In today’s packaging industry, sustainability and performance go hand in hand. Brands and manufacturers are under pressure to deliver packaging that not only protects products but also protects the planet. One of the most effective innovations supporting this shift is solventless lamination — a cleaner, more efficient bonding process used in flexible packaging manufacturing.
What Is Solventless Lamination?
Lamination is the process of bonding two or more flexible materials—such as plastic films, paper, or aluminum foil—to create a multilayer structure with enhanced properties. Each layer contributes something unique, from strength and barrier protection to printability and appearance.
In a solventless lamination process, the adhesive used to bond the layers contains no solvents or volatile organic compounds (VOCs). This means no drying ovens are required, resulting in lower energy consumption and a more sustainable operation overall.
How the Solventless Lamination Process Works
The lamination machine is designed to bring together two webs (or rolls) of material, typically known as web A and web B, to form a single laminated web. Here’s a breakdown of the steps:
- Unwinding the Webs:
- Two large reels of material are mounted on unwinders A and B. These webs are drawn into the laminator.
- Adhesive Application:
- A thin layer of solventless adhesive—often polyurethane-based—is applied to one side of the web coming from coil A. The adhesive has 100% solid content, meaning it contains no solvent to evaporate.
- Lamination (Nipping):
- The two webs pass between two tangential rollers, which apply pressure to bond them together evenly.
- Rewinding the Laminated Web:
- The finished laminate is rewound onto a new roll using a rewinder, ready for curing or downstream processing.
Because no drying is required, the oven section of the laminator remains off, significantly reducing both energy use and carbon emissions.
Switching to solventless technology brings multiple environmental, operational, and economic advantages:
🌿 1. Environmentally Friendly
No solvents mean zero VOC emissions and no hazardous waste. This helps companies meet stricter environmental standards and supports corporate sustainability goals.
⚡ 2. Energy and Cost Efficiency
Without the need for a drying oven, energy consumption drops dramatically. This reduces operating costs and maintenance requirements, improving profitability.
🍽️ 3. Food-Safe Packaging
Since the process leaves no solvent residues, the laminated material is ideal for food and pharmaceutical packaging applications where purity and safety are critical.
🏭 4. Cleaner, Safer Work Environment
Removing solvents also removes fire and explosion risks, creating a safer production environment for plant operators.
💪 5. High-Performance Bonds
Modern solventless adhesives deliver excellent adhesion, clarity, and durability—ensuring the laminate performs reliably under a wide range of conditions.
Solventless vs. Solvent-Based Lamination
FeatureSolvent-Based LaminationSolventless LaminationAdhesive TypeSolvent-based polyurethane100% solids polyurethaneDrying RequiredYesNoEnergy UseHigh (oven heating)LowVOC EmissionsYesNoneEnvironmental ImpactHigherSignificantly lower
Why Solventless Lamination Is the Future of Packaging
As sustainability becomes a central focus for the flexible packaging industry, manufacturers are increasingly adopting solventless adhesive lamination to reduce their carbon footprint and improve operational efficiency.
The technology not only delivers strong, reliable bonds but also supports eco-friendly packaging production — aligning with the growing global demand for greener manufacturing solutions.
Final Thoughts
Solventless lamination represents a perfect balance between high performance and environmental responsibility. By eliminating solvents, manufacturers can produce sustainable, food-safe, and energy-efficient laminated materials without compromising quality.
For packaging converters and brand owners looking to meet both performance and sustainability targets, solventless lamination is more than a trend — it’s the future of flexible packaging manufacturing.
