By Liz Stevens, writer, PostPress

Film laminating is an option that can offer both practical, functional as well as embellishment solutions for printers and finishers. In the past, laminating has posed several challenges for a variety of reasons, but today’s equipment makers have largely tackled and overcome these challenges and have engineered advanced film laminating systems featuring the latest in automation, which makes the addition of the newest laminating equipment an attractive consideration.

PostPress talked with representatives from three leading equipment manufacturers and distributors – Best Graphics Group, Nobelus and Skandacor – to learn about emerging trends in film laminating, how new technologies can solve common laminating problems and the value-add that film laminating can provide for printers and finishers. Best Graphics Group, Waukesha, Wisconsin, offers a full line of graphic arts, bindery, finishing and packaging equipment from 20 global manufacturers. Nobelus, Knoxville, Tennessee, is a lamination system integrator and specialty films innovator. Skandacor, Webster, New York, offers laminating, binding, folding and cutting equipment and supplies.

What are some of the hot markets right now for film laminating? Why has there been growth in these areas?
John Hower, marketing & business development at Best Graphics Group, identified several areas where film laminating is in demand. “One area,” said Hower, “is book publications. Book readership is at the highest it has been since 2008 and, therefore, so is book manufacturing.” Another hot market is in folding cartons and packaging. “In this sector,” Hower said, “laminating adds higher structural integrity to cartons and packaging, and this typically requires unique films. We also are seeing a lot of interest from the marijuana/CBD industry; this market is in its infancy stage. There is a high growth rate of demand from the vast number of companies vying for market control that are looking for unique packaging options.” Hower also noted increased use in the commercial sector. “Differentiation is key, right? Utilizing textured films to create a sensory experience for the end user helps companies stand out.”

Dragan Nikolic, business development manager at Nobelus, pointed to a trio of hot markets. “Prime labels,” he said, “are increasingly being utilized by major and boutique brands to engage the senses and help consumers form a connection with products. Start-up brands want to stand out and make their packaging experience more memorable. Both profiles have a growing demand for embellishments and tactile finishes on prime labels.” Nikolic highlighted the expanding opportunities in flexible packaging. “Many brands are moving to flexible packaging solutions,” said Nikolic, “to accommodate an expanding line of products and meet new standards for sustainability to leave a smaller footprint. With products like Nobelus’ line of unsupported films, flex pack manufacturers can also offer more finishes and effects than ever before.” And Nikolic noted that lamination can provide the luster formerly found in silver halide. “Because silver halide has fallen out of favor with many digital photo producers due to supply issues and price increases, a digital solution that doesn’t use traditional silver halide is of great interest,” he said. “Nobelus integrates sheet-fed and roll-to-roll lamination to replicate a silver halide luster on digital print, preserving the look and feel of a traditionally produced photo almost perfectly.”

Bob Rowden, product development at Skandacor, also sees the tactile quality of film laminating creating market opportunities. “Tactile films continue to be the hottest market right now for film laminating,” he said. “Growth in this area is due to consumer demand and the realization amongst designers that film lamination is no longer just for print protection and durability, but a key component of the graphic design that can make or break the impact of the finished piece.” Rowden commented that Skandacor provides soft touch films that are very popular for their tactile feels but even more so for the special formulation that make them work as an excellent base layer for further embellishments like spot UV coatings and/or digital foils. Rowden also noted that the embossed features of one of Skandacor’s lines of films provides dimension to otherwise flat printing and can link well with the intended impact of the printed piece. “For example,” said Rowden, “Skandacor offers an authentic woodgrain pattern that totally transforms a hardwood furniture marketing piece, giving the visual impact of real wood.”

What challenges are there currently with film laminating applications? What technology does your equipment have to overcome these challenges?
“Digital print,” said Rowden, “has always been a challenging application for film lamination, however progress in film and equipment technology have overcome this, with our UltraGrip adhesives for the films and improved heat and pressure systems on the equipment. It is common to see infrared heaters in the industry, but the issue surrounding infrared heat with air is that the hot air quickly dissipates. Our technology utilizes sealed system liquid heaters which maintain the heat much more effectively, eliminating cold cycles and reducing energy consumption.”

“Another common challenge,” Rowden said, “is producing sheets that are suitable for downstream processing through finishing equipment, with curl and lamination flagging being the most common culprits when issues arise. Design improvements to decurling, cooling the sheet under tension and sheet separation all play key roles in getting
effective output.”

Nikolic brought up rising costs and supply chain issues. “It can be hard for PSPs to keep up with increasing supply chain and cost pressures in lamination,” he said. “In a time when raw material and freight costs are constantly rising, we’ve found some ways to help our customers employ more creative solutions. For instance, we’ve discovered that we can help converters create foil board on-demand with our metalized silver, gold and holographic laminates. This can save money on several fronts: cost of finished material, scaling down paper weight and carrying zero inventory.”

“Another challenge for PSPs,” said Nikolic, “is knowing which adhesives and laminates are compatible with emerging printing technologies and the various inks they use. Nobelus is currently addressing this issue by offering adhesives designed specifically for digital inks – in addition to our traditional adhesives – but we also fund research and development to discover more comprehensive solutions, such as equipment features that can increase bond strength and adhesives that work with any type of ink.”

In Hower’s experience, the primary challenge is that finishers and printers want to offer a wider range of solutions or applications to end users. “Printers can overcome this challenge by using technology that allows them to choose from multiple film materials,” he said. “The hot-knife capability that our equipment offers allows printers to utilize a wider variety of films, such as polypropylene, nylon, polyester and metalized films.”

What advantages does your film laminating equipment offer to the companies looking to add film laminating to their services offering?  
“At Best Graphics Group,” said Hower, “our Ecosystem Film Laminators have a wide breadth of offerings, from short run, small format digital offerings to high volume, long run work, to roll-to-roll water-based solutions. Simply put, there is no single-sided application or price point that we cannot fulfill.”

Nikolic said that automation, a range of production capacity and options make Nobelus equipment attractive. “Labor shortages are making automation more vital than ever,” said Nikolic, “and Nobelus’ extensive catalog of automated systems ensures PSPs get products to market on time while still adding value to finished print. We offer units that can support production volumes ranging from medium to extremely high and have single-sided and dual-sided options.”

Rowden also cited automation. “With an aging workforce being replaced by younger digital-first workers, as well as skilled labor shortages,” he said, “we strive to make our equipment easy to use. A popular feature of Skandacor’s commercial lineup is its automation, allowing the machines to be started with just one button and graphical icon-based user interfaces with touch screens that make job setup intuitive. Time is money, so quick set-up and effective operation have become the most important aspects.”

Equipment design and durability, said Rowden, are also prime features for Skandacor. “Shorter runs and higher customer expectations regarding fast turn times have brought the cost of downtime into sharp focus,” he said. “We’ve analyzed build quality component-by-component to address any weak links in the systems and to eliminate unnecessary design features, while keeping overall machine performance front and center. By stepping back from the competing options and taking a systematic, user-first approach to the machine design, our equipment far surpasses any others in the market, making Skandacor the machines of choice for progressive printers looking for well-built, versatile and compact machines.”

Many of our readers are involved with trade/print finishing services. Do you have any comments on why you believe a finishing operation should consider adding or upgrading their film laminating capabilities?
Nikolic said that finishers can benefit by adding laminating for a choice of finish/embellishment and speedy production. “Getting prints to market quickly is pivotal in giving trade finishers an advantage over the competition,” said Nikolic, “and this requires updated equipment that can optimize the lamination process for improved productivity. Having modern sheet-fed and roll-to-roll lamination equipment in-house also enables trade finishers to offer a broader variety of finishing services and to supply their customers with more options for finishes and embellishments, resulting in higher profit margins.”

Rowden stressed that lamination and specialty finishes are becoming increasingly popular and that with the Great Retirement, shops may want to replace older equipment with new, automated machinery. “Since lamination complements and often is required as part of overall print embellishment, shops without film lamination capability will find it hard to compete as print consumer demands change,” said Rowden. “The growth of the packaging segment also is driving demand for film lamination. For those looking to upgrade, we often find that automation and ease of use are primary drivers as skilled labor retires. Older mechanical equipment is difficult to find operators for and harder to maintain. Also, increased versatility and the ability to apply specialty finishes like digital foils and coatings have driven adoption of
newer technology.”

Hower asserted that for finishers, “film lamination is a further embellishment or offering for users. The ability to offer film lamination is proven to engage the customer and increase margins. Being able to provide film lamination in-house makes for decreased lead times for finishers and gives them increased quality control on the products they produce.”

All three of these equipment providers will be exhibiting live at Amplify, the print finishing & embellishment event taking place June 14 – 16, 2022, in Minneapolis, Minnesota. For more information on Amplify, visit www.amplifyprint.org.

by Jeff Truan, strategic account manager
Nobelus

The decision to add a laminating film to a printed product has become much more than just protecting the piece from moisture or other outside elements.

Today, there are a variety of choices to add specialty effects or special tactile surfaces with film lamination. PostPress sat down with Jeff Truan of Nobelus to ask a few questions on the current landscape for film laminations.

Q: In the past, film laminating was used mostly for protection of a printed piece, but today, there are a lot of different types of laminates for decorative and “touch and feel” applications. What type of laminating films are really popular right now for both decorative and functional applications?

Anything with a “tactile” surface is really getting noticed and requested.

For many years, the lone tactile product has been a smooth, soft-touch feel, but lately – with the linen, leather and even gritty laminates now making their way to the market – it is obvious that the consumer wants more than just something soft. The key of differentiation is what we hear from almost everyone. No one wants to be a “me, too” when it comes to their product or finished goods. The entire point is to make the person touching the product stop and think about why it felt different and notice that it is unique. At that point, the brand or marketer has disrupted the standard thought process and instantly stands out from its competitors. In addition, we continuously receive requests for matte finishes, and standard matte isn’t good enough anymore. Customers are asking for an ultra-matte film. Part of the reason for this is to help highlight further surface embellishments, such as specialty raised coatings or foils that will stand out even more visually when the consumer looks at the product/logo/brand on the finished piece.

It may seem odd in this e-commerce world that there still is a focus on touch, feel and visual impact, but actually it is growing for more than one reason.

First, there is massive competition among brands jostling for space and attention on store shelves to reach the consumer. Second, in
the e-commerce sector, brands find it critical that the first
impression be superb and that, when the product is unboxed and taken out, it meets or exceeds the consumer’s expectations. This dawn of a new day in fickle consumerism is causing every brand to rethink their packaging look and feel due to the growing split between brick and mortar and online shopping. The final – but still critical – piece to the puzzle is how to portray that branding on a computer screen, which is all the more challenging. With excellent photography and design, embellishments can be captured to increase the likelihood of a consumer connection – even through a computer monitor.

Q: What type of products are using these kinds of laminates?

Laminates are going on everything these days – from cosmetics and personal care products to consumer electronics and even now on-demand flexible packaging. It seems that every vertical is pervaded by the need to “be different than the other brand.” Just recently, I ran across a generic brand selling single-use towels spending most likely four or five times the normal cost to have a unique look and feel on the thin BOPP wrap that is on its towel rags. For many years, laminates traditionally have only been in commercial print, which continues to be a more and more demanding market. The first uses of film laminates were more utilitarian, mostly to protect from dirt and grease or to add stiffness. Now, with the cultural shift and more demanding and fickle needs of the everyday person, coupled with a clamoring for uniqueness in retail presence, it almost is more about the finished look and tactile feel rather than the robustness or protection.

Q: Of course, digital printing continues to grow. Are there any special precautions that need to be taken when film laminating digitally printed materials?

This really is answered by splitting digital into three categories – toner, electro-ink and UV inkjet.

Toner still is largely applied with a fuser oil, leaving a silicone residue. This residue typically means additional bonding agents are required on the adhesive of the laminating film so it will adhere over the sheet when using toner-based digital print. In many cases, this type of specialty film carries an upcharge premium due to the additional pass in the extrusion coating process. The additive allows penetration through the fuser oils and lets the glue “lock on” to the toner beneath, creating the bond.

Electro-ink technology, most commonly found on HP Indigo digital presses, is very close to traditional inks, and thus much easier to bond to almost all laminates. Laminating films used over this type of digital print include an adhesive that “crosslinks” with the Indigo technology, therefore creating an instantaneous, permanent “destruct” bond that requires tearing the fibers to pull it away from the ink/paper.

UV inkjet, found on digital units such as the Komori K1 and Fuji J-Press, is yet another hybrid ink technology, and although not as challenging as typical digital toners, it still has a fair amount of additive in the inkset that sometimes creates challenges in bonding. One of the most useful ways to ensure the ability to utilize the lesser expensive laminates on the UV inkjet technology is to consider lamination equipment that has an IR lamp set in the sheet-feeding system, thus reducing the amount of effect the UV ink additives have during lamination and creating a much better instant bond of lamination to the sheet.

Q: In recent years, have there been changes in machinery for applying laminating films that have helped to increase speeds and eliminate waste?

Recently, we have seen several adjustments from equipment manufacturers that include unique options catering to the changing needs of the print industry. Quick reference measurement scales built into the paper load area that coordinate with where the laminate is loaded on the machine make the alignment of paper to the film a far faster process than in yesteryear. Certain newer laminators include a pause/stop feature that allows the operator to stop the machine directly on the overlap of the stock feeding into the nip point, thus decreasing the changes of ruined sheets. This is more important than ever before with variable digital printed sheets – where every sheet can be unique.

Now there are inline sheetfed and roll laminators that can take output from the printing press as the sheets come out and adjust their speed on the fly – depending on the amount of material being pushed to them by the press. Blowers that spew negative ions to reduce the static caused by digital presses, as well as full touchscreen control panels that speed setup, all point to the fact that the lamination equipment of today has to be nimble, simple and carry the ability for a huge range of thicknesses and types of film laminates to be run.

One must go on record to clarify that, in spite of claims that have been put out into the market, there is no one single machine that can effectively run one-sided thin laminates on press sheets and two-sided encapsulation – simply due to the fact that operationally they are in separate worlds.

Q: What are some of the most  common problems with printed materials that need to be laminated? What are some key tips for a printer to ensure proper adhesion and to eliminate any challenges during the film laminating process?

Many times, we see sheets that are not properly humidified or printed on too thin of stock, which create downstream problems by wrinkling – typically in the center of the tail of the sheet as it cannot manage the heat application. Additionally, common problems include curling issues due to improper tension settings on the machine; wrinkling due to defective laminate rolls; or the application of coatings to help inks or toners dry, but which effectively act as a barrier to any type of film lamination.

Companies that invest in certain types of toner-based digital presses many times do not realize that there is a significant upcharge for the laminating film. As with any type of finishing, it is very important that printers and the film laminater communicate on the type of press (digital or offset) on which the printed piece will run. Another tip is to let the printed sheets sit as long as possible before lamination (I know – good joke in an industry where yesterday is not fast enough!). Proper training on the film lamination equipment also is very important to ensure that the operators have a complete grasp of the best way to run the machine on various iterations of product. Lastly, try to let the laminated sheets sit for at least several hours after the lamination process to allow the glue to set up and cure as long as possible to maintain the best bond before cutting/folding/finishing/decorating.

Q: Foil “sleeking” continues to be a popular addition to short-run digitally printed materials. Although it is not laminating film, the process is somewhat similar. Explain how sleeking works and where it best  fits for foil decorating applications.

Sleeking (digital foil through a toner adhesive) is a very unique opportunity for additional margins for finishers or printers. Sleeking has jumped onto center stage with the advent of personalization and greater decoration as requested by the customer. It is essentially a perfect fit for those wanting to do short- to medium-run metallic foil projects and personalized foil projects as it requires no die and very little setup. It is a “transfer foil” – originally designed around adhesion to the HP Indigo Electro-ink so that wherever there is HP ink on the sheet, the foil will adhere. The beauty of this technology is that it requires no dies, can do any design you wish in foil and makes turnaround times incredibly fast. It gives a high value-add for short-run metallic foil and can be combined with film laminates like “soft touch” to create something that is both pleasant looking and tactile – as well as tailored specifically to the person that receives it. Sleeking also is excellent for creating prototypes to showcase how a carton or label would look with a metallic foil finish for potential larger runs on high-volume equipment.

We see the sleeking technology being used for greeting cards, graduation announcements, book covers and direct mail with personalized foil, driving efficiencies and response rates like never before.

Let’s face it: who would have guessed that three years ago you could order your wedding invitations and announcements in a tactile finish, with gold foil showing the name of each person invited – individual to the card?

Jeff Truan is the strategic account representative for Nobelus^® – a worldwide supplier of thermal laminate films, variable-data foils and film laminating and foil “sleeking” equipment for the print, packaging, publishing and photo markets. Nobelus^® products are utilized by top brands, adding protection and attraction through holographic, tactile, anti-scuff and metallic effects. For more information, visit www.nobelus.com.

by MACtac global

Laminating can be a delicate process with several potential process flaws that can affect the final look of a laminated print. Well versed in pressure-sensitive technologies, MACtac has identified some of the most common issues that can occur during the laminating process.

Question: What causes laminating bubbles?

Answer: Few issues look worse than when bubbles appear under the film. Bubbling can occur for many reasons, the most common of which are listed below.

Tension
Lack of supply roll tension can cause the film to not be taut as it enters the nib. This insufficient tension causes bubbles when air gets trapped between the film and image. Too little supply roll tension will cause bubbles before it will cause wrinkles in the film. Insufficient tension easily is fixed by adjusting the tension of the feed spool to the proper specifications for the type of film being used. For instance, thinner film needs less tension.

Speed
Feeding too quickly causes bubbles if the item is pushed into the nib faster than the speed of the laminator. The solution to this problem is too obvious to mention.

Heat
“Hot spots” are a key problem when laminating inkjet prints. Inkjet printers dump a lot of ink onto the print and a rushed operator may try to laminate the image before the ink is completely dry. The problem can be exacerbated by the fact that, if a laminator is allowed to sit for extended periods of time without the rolls turning, there can be varying degrees of temperature on different parts of the rolls. This creates hot spots. When running a laminator at 85°C, the point where the rolls sit together easily can become a hot spot of +95°C. When a moist inkjet print encounters one of these hot spots, the ink easily can boil, creating bubbles. 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 40°C. Always use the appropriate pressure.

Silvering
Silvering is caused by the capture of tiny bubbles of air, which look like hazy or reflective areas in the lamination. It may go unseen over light areas of an image, but will be more obvious over dark or black areas. 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. When a large machine is warmed up without the motor on, one side of each laminating roll remains relatively cool. 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. “Cool spots” are areas that aren’t hot enough to melt the adhesive. If bands of silvering alternate with bands of properly adhered areas, it means one part of the roller was too cool.

Be sure to pay attention to any defect which repeats. This is typical of debris, damage or low temperature on a section of the roller. Bubbles also can be caused if the adhesive doesn’t bond properly to the image. It can look like a sheen on the image. Bonding problems also can be caused by inadequate heat, inadequate or uneven pressure or too much speed. Inadequate pressure can cause silvering if the film isn’t pressed onto the image hard enough, preventing the adhesive from properly bonding.

Question: What causes wrinkles during lamination?

The film will wrinkle if there is not enough supply roll tension. Every laminator needs a certain amount of resistance in the unwinding of the supply rolls so that the film lays flat as it goes into the nib of the laminating rollers. Thinner film needs less tension, thicker film needs more. Also, respect the laminating temperature of 40°C to avoid wrinkling due to damp materials during the laminating process. The moisture content of the printed substrates must be the lowest.

Question: What are “orange peel” wrinkles?

Answer: The industry term “orange peel” refers to very fine wrinkles or waves in the laminate. This is a common condition resulting from too much heat. Simply adjust the temperature to a lower setting. NOTE: A quick fix can be to speed up the laminator. As the film runs at greater speeds, the actual film temperature is reduced. Some orange peel may occur when laminating prints with a lot of solvent residues or oil-based prints.

Question: Why does waving/blistering/dimpling occur?

Answer: These occur from the natural moisture in the item making it swell during printing. When too much heat is used, the moisture is dried out, but the areas that swell prevent the item from lying flat. They can also be caused by too little tension and uneven pressure.

Question: How does pressure affect lamination?

Answer: Users should start with as little tension as possible and then add more as needed rather than starting with a lot and loosening up. 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. For instance, if there is insufficient tension on the image as it is going in, it could end up crooked or folded as it enters the nib of the rolls. When feeding an image into the laminator, make sure it is parallel to the roll. 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.

Print curl occurs when an image is unrolled and wants to roll itself back up again. A little bit of this is normal, but if the print doesn’t lay flat after some gentle smoothing, it is a problem. Print curl happens when one side of an encapsulated image changes size out of proportion to the other side, causing the print to curl towards the smaller side. This can be caused if the user puts a heavy laminate on the top side and something thin and cheap on the back, but doesn’t adjust the tension to allow for the different dimensional stabilities of both types of film. For instance, if the user applies the same tension to both the top and bottom film, the bottom film will likely stretch more than the top since it is weaker. 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.

Boat wake is an undesirable ripple pattern in a “V” shape on a finished print. Boat wake is caused by several things. For example, when trying to encapsulate something thick, the edges of the film hanging off the sides of the print will not get as much pressure, so they’ll drag behind, causing the ripple pattern. “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.

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. To prevent this, make sure the pressure is at the proper ration of speed for the pull and front rolls. Make sure to work with a low temperature without exceeding 40-45°C.

Question: How can static electricity build-up be handled?

Answer: Static electricity is an issue that may arise and is impossible to prevent. However, it easily can be kept under control by taking a few precautions.

Removing or neutralizing static electricity by induction is the oldest and simplest method. Tinsel is the most common tool for this application. However, tinsel oftentimes is misused and, therefore, sometimes not successful. When using tinsel, it must have a metal core. Tinsel with a string (non-conductive) core will not function properly. Secondly, the tinsel must be well grounded electrically, stretched tight and placed ¼ of an inch from the material to be neutralized. There also must be “free air space” under the material to be neutralized, directly under or over the spot where the tinsel is placed. If done properly, the tinsel will reduce static electricity on both sides of the static-laden material.

In addition, grounding all plant machinery and related equipment is most important. Besides the safety factor, a grounded machine will help drain off extremely high charges of static electricity from partial conductors.

Static electricity is an issue when laminating lighter weight films since they have a tendency to curl back towards the rear rolls. The film then can begin to wrap around the rear rolls. To alleviate this problem, put the laminator in reverse and gently pull the wrapped film off the rear rolls. 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.

Question: What causes repeating marks?

Answer: Repeating marks occur when there is something on the roll, usually a piece of paper or a scrap of film. If the defect is adhesive residues, simply clean the rolls.

MACtac is a global company that always has been driven by innovation, discovering future customer needs and developing new products. 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. On top of a high level of in-house manufacturing and R&D excellence, MACtac has been working on developing a strong partnership with its customers and a solid sustainable development policy. For additional information on laminating and MACtac, contact Helene Gobry at [email protected] or visit www.mactac.com.