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How cooler bags were produced? - Chiterion

April 09, 2024

Cooler bags, designed to keep food and drinks cool for longer periods, have been used a lot nowadays for many occasions, such as picnic parties, outdoor adventures as well as grocery shopping trips. It even becomes one of our daily necessities. So do you curious that how cooler bags are produced? Let’s take a detailed look of the production process, from the initial concept to the final product ready for use.

 

Design and Concept:

The whole process starts with an idea. Depending on different application scenarios, the designers and technicians take a lot of things into account, such as size, shape, material, insulation, printing, etc.

Material Selection:

There are three layers of material used on a cooler bag - Outer shell fabric, middle insulation layer and inner lining. For outer shell fabric, normally choose those durable materials like polyester oxford, nylon materials, PP woven fabric, PP non-woven fabric, etc, the fabric as mentioned above are suitable for different printing methods, which makes it easy to add logos and artworks to the bag. For middle insulation layer, mostly use EPE foam, there are different thickness choices, if you want to keep items cool for a longer time, then use thicker insulation, like 8mm, 5mm, otherwise it’s okay to use thinner insulation like 2mm or 3mm. For inner lining, there are several options such as aluminum foil, PEVA, and PVC.

Sampling process:

Once the design and materials are finalized, a proto sample is needed to test the size, printing effect and logo positions. If any part is not correct, modifications will be made accordingly until it meets consumer’s requirement.

Manufacturing Process:

Once the proto sample is approved, the manufacturing process begins. It typically involves the following stages, including cutting, printing, sewing, inspection, and packing. 

Automated cutting machines are used to precisely cut the fabric and insulation materials according to the predefined patterns. This ensures consistency and accuracy in the production process. Then the cutting panels are sent to printing factory for printings, sometimes the fabric are printed before cutting.

Skilled craftsmen then sew the pieces together, paying attention to detail to ensure the seams are strong. Additional features such as zippers, handles, and straps are added during the assembly process, enhancing the functionality and usability of the cooler bag.

                                          

Quality Control and Testing:

Quality control is an absolutely essential part of the production process to ensure that every cooler bag meets the highest standards of quality and performance. Normally there are In-Process Quality Control and Pre-shipment inspection. The IPQC needs to inspect the production lines during the whole process regularly, supervise the product quality, and take note of the key data.

Before shipment, random samples from each production batch undergo strict inspection and testing to evaluate their thermal insulation, waterproofing, and durability.

Tests may include temperature retention tests, water leakage tests, and stress tests to simulate real-world usage scenarios and identify any potential issues.

Packaging and Distribution:

Once the cooler bags have passed quality control checks, they are carefully packaged and prepared for distribution.

Nowadays environmental-friendly packaging materials are used whenever possible to minimize the environmental impact of production and transportation.

The finished products are then shipped to retailers, wholesalers, or directly to consumers, ready to be used and enjoyed.

           

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