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 • Material Properties
• Foil – Moisture Absorption
• Textile – Compatibility with
– Mechanical Properties adhesive
• Tensile – Surface Properties
• Elongation • Surface Energy
– Thickness • Surface Treatment
– Elongational Property – Thermal Properties
– Machinability • 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 • Foils
– LLDPE
• Papers
– Coextr.
• Textile
– BOPP
– PVC
– PC
– Nylon
– PVDC
– PET
– Ionomer
– Metallised
 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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