Walk into any store, and you’ll find flexible packaging everywhere—protecting food, beverages, cosmetics, and electronics. One key element that makes this packaging so effective? Lamination. This innovative process combines various materials to create durable, high-performing packaging designed to keep products fresh and secure.

Want to know how it works and why it’s a game-changer? Let’s break it down!

What is Lamination?

Lamination is the process of bonding two or more materials—such as plastic films, paper, or aluminum foil—into a single composite structure using adhesives or molten polymers.

The end result? Packaging that offers superior protection against moisture, light, oxygen, and physical damage. From frozen veggie bags to snack pouches, lamination is the reason your favorite products stay fresh and intact for longer.

Why is Lamination Important?

Lamination is essential for safeguarding products and extending shelf life, but its benefits go far beyond this. Here’s why it matters to your brand and customers alike:

• Barrier Protection: Blocks moisture, air, light, and contaminants while ensuring the freshness, flavor, and texture of the product inside.
• Durability: Prevents tears and provides extra puncture resistance, keeping products safe during transportation and handling.
• Design Protection: Shields printed graphics from smudging or fading, ensuring your branded packaging looks pristine on the shelf.

How Does the Lamination Process Work?

The science behind lamination might seem complex, but the process is fairly straightforward. Here’s how it typically works:

1. Adhesive Application: An adhesive—whether solvent-based, water-based, or solventless—is applied to one of the layers, usually a printed plastic film.
2. Layer Bonding: The adhesive-coated layer is pressed against a second material (it could be paper, aluminum, or another plastic film) using heat and pressure.
3. Curing: The laminated structure is left to cure under controlled conditions to ensure maximum adhesion.
4. Quality Check: The final product undergoes rigorous testing to confirm bond strength and barrier performance.

Common Lamination Techniques

Lamination isn’t a one-size-fits-all solution. Here are three widely used techniques adapted to meet varying packaging needs:

Dry Lamination

• Adhesives are dried before bonding the layers, offering excellent durability as well as resistance to moisture and heat.
• Popular for packaging coffee, snacks, and other food items requiring robust barriers.

Solventless Lamination

• Uses a solvent-free adhesive that bonds materials under pressure. This environmentally friendly process eliminates harmful emissions while maintaining the highest performance standards.
  • This is our go-to method. We use a two-part adhesive system that reacts during the curing process to form a strong chemical bond (similar to how a two-part epoxy functions in home repairs). This method is both effective and eco-conscious.

Extrusion Lamination

• Molten polymers act as an adhesive layer between materials, providing a cost-effective solution for pouches and frozen food packaging.

Each of these techniques is tailored to meet specific packaging challenges, ensuring optimized performance and protection.

Applications of Laminated Structures

Laminated materials play a vital role across industries. Here’s how they’re making an impact:

• Food & Beverages: Protect snacks, coffee, and perishable items to ensure quality despite supply chain challenges.
• Personal Care: Shield cosmetics and skincare products from UV rays and chemical exposure.
• Pharmaceuticals: Maintain the integrity of medications by offering resistance to punctures, humidity, and light.
• Sustainable Solutions: Many brands are turning to recyclable and bio-based laminated structures to meet consumer demand for eco-friendly packaging.

Is Lamination Sustainable?

Traditional laminated packaging can pose recycling challenges, but sustainability innovations are transforming the game. Here’s how lamination is evolving to minimize environmental impact:

Mono-Material Laminates

Mono-material laminates, such as polyethylene (PE) structures, are composed of a single material, making them easier to recycle. Aperfect example of this is our Smart-LAM series, which takes mono-material innovation to the next level.

Why Use Smart-LAM?

• Recyclable (rated #2 and #4) and approved for store drop-off recycling programs with How2Recycle® approval.
• Options for moisture and oxygen barriers to suit a wide range of packaging requirements.
• Designed with lamination-grade inks, so your stunning graphics stay protected and vibrant.

Smart-LAM lets your brand maintain the benefits of traditional lamination, like durability and quality, in a format that supports a circular economy.

Post-Consumer Resin (PCR)

Laminated packaging is also an excellent way to incorporate post-consumer resin (PCR) into your products without compromising quality.

Benefits of PCR in Lamination

• Reduces use of virgin resins with recycled content.
• Maintains high printing standards, ensuring your designs remain as impactful as ever.
• Cuts carbon emissions during resin manufacturing by up to 78% compared to traditional materials.

Laminated solutions with PCR materials give you an eco-conscious way to meet sustainability goals while delivering exceptional packaging performance, and thankfully these solutions are readily available when you partner with us.

Additional Advancements

• Bio-Based Adhesives & Polymers: Derived from plants rather than fossil fuels, these products lower environmental impact without sacrificing functionality.
• Solventless Processes: Like the ones we usein our operations, these processes reduce energy consumption and eliminate harmful VOC emissions.

Final Thoughts

Lamination is more than just layering materials—it’s an essential process that enables modern packaging to protect products, preserve quality, and delight consumers. By adopting sustainable practices such as mono-material laminates and PCR integration, brands can uphold their environmental commitments without compromising performance.

At Emmerson Packaging, we combine innovative, high-performing laminated solutions with a commitment to sustainability. Let’s create packaging that protects your products and the planet.

Contact us today to learn how we can bring your packaging ideas to life!