How does the dry film process work?

Introduction:

If you want a packing cover with attractively designed lamination? If yes, Dry filming is the right choice. We are all generally attracted to the packing cover when we buy cakes, snacks etc., as these covers have beautiful designs with good pictures.

This is because Dry-filming is widely used in the packaging industries for snacks and bakery items. Let's get into the topic of how this dry-film process is done.

What is Dry film, and how is it used?

Dry film is a photo-resisting element. This process is done by passing an intense UV light, which hardens the film, and this set form resists the cutting solutions.

The film comprises three parts,

The blue layer is in the middle,

The polymer, which hardens with UV, on each side

The polymer acts as a protective transparent film.

Dry films are the kind of films which are thick. Even though the resolution and the aspect ratio are not high compared with other thick films, the images that fall in this film will be more attractive no matter how the resolution and the balance are.

This dry-film process is applied in many different fields. In these cases, a composite comprising two or more layers of material may yield the optimum performance. A widespread way of creating such a composite layer is to laminate various films with other films, foils, papers, etc., with a glue made up of polymer.

This production solution is commonly applicable in the packaging industry, where the end products must be matched with specific parameters, such as high tensile strength and gas permeability. This laminate construction will become more complicated because of the particular application nature.

Process of Dry filming:

Dry laminating adhesives are generally solvent-based chemicals that are less toxic and safer, and meet environmental regulations.

Dry laminations are those in which the liquid glue is first dried before lamination. The bond is either applied to the underlayer and dried or used as a film, also known as another film layer.

This film brings clarity and barrier level, the type of food product being packaged and whether other specifications such as UV protection or odour prevention may be needed.

You'll also want to consider the converting process to determine how the film trims and edges bond.

The glue is then dried as a solid with the other bottom layer. The bonding is generally achieved during a high-temperature, high-pressure nip so that the dry film will be obtained.

Steps to obtain the Dry film for lamination purposes are as follows:

There are some steps to bring the Dry-film laminating according to the various sizes and depending on the quality of the film. The Steps are:

Set the laminator to 120 degree Celsius, so the laminator will have an optimal level of temperature to set.

A slower process will help in glueing to the wafer during the lamination process.

After that, the Micro-etching process is to be done, which involves the size reduction of the materials by cutting the edges.

Once it is glued, the film is moved on. The riveting process is there to complete the process, strengthen the inner layer, and prepare it together. As a result, This process enhances the film and ensures it does not move during the lamination process.

The copper foil is then placed between a stainless-steel patch and prepared well. This stainless steel creates a hard and flat surface. The copper foil completes the stack-up. The panel is now composed at the top and the bottom of a copper foil and a prepreg surrounding the inner layer of the film.

Then the stacked-up film is placed under a high temperature based on the sheets of the materials. The process will take up to 2 hours. After increased pressure and temperature exposure, the layers form a single board, which is moved to a cold press.

Benefits of the Dry-filming:

Since this dry filming process is being done for packaging industries and also done everywhere, there will be several benefits. Here are them.

This film is more resistant to extremely hot or freezing temperatures

The dry film does withstand more loads

These films are more reliable and more protective.

These dry films are devoid of moisture content.

These are very clean and dry and do not have any smell.

Applicable for all metals, plastics, wood and synthetics, and covers.

Hence, these are the benefits of the dry filming process.

Another benefit of the dry film is that several different technologies are available that cover more applications in the food and non-food packaging industries, as well as for the manufacture of technical laminates for the solar energy and insulation panel sectors.

The strength of the foil is improved; hence it will be difficult to tear. Henceforth these foils protect foods from outside deteriorating agents like gases, lights, etc., and Prevent the loss of product qualities, such as freshness and aroma.

Importance of Dry-film:

The Dry Film Lubricant's benefits are its superior lubricity, formability and flexibility when processing and packaging a wide range of metal substrates. It's suitable for deep-draw stamping without impacting downstream processing while delivering cost savings, a cleaner processing floor, and much more.

End Thoughts:

This article taught us how the process is done and obtained through several steps and is a vital part of the packaging industry.

Suba Solutions' equipment lineup includes Met Pet laminators, Carton blank Inspection and sorting systems, Window patchers, Offline Stripping and blanking machines and Folder adhesive machines.

We understand the needs and how they want, and accordingly, they manufacture the Dry-film laminator machines. These are why we are one of the leading dry film laminator machine manufacturer in India.

With a committed team of professionals in properly laminating the covers, Suba Solutions offers dependable and best-in-class Solutions for Packaging companies in India and Sri Lanka.