Solvent-less lamination: a cleaner way to make laminates

Lamination bonds printed film to one or more other layers to build barrier and sealing performance. There are two main methods, and the choice affects cost, speed, emissions and what structures you can make.

Solvent-based lamination

The adhesive is dissolved in a solvent such as ethyl acetate, applied to the film, and the solvent is driven off in a drying tunnel before the layers are joined. It gives very high bond strength and copes with demanding applications such as retort, aggressive chemicals and heavy fills.

Solvent-less lamination

A two-part, 100% solids adhesive is metered on in a very thin coat and the layers are joined straight away. There is no solvent to evaporate, so:

• Emissions are much lower, with no solvent vapour to capture or burn.
• Energy use drops, because there is no drying tunnel.
• Machines run faster and changeovers are quicker.
• Retained-solvent risk falls, which matters for food packaging odour and taint.

When solvent-based still makes sense

For some high-performance structures, such as packs for pesticides, chemicals, or hot-fill and retort, solvent-based adhesives can still give the bond strength and resistance needed. The right answer depends on the product.

Our setup

Our Ghaziabad plant runs two solvent-based lamination machines and one solvent-less lamination machine, so we can match the process to the pack: solvent-less for everyday food and FMCG laminates, solvent-based where performance demands it. Lamination sits alongside rotogravure printing, slitting and pouch making under one roof. See our infrastructure.

Sustainability beyond the adhesive

Solvent-less lamination pairs well with mono-material structures and downgauged films, and it is one of the simplest ways to cut the footprint of converting without changing what the customer sees on the shelf.

Talk to us about the right lamination route for your product.