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TECH HELP DIRECTORY
ENCAPSULATION with THERMAL & HEATSET FILM
This tutorial describes the application of a thermal overlaminate film to one side of a printed graphic and a heatset overlaminate film to the other. The graphic will be loaded into the laminator using the infeed table using no additional support. In most cases, the print will be loaded image up, so that the heatset film is laminated to the front of the graphic.

thermal and heatset encapsulation schematic


SETTINGS
 TEMPERATURE:Thermal films achieve a bonding threshold at temperatures between 185 and 240F. Low temperature films activate at between 185 and 210F. Check the manufacturer's recommendations.

Heatset films require temperatures ranging from 185 to 210F.

NOTE: It should be noted that the upper Main Roller will gain heat from the lower Main Roller and vice-versa. The actual temperature of the upper roller will probably be higher than the display, while the actual temperature of the lower roller will probably be less than the display.

MAIN ROLLER SPEED: 1 - 6 ft / min. Some more rigid films benefit from slower speeds. See manufacturer's recommendations.

PRESSURE: 30 to 60 psi (varies according to machine).

PULL ROLLERS: Down (engaged).

Bring the Main Rollers up to the recommended temperature with the rollers in contact with each other. The upper and lower rollers should always contact each other when the rollers are heating in order to eliminate hot spots on the roller.

When the rollers have reached the appropriate temperature, set a gap to accommodate the thickness of leader board. Remember that once the films have been pushed through the nip, the gap will be 0 (follow detailed procedure sequence below). See Section 4 of the Textbook for more training in laminator set-up and webbing techniques.

Procedure
1. Load a roll of thermal overlaminate film onto the Lower Supply Unwind Shaft with the lead film edge facing up. Make sure the adhesive side of the film is out.
2. Unwind the film and bring the edge underneath the Idler Bar. Then bring it over the bottom of the Lower Main Roller and position is squarely on the roller.
3. Load the roll of Heatset overlaminate onto the Upper Supply Unwind Shaft. Bring it beneath the upper Idler Bar and separate the release liner from the film. Attach the release liner to the Upper Takeup Shaft. Bring the lead end of the Heatset film over the upper Main Roller and drap it squarely over the roller so that it hangs down slightly past the nip.
4. Set a gap between the rollers to accommodate the Leaderboard.
5. Use a Leaderboard to push the ends of the upper and lower overlaminate films into the nip of the Main Rollers until both films are wrapped tightly and evenly around their respective rollers. Then turn on the Main Rollers and process the leaderboard through the rollers. Stop the machine when the leaderboard has passed through.
6. Drop the Main Rollers so that there is no gap.
7. Line up the printed graphic to be encapsulated on the infeed table. Keeping the graphic square to the rollers, turn on the Main Rollers and process the print through the rollers. Do not stop the laminator until the graphic has passed completely through the rollers.

TIP: Do not leave a lip around the edge of the print when using this combination of materials. The acrylic adhesive used on the heatset film is not compatible with the copolymer adhesives used on the thermal film. The may separate over time.

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