Roll-to-Roll Laminating for Industrial Applications
Waterproof membranes, protective films, sound-insulating panels: these are some examples of composites that combine properties of different material layers. Roll-to-roll laminating makes this possible for large volumes. This page explains what roll-to-roll laminating is, when it’s the right technique, and which three systems Zwartz uses for different applications.
What is roll-to-roll laminating?
Roll-to-roll laminating is a continuous production technique where two or more materials are bonded together while being fed from roll to roll. Materials are unwound, fed through a laminating system where they are bonded with heat, pressure and adhesive, and rewound into a new roll. The process runs continuously without intermediate handling.
The technique is used for various materials: synthetic and natural fabrics, nonwovens, films, foils, foams and recycled materials. By combining materials, properties emerge that the individual layers don’t have. A textile becomes waterproof by laminating with a film. A nonwoven gains grip through dot bonding with hotmelt. A membrane remains breathable through selective adhesive application. The bonding between layers is achieved with thermoplastic adhesives. The technique makes it possible to create products with specific functionality from standard materials.
When is roll-to-roll laminating the right choice?
Roll-to-roll laminating is suitable for large volumes of flexible materials that can be supplied on rolls. The continuous production makes it efficient for industrial applications across various sectors. Some examples:
Examples for roll-to-roll appllications
- Automotive: interior upholstery, acoustic panels
- Construction: vapor barriers, underlays
- Packaging: barrier films
- Technical textiles: filters, protective layers
For thick materials, rigid sheets or very small series, flatbed laminating can be a better alternative.
Three systems for different applications `
Which laminating system fits best depends on what the end product needs to do. Does it need to be uniform across the full width? Should it remain flexible and breathable? Or does it involve thick, rigid materials? Zwartz has three different roll-to-roll systems, each developed for specific applications. Below, each system is explained in terms of when it’s used and why.
Belt calender
The belt calender is used when materials need to have the same quality across the full width. Think of geotextile that stabilizes soil: weak spots are unacceptable. Or technical filters where irregularities affect performance. With protective layers, there can’t be any gaps in the protection.
How it works
The belt calender uses a conveyor belt that distributes heat and pressure evenly across the entire surface. This prevents belt marks and pressure points. The system is also suitable for delicate materials that can’t handle point-wise loading. Besides roll-to-roll laminating, the system can apply powder scattering for self-adhesive coatings and add foils or reinforcing layers.
Applications
The belt calender is used for:
- Geotextile in road and water construction
- Technical nonwovens for filtration
- Protective layers in construction
- Delicate materials where uniformity is required
Maximum width: 250 cm
Hotmelt system
The hotmelt system is used when flexibility or breathability needs to be maintained. Think of sportswear that needs to wick away sweat, or anti-slip flooring that needs to provide grip but remain supple. Technical filters need to let air through while catching particles.
How it works
The system applies molten adhesive in dot patterns (dot coating). Between the adhesive dots, gaps remain open, allowing the laminate to stay flexible and breathable. For products that require complete sealing, full-surface coating can also be applied. Besides thermoplastic hotmelt, reactive hotmelt can be used for applications requiring extra bonding strength. The system processes both roll-to-roll and roll-to-sheet. The adhesives contain no solvents.
Applications
The hotmelt system is used for:
- Breathable membranes in clothing and construction
- Anti-slip textile for flooring
- Flexible products where stiffness must be avoided
- Technical filters
- Waterproof laminates with full adhesion
Maximum width: 250 cm
Flatbed system
The flatbed system is used for materials that don’t fit on rolls or for prototype development. Think of construction panels that are rigid and delivered as sheets, or thick composites that can’t be rolled. For product development, this system is suitable because test samples can first be made in small quantities before large volumes are produced.
How it works
The system can do roll-to-roll, roll-to-sheet and sheet-to-sheet laminating. Materials up to 15 cm thick can be processed. Active cooling prevents materials from warping after laminating, which is especially important for composites that might otherwise shrink or warp. Powder scattering, foil laminating and adding reinforcing layers are also among the possibilities.
Applications
The flatbed system is used for:
- Thick composites and construction panels
- Rigid sheets that don’t fit on rolls
- Prototypes and test series
- Materials requiring temperature control
Maximum width: 250 cm
Maximum thickness: 15 cm
Thermoplastic adhesives
The adhesives contain no solvents, making the process safer and cleaner. They are solid at room temperature and become liquid when heated. After cooling, a strong bond is formed. For products that come into contact with food, approved adhesive types are available.
Why roll-to-roll laminating with Zwartz
Advice and guidance from the start
Most customers know what their product needs to do, but not which laminating system fits or which material combination is right. Zwartz thinks along: which properties are needed, which system delivers that, which adhesive works for this combination. This advisory role starts with the first question and continues through to the end product. For new combinations, prototypes are made and tested in the Netherlands. Adjustments can be implemented quickly. Only when the result is right does production start.
Experience with contract laminating
Zwartz handles the laminating process for customers who supply materials. This requires insight into how different materials behave under heat and pressure: which temperature and dwell time are needed, which adhesive works for which combination. Through experience since 1835 with textile processing, Zwartz knows how materials react in the laminating process. The flatbed system is suitable for prototypes and small series. The belt calender and hotmelt systems also run large production volumes.
Contact
Need advice on which laminating system fits an application? Or questions about material combinations, adhesive selection or process parameters? The Zwartz team is happy to think along.
Frequently Asked Questions
Which laminating technique is suitable for a specific application?
That depends on the material and functional requirements. Belt calender for delicate materials, hotmelt for breathable or flexible products, flatbed for thick materials or sheets. Contacting us for advice based on the application is recommended.
Are small series possible?
Yes. The flatbed system is suitable for prototypes and test series. Belt calender and hotmelt can also process small volumes.
Can Zwartz process customer-supplied materials?
Yes. Contract laminating services are available where customers supply the material and Zwartz handles the laminating process.
How long does development of a new laminated product take?
For standard material combinations, samples can be delivered quickly. Extensive development with testing takes several weeks to months. Local production enables flexible switching.
Are laminated products recyclable?
That depends on the material combination. Thermoplastic adhesives can often be remelted. Single-material combinations (for example PP textile with PP adhesive) are more recyclable than mixed materials. Advice on recyclable options is available.
What's the difference between the three systems?
Belt calender uses a conveyor belt for even pressure. Hotmelt applies molten adhesive directly (full-surface or in dots). Flatbed can also process thick materials and sheets with active cooling. Each system has specific advantages depending on material and application.
