In the realm of packaging, where the battle against spoilage and decay rages on, a high barrier film stands as a mighty guardian, shielding products from the elements. Among the arsenal of techniques employed to fortify these films, thermal lamination emerges as a formidable ally. However, this quick guide provides a realm of thermal lamination techniques where innovation meets preservation, and barriers become impenetrable fortresses.
The Lamination Lowdown: Bonding for Better
Lamination combines multiple film layers, each with its unique adhesive and other features. The benefit of thermal lamination happens when heat and pressure activate a special adhesive layer, fusing these individual films into a powerful composite. The core principle relies on the adhesive properties of specific layers within the film stack. These adhesive layers, often termed tie layers or compatibilizers, melt at designated temperatures, fusing the individual films during the lamination process.
However, thermal lamination is primarily categorized into two techniques:
- Solvent-Based Lamination: This traditional technique employs specialized glues activated by solvents to create a strong bond between film layers. It’s a reliable solution, especially adept at uniting dissimilar materials.
- Solventless Lamination: This technique uses 100% active and 0% water or solvent carriers. It relies on the inherent thermoelastic properties, which help to create a strong bond between the films. It is more environmentally friendly.
Common Thermal Lamination Techniques
Several Thermal lamination techniques cater to diverse applications and film combinations.
- Platen Lamination
In this technique, the film stack gets sandwiched between two heated platens, and the heat activates the special adhesive layer within the film stack. It offers precise control over temperature and pressure, making it suitable for various film structures.
- Cast Film Lamination
In this technique, molten adhesive resin is continuously cast onto one of the films. Subsequently, the second film was placed onto the adhesive layer using heated rollers. This technique allows for nonstop processing, making it ideal for large-scale production.
- Extrusion lamination
Here, machines simultaneously squeeze different molten layers of plastic. One of these layers acts as the magic adhesive, bonding the other film layers right there during the extrusion process itself. Extrusion lamination offers excellent production efficiency and material utilization.
- Tenter Frame Lamination
This technique utilizes a frame that holds the films under tension. The tension ensures film stability during the lamination process, minimizing wrinkles and distortions. Tenter frame lamination is particularly suitable for films prone to stretching or warping under heat.
- Pressure-sensitive lamination (PSL)
This method utilizes pre-coated adhesives on the film layers, similar to having double-sided tape. It’s incredibly fast and perfect for high-production lines, ensuring a production floor at all times.
Benefits Beyond Barrier Properties
Thermal lamination offers advantages beyond just enhancing barrier properties. Here are some additional benefits:
- Light Management: Specific film combinations help in creating films with desired light transmission or blocking properties. It is crucial for applications like photosensitive products or food packaging requiring protection from UV light.
- Controlled Gas Permeability: By selecting appropriate film materials, lamination can create films with tailored gas permeability rates. It is beneficial for products requiring specific gas exchange, such as modified atmosphere packaging for fruits and vegetables.
- Aesthetics and Branding: Lamination allows for the incorporation of metalized layers or printed films within the structure.
In Conclusion
Each layer is bound by the fiery embrace of thermal lamination for a high barrier film, guarding against the ravages of moisture, oxygen, and light. It creates a barrier far superior to what any single film could achieve on its own. In the grand tapestry of packaging, thermal lamination by JPFL Films offers a cost-effective solution, ensuring that the fruits of preservation are within reach of all.