Key Takeaways
- Cooling towels are made from PVA, microfiber polyester, or hybrid materials — each with different cooling duration, feel, and printability.
- Standard size is 12″ x 36″; larger 13″ x 40″ and smaller 8″ x 30″ mini sizes are also available.
- Dye sublimation on microfiber polyester is the standard print method, supporting full-color edge-to-edge designs.
- Activation takes about 30 seconds (soak, wring, snap) and cooling lasts 1-3 hours per activation.
- Bulk pricing typically lands $2.50-$4.50 per piece at 500-1,000 quantities.
What is a Cooling Towel?
A cooling towel is a specialty towel made of synthetic fibers (typically PVA, microfiber polyester, or a hybrid) designed to retain water and release evaporative cooling against your skin. When you soak it, wring it out, and snap it, it activates — becoming cold to the touch and staying that way for 1-3 hours via evaporation. Re-soak as needed. They are widely used in athletic, outdoor work, and event-giveaway contexts where heat mitigation matters.
Cooling Towel Materials: PVA vs Microfiber vs Hybrid
PVA (polyvinyl alcohol)
What it is: A synthetic fiber that absorbs and retains a high volume of water relative to its mass. Feels slightly rubbery when dry, soft and chamois-like when wet.
Strengths: Longest cooling duration (2-3 hours per activation), excellent water retention, lightweight.
Weaknesses: Dries stiff and crispy after use; needs to be re-wet before next use; printing options limited (typically screen printing only, not great for full-color).
Best for: Functional cooling — outdoor workers, construction, agricultural work — where cooling performance matters more than design impact.
Microfiber polyester (most common for branded events)
What it is: Synthetic blend (usually 80% polyester / 20% polyamide) engineered for moisture absorption and fast drying. Feels soft and athletic both wet and dry.
Strengths: Full-color dye-sublimation printing with no color limits, soft feel both wet and dry, lighter than PVA, machine washable.
Weaknesses: Slightly shorter cooling duration than PVA (1.5-2.5 hours per activation), slightly less water-retentive.
Best for: Branded event giveaways, athletic team gifts, corporate wellness, retail-ready cooling towels. This is the default choice for most custom cooling towel orders.
Hybrid materials
What it is: Specialty blends combining PVA core with microfiber outer shell, or polyester-polyamide blends with cooling crystal infusion. Engineered to combine performance and printability.
Strengths: Better cooling duration than pure microfiber, better printability than pure PVA.
Weaknesses: Higher cost per piece, less standardized across suppliers.
Best for: Premium athletic brand product launches, sponsor activations where both cooling performance and visual design matter.
Standard Cooling Towel Sizes
12″ x 36″ — the standard
The most common cooling towel size. Fits comfortably around the neck, drapes well, gives full surface area for cooling. Right pick for 80%+ of custom cooling towel orders.
13″ x 40″ — the premium
Slightly larger format for adult athletes who want more towel coverage. Better for marathon kits, premium gym member gifts, and sponsor activations where bigger feels more valuable.
8″ x 30″ — the mini
More economical, smaller-coverage option. Good for youth events, budget mass distribution, kids sports leagues.
Custom sizes
Rally Towels can produce custom cooling towel sizes for specific use cases. Common requests include extra-long 15″ x 45″ for endurance athletes and oversized 24″ x 60″ for chaise lounge cooling.
Print Methods for Custom Cooling Towels
Dye sublimation (most common)
Full-color, edge-to-edge printing that dyes the design into the fiber. No color limit, no per-color fee, no peeling or cracking. Only works on synthetic materials (polyester or microfiber blends). This is the standard print method for the majority of custom cooling towel orders.
Screen printing
Layered ink printing on top of the fabric. Works on PVA cooling towels (which cannot accept dye sublimation). Best for simple 1-3 color designs. Less durable than dye sublimation over time.
Heat transfer
Less common, sometimes used for small-batch or single-piece runs. Lower durability than dye sublimation or screen printing.
Activation Time and How Cooling Works
- Soak: Submerge the towel in cool water for 5-10 seconds
- Wring: Wring out excess water — the towel should be damp, not dripping
- Snap: Hold both ends and snap the towel once to disperse moisture evenly
- Wear: Drape around neck, place on forehead, or hold in hand
The cooling effect lasts 1-3 hours via evaporative cooling. Re-activate by re-soaking with water whenever the cooling effect fades. No power or chemicals required.
Pricing Breakdown
Standard 12″ x 36″ custom cooling towel with full-color dye sublimation on microfiber polyester:
- 100 pieces: $4.50-$6.50 per piece
- 250 pieces: $3.50-$5.00 per piece
- 500 pieces: $3.00-$4.25 per piece
- 1,000 pieces: $2.50-$3.75 per piece
- 2,500 pieces: $2.25-$3.25 per piece
- 5,000+ pieces: custom quote
Setup fees, art fees, and rush charges may apply. Premium materials (PVA, hybrid) typically add $0.50-$1.50 per piece.
Lead Times
Standard production: 1-3 weeks from final art approval. Recommended for most orders.
Rush production: 1-3 business days. Available for race events, last-minute corporate orders, and unexpected deadlines. Surcharge applies.
Recommended order timeline: 4-6 weeks before event date for the smoothest experience with built-in buffer for design revisions.
Frequently Asked Questions
What material is best for custom cooling towels?
Microfiber polyester is the best material for most custom cooling towels because it supports full-color dye-sublimation printing while still delivering 1.5-2.5 hours of evaporative cooling per activation. PVA offers slightly longer cooling but is harder to brand with full-color designs.
How do you wash a custom cooling towel?
Custom microfiber polyester cooling towels are machine washable on cold, tumble dry low or air dry. PVA cooling towels should be rinsed and air dried only. Avoid bleach and fabric softener as both can degrade cooling performance.
How many times can a cooling towel be re-used?
A quality custom cooling towel can be activated and re-activated hundreds of times. The cooling effect does not degrade with re-use as long as the towel is properly washed and stored.
What is the largest order Rally Towels can produce for custom cooling towels?
Rally Towels routinely produces custom cooling towel orders of 10,000-50,000 pieces for major race events, large corporate fleets, and stadium-volume sponsor activations. Larger orders receive custom-quoted pricing with the most aggressive per-piece rates.
How long does production take for custom cooling towels?
Standard production at Rally Towels takes 1-3 weeks from final art approval. Rush production of 1-3 business days is available for additional fee. We recommend ordering 4-6 weeks before your event for a comfortable buffer.
Where are Rally Towels custom cooling towels made?
Rally Towels custom cooling towels are manufactured in the United States. USA production means faster turnaround, better quality control, and full material transparency.
Get Your Instant Custom Quote
Fill out the form below for a free quote and a virtual mockup of your custom design. We respond within 1 business hour Monday-Friday.
Get a Custom Cooling Towel Quote
Rally Towels has produced custom cooling towels for race events, fitness brands, corporate wellness programs, and outdoor workforces since 2003. Request a quote with your quantity, size, material preference, and event date, or call 888-725-5986 Monday-Friday, 8am-5pm PST.