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Trouble Shooting Tips Using Glueless Lamination Film

2013-9-10 15:03:51

No.  Problem  Detail of the Problem Cause Recommendation
1 White Spots or Silvering Consistent or inconsistent spread of white spots between the film and the printed surface also known as Silvering Pressure too low or / and temperature low as well. Increase pressure and temperature until the Silvering effect is removed.
2 Weak bond strength Weak bond strength between the film and the laminated material surface Low pressure and low temperature. Adjust pressure and or temperature up until bond is improved
Excess of Non-polar agent added to the ink Reduce non-polar agent docent
Too much Spray powder or powder granules are too large  Reduce amount of spray powder used
Over high temperature setting of Heating Roller Adjust temperature down till bond is improved
3 Very weak bond strength Very weak bond strength between the film and the laminated material surface Polished paper / UV coated printed paper Unsuitable lamination material
4 Slack edge on film Wavy edge observed in machine direction Uneven heating temperature of Heating Roller Change to oil-conducted heating type laminator
5 Glossy edge  Glossier laminated effect(when use matt type film) observed at edges of the laminate
6 Weak folding bond strength Film delaminates on fold lines after lamination Paper/ink additives/setup conditions not adapted Adjust the running conditions of the laminating machine to ensure correct running conditions. Evaluate the combination of paper and ink thickness and ink additives to ensure the conditions are correct for laminated product.
7 Weak bond strength on box fold lines Film delaminates on fold lines after box is formed Poor lamination bond caused by unsuitable processing conditions, or paper contained high humidity 
8 Weak bond strength after embossing Film delaminates after embossing process
9 Weak bond strength on corrugation lines Film delaminates or whitens on the corrugation and fold lines
10 Laminated product curling at the edge Curling of the outer skin of  corrugated paper or board
11 Box frosting (whitening) Laminated product delaminates after laminated again with White card board
12 Film or paper creasing Film winkling and paper creasing  Over heating of film or the rubber covered pressing roll has become distorted by excess pressure
13  Film Blistering Film bubbling or blistering on the laminated surface Extreme over heating Operate the machine at the recommended temperature
14  Hole punch film lifting Film delaminates around holes after hole punching Lamination conditions not set correctly / punching equipment not setup correctly  Adjust laminating conditions and reset hole punching equipment
15 Delaminating after period of stocking Film delaminated from paper after days of stocking. Seriously affected by high humidity/ non-polar inks with poor ink drying conditions Strengthen pre-delivery inspection of lamination bond / Evaluate storage environment
16 Weak adhesive bond at box folding edge Box folding edges become unglued Film of one-side corona treatment / unfitted glue Change to two-side corona treated film / change glue type
17 Weak UV Cured Ink Bonding Weak adherence of GLF to UV cured Inks Film with low corona treatment level / polishing ink not adapted Increase film corona treat level / Drop down lam. Temp./ Retreat film side of laminated product for enhanced corona treatment level / Change UV inks
18 Weak Foil-stamping Bonding Weak adherence of Gloss GLF to foil-stamped products Film with one side corona treatment  Change to two-sided corona treatment film
19 Weak Box Gluing Poor glue ability of the film when used in glued box application  Film of one-side corona treatment / Cold adhesive glue not adapted Change to two-side corona treated film / Change cold adhesive glue type fitted for polypropylene film
20 Ink on Heating Roller Ink transferring to heating roller during lamination Use two side printed paper and printed side facing Heating Roller for pressing Lower down lamination temperature
21 Red ink printed area delaminating from paper Light red color part stays strong bonding while deep red color delaminates Ink layer too thick or not thoroughly dried Engage the preheating roll process and or adjust for even ink layer thickness, or slow down lamination speed with higher lamination temperature
22 Black ink printed area delaminated after stocking for a period Initial bond strength is strong but bond strength weakens after storage A known cause to this defect is this specific type of ink not properly dried or the ink contains too much reducer Ensure sufficient curing time, reinspection 24 hours after lamination to ensure bond strength is stable. 
23 Frosting Effect after laminating over window Direct window open, film sticks to press roller and cause a frosting effect on the window area of the film Film functional layer stick to rubber covered press roll and cause the film to frost or become hazy Wrap the rubber roller in release polyester film in the area where the window is in contact with the rubber roller to ensure the film does not frost/ Apply two steps back-side heat-ironing method of lamination.
24 Easily layer abscission after 24h of lamination There is no problem at the beginning but 24 hours later the bonding strength reduce Too much Viscosity reducer or drying oil or other additives, usually contained in spot-color ink, causing fake bonding Advanced test shall be applied no less than one day/ high pressure and high temperature test to determine whether GL is applicable for this printed material
25 De-lamination of  foil stamping De-laminate or whiten at edge after Laminate on foil stamped paper and stock for a period. When peeling alum. Foil off GLF, leaves on film surface release ingredients Only process foil stamping after lamination. Avoid high standard, foil-stamping pricess before lamination
26 Poor performance of jet-printing  Poor performance for jet-printing on film surface of laminated material, like indistinct boundary Printed material laminated with GLF is not so applicable for jet-printing, but it can be improved by adjusting the parameter of jet-printer Adjusting the parameter of jet-printer, trial production shall be carried out before mass production.
27 Low ink adhesion Fall in in adhesive tape test(100 times) after jet-printing The surface tension of Gloss GLF doesn’t meet the ink adhesion requirement of jet-printing For Gloss GLF, corona re-treatment is suggested after lamination; For Matt GLF, lamination temperature under 100°C

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