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AD*STAR® Handbook
Appendix B
Film laminated AD*STAR® bags
Copyright
Drawings, installation plans and operating instructions as well as
designs, catalogues, brochures, diagrams etc. are the intellectual
property of STARLINGER. Duplication, reproduction, dissemination and
distribution to third parties are prohibited. Moreover, they must not be
used to produce or have produced machines or machine components.
Great care was taken in the creation of this documentation. However,
Starlinger reserves the right to make changes and improvements to
the documentation.
Intruduction .......................................................................................... 4
1 mode of operation.............................................................................. 6
1.1 Flat wPP laminated with flat film .................................................... 6
1.1.1 Pros & Cons ......................................................................... 6
1.1.2 Specification and quality requirements wPP: ............................. 6
1.1.3 Specification and quality requirements flat film: ........................ 7
1.1.4 Film and print position setup .................................................. 8
1.2 Circular wPP laminated with flat film .............................................. 9
1.2.1 Pros & Cons ......................................................................... 9
1.2.2 Specification and quality requirements wPP: ........................... 10
1.2.3 Specification and quality requirements flat film: ...................... 10
1.2.4 Film and print position setup ................................................ 11
1.3 Circular wPP laminated with two flat films ..................................... 13
1.3.1 Pros & Cons: ...................................................................... 13
1.3.2 Specification and quality requirements wPP: ........................... 13
1.3.3 Specification and quality requirements flat film: ...................... 14
2 Lamination process .......................................................................... 15
2.1 lamination without co-extruder and without special ink tie layer ...... 15
2.1.1 layer structure .................................................................... 15
2.1.2 Pros & Cons: ...................................................................... 16
2.1.3 Raw material specification and mixing ratio ............................ 16
2.2 Lamination with co-extruder and ink tie layer................................ 19
2.2.1 Layer structure ................................................................... 19
2.2.2 Pros & Cons ....................................................................... 19
2.2.3 Raw material specification and mixing ratio ............................ 19
3 lamination of ad*star® patches ......................................................... 23
3.1 Lamination of patches without ink tie layer ................................... 23
3.2 Lamination of patches with ink tie layer........................................ 23
4 settings .......................................................................................... 26
5 Ad*star® quality ............................................................................. 27
5.1 Quality standards ...................................................................... 28
5.2 General advice, testing frequency ................................................ 30
5.2.1 Raw material ...................................................................... 30
5.2.2 Printed, laminated fabric ...................................................... 30
5.2.3 Converted bag .................................................................... 30
INTRODUCTION
Dear Customer,
premium appearance
higher bag stiffness
ability for full surface printing
scratch-resistant printing (in case of reverse printed film)
improved WVTR (moisture barrier)
wide range of surface CoF values
The following chapters will provide you with an insight on required raw
materials, processing guidelines, limitations, quality requirements and
useful hints.
General warning
Important information
The diagrams are example images, which may deviate from your
project slightly, depending on the particular application.
Safety regulations and safety instructions from the operation manual /
documentation must be followed without exception!
1 MODE OF OPERATION
advantage disadvantage
image 1
Winder setup:
image 2
image 3
image 4
Winder setup:
image 5
image 6
Table 8
2 LAMINATION PROCESS
Table 11
Appendix B 08/2019 PAGE 15 / 30
original document
2.Lamination process
***
lyondellbasell Adflex Z101H 27 https://www.lyondellbasell.com/
***
ExxonMobil Vistamaxx 3980 FL 8 vistamaxxelastomers.com
***
ExxonMobil Vistamaxx 3588 FL 8 vistamaxxelastomers.com
Table 12
Co-Extrusion
image 7
2.2.3 Raw material specification and mixing ratio tie layer for
woven fabric:
PP 85%
LDPE 15%
***
lyondellbasell Adflex Z101H 27 https://www.lyondellbasell.com/
***
ExxonMobil Vistamaxx 3980 FL 8 vistamaxxelastomers.com
***
ExxonMobil Vistamaxx 3588 FL 8 vistamaxxelastomers.com
Table 15
Table 17
image 8
image 9
image 10
4 SETTINGS
5 AD*STAR® QUALITY
Printed fabric:
repeat length tolerance ±1mm
fabric core (inside 203mm/8” (preferably on plastic cores – no
diameter) cardboard cores)
print design of main no print 50mm in front of the printing mark
fabric print mark width min. 10mm, length 30-50mm
print design of patch no print 50mm in front of the printing mark
material print mark width min. 6mm, length 30-50mm
finished roll diameter min. 1200mm; max. 1500mm
(main fabric)
finished roll diameter min. 800mm; max. 1000mm
(bottom and valve
patches)
roll quality hard, without longitudinal or crosswise folds, no
telescopic shape, straight edge, uniform diameter
max. edge displacement 50mm (due to traverse motion unit, depending on
(main fabric) machine speed and cutting length)
Table 20
Finished bags:
strength of welding Strip test related to EN ISO 13934 and according to
STARLINGER standard.
The tensile strength of the outer strip (front and
rear triangle) must not fall below 65% of the tensile
strength of the non-welded fabric in warp direction.
The individual tensile strength of the centre strips
(without front and rear triangle) must not fall below
75% of the tensile strength of the non-welded
fabric in warp direction.
elongation bottom min. 10% – recommended 12% Fmax
(strips)
fabric overlap 20mm (10mm on each bottom side)
(beneath the welded
bottom patches)
bottom width ±3mm
tolerance
length tolerance of the ±5mm
bag
air permeability/ According to filling station, in average 10-100m3/h
perforation for powdery goods. (testing pressure 50 mbar)
The perforation may reduce fabric strength and
elongation between 5% - 40%, according to the
needle density, the penetration intensity and the
condition of needle sleeves and counter roller,
therefore, regular maintenance is essential.
drop test minimum requirements:
(Starlinger recommendation)
Flat: min. 1,8m
Lateral : min. 1,4m
Upright: min. 1,2m
(The drop test height may vary due to filling
General:
production ´AD*STAR® handbook´ and ´report of laboratory
findings´ are the guiding documents and support for
the production
faults Weaving, coating and printing faults should be marked
on one side of the rolls with coloured tape (suitable for
the customer’s recycling machinery)
fabric Joining of two rolls by taping fabric ends is not allowed
and may create problems for the effective running of
the conversion line
Table 22