Lamination Presentation

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 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.

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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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