SOLVENT-BASED & WATER-BASED DRY LAMINATING/COATING MACHINES

SOLVENT-BASED & WATER-BASED DRY LAMINATING/COATING MACHINES

A Dry Laminating/Coating Machine is an industrial system that bonds two or more flexible substrates (films, foils, papers) using adhesives that are dried (solvent/water evaporated) before bonding.

1. What is the Work of This Machine?

This machine is used for dry lamination or coating of flexible materials such as:

1. Films (BOPP, PET, PE, CPP, etc.)
2. Aluminum foil
3. Paper
4. Non-woven fabrics

It applies solvent-based or water-based adhesives to bond two or more layers together (laminating) or to apply a functional coating (e.g., barrier coatings, adhesives, or protective layers).

1. Solvent-Based Dry Laminator:
   1. Uses volatile solvent-based adhesives (polyurethane, acrylic) that require high-temperature drying.
   2. Offers superior bond strength and faster production speeds.
2. Water-Based Dry Laminator:
   1. Uses water-soluble adhesives (PVA, acrylic emulsions) that are eco-friendly and low-VOC.
   2. Preferred for food & pharmaceutical packaging due to safety compliance.

Fig. Solvent Based / Water Based Dry Laminating Coating Lamination Machine

Key Components & Working Principle:

a. Unwinding System:

1. Dual unwinders for base material (e.g., PET film) and laminate material (e.g., aluminum foil).
2. Automatic splice for continuous operation.

b. Adhesive Application:

1. Gravure Coating: Precision engraved rollers apply adhesive (1.5–6 gsm).
2. Roller Coating: Metering rods ensure uniform thickness.

c. Drying Tunnel:

1. Solvent-Based: 80–150°C hot air evaporates solvents.
2. Water-Based: 60–120°C drying (slower due to water’s high latent heat).

d. Bonding Unit:

Heated nip rollers press layers together under controlled pressure.

e. Rewinding:

Tension-controlled rewinder for defect-free rolls.

Industry Applications:

✅ Food Packaging (Snack bags, pouches)
✅ Pharmaceutical (Blister packs, sachets)
✅ Industrial Laminates (Protective films)
✅ Labels & Flexible Packaging

Advantages & Limitations:

Solvent-Based:

✔ Pros: Faster drying, stronger bonds, wider material compatibility.
✖ Cons: VOC emissions, higher regulatory costs.

Water-Based:

✔ Pros: Eco-friendly, FDA-compliant, safer operation.
✖ Cons: Slower speeds, higher adhesive consumption.

2. How Many Workers Are Needed to Operate It?

Typically, 2–3 workers are needed:

1. 1 operator (controls the machine)
2. 1–2 assistants (loading/unloading rolls, monitoring quality)

3. What is the Production Capacity?

Speed: 50–300 meters per minute (depending on machine type & material)

Width: 800–2500 mm (standard models)

Daily Output: ~5,000–20,000 sqm (varies with material & adhesive type)

4. What is the Electricity Cost?

Power Consumption: 15–50 kW (depending on machine size & heating system)

Estimated Cost: ~$5–$20 per hour (varies by local electricity rates)

5. How Much Space is Needed to Install This Machine?

Length: 15–30 meters (including drying tunnel & unwinding/rewinding)

Width: 3–5 meters (for operator access & material handling)

Height: 3–4 meters (for ventilation & safety)

6. Where Can We Buy This Machine?

Ultimate Corporation, 18/2, Sahibagh, Savar, Dhaka-1340, Bangladesh.

7. What is the Origin of This Machine?

Originally developed in Europe & Japan for high-precision laminating.

Now widely manufactured in China, India, and Taiwan at competitive prices.

8. Do We Supply Only This Machine?

Yes, we supply standalone laminating/coating machine.

Optional Accessories:

1. Automatic glue mixer
2. Corona treater (for better adhesion)
3. PLC control systems
4. Drying ovens (gas/electric)
5. Best for: Flexible packaging, labels, industrial films.
6. Maintenance: Regular cleaning of rollers & adhesive systems.
7. Ventilation Required: Especially for solvent-based machines.