By Luigi Cristicini, senior technical research and development manager, Drytac

While not required for every application, lamination is one of the most widely used techniques to not only protect printed work but also provide a distinctive finish. There are three key reasons to laminate a printed piece: finish, function and body. Finish refers to the aesthetic – gloss, luster or matte; function includes UV protection, anti-graffiti or slip-resistant properties; and body adds rigidity for handling or installation.

However useful it may be, lamination does not come without its challenges. New developments across hardware and materials have made it easier for industry professionals, but there still are several issues that can cause headaches for those laminating work. If lamination is required, the following questions should be considered:

• Which ink technology is being used, and how long must it cure before lamination?
• Is the print media compatible with both ink and laminate adhesive chemistry?
• What’s the intended environment: indoor, outdoor, high-UV or high-traffic?
• What surface texture or appearance is desired?
• Will the graphic be contour-cut or applied to a curved surface?

While several issues may arise when using a laminator, the good news is that each can be resolved easily – or even prevented – with the right approach.

Challenge #1: Tracking

One stand-out issue is tracking, which can be particularly problematic when laminating long panels or a full roll of printed graphics. Usually, tracking problems are the result of bad webbing practices or an out-of-square laminator, but there are some simple steps to take to avoid these issues.

First, ensure the roll of printed graphics is not “telescoped,” which happens when some of the material comes out of line at the end of the roll. Additionally, check that the roll is centered on the laminator machine as well as being on the correct supply or unwind shaft.

Next, make sure the laminate is webbed correctly: use a single-tape point in the middle of the core release liner to ensure the web remains tight and even in the most important areas.

Once webbed properly, load the media and feed directly through the rollers. It then can be taped to the out-feed table to maintain tension, but this only should be done while maintaining tension and pressure across the entire web. At this stage, attach the laminated print to a take-up core – if the machine has one – or feed the web onto an auxiliary out-feed table.

Should tracking issues persist, check the side cabinets on the laminator that holds the rollers as they could be potentially out of sync. Finally, ensure they are sitting on the same plane in order to achieve a quality finish.

Challenge #2: Wrinkles

Another common issue with lamination is wrinkles. “Lateral wrinkles” often happen when the media has telescoped. While trying to self-correct, the laminate moves and folds over on itself. Align the material at the end of the roll to alleviate the wrinkles.

“Vertical wrinkles” occur in the direction of the feed due to too much brake tension and the release liner splitting too high on the rollers. This can be fixed easily by reducing both the brake on the supply shaft and the clutch, lowering the overall speed.

“D-wave wrinkles” are caused by excessive pinch-point pressure. To fix this, simply reduce the roller pressure, and the issue should disappear immediately.

Technicians also may see “left- or right-side wrinkles,” which can happen when the pinch point is uneven on one side of the laminator. Each laminator has different settings; the manual will provide instructions on how to reset the parallelism on the machine.

Finally, “angled wrinkles,” also known as “boat waking,” occur when pressure on the rollers is too low – something that is very common on laminators with crowned rollers. Finding the right pressure point will solve this issue. These wrinkles also may be caused by using mismatched widths of laminate and printed media; always try to match widths within a few inches – or centimeters – to avoid this.

Challenge #3: Digitally Printed Materials and Ink Formulations

As digital printing continues to expand, the laminating process must adapt to an ever-wider range of inks and substrates. One of the main challenges relate to ink chemistry and surface energy. Certain digital ink sets – particularly UV and some latex formulations – can produce lower-energy surfaces, which reduce the adhesive bond between print and laminate. Selecting a laminate with an adhesive designed for these print types is essential to ensure a secure bond.

Outgassing is another key consideration. Solvent and eco-solvent inks require a 24-48-hour cure period after printing to allow solvent vapors to escape. Laminating too soon can trap these gases – causing bubbling, silvering or delamination.

Ink behavior also influences flexibility and heat tolerance. Solvent inks penetrate the print surface and are well-suited for curved or textured applications, though they may slightly affect dimensional stability. Latex and resin inks sit on the surface – delivering strong durability and color vibrancy – but may require careful lamination settings and adhesives compatible with lower-energy surfaces.

UV-cured inks, meanwhile, can present unique adhesion challenges due to their hard, textured surface. There is a known compatibility issue between solvent acrylic adhesives and some UV inks, which can lead to poor laminate anchorage or premature failure. It’s important to test adhesion on UV output prior to full production and, when necessary, select laminates with softer, more aggressive adhesives or pressure-sensitive films specifically designed for UV prints.

Newly developed laminating films – with a slightly higher adhesive coat weight – can help these products conform more effectively over layered or textured ink surfaces from UV or latex output. These films improve wet-out, deliver consistent clarity and ensure stronger long-term adhesion – even on challenging print profiles.

Finally, environmental and handling factors such as static, dust and roller pressure can impact finish quality. Maintaining a clean, climate-controlled workspace and applying even roller tension will minimize imperfections and ensure a professional, crystal-clear result. By addressing these factors early and properly matching inks, media and laminates to the end application, operators can ensure superior adhesion, long-term durability and a finish that looks just as impressive in the field as it did when it came off the press. 

Luigi Cristicini, senior technical research and development manager for Drytac Canada, has been with the company since 1991. Fluent in Italian, French, and English, Cristicini has played a key role in building Drytac’s global presence, working with photo labs, photographers and the picture-framing industry as well as leading the Canadian sales team since 1993. With over 30 years of expertise, he is a trusted resource for customers, suppliers and colleagues, recognized for his dedication and industry knowledge. For more information, visit www.drytac.com.