Running a three-layer structure requires careful coordination. Start by threading the primary substrate through the first coating station and first drying oven. Apply the first adhesive layer (typical coat weight 2–6 g/m² depending on application) and dry it to less than 5 ppm residual solvent. Then thread the middle substrate through the second coating station and second drying oven, applying the second adhesive layer. Both coated webs meet at the heated laminating nip (typically 60–100°C at 4–8 bar pressure) along with the third substrate unwound directly to the nip. Set individual tension controls for each unwind to prevent wrinkling or stretching—primary and secondary at 100–300 N, middle layer at lower tension to avoid neck-in. Adjust line speed (usually 30–120 m/min) based on oven drying capacity and adhesive curing requirements. After laminating, allow the finished roll to cure at 40–60°C for 24–72 hours before slitting or converting.

Learn more