Wide, Wider, Widest Laminating

As printing devices get wider, laminators are keeping pace. Find out how to shop for a laminator, what features to look for and what to do once you get it.

by Cheryl A. Adams

With the wide-format market getting wider every day, it's no wonder printers are investing in the technology.

Quips Brian Franks, vice president of marketing at GBC Films: "Today, the focus on ink-jet printers is the width of the machine. I call this the 'yacht syndrome,' because once you've owned a 30-foot boat, then you have to have a 40-foot, and so on. The same is true of wide-format printers. Once you've run a 40˝ machine, you want a 60˝. Now printers are available in 80˝ widths."

Not only are printers getting wider, but laminators (which protect this extra-large, outdoor signage from scratching, fading, tearing, etc.) are paralleling printers in size. Besides providing protection for printed materials, laminators enhance the color and contrast of the print, says Franks.

"Beyond protection, lamination is a way of differentiating the product," he notes. "It adds gloss, matte, satin, etc., to a product and makes it stand out. Lamination is a value-added service that people will pay for. It brings revenues into the business."

But with so many models out there—and with a range of features and price tags, ranging from $3,000 to $30,000—which wide-format laminator is right for you?

Buying Tips From The Experts

"Make a list of requirements and expectations, such as: What do you want your laminator to do?" suggests JoAnn Wolff, vice president of sales and marketing at Graphic Laminating. "Look for flexibility, including a wide range of adjustable temperatures and speed controls, as well as ease of use. Also, does the laminator have sufficient cooling/fan systems?

"Compare products that are available in terms of functions, price, support from manufacturer, service available, reputation, and warranty. Get testimonials from satisfied users," adds Wolff. "Do not buy on price. A cheap-quality laminator could end up being the most expensive laminator you ever buy. The more limited the warranty, the greater chance the equipment is suspicious."

Sol Gnatowsky, vice president of sales and marketing at Coda Inc., emphasizes the importance of purchasing quality equipment. He says printers can save money, but they can also ruin prints with a laminator that does not have a solid reputation for quality.

"Ask the vendor for a user reference list if you are not familiar with the equipment," Gnatowsky states. "Also, look at vendor Web sites to compare laminators. Always call vendors for details. Ask questions about the equipment. Inquire about operational tips."

The laminator must meet the individual needs and requirements of the printer, not only today but tomorrow.

"Don't close doors that might be open in six months or a year," warns GBC's Franks. "If the application today is for cold mounting adhesive and you buy a cold [only] laminator, tomorrow you might have an application that calls for heat-activated film. If you buy a laminator that is capable of both, it allows you to do both. It brings revenues into the business."

Designed to accommodate the larger size materials, as well as assist the operator in handling and loading them, today's wide-format laminators are built with a range of innovative features. For example, Franks describes swing-out arm shafts that make the film easier to load, tensioning controls positioned close to the operator, and visuals on the temperature/pressure on the rollers.

Large-format pouch-mounter/laminators represent the latest in lamination innovation. These are generally designed for ease of use and low cost, says Wolff, of Graphic Laminating.

Other innovations include thermal encapsulating lamination.

"Mounting, laminating or encapsulating becomes especially necessary when an ink-jet printer is used," explains Gnatowsky, of Coda. "The paper is usually flimsy, 6- or 7-mil., and the ink jet puts a lot of ink on and in the paper. Lamination/mounting finishes the print, making it stronger and more durable to the touch, as well as offering image protection and print enhancement."

"When you laminate something, it's supposed to come out looking excellent," adds Chris Knutson, product marketing manager, Equipment Americas, Hunt Corp. "That's highly dependent on the operator knowing how to use the equipment and materials to create that great output. We sell a lot of machines because they're simple. They produce good, reliable output with minimal training. The trend is toward simpler machines."

Laminators are becoming easier to use, with automated features, such as laminate handling, which rolls material off quickly for storage, says Knutson. New bidirectional laminators hold up to four supply rolls at a time, he says.

"That saves a lot of time, and you don't have to take material rolls on and off when you want to switch between heat-activated and pressure-sensitive films," he reports. "It saves a little bit on your back, lifting 60˝ rolls."

All manufacturers agree that proper operator training is essential when installing a laminator.

"It's death to have a machine dropped off on your doorstep and then have to try to figure out all the many applications and variables in the laminating process," says Alan Parkhill, vice president of sales and marketing at Banner American. "No matter which machine a printer chooses...he or she must make sure that setup and training is included as part of the package.

"Running a laminator is definitely an art," he continues. "There are so many things to learn, such as ink and media compatibility with laminating films, speed and pressure adjustments, mounting issues, etc. That's why, as a manufacturer, I recommend a full day or two of training when setting up the machine."

The Four Main Variables

Training helps the operator master the four critical techniques of the lamination process, adds Wolff, of Graphic Laminating.

"The art of lamination can be mastered by learning to control four main variables on your laminator: heat, speed, tension and pressure, in combination with various films and substrates," she says. "Trial and error is one way to develop this mastery. We recommend investing in paid training offered by your laminator manufacturer. The cost of this training is offset by quicker production of quality output and by less wasted film."

Interestingly, Knutson, of Hunt, recommends training before buying a laminator, and he recommends using independent training companies.

"Find out what other printers are using and what they like or dislike about their laminators," advises Knutson. "If you're just getting into the wide-format business, take a training course ahead of time. There are several independent training companies, where you can learn how to use materials, work on a few different machines, and get the feel of how things flow."

Training is not only important for proper operation of the equipment, but it opens doors for more business.

"Technicians are experts in making applications work and showing customers how to get the most out of their machines," says Knutson. "Most customers don't use their laminators to their full potential. They get a comfort zone of what works. But with the right training, they can learn how to use more laminates. Training also exposes them to a lot of different products, laminates and substrates that they might not have known were available. Also, training can provide ideas of what works best for each individual application.

"The bottom line," concludes Knutson, "training teaches printers how to get the most out of their laminators, and that ultimately helps them make more money."