A Beginner’s Guide to Document Laminating

If you have ever wanted to add protective lamination to your documents or prints, but are new to the procedure, then this easy-guide will walk you through everything you need to know from beginning to end.

Document Lamination Benefits and Drawbacks

First, let’s discuss the benefits that laminating your documents will offer.  The most important trait of lamination is its protective properties.  The plastic-like material bonds your documents securely on all sides protecting is from damage such as finger prints, scratches, dents and bends, liquid spills and even the harmful rays of the sun.  In addition to these protective assets, lamination also adds an attractive finish to your document or print.  For example, if you get a gloss lamination, then your print will feature a pristine glossy sheen once laminated, increasing the vibrancy of the colors.  If you don’t want the sheen because of high-lighting or glare situations, then matte lamination is also available.  Used properly, laminating your documents will keep them vibrant and protected for years to come.

Something to consider, however, is that document lamination is permanent and cannot be removed, so it is always important to test an unimportant document or print before laminating the actual piece.  This will help you determine the proper heat and speed settings on your laminator without ruining the product you wanted to protect in the first place.

Kinds of Laminating Machines

Next, we should discuss the different kinds of laminating machines available, and what applications and customers they fit best with.  There are four basic kinds of document laminating machines: 1) pouch laminators, 2) roll laminators, 3) cold laminators (also known as pressure sensitive laminators) and, 4) wide format laminators.

Pouch Laminators:

Pouch Laminators are the most popular and least expensive method of laminating. These machines are compact tabletop units designed for laminating applications up to 14″ wide. There are three types of heating configurations that pouch laminators use: heat plates, heat shoes and heat rollers. Older models of pouch laminators use heat plates. These work best for simple black and white copies. Heat shoes are commonly found in roll laminators as well as pouch laminators. The heat shoes provide a better quality than the heat plates, however heat shoes in pouch laminators can cause paper jams. The most consistent and dependable heating method is the heated silicon rollers. This feature is always recommended when laminating photographs.

Pouch laminators offer the protection of lamination film (pouches) for an economical price.  They are most comply used for restaurant menus, book covers, photos, cookbook pages, ID badges and small signs and displays.  Something to consider, however, is that the maximum lamination width for standard laminating pouch machines is eighteen inches; however, there are some wide-format pouch laminators available for large documents.

Selecting A Pouch Laminator:

In today’s market, there are hundreds of laminators to choose from. When searching for the perfect pouch laminator for your specific needs, you should consider the following:

1) What is the largest size sheet you will be laminating?

Pouch laminators are available in a variety of sizes. Binding101 offers pouch laminators capable of laminating product up to 11-1/2″ x 17-1/2″, and there is even a special wide-format pouch laminator available for your large items. Applications larger than this will require a Roll Laminator. Be sure to consider not only the size you will be doing immediately, but any sizes you might need to use in the future as well.

2) What mil (thickness) will you be using?

Many Pouch Laminators are limited to running thinner lamination film, usually up to 3 or 5 mil. This film produces thinner, more flexible product. For thicker, more rigid results, a 7 or 10 mil film is necessary. Make sure that the Pouch Laminator you choose is capable of handling the mil thickness you prefer for your documents.

3) What is your volume?

Speed is an important factor when choosing a Pouch Laminator. For example, if you are laminating high-volumes of documents at a time, then you don’t want a laminator that only goes 12 inches per minute. Instead, you would want one than can do over 100 inches per minute. Production speed may not matter as much for low volume output, however with higher volumes; saving seconds per unit can make a significant difference and help keep costs down.

4) What is your application?

Many Pouch Laminators are designed for specific applications. Some are designed specifically for basic copy paper with only light-coverage black print. For applications such as these, a heated-plate lamination system (typically the least expensive) will work fine. Other Pouch Laminators work well with photographs and specialty paper with fill-coverage printing. For applications such as these, a heated-roller lamination system is the optimum choice. Many pouch laminators also offer the ability to do Foiling; an increasing trend that allows you to add attractive foil accents on your documents.

Roll Laminators:

Roll Laminators are typically designed for higher volume runs and large formats up to 60″ wide and 1″ thick. For two sided laminate, two rolls of laminating film are used. And for one sided laminate, one roll is used. There is a wide variety of lamination film available on the market today, however the most frequently used is thermal film. Thermal film is constructed of two layers; a polyester layer and an adhesive layer. During the laminating process, the adhesive is warmed and melted. It is then pressed into the document acting as a bonding agent. As the adhesive cools, it hardens and creates a permanent seal between the document and the film.

Roll lamination is a process that involves two laminating rolls, a top and a bottom roll, and is placed on the machine with the glue sides facing each other. As the rolls are “uncoiled” a document is placed between the two pieces of laminate and are sealed as they travel through the rollers and the heat is applied. It is important to leave a small edge around the document to allow the lamination to adhere to itself. Some form of trimming is usually required with roll lamination. This lamination process is generally used for larger volume items as it can run at higher speeds and in a continuous roll.

Roll laminators operate by pulling film with a thermally-activated adhesive over a heat source and into a set of laminating rollers. Film from a roll passes over heat shoes to activate a polyethylene adhesive layer on the film. It then passes through rubber rollers to apply pressure and bond the film with the item being laminated. The film will actually fuse into the item.

Some great things about roll laminators are that you can add durable and protective laminate to your documents are high production rates, greatly increasing speed and efficiency.  Roll laminate film is also available in a huge variety of sizes, finishes and thicknesses to choose from.  There are models that are easy-to-use for schools and small offices to heavier-duty machines for the on-demand printing market.
Selecting A Roll Laminator:

With the huge variety of roll laminators on the market, how can you choose the right one for your specific needs? Before you choose a laminating machine, it is important to consider several factors. Our experienced sales specialists have put together the most important questions to ask yourself before choosing a roll laminating machine. Review these below questions to help determine what you need. Once done, feel free to browse our selection of roll laminators or contact us at (866)537-2244 for details on specific models to meet those needs.

1) What is your application?

Different applications will call for different laminating machine solutions. Think about what you need your laminator to do… will you be laminating posters, graphics and signs? Will you be mounting prints to foam boards? Will you be creating pop-up displays? Will you be applying vinyls, tapes or adhesive films? Will the applications be used outdoors, such as outdoor signage and displays? You may need to do just one application, however some systems offer money saving multi-functional capabilities. Once you have determined what you want to achieve with your laminating machine, then we can start discussing the best machine to help you achieve those goals.

2) What is the largest size sheet you will be laminating?

Roll Laminators range in size from 12″ to 27″ wide. Before investing in a roll laminating machine, be sure to consider not only your immediate width needs, but also any possible future needs. You will want to get a machine that has at least an inch or more extra space on each side to ensure proper encapsulation. It is always better to have a machine that can handle larger documents to ensure you are covered.

3) Do you need heat?

Some roll laminators have the capability to do both heated lamination and cold lamination (also known as pressure sensitive laminating). Cold Laminating is required when the paper or ink is too sensitive to withstand the heat that thermal laminators apply.

4) What is your volume?

Speed is an important fact when choosing a roll laminator. For example, if you are laminating high-volumes of documents at a time, then you want a machine that can laminate at high speeds, and be heavy-duty enough to power-through these large jobs. When laminating at high-output, saving seconds per print can make a significant difference and help keep costs down. On the other hand, if you are a school laminating in small intervals, then speed might not be an issue so you can invest in a slower (usually less expensive) laminator.

5) How much space do you have to work with?

Roll Laminators are usually able to sit on desk-tops or stands, so it is important to determine the space you need to work with ahead of time, and compare it to the dimensions of the machine you are considering. You should also keep in mind that you will be inserting the print on one side and it will come out of another side, so additional space on both sides is required.

Cold Laminators:

Cold Laminators, also known as pressure sensitive laminators, are required when the ink or paper used for a print is too sensitive to withstand the heat of a thermal laminator.  Often cold lamination is also used for one-sided laminating.  This type of laminating machine applies a film or adhesive to the application using high pressure rollers. This process requires no electricity, eliminating warm-up and cool down time and confusing adjustments to tension and temperature.  The cold laminators are extremely user friendly; perfect for home, schools, offices, and more. Pressure sensitive (cold) laminate is sticky to the touch, and features a removable release liner that covers and protects the adhesive.

With Pressure Sensitive Lamination you can create either flexible display graphics, or rigid display graphics. Flexible display graphics are perfect for retail stores, grocery stores, trade shows, hotels, etc. They are very popular as pop-ups and directional signs for hotel events. Rigid display graphics are prefect for when you want to laminate and mount in one easy step, creating a firm and durable graphic that is sure to last.

Benefits of cold laminators include the fact that they are often very user-friendly and easy to operate.  They require no electricity, which not only saves you money, but eliminates the risk of burns as well as those accidents when machines are left on after you leave the office.  There is no warm-up time, which means it is ready to go as soon as it is set-up for quick operation.  In addition to all these benefits, cold laminators require little to no maintenance to keep them running smoothly.

Something to consider, however, is that most cold laminators require special laminating film cartridges that are only compatible with the specific machine, limiting the laminate options available.  In addition cold lamination film is usually more expensive than thermal laminating film.
Selecting a Cold Laminator:

Our experienced sales specialists have put together the most important questions that need to be answered before purchasing a cold laminating machine. Review the below questions to help determine what you need. Once done, feel free to browse our selection of Cold (Pressure Sensitive) Laminators or contact us at (866)537-2244 for details on specific models to meet those needs.

1) What is your application?

Different applications will call for different laminating machine solutions. Think about what you need your laminator to do… will you be laminating posters, graphics and signs? Will you be mounting prints to foam boards? Will you be creating pop-up displays? Will you be applying vinyl, tapes or adhesive films? Will the papers or inks you use in your prints be damaged by heat? You may need to do just one application; however some systems offer money saving multi-functional capabilities. Once you have determined what you want to achieve with your laminating machine, then we can start discussing the best machine to help you achieve those goals.

2) What is the largest size sheet you will be laminating?

Cold Laminators are available from 8.5″ to 62″ wide. Before investing in a pressure sensitive laminating machine, be sure to consider not only your immediate needs, but any possible future needs as well. You will want to get a machine that has at least an inch or more extra space on each side to ensure proper encapsulation. It is always better to have a machine that can handle larger documents to ensure you are covered.

3) What is your volume?

Smaller cold laminators are usually built for low-volume users, while the larger machines are meant for use with higher=production poster and sign makers.

4) How much space do you have to work with?

Cold laminators are available as desktop models or floor-standing models with stands. It is important to determine the space you need to work with ahead of time, and compare it to the dimensions of the machine you are considering. You should also keep in mind that you will be inserting the print on one side and it will come out of another side, so additional space on both sides is required.

Wide Format Laminators:

Wide Format Laminating is most commonly used by the printing and trade-show industries where large-scale prints need to be laminated or mounted. They range in size from 42″ to 65″ wide, giving you a huge range of product size opportunities. Wide Format Laminators are floor-standing models, however, some can be placed on a stand or workstation. They are built for heavy-duty and daily users who create large promotional signs, banners and more.

Wide Format Laminating Advantages include the allowance for high production rates, a protective and durable finished product that can be wiped clean, and a wide variety of lamination choices.  However, you should consider the fact that some wide format laminating machines require set-up and training, which can be costly.

Selecting a Wide Format Laminator

With the large variety of wide format laminators available, how can you choose the right one for your? Before we dive into selecting a laminating model, we should first determine the best kind of laminator for your needs. Our experienced sales specialists have put together the most important questions that need to be answered before choosing a large format laminating machine. Review the below questions to help determine what you need. Once done, feel free to browse our selection of Wide Format Laminators or contact us at (866)537-2244 for details on specific models to meet those needs.

1) What is your application?

Different applications will call for different laminating machine solutions. Think about what you need your laminator to do… will you be laminating posters, graphics and signs? Will you be mounting prints to foam boards? Will you be creating pop-up displays? Will you be applying vinyl, tapes or adhesive films? Will the applications be used outdoors, such as outdoor signage and displays? You may need to do just one application, however some systems offer money saving multi-functional capabilities. Once you have determined what you want to achieve with your laminating machine, then we can start discussing the best machine to help you achieve those goals.

2) What is the largest size sheet you will be laminating?

Wide Format Laminators are floor standing models available in sizes ranging from 42″ to 63″ wide. Before investing in a large format laminating machine, be sure to consider not only your immediate width needs, but also any possible future needs. You will want to get a machine that has at least an inch or more extra space on each side to ensure proper encapsulation. It is always better to have a machine that can handle larger documents to ensure you are covered.

3) Do you need heat?

Many wide format laminators have the capability to do both heated lamination and cold lamination (also known as pressure sensitive laminating). Cold Laminating is required when the paper or ink is too sensitive to withstand the heat that thermal laminators apply. Cold lamination is a process in which only one side of a document is laminated.

4) What is your volume?

Speed is an important fact when choosing a wide format laminator. For example, if you are laminating high-volumes of documents at a time, then you want a machine that can laminate at high speeds, and be heavy-duty enough to power-through these large jobs. When laminating at high-output, saving seconds per print can make a significant difference and help keep costs down.

5) How much space do you have to work with?

Because wide format laminating machines are floor-standing models, they require quite a bit of floor space. For this reason, it is important to determine the space you need to work with ahead of time, and compare it to the dimensions of the machine you are considering. You should also keep in mind that you will be inserting the print on one side and it will come out of another side, so additional space on both sides is required.

Laminating FAQ’s (Frequently Asked Questions)

Having been in the lamination industry for many years, we get important questions nearly every day.  This section of the A Beginners Guide to Document Laminating features a compiled list of the most frequently occurring questions, as well as some that we thought were too important not to share.

1) Why can’t I trim the boarder of my document, getting rid of the lamination that extends out from the print on all sides? The border of lamination around your document is an important aspect of the process as it creates an air-tight seal around every curve of your document or print.  If you trim the laminate too close to the print, you will allow air to access it and cancel out the protection against liquid spills.  For optimum protection, documents should have at least a ¼” border on all sides.

2) What kind of Lamination do I need? The laminations will depend on two factors: what your laminating machine can accept, and what finish you want to achieve.  First you want to check the user manual or instruction manual for your laminator to determine any laminate limitations you need to keep in mind, such as a maximum mil thickness, etc.  Once you are familiar with these, then you can browse a selection of compatible films.  Typically there are two lamination finishes to choose from: gloss or matte.  Remember those high lighting situations discussed at the beginning of this guide?  Matte laminating pouches can solve your problems.  The pale finish reduces glare and is perfect for harsh-light situations such as low-light restaurants, super-bright production facilities and more.  The glossy finish, however, is great when you want to add a vibrant appeal to your document or print.  This finish actually makes colors appear more bright and vivid, increasing the appeal of the finished document.  This is the most popular lamination finish choice by customers of all kinds from personal users laminating photos and awards to production facilities that offer signs and displays.

3) Why does my document have air bubbles after I laminate it? When a laminator is set too hot, then the material melts rather than adhered, which causes a bubbling affect.  Try turning the heat down and testing another document.

4) Why does my document look milky after I laminate? If your document looks milky rather than crystal-clear after lamination, this means that your laminator is not hot enough to fully melt the adhesive.  Try increasing the heat on your laminating machine and testing another document.

If you have any additional questions or are interested in purchasing a Laminator, visit Tim the Tutor at Binding101.com.  They have great pricing on a full line of Laminating Machine & Supplies and they charge only $9 for shipping UPS Ground.