Watch our Sales Manager Karst Jan demonstrate how Zwartz approaches contract laminating as a knowledge partner

When clients come to Zwartz, they often arrive with a material challenge, not a finished specification. They know what performance they need but aren’t sure which laminating technique will deliver it. That’s where decades of hands-on experience become valuable.

In this video, Sales Manager and laminating expert Karst Jan introduces our flatbed calender and explains how we use it to solve real production challenges for clients across Europe.

What is a flatbed calender?

A flatbed calender applies controlled heat and pressure to bond or consolidate materials. Unlike continuous roll-to-roll systems, the flatbed works in cycles, pressing one sheet or stack at a time. That batch approach gives precise control over temperature, pressure and dwell time, making it ideal for applications where consistency and material compatibility matter more than pure throughput.

Our flatbed handles materials up to 2.5 metres wide, processing both roll-fed and sheet forma

Two main applications: laminating and consolidation

The flatbed serves two distinct purposes in our facility.

Laminating bonds two or more layers together using heat-activated adhesives. Typical constructions include textile-to-foam, nonwoven-to-film, or fabric-to-fabric combinations. The flatbed works well when substrates are heat-sensitive, when precise pressure distribution is needed, or when testing new material combinations before scaling to higher-volume production methods.

Consolidation compresses loose or flexible materials into stable, rigid panels. Heat and pressure cause fibres or layers to fuse, increasing stiffness and improving surface evenness. This technique is particularly effective for processing recycled materials, turning production offcuts or post-consumer fibres into functional acoustic panels, lightweight boards or form-stable components.

Why work with a laminating partner?

Karst Jan emphasizes a key point in the video: Zwartz is more than machines. Clients come to us because laminating involves dozens of variables. Adhesive type, substrate compatibility, temperature profiles, cooling rates, surface treatments. Small adjustments in process settings can dramatically change the final product.

We help clients navigate those decisions. Before running full production, we discuss material behaviour, test sample layups and adjust settings based on what we see. That collaborative approach reduces trial-and-error costs and gets products to market faster.

Our three laminating technologies (belt calender, hotmelt system, flatbed calender) cover different production needs, and part of our role is matching the right method to each application.

Applications across industries

The flatbed calender supports projects in acoustics, construction, packaging, automotive interiors, technical textiles and composites. Recent examples include acoustic panels from recycled textile waste, laminated nonwovens for filtration, and bonded fabric structures for industrial applications.

Because the flatbed handles both rigid and flexible substrates, it works for clients exploring new material combinations or shifting from synthetic to natural or recycled alternatives.

Experience counts

Zwartz has been producing textiles since 1835. Our laminating division brings that material knowledge into contract manufacturing. Karst Jan and the team have seen thousands of constructions, adhesives and substrates pass through the facility. That experience translates into fewer surprises during production and better outcomes for our clients.

Watch the video to see the flatbed in action and hear how we approach laminating projects from initial conversation through to finished product.

Ready to explore laminating or consolidation for your application?

Contact our team to discuss material options, process feasibility and sample runs. We’re here to help you figure out what will work.

FAQ: Flatbed calender laminating and consolidation at Zwartz

What is the maximum width you can process on the flatbed calender?

Our flatbed calender handles materials up to 2.5 metres wide. We process both roll-fed and sheet formats depending on the material and application.

What is the difference between laminating and consolidation?

Laminating bonds two or more separate layers together using adhesives and controlled heat and pressure. Consolidation compresses loose or flexible materials into a single rigid panel without necessarily adding separate layers. Both processes use heat and pressure, but the goal and material structure differ.

What types of adhesives work with the flatbed calender?

We work with hotmelt adhesives, thermoplastic films, powder adhesives and heat-activated webs. The choice depends on substrate compatibility, required flexibility, bond strength and end-use environment. We can advise on adhesive selection during the project discussion phase.

Can you process recycled materials?

Yes. The flatbed calender is particularly well-suited for consolidating recycled fibres, production offcuts and post-consumer textile waste into functional panels. We regularly produce acoustic panels and lightweight boards from recycled content.

Do you offer sample runs before full production?

Yes. We recommend testing material combinations and process settings with sample runs before committing to larger volumes. This helps verify bond strength, surface finish, dimensional stability and other performance criteria.

What industries do you serve with the flatbed calender?

We work with clients in many varying sectors. Typical examples are acoustics, construction, automotive interiors, packaging, technical textiles, composites and industrial applications. The flatbed suits any project requiring controlled laminating or consolidation with precise pressure and temperature management.

How do I know if the flatbed calender is the right method for my project?

It depends on your material, volume, required bond quality and production timeline. The flatbed works well for medium volumes, heat-sensitive substrates, rigid panel production and projects where precise control matters more than speed. Contact us to discuss your specific application and we can recommend the best approach.

What other laminating technologies does Zwartz offer?

In addition to the flatbed calender, we operate a belt calender for high-volume roll-to-roll production and a hotmelt system for fast adhesive application. Each technology serves different production needs. We help clients choose the right method for their project.

Where is the flatbed calender located?

All laminating equipment is housed at our facility in Oldenzaal, The Netherlands. Everything is produced in-house, giving us direct control over quality, lead times and process adjustments. All our machines run on clean energy from our solar roof. 

How do I get started with a laminating or consolidation project?

Contact our team with details about your materials, application and performance requirements. We will discuss feasibility, material options, process settings and next steps. From there we can arrange sample runs or move directly into production depending on your timeline.