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High Effective Solventless Lamination Technology For Controlling VOCs Emissions
The products in the packaging and printing industry are inseparable from the use of organic solvents, which brings many emissions of VOCs. Solventless lamination technology adopts a solvent-free adhesive instead of solvent-based adhesive, which can avoid VOCs emissions from the source.
What Is Solventless Lamination Technology
Solvent-free laminating technology is an important environmentally friendly technology applied to the flexible packaging industry. It is a machining method which adopts a solvent-free adhesive to make the membrane substrate such as plastic film or other film-shaped material laminate each other, through the curing process which is a chemical reaction of the adhesive, making each layer of substrate firmly bonded together, thus, multi-layer composite films are obtained.
Advantages Of Solventless Lamination Technology
Compared to traditional dry laminating, solventless lamination has significant advantages in the following aspects.
Saving resources
Due to no solvent use, it saves solvent costs and saves a large amount of energy consumption without the dried process. With less gluing, the coating weight of solvent-free lamination unit area adhesive is two-fifths of the coating weight of dry laminating unit area adhesive.
Safety and environmentally friendly
The adhesive of a solvent-free lamination is 100% glue, which does not contain any solvent, thus, in the production process, except that during the time of shutdown, there is a need to clean the gluing portion with a small amount of solvent, there are no emissions of solvent, VOCs and other pollutants, which will not produce pollution for the health and surrounding environment of the production worker. No combustible, explosive organic solvents in solventless laminating technology, there will be good safety. The hygienic performance of the composite film will not be reduced due to the existence of residual solvent.
Low costs
Each solventless laminating production line will have much less energy consumption than a dry laminating production line. The solventless laminating machine has high speed and the production cost can be lowered. The highest speed of the solventless machines is above 600 m/min, generally in 200m/min. As there’s no waste generated, there is no need to configure expensive environmental equipment and corresponding operating expenses.
What Should Be Paid Attention To In The Applications Of Solventless Lamination Technology Determining the components of the solventless adhesive The A component of the two-component solventless adhesive is easy to react with the water, affecting the adhesive ratio, thereby affecting the laminating quality of the product. So the requirements of the solventless lamination process for water vapor are particularly strict. The relative humidity of the workshop and the adhesive storage library are as low as possible. The drying and filtration of the gluing system must be thorough.
For the lamination of paper to aluminum and paper to plastic, a one-component solvent-free adhesive will be an economic choice. However, moisture is involved in the curing process for the application of a one-component solvent-free adhesive and moisture needs to be added to ensure the curing of the lamination. This laminating method is subject to certain restrictions in dry winter and should be paid attention to.
Sample test
Nowadays, each flexible packaging company has its own unique product and technical characteristics. The raw materials used in each company are not the same. The substrates, inks and solvents used in different products are also various. The molecular weight of the solvent-free adhesive is generally Low and it is easily affected by external factors. Therefore, each product is recommended to have a sample test before first adopting solventless lamination technology and then put into mass production after the test is passed.
Pay attention to the individual differences in special products
Due to the low molecular weight of the solvent-free adhesive and the extremely strong penetration, the problems of adopting solventless lamination for some products will occur, which requires special attention. For example, when the laminating substrate is thin and the flexible package products with the auxiliaries which contain a large amount of molecular weight, adopting solvent-free lamination process, the adhesive will penetrate the substrate and In severe cases, it can accumulate on the thermal surface of the substrate, by secondary reactions, generating urea and other derivatives, which affects the heat-seal quality of the product. In addition, due to the high permeability of the solventless adhesive, the color of the product is different when using the solvent-free laminating process for some flexible packaging products which require printing. Moreover, the edge of the printing pattern for the lamination product will become larger and the stroke of the small text will be thicker.
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Useful Knowledge For Solventless Lamination Machine
With the increasing cost of organic solvents and the increasing environmental protection requirements, organic solvent emissions are increasingly strict restrictions. Solventless lamination machine has advantages of health, safety, environmental protection, low cost and flexible packaging manufacturers will adopt solvent-free lamination technology instead of traditional solvent laminate technology for expanding laminating production capacity.
Why Choose Solventless Lamination Machine
The lamination machine adopting safety, healthy and environmentally friendly process is more and more required, which is the reason why solventless lamination machine is developed rapidly all over the world.
1.It adopts 100% adhesive, no solvent residue, reducing the pollution of packaging contents, especially food, drugs, etc. There is no volatile solvent emissions in the production, and there is no pollution on the atmospheric environment.
2. Higher running speed. The speed of the solventless laminating machine can be as high as 480m/min, with no risk for fire and explosion.
3. Less adhesive consumption. Solvent-free lamination machine has Lower production cost than solve machine. Gluing and total cost have a certain decrease.
4. The solventless laminator has lower energy consumption. Since the usual drying system is not adopted, energy consumption can be significantly reduced.
5. Better return on investment. The investment efficiency of the solventless machine is doubled than the solvent-based laminating machine.
6. Reduce the danger of storage for organic solvent transportation.
Working Principe Of Solventless Lamination Machine
The glue of the solvent-free laminating machine is AB glue. Currently, the laminating structure of thin layer laminating thick layer, aluminized lamination, aluminum foil laminating, paper-plastic lamination. There is no solvent and no need to worry about solvent residue. It is greatly affected by the air temperature. The glue operability is only about twenty minutes. So the tension control and the winding taper have high requirements.
Sheet-fed gravure press adopts paper stack continuous sheet feeding and the web-fed gravure press adopts continuous feeding with web paper. There’re three types of arrangement of plate cylinder and impression cylinder, including vertical, horizontally, inclined and the plate cylinder is arranged below the printing portion. Generally, each unit has a printing cylinder and an impression cylinder. In order to increase the printing pressure, some are equipped with 2 impression cylinders.
The technical advantage of the solventless lamination machine is very obvious, with low glue cost and high efficiency, through the step-by-step method of the sample, small batch production, mass production, reducing risks and unnecessary losses.
How To Control The Coating Weight Of Solventless Lamination Machine
1. The effect of coating clearance on coating weight
The coating clearance of solventless laminating machine on the coating weight is very obvious and the coating clearance is various due to different solventless lamination machine manufacturers.
The material of the metering roller and the transfer steel roller are affected by temperature.
Bearing clearance of the coating roller. Bearing clearance of the metering roller. Stability of metering roller under mechanical vibration.
2. The effect of temperature on coating weight
The glue used by the solventless machine is highly affected by temperature. With the different temperatures of solventless lamination glue, the fluidity and viscosity of glue will change greatly. At the same time, The phenomenon of heating expansion and cooling contraction occurs in the coating roller and metering roller with the temperature changing of the gluing, which affects the coating clearance.
3. The effect of transfer rubber roller on coating weight
The hardness, proper alignment, smoothness of the transfer rubber roller directly affects the coating weight.
The corrosion resistance of the transfer rubber roller directly affects the coating weight. The pressure on the transfer rubber roller directly affects the coating weight.
4.Effect of the coating mechanism rotating speed on the coating weight
The coating weight adjustment of the solventless laminating machine is to adjust the ratio of the coating roller and the transfer steel roller. So the linear speed stability of the coating roller and the transfer steel roller will greatly affect the coating weight.
What Are Important For The Use Of Solventless Lamination Machine
1.High control accuracy
The solvent-free machine requires high accuracy control because that the solventless glue substantially has no initial adhesion. There is a considerable high requirement for the soventless laminator tension control and high control accuracy for the coating unit.
2.High accurate production process
A solventless laminator requires precise control for the process settings such as operating temperature, tension match, and coating weight. For different product structures, different production processes are required.
3. High requirement for operator
A qualified operator of a solventless laminator needs good work responsibility and excellent operation skills.
4. Widely applicable structure
Early solvent-free lamination can only be applied to the composite of simple plastic to plastic. With the continuous improvement of the adhesive and the continuous maturity of the operating process, aluminizing film and some multi-layer structural products can also be produced. But for some highly rigid materials, there will be further developed.
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What Are The Differences Between Dry Composite And Solvent-free Composite
When the composite packaging film is produced, the composite method can be divided into extrusion composite, dry composite, wet composite, solventless composite. The most used methods are dry composite and solvent-free composite. What are the differences between the dry composite and solvent-free composite, and can be used for which type of packaging respectively?
Composite Method And Applications
Solvent-free Composite
The solvent-free composite film is different from dry composites that do not use organic solvents, which not only avoids the environmental pollution caused by organic solvents volatilization, but also does not require dry operating work segments, directly reducing production costs, and eliminating the influence of solvent and high temperature drying on the composite substrate, so that the size of the packaging film is more stable.
Dry composite
Dry composite is a kind of composite method. The adhesive is evenly coated on the substrate film by the roller. After dried, The composite film was synthesized by pressing and sticking on the composite part. The dry composite packaging film has a wide range of applications, with excellent chemical dielectric erosion performance, mostly used in packaging containing alkali, spicy, oil, etc., which is also suitable for cosmetic flavors, emulsifiers, especially for the high-temperature cooking packaging, very advantageous.
Coating Method
Solvent-free Composite
1. Multi-roller transfer coating
2. Thin adhesive layer, uniform thickness
3.The amount of coating is mainly determined by each roller speed, which can be adjusted online.
Dry composite
1.Concave roller coating
2.Thick adhesive layer, with a concave-convex shape, uneven thickness.
3.The amount of coating is mainly determined by the number of concave rolls, and the adjustment is limited only through replacing the convex rolls.
Glue Film And Compound Fastness Formation
Solvent-free Composite
1.low initial adhesion
2. The glue film and composite fastness are basically formed during the process of curing.
3. The glue film formation is mainly a chemical process of two components.
Dry composite
1.Heated through the oven, high initial adhesion.
2. The glue film and composite fastness are mainly formed on the machine, and the curing process only plays an auxiliary role.
3. The glue film formation is mainly a physical process for drying volatile and composite pressure.
Dry And Cooling
Solvent-free composite
1.No need to dry
2.Single component glue needs to cool, double-component glue generally does not need cooling.
Dry composite
1. The necessary step
2. Drying is usually under high temperature, and the drying temperature and cooling temperature of each segment have a large impact on the composite.
Curing
Solvent-free composite
Curing is the key process of solventless composite. Effect of curing temperature and time on two-component adhesive, which will have an influence on composite quality.
Dry composite
Curing usually is the auxiliary process and temperature and time have a certain effect on composite quality.
These two packaging composite have their own advantages. For choosing which composite method, should refer to the properties, weight of the packaging content. Although there are still many problems to be solved for solvent-free composite , it surely has advantages in health, safety, environmental protection, and cost.
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Useful Knowledge Shared About Solventless Adhesives
In recent years, with the increasing environmental protection awareness, solvent-free laminating adhesives are more widely used in the flexible packaging industry. This article will introduce the advantages, problems and development trends of solventless adhesives..
Advantages Of Solventless Adhesives
1.Environmentally friendly
Solvent-free laminating composite adopts solventless adhesive, which will not volatilize VOCs nor produce any irritating odor. It solves the problem of residual solvents in the packaging, eliminating the erosion of the organic solvent on the printing ink, can also achieve cleaning production, conducive to environmental protection.
2. Energy saving
The solventless laminating machine does not need to be dried, which reduces energy consumption. Moreover, in the late-ripening process, the maturation temperature of the solvent-free composite is substantially the same as the dry composite, so the energy consumption is also relatively close.
3. Safety
Since there is no organic solvent, so no need to adopt explosive and warm measures during production, transportation, storage and use and no need to specifically build a warehouse for solvent storage, more importantly, there is no harm to the health of the operator.
4.High Efficient
The speed of solventless machine adopting solvent-free adhesive is generally 250 ~ 350 m / min, even up to 400 to 500 m / min, while the solvent-based adhesive composite is generally 150 ~ 180 m / min.
5. Low cost
a. The coating amount of solvent-free adhesive is usually from 1.3 to 1.8 g / m2, while dry composite is 2.5-4 g / m2, and therefore, the amount of adhesive consumption can be reduced by about 50% compared to dry composite.
b. Since the solventless composite process does not require a drying process, energy cost is effectively reduced. After calculating, the energy consumption cost of the solventless lamination machine is 1/15 of the cost of dry composite consumption.
c. From the production efficiency, the efficiency of the solvent-free lamination machine is 1.5-2 times higher than that of ordinary dry composite, effectively reduces production costs.
Problems Existed In Solventless Adhesives
1.A great effect on the smoothness of PE film
When the solvent composite ripening temperature is greater than 40 ° C, it has a great effect on solvent-free composite film which has the inner layer of a PE film, and it is easy to appear the phenomenon that friction coefficient increases obviously. This is mainly because the higher the ripening temperature, the more intensely moved the molecular motion of the PE film, which is easy to migrate to the adhesive layer and the reaction is consumed, resulting in the increasing friction coefficient of the composite film.
2.Aluminum plating layer transfer
Aluminum plating film, especially a polyester plating aluminum film, is prone to aluminum transfer during the solvent-free composite, thereby causing insufficient strength of the composite film peeling.
3.Dissolve with ink
During the solventless composite, the phenomenon of adhesive and ink phase dissolution may occur, especially the dye-type ink.
4. Low peel strength of aluminum foil composite
At present, for the solventless composite of the aluminum foil, since the peel strength is not enough, it is still necessary to satisfy the heavy-duty packaging and requirements for cooking resistance.
5. Frequent replacement of solventless adhesive types
With the development of the solventless composite process, many solvent-free adhesive suppliers have introduced general solvent-free adhesives, cooking solvent-free adhesives, aluminum foil special solventless adhesive, low friction coefficient no solvent adhesive, etc. Although the diversification of the product can meet the composite requirements of different materials, the flexible packaging company also has to clean the gluing equipment and solventless machine according to the different composite materials. Not only it wastes time, human resource, financial, but also has low production efficiency.
Development Trend of Solventless Adhesives
1. Functional solventless adhesive
Solventless adhesives should develop to functional products, such as DMF organic solvent mixture with content less than 20%, a product resistant to pesticide corrosion.
2.UV curable solventless adhesive
UV curable solvent-free adhesives have the advantages of fast curing speed, transparent peel strength, non-toxic, non-corrosive, energy-saving and environmentally-friendly, widely used for plastic/plastic, plastic/paper, plastic/metal film, or other materials rapidly solvent-free composite. At present, UV cured solventless adhesive has been developed, but it still needs to increase research and development efforts to launch more mature products to the market.
3.Solventless adhesive used in other industries
The solventless adhesives used for textile, automotive interiors and other industries, as well as paper including kraft paper, cardboard paper, ordinary paper, plastic including various transparent films, aluminum plating films, aluminum foil, should be developed.
Solventless adhesives bring great benefits to environmental protection, health, safety, cost, etc, but still, have some problems that need to be paid attention to. The future development trends of solvent-free adhesives are multi-functional, can be used with various materials in different industries.
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Why Select Solventless Adhesive
Solventless adhesive adopts a solvent-free adhesive composite film to reduce energy consumption and comprehensive production costs, improving productivity and quality.
The solvent-free adhesive is a viscous material and two separate materials are connected together by means of its viscosity, a viscous liquid shape at normal temperatures, such as an epoxy resin. It is one of the most important auxiliary materials. Due to the solvent-free, it is beneficial to protecting the environment and cleaning products, is extremely widely applied in the flexible packaging industry.
Solvent-free adhesives are commonly used in solventless composite processes, which is of great significance for promoting and adopting solvent-free composite technology. It can solve the problems of different composite structural materials in a flexible packaging company. Frequent cleaning mixers and solventless machine can save time, improving production efficiency, and more importantly, saving the labor force of cleaning equipment, and further reducing the solvent quantity of cleaning equipment, more beneficial to reduce VOCs.
Analysis Of The Problems During Using Solventless Adhesive
1. Flying gel phenomenon
In solventless composite equipment, the gluing unit will find flocculation around the exhaust port, which is caused by fly ash when the solvent-free adhesive is used. The solventless adhesive has high viscosity. During high-speed production, the adhesive is sucked into the air and adheres to the surface of the device during exhaust. By increasing the exhaust volume, the adhesion of the fly ash on the device surface can be reduced, and the frequency of the cleaning vents can be increased to maintain the stable exhaust volume.
2.Influence on the friction coefficient of the slip agent
The use of a solventless adhesive can affect the friction coefficient of the inner layer containing the slip agent, the thinner the inner layer, the more obvious effect, the higher the curing temperature, the longer the time, the more significant effects of the curing process and the inner layer formulation. It is effective to properly reduce the amount of adhesive or choosing the adhesive which little effect on the slide agent.
3. Solubility
During solventless compounding, the adhesive sometimes dissolves the ink. It is necessary to verify the work before mass production, stabilization process and avoid free replacement of ink and solventless binders. Further, by adjusting the solventless composite process, the solvent-free complex is first cured for 2 hours at room temperature and then curing in the curing chamber to alleviate the problem of ink dissolution.
4. Adhesive cannot be completely cured or dried
The main agent and curing agent of two-component solvent-free adhesive are mixed in a certain proportion. If the mixing is uneven, an intermittent problem occurs. If the ratio is wrong, the glue does not dry. It is very sticky. In order to prevent unevenness mixing, in addition to controlling the instability of manual rubber, using the glue mixer, it is also necessary to regularly inspect the equipment status.
5. Bubble Failed Bubble problems are also commonly occurred in solventless compounding. The so-called bubble means that the two films are not fully adhered, and there is a gas between the composite film and the substrate. When composite the aluminum foil, a small white point is generated. As long as the two layers are not completely adhered and the transparency is different, there will be bubble phenomena.
Insufficient glue will increase the bubbles caused by uneven coating, which can be solved by applying an appropriate amount of glue. The bubbles caused by high ambient humidity, are CO2 which is formed by the NCO in the binder and the water in the air. The problem will be solved by appropriate control of the humidity in the composite environment and keep the relative humidity is 70% or less. If the curing is not suitable, the secondary flowing of the adhesive can also cause bubbles, which can be solved by appropriately increasing the curing temperature.
The application of a solventless adhesive has unique advantages of high efficiency, environmental friendly and low cost. It will gradually substitute dry composite applied in the solventless composite.
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Why Select Solventless Adhesive
Solventless adhesive adopts a solvent-free adhesive composite film to reduce energy consumption and comprehensive production costs, improving productivity and quality.
The solvent-free adhesive is a viscous material and two separate materials are connected together by means of its viscosity, a viscous liquid shape at normal temperatures, such as an epoxy resin. It is one of the most important auxiliary materials. Due to the solvent-free, it is beneficial to protecting the environment and cleaning products, is extremely widely applied in the flexible packaging industry.
Solvent-free adhesives are commonly used in solventless composite processes, which is of great significance for promoting and adopting solvent-free composite technology. It can solve the problems of different composite structural materials in a flexible packaging company. Frequent cleaning mixers and solventless machine can save time, improving production efficiency, and more importantly, saving the labor force of cleaning equipment, and further reducing the solvent quantity of cleaning equipment, more beneficial to reduce VOCs.
Analysis Of The Problems During Using Solventless Adhesive
1. Flying gel phenomenon
In solventless composite equipment, the gluing unit will find flocculation around the exhaust port, which is caused by fly ash when the solvent-free adhesive is used. The solventless adhesive has high viscosity. During high-speed production, the adhesive is sucked into the air and adheres to the surface of the device during exhaust. By increasing the exhaust volume, the adhesion of the fly ash on the device surface can be reduced, and the frequency of the cleaning vents can be increased to maintain the stable exhaust volume.
2.Influence on the friction coefficient of the slip agent
The use of a solventless adhesive can affect the friction coefficient of the inner layer containing the slip agent, the thinner the inner layer, the more obvious effect, the higher the curing temperature, the longer the time, the more significant effects of the curing process and the inner layer formulation. It is effective to properly reduce the amount of adhesive or choosing the adhesive which little effect on the slide agent.
3. Solubility
During solventless compounding, the adhesive sometimes dissolves the ink. It is necessary to verify the work before mass production, stabilization process and avoid free replacement of ink and solventless binders. Further, by adjusting the solventless composite process, the solvent-free complex is first cured for 2 hours at room temperature and then curing in the curing chamber to alleviate the problem of ink dissolution.
4. Adhesive cannot be completely cured or dried
The main agent and curing agent of two-component solvent-free adhesive are mixed in a certain proportion. If the mixing is uneven, an intermittent problem occurs. If the ratio is wrong, the glue does not dry. It is very sticky. In order to prevent unevenness mixing, in addition to controlling the instability of manual rubber, using the glue mixer, it is also necessary to regularly inspect the equipment status.
5. Bubble Failed Bubble problems are also commonly occurred in solventless compounding. The so-called bubble means that the two films are not fully adhered, and there is a gas between the composite film and the substrate. When composite the aluminum foil, a small white point is generated. As long as the two layers are not completely adhered and the transparency is different, there will be bubble phenomena.
Insufficient glue will increase the bubbles caused by uneven coating, which can be solved by applying an appropriate amount of glue. The bubbles caused by high ambient humidity, are CO2 which is formed by the NCO in the binder and the water in the air. The problem will be solved by appropriate control of the humidity in the composite environment and keep the relative humidity is 70% or less. If the curing is not suitable, the secondary flowing of the adhesive can also cause bubbles, which can be solved by appropriately increasing the curing temperature.
The application of a solventless adhesive has unique advantages of high efficiency, environmental friendly and low cost. It will gradually substitute dry composite applied in the solventless composite.
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Sinstar Solventless Laminating Machine Is Worth For Your Choice
The solventless machine is widely used for flexible packaging industry with good performance, green environmentally friendly, low energy consumption, no residual solvent and high precise coating.
Now Sinstar has several series of solventless laminating machines, including the series of WRJSi9, WRJi9, WRJFi9, SIL90, WRJSLi5, C180, E280, S380. Compared with the single station solventless laminating machine, the double station type mainly has the following advantages.
WRJSi9
On June 8, 2021, Sinstar has launched a new product - three-layer solventless laminator and machine model is WRJSi9.
Three-layer composite machines, as the name implies is a solventless machine realizing one-time composite forming of three-layer materials. In recent years, there is a high-speed development for solventless composite, and the requirements for composite process and equipment functions are increasing. The solventless lamination equipment which can carry out the substrates compounding of multi-layer materials on a composite machine, is in urgent need.
Sinstar three-layer solventless machine has a reasonable structural layout, simple loading, saving time and effort, realizing one-time molding for three-layer composite, which is beneficial to improve production efficiency and product quality.
Advantages
1. Simple and convenient to load
2.Shorten the delivery term
3.Increase productivity
4. Greatly reduces the labor intensity of employees
5.Save electricity energy
6. Easy to operate
S1L90 Series
The S1L90 series solventless laminator includes models of S1L90-1000A, S1L90-1300A, S1L90-1600A.
Features
1. Combination of ergonomics &green packaging technology
2.Redefining tension(Rational tension)
3.Farewell to sensuous tension（Tactile tension)
4.Same tension at high and low speeds
5.Digital tension system
6. External roll-diameter status display
WRJ i9 Series
The WRJ i9 Series solventless machine includes models of WRJ i9-1000A, WRJ i9-1300A, WRJ i9-1600A.
Advanced systems
CWDS: Coating Weight Directly Inputting system
MRPS: Multiple Ratio Protection System
CCMS: Coating Clearance Memorizing System
FCS: Fast Cleaning System
PCWD: Precise Coating Weight Detecting system
WRJF i9 Series
The WRJF i9 Series solventless lamination machine includes models of WRJF i9-1000A, WRJF i9-1300A, WRJF i9-1600A.
Characteristics
1. Simple Operation.
2. Automatic analyzing.
3. One-button multiple-points position system.
4. High viscosity glue feeding and coating applicable.
5. Accurate swinging arm tension to control aluminum foil movement.
6. Active unwinding for aluminum foil through motor control.
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Why Select Sinstar Solventless Laminating Machine
The solventless machine adopts a method that can composite two or more substrates by using solvent-free adhesives. The solventless laminating machine has a wide application with the advantages of environmental, hygiene, and high efficiency, especially used for the packaging industry of the food and the drug.
Development Of Solventless Laminating Machine
In 1974, the German company adopts the single component solventless-free adhesive in industrial production, marking the formal promotion of solvent-free composite.
In the 1980s, there was rapid development in developed countries such as Europe and the United States.
At the end of the 1990s, Japan gradually began to play an important to no solvent composite and had a great development. In India, Russia, Brazil, the solventless composite has gradually become the leading composite process.
In 1985, China had introduced the production technology and equipment of the solvent-free polyurethane adhesive from Germany, thereby enters the era of solventless composite process.
Competitive Solventless Laminating Machine Manufacturer In China - Sinstar
Sinstar, which is the abbreviation of Sinstar Packaging Machinery Co., Ltd, was founded in 2005. It is a professional company which focused on the R & D, production, sales and service of a solventless laminating machine. It is located in the National High-tech Industrial Park, Rongchang District, Chongqing, with an annual production capacity of 200 sets. Since its establishment, the company has characterized simple-operate, safety, high durability and perfect service. Sinstar has become one of the most competitive solventless laminating machine manufacturers in China.
Solventless lamination machine supplied by Sinstar, has independent innovation patented technology, including "CCMS coated clearance memory system"; "FGPS foolproof glue preparation system"; "precision metering control system"; "coating weight directly inputting system", "ratio pressure protection system" "quick cleaning system", "zero error tension control system", etc.
Sinstar has 135 authorized patents, including 7 authorized invention patents, 123 utility model patents, 5 appearance design patents. Sinstar is devoted to providing green and environmentally friendly solventless composite packaging machinery, technical guaranteeing the safety of food and drug packaging.
Sinstar is your trustworthy solventless laminating machine manufacturer and the solvent-free machine supplied by Sinstar has advanced systems, easy-to-operate, high safety, high efficiency and long service life.
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Development Trend Of Solvent-free Adhesives For Flexible Packaging Industry
In the flexible packaging color printing composite industry, the solvent-free adhesive will be the direction of future development, affecting the development trend of the flexible packaging industry. As the enhanced awareness for environmental protection and the importance for the safety of food packaging, how to reduce costs and improve competitive advantage, producing the commodities conforming to the hygienic requirements for food packaging, is the problem of most food manufacturer concerning. The promotion of solventless adhesive in the market is in line with this trend. In Europe, the solvent-free adhesive has a share of 40% in the flexible packaging composite adhesive market.
High-temperature resistant solvent-free adhesive
The universal solvent adhesive is suitable for general flexible packaging composite applications, not suitable for cooking with a temperature above 100 ° C . Usually the solventless adhesive can be classified into 3 grades. Low-grade type is generally used for dry content packaging with lightweight and simple structures. Medium grade type is typically applied to multi-layer composite products which can withstand load or having a liquid content and is resistant to cooking and steaming. High-grade types could have adhesive applications with certain tolerances. Currently, the solvent-free adhesive is rarely used for high-temperature cooking, but the solventless composite material completely replacing the dry composite material and developing high temperature resistant solventless adhesive will be inevitable trends.
Two-component coating solvent-free adhesive
Two-component coating solvent-free adhesive is developed in 2016. The so-called two-component coating, that is, a primary agent, a curing agent, is a separate coating, when the two-component adhesives are mixed, the curing reaction is rapidly generated and the corresponding mechanical strength is achieved. The entire composite process does not require an ultraviolet lamp. It is a new type of flexible packaging composite technology. It has been widely concerned in the flexible packaging industry, mainly because it has the advantages of separate coating, quickly curing at normal temperature, easy to operate. It is clear that the two-component coating type will become the trend of solvent-free adhesive in the future.
Solvent-free adhesives are the trend and direction of flexible packaging composite adhesives, with the advantages of high efficiency, environment-friendly, lost-cost, no residual solvent, high safety, and high initial adhesion.
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Why Select Solvent-free Adhesives For Flexible Packaging Industry
Environmentally friendly, High efficiency will be the main trend of future packaging industries. In terms of composite adhesives, solvent-free adhesives will replace traditional solvent-based adhesives, which has become a consensus of the packaging industry. The solvent-free adhesive is more widely used in the flexible packaging industry.
What Are Solvent-free Adhesives
Solvent-free adhesives are a viscous substrate, which can connect together by means of their viscosity. They are viscous liquid at normal temperatures, such as an epoxy resin which Is one of the most important auxiliary materials and has extremely wide applications in the packaging industry. Solvent-free adhesive mostly is adopted for the solventless laminating machine, also can be used on existing solvent drying compound equipment which is suitable for many color printing plants to improve the high residual solvent, reducing production costs, no need to input new equipment.
Composite adhesive for flexible packaging is constantly undergoing technical improvement and innovation. The new type of solventless adhesive performance can completely meet the dry composite requirements among the most flexible packaging materials and can be used on a solvent dry compound machine. It can meet the requirements of drug & food packaging.
Features And Advantages Of Solvent-free Adhesives
Solvent-free adhesive is an ideal replacement for solvent adhesive.
1. Effectively reducing the residual solvent
Since it is a solvent-free adhesive, the adhesive itself does not bring the second solvent contamination, the printed film can further decrease the residual solvent when passing through the drying oven, adopting a solventless adhesive is quite effective to control residual solvent.
2.High initial adhesion
The high initial shear strength of solventless adhesives makes it possible for real-time slitting and delivery without curing. This performance is quite effective for shortening delivery time.
3.Relatively low cost
Usually, the required coating amount is 1.6g to 2.4 g per square meter, not any solvent used, so its composite cost per square meter will significantly lower than solvent-based composite.
4.Improving the working environment, reducing pollution, reducing work strength, and avoiding the risk of the fires
Since the solventless adhesive does not need to be diluted, it can be directly used for production, reducing the labor of the operating worker and also avoiding the concentration of solvent in air, which is advantageous for workers. Of course, without the existence of solvent, it also can avoid the hidden risks of fire.
5.Effectively reducing the occurrence of quality accidents
With a solventless composite product, it can directly see the quality of the product. Only the appearance and composite intensity of the product should be carefully checked when going off the production line. After a period of time, as the increase of adhesive composite strength among the adhesive molecules, the appearance will become better. For the composite of the aluminized product, the solventless adhesive can effectively prevent aluminizing transfer.
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Benefits Of Solventless Laminator Applied In Flexible Packaging Industry
Solventless laminator adopts green environment-protection technology. It has occupied a high market share in Europe and the United States, accounting for 80% to 90% of the composite machine. It can ensure the non-pollution of the composite packaging of food & drugs, increasingly applied to the composite film packaging industry and the flexible packaging industry.
Solventless laminator has many advantages such as reducing cost, improve product quality, environmental protection, safety and stability production, which has a high production practical value.
1.Taking the S1 L90 series solventless lamination machine as an example, solvent composite is safer and more healthy, compared with the ordinary dry compound process, 100% of the adhesive can be achieved when using S1 L90 Series laminator, because there is no solvent composite in the production process, avoiding the use of organic solvents, at all solve the residual solvents problem. Solvent-free composite is a healthier composite process. And there is no solvent residue, reducing the contamination of packaging content, especially for the packaging of food, pharmaceuticals, etc.
2. Solventless composite equipment can reduce production costs. It doesn’t have a drying channel, so the structure is compact, with small occupied space. The equipment cost is low, which can significantly reduce the cost of composite film production.
3. In general, the coating amount solvent-free composite is usually from 1.3-1.8 g / m2, while dry composite is 2.5-4 g / m2, and therefore, the amount of adhesive consumption can be reduced by about 50% compared to dry composite. Although solvent-free glue has a higher price, the overall raw material cost can also decrease by about 20%.
4. There’s no solvent-type adhesive and can reduce energy consumption. At the same time, eliminating the long-time volatility of the solvent adhesive in a drying oven.
5. Solvent-free machine has a high-speed composition production line and the highest speed can reach 480m/minute, generally approximately at 300m/minute, with high production efficiency.
6. The structure of the solvent lamination machine is compact with fewer operators, reducing labor costs.
7. Solvent-free composite has a high safety and fire and explosion risk can be reduced to the minimum. The factory and production workshops do not require special measures for fire prevention, explosion-proof.
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What Is A Solventless Laminator
Solvent-free composite has a wide range of applications. With the advantages of environmentally friendly, hygiene, high efficiency, the solventless laminator is especially applied for the flexible packaging industry.
Solventless lamination is a method for the composite of two or more substrates using a solvent-free adhesive. The solventless laminator is the equipment which can be applied for a solvent-free adhesive composite. Composite substrates mainly include BOPP, PET, NYLON, CPP, PE, VMPET, VMCPP, PVC, aluminum foil, paper, etc.
Types of solventless laminator
There’re three types of solventless laminator including types of exclusive solvent-free, the combination of solvent-free and dry compound, multifunctional combination.
Exclusive solvent-free laminator is only used for solventless composite, once molding with two-layer structure or three-layer structure. It can be classified into types of manual roll changing and automatic roll changing.
The equipment adopting the combination techniques of solvent-free and dry compound can be used for solventless composite and the coating unit can be switched. This type of equipment can be connected with two machines, thereby achieving a one-time molding of three-layer structure. For example, the first machine produces PET / AL adopting a dry compound method and the second machine can complete the composite of PET / Al and PE using a solventless method.
The Multi-function type equipment can achieve solventless, dry compound, PVDC coating, cold sealing positioning coating, hot melt adhesive coating, reverse printing, etc, through switching coating units.
Work Principle Of Solventless Laminator
The mostly used solventless laminator has a structure of two-layer composite, a single station unwinding, which mainly constitutes of an unwinding unit and coating unit as a first-layer, and an unwinding unit, a composite unit, a rewinding unit. The structure of the solventless laminating machine includes a two-roller device, a winding device, and solvent-free adhesive coating composite equipment. The outstanding feature is that after entering the composite through a special coating device, it is not necessary for drying. The solventless composite machine satisfies the requirement of a solvent-free adhesive coating,which is a significant difference from the solvent drying compound equipment. The solvent-free machine has precise control for the temperature of the coating equipment, relying on the adjustment of temperature and the viscosity of the adhesive for promoting the coating application. It is equipped with a closed-loop tension controller which can strictly control the winding tension.
For more professional introduction, please visit the article page of why choose a solventless laminator.
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Analysis For Three Common Risk Control Points of Solventless Composite Technology
machine.html">solventless lamination machines. Significant advantages of the solventless composite process are reducing cost, high efficiency and energy saving, improving production safety, stability and product quality.
However, due to the immature solventless composite technology , and there are still some technical risks that are easily overlooked in the application for a flexible packaging company, leading to quality problems. Now we summarize three common risk control points of solvent-free composite technology.
1. The Technical Risk Of Increasing A Glue In Solventless Composite
Solvent-free composite adhesive with A glue and B glue, the adhesive mixing ratio is generally the weight ratio of A glue and B glue, rather than the volume ratio of both. The mixing ratio of the binder is usually determined by the adhesive manufacturer, as the proportion of the binder in different brands is generally different. The common ratios of A glue and B glue are 100: 80,100: 75,100: 50,100: 45. However, in the actual solvent-free composite production of flexible packaging companies, the ratio of the two-component adhesive will be disordered, which will affect the solventless quality of flexible packaging products.
Case
After printing, solvent-free compounding, the flexible structure of OPP / VMPET / PE has no quality problems.
The structural composite flexible bag is a low viscosity-free solvent-free binder brand and the proportion of A glue and B glue in actual composite production is 100: 67. When analyzing the cause of failure, we find that the bag is curled and the inner binder is not dry. Originally, because the composite film maturity is incomplete, prolongs the maturation time and then cuts into a bag. The problem of bag curling still exists and the opening performance has also deteriorated.
Combined with a ratio of A glue and B glue, it is not difficult to find that the bag is mainly caused by the excess of the A glue, because the solvent-free composite film is usually large and the effect of prolonging maturity is not obvious, water must be introduced into the cross-linking curing reaction with the -NCO.
The much more efficient methods are to rewind the composite film roll on a slitting machine and then increase the humidity of the workshop environment to absorb some moisture between the layer and the surface. The composite film, during aging, water will penetrate into the adhesive layer and reacted with an excess-NCO cross-linking curing reaction, so that the self-adhesive layer will be further completely cured, thereby effectively release the curling of the flexible packaging bags.
2. Risk Control For The Attenuation Of PE Membrane Peel Strength At Solventless Composite Material
A certain amount of linker is added to the film blow molding for reducing the friction between the film and the film, the film and the device, so that the surface of the film will be smoother, in order that the composite film operates successfully in the production process. Under normal circumstances, an excess sliding agent has added appropriately in the PE film, which can solve the phenomenon of abnormal increase in the friction coefficient of the solvent composite film after a certain extent, but this can also cause peel strength to be weakened, which is serious. When the aging is completed, the peel strength of the composite film is exceeded and in most cases, the peeling strength is reduced during the process of placing the composite film or during the cycle of the flexible packaging.
Case
The composite structure is a BOPA / PE film
Main parameters: a brand solvent-free adhesive, the amount of glue is 1.5 g / m2, aged at 40 ° C for 24 hours. The tracking and detection data of the peel strength of the composite film is as follows:
On October 13, the lateral peel strength was 15.37 N / m.
On November 4, the lateral peel strength was 4.62 N / m.
After the complex layer is peeled off, the surface of the PE film has a mist-like substance that can be wiped off.
On November 18, the lateral peel strength was 4.69 N / m.
It is closed to the final test data indicating that the peel strength of the composite film has reached a stable value.
Typically, the flexible packaging company only detects the peel strength of the composite film shortly after maturity. The composite film is rarely tracked during the process or the peel strength in the soft bag, which should be noted.
The migration of the solventless adhesive in the PE film produces a slipping agent, which is the main reason for the decrease in the peel strength of the composite film. We recommend a solvent-free adhesive. Add the formulated slipping agent to the formulation, so that the friction coefficient of the PE film in the solvent-free compound can be solved, and the problem of decrease in peel strength can also be solved.
3. Pay Attention To Identifying The Smell Characteristics Of The Solventless Adhesive
There are many factors that produce scent in the flexible packaging bag, such as residual solvent, ink resin, thin-film raw material resin, adhesive, etc. Although there is no solvent residue in a solventless composite, the resins and formulations in the solventless adhesive have a certain odor feature and some have effects after composite curing, even after the packaging. For flexible packaging companies, it is necessary to pay attention to the identification of the solventless composite film after the smell and prevent the problem.
a. In GB / T 10004-2008 standard, the detection method of packaging sensory indicators is specified, which is opening the box and lining the packaging film and immediately detect the smell.
b. Usually take a certain area of the composite films, cut into a 500 ml glass bottle, baked for 30 minutes at 60-80 ° C for detecting smell. It is also possible to seal the package in the air or actual content, rotating at a temperature of 50 to 60 ° C, tearing the package, and feel whether there is odor.
The odor of the composite film is mainly from a solvent-free adhesive. Therefore, the odor feature of the general solventless adhesive can be identified by the following method.
a. Take a certain amount of A glue and B glue with different brands for sensory testing and comparison.
b. Add a mixed solvent-free binder according to the specification to the glass bottle. Plastic film is placed in the bottom of the bottle and the cured adhesive is easily taken out and the crosslinking reaction is under 40-50 ° C. After an hour, the odor characteristics are determined. This method is more suitable for practical applications, including the odor characteristics of the resin itself.
Solvent-free composite technology is a production technology which is more and more widely used in the flexible packaging industry with the advantages of safety, environmental protection, saving costs. Through the learning of the common risk control points of solventless composite technology, the efficiency of solventless lamination will be improved.
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What Is The Tension Control Of Solventless Lamination Machine
During the entire solventless composite process, tension control is important, and the precise tension control of solventless laminator is the premise of ensuring the quality of the composite film.
Tension Control Methods Of Solventless Lamination Machine
The solventless lamination machine mainly has two tension control modes, one mode is a "floating roller" and the other mode is a "micro shift".
The "floating roller" tension control has the advantages of large range control, adapting to the wide substrates, but the structure is more complicated.
The "micro displacement" type tension control has the advantages of high precision, high sensitivity, but since the detection range is small, the absorbance of the material roll fluctuation is small, so this method is generally only suitable for relatively thick or non-molar material.
In actual solventless composite production, a solventless laminating machine may adopt different tension control methods in different sections.
Instruction For Tension Control Of Solventless Lamination Machine
1. During the solvent-free composite, the requirements for tension control are higher than that of ordinary compounds. The main reason is that there is no solvent composite initial adhesion, and the operational control is difficult, which may lead the quality problems. In addition, the solvent-free composite speed is much higher than the dry lamination machine.
During the solvent-free composite, the tension after the thin film is slightly greater than the main arrangement, and the winding tension is greater than the rewinding tension. The winding taper is controlled within 20%. For different materials, each part of the tension control is different, and even the film of the same material produced by different manufacturers, its tension has to be slightly adjusted.
2. In the solventless composite, not only the accuracy of the tension control system, the matching of the tension between the two composite rolls is emphasized. Under the current technical conditions, many tension control systems have very high accuracy performance, which can meet the needs of solventless composite production. However, in the process of solventless composite operation, this is often encountered, which the matching of the two-layer materials is more difficult, which not only requires a good tension control system but also carefully understand the material features. More accurately, the tension of solvent-free composite requires that the elongation of the two-layer rolls is consistent by controlling the tension to ensure that the two-layer material does not occur the relative slip during the solventless composite.
3.The rewinding tension and pressure are the key to solventless composite tension control. Since the combination of the composite film and the overall condition of the material roll, are determined by the rewinding tension and pressure, adopting the segmentation independent tension and segment tension taper are the most ideal control mode.
It should be noted that the segment tension taper is mainly to compensate for the need for linear tension to the requirements of different material winding tension. Different tension tips can be effectively guaranteed to ensure the neatness of the winding while reducing the generation of core wrinkles.
Unwinding Device And Loading Pattern Of Solventless Lamination Machine Unwinding device The solventless laminator is mounted with an aluminum foil unwinding frame and an ordinary unwinding frame. In general, the path of the aluminum foil unwinding frame is shorter with a smooth guide roller, often adopting "micro displacement” tension control. The ordinary unwinding frame is long, often adopting the "floating roller" tension control.
When using an aluminum foil unwinding frame, only one frame is in a working condition during the composite process, that is, the ordinary unwinding frame is in a non-working state. Due to the simultaneous compounds of the two films, two unwinding frames are required to work at the same time.
Accordingly, there must be two tension control systems in the working condition.
Loading Pattern
There are two main methods of the solventless laminating machine and the reliability of the air shaft and shaftless pneumatic shaft are high.
The shaftless cone top type of loading pattern has the advantages of simple, fast, high efficiency, low operation intensity, but it has high requirements for the core tube and in order to ensure safety, this loading pattern has a higher requirement for equipment parts Also the manufacturing cost is relatively high.
In the current market, medium and high-speed solvent-free lamination machines with speed at 400 to 600 m / min, basically adopt air shaft loading patterns.
Tension control plays an important role for the whole solventless composite process and learning the tension control well can do a great favor for the work efficiency of solventless laminating machine.
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Reliable Solventless Lamination Machine Manufacturer - Sinstar
Sinstar Packaging Machinery Co., Ltd is founded in 2005, is a professional solventless laminating machine manufacturer with advanced systems, such as “Coating Clearance Memory System”, “Foolproof Glue Preparation System”, “Accurate Coating Weight Detecting System”, “Zero Error Tension Stabilizing System”, types including WRJi9 series, S1L90 series, and WRJFi9 series solventless laminator. Sinstar has professional and unique invention patents, appearance patents and utility model patents.
Why should choose Sinstar solventless lamination machine
1. Adopts advanced green and eco-friendly packing technology
2. No wrinkle when 0.06 mm thickness aluminum foil goes through the running roller.
3. Process parameters online printing out.
4. High viscosity glue feeding and coating applicable.
5. Active unwinding for aluminum foil through motor control.
6. Simple operation.
7. More capable, more refined, with a five roller coating system.
8. Width setting for digital glue spray.
9. Digital tension system
10. Intelligent dynamic analyzing system
The solventless lamination machine is equipment which is applied to solvent-free adhesive composite. There’re two types including single station solventless lamination machine and double station type. Sinstar solventless laminating machine will be one of the best choices for advanced flexible packaging machinery.
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Two Types Of Solventless Laminating Machines
Solventless lamination is a method of compositing two or more substrates by using a solvent-free adhesive. The solventless lamination machine is mainly composed of two major parts including the solventless laminator and adhesive mixer. It mainly completes the operation of the unwinding, tension control, glue, composite and rewind. The adhesive mixer is a special device for quantifying the adhesive to the host. Here, we mainly introduce the types of solventless laminating machines.
Single Station Solventless Lamination Machine
Today, the single station solventless machine is widely used, which is determined by a variety of factors.
1. Due to the low initial adhesion of the solvent, the tension control requirements of the substrate are high. Therefore, during the solvent-free composite, the single-station solventless lamination machine has the advantages of shorter material feeding, high accuracy tension control and low waste rate.
2. Since the solvent-free adhesive has a certain opening time, it does not require a dry composite high-temperature drying system, using a single station solventless laminating machine, can realize the operation of the roll change during the downtime.
3. the manufacturing of the single station solventless laminator is relatively simple, and the cost is low. Moreover, the single station solvent-free lamination machine is compact, covering a small area, and one person can operate in general.
Overall, most of the solventless lamination machines, are the single station model, accounting for more than 70%.
Double Station Solventless Lamination Machine
The double-station solvent-free lamination machine is installed on an unwinding rack with two material rolls and can realize the reel alternation without downtime. Advantages And Disadvantages Of Double Station Solventless Lamination Machine Advantages
Compared with the single station solventless laminating machine, the double station type mainly has the following advantages.
1. High efficiency. Normally, the stable working speed of the solventless laminating machine is 300 ~ 600 m / min, which is about 2 to 3 times higher than the dry laminating machine. The double-station solventless laminator can greatly reduce the time of roll changing and downtime, improving production efficiency, with generally 70% higher yield.
2. Significantly reducing operational difficulties. Single station solventless laminating machine requires frequent replacement rolls, one unwinding or rewinding unit is replaced once every 15 to 30 minutes, which greatly consumes the operator’s physical strength. The physical strength of the personnel will be accompanied by a certain degree of tension, which will inevitably affect the progress and product quality. The roll changing without the downtime of a double station solventless lamination machine can avoid this.
3. Improve production stability. The double-station solventless lamination machine greatly reduces downtime, improving tension control and adhesive viscosity consistency, which will improve production stability.
Disadvantages
However, there are some potential disadvantages for double station solventless lamination machine, because the material feeding is long with higher tension control requirements and the waste rate will also increase accordingly, and there may be unfavorable effect for solventless composite products with lower initial adhesion. In addition, the cost of a double-station solventless lamination machine is also significantly higher than the single station type.
For more information, please visit the article page of useful knowledge of solventless lamination machine.
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Professional Solventless Laminator Supplier - Sinstar
Sinstar, the full name is Sinstar Packaging Machinery Co., Ltd, which is founded in 2005 with location at high-tech industry zone of Rongchang District Chongqing City and is a professional supplier which is engaged in the research, development, production, sales and service of solventless laminating machine with annual production capacity of 200 sets.
Since the very beginning, Sinstar has been adhering to the design concept of “Innovation Changes The World, Innovation Masters The Future”, insisting on continuous technological innovation. We develop many unique technologies such as “Coating Clearance Memory System”, “Foolproof Glue Preparation System”, “Aimed Coating Weight Direct Input System”, “Accurate Coating Weight Detecting System”, “Multiple Mixing Ratio Protection System”, “Zero Error Tension Stablilizing System”, “Fast Cleaning System”. Now we have several series of solventless laminators including WRJi9 series, WRJFi9 series, S1L90 series, WRJSLi5 series and in China market so far we have more than 1000 customers because of the excellent characters of our machines: simple operation, safety, durability and perfect service.
Sinstar has a strong team of research and development, 30% of the company’s total staff are engineering and technical personnel who have been engaged in flexible packaging machinery industry for more than 20 years. Some of them are packaging industry engineers or doctoral talents and have ever participated in the formulation of the national standard GB/T 34150-2017 for non solvent laminating machine. In 2015, the design of Sinstar solvent free laminating machine won the second prize (Innovation category) of the second Cross-strait (Zhangzhou) Industrial Design Innovation Competition.
Sinstar has 220 authorized patents, including 8 for invention, 204 for utility model and 8 for appearance design. It has 10 trademarks and 2 software copyrights. The company has been awarded as “National High-Tech Enterprise”, “National Intellectual Property Advantage Enterprise”, “Chongqing Gazelle Enterprise”. In the 2019 Boao Forum for Chinese Entrepreneurs, Sinstar was selected as one of the brands symbolizing China’s economic resilience.
Determined to provide green and environment friendly flexible packaging machinery for the world, Chongqing Sinstar Packaging Machinery Co., Ltd helps to set up the first line of defense for food and drug.
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