Laminating

Laminating (or mounting) is a popular bookbinding and printing technique that involves permanently bonding two or more different materials together (most commonly a thinner paper or cardstock with a thicker corrugated or solid board).

The goal of this process is to create a rigid, thick, and durable substrate that also features a high-quality, aesthetic exterior print.

Main stages of the laminating process

  1. Preparation of components
    • Cover (liner): Thinner paper or cardstock (usually with a basis weight of 130–250 g/m²) that has already undergone high-quality printing (e.g., offset or digital) and any necessary finishing treatments (lamination, UV varnish).
    • Substrate (base): A rigid supporting material—such as solid board, corrugated board (types E, B, F, C, EB, BC), or mounting foam—that provides thickness and rigidity to the final product.
  2. Adhesive application
    • The substrate sheet or printed cover passes through a laminating machine, where an even layer of adhesive is applied using rollers.
    • Depending on the materials involved, dispersion (water-based) adhesives, hot-melt adhesives, or polyurethane adhesives are used.
  3. PBonding and pressing (The lamination process itself)
    • The two layers are precisely joined (aligned and registered) to ensure the print is not crooked relative to the base.
    • The bonded materials pass through a system of pressure rollers (calenders) that remove air bubbles and ensure strong, uniform adhesion across the entire surface.
  4. Drying and conditioning
    • After leaving the machine, the sheets must be set aside to dry (especially when using water-based adhesives) to prevent the paper from warping due to moisture.
  5. Finishing (Post-press)
    • Once dry, the bonded and reinforced sheets are trimmed to their final size, die-cut (cut into custom shapes, such as box layouts), and subjected to processes like creasing (scoring fold lines).

Applications of lamination/mounting

  • Laminated packaging: Premium product boxes, packaging for cosmetics, alcohol, or electronics (where the inner layer is durable corrugated board, while the outer layer is elegant, printed paperboard with a glossy or matte finish).
  • POS/POP advertising materials: Display stands, totems, and cardboard store displays.
  • Board games and puzzles: Game boards and thick puzzle pieces that require rigidity and resistance to bending.
  • Book and binder covers: Hardcover book covers reinforced with board.

Advantages of lamination/mounting

  • Combining aesthetics with durability: Allows for printing on thin, high-quality paper and subsequently mounting it onto thick, durable board.
  • Greater finishing options: Enables easy varnishing or film lamination of the sheet prior to bonding—processes that are not always feasible directly on thick corrugated board.
  • Rigidity and a premium look: Packaging gains a luxurious feel while protecting the contents from mechanical damage.