COMEXI - Advanced lamination session

ADHESIVES

Andreas Wenzlaff: Technical Manager Keyaccounts EMEA

Enrique Tejedor : Regional Technical Sales Manager

Girona, November 9, 2016

What we will cover today !
1. Laminating with different adhesives technologies
2. “Safety”
3. New systems
4. Coatings, primers and technical laminates
5. Troubleshooting
6. Wetting vs. Machine settings
7. Handling of PUR adhesive systems
8. Cases

Págie 2 October 31, 2016 Advanced lamination– A. Wenzlaff

Dry lamination – different adhesive technologies

• Solvent based
• 1 and mainly 2 component PUR systems diluted in ethylacetate

• Water based
• 1 and 2 component systems based on acrylic dispersion and
aliphatic isocyanate hardener

• Solvent free
• 1 and 2 component PUR systems

Págie 3 October 31, 2016 Advanced lamination– A. Wenzlaff

Energy requirements

SB
[kW]
SF

0 5 10 15 20 25 30 35

Solvent based needs 16 times more energy!

(Energy shut down)

Págie 4 October 31, 2016 Advanced lamination– A. Wenzlaff

Cost / 1,000m2 @ recommended CW
Standard laminate

SB (€1.54/kg, 30% SC, 3.0g/m2) 11,27

SF (€4.15/kg, 100% SC, 2.1g/m2) 8,62

0,00 2,00 4,00 6,00 8,00 10,00 12,00

€ / 1,000m2
(Adhesive- / solvent prices excluding VAT)
Págie 5 October 31, 2016 Advanced lamination– A. Wenzlaff
Cost / 1,000m2 optimized
Standard laminate

SB (€1.54/kg, 45% SC, 3.0g/m2) 8,48

SF (€4.15/kg, 100% SC, 1.5g/m2) 6,15

0,00 2,00 4,00 6,00 8,00 10,00

€ / 1,000m2

(Adhesive- / solvent prices excluding VAT)

Págie 6 October 31, 2016 Advanced lamination– A. Wenzlaff
Water based adhesive technologies

• Solvent free
• Safe and easy handling
• Possible to use on a wide range of laminates (including
film / film, film / met. film and film / foil)
• Excellent clarity on clear film laminates
• No PAA‘s
• High initial tack
• Fast processing
• Long pot life
• Low odor
• Easy cleaning with water and soap

Págie 7 October 31, 2016 Advanced lamination– A. Wenzlaff

Water based wet and dry lamination systems

High Dry Lamination

Loctite Liofol LW 8059

Loctite Liofol LA 29-208 / LA 5804 New
New Loctite Liofol LW 8072 L Medium-High

Loctite Liofol LW 29-301 Medium Liofol LA 4503 / LA 5804 New

Loctite Liofol LW 9112

Standard performance Loctite Liofol LA 4505 New

Págie 8 October 31, 2016 Advanced lamination– A. Wenzlaff

Sustainability – carbon foot print

Greenhouse gas emissions of Liofol adhesives1)

Production of
Base Component

Energy needed
For Laminating
Process

Lamination <5% of
Base component (polyurethane-based) CO2 footprint of
Hardener Entire Packaging
Solvent losses
Adhesives production
Energy consumption during the
application phase
Transport and packaging Smallest carbon footprint:
1) For 100 m² of laminated film/foil Solvent-free Adhesives

Págie 9 October 31, 2016 Advanced lamination– A. Wenzlaff

Adhesives for flexible packaging
Solvent free

Application:
• medium performance laminates

• Properties:
• high bond-strength
• high chemical and heat resistance
• High slip agent suitability
Application: • Very fast free of migration
• Medium-high performance
laminates Examples:

• PET/Foil/PE:
• Properties:
for vacuum coffee pouches, hot
• high bond-strength
sealing > 200 °C, vacuum tight
• high chemical resistance on foil
sealing areas, high slip structures
• very good thermal resistance
Examples: • PET/PE or PE/PE:
for detergent laminates, high
• PETmet/PE: for sauce sachets,
aggressive fillings mechanical stability, good chemical
resistance

Págie 10 October 31, 2016 Advanced lamination– A. Wenzlaff

Solvent free dry lamination systems

• 1 component for paper / film or foil laminates

• 2 component PUR systems (isocyanate / hydroxyl) w/o solvent for

film / film and film / foil lamination

• Coating by state of the art 4 roller system

Págie 11 October 31, 2016 Advanced lamination– A. Wenzlaff

Two step curing process
Reaction adhesive / hardener

H O
HO OH + OCN NCO N C O

Polyol Isocyanate Urethane link

diols/triols monomer/prepolymer

Reaction of excess of isocyanate with water

O
OCN NCO + H2O OCN NH C OH OCN NH2 + CO2

free isocyanate moisture unstable carbamic acid amine

O
OCN NCO + OCN NH2 OCN NH C NH

free isocyanate amine urea

Págie 12 October 31, 2016 Advanced lamination– A. Wenzlaff

Curing process 2 comp. PUR adhesives
 Bond strength

Primary aromatiic amines

Lamination chemical and thermal resistance

24 Hours 48 Hours 14 Days

Págie 13 October 31, 2016 Advanced lamination– A. Wenzlaff

 Migration of Primary Aromatic Amines (PAA)
Most important example for lam. adh. migration

“Danish Food Scandal”

Source: Danish Nyheds Magasin, Internet

Págie 14 October 31, 2016 Advanced lamination– A. Wenzlaff

Migration in flexible packaging
reverse
clear PET print layer PE food or
film heatseal film filling good
aluminium

potential for migration

can be an adhesive only a functional barrier

absolute
barrier
15 October 31, 2016 Advanced lamination– A. Wenzlaff
„Danish Food Scandal“ - Measurements

Source: Danish Nyheds Magasin, Internet

Págie 16 October 31, 2016 Advanced lamination– A. Wenzlaff

Challenge of Measure Conformity:
Migration of Primary Aromatic Amines (PAA)
Photometric test, “BfR-test”- principle

141,4 mm

141,4 mm
Sample from Reel Make Pouch (200cm²) Store in oven
+ 100ml Acetic Acid 2h@70°C

Chemistry!

Derivatisation of Filling

Págie 17 October 31, 2016 Advanced lamination– A. Wenzlaff UV-Detection

 The Level of aromatic Amines decreases with Time

Detection limit of this method:

0,2µg/100ml or 2 ppb
60
60 For compliance testing with this method:
(µg/100 ml) x 10 = ppb

50 only 2ppb is ensuring to be below the

Aromatic Amines

40 10ppb SML limit

30 given in 10/2011!

20 12
7,6
10
1,2 0,16
0
1 2 3 7 10

Days after lamination

EXAMPLE for illustration
Págie 18 October 31, 2016 Advanced lamination– A. Wenzlaff
Most important Factor: PUR-Curing Mechanism

Conventional Smart-Cure

Content of
NCO-Monomer
• High •Low
Curing
•Conventional • Smart: Short physical
Mechanism and chemical curing

PAA • long migration times • fast free of migrates

The selection of the right adhesive is crucial!

Págie 19 October 31, 2016 Advanced lamination– A. Wenzlaff

Effect in Practice* OPA(15µ)/PEtr. (70µ)
Comparison of Times until PAA <2ppb (photometric)

100
90
80 Conventional System

70
PAA [µg/100ml]

Smart system LA 7738 / LA 6087

60
50
40
30
<0,2 (2 ppb):
20 - safe -
10
0
1d 2d 4d 7d 14d
* „BfR-Method“/photometric (values can differ due to different laminating and curing conditions)

Págie 20 October 31, 2016 Advanced lamination– A. Wenzlaff

Two Parts per Billion - Illustration

• Mankind: 6.625 Bill. people (2007)

• 2ppb are:
• 13 People !
• Or: a soccer team with two substitutes.

Págie 21 October 31, 2016 Advanced lamination– A. Wenzlaff

Limitations of photometric-test
• SUMMARIZING method, all PAA are measured at once.

• Known to give false positive results!!!

• No distinction between PAA and others substances possible.
• Problematic in presence of additives (films/ink)
• Results for retort applications & higher temperatures are doubtfull
and have to be cross-checked

• It‘s like you have identified, yes, it‘s football, but you cannot see,
whether all players are in and f.i. it is:

 A specific method is required for cross-check!

Págie 22 October 31, 2016 Advanced lamination– A. Wenzlaff
Summary: Compliance testing for PAA

Regulation (EU) No. 10/2011

LOD = 0,01 mg/kg
compliance testing

Screening method Specific method

BfR photometric test HPLC-UV
considers lower response
factors of real PAA vs aniline

if >0,002 mg/kg DL = sum PAA <0,01mg/kg

threshold of action limit
0,002 mg/kg

2 10

Págie 23 October 31, 2016 Advanced lamination– A. Wenzlaff

 Again: How can I pass the limit earlier?

PAA Migration Level

Conventional System

Smart System

10ppb Smart = Earlier being safe for use

0 Time

Págie 24 October 31, 2016 Advanced lamination– A. Wenzlaff

Adhesives for flexible packaging
Solvent based

Application: Application:

• high performance laminates • medium performance laminates

• Properties: • Properties:

• high bond-strength • high bond-strength

• high chemical resistance on foil • high chemical and heat resistance

• very good thermal resistance • High slip agent suitability

• Very high initial tack
Examples:
Examples:
• PET/Foil/PE:
for fruit-juice packaging, hot filling • CPA/CPP:
for retort able infusion bag
• PET/Foil/PVC: laminates, sterilization at 134 °C
for deep drawn pharma packaging
30 min., high demands on
• Retort e.g. 30 minutes 130°C on foil toxicological properties

Págie 25 October 31, 2016 Advanced lamination– A. Wenzlaff

Solvent based adhesive systems

• 1 component isocyanate based systems crosslinking with humidty for

paper laminates

• 2 component (isocyanate / hydroxyl) dissolved in ethylacetate at

various concentration for fil / film and film / foil

• Solvent carrier to help to apply higher molecular polymers

• Cross-linking in 2 steps

Págie 26 October 31, 2016 Advanced lamination– A. Wenzlaff

Solvent based adhesives
Mixing and diluting

1. Weigh out 2. Add the 3. Add the hardener

the adhesive solvent and mix component and mix
thoroughly
Solid content 30-40%
Págie 27 October 31, 2016 Advanced lamination– A. Wenzlaff
Measure the viscosity

Ford cup Zahn cup

Págie 28 October 31, 2016 Advanced lamination– A. Wenzlaff
Potlife comparison

Págie 29 October 31, 2016 Advanced lamination– A. Wenzlaff

Preparation – “Less is more”
The amount of adhesive to be mixed should be
possible to be consumed within a max. of 2 hours:

Width of laminate: 0.87 m

Machine speed: 100 m/min.
Coating weight dry: 3.2 g/m2

0.87 m x 100 m/min.= 87 m2/min.

87 m2 / min x 120 min = 10,440 m2 for 2 hrs.
10,440 m2 x 3.2 g/m2 dry = 33,408 g dry
33.41 kg dry = 111.4 kg 30 % solid content
111.4 kg x 80 % efficiency =
89.1 kg should be mixed !!!

Págie 30 October 31, 2016 Advanced lamination– A. Wenzlaff

Gravure rollers - challenges

36 hrs. = 3.0 g/m2

Optics still ok!

72 hrs. = 2.7 g/m2

Small bubbles appear!

108 hrs. = 2.3 g/m2

Bubbles not bearable!
Fresh = 3.2 g/m2
Optics ok !

Págie 31 October 31, 2016 Advanced lamination– A. Wenzlaff

Viscosity SB adhesives

Changes in viscosity could come from:

• evaporation of solvent
• water content of solvent too high

Viscosity should be checked regularly,

if too high to be diluted with solvent

Págie 32 October 31, 2016 Advanced lamination– A. Wenzlaff

Dry laminating machine

60°C 70°C 80°C

drying tunnel Lamination

station
50-90°C
unwind 1
secondary
rubber web
chill roll
Carrier
web unwind 2

gravure roller finished

adhesive pan laminate
rewind

Págie 33 October 31, 2016 Advanced lamination– A. Wenzlaff

Solvent based systems

Performance
High Medium Standard
- PETP/OPA SiOx/ CPP OPA / CPP deep draw ing PETP m et./ LDPE
- PETP/PETP SiOx/CPP deep draw ing CPA / CPP sterilization OPP / m et. CPP high bond strength
- Alu/PETP/HDPE retortable pouches CPA / EVA boil in bag PETP / m et. PETP - good optical appearance
- Alu/ CPP chem ical resistance PETP / HDPE high bond strength Alu / paper
- Alu/HDPE high bond strength PVC / LDPE high heat seal strength OPP / paper
- Alu/LLDPE high heat seal strength good optical appearance coex. OPP / LDPE
PETP / Alu - good optical appearance
OPA / Alu - PETP / alu / CPP
dry filling good
OPP / Alu - PETP / alu / LLDPE

LA 2760 / LA 5891

LA 2760 / LA 5028

LA 3966 / LA 6170

LA 2615 / LA 5021

LA 3720 / LA 6807

LA 3720 / LA 6136

LA 3760 / LA 6200

LA 2850 / LA 5000

Págie 34 October 31, 2016 Advanced lamination– A. Wenzlaff

Laminating adhesive performance range

Relative content

Cross- Aliphatic Adhesion

Polyether Polyester
links NCO promoter

High none +++ +++ ++ ++

Medium-High o ++ ++ + +

Medium + + + o none

Standard performance ++ o o o none

35 October 31, 2016 Advanced lamination– A. Wenzlaff

 Aggressive filling good resistance
Filling good resistance comparison
100 hrs. at 60°C
9

5
[N/15mm]

LA 3640/LA 6800
(MV 50:1)
4
LA 3640/LA 6000
(MV 85:1)
3

0
initial * salt * gloves * lavendel * acidic acid* ammonia ketchup mustard mayonnaise Ethanol water
* 3% solutions in H2O

Págie 36 October 31, 2016 Advanced lamination– A. Wenzlaff

Impact of aggressive filling goods

• Fragances from the filling goods are able to penetrate through the
seal layer affecting the adhesive anchorage on the i.e. carrier film

Págie 37 October 31, 2016 Advanced lamination– A. Wenzlaff

Basic safety instructions for handling reactive PUR

• Avoid skin contact, use cloves for cleaning operations

• Secure proper ventilation at the application station, use

exhaust systems

• Avoid inhalation of adhesive vapors

Págie 38 October 31, 2016 Advanced lamination– A. Wenzlaff

Adhesive portfolio update

Págie 39 October 31, 2016 Advanced lamination– A. Wenzlaff

Liofol solvent based adhesive system

• Excellent product resistance especially with acidic filling goods

• Improved running properties
- No cell blocking
- Reduced moisture sensitivity

Mustard filling good resistance after 35 days at 40°C

Alu/PE (Inner Layer)

Conventional product
shows delamination after
5 weeks product exposure!
Picture* Picture*
Conventional Product LA 3819 / LA 6141

*Comparison pictures of laminates after 5 weeks exposure at 40°C

Págie 40 October 31, 2016 Advanced lamination– A. Wenzlaff

Long pot-life solvent free system
LA 7707 / LA 6707

20.000

18.000 Liofol LA 7732 /

LA 6084
16.000 100:40
50°C
14.000
Viscosity (mPa.s)

12.000
Lfl LA 7707 /
LA 6707
10.000
100:85
50°C
8.000

6.000

4.000

2.000

0
1 3 6 8 11 13 16 18 21 23 26 28 31 33 36 38 41 43 46 48 51 53 56 58
Elapsed time (min)

Págie 41 October 31, 2016 Advanced lamination– A. Wenzlaff

Liofol - Primers

In PE extrusion processes

• on film with waterbased Liofol A 1883 (off line possible)

• PE imine primer applying rather low coating weights = 0.01 g/m²

• on foil with Liofol LA 4501 (only inline)

• 1 component PUR primer cross-linking with moisture

• Coating weights between 0.5 to 1.0 g/m²

For heat seal coatings on PETP films

• LA 8193-21 as in-line primer

Págie 42 October 31, 2016 Advanced lamination– A. Wenzlaff

Heat seal coatings

Aluminium lids
Heat seal coatings to be sealed against cups made of PS,
PVC, PP

Lioseal for mixpap/PET

Heat seal coatings to be sealed against cups
made of PS, PVC, PP

Págie 43 October 31, 2016 Advanced lamination– A. Wenzlaff

Loctite Liofol HS 1138 – The product

1. A solvent-based heat seal coating w/ anti-mist properties

2. Suitable for BOPET lidding films for fresh and ready meal food
packs
3. To produce peelable lidding film to open w/o film breaks and w/o
tools
4. To be used on BOPET film to seal onto CPET, RPET and APET
food trays
5. Microwavable solution
6. Fully compliant for direct food contact

Págie 44 October 31, 2016 Advanced lamination– A. Wenzlaff

Loctite Liofol HS 1138 - Properties

1. Very low haze (3-6%) vs. competitive grade (8-12%)

2. Consistent sealing properties through contaminants like grease,
blood and sugar
3. Excellent anti-mist performance
4. No blocking effect
5. Lower coating weights with same performance 2.5 vs. 3.5 g/m²
6. Plain side of BOPET to be coated; treated side printable

Págie 45 October 31, 2016 Advanced lamination– A. Wenzlaff

Liofol CS – cold seal coatings

Págie 46 October 31, 2016 Advanced lamination– A. Wenzlaff

Cold seal coatings and release lacquer

General: Tailor made:

• For wide range of substrates • Easy opening
• Low cling • Low tack
• Good seal performance • Very high product resistance
• Low foaming and odor • Medical applications
• Good machine ability • Natural + synthetic rubber
• For mono film and laminates

Págie 47 October 31, 2016 Advanced lamination– A. Wenzlaff

Reclosable lids

• Easy first opening (force < 15 N/cm)

• Good bond strength to PET and PE
(> 10 N/15 mm)
• Good adhesion at – 5°C up to 30 °C
• Low /no odor
• No cold flow, especially under the influence of
pressure
• Resistant against moisture and fat/oil
• Good machinability
• No curling of the film after reclosing and
successive storage in the refrigerator
• Approval for direct/indirect food contact

Págie 48 October 31, 2016 Advanced lamination– A. Wenzlaff

Reclosable lids

First opening and reclosability is a function of:

 lid construction
 films used
 thickness of coextruded PSA hotmelt / film

Págie 49 October 31, 2016 Advanced lamination– A. Wenzlaff

Product Description
TECHNOMELT PS 7120

• Based on a novel polymer composition

• Fully synthetic raw materials for indirect food
contact
• Melt Flow Index 190°C with 2mm nozzle:
>130 g/10min

• Packaging:
20 kg carton box (with LDPE inliner/pouch)
1 pallet = 360 kg ( 18 cartons)

Págie 50 October 31, 2016 Advanced lamination– A. Wenzlaff

Technical lamination

• solvent based

• water based

• solvent free

Laminating adhesives for

non-food application

Págie 51 October 31, 2016 Advanced lamination– A. Wenzlaff

Textile lamination

• Casual and sports wear

• Medical and health care
• Protection wear and
technical applications
• One component PUR systems

Págie 52 October 31, 2016 Advanced lamination– A. Wenzlaff

Fibre and fabrics

Fields of application:
• Carpet backing
• Lingerie
• Protection cloth
• Roof protection
• General: technical non-woven lamination

Págie 53 October 31, 2016 Advanced lamination– A. Wenzlaff

Parameters in the solvent free lamination process

Págie 54 October 31, 2016 Advanced lamination– A. Wenzlaff

Temperature vs. viscosity
(mPa.s)
h

Págie 55 October 31, 2016 Advanced lamination– A. Wenzlaff

Temperature adjustment vs. real temperature

50°C

Difference > 3°C  heat transfer insufficient

40°C

Págie 56 October 31, 2016 Advanced lamination– A. Wenzlaff

Temperature control
48°C 45°C
Lower viscosity Higher viscosity
Application weight low Application weight high
1.6g/m² 2.0g/m²

Hot water
In- / outlet
50°C

Surface temperature is important !!

Págie 57 October 31, 2016 Advanced lamination– A. Wenzlaff

Application temperature

Carrier web

Poor wetting

Carrier web

Optimum wetting

Págie 58 October 31, 2016 Advanced lamination– A. Wenzlaff

Temperature / pressure in the laminating station

Insufficient wetting

Secondary film – poor optics

Carrier web – good optics

Good wetting

Secondary film – good optics

Carrier web – good optics

Págie 59 October 31, 2016 Advanced lamination– A. Wenzlaff

 Temperature in the laminating station
secondary web
adhesive
primary web

cold - adhesive high viscosity --> poor wetting

right - adhesive low viscosity / films soft -> proper wetting

Págie 60 October 31, 2016 Advanced lamination– A. Wenzlaff

 Coating weights

Coating weight too low

- poor optical appearance
- poor bond strength

Coating weight right

- excellent optics
- good bond strength

Págie 61 October 31, 2016 Advanced lamination– A. Wenzlaff

Coating weight check during production
(always at machine speed)

When machine has desired speed

a flag should be placed and machine
to be stopped then

Págie 62 October 31, 2016 Advanced lamination– A. Wenzlaff

Checking the coating weight

• Fresh laminate and single printed film to be put into match

• To cut 100 cm² samples from 3 locations across the width, left,
middle and right

• Separate fresh laminate, place printed film (w/ adhesive) on

analytical balance – press „tara“
• Replace by single printed film (w/o adhesive) and record weight

• Place PE film (w/ adhesive) on balance and press „tara“

• Clean PE film with EAC, dry briefly, place on balance and record
weight

Págie 63 October 31, 2016 Advanced lamination– A. Wenzlaff

Coating weight calculation

weight
sample @ 100 cm²
[g/100cm²]
PETP printed w/ adhesive 2,1298

PETP printed w/o adhesive 2,1178

adhesive on PETP printed 0,0120

PE film w/ adhesive 1,2543

PE film w/o adhesive 1,2483

adhesive on PE film 0,0060

adhesive on PETP printed 0,0120

adhesive on PE film 0,0060

total adhesive weight 0,0180

1 m² = 100 cm² x 100 cm² 1,8000 g/m²

Págie 64 October 31, 2016 Advanced lamination– A. Wenzlaff

Comparing the optical appearance across the web

Drive side Operator side

A B

1.4 g/m² 1.8 g/m² 2.2 g/m²

Lot of wetting failures Almost no wetting Coating weight high
failures giving orange peel

Págie 65 October 31, 2016 Advanced lamination– A. Wenzlaff

 The roller gap

4
3

1 2

Adjustment: 0,08 mm for cold applied systems (40°C)

0,10 mm for warm applied systems (70°C)

Adjustment to be done at operating temperature

Improper adjustment may cause differences in coating weights

Págie 66 October 31, 2016 Advanced lamination– A. Wenzlaff

Temperature control in the coating station

°C 3
4

1 2

Págie 67 October 31, 2016 Advanced lamination– A. Wenzlaff

Roller gap vs. adhesive quantity

In order to minimise the influence of the pot life ......

• the sensor need to be adjusted to make the difference between min. and maximum as small
as possible
• the lowest possible level should be aimed for
• permanent refilling with fresh adhesive will keep viscosity in a narrow range

Max. Level
Min. Level

Págie 68 October 31, 2016 Advanced lamination– A. Wenzlaff

Adhesive vs. temperature
h(mPa.s)
(g/m²)

Standard pot life

Adhesive too hot

time 

Refilling with fresh adhesive

Págie 69 October 31, 2016 Advanced lamination– A. Wenzlaff

Influence of the oszillating:

Págie 70 October 31, 2016 Advanced lamination– A. Wenzlaff

Without using a traveler you may run into
trouble with uneven viscosity / application
weights across the web



h (mPa.s)

Time 
Págie 71 October 31, 2016 Advanced lamination– A. Wenzlaff
Solvent free systems

Performance
High Medium Standard
- PETP/OPA SiOx/ CPP OPA / CPP deep draw ing PETP m et./ LDPE
- PETP/PETP SiOx/CPP deep draw ing CPA / CPP sterilization OPP / m et. CPP high bond strength
- Alu/PETP/HDPE retortable pouches CPA / EVA boil in bag PETP / m et. PETP - good optical appearance
- Alu/ CPP chem ical resistance PETP / HDPE high bond strength Alu / paper
- Alu/HDPE high bond strength PVC / LDPE high heat seal strength OPP / paper
- Alu/LLDPE high heat seal strength good optical appearance coex. OPP / LDPE
PETP / Alu - good optical appearance
OPA / Alu - PETP / alu / CPP
dry filling good
OPP / Alu - PETP / alu / LLDPE

LA 7792/ LA 6181

LA 7755/ LA 6156

LA 7780 / LA 6147

LA 7716 / LA 6155

LA 7715 / LA 6155

LA 7735 / LA 6088

LA 7732 / LA 6159

LA 7707 / LA 6707

Págie 72 October 31, 2016 Advanced lamination– A. Wenzlaff

Surface tension vs. adhesive wetting

Págie 73 October 31, 2016 Advanced lamination– A. Wenzlaff

Check the right side is laminated !

treatment

No treatment

Treated side always to face the adheisve

Págie 74 October 31, 2016 Advanced lamination– A. Wenzlaff
 Surface tensions vs. films

Surface tension N/m (dyne/cm )

60
54
50
50 48
Minimum treatment level
40 40 > 38 Dyne/cm
40 38
32
30 29
30 w/o treatment
w/ treatment
20

10

0
LDPE CPP PETP met.
films

Págie 75 October 31, 2016 Advanced lamination– A. Wenzlaff

Surface tensions

Ethanol

Aceton

Methanol

Wasser
[Substrat]

Teflon

PE

PVC

PA

PETP

0 10 20 30 40 50 60 70 80
[N/m = dyne/cm]

Págie 76 October 31, 2016 Advanced lamination– A. Wenzlaff

 Corona treatment inline

Cleaning the surface Increase the surface tension,

( > 38 mN/m)
Antiblock
Additives PE´s
OPP
CPP
OPA

Págie 77 October 31, 2016 Advanced lamination– A. Wenzlaff

Corona treatment on PE

PE-film with corona treatment

OH O OH NH O
CO2-

PE w/o Corona PE w/ Corona

Págie 78 October 31, 2016 Advanced lamination– A. Wenzlaff
 Determination of the surface tension

 


0  < 90°  > 90°

Almost perfect Good wetting Poor wetting

wetting

Págie 79 October 31, 2016 Advanced lamination– A. Wenzlaff

Delamination ?
Improper surface tension

oPP Monofilm
adhesive

Corona w/o treatment

Delamination

oPP PE

Págie 80 October 31, 2016 Advanced lamination– A. Wenzlaff

Impurities on the film surface

antiblock prozessing
slip additives monomeres
agent aids
OPA / CPA X X
OPP X
CPP X X
PE X
PVC X X
PETP X
printing inks X X

Págie 81 October 31, 2016 Advanced lamination– A. Wenzlaff

Treatment of different films
energy requirements for treatment
> 45 mN/mm

OPP

CPP
substrates

LDPE

PETP

0 5 10 15 20 25 30
[Wmin/m²]

Págie 82 October 31, 2016 Advanced lamination– A. Wenzlaff

Poor bonding due to both side none
treated PE film !

Delamination!

Págie 83 October 31, 2016 Advanced lamination– A. Wenzlaff

Monitor the distribution of adhesive right
before the nip

or ?
 The application station is
set up properly 
Re-adjust the settings

Págie 84 October 31, 2016 Advanced lamination– A. Wenzlaff

Monitor the distribution of the adhesive after
the nip
Even adhesive coating before the nip, but bad optical appearance after
lamination. Re-adjust the nip settings.
but ?

Págie 85 October 31, 2016 Advanced lamination– A. Wenzlaff

 Wetting failures

Págie 86 October 31, 2016 Advanced lamination– A. Wenzlaff

Wetting failures
h (mPa.s)

poor
good

carrier film

wetting failures will

be found here
Págie 87 October 31, 2016 Advanced lamination– A. Wenzlaff
The shape of the wetting failure can tell us
its cause
Machine direction

low adhesive temperature poor contact between rollers

low pressure on pressure roller roller not set correctly
low surface tension dirty roller
ink/adhesive incompatibility roller has flat spots

Págie 88 October 31, 2016 Advanced lamination– A. Wenzlaff

Wetting failures in the center of the web

Págie 89 October 31, 2016 Advanced lamination– A. Wenzlaff

Wetting failures on one side of the web
Adjust the nip pressure correctly !

Págie 90 October 31, 2016 Advanced lamination– A. Wenzlaff

Wetting failures at regular intervals

One roller is „out of round“. Store suspended in a rack.

Págie 91 October 31, 2016 Advanced lamination– A. Wenzlaff

Wetting failures
Sufficient adhesive needs to be applied, coping with
adsorbtion by inks

Págie 92 October 31, 2016 Advanced lamination– A. Wenzlaff

Recommended coating weights

Fresh laminate Coating weight Optical appearance

( g/m² )

Un-printed, transparent films 1.6 Slight greyish effect, small oval spots

printed, transparent films 1.8 - 2.2 printed: no or few spots

un- printed: no orange peel

Un-printed films/ Aluminium 1.8 un- printed: no orange peel

Printed films / Aluminium 1.8 - 2.1 printed: no or few spots

Págie 93 October 31, 2016 Advanced lamination– A. Wenzlaff

Wetting failures are caused by :
- the inability of the adhesive to flow out onto the surface
of the film
- a low surface tension on the film‘s surface
- a too low coating weight

adhesive

good wetting bad wetting

Págie 94 October 31, 2016 Advanced lamination– A. Wenzlaff

Adjustments to eliminate wetting failures
(mPa.s)
h

4 4
3 3

1 2 1 2

raise the temperature of increase the pressure increase the pressure

the adhesive by 5 – 10°C on the transfer roller on the pressure roller

Págie 95 October 31, 2016 Advanced lamination– A. Wenzlaff

Machine adjustments vs. troubleshooting

Págie 96 October 31, 2016 Advanced lamination– A. Wenzlaff

Temperature influence:
Adhesive too cold

Coating weight too high

As of a higher adhesive
Fogging viscosity more adhesive is
transferred

Orange peel
Carrier web “looping”
The tension control becomes
3
4

instable, folds in machine

Wrong mix ratio
direction become visable. The base material has a
2
higher viscosity, less material
was pumped.

Power strain on drives

Wetting failure Because of the higher
The adhesive is too high in viscosity more pawer is
viscosity and does not wet well. necessary to keep the rollers
A in morion.

Págie 97 October 31, 2016 Advanced lamination– A. Wenzlaff

Stringing

stringing
presseur

stringing due to too high

viscosity
+10°C
application
Application
applicationroller
roller
roller

no stringing
Págie 98 October 31, 2016 Advanced lamination– A. Wenzlaff
Stringing

presseur

stringing
application
application
applicationroller
roller

Págie 99 October 31, 2016 Advanced lamination– A. Wenzlaff

„Fogging“

• Increase the temperature of the application roller

• Lower the pressure on the application roller
• Check the application weight after any change of
parameters.

Págie 100 October 31, 2016 Advanced lamination– A. Wenzlaff

The carrier web sticks to the application
roller

4
3

2 raise the temperature of the application roller (monitor

the effect on the coating weight)
decrease the pressure on the pressure roller (monitor
the effect on the coating weight)

increase the rewind tension (only as a last resort)

if ignored the carrier film may wrap itself around the application roller

Págie 101 October 31, 2016 Advanced lamination– A. Wenzlaff

 Tunnel formation

Machine direction

Description:

• small, capillary wrinkles in the stiffer film

across the web.
• become longer in the outer layers after the
lamination process

Polyolefine film contracts

Págie 102 October 31, 2016 Advanced lamination– A. Wenzlaff
 Wrinkles across the machine direction

Machine direction

Reduce pressure and /

or temperature

Págie 103 October 31, 2016 Advanced lamination– A. Wenzlaff

 Adhesive did not cure - Effects

• Adhesive is tacky in either printed or unprinted area, problem

likely from wrong mix ratio

• Adhesive is tacky only in printed areas – likely caused by

retained solvent from printing process

Actions:
• Place a sample in an over for 1 night @ 50°C and check the
bonding the next day. In case the laminate has cured it was an
excess of NCO, which has reacted with humidity. Rewinding
the material in humid condition will make the whole reel cure.

• In case the behaviour remained the same an excess of OH has

caused the failure, unfortunately no other action will help.

Págie 104 October 31, 2016 Advanced lamination– A. Wenzlaff

Mixing ratio

Adhesive: Liofol LA 7780 Liofol LA 6080

Parts per recommended

weight 100 : 45
extended Permanent
Tolerance 100 : Curing time 42 - 48 tackiness

Págie 105 October 31, 2016 Advanced lamination– A. Wenzlaff

 IR analysis for an OH excess
ca. 3 500 cm-1
115

110

3500 cm-1, OH excess relative to std

105

100

Std IR trace
95

90

85
%Transmission

80

75

70

65

60

1535 cm-1, urethane

55

50 ------ standard IR trace

45 ------ sample with excess -OH
40

3000 2000
Wellenzahlen (cm-1)

Págie 106 October 31, 2016 Advanced lamination– A. Wenzlaff

Case

A sample of PET/PE laminated with SF LA 7780 / LA 6080.

At one side of the laminate delaminations are visible

Págie 107 October 31, 2016 Advanced lamination– A. Wenzlaff

Case

OH

%T

Urethane

blue: LA 7780 / LA 6080 100:45

black Euroflex side of delamination Urea

4000,0 3600 3200 2800 2400 2000 1800 1600 1400 1200 1000 800 600 400,0
cm-1

Págie 108 October 31, 2016 Advanced lamination– A. Wenzlaff

Case

OH

%T

Urethane

blue: LA 7780 / LA 6080 100:45

black Euroflex side without delamination
Urea

4000,0 3600 3200 2800 2400 2000 1800 1600 1400 1200 1000 800 600 400,0
cm-1

Págie 109 October 31, 2016 Advanced lamination– A. Wenzlaff

 Orange peel effect

• Increase temperature of the application roller (please pay

attention to the change in coating weight)

• Increase temperature of the nip

• Increase the winding tension

• Rewind the stretchable (softer) film to the outside

• Use a suitable winding profile

Págie 110 October 31, 2016 Advanced lamination– A. Wenzlaff

 Laminating station

 

100 m/min 300 m/min

The higher the speed the less any heat can be transferred to the films to be
laminated.

Consider to increase the temperature when increasing the machine speed.

Págie 111 October 31, 2016 Advanced lamination– A. Wenzlaff

Film tension

LDPE 30

HDPE 60

Alu 9µm 80

CPP 90

Alu 40µm 320

0 100 200 300 400

web tension ( N )

Págie 112 October 31, 2016 Advanced lamination– A. Wenzlaff

 Web tension
PE

Machine direction

Make a cross cut to test balance between films !

Págie 113 October 31, 2016 Advanced lamination– A. Wenzlaff

 Web tension

PET
PE

Clear tendency to the PE  reduce tension

on the PE film

Págie 114 October 31, 2016 Advanced lamination– A. Wenzlaff

 Web tension

Laminate curls across the machine

direction  clear indication for too high
laminating temperature
Págie 115 October 31, 2016 Advanced lamination– A. Wenzlaff
 Curling

The PE stretches and the PET does not.

The PE is held in place by the adhesive,
but still tends to recover (contract). This
results in curling.

Possible reasons
• Incorrect or unbalanced web tension
• calendar nip temperature too high

Págie 116 October 31, 2016 Advanced lamination– A. Wenzlaff

Films, additives and inks: possible impact

Págie 117 October 31, 2016 Advanced lamination– A. Wenzlaff

 Films and additives: effect on the lamination
process

Págie 118 October 31, 2016 Advanced lamination– A. Wenzlaff

Delamination – weak bond due to slip additives on
the PE surface

Additives
Separar capa
show upblanca
as a
y limpiable
white, greasyencoating
el PE on
the PE
Adhesivo
Adhesive on enPET
el
prt .
PET nada
No adhesive
prt, en
on PEPE
el

PETprt /PE → PETprt/ + PE

Págie 119 October 31, 2016 Advanced lamination– A. Wenzlaff
The migration of the substituted urea to
the surface of the film produces the
Antiseal effect

Melting point > 250°C

No seal between the

jaws of the heat sealer

Págie 120 October 31, 2016 Advanced lamination– A. Wenzlaff

 Actions to take in case of a suspected ASE

1. Compare the heat seal strength before and after wiping with
ethyl acetate

2. Test the surface tension of the sealing layer on the sealing side,
could be a case of „backside treatment“

3. IR analysis, the presence of aromatics can be recognized by the

absorbance at 1510 cm-1 and 1600 cm-1 as well as at 1646 cm-1 and
1545cm-1. These peaks are typical for an ASE.

Págie 121 October 31, 2016 Advanced lamination– A. Wenzlaff

 The effect of slip agents

O
CH3 (CH2 )7 CH CH (CH2 )7 C NH2
Oleo acid amide
O
CH3 (CH2 )7 CH CH (CH2 )11 C NH2

Eruca acid amide

Slip agents (which reduce the coefficient of friction) like olea-acid-amide and eruca-acid-amide
contain an active side which reacts with free isocyanate monomer in the adhesive to form
substituted polyurea.
O O H H
CH3 (CH2 )7 CH CH (CH2 )7 C NH2 + O C N R' CH3 (CH2)7 CH CH (CH2)7 C N C N R'
substituted amide free isocyanate O
substitued urea

Págie 122 October 31, 2016 Advanced lamination– A. Wenzlaff

Retarders have only one active side

CH3 CH2 OH ethanol

CH3 CH CH3 isopropanol

OH

CH3 CH2 CH2 CH2 OH butanol

< 5mg/m²

OH
Dowanol PM
H3C O CH2 CH CH3
(propylene glycol methyl ether)

Págie 123 October 31, 2016 Advanced lamination– A. Wenzlaff

Retarders act as chain terminators

CH3 CH2 OH
Ethanol

CH3 CH2 CH2 CH2 OH

Butanol

Adhesive remains tacky in printed areas all the time

The laminate is rather easy to separate.

Overall retained solvents should be kept < 10mg/m².

Págie 124 October 31, 2016 Advanced lamination– A. Wenzlaff

Actual case (I)

Information about the samples:

• PETP printed // LA 3644/LA 6055 // Alu // LA 7732/LA 6084 // PE

• Monofilm PET printed, NC-PUR modified ink

• Monofilm PE

• All samples were sealed in a laminated triplex of the same structure.

Págie 125 October 31, 2016 Advanced lamination– A. Wenzlaff

Actual case (II)

Tests carried out / test conditions:

We had done a smell test direct after opening of the sealed bags.
We measured the retained solvent of the printed monofilm PET and of
the laminate.

Test analysis and results:

We recognized a slight smell of solvent at the sample.

Furthermore we see delaminations in the triplex laminate and the PET

mono film was tacky and the printed layers stuck together.

Págie 126 October 31, 2016 Advanced lamination– A. Wenzlaff

Actual case (III)

Retained solvents:
PET mono-film triplex laminate:

Págie 127 October 31, 2016 Advanced lamination– A. Wenzlaff

Rewinding vs. telescoping

Págie 128 October 31, 2016 Advanced lamination– A. Wenzlaff

 Rewinding

Tension / pressure in reel

(i.e. rewinding speed)

Incorrect taper tension can lead to corrugation or wrinkles on the inside of the rewound reel !

Págie 129 October 31, 2016 Advanced lamination– A. Wenzlaff

Lay-on-roller

Págie 130 October 31, 2016 Advanced lamination– A. Wenzlaff

 Optical appearnce in the none printed
area is not good as there is not
pressure within the rewound roll

Págie 131 October 31, 2016 Advanced lamination– A. Wenzlaff

 Rewound roll

Setting the taper tension

correctly will help to get
a good roll Pressure

The softer, more stretchable film should be rewound outside

Págie 132 October 31, 2016 Advanced lamination– A. Wenzlaff
Incorrect rewinding profile: The reel is too loosely rewound at the start of
the reel (core) and too tightly at the end (outside) of the reel. This leads
to wrinkles at the core of the reel.

Págie 133 October 31, 2016 Advanced lamination– A. Wenzlaff

tension/pressure in reel
(i.e. rewinding speed)

Pressure outside > inside

30 N at 15%  30 x 0,85 N

Pressure outside < inside of reel

Págie 134 October 31, 2016 Advanced lamination– A. Wenzlaff

 Telescoping

Págie 135 October 31, 2016 Advanced lamination– A. Wenzlaff

 Telescoping – different effects

• coating weight on one side too high

Telescoping to one side • improper films thickness
• temperature differences across the web
• air entrapment

Págie 136 October 31, 2016 Advanced lamination– A. Wenzlaff

 or or

telescoping to one telescoping only telescoping to

side only near the core, both sides
straight in the
outside of the reel

Págie 137 October 31, 2016 Advanced lamination– A. Wenzlaff

 To one side

Drive side Operator side

A B

1,4 g/m² 1,8 g/m² 2,2 g/m²

• The application weight is too high

• The application weight is not even across the web

Págie 138 October 31, 2016 Advanced lamination– A. Wenzlaff

 To one side

The pressure on the lay-on roller is not balanced, forcing

the laminate to move to one side of the rewound reel

Págie 139 October 31, 2016 Advanced lamination– A. Wenzlaff

 To one side

The calendar nip pressure is not even and the layers of

laminate in the rewound reel stack up on one side

High bond strength Poor bond strength

good optics bad optics

Págie 140 October 31, 2016 Advanced lamination– A. Wenzlaff

 Telescoping only around the core

the taper tension is not correct, which means:

tension/pressure in reel
(i.e. rewinding speed)

pressure outside > inside of the reel

the outside layers put pressure on the inside
layers, forcing them to move

30 N at 15%  30 x 0,85 N

Págie 141 October 31, 2016 Advanced lamination– A. Wenzlaff

 Telescoping to both sides

• Entrapped air between the laminate layers of the

rewound reel will lead to slipping of the layers on
this air cushion from one side to the other.

• Increase pressure of the lay-on roller

Págie 142 October 31, 2016 Advanced lamination– A. Wenzlaff

 Telescoping to both sides

Wrong setting of the taper tension which

means: the pressure at the outer layers is much
lower than at the core.
tension/pressure in reel
(i.e. rewinding speed)

Material will try to lever the pressure inside the

reel – this leads to telescoping and entrapped
air will cause the layer to slip from one side to
the other.

30 N at 15%  30 x 0,85 N

Págie 143 October 31, 2016 Advanced lamination– A. Wenzlaff

Control the mix ratio every shift ao every new job !
Check should be done be controlling the weight of each component !

Stream Splitter

Págie 144 October 31, 2016 Advanced lamination– A. Wenzlaff

 ?
Check the level !
Enough to give an appropriate measurement !
Base Hardener

Check the temperature!

Attention! A too cold adhesive should not be

applied onto the laminating machine !

Págie 145 October 31, 2016 Advanced lamination– A. Wenzlaff

  
Skin

Keep the lid closed – always !

Reduce the volume of air by

refilling with respective component

  Isocyanate material will cross linking with humidity

Observe the level of adhesive !

Págie 146 October 31, 2016 Advanced lamination– A. Wenzlaff
Always put some grease on the tip
of the mixing head !

Págie 147 October 31, 2016 Advanced lamination– A. Wenzlaff

 Non-stop maintenance is vital !

Págie 148 October 31, 2016 Advanced lamination– A. Wenzlaff

 QUESTIONS ????

Págie 149 October 31, 2016 Advanced lamination– A. Wenzlaff

Vielen Dank für Ihre Aufmerksamkeit !

Thank you very much for your attention!