by DPS Magazine Staff
Laminating is a popular finishing technique with big potential in both web- and sheet-fed digitally printed applications. Lamination offers both practical and aesthetic uses, including extended UV protection, adding chemical and abrasion protection, and enhancing or modifying the look of digitally printed output.
Above: Nobelus offers a range of laminate finishes and thermal laminating systems.
For some print providers, lamination is an occasional need. To many others, it may be a daily requirement. “By adding the capability in house a printer is able to include long-lasting/durable print as a key additional sales benefit,” states Ray Hillhouse, VP sales and marketing, Plockmatic Group Offline Business Unit.
Print providers are discovering ways to offer more applications and types of laminating that can be done with a single asset, suggests Jeff Truan, strategic account solutions specialist, Nobelus. Many pretreat laminates are used to increase bond strength while choosing newer adhesives that reduce the previous high costs of digital lamination.
In terms of value enhancement, more laminate finishes are available than ever before, including tactile finishes and holographic patterns. “We’ve also seen wider adoption of laminating equipment that can give prints texture through embossing and shining effects using on demand digital cold foils,” suggests Truan.
Advancements for Digital Output
More laminators target shorter run lengths and smaller sheet sizes for the digital print space.
“Toners and digital inks used for digital prints don’t play nicely with traditional laminate films,” explains Neil Drever, product consultant, Skandacor. “Traditional laminate films are made for offset prints, which are easier to adhere to. However, because of the high oil content in toners and digital inks, digital prints are notorious for peeling and other adhesion issues.”
As smaller digital print shops start offering lamination, factors like compactness, user friendliness, etc. become make or break. “These shops typically have limited floor real estate and younger, tech-savvy staff members. So big, clunky, machinery doesn’t suit the fast-paced environment of these shops,” notes Drever.
“Quicker machine setup times and practices that create less waste through reprints and waste sheets help increase productivity and decrease lead times. Advancements in laminating systems also mean operators have to be less technical to get high-quality results,” adds Truan.
Another important development in recent years is the emergence of low-cost digital laminating solutions. “These have been developed particularly with the needs of the short-run digital sector in mind. At the vanguard of this type of machine have been our partners at Intec. The ColorFlare range of digital laminator products require no dies to be manufactured. As that typically happens with an external supplier it means significant time and cost savings, which in turn can lead to the potential for better margins for the printer,” says Hillhouse.
The shorter run length of digital means that fully automatic feeders aren’t always practical. “There’s very little sense in setting up an automatic feeder to run 50 sheets. So we’re seeing more demand for semi-automatic feeders, which offer the perfect middle ground for shops with run lengths too long for a manual feeder, but too short for a fully automatic machine,” suggests Drever.
If you look specifically at laminating flexible digitally printed output, Sam Crosby, dealer manager, Graphic Finishing Partners (GFP), says the technology has remained relatively unchanged over the past 25-plus years. “It’s primarily due to the straightforward process of two rollers putting a flexible film over a flexible or rigid print. While always looking for ways to make laminating more consistent while adding efficiencies like temperature, speed, and pressure presets.”
Gfp has developed a way to better manage costly inventory and reduce waste while making better use of partial rolls. Specifically, the Gfp 663TH 63-inch top heat-assist roll laminator features swing-out supply shafts, rear-rewind with inline trimmers, electronic nip control, counter and onboard label printer, and preset production lengths so operators won’t have to physically stand in front of longer runs helps frustrated shop owners while better managing inventory loss and/or reducing waste.
Inspired Output
Digital print providers witness huge gains in a range of areas due to advancements in lamination, according to Truan. “In the past, value-add lamination was seen mostly as a niche offering with the majority of printers outsourcing post-print lamination. But Truan says this has changed significantly as differentiation becomes more important. “In fact, lamination has become almost a requirement in many spaces due to the need to enhance digital print in hyper-competitive markets.”
Drever believes that in order to stay competitive and increase profits, PSPs need to have a better solution for customers. “The progressive printers offering embellishment and in-house print finishing are the ones who are gaining traction and bringing embellishment more mainstream.”
Truan agrees, noting that marketing pieces are more crucial for brands, which leads to higher value packaging, special attention to tactile finishes like soft-touch and rough-touch options, and visual enhancements that draw the attention of consumers to increase the chances of interaction. “In an increasingly virtual age, we are actually seeing increased response rates at the mailbox for laminated direct mail, and we expect this trend to continue growing. Lamination is also becoming more important for protection purposes, such as keeping book covers from scuffing during shipping and ensuring collectible items with attractive, unique finishes that remain in pristine condition long term.”
Drever notices a lot more print providers going beyond the typical traditional gloss, matte, and soft-touch lamination. “A lot of people offer creative options such as foil under a 10-mil laminate, incorporating metallized boards or films, etc. Another application that’s becoming more common is laminated Teslin. When done with a 10-mil laminate film, even though the final result often isn’t edge sealed, it makes a nice, thick, completely waterproof card.”
Films like Skandacor’s UltraGrip laminate line are specially formulated with an aggressive adhesive for digital prints.
Insourcing this type of lamination enables printers to increase margins in competitive spaces, offering brands more rapid turnaround times, and increase their top line revenue. “More brands are asking for ways to differentiate their products in increasingly competitive markets, and the value-add features modern lamination offers provide a perfect way to create unique designs that appeal to multiple senses,” adds Truan.
Estimated Value
The value lamination adds can vary between job size and market, but there tends to be a higher margin with digital lamination. “This is typically because of the short-run length and quick turnaround times that digital print customers usually require. On average, you can expect a 50 to 80 percent profit increase,” shares Drever.
“From what we have seen with our own customers, we estimate that the physical value of print and packaging can increase revenue by more than 40 percent in many spaces, while margins are growing as much as ten to 15 points. This growth is most likely due to the greater importance brands place on differentiation,” offers Truan.
The value lamination can bring varies greatly. “For example, from 500 soft-touch business cards, which might add a small profit increase—let’s say $25—to a rush job of 500 backstage passes with 10-mil laminate that could bring a large profit increase—up to 80 percent,” says Drever.
Modern Lamination
Laminators support the digital print space by targeting shorter run lengths and smaller sheet sizes with features like semi-automatic feeders. In addition to protection, these devices also add value to prints.
Jul2025, DPS Magazine
