The coating web
Keep the coated web running consistently through the dryer and into the nip. Its behavior must be considered alongside the foil and PE layers.
Application study / HGF-300-P
Three materials.
One coffee pouch.
Dry lamination of PET, thin aluminum foil and PE — balancing web tension, adhesive coverage and drying for coffee powder stand-up pouches.
Explore the process
- Machine
- HGF-300-P ↗
- Package
- Coffee powder stand-up pouch
- Structure
- PET 12 / AL 6 / PE 80 μm
- Dryer
- Three zones × 3 m
01 / Material & process
Build the structure
in two passes.
The HGF-300-P single-station high-speed dry laminator produces the three-layer structure through two separate lamination passes.
01
PET → AL
Adhesive is applied to the PET.
- PET unwind
- Coating on PET
- Three-zone drying
- Lamination with AL
- PET/AL rewind
The 6 μm foil enters at the lamination nip; it does not travel through the first-pass dryer.
02
PET/AL → PE
A second pass adds the PE sealing layer.
- PET/AL unwind
- Coating & drying
- Lamination with PE
- PET/AL/PE rewind
The second-pass coating side and the curing sequence between passes have not been specified in the supplied case notes.
| Pass | Base range | Adjusted range | Cylinder mesh reference |
|---|---|---|---|
| PET → AL | 3.0–3.5 g/m² | 3.5–4.0 g/m² Large printed areas on PET | 140–120 mesh |
| PET/AL → PE | 3.5–4.0 g/m² | 4.0–4.5 g/m² Powder or high-oil contents | 120–110 mesh |
These are supplied reference ranges, not confirmed measured coating weights for this run. Cylinder mesh alone does not establish coating weight; confirm cell volume, adhesive working solids and measured dry coat weight.
02 / Tension balance
Different materials.
Different responses.
PET, aluminum foil and PE respond differently to tension and heat. A stable web path must be achieved without building excessive deformation into the laminate.
A delicate barrier layer
Thin foil has limited tolerance for stretching. Excessive unwind tension can deform the foil and contribute to wrinkles that become evident during later processing or curing.
A readily extensible film
Excessive tension can stretch the PE. Recovery after lamination creates a strain mismatch between layers, potentially contributing to curl or tunneling.
Control objective
Stable handling, without unnecessary stretch.
Review unwind, nip and rewind behavior together, including acceleration and deceleration. The supplied notes do not include tension setpoints or a recorded PID tuning sequence.
03 / Drying strategy
Remove solvent
before the layers meet.
Both passes use a rising temperature profile. The objective is solvent removal before lamination; subsequent adhesive curing is a separate part of the process.
Zone 1 / 3 m55–65°C
Controlled initial evaporation
Zone 2 / 3 m70–75°C
Continued solvent removal
Zone 3 / 3 m75–80°C
Further drying
Avoid an overly hot first zone.
The supplied process notes emphasize avoiding rapid surface drying at the dryer entrance, which can leave solvent within the adhesive layer. The foil layer makes reliance on solvent escape after lamination inappropriate.
Hot air does the drying.
Air is directed onto the coated web. Temperature, airflow, exhaust, coating weight and line speed must be evaluated together. The temperature ranges here are case-reported values; the measurement location has not been specified.
04 / Defect investigation
White spots are a clue.
Not a diagnosis.
The case notes identify fine white spots and small bubbles that may remain after curing. Their timing and distribution help guide investigation.
01Drying & retained solvent
Check the temperature progression, exhaust and actual drying conditions. Relate the defect to coating weight and speed, and use residual-solvent testing to establish whether drying is adequate.
02Air entrapment & adhesive coverage
Review coating uniformity, dry coat weight, wetting and lamination-nip conditions. Insufficient adhesive coverage or trapped air may leave visible voids.
03Moisture & adhesive chemistry
For polyurethane systems with an isocyanate-containing curing agent, investigate moisture in materials, solvent and handling conditions. Moisture-related reactions can generate CO₂; confirm the adhesive system before attributing bubbles to this mechanism.
04Printed surface & leveling
Compare printed and unprinted areas. Uneven ink coverage, coating laydown or inadequate leveling can contribute to white spots; check adhesive and ink compatibility as part of the review.
Appearance alone does not prove leakage or reduced barrier performance. Laminate bonding, foil integrity and finished-pouch sealing need separate checks.
05 / Speed trial
Increase speed.
Observe the laminate.
The supplied trial sequence increases line speed in 50 m/min steps. Good laminate quality was reported at the final 250 m/min stage.
- Starting stage150 m/min
- +50 m/min200 m/min
- +50 m/min250 m/min
Reported observation
Good laminate quality at 250 m/min.
This is the operator-reported observation supplied for the case. Trial duration, per-pass speed records and laboratory results have not been provided.
From a good-looking laminate
to a verified package.
For a complete production assessment, record actual conditions and check the laminate after the specified curing cycle.
- Appearance and flatness before and after curing
- Interlayer peel strength
- Residual solvent
- Finished-pouch seal integrity and leakage
Your application
Start with your
material structure.
Share your films, foil thickness, packaging use and target output. We can discuss the equipment and the process information needed for an informed review.
Prepared from supplied process notes. Packaging and dryer visuals are explanatory illustrations; they are not customer-site photographs.