankets with tight cost and bulk targets

What To Ask Your Mill Before You Approve Bulk

Request the edge swatch, not just the blanket. Ask for the thread ticket, stitch density, tape width, and corner method in writing. Ask whether the factory has run fold-cycling, wash, and pull checks on the actual substrate, not a similar one. Ask whether the RPET fleece uses a stable binder system compatible with ultrasonic or heat-cut if those methods are on the table. Ask for the rejection criteria in the inspection report so the buyer and mill are using the same language.

For commercial alignment, lock the commercial term separately from the quality term. If the shipment is FOB or DDP, that changes freight and duty responsibility, not edge performance. Keep logistics and quality criteria distinct in the PO and PPS sign-off.

Frequently asked

Which edge finish is the safest default for a reusable 240gsm RPET fleece airline blanket? A 4-thread overlock or a narrow binding are the safest defaults. Overlock is cheaper and lighter; binding is more secure and easier to inspect. For 10-30 wash reissue, binding usually gives the clearest control, but it adds bulk and sewing time.

Is blanket stitch the same as whipped stitch? Not always. Factories use both terms loosely. In the PO, attach a photo sample and specify the stitch path, loop height, and whether the construction is a decorative overcast or a true edge wrap. Do not rely on the name alone.

Can ultrasonic or heat-cut work on RPET fleece? Yes, but only on suitable substrates. Short-pile, polyester-rich fleece with a stable edge responds best. Lofty brushed fleece, mixed fibre content, and unstable binder systems can give brittle, fuzzy, or open edges after folding or washing.

What should I inspect on first article approval? Check stitch density, edge coverage, corner quality, raw edge exposure, thread tails, curl, and packability. For reusable blankets, add a wash trial under ISO 6330 and a post-wash check for edge opening and appearance retention.

What AQL should I use? A common starting point is AQL 2.5 for major visual defects and AQL 1.0 for critical defects such as open edge, contamination, or missing finish at a corner. The exact level should match the programme risk and the buyer's tolerance for rejects.

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Top 5 Edge Finishes for Airline Blankets