The side frame configuration of a piece of laminating equipment is the foundation for the overall performance and longevity of the machine. The side frame rigidity is integral to the overall integrity of any laminator design. The Duty Cycle requirements, overall speed, and tension levels of the materials being processed through the laminator must be taken into consideration.
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AGL's side frames are made from 3/8” to 1" thick laser cut steel with properly placed steel cross bars tying the machine frame together. These construction traits have been proven to provide longer stability over other machines constructed out of structural steel weldments and stamped sheet metal.
The nip roller assemblies are the most important components in any piece of lamination equipment. The overall construction and integrity of the nip rolls will determine the type of lamination output from any given laminator. In order to provide good adhesion, flatness and finish to any material of a laminators output you must start with steel nip rollers. The wall thickness is based upon the width of the nip roll as well as the amount of pressure exerted onto the nip rolls. The amount of deflection at the maximum pressure of the nip rolls must be .004” across the roll face. AGL consistently designs each and every nip roller to be within this specification and concentrically grinds the finished outside diameter to be within .003” to .005” TIR (Tolerance In Round).
These manufacturers will claim that the “Crown” in their rollers is there to “Smooth Out” the film during the lamination process. The actual result of crowning a roller covering is to compensate for the nip rolls deflecting while it is under load during the laminating process. The crowned rollers contact each other and the laminating materials in the middle before touching the outside edges. This moves the middle of the product through the machine at a slightly faster rate than the outside edges causing a condition referred to as “Boat Waking or D waves”. Crowned roller assemblies must be operated in one very specific pressure range for them to perform properly because of this inherent design weakness.
The AGL nip roller assemblies are designed to incorporate a roller core assembly that does not bend or deflect as described above. The benefit of this design is even and uniform contact between the two nip rolls and the laminating materials across the entire working surface of the roller regardless of the pressures being utilized for a given lamination process. This results in no “Boat Waking or D waves” during the lamination process which results in more profits and less wasted lamination material at the end of the project. You do not have to print three to sell one with AGL’s design!
AGL has elected to utilize air cylinders in all of their laminators to open and close their nip roller and pull roller assemblies. Utilizing air cylinders greatly increases the safety factor of the machine as well as allows for repeatable setup and processing for laminating. If an operator triggers an emergency stop switch with their hand or foot while running the AGL laminator, the air cylinders will immediately open the roller assemblies, eliminating the pinch point between the rollers. Many laminator manufactures are turning to “crank” assemblies to open and close the laminating roller assemblies. We have always wondered how an operator would open these rollers in an emergency scenario.
Air cylinders also provide repeatable laminator setup and production control by giving the operators or supervisors the ability to see and adjust how much pressure is being applied.
Air consumption with nip roll air cylinders is minimal and many shops will have compressed air available for other needs. In today’s market, there are also many reliable, low cost options available for adequately sized air compressors for locations that do not have compressed air available on-site.
Tension control and more importantly “repeatable” tension control, is one of the most overlooked and under emphasized areas of the lamination process control. Improper tension control can be the primary cause of product failure during the lamination process. Product failures such as “wrinkles” or “silvering” are often caused by the lack of tension during the laminating process. Product curl and delamination may be the outcome of too much tension during the laminating process. This tension induced delamination may occur several weeks after the product has been delivered to a customer which never plays out well for either party. AGL has always provided tension control devices that provide information and feedback for the operators to help them avoid the issues associated with improper tension during lamination. These tensioning control options range from a simple manual set point position on a supply station to fully “closed loop” electronic feedback and automatic control for critical production requirements.
A high percentage of today’s lamination needs can be satisfied with a simple and straightforward laminator configuration. A typical laminator configuration consists of a laminate unwind, release liner windup, an unwind for certain printed medias and in some cases a finished product windup. However, for those in need of something a little more customized for your product requirements, AGL offers a unique option. AGL specializes in getting a clear understanding of what lamination and production needs are required for a given customer. This allows us to design a machine configured to satisfy the manufacturing needs of the customer.
Our standard wide format product line of laminators are designed to give an end-user the flexibility to configure their equipment needs specifically for what they want to do while meeting the price range of the customer.
Our custom designs may include multiple unwind and rewind stations, heavy-duty roll handling capabilities, web alignment, high temperature requirements, web cooling, web conveyance and automated HMI systems. These are just a few of the features that AGL has incorporated into their manufacturing line of equipment over the last 65 years of operation.
Establishing if your laminator requires heated rollers is the first decision that a company should make. In order to determine if your machine requires heat will depend upon the type of adhesive you intend to process through the laminator. Thermal adhesives require heat activation in order to adhere the laminate to the product being laminated. Pressure sensitive adhesives (PSA) on the other hand, merely require peeling off a release liner and adhering the over-laminate to the product. This heat versus no heat consideration, primarily comes into play when your process requirements are utilizing pressure sensitive over-laminating films and PSA medias.
In PSA applications, adding heat to the process is not generally a specific requirement for the materials to do what they are intended to do. What heat does in a PSA process is soften the adhesive or make the adhesive more pliable. This softening of the adhesive, facilitates pushing the adhesive down into the hills and valleys between the droplets of ink that are laid down by your printer. By filling these ink droplet valleys with adhesive, it will help eliminate or greatly reduce a condition referred to as “silvering” in laminated materials. Silvering is when tiny air pockets are captured in the ink droplet valleys once the over laminating film is applied to printed sub-straights.
For years, many of the PSA coated film manufacturers have stated that heat is not required for their products.This is a true statement, however, today some of these manufacturers are actually recommending that you heat the printed media verses the PSA coated over laminating films. This heated production scenario allows the adhesive to be warmed at the point of contact with the printed surface thereby allowing the adhesive to flow more easily eliminating the “silvering” problem.
Having a quality dual heated roller laminator also allows the shop owner to offer thermal over-laminating films providing a full range of finishing services to their customer base. Heat available in your laminator regardless of your primary production requirements today will have its benefits. The final thing to consider is that your laminator should last 20+ years with proper care. In that time frame, post print finishing material requirements may change dramatically, just as they have done in the past 20 years.
An industrial laminating machine is a specialized equipment used to apply a protective layer or coating onto various materials such as paper, fabric, plastic, or metal. The laminating process involves bonding multiple layers together using heat, pressure, or adhesives to create a composite material with improved durability, strength, and aesthetics. Industrial laminating machines are commonly used in industries such as printing, packaging, automotive, and construction.
There are different types of industrial laminating machines available, each designed for specific applications and materials. Some common types include:
These machines use rolls of laminating film or adhesive-coated paper to laminate materials. Roll laminators are versatile and suitable for a wide range of materials and thicknesses.
Pouch laminators utilize pre-sealed laminating pouches. The material to be laminated is placed inside the pouch, which is then passed through the machine to activate the adhesive and bond the layers.
Hot-melt laminators apply a heat-activated adhesive to the material's surface, bonding it with the protective layer. These machines are commonly used for laminating larger or irregularly shaped items.
Cold laminators use pressure-sensitive adhesives to bond the layers without the need for heat. They are suitable for heat-sensitive materials or delicate items.
The working principle of industrial laminating machines varies depending on the type of machine. However, the basic steps involved in the laminating process are as follows:
Preparation: The material to be laminated is prepared by cleaning and ensuring its surface is free from dust or contaminants.
Application of Adhesive: In roll laminators and hot-melt laminators, the adhesive is applied to either the material or the protective layer. In pouch laminators, the adhesive is already present in the laminating pouch.
Assembly: The material and the protective layer are aligned and fed into the laminating machine, ensuring proper placement and alignment.
Heating and Pressure: In roll laminators and hot-melt laminators, the assembled layers pass through heated rollers or plates. The heat activates the adhesive, and pressure is applied to ensure proper bonding between the layers.
Trimming and Finishing: After lamination, the excess material is trimmed off, and the finished product is cut to the desired size or shape.
Industrial laminating machines offer several advantages, making them a preferred choice in various industries. These advantages include:
Enhanced Durability: The protective coating provided by laminating machines improves the durability and resistance of materials against wear, tear, moisture, and UV radiation.
Improved Aesthetics: Lamination enhances the visual appeal of materials by adding a glossy or matte finish, making them more attractive and professional-looking.
Protection from Damage: The laminating layer acts as a barrier, protecting materials from scratches, stains, fading, and other forms of damage, extending their lifespan.
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Easy Maintenance: Laminated materials are easier to clean and maintain, as the protective layer prevents the absorption of dirt, liquids, and contaminants.
Versatility: Industrial laminating machines can handle a wide range of materials, including paper, fabric, plastic, and metal, making them versatile for different applications.
Cost-Effective: Lamination can be a cost-effective solution compared to using specialized materials or undergoing complex manufacturing processes to achieve desired properties.
Industrial laminating machines find applications in various industries, including:
Printing and Packaging: Lamination is commonly used to enhance the appearance and durability of printed materials such as brochures, labels, posters, and packaging boxes.
Automotive and Aerospace: Laminating machines are utilized in the automotive and aerospace industries to laminate components, providing protection and improving aesthetics.
Construction and Architecture: Lamination is used in construction materials such as flooring, countertops, and wall panels to enhance their durability, water resistance, and visual appeal.
Food and Beverage: Packaging materials for food and beverages can be laminated to provide barrier properties, prolong shelf life, and ensure product safety.
Signage and Displays: Laminated materials are widely used in signage, banners, trade show displays, and retail advertising to enhance their visibility and longevity.
When selecting an industrial laminating machine, several factors should be considered to ensure the machine meets specific requirements. These factors include:
Material Compatibility: Determine if the machine is suitable for the materials you intend to laminate, considering factors such as thickness, size, and surface properties.
Machine Capacity: Consider the machine's speed and capacity to determine if it can meet production requirements and handle the desired workload.
Laminating Method: Choose a machine that offers the appropriate laminating method (roll, pouch, hot-melt, or cold) based on the materials and desired outcomes.
Size and Space: Consider the available space in your facility and choose a machine that fits within the allocated area.
Cost and Budget: Evaluate the cost of the machine, including upfront investment, maintenance, and operational costs, to ensure it aligns with your budget.
Additional Features: Look for features such as adjustable temperature and pressure settings, ease of use, and safety mechanisms to enhance usability and efficiency.
Proper maintenance and care are essential for the optimal performance and longevity of industrial laminating machines. Here are some key maintenance tasks:
Regular Cleaning: Clean the machine's rollers, plates, and surfaces to remove any adhesive residue, dust, or debris that could affect performance.
Lubrication: Apply lubricants to the machine's moving parts as per the manufacturer's recommendations to ensure smooth operation and prevent wear.
Inspection and Calibration: Regularly inspect the machine for any signs of wear, damage, or misalignment. Calibrate the machine if necessary to ensure accurate lamination.
Replacement of Parts: Replace worn-out or damaged parts, such as rollers, heating elements, or blades, to maintain the machine's performance and safety.
Operator Training: Provide proper training to machine operators to ensure they understand the correct operation, safety procedures, and troubleshooting techniques.Challenges in Industrial Laminating
While industrial laminating machines offer numerous benefits, there are some challenges to be aware of:
Material Compatibility: Certain materials may pose challenges in terms of adhesion, temperature sensitivity, or flexibility, requiring specialized laminating techniques or materials.
Maintenance and Downtime: Regular maintenance and occasional machine downtime for repairs or part replacement can affect production schedules and efficiency.
Cost Considerations: The upfront cost of industrial laminating machines and ongoing operational costs, including energy consumption and maintenance, should be carefully evaluated.
Operator Training: Proper training of operators is crucial to ensure the correct use of the machine, as improper handling can lead to product defects or machine damage.
Industrial laminating processes can have environmental implications, primarily related to energy consumption and waste generation. Manufacturers are taking steps to minimize the impact, including:
Energy Efficiency: Advancements in machine design and control systems aim to reduce energy consumption during the lamination process.
Waste Reduction and Recycling: Efforts are being made to reduce waste generated during the lamination process and promote the recycling of materials whenever possible.
Sustainable Materials: Manufacturers are exploring the use of eco-friendly laminating materials that are biodegradable, recyclable, or made from renewable resources.
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