3. • Laminating is the process in which two or more flexible packaging
webs are joined together using a bonding agent. These webs are
comprised of films, papers or aluminum foils.
• Lamination is the technique of manufacturing a material in multiple
layers, so that the composite material achieves improved strength,
stability, sound insulation, appearance or other properties.
• flexible packaging films and laminates create a layer of insulation
that protects products when packaged.
• Today in printing packaging many verity laminates are used because
they are more durable, and good strength, good printability, and
they maintain the quality and freshness of food, and also protect
food from oxygen, moisture etc.
INTRODUCTION
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4. TYPES OF LAMINATES
There are the following different type of Laminates:-
• Matt Laminate
• Gloss Laminate
• Velvet Laminate
• Anti-Scuff Matt Laminates
• Metalized Film Laminates
5. TYPES OF LAMINATES
Matt Laminate
Matt Laminate having less reflection then
gloss and produce more natural look and
resulting overall softer look. and Scratch
and Scuff are more readily absorbed by
Matte Lamination.
Gloss Laminate
Gloss is visually stunning . The reflective
finish grabs attention and implies a richer
look. It is durable because it repels dust and
dirt but scratches and scuff’s are more
visible on high gloss surface.
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6. Velvet Laminate
It is very unique and is not being
used commonly within the industry
yet. This finish is more expensive
than Matt Laminate, but it really
put your print on the next level
Anti Scuff Matt Laminate
It is scratch and scuff resistance and
having good appearance.
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TYPES OF LAMINATES
7. Metalized Film Laminates
Metalized films are polymer films coated with a thin layer of metal,
usually aluminum. Metalized films are widely used for decorative
purposes and food packaging, and also for specialty applications
including insulation and electronics.
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TYPES OF LAMINATES
8. FUNCTIONS OF FLEXIBLE PACKAGING
LAMINATES
Flexible packaging laminates have three main functions:
Mechanical Properties:
– Improve the strength of the material by making it more resistant to
tearing
– Protect it during packaging, distribution and storage
Barrier Properties:
– Protect it from outside deteriorating agents (light, moisture, gas)
– Prevent loss of product qualities, such as freshness and aroma (food)
Substrate Sealability:
– Closes the flexible packaging
9. FLEXIBLE PACKAGING LAMINATE
APPLICATIONS
Applications for food products include:
• Ready-to-eat such as snacks, ice creams, coffee
• Freezer-to-microwave
• Boil-in-bag pouches (bags can be porous or perforated)
Applications for non-food products include:
• Insulation
• Medical
• Cosmetics
• Decorative laminates such as sunmica.
10. GENERAL LAMINATE FILM MATERIALS
Polyethylene PE
Low Density Polyethylene LDPE
Linear Low Density Polyethylene LLDPE
Medium Density Polyethylene MDPE
High Density Polyethylene HDPE
Polypropylene PP
Cast Polypropylene CPP
Oriented Polypropylene OPP
Metalized Polyester METPET
Metalized Oriented Polypropylene METOPP
Polyester PET
Nylon NYL
Paper Poly Foil Poly PPFP
Film Foil Laminations FFL
11. SOME LAMINATES FOR FOOD SECTOR
different laminates commonly used in the food sector for varied products
categories
these laminates can be compounded with different:
• Microns per layer
• Materials for the sealing layer (PE, Surlyn, Coex, etc.)
• Lamination methods (extrusion / with glue, with solvents / Wo solvents)
• Printing techniques (Rotogravure, Flexo, etc.)
For examples:-
1.For coffee pouches
• PET + AL + PE
• PAPER + AL +PE
• PET + MPET + PE
• PET + MOPP + PE
• OPP + AL + PE
12. 2. RICE + PASTA
• PE + PE
• PAPER + CPP
• OPP + CPP
• OPP + PE
• OPP
3.SNACKS + CHIPS
• OPP + OPP
• OPP + OPP barrier
• OPP + PE
• OPP +MPET + PE
• PAPER + MOPP + PE
• PAPER + MOPP
4. - BREAD + CAKES
• CPP bag
• OPP
• OPP treated
• OPP + MOPP
• PET + MOPP
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SOME LAMINATES FOR FOOD SECTOR
13. MANUFACTURING OF LAMINATES
Just as there are many different types of film materials, there are
various manufacturing processes and technologies. Each having its
own pros and cons, it is important to distinguish between them, and
know the impact that they will ultimately have on the film. With every
combination of resin type, and processing method, a unique set of
characteristics will be produced.
basic 3 process and technologies are:-
– blown film extrusion process
– cast film extrusion process
– Co-extrusion process
14. Blown film extrusion process
Blown film manufacturing involves using a jet of air to
blow the (melted) plastic polymer through a circular
blown film die. The melted plastic then forms a
continuous tube, which is inflated, flattened by
rollers, and cut to length—resulting in
double‐thickness film. Blown film is one of two main
processes that are used in the manufacture of film
products since it is efficient (little polymer is needed
to produce a lot of film) and used in a wide variety of
applications.
17. Cast film extrusion process
Cast film is manufactured by extruding the melted
polymer through a flat die or slot and forming a thin
sheet or film. After extrusion, it is attached to the
surface of a chilled (rotating) roller so that it is cooled
extremely fast. It is the surface of the rotating roller
that gives cast film its characteristic smooth and clear
appearance. While cast film can be produced at much
higher line speeds, there is higher waste along with
little orientation in the cross direction
20. Co-extrusion process
Barrier packaging would not be what it is today had it
not been for the discovery of the multilayer structure
(MLS). Prior to the development of co-extrusion
technology, multilayer films were produced by
laminating thin plastic layers together. While this
process of lamination worked, it was found to be slow
and not very efficient. Co-extrusion involves
combining two or more layers of melted plastic into a
single extruded web.
22. Co-extrusion provides the unique opportunity to combine
desired properties of various polymers to ultimately form one
material that would otherwise be impossible to achieve by
using a single polymer alone. Barrier packaging introduced
additional benefits to the flexible packaging industry and
since its premier in the packaging world; MLSs have been the
catalyst for numerous innovations to come.
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Co-extrusion process
24. PROPERTIES OF LAMINATES
A few of the key factors used to evaluate film properties are:-
• Thickness
• Stretch
• tear direction
• tensile strength
• appearance
25. MAJOR PROBLEMS DURING LAMINATE
MANUFACTURING
• Bubbling issues
• Wrinkling issues
• Orange peel issues
• Waving, blistering, dimpling issues due to moisture
• Waving, curling and other issues due to tension & pressure
• Static electricity issues
• Repeating marks issues
26. INNOVATIONS AND ADVANCEMENTS
Along with the continual development and demand
for new, different, and desirable characteristics and
properties of film types has come the creation of new
polymers to fill these needs
• Metalized Films
• Modified Atmosphere Packaging
• Active Packaging
• Edible and Soluble Films
