Pre-coated film lamination and Instant film lamination

The pre-coating film refers to a process in which a plastic film is sized and re-rolled before being combined with a paper printed product. It is firstly applied to the film by the pre-coated film processing factory according to the size of the specification. The glue is applied to the film for re-rolling, and then combined with the printed matter.

The pre-coated film was first used in 1989 and has been widely used in Europe and the United States. It entered Asia around 1996. At the same time as entering Asia, Europe and the United States have announced that it is forbidden to use the film as a pre-coating film. Due to the late use, all the countries in Asia except Japan have used pre-coated films, and other countries (such as China, South Korea, etc.) are in the state of pre-coating and film coating.【Roll Laminator Manufacturers】China has only used pre-coated films since 2000, and the market share of pre-coated films in China is still small. Precoat films have many advantages over instant coatings. If the pollution is reduced, there is no damage to the human body; the quality of the film will not be affected by the different properties of the paper or the color of the ink; the pre-coating film laminating machine is simpler to operate, and the processed image is better; the wrinkles are basically eliminated. , bubbles, shedding and other phenomena. Most notably, this is an environmentally friendly process, and the entire production process is harmless to the human body.

However, the promotion of pre-coated film in China is still relatively slow. Among them, the cost issue is a big influential factor, which determines the enthusiasm of investors for the pre-coating process. 【Reel to Reel Lamination Machine】In a recent survey, more than half of the respondents believe that pre-coated products are expensive in terms of price, because pre-coated products are printing consumables, and the cost of printing is a non-negligible problem for printers when selecting consumables. . In addition, due to the lack of paper and film separation technology in China, pre-coated films cannot be completely called an environmentally friendly process in China. In response to this situation, pre-coated products should reduce costs through mass production, so that market prices are getting closer to the needs of printers. At the same time, the research and development or introduction of the paper membrane separation technology should also attract the attention of relevant departments, in order to achieve environmentally friendly coating and rational development of the laminating process without being able to discard the laminating process.【Laminating Machine Supplier】It is a brand-new transfer technology that can cope with complex workpieces and is suitable for different materials. It also greatly increases the added value of products due to vivid patterns and vivid colors. This technology is a special chemical treatment film, after printing a certain color pattern, it is sent to the surface of the water, using water pressure to write the pattern evenly on the surface of the product, while the coated film is automatically dissolved, washed and baked. After drying, a layer of transparent protective coating is applied, and the product has a completely different visual effect.

Will UV varnishing replace the pre-coated film lamination process ?

The printing technology continues to advance, the printing materials are constantly updated, the influence of various post-press processing conditions on the film is increasing, the printing quality standards and market demand are constantly increasing, which requires the film industry to change according to objective conditions. New quality technical standards for structural adjustment. At the same time, we should also look for other processes that can replace the film in time to reduce the pressure on the environment. In fact, in addition to the film coating process, UV glazing can also play a certain role in protecting and decorating the surface of the printed matter. The two are similar in many functions. Due to the relatively low cost of UV glazing, 【Laminating Machine Supplier】the development is relatively rapid, and the product is very attractive, so it also has a certain market share in some post-press processing fields. Some people who are optimistic about UV glazing technology even believe that this technology can be independently developed instead of laminating technology.

In fact, this is just a wish of people. According to some printing companies that use UV glazing technology, UV glazing applications are mostly partial glazing. Local UV glazing can improve the grade of books, but in most cases, this partial UV glazing process is also This is done after the film is applied, and the previous film coating process must be a solvent-based film. In addition, there is still a lot of deficiencies in UV glazing compared to film coating. Such as UV glazing protection, folding resistance, wear resistance, etc. are not as good as the film, there are limitations in many areas, 【Lamination Machine Manufacturer】 such as packaging boxes; UV glazing also needs to put into printing equipment and UV curing equipment, and the film has Off-the-shelf equipment foundation and mature technology; in addition, some UV varnish will also volatilize odor during the coating process, which will affect the operator.

Today's printing houses and publishing houses pay great attention to this process, and believe that UV glazing can replace the laminating process in book printing. But in general, UV glazing is still limited in many aspects, there are still many problems in the process, and it is impossible to completely replace the laminating process.

Pre-coated Film Lamination is the Developing Trend

In China, I think there are four important reasons for the comprehensive replacement of pre-coated films: The first reason is that after 12 years of development, the whole industry has already recognized the pre-coated film, the pre-coated film is of good quality, and the pre-coated film. Environmental protection, which is recognized by the entire printing industry.

Now everyone knows that the industry is aware of pre-coated film, which is a very important point; the second point is the formation of industrial clusters.【Water Based Lamination Machine 】After 12 years of development, I believe that there are currently 30 manufacturers of pre-coated films in China. The third important factor is the cost reduction due to the improvement of industrial clusters and industrial technology. The original pre-coated film has three sentences, one sentence. It is good quality, one sentence is environmental protection, and one sentence is expensive. Many manufacturers use our products to proof, and do not produce after the completion of the test. Because he costs a lot. But today, the pre-coated film is already not expensive, and the pre-coated film is now flat with the solvent-based water-based film.The reduction in film cost is one reason for the overall replacement of the precoat film. Another important basis is the policy. 【Fully Automatic Lamination Machine 】A series of national policies will play an important role in promoting the development of pre-coated films, especially green printing.

The global market share is like this. According to the statistics of the National Press Center in 2009, the US pre-coated film has reached 95%, Japan has reached 70%, Europe has reached 60%, South Korea has reached 50%, and China in 2009. In April, the pre-coated film only accounted for 10%. China Information Center statistical pre-coating film accounted for 10%, water content accounted for 21%, solvent type accounted for 69%, today the number is greatly reduced, today water includes PUR glue and so on, and today's pre-coated film is not 10% It is also highly developed. This is 2009, because we want authoritative data. 【Automatic Film Laminating Machine 】This standard rose to the national standard in 2010, and it is clear in the standard that there are no contaminated items in the laminating machine. In particular, the signing of the green environmental protection agreement in 2010 will further promote the comprehensive replacement of the pre-coated film.   

Therefore, in order to develop the green and digital development of China's printing, and for the sake of national health, it is necessary to jointly promote the pre-coating film to be a comprehensive replacement for the benefit of the people.

Pre-coated Film Lamination Process

The pre-coating film refers to a process in which a plastic film is sized and re-rolled before being combined with a paper printed product. It is firstly applied to the film by the pre-coated film processing factory according to the size of the specification. The glue is applied to the film for re-rolling, and then combined with the printed matter.The pre-coated film was first used in 1989 and has been widely used in Europe and the United States. It entered Asia around 1996. At the same time as entering Asia, Europe and the United States have announced that it is forbidden to use the film as a pre-coating film.【 Fully Automatic Lamination Machine 】Due to the late use, all the countries in Asia except Japan have used pre-coated films, and other countries (such as China, South Korea, etc.) are in the state of pre-coating and film coating. China has only used pre-coated films since 2000, and the market share of pre-coated films in China is still small.


Pre-coated films have many advantages over instant coatings. If the pollution is reduced, there is no damage to the human body; the quality of the film will not be affected by the different properties of the paper or the color of the ink; the pre-coating film laminating machine is simpler to operate, and the processed image is better; the wrinkles are basically eliminated. , bubbles, shedding and other phenomena. Most notably, this is an environmentally friendly process, and the entire production process is harmless to the human body. 【 Laminating Machine Supplier 】 However, the promotion of pre-coated film in China is still relatively slow. Among them, the cost issue is a big influential factor, which determines the enthusiasm of investors for the pre-coating process. In a recent survey, more than half of the respondents believe that pre-coated products are expensive in terms of price, because pre-coated products are printing consumables, and the cost of printing is a non-negligible problem for printers when selecting consumables. 


In addition, due to the lack of paper and film separation technology in China, pre-coated films cannot be completely called an environmentally friendly process in China. In response to this situation, pre-coated products should reduce costs through mass production, so that market prices are getting closer to the needs of printers. At the same time, the research and development or introduction of the paper membrane separation technology should also attract the attention of relevant departments, in order to achieve environmentally friendly coating and rational development of the laminating process without being able to discard the laminating process. 【 Film Lamination Machine 】It is a brand-new transfer technology that can cope with complex work pieces and is suitable for different materials. It also greatly increases the added value of products due to vivid patterns and vivid colors. This technology is a special chemical treatment film, after printing a certain color pattern, it is sent to the surface of the water, using water pressure to write the pattern evenly on the surface of the product, while the coated film is automatically dissolved, washed and baked. After drying, a layer of transparent protective coating is applied, and the product has a completely different visual effect.

Basic Knowledge for Thermal Film Laminating Machine

The pre-coating film lamination is less polluted than the instant coating film lamination and has no harm to the human body. There is no difference in the nature of the paper and it affects the quality. There is no difference in ink color and it affects the filming effect. There is no effect of using adhesives with vinyl binding. The pre-coated film laminating machine is easy to handle and easy to process.【 Thermal Laminator 】The processed graphics are more beautiful and have a good effect. Basically eliminate wrinkles, bubbles, shedding and so on. It has a wide range of applications and can be used for film processing other than printing.


The pre-coating film refers to a process in which a plastic film is sized and re-rolled before being combined with a paper printed product. It is firstly applied to the film by the pre-coated film processing factory according to the size of the specification. The glue is applied to the film for re-rolling, and then combined with the printed matter.【 Lamination Machine Manufacturer 】The film, that is, the film, is a processing technique in which a plastic film is coated with a binder and the paper print is heated and pressurized to bond it together to form a paper-plastic product. The film-coated printed matter has a thin and transparent plastic film on the surface, and the surface is smoother and brighter, thereby improving the gloss and fastness of the printed matter. The color of the graphic is more vivid, three-dimensional, and waterproof. Anti-fouling, abrasion resistance, folding resistance, chemical corrosion resistance, etc.


The pre-coated film is composed of a substrate and a binder layer, and the substrate is usually a polyester (PET) film and a biaxially oriented polypropylene (BOPP) film. BOPP film has the characteristics of high transparency, good brightness, non-toxic and tasteless, water resistance, heat resistance, low cost and soft texture. It is an ideal material in the film coating process, and its thickness is about 12-20um. Therefore, the material cost From the perspective of processing technology, most of the pre-coated film substrates use BOPP film.【Best Thermal Laminator Machine 】The adhesive layer of the pre-coated film has two types of melt type and solvent volatilization type. According to different processing equipment and process conditions, adhesive layers of different thicknesses are selected, and the thickness of the adhesive layer is generally between 5-15 um. At present, the adhesive layer of the domestic pre-coated film is mainly composed of hot melt adhesive or organic polymer low temperature resin. Hot melt adhesive is made by blending and modifying several main materials such as main adhesive resin, tackifier and conditioner. The organic polymer resin is a single polymer low temperature copolymer. Since the hot melt adhesive is a mixture of several materials, the transparency after coating is significantly lower than that of the low temperature pure resin type pre-coated.


The production process of the solvent volatilization type pre-coated film is similar to the film coating process, and the colloid is dissolved in an organic solvent and then coated on the film substrate, so that the organic solvent may be volatilized incompletely, and the odor may be generated during the film operation. 【 Film Lamination Machine 】The operator causes damage (relative to the coating film coating process, the damage is much smaller), etc., the solvent evaporates after the film is coated, and it is easy to form bubbles on the surface of the printed matter.

Short Introduction of Thermal Film Laminating Machine

Such kind of laminating equipment does not need adhesive heating and drying system, the laminating process greatly simplifies the laminating process, and the operation is very convenient. It can be used with the booting machine, and has great production flexibility, no solvent smell, no environmental pollution, and more importantly, it can be completely.[ Thermal Lamination Machine ] Avoiding bubbles, delamination and other failures, the finished product has extremely high transparency, and has broad application prospects and promotion value.


The pre-coated film structure is composed of a substrate and a glue layer. The substrate is usually a PET film and a BOPP film. From the viewpoint of material cost and processing technology, most of the pre-coated film substrates are made of BOPP film and have a thickness of 12-20 micrometers. The thickness is 5-15 microns. [ Automatic Thermal Lamination Machine ] According to different processing equipment and process conditions, different thicknesses of glue layer are selected, and the glue layer is divided into hot melt adhesive and organic polymer low temperature resin. The difference between the two is that the hot melt adhesive is made by blending and modifying several materials of the main adhesive resin, the tackifier and the modifier, and the organic polymer resin is a single polymer low temperature copolymer.


Pre-coated film laminating machine
The pre-coated film laminating machine is the least investment and the best film laminating equipment. It is because the pre-coating laminating machine adopts an environmentally-friendly laminating process and operates.Simple, low investment, easy to use, whether it is mass production, or a small amount of film, it can be used easily, and is widely used in the market.The laminating machine is a small laminating machine.[ Automatic Lamination Machine ] Therefore, the market potential of small laminating machines is huge, and products processed by laminating machines must have strong products.Market Competitiveness. We develop and sell a series of small laminating machines to bring the most affordable, most direct and most convenient services to the vast number of users.

Problems probably occurred during lamination process

Blistering

1. The printed ink layer is not dry. It should be hot pressed and then glued; delay the filming time and make it dry thoroughly.
2. The printed ink layer is too thick. The amount of adhesive applied should be increased to increase the pressure and compound temperature.
3. The drying temperature is too high and the surface of the adhesive is crusted. Should reduce the drying temperature
4. The surface temperature of the composite roll is too high. The composite roll temperature should be lowered.
5. The film has wrinkles or slack, and the film is uneven or curled. [ Lamination Machine Manufacturer ] The film should be replaced and the tension adjusted.
6. There are dust impurities on the surface of the film. It should be cleared in time.
7. The adhesive coating is uneven and the dosage is small. The amount of coating and uniformity should be increased.
8. The binder concentration is too high, the viscosity is large, and the coating is uneven. Apply a diluent to reduce the binder concentration.


Wrinkles

1. The film transfer roller is unbalanced. The transfer stick should be adjusted.
2. The ends of the film are inconsistent or wavy. [ Film Lamination Machine ] The qualified film should be replaced.
3. The glue layer is too thick, the solvent evaporation is not thorough, affecting the viscosity, squeezed by the pressure roller, and slippage between the paper and the film. The amount of glue should be adjusted to increase the temperature of the drying tunnel.
4. The electric heating roller and the rubber roller are unbalanced at both ends, the pressure is inconsistent, and the line speed is not equal. The two rollers should be adjusted.

How to properly store white glue ?

                                 
                                Thermal Lamination Machine


01
Store before opening
Avoid glue exposure, rain (will reduce glue storage time, reduce stickiness)
Keep the room temperature at 15-25 degrees Celsius (storage temperature below 8 degrees Celsius will reduce the glue adhesion, below 4 degrees Celsius will lose the viscosity of the glue).

02 
Stored after opening
Do not infiltrate other substances into the glue bucket, otherwise local clumping, discoloration and deterioration will occur. [ Automatic Thermal Lamination Machine ] There is no need to add water to adjust the quality, and the addition of water will reduce the bonding strength of the glue, so the paste effect will not be achieved. Seal the plastic bucket and plastic bag immediately after use according to the amount until the next time you use it again. 

03
Storage after use
Clean the rubber bucket and plastic bag mouth and seal them intact, so as to prevent the dry film of glue remaining in the mouth of the barrel or the bag from falling into the glue, thus causing granulation. If it is not sealed, the glue will peel.
The pumping pump is immediately pumped into clean water to avoid accumulation of residue and gelation after solidification, which may cause blockage and affect production and use.

Development trend of film lamination

The paper after the film lamination process is unrecoverable and becomes a white pollution, and toxic substances such as toluene and water are volatilized during the film coating process, which impairs people's health. Today, advocating "protecting the environment and protecting resources", the plastic film coating process has been eliminated in Europe and the United States, and European and American countries have even refused to import various packaging materials with plastic film. [ Thermal Lamination Machine ] Although there are water-based plastic film coating processes and hot-melt pre-coating film dry plastic compounding processes, the former still fails to solve the problem that the film printing waste cannot be degraded and cannot be recycled. The latter requires a large amount of heat in the production process and is discarded. The material needs to be separated in paper and plastic at 60 ° C, and the cost is high.



With the improvement of environmental awareness, new scientific and technological achievements will eliminate the old process products, so that the film process will undergo qualitative changes. "Non-toxic, harmless, green and environmentally friendly" naturally becomes an inevitable development trend of the film coating process. In addition, the glazing process is therefore optimistic. Glazing is a method of coating, spraying or printing to add a colorless transparent coating on the surface of the printed matter, that is, UV varnish. After calendering and drying, the gloss of the surface of the printed product is increased, and the stiffness is also improved. [ Thermal Laminator ] At the same time, the printed waste after glazing can be recycled or decomposed by itself, and does not pollute the environment. Therefore, glazing is a processing technology with great development potential, and it is possible to gradually occupy the plastic coating process market. Although the dilute machines used in oil glazing and alcohol glazing on the market are toluene and alcohol, respectively, which are harmful to the human body and unfavorable to environmental protection, water glazing has gradually become the mainstream of glazing process.[ Lamination Machine Manufacturer ] The water-based UV glazing process that has been developed so far is an ideal environmentally friendly glazing process and the development direction of glazing process in the future.

Commonly Used Lamination Film Are ?

Commonly used plastic films are: polyvinyl chloride (PVC), polypropylene (BOPP) and polyester (PET) films. Among them, BOPP film (15-20pm) is flexible, non-toxic, high transparency and low price, and is an ideal composite material in the film coating process. [ thermal lamination machine ]


Depending on the properties of the film itself and the purpose of use, the thickness of the film is preferably between 0.01 and 0.02 mm. It must be treated by corona or other methods. The surface tension of the treated surface should be 4 Pa, so as to have better wettability and adhesion. The corona treatment surface should be uniform and the transparency should be as high as possible to ensure the best definition of the covered print. [ thermal laminator ] The transmittance of PET is generally 88-90%, and the transmittance of other films is usually between 92-93%. The film needs to have good light resistance, is not easy to change color under long-time illumination, and the geometric size is stable.


Since the film is in contact with a solvent, a binder, an ink, etc., it must have a certain chemical stability. The appearance of the film surface should be flat, without unevenness and wrinkles, and the film is required to have no bubbles, shrinkage holes, pinholes and pitting. Due to the limited adjustment ability of the laminating machine, it is also required that the rewinding is neat and the two sides are elastic and uniform to ensure uniform coating.[ lamination machine manufacturer ] Of course, the cost is low.

The method of solving paper and plastic film separation

Analysis of the reasons that affect the separation of paper and plastic film

[ Thermal Film Lamination Machine] 

The reason for the influence of paper-plastic detachment, the smoothness, uniformity, water content of the paper, the performance of the plastic film, the thickness of the printed ink layer, the amount of auxiliary materials, the temperature and pressure during the paper-plastic composite, and the hygienic condition of the production environment And temperature, relative humidity, etc. will have a certain impact on the final result of paper-plastic composite!

[ Lamination Machine Manufacturer ]

The method of solving paper and plastic film separation:

1

The ink layer of the ink is too thick, causing penetration and diffusion of the adhesive, causing the paper to detach. The treatment is to increase the amount of adhesive applied and to increase the pressure.

2

When the ink layer is not dried or is not dried, the component of the residual solvent in the ink layer weakens the adhesive force to form a paper-like detachment. The treatment method is to re-compound after the product ink is dried.

3

The residual powder on the surface of the printed matter also hinders the adhesion of the paper to the plastic film to form a paper-plastic release. The treatment method is to mechanically and manually erase the powder on the surface of the printed matter and then recombine.

4

The operation process is not standardized, the pressure is too small, and the machine speed is fast, which causes the paper to detach. The treatment method is strictly in accordance with the process specification, and the pressure of the film is appropriately increased to reduce the machine speed.[ double side lamination machine]

5

The adhesive is absorbed by the paper and the printing ink, and the paper is detached due to insufficient coating amount. The adhesive should be re-formulated and the amount of glue applied should be determined according to the manufacturer's requirements.

6

The corona treatment of the surface of the plastic film is insufficient or exceeds the service period, so that the paper is separated from the failure of the treated surface. The plastic substrate should be corona or renewed in accordance with the corona standard of the film coating.

7

When a one-component adhesive is used, the paper-plastic detachment due to insufficient air humidity should be artificially humidified according to the humidity requirements of the one-component adhesive processing process.

8

Ensure that the adhesive is kept and used according to the manufacturer's requirements during the warranty period. If the automatic mixer is in good condition, the ratio is accurate, uniform and sufficient.

Film Laminating Process

Film coating refers to the transparent plastic film applied to the surface of the printed matter by hot pressing. After the film is covered, the film is smoother and brighter. The color of the graphic is more vivid. At the same time, it is also waterproof and antifouling. It can be divided into surface processing and forming. Hot stamping, glazing and other processing techniques; molding process. The film not only makes the surface of the printed matter wear-resistant, folding-resistant and chemically resistant. However, traditional plastic films are not degradable, difficult to recycle, and easily cause pollution. 

Therefore, in the major printing cities, environmentally friendly PET films are used to improve the laminating process. The film laminating machine manufacturers have also developed various excellent equipment for PET slitting (such as chain knife slitting) to complete the elegant upgrade in laminating process.