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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