solventless lamination problems

However, after significant improvement in this context, they have now made their way into applications that have foil in them including. This process results in the laminated web which is rewound into the complete roll. Answer: Static electricity is an issue that may arise and is impossible to prevent. 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. The article introduces the common problems that occur in the solvent-free composite and the effective solutions. The properties and stability of solventless lamination on ultra-high temperature food packaging application still have some problems that need to be overcome in the future. Some flexible packaging producers like NJ-based LPS Industries have moved entirely to the use of a solventless lamination process. More information about laminating adhesive, please finds us in: This button displays the currently selected search type. Thinner film needs less tension, thicker film needs more. Make sure the leading edge of the item being laminated is laying flat and is inserted parallel to the laminating rollers. While too much coating amount contributes to adhesive flowing out, skewing rewinding and so on. Also, respect the laminating temperature of 40C to avoid wrinkling due to damp materials during the laminating process. The resulting, The solventless adhesive is used in a wide array of packaging applications as it is a high-quality laminating adhesive. Adjust tension and taper on rewind to prevent the adhesive from moving cohesively until adhesive is cured. Google Scholar, Almeida CMVB, Rodrigues AJM, Bonilla SH, Giannetti BF (2010) Emergy as a tool for ecodesign: evaluating materials selection for beverage packages in brazil. 2) Do not store adhesive laminate below 60F if possible during cure cycle. Over the past decade, more and more companies have abandoned rigid packaging for consumer goods and instead, adopted flexible packaging understanding that the attributes will benefit both the consumers and themselves as the brand owners. The utmost problem facing the laminating converter today is the manufacture of a quality high performance lamination in the face of today's environmental concerns. It should be cleaned every time the line stops. Make sure to work with a low temperature without exceeding 40-45C. 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. Solventless adhesive generally indicates a specific type of adhesive composed of two components reacting with each other and consequently not requiring drying. 3) Do not ship lamination before cure completed in winter months if at all possible. Thicker films may be run at lower speeds with no problem. The cooling performance of the back film roll which is from the composite roller, is poor. The two-part polyurethane laminating adhesives require a mixing and metering unit since pot life is limited. 1. Currently, there are many film lamination technologies applied in products such as wet lamination, dry lamination, and especially solventless lamination. Solventless Lamination The solvent is not used when it comes to producing adhesive substance. The most important solventless and high solids adhesives used in, Two-part solventless polyurethanes were also developed to negate some of the disadvantages of the moisture-cured type, such as bubbling, inconsistent cure rate, and cloudiness. It can look like a sheen on the image. The most important solventless and high solids adhesives used in laminating flexible packaging are those belonging to the polyurethane family. Trademark of The Dow Chemical Company("Dow") or an affiliated company of Dow. Sinstar Triplex solventless co-laminating machine, is a professional supplier whos engaged in the research, development, production, sales and. Conserv Recycl 122:295306, Hu RY, Liu GJ, Zhang H, Xue HQ, Wang X (2018) Levels, characteristics and health risk assessment of VOCs in different functional zones of Hefei. When expanded it provides a list of search options that will switch the search inputs to match the current selection. Guidelines for nip pressure often is 30-40 psi, When a smoothing bar is needed to improve flow/leveling of adhesive steps must be made to use it properly to insure optimum benefits of the bar. When running a laminator at 85C, the point where the rolls sit together easily can become a hot spot of +95C. In this case the thicker film may not have enough time to heat on the roller to reach its adhesive melt temperature. 1) Ideally overflow pipe should be located under adhesive level to prevent "free fall" creating bubbles Low nip temperature prevents adequate re softening of the adhesive and prevents proper wetting of the secondary web thus creating voids which can createa hazy appear acne, Proper nip temperature allows proper secondary film wetting. 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. Correspondence to Use correct diameter blade to create vortex but not create foaming. The resulting laminated film is then rewound into a finished roll. Plus, there is no need to use ovens as well. Solventless adhesive is quite essential in coating technology, it undergoes a curing treatment of certain temperature and humidity conditions to prepare a firmly bonded composite film, has the advantages of environmental protection, energy saving and emission reduction . Read more: Dry lamination in the production of laminated film packaging. The peeling strength of OPP / AL / PE is above 3.5 N, close to or higher than that of some solvent-base laminating adhesives. Tax code: 3702520171 - Issue date: 06/12/2016. This laminating method is subject to certain restrictions in dry winter and should be paid attention to. 2) Slow feed pump to prevent surging into pan. The two-part polyurethane laminating adhesives require a mixing and metering unit since pot life is limited. Not to mention, each variety is better than its predecessors when it comes to performance, regulatory compliance, and processing. A little bit of this is normal, but if the print doesnt lay flat after some gentle smoothing, it is a problem. PubMedGoogle Scholar. Low treatment of films (less than 36 dynes for solvent adhesives and 40 dynes for waterbased adhesives. Confirm via FTIR Mix adhesive for five minutes minimum on any two part system. The temperature setting in solventless lamination includes A&B Component, Adhesive Supply Pipe, Fixed Roller & Metering Roller, Coating Roller, Laminating Roller and Curing. The temperature of mixing roller, metering roller and coating roller in coating system will directly affect the application time of adhesives. 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. Plastic Film High Speed Solventless Lamination Machine It can be judged by measuring the spacing of the two spots to find that which rolls have foreign matter and clean up. Pic 3 shows how the temperature of coating system (fixed roller, metering roller, coating roller) influences viscosity. [Solventless PU Lamination Technique] General View of - LinkedIn 2021-08-19 The products in the packaging and printing industry are inseparable from the use of organic solvents, which brings many emissions of VOCs. 2) Insure balances used to weigh components are accurate for weights being usedand properly calibrated The film then can begin to wrap around the rear rolls. The temperature of the laminating roller should be useful to the second leveling of adhesives, and not result in deformation of plastic films. Take a solventless lamination with max speed of 350m/min as an example. This process does not offer the same range of color options as solvent-based lamination. A hot room can be used to accelerate cure often set at 115F Low surface energy on the primary surface(film, ink, coating, etc.) For example, when the laminating substrate is thin and the flexible package products with the auxiliaries which contain a large amount of molecular weight, adopting solvent-free lamination process, the adhesive will penetrate the substrate and In severe cases, it can accumulate on the thermal surface of the substrate, by secondary reactions, generating urea and other derivatives, which affects the heat-seal quality of the product. 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. When a moist inkjet print encounters one of these hot spots, the ink easily can boil, creating bubbles. All the factors should be treated properly. 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. The glue coating amount in the left and right sides of the film is too large and it is best to control the difference within 0.2g. prevents adequate adhesive wet out of this surface creating the fish eye appearance. All Rights Reserved. SYMBIEX Solventless Adhesives technology, SYMBIEX 100 / SYMBIEX CR 001 adhesives will simplify your lamination process, make it flexible as never before, and allow you to accelerate packaging innovation into the value chain. Low bonds can allow extensible and non-extensible webs to move on each other resulting in tunnels. 1) PVDC coating Atmos Res 209:123130, Hickenbottom KL, Leslie MR, Vanneste J, Marr JM, Heeley MB, Cath TY (2018) Comparative life-cycle assessment of a novel osmotic heat engine and an organic Rankine cycle for energy production from low-grade heat. In the packaging printing industry, this method is becoming increasingly popular due to its environmental benefits and cost-effectiveness. Trustworthy Solventless Laminating Machine Manufacturer | Sinstar Platform scales are not accurate enough for small amounts of coreactant. The Fluent software is used to simulate the mixer results under different diameters of pipe and different inlet velocities of A/B. No combustible, explosive organic solvents in solventless laminating technology, there will be good safety. 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. 2. 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. 3) Insure dyne level on primary web is high enough to accept adhesive and allow proper flow and wetting. Required fields are marked *. Silvering is caused by the capture of tiny bubbles of air, which look like hazy or reflective areas in the lamination. General haziness or cloudiness in the film after lamination. This process reduces the emission of volatile organic compounds (VOCs) and helps to decrease pollution. The solvent is not used when it comes to producing adhesive substance. Bubbles are often seen in machine direction. Some of the most common problems with laminated prints due to the wrong amount of tension or pressure are as follows: Infeed waves are mars in the finished product that result from the original image being somehow distorted before it went in. Insufficient tension easily is fixed by adjusting the tension of the feed spool to the proper specifications for the type of film being used. Wrinkling of the material as it goes into the laminating rollers. Solvent based adhesives require a minimum of 36 dynes, and water based adhesives require minimum dyne level of 38-40. Secondly, the tinsel must be well grounded electrically, stretched tight and placed of an inch from the material to be neutralized. 2. Shanghai Kangda New Material Group Co., Ltd. Besides the safety factor, a grounded machine will help drain off extremely high charges of static electricity from partial conductors. Confirm solvent via GC/MS, look for capping via NMR and SIMS/MALDI, Some end users want less than 1,000 mg/ream. Take note that in traditional practices, solventless adhesives did not go well in things that contain foil. Int J Life Cycle Assess 26, 561574 (2021). As the film runs at greater speeds, the actual film temperature is reduced. Long time store of mixed adhesives makes the viscosity high, thus influencing the stability and appearance of lamination products. Resour. Lack of supply roll tension can cause the film to not be taut as it enters the nib. As showed in Pic 1, the viscosity clearly goes down when the temperature gets high. Use high resolution balance for coreactants. SELECT THIS PROBLEM: Ink Bleeding with 100% Solids Adhesives Ink bleeding is a reduction in print quality or crispness of the print job. That is why solventless adhesives have become a crucial part of the laminating industry in a short time. This is a common condition resulting from too much heat. 1) Insure correct mix ratio is being used and balances used to weigh are calibrated. Apply enough pressure to give uniform footprint across web of no more than 0.5 inches, often 30-40 psi. When considering whether to use solventless lamination, it is important to weigh the pros and cons and determine if it is the right choice for your specific packaging printing needs. It should use high-quality materials or increase coating. 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. Limited Color Options: Solventless lamination is limited in terms of color options. All Rights Reserved. Poor ink adhesion-additives such as anti-blocks, glycols, and other OH additives can adversely affect adhesion of sensitive NCO terminated adhesives. Insure inks you are using are completely dried prior to laminating. Cool spots are areas that arent hot enough to melt the adhesive. To insure proper cure : 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. 3) Inks The first solventless laminating adhesives were primarily moisture-cured polyurethanes. According to Adhesives Age magazine, 25% of all consumer goods today are marketed in flexible packaging, in a continuing shift away from traditional folding cartons, boxes and fiberboard cases and trays. To promote cleaner packaging and printing production in China, we applied life cycle assessment (LCA) to compare solventless and dry film lamination processes in retort pouch packaging production and further validate the environmental advantages of the solventless approach. On one side, with temperature rising, adhesives absorb slipping agent more easily, making some agent invalid. The adhesive bond can only be as good as the anchoring of the layer it is adhering to. 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. The substrates, inks and solvents used in different products are also various. Q&A: Common Issues in Laminating PostPress 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. When applying solventless adhesives to lamination, the pot life should accord to the viscosity curve. PDF Packaging lamination redefined in 90 minutes SYMBIEX Solventless The Influence to The Products with Solventless Lamination 2.1 Temperature. Solventless lamination: where the adhesives used do not contain solvents. 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 mixture goes into the gap between fixed & metering roller, and then coats on the film. For the lamination of paper to aluminum and paper to plastic, a one-component solvent-free adhesive will be an economic choice. Flexible packaging film is mainly applicable to consumable goods that need an extended shelf-life. We would like to show you a description here but the site won't allow us. Low bonds are any reduction in inter ply bond strength from the normal bond values seen. Environmental Benefits: Solventless lamination eliminates the need for solvents, which are harmful to the environment. In dry lamination, the bonding agent is applied on the substrates that have been dissolved into a liquid. Atmos Environ 39:73747383, Winans Kiara S, Macadam-Somer Ilan, Kendall Alissa, Geyer Roland, Marvinney Elias (2019) Life cycle assessment of California unsweetened almond milk. Applied properties and life cycle assessment of flexible packaging However, tinsel oftentimes is misused and, therefore, sometimes not successful. Due to no solvent use, it saves solvent costs and saves a large amount of energy consumption without the dried process. https://doi.org/10.1007/s11367-021-01883-4, DOI: https://doi.org/10.1007/s11367-021-01883-4. Clean. These solventless adhesives are suitable for making laminates using most types of films, foils, and paper. Run G.C.s to confirm low retained solvents. Part of Springer Nature. 1. However, it easily can be kept under control by taking a few precautions. For older films or films that have not been pretreated a higher watt density will be needed. Below are several common issues and suggested solutions. The paper core is not aligned with the film. These areas are often relatively large and randomly dispersed. The peeling strength of OPP / AL / PE is above 3.5 N, close to or higher than that of some solvent-base laminating adhesives. The packaging-printing industry is considered as one of the main contributors to air pollution in China. Previously, these adhesives were used in certain applications only, such as, 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. Low bonds can reduce the integrity of the package and lead to a variety of package defects. 3. The coated pressure roller of the composite roller has glue or other impurities. The voids may be consistent in shapeor highly irregular. 4) Adjust temeprature of adhesive puddle and dosing roll pressure on solventless adhesives. 2. We also hold ISO 8 (100,000) Cleanroom certification and SQF 9 certification. These problems were generally associated with variations in the ambient moisture content. Answer: Few issues look worse than when bubbles appear under the film. Causes reduction in visibility into package. The Dow Chemical Company (1995-2017). This means that solventless adhesive flexible packaging film is suitable for products like the following. 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. 2023 LPS Industries. Less than 1,000 mg/ream total solvents are desirable. The solution is to adjust the deflection roller and keep the film neat before entering the composite roller. of Printing & Packaging Materials and Technology, Beijing Institute of Graphic Communication, Beijing, China, Haowei He,Yabo Fu,Siqi Liu,Pengfei Guo&Wencai Xu, Shanghai Kangda New Materials Co., Ltd, Shanghai, China, Guangzhou Sinomech Co., Ltd, Guangzhou, China, You can also search for this author in 1. service of non solvent laminating machines with annual production capacity of 200 sets. Heat "Hot spots" are a key problem when laminating inkjet prints.
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