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Thermal LaminatorLaminating is the process of bringing two or more materials together and bonding them. There are many variations on the methods for bonding the materials:

The most common foam lamination is with the use of PSA (pressure sensitive adhesive) as a bonding agent. The adhesive can be applied as 'transfer tape' which is adhesive precoated onto a release liner (with or without a carrier) or coated directly onto one of the surfaces.

Heat preparation is often used to melt the surfaces or thermoplastic adhesive that was previously coated and get the materials to bond under the pressure of the lamination rollers. Heat is the method of choice for selective lamination such as sealing bags.

Thermal LaminatorOther forms of surface activation such as flame treating or corona treating can be used to bond materials.

Some materials such as filter papers respond to 'knitting' which involves passing the layers between rollers with a raised pattern that forces the fibers together and makes a bond.

PLI can laminate almost any web material from a filament to a 118" wide web with many of the processes mentioned above. For webs wider than 10", we can combine adhesive coating, lamination, and slitting. In the narrower widths, we can combine any number of processes such as multiple lamination, stripping, die cutting, embossing, and coating.

We specialize in the lamination of all foam materials like PE polyethylene, PP polypropylene, EVA, open-cell, closed cell, cross-link foam, rubber materials, felts, fleece, nonwovens.


The infrared system consists of infrared heating bands with ceramic insulation for increased efficiency when thermal laminating foams and other dense materials.

Heat is transmitted down onto the adhesive / substrate that needs to be pre-heated. To allow for different heat intensity and for special heat applications, the infra red hood is provided with both height and tilt adjustment.

Height adjustment is achieved by turning the lower of two adjustment wheels. Air jacks on each side support the hood which are balanced to allow easy upward and downward movement.

A second wheel adjuster at the central pivot point of the hood, with a locking screw allows the upper hood to be tilted to the required angle.

This unit can be fitted with up to 3 zones across the width heating with or without optical pyrometers and variable power control.

Key Features

  • 00cm / 140cm / 180cm / 220cm operating widths
  • Tilt adjustment
  • Height adjustment
  • Optional variable power control
  • Optional non-contact temperature regulation
  • Standard length 1m
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Powder Coating

The Powerline Powder Coating Unit allows the even distribution of adhesive powders onto substrates ready for laminating or sintering.

The powder is held in a hopper above the conveyor. This hopper has adjustable end dams allowing the powder to be scattered over various widths of substrate. If required, more dams can be added to allow multiple lanes of powder to be spread.

The powder in the hopper falls between the needles in the scatter roller. As the roller rotates, a doctor blade levels the powder with the top of the needles ensuring an even quantity of powder across the width of the coater. Powder contained in the roller rotates around until it meets the oscillating brush where it is cleaned out from between the needles. As the powder falls, there is a secondary oscillating sieve to further ensure even distribution of powder.

Powder Reservoir
Mounted above the machine centerline and holds the adhesive powder in a ready state for supply to the spreading equipment. A pneumatically operated levelling paddle (option) moves across the full width of the reservoir to ensure that the powder levels are always equal and to prevent coagulation and "bridging" build-ups in the reservoir. Upper and lower powder level sensors (option) are fitted to the reservoir to monitor either low powder levels or over filling.

Applicator Mechanism
A metal dispensing roller receives the adhesive powder equally across the full length of the roller. The powder is held in place by the needles on the surface of the roller and the volume of powder collected is governed by the rotational speed of the roller. A 0.75 kW inverter driven AC motor operates the dispensing roller and the rotation speed is directly controlled from the PLC computer unit. Adjustment (as a percentage) of the conveyor line speed through the PLC increases or decreases the volume of powder collected by the dispensing roller. The adhesive powder is removed from the dispensing roller by a reciprocating brush driven by a cam action and a 0.37kW AC motor. At the front and back of the powder reservoir and dispensing equipment are Plexiglas shields to retain the powder scattering onto the substrates and prevent dispersion from the immediate area.

Dedicated Conveyor(option)
A banded conveyor or PVC belt forms a link between the PTFE conveyors of the transporting system and is an incorporated component of the powder coating equipment. The bands revolve around driven grooved rollers that anchor the individual bands and prevent any tracking problems. Surplus powder that falls across the full width of the conveyor is able to fall between the individual bands of the conveyor into the powder recovery unit (option). An 0.375 kW, AC inverter drive motor is fitted to drive the conveyor and the speed of movement is controlled from the PLC in conjunction with the overall line speed.

Key Features

  • 100cm / 140cm / 180cm / 220cm operating widths
  • Low level warning option available
  • Variable speed of roller
  • Variable speed of conveyor
  • Conveyor cleaning system
  • Adjustable operating width
  • Optional powder reclaim system
  • Optional automatic refill system
  • Optional powder levelling paddle
  • Optional anti-static device

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Phone: 800-449-9460
E-mail: sales@pliusa.com