High alcohol content from inks or alcohol contamination in solvents when using NCO containing adhesives. The Curve inflects that in 18 min, the viscosity drops down for the rising temperature. Office Tower:25 Ngo Quyen Street, Ward 10, District 5, Ho Chi Minh City, Your email address will not be published. If the defect is adhesive residues, simply clean the rolls. The film then can begin to wrap around the rear rolls. Life Cycle Assess., December, Int. 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. When two webs are pulled though machine at mismatched elongations theywill return to normal state once tension is relieved. Solventless laminating adhesives contain 100% actives and do not have water or solvent carriers. 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. Low bonds caused by poorly cured adhesive should be corrected in the following manner: The peeling strength of OPP / AL / PE is above 3.5 N, close to or higher than that of some solvent-base laminating adhesives. Solventless PU lamination adhesive is sensitive to temperature. your institution, https://doi.org/10.1080/1073161X.1994.104672901994, https://doi.org/10.1007/s11367-019-01716-5. 112:44304434, Zhang WJ, Guo JF, Gu F, Gu XJ (2018) Coupling life cycle assessment and life cycle costing as an evaluation tool for developing product service system of high energy-consuming equipment. 2. Confirm using GC head space and insure GC trace picks up any high boiling solvents that may impede cure by reacting with adhesive, Make sure you use urethane grade solvents. The resulting, The solventless adhesive is used in a wide array of packaging applications as it is a high-quality laminating adhesive. All Rights Reserved. If bands of silvering alternate with bands of properly adhered areas, it means one part of the roller was too cool. Peeling Strength of Solventless Lamination Films for Retort - Springer Pros: Environmental Benefits: Solventless lamination eliminates the need for solvents, which are harmful to the environment. Plastic film high speed solventless lamination machine is based on the characteristics of the solvent-free laminating process itself, especially the problems such as . A milky, hazy line about an inch wide appears periodically across the width of the web immediately after initial warm-up. The other likely cause of this symptom is worn rollers. 5. The solutions are to appropriately increase the amount of glue and adjust the composite temperature and composite pressure. 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. A little bit of this is normal, but if the print doesnt lay flat after some gentle smoothing, it is a problem. 3) Inks Dow's solventless adhesives also offer moderate chemical resistance and allow for aggressive fill and fatty food applications. In this situation, the laminating rollers should be replaced. Solventless Lamination: The Modern Answer to Lamination, 1991 - TAPPI Solventless Lamination Benefits Products As Well As the Environment This process requires specialized equipment and may require modifications to existing equipment. If you have any question, plz kindly contact with me. 2) Insure balances used to weigh components are accurate for weights being usedand properly calibrated J Clean Prod 131:2842, Shen L, Wang YY (2018) Supervision mechanism for pollution behavior of Chinese enterprises based on haze governance. 4) Adjust temeprature of adhesive puddle and dosing roll pressure on solventless adhesives. These laminating adhesives are typically used in flexible packaging applications. This is a common condition resulting from too much heat. Heat At present, traditional lamination technologies, e.g., dry lamination, consume considerable resources and generate massive pollution. https://doi.org/10.1080/1073161X.1994.104672901994, Chen RJ (2013) The health effects of complex air pollution in 17 Chinese cities, Fudan University, Dewulf J, Langenhove HV (1999) Anthropogenic volatile organic compounds in ambient air and natural waters: a review on recent developments of analytical methodology, performance and interpretation of field measurements. 4. Analysis of the Pros and Cons of Solventless Lamination in the Why choose laminated film packaging for non-food products. Trademark of The Dow Chemical Company("Dow") or an affiliated company of Dow. In this process, the combining agents are kept in liquid form when substrates are needed to be combined. If you enter the market for the first time, using solventless adhesives can reduce your capital investment costs as compared to solvent-based laminators. Continue below to view Dow's solventless laminating adhesive options. The new lamination technology is a result of a joint development effort, combining When applying solventless adhesives to lamination, the pot life should accord to the viscosity curve. In addition free fall of adhesiev into sump can cause this. 2) Use of smoothing bar to help level adhesiev after application Q&A: Common Issues in Laminating PostPress Low nip pressure causes inadequate adhesive wetting of secondary substrate leading to voids which can create a hazy appearance. Speed Feeding too quickly causes bubbles if the item is pushed into the nib faster than the speed of the laminator. PDF Compact LME Solventless Lamination Machine - Karlville Coated substratesare subsequently nipped and bonded to a secondary substrate to make the lamination. 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. J Clean Prod 179:160168, Article The voids may be consistent in shapeor highly irregular. This process reduces the emission of volatile organic compounds (VOCs) and helps to decrease pollution. Tax code: 3702520171 - Issue date: 06/12/2016. Each solventless laminating production line will have much less energy consumption than a dry laminating production line. Solventless adhesive is used in a wide array of packaging applications as it is a high-quality laminating adhesive. https://doi.org/10.1007/s11367-021-01883-4, DOI: https://doi.org/10.1007/s11367-021-01883-4. Voids may be in machine direction or randomly dispersed accross lamination. The mixture will have 6000mPa.S, which wont reach an expected performance. Turbulance in pan due to recirculate pump running at too fast a rate can also cause this. Moreover, using solventless adhesives means there is no solvent and no risks of emissions. I some cases the voids may look like haze without proper magnification. The adhesive is not configured in accordance with the correct matching requirements. 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. The solution to this problem is too obvious to mention. If it applies inorganic anti-blocking agent to material film, which has high melting point, the temperature influence to friction coefficient will decrease. .-OH bearing inks may react with isocyanate portion of adhesive and/or plasticize. The Dow Chemical Company (1995-2017). All Rights Reserved. 2. Slitting of the laminate generally can occur in 24-72 hours. Ink companies are adding more and more glycols to improve flow in inks to give better clarity on flexo presses. Even with this it is advisable to "bump" treat films at a 1 watt density to help insure clean laminating surface. Solventless adhesive generally indicates a specific type of adhesive composed of two components reacting with each other and consequently not requiring drying. This creates hot spots. With the emphasis of lamination packaging companies on solvetless lamination Technology, this new type of laminating process has a significantly accelerated development trend. That is why solventless adhesives have become a crucial part of the laminating industry in a short time. - 152.89.236.36. The products in the packaging and printing industry are inseparable from the use of organic solvents, which brings many emissions of VOCs. The first unwind film with adhesive goes through the laminating roller and then compound with the second unwind film. So the requirements of the solventless lamination process for water vapor are particularly strict. Make sure to work with a low temperature without exceeding 40-45C. Long time store of mixed adhesives makes the viscosity high, thus influencing the stability and appearance of lamination products. When feeding an image into the laminator, make sure it is parallel to the roll. In addition, due to the high permeability of the solventless adhesive, the color of the product is different when using the solvent-free laminating process for some flexible packaging products which require printing. Smarter plastics manufacturing starts with I.O.T., Industry 4.0 & Digital Transformation. > 200F. Solventless PU Lamination Adhesive, which has no solvent during production, is a kind of green adhesive. Wet lamination is best for the production of aluminum foil or paper laminate where the material is also flexible. The glue portion, the composite portion of the rollers have a poor surface finish. Solvent based adhesives require a minimum of 36 dynes, and water based adhesives require minimum dyne level of 38-40. NOTE: A quick fix can be to speed up the laminator. Static electricity is an issue when laminating lighter weight films since they have a tendency to curl back towards the rear rolls. The poor finish of the glue pressure roller, the transfer roller, or the composite roller. In the packaging printing industry, this method is becoming increasingly popular due to its environmental benefits and cost-effectiveness. To alleviate this problem, put the laminator in reverse and gently pull the wrapped film off the rear rolls. Discuss with adhesive supplier. The simulation results are analyzed . 1) Consult adhesive TDS for proper mix ratio When it comes to laminate, it has medium to high residual isocyanate monomer and minimum initial bond power. Limited Color Options: Solventless lamination is limited in terms of color options. 2. If there is an ink bleeding problem, work with both the ink and adhesive suppliers to resolve the problem. 1) Insure correct mix ratio is being used and balances used to weigh are calibrated. 1.25 lb/ream of adhesive suits most applications; however, certain inks and heavy gauge films may require 1.75-2.0 lb/ream to resolve problem. 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. It also determines the coating amount. Adopting the solutions can greatly improve the work efficiency of the solventless laminator. Confirm solvent via GC/MS, look for capping via NMR and SIMS/MALDI, Some end users want less than 1,000 mg/ream. MACtac is a global company that always has been driven by innovation, discovering future customer needs and developing new products. On a variable speed machine loaded with thicker film it may be that the film is being run too fast and is not getting enough time on the heat shoes. Form 1 Coating Amount of different Lamination Structure. Learn more in our Cookie Policy. Provided by the Springer Nature SharedIt content-sharing initiative, Over 10 million scientific documents at your fingertips, Not logged in Below are several common issues and suggested solutions. Find out the quality problems in time to reduce the lot loss Early detection of quality problems will reduce material loss and customer returns MINIMIZE QUALITY PROBLEMS Inspect if any factors causing defects: 1. The peeling strength of OPP / AL / PE is above 3.5 N, close to or higher than that of some solvent-base laminating adhesives. When warming up the machine, keep the rollers open and keep the forward drive on a low speed. The resulting laminated film is then rewound into a finished roll. Among the solutions to heat-related bubbling is not to let the rolls sit idle for extended periods of time, to speed up the laminator so less heat gets into the printer or to work with a temperature about max 40C. The mixture goes into the gap between fixed & metering roller, and then coats on the film. (PDF) Lamination Suitability for Flexible Packaging - ResearchGate Apply enough pressure to give uniform footprint across web of no more than 0.5 inches, often 30-40 psi. FSEA Announces 22nd Annual Gold Leaf Award Winners, Working with Paper Stocks and Laminations for Digital Inkjet Embellishments, Laminate, Coating or Cast and Cure: Which Type of Soft-Touch Application to Use and When, Trends and Troubleshooting with Laminated Film Equipment. 2. It should be cleaned every time the line stops. Some flexible packaging producers like NJ-based LPS Industries have moved entirely to the use of a solventless lamination process. Thicker films may be run at lower speeds with no problem. Boat wake is caused by several things. Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations. And, LPS industries widely opts for fourth-generation adhesives that are VOC-free when it comes to flexible packaging varieties. If you enter the market for the first time, using solventless adhesives can reduce your capital investment costs as compared to solvent-based laminators. 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. The solventless adhesive is used in a wide array of packaging applications as it is a high-quality laminating adhesive. The adhesive bond can only be as good as the anchoring of the layer it is adhering to. We can provide high quality solvent free PU laminating adhesive, which is environment-friendly, innocuous and certificated by FDA, RoHS, REACH. High residual monomers and low initial bond strengths somewhat limit theapplication of these adhesives. In this process, the bonding agent is hot and in a melted form, which is applied to one substrate. There also must be free air space under the material to be neutralized, directly under or over the spot where the tinsel is placed. This means that solventless adhesive flexible packaging film is suitable for products like the following: Amiba companys products are widely used by ensuring quality management, environmental protection, and integrated ISO standards: It has been assessed and certified to meet the requirements ofHazard Analysis and Critical Control Point (HACCP) Codex Alimentarius, It has been assessed and certified to meet the requirements ofFood Safety System Certification (FSSC) 22000, It has been assessed and certified to meet the requirements ofISO 22000: 2018, It has been assessed and certified to meet the requirements ofISO 9001: 2015. Often seen forming in the heat seal edge and working inward but can occur anywhere in package. For instance, thinner film needs less tension. Analysis of Packaging Coefficient Friction & Anti-block Problems in This manufacturing decision also eliminates the . 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. Less than 1,000 mg/ream total solvents are desirable. Solventless adhesive generally indicates a specific type of adhesive composed of two components reacting with each other and consequently not requiring drying. This button displays the currently selected search type. The International Journal of Life Cycle Assessment, https://doi.org/10.1007/s11367-021-01883-4, access via Flexible packaging is made of multiple layers of different kinds of films. 1. For one hand, when A&B component get mixed, the sol-gel reaction get start, making the viscosity go up. As is shown in Pic 3, the friction coefficients have great differences between the circumstances of 25 and 35 curing. Tinsel is the most common tool for this application. Difficulties: The main problem to manufacture four-layer aluminum retorting pouches is to find the proper combination of different materials, including films, adhesives, ink and solvent.. Silvering usually is caused by too low an operating temperature and most often is seen when a machine is not given time to warm up or if the film temperature drops too low. The Dow Chemical Company (1995-2017). Table 2 below outlines lamination results for Ingeo based lamination structures. For additional information on laminating and MACtac, contact Helene Gobry at hgobry@mactac.com or visit www.mactac.com. Laminating problems and solutions 1.Bubbling issues - Academia.edu Solvent less lamination is suitable for ready to eat Extrusion lamination is used for all bulk products packaging which require more In all type of laminated woven BOPP bags we will use. We utilize cookies to understand how you use this site and to improve your browsing experience. Reduction in chemical resistance can effect ability to withstand internal package contents or external chemical exposure. At this time, it appears as a small and uniform spot in the entire composite film. 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. In dry lamination, the bonding agent is applied on the substrates that have been dissolved into a liquid. Trademark of The Dow Chemical Company("Dow") or an affiliated company of Dow. However, there are also some drawbacks such as slower production, limited availability, limited color options, and higher initial investment. Use correct diameter blade to create vortex but not create foaming. Applied properties and life cycle assessment of flexible packaging lamination processes: a comparative study. It is important to adjust web tensions so that each film elongates roughly the same amount through process. Higher Initial Investment: Solventless lamination requires a higher initial investment in equipment. Solventless lamination technology adopts a solvent-free adhesive instead of solvent-based adhesive, which can avoid VOCs emissions from the source. Once it gets pulled in, grab the back of the image and hold it taut so any wrinkles get smoothed out before they enter the nib. J. The machine was researched and developed by our company combined with the gradually matured solvent-free laminating technology. These problems were generally associated with variations in the ambient moisture content. At this point, the coating unit should be downtown, or the transfer roller is changed, and the blanket is eliminated. Run G.C.s to confirm low retained solvents. The incorrect mixing ratio 3. The adhesive can only reduce this movement slightly(thus causing laminate curl) this will result in tunneling in lamination. Unless there is something wrong with the film this problem comes from film being run at too low a temperature. The cooling performance of the back film roll which is from the composite roller, is poor. Insure inks you are using are completely dried prior to laminating. Solventless adhesive generally indicates a specific type of adhesive composed of two components reacting with each other and consequently not requiring drying. In fact, the flexible packaging market is the only packaging segment . Contact us for additional technical support. PROBLEM: Haze in lamination 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. The hygienic performance of the composite film will not be reduced due to the existence of residual solvent. Inadequate pressure can cause silvering if the film isnt pressed onto the image hard enough, preventing the adhesive from properly bonding. By continuing to use this site you are giving us your consent to use cookies in accordance with our privacy policy. The highest speed of the solventless machines is above 600 m/min, generally in 200m/min. 1. Answer: These occur from the natural moisture in the item making it swell during printing. However, moisture is involved in the curing process for the application of a one-component solvent-free adhesive and moisture needs to be added to ensure the curing of the lamination. Solventless laminating adhesives provide packaging converters with cost savings by eliminating the requirement of ovens to remove water or solvent carriers in water-based or solvent-based adhesives. 3 Reasons Why Going Solvent-Free Improves Sustainability You can update your choices at any time in your settings. Picture 1 shows the relationship. Poor heat and chemical resistance is any reduction in the ability of the adhesive to withstand heat or chemical exposure from what was considered normal. 2. It is sometimes essential to smooth out an item as it passes over the feed table and through the rollers to ensure an even . In addition, grounding all plant machinery and related equipment is most important. 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. Poor solubility of the ink and the adhesive, such as using polyamide ink. Six environmental indicators, including global warming potential (GWP), photochemical oxidant formation potential (POFP), primary energy demand (PED), water use (WU), acidification potential (AP), and respiratory inorganics (RI) were selected, with a particular focus on the first two indices. Required fields are marked *. Solventless Laminating Machine is machine solution for taking place of Solvent Lamination machine to make laminated films in Pouch Making Industry. Packaging Engineering 39(9):4450 ((in Chinese)), Han D, Gao S, Fu QY, Cheng JP et al (2018) Do volatile organic compounds (VOCs) emitted from petrochemical industries affect regional PM 2.5. As showed in Pic 1, the viscosity clearly goes down when the temperature gets high. 4. The first generation is based on one component solventless laminating adhesives that have sturdy green bond strengths and high viscosity. Practical test shows that, the leveling property gradually become low when the viscosity gets high. Take note that in traditional practices, solventless adhesives did not go well in things that contain foil. Environmental pollution is a growing problem in developing countries, including China. Copyright. Improved Quality: Solventless lamination provides a high-quality bond between materials. Film is not properly adhered or starts to come off sometime after lamination. 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. 3) Insure only urethane grade solvent are used for diluting adhesive's when dilution required The Influence to The Products with Solventless Lamination 2.1 Temperature The temperature setting in solventless lamination includes A&B Component,. Compared to traditional dry laminating, solventless lamination has significant advantages in the following aspects. Before moving on to solventless or solvent-based adhesives, here is some key information on lamination processes that will help you understand how these layers are laminated together by using the following lamination processes. The temperature gets higher, faster and more completely the reaction will be. Tension Take note that in traditional practices, solventless adhesives did not go well in things that contain foil. Trustworthy Solventless Laminating Machine Manufacturer | Sinstar For example, if hundreds or thousands of 18 wide sheets are laminated on a 38 machine, the center of the rollers can get worn down more than the ends of the rollers. 2. Select Accept to consent or Reject to decline non-essential cookies for this use. Atmos Environ 98:168178, Garciaceballos L, de AndresDaz JR, Contreraslopez MA (2018) Life cycle study of different constructive solutions for building enclosures. (Consult Ink manufacturer to confirm). However, web can be clear and still have too much water retention. 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.
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