Lamination Waste
Material waste occurring during the bonding of polymer films to paperboard substrates represents a significant cost and efficiency factor in the production of high-barrier packaging. This loss, known as plastic lamination scrappage, includes both the untrimmed edges of the laminated roll and the out-of-specification board rejected due to poor adhesion, wrinkling, or bubbles. It directly influences the yield calculations of the extrusion or adhesive lamination line and must be closely monitored to control raw material costs.
Modern laminators incorporate continuous inspection systems to identify and mark these defective sections before they reach downstream converting processes.
Process Cause
Temperature fluctuations and tension imbalances between the paperboard web and the polymer film represent the primary causes of bonding failures. When plastic lamination scrappage rises, it is often due to improper surface pre-treatment of the board or incorrect melt temperatures at the extrusion die. Inadequate tension control can cause the film to stretch or the board to curl, rendering the resulting composite unsuitable for subsequent printing or die-cutting.
Regular maintenance of the corona treatment systems and tension rollers helps mitigate these issues.
Material Recovery
Disposing of this composite waste is difficult because the bonded plastic film prevents direct repulping. These rejects cannot be mixed with standard paperboard broke and must instead undergo specialized mechanical separation or be routed to incineration. This restriction increases the operational costs associated with running laminated grades.
