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

Material Properties
Moisture Absorption Compatibility with adhesive Surface Properties
Surface Energy Surface Treatment

Mechanical Properties
Tensile Elongation

Thickness Elongational Property Machinability

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 Lamination 2. Hot-melt Lamination 3. Non-solvent Lamination 4. Wet Lamination 5. Dry Lamination 6. Extrusion Coating / Lamination 7. 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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