Lamination• Bhupendra Singh

Lamination

• Two or more films laminated to combine their characteristics

Lamination Advantages• Good heat Sealing

properties can be achieved

• Good Barrier Property• Better Printing • Better Strength• Flavor Retention• Improved Puncture

Strength

Lamination Process

Lamination Process • Heat

Lamination

Lamination Process • Wet

Lamination

Lamination Process • Dry

Lamination

Lamination Process • Pressure• Lamination

Variable Parameter• Material Properties

– Chemical Type• Plastic • Paper • Foil• Textile

– Mechanical Properties• Tensile• Elongation

– Thickness– Elongational Property– Machinability

• Material Properties– Moisture Absorption – Compatibility with

adhesive– Surface Properties

• Surface Energy• Surface Treatment

– Thermal Properties• Heat Sealing Properties• Melting Range/Point• Heat Stability

Variable Parameter• Adhesive Properties

– Chemical Type– Solids– Thickness– Viscosity– pH– Morphology– MFI (Hot Melts)– Melting Range– Flow Properties

Variable Parameter• Machine Properties

– Machine Type– Machine Output– Semi/Automatic– Feeding Arrangement– Guiding Mechanism– Spreader Roller– Heaters

Laminating Materials• Films

– LDPE– HDPE– LLDPE– Coextr.– BOPP– PVC– PC– Nylon– PVDC– PET– Ionomer– Metallised

• Foils• Papers• Textile

Laminating Webs• LDPE

– Light weight– flexible– stretchable– heat sealable at low temp.– good moisture barrier

• LLDPE– Tougher than LDPE– high tensile strength than LDPE– High Puncture resistance– High Elongation– good moisture barrier

Laminating Webs• HDPE

– High Strength– High tensile properties– High Barrier properties for gas &

water– High tear in one direction

• PP– Low cost– Excellent moisture & gas barrier– High Puncture resistance– Low density

Laminating Webs• PET

– High Transparency– Good Chemical Resistance– High tensile properties– High Barrier properties for gas &

water

• PVC– Strong Film– Excellent Clarity– Easy Sealing– Low Cost

Laminating Webs• Nylon

– High Transparency– High Sealing Temp.– High tensile properties– High Barrier properties for gas &

flavor

• PVDC– Excellent Moisture & Gas Barrier– High Gloss– High tensile strength– Clear Film

Laminating Webs• Aluminium Foil

– Excellent dead fold Properties– Easy tear – Good Flexibility– High Barrier properties for gas &

flavor

• Paper– Excellent Printability– High strength– Decorative property

Adhesives• Water borne adhesive

– Acrylic Copolymer adhesives– Pressure Sensitive Adhesive– Starch based– Silicates

• Solvent Borne– PU adhesives

Adhesives• Hot Melt (100 % solid)

– EVA based – PE based

Lamination Techniques

1. Thermal Lamination2. Hot-melt Lamination3. Non-solvent Lamination4. Wet Lamination5. Dry Lamination6. Extrusion Coating / Lamination7. Co-extrusion Lamination

Coating Methods for Adhesives

– Gravure Coating– Reverse Roll Coating– Knife Over Roll Coating– Metering Rod (Meyer Rod)

Coating– Slot Die (Slot, Extrusion)

Coating– Curtain Coating– Air Knife Coating

Coating Methods for Adhesives• Gravure Coating

Coating Methods for Adhesives• Reverse Roll Coating

Coating Methods for Adhesives• Knife Over Roll Coating

"Gap Coating”

Coating Methods for Adhesives• Metering Rod (Meyer

Rod) Coating

Coating Methods for Adhesives• Slot Die (Slot, extrusion)

Coating• In extrusion coating and lamination,

resin is melted and formed into thin hot film, which is coated onto a moving, flat substrate such as paper, paperboard, metal foil, or plastic film.

• The coated substrate then passes between a set of counter-rotating rolls, which press the coating onto the substrate to ensure complete contact and adhesion

Coating Methods for Adhesives• Slot Die (Slot, extrusion)

Coating

Coating Methods for Adhesives• Immersion or Dip Coating

Coating Methods for Adhesives• Curtain Coating

Coating Methods for Adhesives• Air Knife Coating

Co-extrusion Lamination

Co-extrusion Lamination

• LDPE/HDPE/LDPE

• LDPE/Nylon/LDPE

• HDPE/Nylon/EVA

Film Lamination (Cartons)• Advantages

– Will not yellow with age – Will not Flake off– Will not Crack– the ink is protected from cracking– It gives an odorless and wipeable

surface• Disadvantage

– High Cost

Gloss Lamination (Cartons)• high shine• hard wearing• high performance gloss finish• Applications

– Company report , brochures, catalogs, book jacket covers, magazines, folders and point-of-sale displays

Matt Lamination (Cartons)• Offers

– sophisticated non-reflective silky image to premium printed items such as annual reports

– suited to surfaces which need to be easily read such as wall maps

– prone to scuffing and should be handled with care.

Lamination Applications

Lamination Applications

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