PUL Fabric: Properties, Pricing & Sustainability (2023)
Polyurethane laminate, commonly known as PUL, is a waterproof fabric that has a plastic coating. This fabric was initially developed for the hospital industry but has now become popular among cloth diaper users due to its waterproof properties. Apart from diapers, PUL has various other practical applications around the home. TPU is the name of the laminate that is used to make PUL and can be applied to different types of fabrics.
What is PUL Fabric?
Polyurethane laminate (PUL) is a type of material that is created by treating fabric or textile with a polyurethane laminate coating, which makes it waterproof. Although PUL can be applied to any fabric, it is usually used in cotton, polyester, or cotton-poly blends.
The polyurethane laminate coating is similar to the plastic coating applied to paper in the lamination process. Apart from fabric, it is also used in kitchen and bathroom sealers, finishers, and glues.
Originally, PUL fabrics were used in hospitals because they are durable, waterproof, and easy to clean. Polyurethanes were invented in Germany in the 1930s, but it took several decades before they were applied to fabrics.
Nowadays, PUL textiles are commonly used for various products such as mattress covers, bibs, cloth diapers, sanitary pads, lunch bags, and wet bags. Many home crafters also prefer PUL fabric for creating baby and child items. Polyurethane laminate (PUL) is a type of material that is created by treating fabric or textile with a polyurethane laminate coating, which makes it waterproof. Although PUL can be applied to any fabric, it is usually used in cotton, polyester, or cotton-poly blends.
PUL, or Polyurethane Laminate, is a synthetic fibre with unique properties that make it ideal for various applications. It is a breathable yet water-resistant fabric that is soft, stretchy, and durable. Due to its waterproof nature, PUL is commonly used for making cloth diapers, tablecloths, wet bags, bibs, and changing pads. PUL should be washed with hot water and, if needed, ironed on the lowest setting.
PUL vs. TPU vs. Fleece
It’s common for people to mix up PUL and TPU, believing them to be different types of materials. However, TPU, or thermoplastic polyurethane, is actually the plastic coating used to produce PUL fabrics. TPU is a combination of plastic and rubber that seamlessly sticks to the fabric when applied. It’s a thin, transparent material that’s flexible and elastic, making it easy to bond with other materials.
On the other hand, Fleece is an artificial fabric designed to imitate the texture of sheep’s wool. Fleece shares many similarities with PUL, such as being waterproof and breathable, making it a popular choice for cloth diapering and washable sanitary pads. Unlike PUL, Fleece is thicker and provides better warmth.
However, it’s not entirely waterproof like PUL. Additionally, unlike PUL, Fleece doesn’t delaminate, which is when the TPU coating begins to peel off the fabric.
Types of PUL Fabric
The main difference between different types of PULs is the weight of the lamination. The most common is 1-mil and 2-mil PULs. PUL fabrics are typically available in cotton, polyester, or a cotton-poy blend. Relatively new to the market is the eco-friendly PUL, which is free of additives like latex and does not emit volatile organic compounds (VOC) when manufactured.
1-mil PUL
PUL fabric with a thickness of 1 mil is the most commonly used type of PUL. It is widely used for a variety of items, such as cloth diapers, bibs, changing pads, mattress pads, tablecloths, and lunch bags, among others. This type of PUL is available in various colors, patterns, and widths.
If you plan on using PUL fabric to create lunch or sandwich bags, it is essential to ensure that it is safe for use with food. ProSoft FoodSAFEⓇ by Wazoodle is one of the few PUL fabrics that meet the qualifications of The Consumer Product Safety Improvement Act (CPSIA) and is safe to use with food.
2-mil PUL
2-mil PUL cloth is a thicker type of PUL fabric that is commonly used for industrial purposes. It offers better durability and an extra layer of waterproof protection. Although it can be used to make cloth diapers, especially for overnight use, it is more commonly utilized as patio furniture upholstery, mattress pads, changing cover pads, and wet bags.
Apart from the uses above, 2-mil PUL is also an excellent option for children’s art projects, such as a drop cloth or tablecloth. It comes in various colors, patterns, and thicknesses, similar to 1-mil PUL.
Cotton PUL
Cotton PUL comes in two thicknesses, 1-mil or 2-mil, and is sometimes made from 100% organic cotton. Wazoodle, a fabric company, offers organic cotton PUL made from cotton directly sourced from American farmers. One side of the fabric has a soft, smooth texture, while the other side is coated in PUL.
Cotton is a popular choice for PUL fabric used in diapers because of its natural softness and breathability. You can also find cotton PUL used in athletic shorts, washable sanitary pads, makeup bags, diaper bags, wet bags, and more.
polyester PUL
Polyester is a commonly used synthetic fabric that is available in both 1-mil and 2-mil thickness and various widths. It is often used as PUL and can be found at craft and fabric stores. However, some people prefer to stick with 100% cotton, which is a natural fabric, as polyester is not as breathable and doesn’t feel as soft next to the skin.
It is also worth noting that PUL fabrics, even when made with organic fibers, cannot be certified organic due to the TPU coating. Despite this, polyester PUL is often used for mattress pads because of its durability and warmth, and it is usually more affordable than cotton.
Cotton-Poly Blended PUL
Cotton-poly blended PUL is the best of both worlds. It provides the strength and durability of polyester while offering the softness and breathability of cotton.
Cotton-poly blended PUL is a popular choice for cloth diapers because polyester aids in the moisture-wicking process. Additionally, cotton is prone to shrinking and changing shape, whereas polyester is not, so when the two are combined, they can withstand multiple washes better than cotton.
Cotton-poly blends typically consist of a 65/35 or 50/50 split and are made in a variety of PUL fabric colors, patterns, and thicknesses.
Eco-Friendly PUL
Eco-friendly PUL is the latest innovation in PUL cloth technology. Conventionally made PUL employs a variety of chemicals in the lamination process that are detrimental to the environment and cause pollution in local air, water, and land.
This new PUL fabric is free from toxins, lead, BPA, and heavy metals. A few fabric manufacturers currently produce and offer eco-friendly PUL through the “green lamination” process.
Wazoodle,Nature Fabrics, and Eco-PUL Textiles are among the companies that manufacture eco-friendly fabrics in the United States. All three companies provide the material in a range of colors, patterns, and weights, and it is available for purchase directly from their websites.
Eco-friendly PUL is an excellent choice for parents who want to use PUL for cloth diapers but want to ensure that the fabric is environmentally conscious.
Characteristics of PUL
PU laminate cloth is a versatile material that is waterproof, breathable, and has some stretch to it. It is also soft and flexible and can be easily machine-washed and dried. You can clean it with a diluted solution of bleach or alcohol.
PUL is considered, by many, the number one waterproof baby fabric and is used widely to make baby items such as cloth diapers, changing pads, mattress pads, and bibs. Parents find PUL an accessible material to work with because it is breathable, waterproof, and simple to clean.
Its stretchiness and ability to maintain its shape is another reason it is popular among cloth diapering parents. Babies need flexibility as they move and kick, but they also need diapers that keep mess and wetness contained!
Because PUL is moisture-wicking, it pulls wetness away from your baby’s bottom and prevents diaper rash, which is more common with disposable diapers.
Additional PUL fabric properties include that it is hypoallergenic and doesn’t produce lint or pills.
PU fabric is a popular choice for constructing protective clothing, such as fluid-splash garments, shower curtains, and outerwear. It’s also used as upholstery, particularly in cars and restaurants.
The material is widely used in watersports clothing and equipment, and it’s also common in tents and backpacks that require waterproofing.
PUL (Polyurethane Laminate) is easy to clean and sterilize, making it suitable for medical bedding, mattress protectors, reusable incontinence products, diapers/nappies, wet bags, and other similar items.
Downsides of PUL Fabric
PUL fabric has a significant drawback: it can delaminate. Delamination happens when the TPU layer separates from the fabric, causing it to peel off. Even with careful maintenance, PUL fabric is likely to delaminate eventually. However, air drying can slow down the process.
Washing PUL clothing in hot water is safe, and it may even help to reseal small holes or tears in the lamination. However, dying PUL fabric at high temperatures can make it brittle and prone to cracking. If you have to iron PUL, use low heat and iron on the backside of the material.
Crafters often find PUL challenging to work with because the laminate makes it harder to sew, and the sticky surface can stick to the sewing machine’s foot. To overcome this, it is recommended to use a walking foot and sew with the sticky side facing downwards.
Common Uses of PUL Fabric
Although waterproof PUL is mainly used in cloth diapering, it has a wide range of other applications for crafters and manufacturers. For instance, PUL fabric’s qualities make it an excellent choice for various baby gear, including wet bags for storing dirty cloth diapers, bibs, changing pads, car seat covers, and mattress pads. You can also find PUL in raincoats, rain hats, purses, make-up bags, patio furniture covers, and washable sanitary pads.
Furthermore, PUL fabric is used to make reusable swim diapers that do not have the extra-absorbent layer inside, unlike standard cloth diapers, to avoid soaking in pool water.
Since PUL fabric is smooth, waterproof, and easy to wash, it works excellent as tablecloths, art smocks, or drop cloths for children’s art projects.
PUL Fabric in Cloth Diapers
PUL fabric is widely used in cloth diapering. It’s the same type of fabric as any other PUL, but fabric stores might advertise certain prints, styles, and colors specifically for diapers because of cute patterns or prints geared toward kids. The most common PUL types used in diapers are polyester or a cotton-poly blend, although 100% cotton is also used.
Some claim that modern or eco-friendly PULs aren’t as durable as the older PUL fabrics, but manufacturers attest to their PUL fabric durability and state that their diapers can withstand 200-300 washes on a hot cycle.
PUL fabric is typically used to make diaper covers for all-in-ones (AIO), hybrids (AI2), and pocket diapers, but you can also use it to make covers for pre folds and flats. Regardless of how it’s used, an absorbent layer needs to be added for cloth diapering.
PUL Fabric Pricing
PUL fabric is widely available, making it affordable. On average, one yard of PUL fabric costs between $10 and $15. An experienced sewer can make up to ten diaper covers from one yard of fabric. However, this would leave no room for error, and all your diapers would have the same color or pattern.
If you’re looking for a high-quality or eco-friendly PUL, it will cost around $18 per yard. To save money, consider buying PUL wholesale, especially if you plan to make several cloth diapers or other products for selling or gifting. Wholesale PUL can cost up to 50% less than retail.
Since most eco-friendly PUL is made in the U.S., it can remain competitive with overseas manufacturers due to lower shipping costs.
How is PUL Fabric Made?
There are two main ways in which manufacturers produce PUL fabric: hot melt or solvent lamination. Typically, PUL is made using cotton, polyester, or a blend of cotton and polyester. Polyester is the most common type of PUL fabric available because it provides the best bonding.
To create a hot melt or eco-friendly PUL, heat-activated glue is used to affix the plastic T.P.U. Layer onto the fabric. This process is also known as green lamination. Eco-friendly T.P.U. is made from natural sources and does not contain harsh chemicals. As a result, it is safe to use around food and is considered better for your health.
On the other hand, traditional PUL is made by combining the fabric and the polyurethane and then weaving a thread into the fabrics. However, the solvent lamination process uses petroleum, which creates wasteful by-products and is not considered food-safe.
Where is PUL Fabric Manufactured?
There are three major manufacturers of eco-friendly PULs in the United States: Wazoodle, Nature Fabrics, and Eco-PUL Textiles. Both Wazoodle and Nature Fabrics are based in Pennsylvania. Eco-PUL Textiles claims that all of its products are made in the U.S.A., although its webpage does not list its contact information.
Another U.S.-based eco-friendly PUL manufacturer is Forget Me Not Fabrics, located in Missouri.
Fibro Laminates, based in India, is one of the leading manufacturers and exporters of PUL fabric in the U.S. and worldwide. They specialize in producing mattress pads and PUL fabric.
In addition to the United States and India, other countries that produce PUL in large quantities include Pakistan, Cambodia, Italy, Vietnam, and Bangladesh.
However, overseas companies tend to have traditional PUL, and their manufacturing process needs to be more transparent. Many modern and eco-conscious consumers prefer to avoid using traditional PULs. Therefore, the demand for eco-friendly PULs in the U.S. has been increasing over the past few decades.
PUL Fabric Environmental Impact
Traditional PUL fabric is made by using petroleum to create the polyurethane laminate. Unfortunately, the process of creating the laminate produces hazardous chemical waste that can harm local waterways, land, and air. This pollution negatively impacts both the wildlife in the region and the people who reside close by.
Moreover, most PUL fabric is made of polyester, which is also a petroleum-based product—the production of polyester results in by-products similar to those produced by polyurethane. Lastly, PUL is non-biodegradable, which means that it can take up space in landfills for an indefinite amount of time.
However , despite these drawbacks, using PUL fabric for cloth diapering is still a more environmentally friendly option than disposable diapers. This is especially true when you consider that a typical baby will require 3,600 to 4,300 diapers in just their first year alone! By using a few dozen PUL diapers repeatedly, the environmental impact is significantly reduced.
Eco-friendly PUL is, of course, much better for the environment because it doesn’t involve the use of harsh or hazardous chemicals in the manufacturing process.
PUL Certifications
Eco-friendly PUL is eligible for a handful of certifications, showcasing that it is safe to be used with food products. The Consumer Product Safety Improvement Act (CPSIA) has a series of qualifications. PULs must meet in order to receive their stamp of approval for use with food. Additionally, eco-friendly PUL designed to be used with food can receive a Food Safe certification by adhering to specific F.D.A. guidelines.
Another certification that eco-friendly PUL may obtain is the CertiPUR-US. This certification verifies that the fabric does not contain any harsh or dangerous chemicals and that the manufacturing process has low V.O.C. (Volatile Organic Compound) emissions.
Factories that produce PUL are eligible to earn the Worldwide Responsible Accredited Production (WRAP) certification. This certification ensures that no children under the age of 14 are employed, workers earn a liveable wage, workhouses and factories are safe, and no forced labor is occurring.
History of PUL Fabric
PUL fabric has a fascinating history, although some details could be more precise. We do know that the main component of T.P.U., polyurethane, was invented by Otto Bayer in Germany during the late 1930s. Together with his colleagues at I.G. Farben Leverkusen, Bayer discovered the process of creating polyurethane and patented it in 1937. In 1983, Bayer’s continued research led to the production of the first all-plastic-body automobile in the U.S., the Pontiac Fiero. Nowadays, T.P.U. and PUL fabrics are widely used in the automotive and industrial sectors.
Hospitals initially used PUL fabric as they needed waterproof and easy-to-clean materials. Users then transferred the application to cloth diapering and baby products for similar reasons. Today, consumers can find PUL fabric being used in the production of bedding, upholstery, baby items, lunch boxes, sanitary pads, reusable bags, and clothing.
The invention of eco-friendly PUL has created a surge of interest among cloth diapering parents who previously avoided PUL due to its environmental impact.
PUL Fabric Alternatives
When it comes to cloth diapering, there are three main types of fabric alternatives to PUL: wool, fleece, and other synthetic options. Fleece has a similar weight to PUL but is naturally absorbent without a T.P.U. Layer. Wool is also naturally absorbent, but it tends to be heavier. All three fabrics are breathable and gentle on a baby’s skin.
Wool is the most eco-friendly of the three because it is a natural and biodegradable product. However, for those who avoid animal products, wool is not a viable option.
Other synthetic alternatives include waxed cotton, vinyl or plastic, and laminated cotton or linen. Waxed cotton is a tightly woven cotton textile coated with paraffin wax. It is a good alternative if used as a canvas, drop cloth or similar industrial item.
You can use vinyl and plastic for many of the same uses as PUL, such as cloth diaper covers and raincoats. However, they are not breathable and may not be comfortable against the skin, especially for babies.
Laminated cotton or linen is similar in quality to PUL fabric and can be used for many of the same uses, but it is less durable or flexible. However, it is much more breathable than PUL fabric.
FAQ
Q-1 What is polyurethane laminate fabric?
Polyurethane laminate fabric is a fabric that has a thin, waterproof plastic coating adhered to it. The fabric is usually made of cotton, polyester, or a blend of the two.
Q-2 Is PUL fabric toxic?
The fabric is non-toxic but must be certified as food-safe for use. The material is non-toxic but must be certified as food-safe for use.
Q-3 Can PUL fabric go in the dryer?
PUL can be put in the dryer, but it is recommended to air dry to prevent cracking and delamination caused by high dryer temperatures.
Q-4 Is PUL eco-friendly?
Traditional PULs are not considered eco-friendly, but more modern heat press or green PUL fabrics are made through an eco-friendly process and are usually labeled.
Q-5 How do you sew PUL fabric?
Sew PUL with laminate side down. Use thicker thread and walking foot if possible.
Q-6 How do you clean PUL diapers?
Wash PUL cloth diapers in hot water with approved detergent and hang them to dry.
Q-7 Is PUL fabric waterproof?
Yes, PUL fabric is waterproof. Different thicknesses exist, such as 1-mil, 2-mil and 5-mil.