Multilayer Laminated Packaging Material Manufacturing Process
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Solution Overview
Problem
Current processes for manufacturing multilayer laminated packaging material for aseptic carton packages are hindered by high equipment costs, operational downtime due to layout changes, and the need for expensive printing and laminating equipment, as well as challenges in maintaining low humidity storage conditions, which increase capital and operating expenses and reduce competitiveness.
Innovation Solution
A process that involves laminating odor, light, and gas barrier layers with adhesive and protective sealing layers onto the paperboard, followed by printing the artwork on the outer face, and then slitting the material, allowing for flexible production runs and reducing the need for expensive equipment by performing printing after laminating and enabling storage in various humidity conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If printing is performed before laminating using expensive broadband flexographic printers, then high-quality artwork printing is achieved, but equipment costs and operational complexity increase
Solution Approach 1:
The patent inverts the conventional sequence by performing laminating before printing. This allows the use of simpler, less expensive printing equipment on the already-laminated material, reducing device complexity while maintaining printing quality. The laminated material provides a stable substrate that is easier to print on compared to raw paperboard.
Solution Approach 2:
The patent performs the laminating action in advance before printing. This preliminary lamination creates a prepared substrate that simplifies subsequent printing operations and allows for the use of less complex printing equipment, thereby reducing overall device complexity while maintaining manufacturing precision.
2Manufacturing precision
If printing is performed before laminating, then artwork can be applied to paperboard, but operational downtime increases due to layout changes
Solution Approach 1:
By inverting the process sequence to laminate first and print later, the patent eliminates the need to stop production for layout changes between printing and laminating. The laminating line can run continuously producing blank laminated material, which is then printed in separate batches, thereby increasing productivity and reducing operational downtime.
Solution Approach 2:
The patent segments the production process into independent laminating and printing operations. The laminating line operates continuously to produce blank laminated material, while printing can be performed in separate batches on different layouts without affecting the laminating line, thus eliminating downtime caused by layout changes and improving overall productivity.
3Object-affected harmful factors
If water-based ink is used for environmentally friendly printing, then solvent migration is prevented, but drying time increases reducing printing speed
Solution Approach 1:
The patent performs laminating in advance before printing with water-based ink. This preliminary lamination creates a barrier layer that facilitates faster drying of the water-based ink during subsequent printing operations, thereby reducing drying time and increasing printing speed while still using environmentally friendly water-based ink that prevents solvent migration.
4Manufacturing precision
If low humidity storage conditions are maintained for paperboard, then material quality is preserved, but storage costs and operational complexity increase
Solution Approach 1:
The patent performs laminating in advance while the paperboard is still in its original packaging and storage conditions. This preliminary lamination protects the paperboard from humidity concerns, allowing subsequent storage and handling without requiring controlled low-humidity conditions, thereby reducing storage costs and operational complexity while maintaining material quality.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces operational downtime, lowers equipment costs, and allows for strategic placement of printing facilities, enhancing production flexibility and reducing storage and operational expenses while maintaining product quality.
Implementation Method 1
The longitudinal edges are juxtaposed and adhered to each other in a following final folding station, to form longitudinal regions of joining and sealing
Implementation Method 2
the heat treating comprises flame treating
Data Source
AI summary
The invention provides a process to manufacture multilayer laminated packaging material to produce carton packages comprising the steps of: feeding a paperboard layer to a laminating equipment; laminating at least one inner layer onto a non-printable inner face of said paperboard layer, thereby forming a web of a multilayer laminated packaging material, wherein the at least one laminated inner layer forms a protective sealing and odour, light and gas barrier layer; winding said web of the multilayer laminated packaging material to form a master roll; feeding said master roll containing the web of the multilayer laminated packaging material to a printing equipment; printing a commercial artwork onto a printable outer face of the paperboard layer of the web of the multilayer laminated packaging material, opposed to said non-printable inner face; winding the printed web of the multilayer laminated packaging material to form a printed master roll; and slitting the printed master roll to form rolls of smaller width containing the web of the multilayer laminated packaging material.