solventless lamination problems
150-180F is normal; however, some high performance adhesives with high molecular weight can require nip temperature Moreover, using solventless adhesives means there is no solvent and no risks of emissions. 5. But at the same time, there are different technologies used to manufacture the finished film used to make the packaging and brand owners should be aware of what they are and how they may impact a product. Turbulance in pan due to recirculate pump running at too fast a rate can also cause this. Save my name, email, and website in this browser for the next time I comment. Environ Int 71:118138, Latif MT, Othman M, Idris N, Juneng L, Abdullah AM, Hamzah WP et al (2018) Impact of regional haze towards air quality in Malaysia: a review. J. Improved Safety: Solventless lamination reduces the risks associated with the use of solvents. Inadequate pressure can cause silvering if the film isnt pressed onto the image hard enough, preventing the adhesive from properly bonding. Moreover, using solventless adhesives means there is no solvent and no risks of emissions. Solventless adhesive generally indicates a specific type of adhesive composed of two components reacting with each other and consequently not requiring drying. Reduction in heats resistance can effect ability to be heat sealed or withstand external heat source in package. This means that solventless adhesive flexible packaging film is suitable for products like the following. If practiced at 10, A component has a viscosity of 9100 mPa.S, and B has 2000 mPa.S. A little bit of this is normal, but if the print doesnt lay flat after some gentle smoothing, it is a problem. There is no doubt that flexible packaging has become the need of the time. The adhesive can only reduce this movement slightly(thus causing laminate curl) this will result in tunneling in lamination. The higher the temperature is, the faster the reaction will be. MACtac offers a wide array of products used in various fields, including graphics and decoration, the self-adhesive label industry and fixing and mounting solutions in several industries. Rotating speed ratio is the speed ratio of different rollers in coating system of solventless lamination machine. All Rights Reserved. Ecotoxicol Environ Saf 160:301307, Huang B, Lei C, Wei C, Zeng G (2014) Chlorinated volatile organic compounds (Cl-VOCs) in environment - sources, potential human health impacts, and current remediation technologies. Cool spots are areas that arent hot enough to melt the adhesive. Confirm via FTIR Mix adhesive for five minutes minimum on any two part system. 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. The solventless laminating machine has high speed and the production cost can be lowered. 1. Nowadays, each flexible packaging company has its own unique product and technical characteristics. Haze in a lamination is a reduction in clarity of the film or adhesive most pronounced in window areas of the package or lamianted film. 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. Platform scales are not accurate enough for small amounts of coreactant. Laminate Trouble Shooting Guide - Nobelus University In this situation, the laminating rollers should be replaced. Wrinkling of the material as it goes into the laminating rollers. Article Analysis And Solve The Undesirable Phenomenon In Solventless Composite 2021-04-13 Here, we give a detailed analysis of the undesirable phenomenon in the solventless composite and solventless laminating machine, such as the uniform winding, poor coating effect, etc and how to solve the problems. A hot room can be used to accelerate cure often set at 115F Make sure the leading edge of the item being laminated is laying flat and is inserted parallel to the laminating rollers. Low bonds caused by poorly cured adhesive should be corrected in the following manner: Often 30-40 psi on nip roller recommneded but foot print of .5 inches should not be exceeded. Practical test shows that, the leveling property gradually become low when the viscosity gets high. This generation of adhesive is made from a process that removes nearly all of the excess isocyanate monomer from the prepolymer. Slower Production: Solventless lamination can be slower than solvent-based lamination. Environmental pollution is a growing problem in developing countries, including China. The resulting, The solventless adhesive is used in a wide array of packaging applications as it is a high-quality laminating adhesive. Your email address will not be published. For additional information on laminating and MACtac, contact Helene Gobry at hgobry@mactac.com or visit www.mactac.com. Low adhesive coating weight can result in poor wetting of secondary web due to insufficient adhesive to adequately flow and level creating voids which create a hazy appearance in lamination. 1. 4.The pressure of the composite portion of the glue portion is not properly set. As the image cools, the bottom film will tighten up a little more than the top film since it was stretched farther, causing the image to curl towards the back. The simulation results are analyzed . Flexible packages made with Dow's MOR-FREEand PACACELsolventless laminating adhesives are used in an array of packaging applications for food and beverages and meet a broad range of FDA regulations. The solvent is not used when it comes to producing adhesive substance. The packaging-printing industry is considered as one of the main contributors to air pollution in China. Q&A: Common Issues in Laminating PostPress https://doi.org/10.1007/s11367-021-01883-4, DOI: https://doi.org/10.1007/s11367-021-01883-4. Product Selector - Dow Laminating Adhesive Products The max speed of lamination machine concerns with itself, as well as properties of material films and viscosity of adhesives. Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations. Film lamination represents a critical proportion of flexible packaging products. This work is supported by the National key R&D Project (No.2016YFC0204200), the research fund from Beijing Municipal Committee of Education(No. your institution. Analysis Of Packaging Coefficient Friction And Anti-Block Problems In Sci Total Environ 626:11671174, Geueke B, Groh K, Muncke J (2018) Food packaging in the circular economy: overview of chemical safety aspects for commonly used materials. Dry lamination in the production of laminated film packaging, the plastic and complex film packaging industry, Hazard Analysis and Critical Control Point (HACCP) Codex Alimentarius, Food Safety System Certification (FSSC) 22000, The interesting things about laminated film packaging, RECRUITMENT: PLASTIC PACKAGING INDUSTRY PRODUCTION MANAGER, Laminated film packaging for fresh noodles / squeezed noodles / egg noodles. If there is an ink bleeding problem, work with both the ink and adhesive suppliers to resolve the problem. PDF Packaging lamination redefined in 90 minutes SYMBIEX Solventless 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. This contributes to rapid improvement of peel strength. Part of Springer Nature. To prevent this, make sure the pressure is at the proper ration of speed for the pull and front rolls. 3. On the other side, some slipping agent with low melting point become adhesion, making itself invalid. Adjust tension and taper on rewind to prevent the adhesive from moving cohesively until adhesive is cured. However, after significant improvement in this context, they have now made their way into applications that have foil in them including high-barrier films and high-slip films. It is important to adjust web tensions so that each film elongates roughly the same amount through process. Finite volume method is applied to solve an engineering problem in solventless laminating, in another word, mixing result. The resulting laminated film is then rewound into a finished roll. The increased viscosity reduces the cure time to 12-24 hours before slitting. 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. When using a single-component adhesive, the humidification moisture content is insufficient. New trends of solvent-free laminating technology on - LinkedIn Heat But at the same time, there are, different technologies used to manufacture the finished film, In current times, solventless adhesives are used virtually in many applications. Previously, these adhesives were used in certain applications only, such as snack foods, bottle labels, and candy bar wrappers. 1. 3) Insure only urethane grade solvent are used for diluting adhesive's when dilution required 5. However, web can be clear and still have too much water retention. The cloudiness is a function of incomplete adhesion. You can update your choices at any time in your settings. There also must be free air space under the material to be neutralized, directly under or over the spot where the tinsel is placed. The flatness of the squeeze roll in the rewinding is poor. If you are running thicker films you may have the problem if you try to go too fast. The reaction between A&B components increases the viscosity, while the rise of temperature decreases the viscosity. Smarter plastics manufacturing starts with I.O.T., Industry 4.0 & Digital Transformation. At 25, the viscosity of component A is 2200 mPa.S, while at 10, it rises to 9100 mPa.S, and drops to 710 mPa.S at 40 . 3 Reasons Why Going Solvent-Free Improves Sustainability Plastic film high speed solventless lamination machine is a product researched and developed by our company combined with the gradually matured solvent-free laminating technology. Poor solubility of the ink and the adhesive, such as using polyamide ink. So the requirements of the solventless lamination process for water vapor are particularly strict. Currently, there are many film lamination technologies applied in products such as wet lamination, dry lamination, and especially solventless lamination. Treating to achieve a dyne/cm reading of 36 dyne/cmfor solvent based adhesive's and ideally 40 dyne/cmfor solventless and waterbased is recommended. Manydual component urethane adhesives give off some level of CO2 during cure, barrier to barrier laminations do not allow release of this CO2 causing bubbles gas to be trsapped creating bubbles, Some adhesives will work in this application depending on end use. Solventless lamination attracts more and more attention in many fields including flexible packaging, textile, leather and etc. For one hand, when A&B component get mixed, the sol-gel reaction get start, making the viscosity go up. The other likely cause of this symptom is worn rollers. Below are several common issues and suggested solutions. The LCA results showed that the environment impact of solventless lamination was markedly smaller than that of traditional dry lamination, with critical differences reflected in power consumption and adhesive type. WRJSi9 On June 8, 2021, Sinstar has launched a new product - three-layer solventless laminator and machine model is WRJSi9. I some cases the voids may look like haze without proper magnification. Copyright. your institution, https://doi.org/10.1080/1073161X.1994.104672901994, https://doi.org/10.1007/s11367-019-01716-5. Therefore, each product is recommended to have a sample test before first adopting solventless lamination technology and then put into mass production after the test is passed. Make sure inks you use are laminating grade for NCO curing adhesive. If done properly, the tinsel will reduce static electricity on both sides of the static-laden material. This laminating method is subject to certain restrictions in dry winter and should be paid attention to. Mechanical brake adjustment error of transfer roller. The process requires more time to cure, resulting in a slower production rate. They can also be caused by too little tension and uneven pressure. Hi, let us know if you have any product questions as you visit our website. Read more: Dry lamination in the production of laminated film packaging. This may include: Solventless Laminator | Lida Machinery is a Supplier in China Solventless laminating adhesives are applied to base substrates like films or foils using solventless laminators that can coat the adhesive viasmooth roll transfer coating techniques. 6. Plus, there is no need to use ovens as well. 2) Insure balances used to weigh components are accurate for weights being usedand properly calibrated As showed in Pic 1, the viscosity clearly goes down when the temperature gets high. Speed Ripples occur when too much pressure is exerted on the item when it goes through the rolls on the way out of the laminator while the film is still hot. 2. If the defect is adhesive residues, simply clean the rolls. 2. MACtac is a global company that always has been driven by innovation, discovering future customer needs and developing new products. 4. 2023 Springer Nature Switzerland AG. The International Journal of Life Cycle Assessment, https://doi.org/10.1007/s11367-021-01883-4, access via This process requires specialized equipment and may require modifications to existing equipment. As well known by the globe, solventless PU lamination is an Environmental Friendly lamination technology. Finally, the various functions of products will be affected. It can be judged by measuring the spacing of the two spots to find that which rolls have foreign matter and clean up. Mix only long enough to incorporate both components do not overmix, Fish eyes are visible defects in the laminated webs that looksimilar to acrater. Heat "Hot spots" are a key problem when laminating inkjet prints. Here, we give a detailed analysis of the undesirable phenomenon in the solventless composite and solventless laminating machine, such as the uniform winding, poor coating effect, etc and how to solve the problems. 3) Insure dyne level on primary web is high enough to accept adhesive and allow proper flow and wetting. LinkedIn and 3rd parties use essential and non-essential cookies to provide, secure, analyze and improve our Services, and (except on the iOS app) to show you relevant ads (including professional and job ads) on and off LinkedIn. Transfer roller is attached with foreign matter or scars and should be scrapped with bamboo pieces. J Food Eng 147:3948, Pommier R, Grimaud G, Prinaud M, Perry N (2016) LCA (life cycle assessment) of EVP engineering veneer product: plywood glued using a vacuum moulding technology from green veneers. Edges of the print are no longer crisp and show outward movement into the non print area. To prevent wrap around, laminate all documents using a continuous feed as the weight will hold the laminations away from the rear rolls or leave a few inches of extra film as the weight will not allow the static to pull the film back into the rolls. Poor ink adhesion-additives such as anti-blocks, glycols, and other OH additives can adversely affect adhesion of sensitive NCO terminated adhesives. Tinsel with a string (non-conductive) core will not function properly. Form 1 Coating Amount of different Lamination Structure. The moisture content of the printed substrates must be the lowest. Bubbles in the center of the web and/or film not sticking to the center of an item. Roll VS. Shoe Laminators The Pros & The Cons, Sleeking & Stamping VS Traditional Foil Stamping, Tips From A Service Tech Cleaning Your Laminator Rollers, How to Enter a New Flexible Packaging Market Segment. Solventless Lamination Machine - AB PLAS MACHINE SOLUTIONS The viscosity of mixture of A&B component has great effect on the appearance of the lamination products. 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. This process eliminates the need for solvents, reducing the cost of raw materials, and the cost of waste disposal. The film then can begin to wrap around the rear rolls. High alcohol content from inks or alcohol contamination in solvents when using NCO containing adhesives. Also, opting for solventless adhesive needs two or more substrates, which react during this lamination process and there is no need for any drying component. No combustible, explosive organic solvents in solventless laminating technology, there will be good safety. J Clean Prod 183:10431053, Zhao ZT, Liu Y, Wang F, Li XK, Deng SP et al (2017) Life cycle assessment of primary energy demand and greenhouse gas (GHG) emissions of four propylene production pathways in China. If you have any problems when conducting production, we can provide a series of solution for you. Coim's Dave Engel discusses how this happened and why solventless is such an attractive alternative to solvent-based adhesives. 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. 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. 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. All Rights Reserved. The two-part polyurethane laminating adhesives require a mixing and metering unit since pot life is limited. 2) Run ink smear testing on fully dried inks with chosed solventless system, work with adhesive supplier on running this compatibility test. This article focuses on two common processes used to bond the different film substrates to create the finished packaging material, one using a solvent-based adhesive and one using solventless adhesive. Flexible packaging film is mainly applicable to consumable goods that need an extended shelf-life. If adhesive is mixed improperly foam can be generated which will then applied to primary web. While this is by no means a complete list of the available technologies and products, it does provide the converter a starting point for product development. Flexible packaging produced using a solventless lamination process can enhance the organoleptic appeal of a product in an environmentally responsible fashion. Office Tower:25 Ngo Quyen Street, Ward 10, District 5, Ho Chi Minh City, Your email address will not be published. Engineering 3:266271, Dumanoglu Y, Kara M, Altiok H, Odabasi M, Elbir T, Bayram A (2014) Spatial and seasonal variation and source apportionment of volatile organic compounds (VOCs) in a heavily industrialized region. Wavy or rippled sections in the laminate, especially toward the center or the web. The first solventless laminating adhesives were primarily moisture-cured polyurethanes. Be sure to pay attention to any defect which repeats. When two webs are pulled though machine at mismatched elongations theywill return to normal state once tension is relieved. Telescoping is a phenomenon seen on the rewound laminated roll in which there is horizontal movement of the layers leading to uneven ends or roll. High residual monomers and low initial bond strengths somewhat limit the, Being a close partner of many large companies and large enterprises, The production environment is safe for humans and the environment, It has been assessed and certified to meet the requirements of. All Rights Reserved, LPS Industries | Terms & Conditions | Privacy Policy | Atlanta SEO - SocialSEO, Over the past decade, more and more companies have abandoned rigid packaging for consumer goods and instead, adopted, And, the final composition is always according to the requirement of brand owners and the nature of their products. As theres no waste generated, there is no need to configure expensive environmental equipment and corresponding operating expenses. Solventless adhesives come with a variety of benefits. Previously, these adhesives were used in certain applications only, such as snack foods, bottle labels, and candy bar wrappers. https://doi.org/10.1007/s11367-019-01716-5, Book For another hand, when the temperature rises, the viscosity of adhesives will have a trend to drop. J Clean Prod 193:491505, Guo PF, Fu YB, He HW, Zuo JJ, Zhao YZ, Xu WC (2018) Research progress of solvent-free laminating technology of flexible package. 3) Do not ship lamination before cure completed in winter months if at all possible. Environmental Benefits: Solventless lamination eliminates the need for solvents, which are harmful to the environment. Characteristic Research of Static Mixer Used in Solventless Laminator The mixture will have 6000mPa.S, which wont reach an expected performance. and why this method is popular in the market, please refer to the detailed content of this article. The more and more laminating machine adopts the solvent-free laminate process, which can avid the emissions of VOCs with the advantages of healthy, safety, low energy consumption, saving resources and production cost. Secondly, the tinsel must be well grounded electrically, stretched tight and placed of an inch from the material to be neutralized. At this point, the coating unit should be downtown, or the transfer roller is changed, and the blanket is eliminated. Solventless film lamination method in the production of laminated film The poor finish of the glue pressure roller, the transfer roller, or the composite roller. With locations across the country, from California to New Jersey, LPS Industries provides high-quality products and services to a variety of customers and market segments. Coated substratesare subsequently nipped and bonded to a secondary substrate to make the lamination. A dirty bar will not smooth adhesive uniformly and in some cases make the lamination look worse. By being diligent in recording and monitoring tests for each laminated structure many potential laminate problems can be averted. It is a machining method which adopts a solvent-free adhesive to make the membrane substrate such as plastic film or other film-shaped material laminate each other, through the curing process which is a chemical reaction of the adhesive, making each layer of substrate firmly bonded together, thus, multi-layer composite films are obtained.