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The trend towards duct-fresh offset printing inks, single-component laminating adhesives and short production times repeatedly gives rise to quality problems in film lamination – especially when the film lamination is subjected to mechanical or thermal process stresses. A particularly problematic effect is time-delayed delamination.
Solution steps
The laboratory laminating system is to be developed based on a laboratory flexographic printing unit F1 from IGT in order to be able to produce one- and two-component wet laminations with and without pre-drying. Graded thermal/mechanical stress tests will be developed, based on real processes (creasing, folding, sealing). In printing tests, printed sheets (substrate, ink and primer variation) are produced, then film laminated using the laboratory method (adhesive and film variation) and fed to the stress tests. The time sequences between printing and lamination and between lamination and stress tests are varied. Further investigations concern existing test options on the printed sheet (e.g. test inks, adhesive tape test, wipe test) and on the laminated printed sheet (e.g. peel force measurement). The influence of curing agent dosing and its detection by ATR-IR spectroscopy will be investigated.
Targeted results
The aim is to develop a prediction model to determine the degree of difficulty of a film lamination in order to estimate the production risk and to be able to take measures. This model is to be based on material and process parameters of a film-laminated product and verified by laboratory and industrial tests. The results of the research project will contribute to improved process control in film lamination.