Insulation Types Explained: Comparing Quilted, Fleece, Softshell & Padded Outerwear

From cold warehouses to sub-zero outdoor sites, workwear insulation plays a critical role in protecting workers and maintaining productivity. But with so many insulated fabric constructions - quilted linings, fleece, softshells, padded synthetics, it’s easy for sourcing teams to get lost.

Choosing the right insulation isn’t just about warmth. It’s about balancing weight, breathability, wash performance, and layering compatibility - all within cost and compliance requirements.

This article breaks down the most common insulation types in workwear and outerwear, comparing their technical trade-offs to help brands and buyers specify smarter.

The Role of Insulation in Outerwear

Insulation works by trapping air, creating a thermal barrier between the body and the environment. But different materials and constructions trap air in different ways, with varied results in warmth retention, flexibility, and moisture management.

Unlike casualwear, insulated workwear must often meet EN 342 (cold protection), resist compression during use, and stand up to frequent industrial laundering—without restricting movement.

Key Insulation Types in Outerwear

1. Quilted Insulation (Polyfill or Fibrefill Linings)

What it is: A synthetic fill (often polyester) stitched between inner and outer layers, usually in a grid or diamond pattern.

Best for: Cold storage, general winter workwear, or midweight outerwear.

Pros:

• Excellent warmth-to-weight ratio

• Durable and widely available

• Low-cost to produce

• Compatible with shell fabrics or used as linings

  
  

Cons:

• Bulky in high-fill variants

• Stitching can create cold spots

• May compress over time with washing/wear

Considerations: Look for channel-free quilt constructions or thermobonded fills for smoother surfaces and fewer cold spots.

2. Fleece

What it is: A brushed synthetic knit (typically polyester) known for its soft handfeel and breathable warmth.

Best for: Mid-layers, indoor/outdoor transitional wear, or garments needing stretch.

Pros:

• Lightweight and breathable

• Retains warmth when damp

• Easy to wash and fast-drying

• No fill migration

Cons:

• Poor wind resistance unless laminated

• Pilling after repeated wash cycles

• Lower thermal efficiency than insulated fill per gram

Considerations: Use anti-pill or recycled fleece options. Fleece is great for modular systems (e.g. zip-in liners or hybrid layering).

3. Softshell with Bonded Fleece or Microfleece Backing

What it is: A multi-layered fabric with a smooth outer surface, breathable membrane (optional), and inner fleece layer.

Best for: Mild to moderately cold conditions, layered garments with movement requirements.

Pros:

• Wind-resistant and water-repellent (DWR-treated)

• Sleek appearance; no quilting needed

• Often includes stretch

• Breathable and washable

Cons:

• Less insulation than thick quilted garments

• DWR may degrade over time

• May not meet EN 342 on its own

Considerations: Ideal for active outdoor roles or as part of a layered PPE system. Add external shell or liner if needed for extreme cold.

4. Padded Insulation (Thermal Foams or Sheet Liners)

What it is: Flat insulation sheets made from synthetic microfibres, often laminated or bonded inside outerwear layers (e.g. Thinsulate™, Climashield®, etc.)

Best for: Lightweight outerwear, tactical wear, or garments requiring high warmth with low profile.

Pros:

• High-performance warmth in minimal bulk

• Good compression resistance

• Uniform insulation (no stitching required)

• Many options meet EN standards

Cons:

• Can be expensive

• Needs expert construction to avoid moisture trap

• Not always easy to repair or recycle

Considerations: These are ideal when mobility + warmth is critical (e.g. fieldwork, logistics, patrol). Match insulation weight (gsm) to expected temperature exposure.

How to Choose the Right Insulation Type

Sourcing the right insulation means balancing competing priorities:

Performance Priority	Top Choice	Why It Works
Warmth-to-Weight	Synthetic padding (e.g. Thinsulate™)	Delivers high thermal performance without bulk—ideal for lightweight warmth.
Cost-Effectiveness	Quilted polyester fill	Affordable and versatile, especially for basic cold-weather uniforms.
Breathability	Fleece	Allows airflow while offering core warmth—great for layering or active roles.
Industrial Wash Durability	Fleece or quilted polyfill	Withstands repeated washing with minimal loss of loft or shape.
Stretch & Freedom of Movement	Bonded softshell with insulation	Offers flexibility and thermal regulation in dynamic work settings.
Sleek, Bulk-Free Fit	Softshell or laminated insulation	Maintains a clean silhouette—ideal for layering.
Cold Climate Certification (EN 342)	Mid- to high-GSM quilted or padded fill	Provides required insulation levels for certified protection in sub-zero work zones.

Tip: Where possible, test insulated prototypes under actual working conditions. Warmth can vary drastically depending on wind exposure, activity level, and garment layering.

Sustainability Considerations

Insulation can be a barrier to recyclability when it complicates mono-material construction. However, better options are emerging:

• Recycled polyester insulation (e.g. from rPET bottles) is now widely available

• Biodegradable polyester fills are in early market stages

• Natural fills (e.g. TENCEL™-based insulation) are gaining attention for softness, and biodegradability. Not as thermally efficient as synthetics, but performs well in lifestyle and light-duty workwear.

• Designing for disassembly can improve recycling of insulated garments

• Fleece made from recycled yarns offers closed-loop potential

Workwear brands looking to reduce impact should focus on:

• Insulation made from certified recycled content

• Products that balance durability and thermal performance to minimise replacements

How Lyfcycle Can Help

At Lyfcycle, we help brands match insulation performance with real-world usage, compliance needs, and sustainability targets. Whether you’re sourcing bulk polyfill jackets or premium hybrid outerwear, we guide you through fabric selection, EN 342 testing, and supplier benchmarking.

We also support circular design reviews, helping you create garments that don’t just protect workers—they protect the planet too.

If you’re building a new insulated range and need support on specs, sourcing, or sustainability—get in touch.

Editor’s Note:

• ISO 11092: Thermal Resistance (Rct) Measurement

• EN 342:2017 – Protective Clothing Against Cold

• OEKO-TEX®: Certification for Recycled and Safe Insulation

• 3M Thinsulate™, Climashield®, Primaloft®: Comparative Data Sheets

• Textile Exchange: Recycled Polyester Market Report