Extrusion Coating/Lamination

In extrusion coating and lamination, resin is melted and formed into thin hot film, which is coated onto a moving, flat substrate such as paper, paperboard, metal foil, or plastic film. The coated substrate then passes between a set of counter-rotating rolls, which press the coating onto the substrate to ensure complete contact and adhesion.

Extrusion laminating, also called sandwich laminating, is a process related to extrusion coating. However, in this case, the extrusion coated layer is used as an adhesive layer between two or more substrates. A second layer is applied to the extrusion coating while it is still hot and then the sandwich is pressed together by pressure rolls. The extrusion coated layer may also serve as a moisture barrier.

In film lamination, a fabricated film is adhered to a moving substrate by application of heat and pressure. Film lamination methods include hot roll, belt, flame, calender lamination and sheet extrusion; each type providing a different combination of heat and pressure. The laminated film can add a functional surface to a substrate, or be used between two substrates to stick them together.

Substrates that can be coated with polyolefins include paper, paperboard, biaxially-oriented polypropylene (BOPP), biaxially-oriented nylon (BON), polyester and other plastic films, metal foil, fabrics, glass fiber mat, metal sheet and flexible foams.

For additional information on lamination, also visit our page on Lamination for Film Substrates