From velvety rich cosmetics packaging to the simplest information sheet, plastic film lamination beautifies as it protects, adding substance and longevity to your printed product.

• • • Use thinner films for PB Book Covers and Cover Wraps, Carton and Binder Wraps, Boxes, Bags, Spec Sheets, Posters and Calenders, Store Displays, and much more.

• • • Use thicker films for Spiral and Wire Bound Covers, Menus, “Back Stage Pass” style cards, Product Cards, Wallet and Pocket Cards, Process Control Books, and literally 1000’s of applications.

Design and Production Notes

Design

• Gloss Laminations tend to intensify your printed graphics, adding depth and brightness to the overall appearance. Color tones can appear richer.
• Gloss levels of Polyester films range from the upper 90’s and higher. Gloss levels of Polypropylene films are generally in the mid 80’s.
• Polyester Matte films show gloss levels in the mid 20’s, with Polypropylene Matte in low single digits (2-3).
• For a velvet-smooth feel, use Soft Touch Matte lamination. This can be combined with UV coating for an amazing look with an amazing feel.
• Scuff and scratch resistant finishes are also available.
• Thicker films provide that heavy “credit card” look, increasing durability for a longer life span.
• Lamination can be applied with a clear border (Sealed Edge), flush to the edge of your finished size, or keeping your guide and gripper clean of film for trimming, die cutting, or other processing after lamination.
• Specialty films are available, with textures and holographic effects.
• Thin laminating films can pick up the texture of the paper, such as a 1.5 mil Matte laminating film applied to a Linen embossed cover paper, resulting in a linen-look finished product. Special effects like this should always be tested first before committing to production.
• Matte film tends to mute colors. Gloss film tends to embolden colors. Gloss UV over matte lamination can combine these effects.
• While resistant to water, Laminating films are not waterproof.
• UV-Inhibitor Laminating film is available.

Image and Sheet Preparation

The style of finished lamination you desire will determine the form in which you will supply your material.

For Guide and Gripper Clean (GG):

This is for sheets that require clean guide and gripper edges to allow registration during post lamination processes. All single-side lamination is done in this style.

Send untrimmed press sheets. Include 1 sheet ruled out with your required laminating film image area. Be sure to include bleeds. Mark your rule out to show the guide and gripper sides. This will ensure we keep the correct sides free from film, so you can register subsequent processes such as die cutting, scoring, or any other registered processes.

We can produce 1 or 2 sided lamination with guide and gripper sides clean.

For Flush Cut (FC):

This is for lamination that will trim at the edge of the sheet. Send sheets trimmed to 1 up, finished size. This is for 2 sided lamination only. If 1 side lamination is desired for a flush cut finished piece, please supply press sheets, and we will run GG Clean (see above), for trimming after lamination.

Please note that our cutters have a +/- tolerance of 1/32”. If you require closer cutting registration, we recommend using the GG option, trimming after lamination.

For Sealed Edge (SE):

This is for sheets that will have a clear border of laminating film outside the edge of the printed sheet. Send sheets trimmed to 1 up, finished size. This is for 2 sided lamination only. The minimum amount of film for a sealed edge is 1/8” outside of the paper. Normal sizes for sealed edges are 1/8”, 1/4”, 3/16”, or 1/2” for binding edges or slot/hole punch. Extended sizes are also available.

Spiral or wire bound books can be created using a standard 1/8” sealed edge on the head, foot, and face, with a 3/16” or 1/2” sealed edge on the binding side. This allows the binding punch to be on the film only, preserving the integrity of the printed page. This allows the full image area to be usable, and also enhances the books moisture resistance.

Paper

Smooth or coated stocks are best for film lamination. We recommend 80# book or heavier, as lighter stocks have the tendency to wrinkle. Uncoated and textured paper may result in pockets of air under the finished lamination.

Ink

Inks must be dry, and wax-free. Please note that thermal lamination is not manufactured for application over Aqueous Coatings. It is intended to be applied directly to ink and paper. This will give the best results. For products that require strong adhesion performance, we recommend that you do not use Aqueous Coating. These would include binder and cover wraps with hinge scores, box wraps, book covers, or any other application that requires a strong finished bond. If Aqueous Coatings must be used, we have found that lower gloss levels (<45) tend to perform better. Primer, Satin, Breathable, and Writeable primers have shown reasonable results. High Gloss, Work and Turn primers tend to result in lower adhesion strength. As with all unknows, we recommend testing first to determine your results before committing to production.

Digital Printing

Please let us know when you will be supplying digitally printed sheets, so we can use the correct film and processes. Inks and fuser oils can cause reduced bonding strength from the laminating film to the paper. Please allow the manufacturer’s recommended time after printing to allow the fuser oils to absorb into the paper before laminating.

Spray Powder

Spray powder remaining on the paper before laminating will appear after laminating. The larger the particle size, and the more powder used, the more speckled the finished result will be. We recommend using the smallest particle size possible (e.g. 30-50 micron), and dusting or polished the printed sheets to remove the spray powder before laminating.

Converting and Finishing

Scoring or creasing are performed after laminating with 1.5 mil films. 3 mil films can be scored either before or after lamination. Stocks that will have 5 or 10 mil films applied should be scored prior to laminating.

When selecting 5 or 10 mil films for products that will be folded, remember that these films are fairly rigid, and can be difficult to fold.

If the product is to be foil stamped, printed, or glued after laminating, please specify printable/stampable/glueable gloss film. If matte film is desired, we recommend testing first. Many films are compatible with various post-production processes, however, films are generally not warranted by the manufacturer for additional processes, so we always suggest testing first.

If sheets are to be foil stamped before laminating, please specify to your foil stamper a thermal lamination compatible product.

Due to the high volume of plastic in 10 mil lamination, the finished corners can be very sharp. We recommend pieces be finished with round corners.