3) Do not ship lamination before cure completed in winter months if at all possible. These problems were generally associated with variations in the ambient moisture content. In addition, grounding all plant machinery and related equipment is most important. A milky, hazy line about an inch wide appears periodically across the width of the web immediately after initial warm-up. In this process, the bonding agent is hot and in a melted form, which is applied to one substrate. Learn more in our Cookie Policy. Solventless Laminating Machine is machine solution for taking place of Solvent Lamination machine to make laminated films in Pouch Making Industry. To insure proper cure : Solventless lamination: where the adhesives used do not contain solvents. It may go unseen over light areas of an image, but will be more obvious over dark or black areas. This process eliminates the risk of fire or explosion and ensures a safer work environment. Solventless lamination technology utilizes a computer controlled Meter, Mix, Dispense Unit (MMDU) that continuously measures a precise amount of each component, then mixes and dispenses small amounts of the solvent-free adhesive into the laminating equipment. High alcohol content from inks or alcohol contamination in solvents when using NCO containing adhesives. The film then can begin to wrap around the rear rolls. Bubbles are caused by a lot of problems: insufficient tension on the supply roll; feeding the leading edge of the print too quickly into the laminator; too much heat on a wet print, causing "outgassing" of the ink; the adhesive not bonding properly to the media, and others. General haziness or cloudiness in the film after lamination. 3) Insure adhesive is properly mixed by using correct mixing blade for container size, insure adequate vortex during mix and allow for proper mix time. The mixture goes into the gap between fixed & metering roller, and then coats on the film. The voids may be consistent in shapeor highly irregular. 2. Moreover, this procedure of combining films is known as lamination. It needs proper range. When lamination is begun, a pattern of repeated silvering can be seen each time the cool side of a roller is applied to the lamination. CAS > 200F. The temperature gets higher, faster and more completely the reaction will be. Film is not properly adhered or starts to come off sometime after lamination. When operating solventless lamination, several basic factors have great effect on the quality of flexible packaging products. Compared with dry lamination, solventless lamination reduced electrical energy consumption and CO2 emissions by 74.1% and 86.37%, respectively, and the unique adhesive reducing VOC emissions by more than 94.5%. At this time, it appears as a small and uniform spot in the entire composite film. By Brendan O'Neill November 1, 2008 Once a fringe player, solventless adhesives have become a workhorse in the laminating industry. We utilize cookies to understand how you use this site and to improve your browsing experience. Different kinds of adhesives cost different time in stage I. If there is an ink bleeding problem, work with both the ink and adhesive suppliers to resolve the problem. The reaction between A&B components increases the viscosity, while the rise of temperature decreases the viscosity. 6. Moreover, using solventless adhesives means there is no solvent and no risks of emissions. Plastic film high speed solventless lamination machine is based on the characteristics of the solvent-free laminating process itself, especially the problems such as . Poor Coating Performance 1. Solvent less lamination is suitable for ready to eat Extrusion lamination is used for all bulk products packaging which require more In all type of laminated woven BOPP bags we will use. Silvering is caused by the capture of tiny bubbles of air, which look like hazy or reflective areas in the lamination. Meanwhile, comparing with Solvent lamination, Solventless PU lamination technology possesses the advantages of less coating amount, lower energy consuming and faster laminating speed, as well as higher production efficiency, etc. The increased viscosity reduces the cure time to 12-24 hours before slitting. This isa problem mostly associated with solventless adhesives which have littel cohesive strength until cure initiates. 1) Follow cure guidelines on TDS for length of time needed to further process lamination 5. Edges of the print are no longer crisp and show outward movement into the non print area. J Clean Prod 131:2842, Shen L, Wang YY (2018) Supervision mechanism for pollution behavior of Chinese enterprises based on haze governance. Under the suggested conditions, laminating film. This means that solventless adhesive flexible packaging film is suitable for products like the following. For instance, these are great to lower coat weight. Sometimes problems come up. In fact, the flexible packaging market is the only packaging segment . 2. Tunneling is a phenomenon in which narrow tunnels or pipes form within the laminate layer. Solventless PU Lamination Adhesive, which has no solvent during production, is a kind of green adhesive. Our tests show that, 45~55 will be better for laminating roller. By continuing to use this site you are giving us your consent to use cookies in accordance with our privacy policy. 3. 4.The pressure of the composite portion of the glue portion is not properly set. This work is supported by the National key R&D Project (No.2016YFC0204200), the research fund from Beijing Municipal Committee of Education(No. Its benefits also include that it runs at high speed using less energy. However, web can be clear and still have too much water retention. Clean. 4) Metalization Due to the low molecular weight of the solvent-free adhesive and the extremely strong penetration, the problems of adopting solventless lamination for some products will occur, which requires special attention. So the requirements of the solventless lamination process for water vapor are particularly strict. Solventless lamination: where the adhesives used do not contain solvents. Different film structure also requires different coating amount. Here are some of the pros and cons of using solventless lamination in the packaging printing industry: In conclusion, solventless lamination offers many advantages in terms of environmental benefits, safety, cost-effectiveness, and improved quality. Don't see what you are looking for? Wax Lamination J. All Rights Reserved. If the defect is adhesive residues, simply clean the rolls. In 2012, Steve was one of the founding partners in LuxeFilms Group, which brings new and innovative thermal film technology to the packaging world, coordinating brand owners, packaging designers, and print manufacturers to bring new films and client-grabbing design elements to the retail shelf. Cost-Effective: Solventless lamination is a cost-effective alternative to solvent-based lamination. Because the reaction starts immediately when A&B components get mixed, the solventless adhesive should be employed instantly. Nowadays, each flexible packaging company has its own unique product and technical characteristics. 3. Boat wake is an undesirable ripple pattern in a V shape on a finished print. Using a nip roll that is too soft, creating a footprint creater then .5" and/or not enough nip pressure on nip roll can cause inadequate wetting of secondary web to primary web causing voids. Turbulance in pan due to recirculate pump running at too fast a rate can also cause this. Use of fresh pretreated films is desirable. Its benefits also include that it runs at high speed using less energy. Tests show that, when the viscosity of adhesive and electric current of the machine are too strong, the equipment shakes heavily, which has huge damage to the machine and quality of products. Smarter plastics manufacturing starts with I.O.T., Industry 4.0 & Digital Transformation. Find out the quality problems in time to reduce the lot loss Early detection of quality problems will reduce material loss and customer returns MINIMIZE QUALITY PROBLEMS Inspect if any factors causing defects: 1. With less gluing, the coating weight of solvent-free lamination unit area adhesive is two-fifths of the coating weight of dry laminating unit area adhesive. In earlier stage, the decrease takes control (stage I), while in later stage, the increase takes control (stage II). 3. 2) Do not store adhesive laminate below 60F if possible during cure cycle. Often seen forming in the heat seal edge and working inward but can occur anywhere in package. 1. Take note that in traditional practices, solventless adhesives did not go well in things that contain foil. On one side, with temperature rising, adhesives absorb slipping agent more easily, making some agent invalid. Some flexible packaging producers like NJ-based LPS Industries have moved entirely to the use of a solventless lamination process. The International Journal of Life Cycle Assessment, https://doi.org/10.1007/s11367-021-01883-4, access via There is no doubt that flexible packaging has become the need of the time. That is why solventless adhesives have become a crucial part of the laminating industry in a short time. 2) Slow feed pump to prevent surging into pan. While water-based systems have been developed as an economic alternative to overcome some of the drawbacks associated with solvent, in practice the performance of water-based adhesives, especially in wet environments, is not as good as their solvent counterparts. These heat wrinkles are caused by excess temperature and/or speed for the film being used. The adhesive of a solvent-free lamination is 100% glue, which does not contain any solvent, thus, in the production process, except that during the time of shutdown, there is a need to clean the gluing portion with a small amount of solvent, there are no emissions of solvent, VOCs and other pollutants, which will not produce pollution for the health and surrounding environment of the production worker. If you need to learn more aboutlaminated film packaging,or need advice regarding placing an order or getting a price quotation, please call now+84 966 290 555for the best support. As theres no waste generated, there is no need to configure expensive environmental equipment and corresponding operating expenses. Components of ink systems including glycols can be re-softened by some 100% solids adhesives, resulting in bleeding. Experiments show that, few coating amount contributes to low strength of clean film, uneven coating and white dots of polychrome printing film. Certain materials may not be compatible with solventless lamination, limiting its availability. The A component of the two-component solventless adhesive is easy to react with the water, affecting the adhesive ratio, thereby affecting the laminating quality of the product. Low nip pressure causes inadequate adhesive wetting of secondary substrate leading to voids which can create a hazy appearance. Packaging Engineering 39(9):4450 ((in Chinese)), Han D, Gao S, Fu QY, Cheng JP et al (2018) Do volatile organic compounds (VOCs) emitted from petrochemical industries affect regional PM 2.5. If adhesive is mixed improperly foam can be generated which will then applied to primary web. E-footprint software and databases were used to assess environmental impacts based on the ISO 14040 standards. Some orange peel may occur when laminating prints with a lot of solvent residues or oil-based prints. J Chromatogr A 5:869879, Ding YH, Wu P, Liu YJ, Song YF (2017) Environmental and dynamic conditions for the occurrence of persistent haze events in North China. Copyright. The Importance of Quality Control Testing, FDA Regulation 21 CFR177.1395,FDA Regulation 21 CFR175.300,FDA Regulation 21 CFR175.105,FDA Regulation 21 CFR177.1390, Food,Home & Personal Care,Medical & Pharmaceutical, Retort Pouches,Hot Fill Pouches,Outdoor Bags,Microwave Packaging, Fast Run Speed,UV Resistance,Good Clarity,Moisture Resistance,High Heat Resistance,Adhesion to Foil and Metallized Films,High Chemical Resistance,Low Odor, 100:60 with C-411, 100:100 with C-117, 100:100 with C-132-2, Stand-Up Pouches,Coffee Bags and Pouches,Snack Food Packaging,Frozen Food Packaging,Confectionary Packaging,Condiment Packaging, Adhesion to high slip films,High Heat Resistance,Low Nip Temperature,Adhesion to Foil and Metallized Films,High Chemical Resistance, 100:33 with C-145, 100:63 with C-132-2, 100:40 with C-411, Stand-Up Pouches,Large Format Bags,Snack Food Packaging,Frozen Food Packaging,Confectionary Packaging, Fast Run Speed,Adhesion to high slip films,Easy Clean-up,Low Nip Temperature,Adhesion to Foil and Metallized Films,Fast Bond Development,Fast Slitting Time, Bottle Labels,Large Format Bags,Meat and Cheese Packaging,Snack Food Packaging,Confectionary Packaging,Fresh Produce Packaging, Fast Run Speed,Adhesion to high slip films,Good Clarity,Easy Clean-up, Bottle Labels,Meat and Cheese Packaging,Snack Food Packaging,Confectionary Packaging,Shrink Labels,Condiment Packaging, Fast Run Speed,Adhesion to high slip films,Good Clarity,Adhesion to Foil and Metallized Films,Fast Bond Development,Fast Slitting Time,Low Odor, FDA Regulation 21 CFR177.1395,FDA Regulation 21 CFR175.105, Stand-Up Pouches,Hot Fill Pouches,Snack Food Packaging,Frozen Food Packaging,Confectionary Packaging,Condiment Packaging,Microwave Packaging,Fresh Produce Packaging, Fast Run Speed,Adhesion to high slip films,Moisture Resistance,Easy Clean-up,High Heat Resistance,Low Nip Temperature,Adhesion to Foil and Metallized Films,High Chemical Resistance,Fast Bond Development,Fast Slitting Time, CR 85 100:50, CR 89 100:60, CR 88-141 100:65, Food,Home & Personal Care,Medical & Pharmaceutical,Industrial, Stand-Up Pouches,Bottle Labels,Coffee Bags and Pouches,Large Format Bags,Hot Fill Pouches,Meat and Cheese Packaging,Snack Food Packaging,Frozen Food Packaging,Confectionary Packaging,Medical and Pharmaceutical Packaging,Condiment Packaging,Portion Packs,Microwave Packaging,Fresh Produce Packaging,General Industrial, Fast Run Speed,Adhesion to high slip films,Good Clarity,Moisture Resistance,Easy Clean-up,High Heat Resistance,Low Nip Temperature,High Running Solids,Adhesion to Foil and Metallized Films,High Chemical Resistance,Fast Bond Development,Fast Slitting Time,Low Odor, 100:60 (pbw with CR-201), 100:45 (pbw with CR-202). Use correct diameter blade to create vortex but not create foaming. It can be judged by measuring the spacing of the two spots to find that which rolls have foreign matter and clean up. Atmos Environ 98:168178, Garciaceballos L, de AndresDaz JR, Contreraslopez MA (2018) Life cycle study of different constructive solutions for building enclosures. Moreover, using solventless adhesives means there is no solvent and no risks of emissions. Reduction in heats resistance can effect ability to be heat sealed or withstand external heat source in package. Solventless lamination technology adopts a solvent-free adhesive instead of solvent-based adhesive, which can avoid VOCs emissions from the source. As is shown in Pic 3, the friction coefficients have great differences between the circumstances of 25 and 35 curing. Reverse boat wake can be caused when too much pressure is applied to the sides of the roller, forcing the middle up and causing the film to drag behind the film on the sides. Always use the appropriate pressure. Trademark of The Dow Chemical Company("Dow") or an affiliated company of Dow. Slower Production: Solventless lamination can be slower than solvent-based lamination. Wrinkling of the material as it goes into the laminating rollers. CO2 generated in curing cannot form in a film which has a good barrier property, mainly due to the use of a single-component solventless. On the other hand, the footprint is also minor in comparison to a solvent-based laminator. Trademark of The Dow Chemical Company("Dow") or an affiliated company of Dow. Bonding problems also can be caused by inadequate heat, inadequate or uneven pressure or too much speed. Print curl happens when one side of an encapsulated image changes size out of proportion to the other side, causing the print to curl towards the smaller side.
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