Course Title: The Science & Art of Lamination & Blown Film in Flexible Packaging

Course Duration: 2 Days (6 Hours per Day) | Total: 12 Hours

Target Audience:
Production Supervisors & Managers Quality Assurance Officers & Managers Machine Operators Supply Chain Officers

Course Outline & Detailed Sessions

Day 1: Blown Film Technologies & Core Lamination Processes

Session 1: Introduction to Blown Film Technologies (Duration: 45 min)
Objective: Understand the role of blown film extrusion in flexible packaging and its impact on lamination.

Topics Covered:

• Basics of blown film extrusion
• Key materials: LDPE, LLDPE, HDPE, PP, EVOH, tie layers
• Mono-layer vs. Multi-layer structures (3-layer, 5-layer, 7-layer films)
• Effect of film thickness, flexibility & barrier properties on lamination

Session 2: Blown Film Extrusion Process & Equipment (Duration: 1 hour)
Objective: Learn how to operate and control blown film extrusion for high-quality flexible packaging.

Topics Covered:

• Extrusion process: Melting, die extrusion, inflation, cooling & winding
• Blow-up ratio (BUR) and its impact on film strength & barrier properties
• Film thickness & gauge control
• Equipment: Extruder, die head, air ring, take-up unit, winding systems

Session 3: Quality Control & Defects in Blown Film Production (Duration: 45 min)
Objective: Identify key quality parameters and troubleshoot common defects in blown films.

Topics Covered:

• Quality testing: Haze, gloss, dart impact, elongation, WVTR & OTR
• Defect analysis: Gels, pinholes, gauge variation, shrinkage, curling
• Process adjustments for defect minimization

Session 4: Dry & Wet Lamination Technologies (Duration: 1 hour)
Objective: Learn the working principles of dry and wet lamination techniques.

Topics Covered:

• Dry Lamination:
  Process flow & curing requirements
  Suitable substrates: PET, BOPP, CPP, paper, foil
  Key adhesives & curing mechanisms
• Wet Lamination
  Adhesive preparation & drying methods
  Surface treatment & bonding strength
  Common applications & quality requirements

Day 2: Advanced Lamination Technologies & Modern Trends

Session 5: Solvent-Based vs. Solvent-Free Lamination (Duration: 1 hour)
Objective: Compare the advantages and limitations of solvent-based and solvent-free lamination processes.

Topics Covered:

• Solvent-Based Lamination:
  How solvent-based adhesives work
  Drying requirements & VOC regulations
  Process setup & efficiency improvements
• Solvent-Free Lamination:
  Advantages over solvent-based techniques
  Equipment modifications & adhesive curing
  Cost, sustainability & operational efficiency

Session 6: Extrusion Lamination – Process & Applications (Duration: 1 hour)
Objective: Understand the working principles of extrusion lamination in flexible packaging.

Topics Covered:

• Process steps: Coating, nip roll bonding, cooling, winding
• Key polymers: LDPE, EVA, PP, tie layers
• Equipment: Extruder, dies, rollers & tension control
• Applications in food, pharma & industrial packaging

Session 7: Machinery & Equipment in Lamination & Blown Film (Duration: 1 hour)
Objective: Learn about the essential components and maintenance of lamination and blown film machines.

Topics Covered:

• Lamination Machines:
  Adhesive application systems
  Dryers & curing ovens
  Nip rollers, tension control & inline QC
• Blown Film Machines:
  Die heads & air rings
  Gauge control systems
  Winding techniques

Session 8: Process Optimization & Troubleshooting (Duration: 1 hour)
Objective: Identify common problems in lamination & blown film production and implement process improvements.

Topics Covered:

• Lamination Defects & Solutions:
  Tunneling, bubbles, delamination, wrinkles
  Adhesive bonding failures & their root causes
• Blown Film Defects & Solutions:
  Uneven thickness, gels, streaks, gauge bands
  Process parameter adjustments & machine tuning

Session 9: Modern Innovations & Sustainability Trends (Duration: 45 min)
Objective: Explore the latest advancements in sustainable lamination and flexible packaging films.

Topics Covered:

• Bio-based & recyclable adhesives
• Energy-efficient drying & curing technologies
• Digitalization & AI-driven quality control
• Trends in high-barrier & high-performance laminates

Final Discussion & Q&A: (Duration: 45 min)
Objective: Wrap up key learnings and allow participants to discuss industry challenges and solutions.

Topics Covered:

• Recap of key takeaways
• Live problem-solving & troubleshooting discussion
• Participant Q&A & industry case studies

Key Benefits of the Course
Comprehensive coverage of Blown Film + Lamination Industry-relevant content with practical insights Process optimization & troubleshooting focus Sustainability & modern packaging innovations