How does the solvent-free lamination process revolutionize the production of printed packaging films?

In the production and manufacturing of printed packaging films, the lamination process is one of the key links that determine the performance and quality of the product. The traditional dry lamination process has long dominated the market with its mature technical system. This process is to evenly apply the organic solvent-based adhesive on the surface of the film, wait for the solvent to evaporate, and then use a hot pressing roller to laminate two or more layers of film. However, with the deepening of environmental protection concepts and the improvement of product safety requirements, the dry lamination process has gradually exposed its limitations due to the emission of volatile organic compounds (VOCs) caused by the large-scale use of organic solvents, and the potential pollution risks that solvent residues may cause to packaging products. It is difficult to meet the current sustainable development needs of the industry.

The solvent-free lamination process is an innovative technology born to meet the above challenges. It fundamentally changes the way printed packaging films are laminated. This process abandons the use of organic solvents and directly applies the highly reactive two-component adhesive evenly on the surface of the film in a precise ratio through a special coating equipment. Among them, one group is a curing agent containing an isocyanate group, and the other group is a main agent containing a hydroxyl group. Once the two are mixed at room temperature, they will react chemically quickly to form a high molecular polymer with strong bonding force. Subsequently, the coated film is closely attached to another layer or multiple layers of film through a hot pressing roller under specific temperature and pressure conditions. The adhesive continues to react and solidify during the composite process, so that each layer of film is firmly combined, and finally a composite packaging film with excellent performance is formed.

The environmental advantages of the solvent-free composite process are particularly prominent. Since no organic solvents are used at all, no VOCs emissions are generated during the production process, and the pollution of the atmospheric environment by the volatilization of organic solvents is completely eliminated. At the same time, the air quality of the production workshop is significantly improved, and the risk of operators being exposed to harmful chemicals is reduced, creating a safer and healthier working environment for the company. This green production method not only conforms to the global environmental protection trend, but also helps companies meet increasingly stringent environmental protection regulations and effectively avoid operating risks caused by environmental problems.

In terms of product quality and safety, the solvent-free composite process also performs well. Compared with traditional processes, this process avoids the problem of solvent residues, eliminates the possibility of organic solvents migrating to the packaging contents from the source, and greatly improves the hygienic and safe performance of the composite film. Especially in areas such as food and medicine that have extremely high requirements for packaging safety, solvent-free composite films can effectively protect products from contamination, maintain product quality and efficacy, and meet consumers' core demands for health and safety. In addition, since the adhesive reacts fully and cures completely during the composite process, the interlayer bonding strength of the solvent-free composite film is higher, the structural stability is better, and it can withstand higher-intensity stretching, extrusion and other physical effects. It is not easy to have problems such as stratification and demolding during transportation and storage, ensuring the integrity and protection of the packaging, and providing reliable protection for the product.

The solvent-free composite process also shows significant advantages in production efficiency and cost control. It does not require the setting of complex solvent volatilization and drying devices, simplifies the production process, shortens the production cycle, can achieve higher production speeds, and greatly increases the output per unit time. At the same time, it reduces the cost investment in solvent procurement, storage, recycling and other links, as well as the economic losses caused by solvent loss. In addition, the coating amount of solvent-free adhesive is relatively low, and the utilization rate is high, which further reduces the cost of raw materials. Overall, this process effectively improves the production efficiency of enterprises and enhances market competitiveness.

The solvent-free composite process has good adaptability to a variety of printing and packaging film materials. Whether it is common plastic films such as polypropylene (PP) and polyethylene (PE), or polyvinylidene chloride (PVDC) and ethylene-vinyl alcohol copolymer (EVOH) films with high barrier properties, or new biodegradable material films, high-quality composites can be achieved through the solvent-free composite process. This enables the process to be widely used in food packaging, pharmaceutical packaging, daily chemical packaging, electronic product packaging and other fields, meeting the diverse needs of different industries for the functionality, safety and aesthetics of packaging films.

From the perspective of industry development, the emergence of solvent-free composite technology has brought new development opportunities and driving forces for change to the printing and packaging film industry. It not only promotes enterprises to accelerate green transformation and promotes the entire industry to move towards sustainable development, but also provides technical support for the innovation and upgrading of packaging film products. With the continuous advancement and improvement of technology, solvent-free composite technology is expected to play a greater role in more fields, continue to promote the printing and packaging film industry to develop in a more environmentally friendly, safe and efficient direction, and bring more high-quality and green packaging solutions to the market.