How to Choose the Right Laminator

Laminators are a key component to successful wide-format print finishing. They apply a film to an image to protect it from potentially harmful environmental conditions and scratching, extending the life of the print. The laminate can also enhance the image’s appearance, making it more vibrant by adding a gloss finish or a unique texture. Laminators are also used to mount flexible images to rigid substrates.

Some print service providers, however, forgo the laminator following the purchase of a wide-format device. “There is often a misconception that getting the image on the material is enough, but that is not the case most of the time,” said Nate Goodman, Drytac product manager. “The image must be transformed into a print, or in other words, a usable and sellable product. With a laminator, the appearance and durability of the image is improved upon by adding an overlaminate or mounting to a substrate.”

Drytac’s JetMounter roller laminators are available as cold, thermal, and heat-assist models, in 55- and 63-inch widths.

When making the decision to purchase a laminator, there are several factors to consider, starting with end use application, which will determine the type of laminator and materials used. For example, vehicle wrap graphics are printed and laminated using cold UV Vinyl, while a pop up display could be printed on paper and then laminated using a thermal PET.

Hot laminators work with heat-activated, heat-assist, or pressure-sensitive films, while cold laminators process pressure-sensitive materials.

Cold pressure-sensitive roll laminators apply cold adhesive films, laminates, adhesives, and adhesive-coated boards to one side of the printed piece, explained Ike Harris, president of Daige, Inc.

Daige’s Solo cold laminator accommodates boards up to a half inch thick (can be made to accommodate one inch upon request) and is available in 25-, 38-, 55-, and 65-inch widths.

“You can run anything through a cold laminator, but there are limitations in terms of what can run with heat,” said Harris. “With cold laminated, you can run different finishes—gloss, luster, and satin for example. With thermal laminating, you are restricted to one finish—basic gloss.”

High heat can also be a problem for digitally printed graphics, which can deteriorate at high temperatures. Many manufacturers now offer heat activated laminates that are engineered to activate at temperatures below 200 degrees F, for compatibly with most digital media.

“Hot laminators can apply the heat-activated thermal film to both sides, to encapsulate the printed piece, sealing it on both ends,” said Steve Frazier, project engineer, Coda, Inc. The Codamount laminator is available with optional features with pressure-sensitive, heat-assist, or thermal technology in 26-, 34-, 44-, 54, and 64-inch widths.

The end result is trimmed, leaving a clear border around the edge of the print. Encapsulation provides protection to both sides of the piece. Menus at family-style restaurants are a good example of an encapsulated printed piece.

Cold laminators don’t have the same power requirements as hot machines. Thermal films have to heat up to a certain temperature to activate; the laminating machine has to have enough power to heat the films to get to their activation level, explained Frazier. Thermal machines draw more power, so electrical specifications need to be considered.

“However, while the initial investment in a thermal machine is higher, the consumable cost over time is lower,” he noted.

When you cold laminate, the cost per square foot is more expensive. The main reason is the silicon release paper, on the back of the pressure-sensitive material, which protects the adhesive. It’s the silicon release that is expensive, explained Harris.

“Heat sensitive materials don’t need that protection,” he added.

There is a third option, which is becoming increasingly popular—heat-assisted cold laminators. The top roller on laminator is heated, but does not reach the same temperature as it would for a hot laminator. The heat provided by these machines isn’t high enough to apply heat-activated films, and is not designed to melt adhesive. Instead, the warm roller can make pressure-sensitive films more pliable, so they are easier to apply and lay down smooth and flat.

Think of this analogy, offered Daniel Kane, Royal Sovereign marketing assistant. “If you take an English muffin and put cold butter on it, the butter will eventually melt,” he said. “With heat assist, it’s like warming up that butter and then pouring it onto the muffin, so the butter gets into all the nooks and crannies. Warming up the adhesive adheres to all the nooks and crannies of media faster and creates a stronger bond.”

The warm heat helps to reduce bubbles, wrinkles, and to speed up production, by slashing laminate cure times. The added heat also helps reduce the phenomenon known as "silvering" when using some cold lamination films.

Heat assist laminators also don’t require as much power as traditional heated roller machines. While many wide-format hot roll systems have special power requirements, heat assist models will often run off standard 120v power, noted Kane. Also, they can be used with the heat assist function on or off, as a cold laminator. If the heat isn’t required, it doesn’t need to be turned on.

Cold lamination with heat is our most popular segment, said Kane. “This is a perfect fit for sign and print shops, which are typically not doing encapsulation, but are involved with single side lamination for displays and vehicle wraps,” he said.

Royal Sovereign’s roll laminator portfolio includes hot thermal roll laminators, cold pressure sensitive roll laminators, and heat assist roll laminators ranging from 15 inches wide to 65 inches wide.

Beyond the heat vs. cold issue, the PSP should also consider the capability of the printer, including the type of ink when purchasing a laminator, said Goodman. Other questions to ask:

• Will roll-to-roll capability be needed for output such as vehicle graphics?
• What is the amount of use the machine will warrant, or how heavy duty does it need to be?

Additionally, ask yourself how much space is needed to be able to use the machine effectively. Shop space is always a concern,” said Goodman. “Machine footprint and the type of supply shafts affect the amount of room necessary for placing a machine. The operator will need room to load and unload the rolls onto the machine as well as tables to work with the print media and substrates used.”

The width of the laminator has to be at least equal to the width of the printer. Ease of use for the operator is vitally important, so take the time to note features such as the controls being on the same side of the machine. Consider the processing speed of the machine and whether or not the space between the rollers will fit the thickest possible substrate.

While the tendency is to go with the cheapest model, laminating can be tricky, said Frazier. The machine must be capable of performing the desired final process. “Its key to buy a laminator with sold diameter rolls so they don’t deflect. If you use a laminator with cheap, lightweight rollers, you can get silvering,” said Frazier.

“The cheaper rolls will work in some applications, but the wider the media the more of an issue will be,” he added. “The larger span the roller has to cover, the more opportunity to deflect.”

While film is more typically used as the laminate, another option is liquid laminating. Liquid laminating is a top coat applied to print, mostly used for art prints on canvas and on outdoor signs. Liquid laminates are lower cost per square foot than film laminators, and have UV capability that protects the material from abrasion, dust, and scratches.

Liquid laminating is not as well understood as print, but offers a lot of benefits, said Harris. “You can apply it to the printed piece right away, and cut. There is both a cost and time savings.”