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Direct Coating

Mid adult driver tightening truck tarpaulin on parking lot.
Asparagus field covered with plastic foil
Direct Coating

Durable. Customisable. Proven in Harsh Conditions.

Neucoat’s direct coating technology delivers high-performance coated fabrics engineered for heavy-duty applications. Commonly known as PVC tarpaulin, our direct coated products are designed to meet the exacting needs of industries ranging from agriculture and construction to mining and transport.

What is Direct Coating?
Direct coating involves applying a liquid PVC paste directly onto a polyester basecloth. This process forms a strong, flexible material known for its tensile strength, resistance to weathering, and adaptability to custom specifications.

We manufacture coated fabrics ranging from 180gsm to 1100gsm, with standard widths of 1.5m, 2.04m, 2.5m, and 3m.

Direct Coating

The Production Process

1. PVC Paste Formulation

All PVC pastes are mixed on-site in Neucoat’s mixing department. Each formulation is customised with specific ingredients including:

  • Plasticizers for flexibility
  • PVC resins for strength
  • Pigments for colour
  • Stabilisers for UV and heat resistance
  • Additives for targeted performance (anti-fungal, flame retardant, etc.)


We use various application methods such as:

  • Dip-coating
  • Knife-over-roll coating
  • Airknife coating

Once coated, the fabric passes through an oven at approximately 200°C, where the paste sets into a durable, solid PVC layer.

The basecloth plays a crucial role in the product’s performance. Its construction determines the fabric’s tear strength, tensile strength, and dimensional stability.


Yarn Properties:

  • Made of polyester filaments
  • DTex range: 280DTex to 2200DTex
  • Most common: 1100DTex


Weave Options:

  • Plain Weave: One yarn in each direction (WARP & WEFT)
  • Half Panama: Two yarns in one direction for increased tear strength
  • Full Panama (Oxford): Two yarns in both directions for superior tear resistance


Example:

An 8 x 7.5 weave means there are 8 yarns per cm in the WARP direction and 7.5 yarns per cm in the WEFT direction.

Every Neucoat direct coated fabric can be engineered to meet specific technical or visual requirements.

Available Customisation Options:

Basecloth Selection

Choose the optimal basecloth based on strength, durability, flexibility, and cost.


PVC Formulation Adjustments

  • Colour Matching – Match any sample or Pantone reference
  • Flame Retardant Additives – For compliance with international FR standards
  • Anti-Static Properties – Suitable for mining ventilation (SABS1287:1980)
  • Stiffness Control – Adjust hardness/softness for specific handling
  • Food Grade PVC – Safe for storing consumables and potable liquids
  • Anti-Fungal Additives – Prevent mould growth in humid conditions

Lacquer Coatings

Enhance product durability and maintain cleanability:

  • Acrylic Lacquers
  • PVDF Lacquers


Emboss Finishes

Choose from a range of emboss textures to alter surface appearance and tactile properties:

  • Matt
  • Gloss (Standard)
  • Leather-textured options
Applications

Where Direct Coating Performs Best

Neucoat direct coated fabrics are used across various industries for applications that demand resilience and versatility:

Tarpaulins

Dam and pond liners

Mining ventilation ducting

Truck and trailer curtains

Agricultural storage covers

Industrial tenting and shelters

Inflatable structures

Why Choose Neucoat for Direct Coating?

  • In-house PVC Paste Formulation
  • Polymer Science-Led R&D
  • Custom Engineered Solutions
  • Local Production with Global Quality
  • Responsive Lead Times and Technical Support

Get in Touch

Need a custom solution or technical advice?
Let us help you specify or design the ideal direct coated fabric for your project.

Location

Head Office: 9 Young Rd, New Germany, Pinetown

Email

info@neucoat.co.za