Laminating: The Perfect Finishing Touch

A wide-format laminator is a perfect – many would say a necessary – complement to wide-format latex, aqueous, UV, solvent, and eco-solvent printers. Virtually all output from a wide-format printer can benefit from lamination, which offers scratch resistance, UV protection, anti-graffiti protection, improved handling, plus protection from fuel, solvents, and other chemicals. Lamination is especially critical when it comes to graphics that need to be protected from the environment, or those that live in high-traffic areas, such as floor graphics.

If a graphic needs to be installed in a long-term outdoor application, laminating prevents oxidation and can increase the ink life by up to three times, noted Frank Corey, senior area sales manager, Quality Media and Laminating Solutions.

Laminated materials raise the quality bar: When laminating a customer’s product, you're providing the customer with materials that are of a higher quality and professional finish. “Lamination can improve your customer's overall business image, which helps to bring in more sales to them. It also saves the customer money in the long-term, because the finished product can be reused without getting scratched or torn,” said Bruce Cozens, export manager, Vivid Laminating Technologies. “Valuable graphics are protected, signs and posters are stiffened, and low-cost weather-resistant signs can be produced.”

While laminating’s first order of business is protection, you can also alter the appearance of the image by applying a special-effect film over the image. Special-effect laminates include 3D, embossed, lenticular, and texture films. 

But there are many different types of laminates available that can be used to enhance the image. “For example, a gloss film would make the colors pop, while a matte or luster would soften the colors and image,” said Steve Frazier, Codamount project engineer, Coda.

Lamination will even out the gloss level of graphics where the inks and media may have a different sheen due to the presence or absence of ink. “Your customer may want added gloss for a slick look or reduced reflection with the addition of a matte or textured matte finish,” noted Tony Caruso, Eastern Territory sales, AGL

For the most part, lamination imparts a change in color saturation -- as a result, colors appear richer and more vibrant while allowing the details in the graphic to be relatively unaffected.

One other enhancement is the ability to add texture for graphics in high-traffic areas. This can add life to your image where a smooth finish would show scuff marks and scratches. Textures like linen and canvas can also be added for effect, while simultaneously providing slip resistance.

You can also add some cool special effects with lamination, like holographic images and write-erase or anti-graffiti, said Tom Snooks, new product development, LexJet.

LexJet’s new Clear PreLume HD is a clear polycarbonate film designed to bring a visible difference to digital graphics output. “Customers produce whiter, brighter, and longer lasting images,” said Snooks. “Like the original LexJet Clear, this film is designed to deliver the durability that roll-up tradeshow graphics demand; its non-glare, textured surface makes the graphics easy to see under bright lights and free of visible fingerprints.”

Making a Laminator Choice

Given the value that laminating adds to the final product, it’s ironic that the purchase of a laminator is often an afterthought following the purchase of a wide-format printer.

But a well-thought out purchase will save you headaches down the road, especially as your shop grows or takes on new types of applications. According to Michael Pender, president, Supply55, the first consideration when purchasing a laminator should be whether or not the laminator will provide growth as new printers are added to the workflow. “We see many customers purchase a 55” laminator to match their 54” printer, resulting in the need to purchase a new laminator if they add a 64” printer to their workflow,” he said. (That’s why Guardian Laminators are only available in a 65” format, Pender pointed out, to avoid the 55” trap.)

There are three types of laminating adherence processes: cold, heat assist, and hot/thermal, and you’ll want to match the lamination process to the application.

“Ensure that your new system is ‘future proof,’” echoed Cozens. “If you’re currently laminating vinyl and applying them as vehicle wraps, then a cold system is the best solution. But if you move into other markets such as laminating rollup banners or tradeshow graphics, then you’ll need a system that can run heat-assisted. All Easymount heat-assist models can also be run on a cold setting, so they’re multifunctional.”

Outdoor signage and vehicle graphics need to be laminated cold, because the vinyl used can only be heated once. Mounting prints to board are also best on cold systems, as you are using the mounting capabilities of the system, not the lamination functions.

Cold roll film or pressure-sensitive film can be best utilized in single-side lamination of graphic displays (displays not requiring encapsulation).

“We’ve seen a big shift to cold laminators as most vinyl films produced today are engineered for cold application,” said Pender. The advantage of cold roll film is that it's ready to use without worry of rollers or shoes warming up.

The initial investment for a cold laminator is significantly less than that for a thermal laminator. Frazier commented that Coda's Codamount laminator can be configured as pressure-sensitive, heat-assist, or thermal, with widths available from 26" to 64".

Cold laminators are versatile in the fact they not only allow print providers to laminate printed graphics, but also allow shops to mount self-adhesive vinyl to a variety of substrates, said Daniel Kane, marketing manager, Royal Sovereigns Graphic Finishing Division.

Heat-assist laminators’ 90 degrees of heat serves to reduce silvering, ensures a strong bond of laminate to vinyl, and allows for a faster processing speed. Posters, graphics, signs, pop-up displays, and rollup banners are best used with heat-assist laminators.

Laminate selection must be based on compatibility of the component products, said Brian Beauban, Midwest sales, AG. “Thermal laminates work best on media that can be subjected to the temperature involved and the thermal adhesive must be compatible with the ink and media,” he remarked. “This can be a limiting factor since this process was originally developed with porous media in mind. However, it can be used on heavier PET media and substrates with good result. Rigidity is the one standout characteristic of most thermal films, especially when encapsulating and using 5mil - 10mil laminate.  Its lower cost usually drives the decision but all factors must be considered.”

Nate Goodman, product manager, Drytac, commented that,  “Liquid laminators are best used on materials that are meant to stretch and conform as well as materials with a textured surface, such as canvas or wallpaper."

Additional Considerations

During the due diligence process, you’ll also want to match the volume capability; Will you be laminating 10 prints a day, 100, or 1,000? But you need to look at your volume -- not just for the present, but also what it will be 10 years down the line, urged Frank Romanello, CEO, Rolinx.

So you’ll want to consider the longevity of the equipment; wide-format print providers should figure on a lifetime of 10 years of service from their laminator, said Romanello.

Consider potential output width, to ensure that the laminator is wide enough to accept the widest media that the printer produces; and length, to ensure that the laminator is capable of winding up long runs of laminated media and graphics.

Ease of use is also very important. The labor situation today is such that there is high turnover, or difficulty in finding employees. So you want training to be as quick as possible, which means the equipment has to be as easy to use as possible. “The type of laminators we manufacture, anyone that is working in finishing environment can use, without having specialty skills,” said Romanello. “The reality is laminating is just a process, and like anything else in production the process needs to get done.”

Snooks recommends looking at four areas: versatility – the ability to use both thermal and pressure-sensitive films; size; ease of use; and safety, service, and warranty.

Accurate nip control, ease of use, and consistent web control settings are three standout features required for successful and consistent results. “AGL features an unsurpassed nip roll design for consistent and easy application of laminate and every day mounting requirements, said Beauban. “Our RTS web tension control allows accurate process control for consistent results every time. “

Added Beauban, “Unlike a printer, a laminator should last for decades; a good laminator should only require general upkeep and replacement of worn parts. Not a complete replacement.”

Additional factors, said Corey, include whether or not the rollers have enough pressure to eliminate silvering (tiny bubbles) when laminating UV prints. “Some “crank” pressure laminators do not have enough pressure,” he cautioned.

A related issue is whether or not the top roller has large “crown” that can cause the laminate to skew (go to left or right) after 20-30 feet. “This requires rewebbing the laminator and wasting print media and laminate,” said Corey.

While laminator basic technology hasn’t changed much over the years, laminates do evolve as new plastic films are developed and new requirements and compatibility issues are addressed. “New products are entering the market to address environmentally responsible approaches to manufacturing and the proper disposal of graphics after they are no longer needed,” said Beauban. “Unlike printing, where the technology changes rapidly, lamination has remained somewhat stable. All the more reason to look to equipment that will stand up to rigorous daily use,” he concluded.

Laminator Line-Up  

AGL

AGL’s large diameter rollers mean a larger surface area to activate which leads to faster more efficient production. Also, every AGL laminator allows an operator to identify how much tension is being applied so they can adjust accordingly. AGL’s unique curl cam assembly was designed to flatten laminated images without having to apply excess tension to one side. This feature not only overcomes the issue of image curl and delamination, it also allows the operator to two films of different thicknesses and still achieve a smooth, flat output.

Coda

The Codamount laminator leverages Coda’s award-winning laminator technology in a unit with optional features so you can configure (and afford) just what you need. It can be configured as pressure-sensitive, heat-assist or thermal in widths available from 26" to 64". Easy to use, it can be run by one operator.

Drytac

Drytac laminators are designed for ease of use and durability. All of the controls are on one side of the machine so the operator does not have to go from one side to the other to tighten the brake or turn on the rollers. The machines have a heavy-duty metal construction and are robust in order to withstand daily use.

Quality Media and Laminating Solutions and Rolinx,

The Kala Mistral 1650 laminator, marketed by Quality Media and Laminating Solutions and Rolinx, was voted SGIA 2015 Product of the Year. It offers a patented auto-calibration feature that constantly monitors the pressure and powers of the rollers, and calibrates nip pressure for repeatable precise pressure. If there is any slight deviation, the machine corrects itself, assuring uniformity throughout full rolls (300’-0”+) from start to finish.

Royal Sovereign Corporation

Royal Sovereign RSC-1402 and RSC-1651 series laminators feature optimally placed idle bars and crowned rollers. The idle bars help to ensure the proper amount film tension during the lamination process while the crowned rollers help to squeeze out any air pockets between the media and the film.

Supply55

Guardian laminators are an affordable, easy to use solution featuring solid, all steel construction for high quality performance. It also offers upper and lower idler bars, and crowned high-quality silicone rollers. 

Vivid Laminating Technologies

The Easymount Air recently won the Wide-Format & Signage 2016 Readers' Choice Top Product Awards in the Finishing: Laminating Equipment category. Pneumatic air pressure controls the laminating rollers, for accuracy and speed while mounting and laminating. Rollers can be locked in place at the exact thickness of the board to prevent crushing the front edge and giving rollers a longer life. The roller 'floats' down to sit on the board without damage, even on to glass.