Surf and Turf Instant Shelters has switched to PVC-free Kavalan and UFABRIK textiles from CMYUK.
It has also adopted a robust policy of reusability to give products a valuable second life.
“At Surf and Turf, our commitment to innovation and social responsibility drives us to continually reduce our environmental impact without compromising on durability or print quality. By offering greener alternatives, we help our customers meet their own sustainability goals while ensuring our products remain at the forefront of industry standards,” said Hanna Kille, Surf and Turf, Project Manager.
The company, a family-run business with over two decades of industry experience, produces pop-up gazebos, inflatables, flags, banners and signs, promotional items, parasols, custom printing, and more.
Responsible eco materials
Kavalan is a PVC-free banner material exclusive to CMYUK. It has all the advantages of PVC but none of its malignancy.
Lighter in weight, softer, and more pliable, it not only makes production and installation more efficient, but also maintains a professional finish even after prolonged outdoor use.
Surf and Turf is currently using Kavalan Sunlight Tai Chi 300, available in 1.6m, 3.2m, and 5m widths. Suitable for both indoor and short-term outdoor applications and compatible with UV and Latex inks, this woven 300gsm textile has a black reverse offering single-sided printing. Meeting stringent health and safety certifications, it has EN13501-1 fire rating, is REACH compliant, and Life Cycle Assessment (LCA) approved.
Typically, Tai Chi is used for wide format banner work for shop fronts, as well a sky banners, raised overhead banners that extend beyond the roofline for maximum visibility. With gazebos, it’s often an extra panel fixed to the top edge of the roof frame, pointing upwards like a sail.
“Kavalan is lighter more flexible and doesn’t compromise on quality. It’s a noticeable improvement both for handling and the final appearance,” says Hanna.
Instant Shelters: Next generation textiles
The business uses several PVC-free UFABRIK products currently including Watertight & Airtight Tent textile, Flag textile, and Beach Flag Belt Black 130mm x 50m. Water & Airtight Tent Textile is a 350gsm (10oz/yd) 100% recyclable REACH compliant polyester material woven at 600D x 600D. Uniquely engineered for the production of tents, gazebos, pavilions, canopies, and marquees, it features a lotus effect composition on its print face that repels moisture, keeping structures dry and secure. Pre-and post-fixation water column resistant levels are > 2000mm.h2o, and > 1200mm.h2o respectively, while opacity rates are at 92%. This textile is designed for direct and paper transfer printing ensuring the ink won’t smudge or transfer when the fabric gets wet. It can also be folded, stored, and transported without issue.
“We use this product for producing bespoke sublimated graphics for our gazebo walls, which are printed in-house with our Mimaki sublimation print technology. The printed textile is then stitched into the insides of the gazebo,” explains Hanna.
Flag Textile is a 110gsm knitted flag textile designed for water-based dye ink. Designed for dye-sublimation, direct or transfer processes, it is a knitted tearproof recyclable textile with excellent show through. Designed for all interior and exterior flag applications, it’s certified to fire standards B1, NFPA701 & EN13501-1, is REACH-compliant, PVC- and DOP-free.
The business often finishes its printed graphics with UFABRIK Beach Flag Belt Black, developed to edge a strong elasticated fringe onto a flag. Recyclable, and available in a width of 130mm, it’s ideal for barriers/fence jackets, external graphics, flags, and soft signage.
All finishing is also now done in-house. In addition to a highly skilled seamstress, the business purchased an AE sewing machine with a conveyorised bed from CMYUK. This is designed for use by a non-experienced operative and provides superb back-up to the finishing department.
Second chance
The addition of this sewing machine in part at least, has led the business to consider wider sustainability issues.
Traditionally, misprinted or faulty items would end up in landfill. Now, rather than discarding these, Surf and Turf repurposes them, producing gazebo storage bags and covers, which are available in a range of sizes on the company’s website. This development has also inspired a line of accessory storage bags in response to customer demand.
“We’ve turned what used to be material waste into opportunity,” says Hannah. “Everything gets reused from excess fabric to printing errors, we make something functional and useful.”
This initiative has both commercial and charitable impact. The company has donated 200 pencil cases, made from repurposed materials to a Stockport-based children’s charity network, and is currently producing more for a Mountain Rescue charity fundraiser later this year. It is working with two customers that have recently rebranded, helping them to repurpose incumbent marketing collateral into second life products.
CMYUK contribution
CMYUK has been key in supporting the company’s shift to a greater sustainable workflow, introducing innovative materials that deliver both environmental and commercial benefits.
“Working with CMYUK has given us the confidence to embrace new eco materials. They’ve shown us what’s possible and helped us make the transition away from PVC without compromising on quality,” says Hanna.
These new generation eco-materials are creating a great deal of interest. Customers are embracing the change, creating excitement and further strengthening relationships.
“There’s an awareness now about the environmental impact and the ability to offer greener choices at the same price is very advantageous,” Hanna notes.
Looking to the future, Surf and Turf is committed to broadening its sustainability offer: researching more materials and production methods, expanding up-cycling programmes and establishing relationships with third parties dedicated to textile re-purposing. Transparency and reporting will also become key priorities.
“We want to be recognised as a leader in sustainable branding,” says Hanna. “With CMYUK’s support and access to next generation products like UFABRIK and Kavalan, we’re confident we can get there.”
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