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Technology

Quality Assurance

Quality is for us the most important value of our product portfolio, therefore we approach it accordingly. The complexity of compliance with quality in the entire range of production and business activities is guaranteed by the quality system according to ČSN EN ISO 9001. This was introduced in our company on the verge of the new Millenium. During our production, we make sure that the impacts, not only on the environment, but also on energy usage, are as small as possible, therefore we have implemented the requirements of the ČSN EN ISO 14001 and ČSN EN ISO 50001 standards into the management system.

Our integrated system is audited internally and externally every year and is completely recertified every 3 years.

We are proud to announce that we are also holders of the OEKO-TEX Standard 100 class I certificate for the production group of zippers and zipper tapes.

Upon request we can issue for each product the following documents:

QUALITY CERTIFICATE

Atest is a document by which we confirm to the customer that the parameters of the product correspond to the requirements of the order - including the measured values.

TECHNICAL DATA SHEET

Contains complex requested values such as (elasticity, strength, shrinkage, tensibility, colour fasteness, burning rate, ...) that we are able to meassure internally on our certified testing machines.

SAMPLING PROCESS ACCORDING TO VDA2

Is used in the automotive supply chain for establishing confidence in suppliers and their production processes.

DECLARATION OF CONFORMITY

Declares that the delivered product is in acordance with requested parameters and quality. Free of charge.

EXTERNAL LAB TESTS

Contains requested parameters that reuire certified testing in an acredited Laboratory.
These tests are charged according to the laboratory´s tariff.

Most of these documents are charged.


Research and Development

Stap, a. s. has long been engaged in research and development, where the company's research and development activities consist in the design and testing of new types of woven ribbons of various types, especially according to customer requirements and technical requirements. Recently, various modifications of needle punched and laminated nonwovens have also been developed to improve their mechanical properties, especially for the automotive and construction industries. Since 2013, we have been working closely with TU Liberec on the development of new products using side emitting optical fibers. One project is already closed, where the result of the project are products for active safety and currently a project is underway for linear exposure, mainly used in hospitals and other buildings.

Other projects that include a valuable element of novelty and overcome the technical or research uncertainties have been, for example, camouflage patterns for various armies, non-flammable fibers for automotive products, controlled capacity planning in weaving mills, reduction of cuts in zipper production, high color fastness pigmentation and Elastic ribbons for the automotive industry.

The company has created an organizational unit operating R&D activities, research and development department (design, technological and technical development) and cooperates in solving research and development projects with the following research institutions:

  • University - TU Liberec
  • Research organizations - TZÚ Brno, VÚT Brno
  • Public Research Organizations – Clutex

Sampling

Every year we do our best to expand our product portfolio with new types and designs. If you have not found a suitable type of product in our offer and you are interested in processing your own design, we are ready to help you with that.

Sampling process

1st Phase

Please specify to us the required product as accurately as possible - especially what parameters are the most important to you (eg. width, thickness, material, ...), purpose of use, expected volume after sampling, etc. By any kind of patern we need to know the height, length, gap between two patterns and the gap from the edges. Please note that the minimum quantity for production after sampling is 2,000 m by default, in the case of woven labels it is 300m, or 3,000 pieces.

2nd Phase

We will evaluate your request and tell you whether we are able to produce the required product and its approximate price.

3rd Phase

In case you will be happy with the result and our offer, please send us a firm order for sampling, which is charged 1000 CZK without VAT. This fee is refunded in case of a subsequent order. Sampling takes approximately 4 weeks depending on the material and the utilization of production capacities.

4th Phase

After testing the provided sample and in case you are happy with the result, please send us a firm order, which we will confirm immediately.


Production processes

Weawing

Weaving takes place exclusively on modern needle looms of European companies Jakob Müller and Cometa.

We produce on 2 to 6 stripes looms in working widths from 4 mm to 300 mm.

Nonwovens production - needlepunching

  • Material
    • PP virgin, PP recycled, GF recycled, PAD
    • Mixing ratios - 70%PP/30GF or 30%PP/70%GF
  • Weight
    • 500 – 2500 g/m2
  • Width
    • Max. 3,5m in sheets
    • Max. 5 m in rolls
  • Production process
    • Feeding
    • Blending
    • Carding
    • Layering (Crosslapper)
    • Needlepunching
    • Longitudinal Cutting
    • Cross Cutting

Lamination – Double belt press

  • Laminated product is more compact and manipulation friendly
  • Economical in regards of Transportation cost, Warehousing, Emissions, ...
  • Better mechanical properties
  • Lamination working width max. 2m
  • Lamination is based on contact heat and pressure applied

Heating zone

Cooling zone

Lamination – Double belt press

Dyeing

We dye our products either on continuous dyeing lines or in a pull-out method (pressure).

In the form of wage work, we also dye other goods for our customers, such as polyester and cotton yarn or women's stockings.


Material

Cotton yarn

Cotton products are characterized by an average strength and elongation of about 6 - 10%. In wet condition the strength and ductility increase. The moisture content of cotton is (24 -27%). At higher temperatures (120 ° C) they turn yellow, at a temperature of 200 ° C they turn brown. Due to sunlight, they turn yellow and lose strength. They do not change in water. They are resistant to weak acids. They decompose in hot and concentrated acids. They do not resist the action of microorganisms. They have good dyeability.

Linen yarn

Products made of linen yarns are stronger than those made of cotton yarns and have a lower elongation of about 1%. In wet condition the ductility increase. They have high moisture content, up to 30%. The products do not age, but slowly lose their strength under sunlight. They are well resistant to alkalis, organic solvents and weak acids. They decompose in warm and concentrated acids. Dyeing is not as good as in case of cotton. They can be washed.

Viscose

Viscose fiber products are very prone to moisture. Their strength under wet condition can get reduced by about a half. Undesirable properties include crumpling. They do not resist the effect of microorganisms. Their touch and shine are evaluated favorably. The products are easy to dye, have very good color - fastness to light and washing.

Polyamide fibers

The products have high abrasion resistance (10 times more than cotton, 2 times more than polyester). They have exceptional strength and ductility (25 - 30%). Relative strength 700 - 800 mN tex. Moisture content can get to approx. 4%. They are easy to wash and dry quickly. They withstand low and high temperatures well. They are hard to ignite. Due to long exposure to sunlight, they turn yellow and loses strength. Under normal conditions, they resist chemicals well. The products can be dyed in pieces. Neither microorganisms nor insects attack them.

Polypropylene fibers

Polypropylene fiber products have a pleasant feel and low weight. They are highly strong and ductile. Relative strength: 400 - 550 mN tex. Possible moisture content is minimal. They are resistant to most acids, bases and solvents. The fibers can only be dyed in the mass. The disadvantage is a low heat resistance. Neither microorganisms nor insects attack them. They do not cause allergies, they have excellent hygienic properties.

Aramid fibers

Products made of aromatic hydrocarbons - Kevlar, Nomex, Twaron, etc. are characterized by high strength and temperature resistance. It is dyed only in the mass and is available in a limited range of colors.

Kevlar - high-strength fiber for special purposes such as cable and rope reinforcement.

Nomex - thermostable fiber, decomposes at high temperature (above 400 °C) without melting.

Reflective fiber

It is woven into products to increase visibility and safety in the dark.

Rubber fibers

The rubber fibers are circular in cross section. They are characterized by a high elongation of 700 - 900%. This property is used in the production of highly flexible ribbons. The products are resistant to sunlight, oils and cosmetics. They are damaged during washing if the water contains only trace amounts of copper and manganese. Bare and braided rubber fibers are used in the products.

Metal-plastic fibers

Metal-plastic fibers are formed by cutting a double-sided polyester foil. Smooth or wrapped fibers of various textile fibers are used. They are used exclusively in a combination with other textile materials. They are mostly used as a decorative element in the product.

Color cards

Color card upon request.

Cotton Color Card
Cotton Color Card
Polyamide Color Card
Polyamide Color Card
Polyester Color Card
Polyester Color Card
Polypropylene Color Card
Polypropylene Color Card

Special material modifications

Water-resistant treatment (permanent - dry cleaning and washing 40 °C is allowed).
At the same time, the water-repellent treatment includes an oleophobic, non-staining treatment. Improves the resistance of the fabric to weathering and has a good air permeability. Another accompanying feature is increased abrasion ability. This treatment is resistant to dry cleaning and gentle washing. The product can be marked with the label "PLUVIOPERL".

Non-flammable treatment (permanent - dry cleaning and washing 40 °C is allowed).
Polyester products with this treatment show reduced flammability in accordance with the TL1010 standard for the automotive industry.

Antifungal treatment (washable - only dry cleaning is allowed).
Prevents the growth of mold. It is not a permanent treatment; it is intended more for long-term storage under adverse conditions.

Antibacterial treatment I. (washable - only dry cleaning is allowed).
Prevents the development of bacterial strains. It is not a permanent treatment, it is intended more for long-term storage under adverse conditions.

Algal growth treatment (washable - only dry cleaning is allowed).
It is not a permanent treatment; it is intended more for long-term storage under adverse conditions. Anti-fungal treatment, antibacterial treatment I. and treatment preventing the growth of algae can be freely combined.

Antibacterial treatment II. (Permanent - dry cleaning and washing 40 °C is allowed).
This treatment is intended for products that touch human skin. It prevents the development of bacteria, decomposition of human sweat, etc.

Modification increasing resistance to UV radiation (permanent - dry cleaning and washing 40 °C is allowed).
Polyester goods processed in this way have an increased product life of about 30% under intense exposure to UV rays compared to non-treated material.

Application of PVC film on the back of the product.
After application, the product is impermeable to water, resists blowing by strong wind, in case of application of PVC film on the zipper tape, it shows a difficult movement of the slider. It is mainly used for extreme conditions, such as in case of accessories for climbers.

Antistatic, softening treatment (washable - only dry cleaning is allowed).
We currently apply softening agents to all zipper tapes, which reduce the coefficient of friction between the individual elementary fibers, which reduces the formation of electrostatic charge.

Special treatments of our products

treatment / product group Wowen Labels, Jacquard & Decorative Ribbons Tapes, Insulation tapes Chain Zippers & Zipper Tapes Webbings & Straps Elastic Tapes
Water-resistant
treatment
Anti-rot
treatment
Antifungal
treatment
Oleophobic
treatment
Antistatic
treatment
Anti-tick
treatment
Anti-abrasive
treatment
bactericidal
treatment
(silver salts)
reduced flammability
standard
reduced flammability
permanent
increasing resistance
to UV radiation
self-adhesive layer
(standard, rubber,
special ABS)
PU coating

Ultrasonic cutting and wage work

We offer cutting of straps from synthetic materials on an ultrasonic cutter to the required length, including melting ends and cutting holes of various shapes and diameters.

We are also able to sew simple finished products from straps and metal components.


Packaging

We supply products in the following adjustment units:

  • wheel (usually 25 m, 50 m or 100 m),
  • paper and plastic spools
  • plastic bag
  • goods in bulk in a carton
  • according to customer requirements.

Adjustment units may contain cuts and marked defects. Their number is specified in the company standard.


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