The Complete Handbook of Laminating Film, Pouches & Sheets

Chapter 1: Understanding Laminating Film, Pouches & Sheets

Laminating film is a solution to a very old problem: how to protect a flat, printed surface from the world. It is a thin plastic envelope that is fused to paper or cardstock using heat and pressure, creating a barrier against moisture, oils, dirt, and physical wear. The item inside is not just coated; it is encapsulated. The film creates a new, durable outer surface that takes the punishment the original paper would otherwise suffer.

Consider the menu at a busy diner. It is presented to hundreds of people each week, wiped down with a damp rag, and occasionally dropped on the floor. An unprotected paper menu would be greasy, stained, and falling apart within a month. A laminated menu, typically a 10-mil pouch, can last for years. It does not absorb the coffee spills; it resists the tearing of a careless turn of the page; and it can be sanitized without being destroyed. This single, simple example explains why lamination is a fundamental process in many industries.

The Physical Process

To understand lamination, you must understand its mechanics. The process involves a plastic film made of a thermoplastic material, most commonly polyester which is often marketed under the trade name Mylar. This film is manufactured in the thickness required for the job, from a thin 1.5-mil protective coating to a rigid 10-mil board-like finish. The film is coated with an adhesive. In the thermal lamination that dominates offices and print shops,