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Insufficient Bond Strength in Extrusion Laminators: Causes & Solutions（2）

Mismatched Molten Resin and Substrate

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Reasons for and Solutions to Insufficient Lamination Fastness in Extrusion Laminating Machines (Part 1)

Inadequate Substrate Surface Tension

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Top Easily Overlooked Details When Purchasing High-Speed Extrusion Laminating Machines (Part 1)

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Technical Advantages of Extrusion Laminating Machines Laiyi Coating Machine Technology Insights Solvent-Free: No glues or solvents are used, eliminating VOC (Volatile Organic Compound) emissions and making the process highly eco-friendly.

High Bonding Strength: The molten polymer creates a permanent chemical bond with the substrate, effectively preventing delamination.

Excellent Barrier Properties: The multi-layer composite structure provides superior resistance against moisture, oxygen, oil, and light.

High Production Efficiency: Designed for high-speed continuous production, reaching operational speeds of 120–350 m/min.

Excellent Cost-Effectiveness: Eliminates the need to purchase additional adhesives, resulting in significantly lower long-term operational costs.

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Workflow of an Extrusion Lamination Machine

Feeding: Raw materials are delivered into the feed throat of the extruder via a conveyor belt or screw conveyor.

Melting: The raw materials are melted into a fluid state under the high-temperature environment inside the extruder.

Mixing: The molten materials are thoroughly blended in the mixing zone to ensure an even distribution of the different components.

Extrusion: The mixed material is extruded through a T-die to form a uniform molten film.

Lamination: The molten film is immediately coated onto a moving substrate, achieving a firm bond through the use of a chill roll and a pressure roll.

Cooling and Setting: The circulating cooling water system rapidly dissipates heat, ensuring the laminated film cools, flattens, and properly sets.

Winding: The finished product is wound into a roll after edge trimming.

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Laiyi Extrusion Lamination Machine Performance, Advantages

Laiyi Extrusion Machine Knowiedge Guide

Using LAlYl patented screw with characteristics of high revolving speed,high shear,high mixing,wear-resistant and energy-saving,to ensure the temperature difference between die lips and the polymer coming out of the die less than 30 ℃, which will greatly enhance the peeling strength.

The inner wall of the barrel and the surface of the screw are centrifugally cast with special technology,which has the characteristics of corrosion and wear resistance. lt is normally three times of the ordinary screw's service time.

Shaftless unwinder, equipped with auto-splicer, can achieve butt to butt splicing,thus to reduce the damage to corona and laminating rolls.

Heavy duty roll-pressing rewinder can achieve up to 300m/min auto-splicing with neat paper reel sides.

Optional automatic shaft pulling system, improves robotic level and reduces dependence on people

Equipped with international first-class electricalbrands to ensure efficient and stable operation of electrical systems.

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Daily Maintenance Key Points for Extrusion Coating Machine Die

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Extrusion Lamination MachineBasic Principles of Tension control

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Main Functional Features of Automatic Extrusion Laminating Machine

Laiyi Lamination Machine Knowledge Guide

PLC Human-Machine Interface (HMI) Centralized Control: Integrates mechanical, electrical, and pneumatic systems into a unified design.

Fully Automatic Constant Tension Control: Ensures smooth and stable operation.

Photoelectric Web Guiding + Corona Treatment: Effectively enhances peel strength.

Dual-Station Unwinding and Rewinding: Supports non-stop roll changing for continuous production.

Hydraulic Screen Changer + Quick-Change Mechanism: Minimizes downtime during screen replacements.

Advanced Temperature Control System: Automatically regulates temperatures across individual heating zones.

Multi-Layer Co-Extrusion Capability: Supports 2 to 7 layers of composite lamination (requires additional extruder units).

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What is an Extrusion Coating and Lamination Machine? An extrusion coating and lamination machine is an industrial system used to apply a "plastic raincoat" to substrates such as paper, paperboard, non-woven fabrics, woven fabrics, and aluminum foil.

Its core function can be summarized as follows: it melts plastics like polyethylene (PE) and polypropylene (PP) at high temperatures and coats them uniformly onto the substrate surface. This creates a protective film layer that provides waterproofing, moisture resistance, oil resistance, and enhanced structural strength.

Process Overview The typical workflow of an extrusion coating line follows this sequence: Unwinding → Pre-heating → Corona Treatment → Extrusion Coating → Cooling → Edge Trimming → Rewinding

Driven by a screw extruder, plastic resin pellets are heated and melted. Once extruded through the die, the molten plastic cascades down like a "waterfall" onto the substrate surface. After being hot-pressed and cooled, the plastic layer bonds securely with the substrate. The entire process is highly automated, with production line speeds reaching 100–150 meters per minute or even higher.

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Core Advantages of Extrusion Lamination Machines

Laiyi Lamination Machine Knowledge Guide

Eco-Friendly and Safe Zero Solvent Residue: Since it does not utilize organic solvent-based adhesives, it fundamentally eliminates VOC (Volatile Organic Compound) emissions and solvent retention issues.

Food Packaging Friendly: It is particularly well-suited for fields with stringent safety and hygiene standards, such as food and pharmaceutical packaging.

Aligned with Green Trends: It eliminates the need for auxiliary solvent recovery systems or RTO (Regenerative Thermal Oxidizer) incineration systems.

High Cost-Efficiency Eliminates Adhesive Costs: It replaces expensive laminating adhesives with cost-effective raw resin pellets (such as PE or PP).

Optimized Energy Consumption: Without the need for high-energy long drying tunnels, its overall energy consumption is typically lower than that of dry lamination.

Simplified Material Sourcing: Resin raw materials enjoy a stable supply chain and relatively predictable price fluctuations.

Integrated Functionality Dual-Purpose Interlayer: The extruded resin layer simultaneously acts as the bonding agent, heat-seal layer, and moisture barrier.

Single-Step Forming: It shortens the process chain by transforming raw pellets into finished laminated structures in one continuous run, maximizing production efficiency.

Ideal for Mass Production: It delivers exceptional economics for high-volume products with standardized structures (e.g., aseptic milk cartons, instant noodle packaging).

High Production Efficiency High-Speed Operation: Typical production speeds range between 100–300 m/min, significantly outperforming dry lamination.

Seamless Roll Changing: Because it requires no curing time or solvent evaporation waiting periods, it excels at continuous, heavy-duty production runs.

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Extrusion Casting/Lamination vs. Dry Lamination: Key Differences

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How to Maintain Lubrication for Extrusion Coating Machines?

Laiyi Extrusion Coating Machine Knowledge Sharing Regularly add lubricating oil to all lubrication points, and select lubricants suitable for the working environment. Pay special attention to the lubrication of the bearings at both ends of the heating roller and the gearbox reducer. Apply high-temperature resistant grease (such as molybdenum disulfide grease) to transmission components like screws and other drive parts.

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How to Conduct Periodic Inspections for an Extrusion Coating machine?

Laiyi Knowledge Guide 1.Coating Roller Weekly cleaning and radial run-out detection(s0.05mm) 2.Hydraulic SystemMonthly filter element replacement and pressure testing. 3.Electrical Cabinet Quarterly terminal tightening (wiring reinforcement) andinsulation resistance testing. 4.Transmission Components Inspect chain tension and bearing lubrication, Replacegearbox lubricant every 2,000 hours (Grade lsO VG 220).

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Daily Maintenance of Extrusion Coating Machine

(Laiyi Knowledge Guide)

Routine Cleaning

Clean key parts such as the material tray, rotary table, and coating rollers after each shift to prevent corrosion and material residue buildup. Regularly remove dust from the electrical control cabinet to ensure proper operation of electrical components. When the machine is shut down, wipe the surfaces of the heating rollers and rubber rollers. If oil stains or scratches are found, repair them promptly.

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About Laiyi Extrusion Lamination Machine Q&A

Addressing your questions about Laiyi Extrusion Lamination Machine.

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LY-AFP Flexible Packaging Extrusion Laminating Machine Using two or multi-layer co-extrusion technology,can achieve a variety of polymers co-extrusion,improve product quality and reduce costs; It can be configured with automatic sandwich unwinder to improve the automation level of the whole line.