Automated Lamination with the Fujipla ALM3220 Laminating System

An excellent way to cut down on your labor costs during high volume laminating projects without sacrificing a quality end product is to utilize a commercial laminating system. The Fujipla ALM3220 automatic laminator is an exemplary piece of laminating equipment; it automatically feeds, laminates, and trims projects, virtually unattended!

Aside from some of its great features (including the ability to toggle between encapsulation or single-sided lamination, an ultra-quick warm-up time of less than 5 minutes, a footprint of less than 3 square feet, locking roller casters that enable portability, and a feeding tray capacity of up to 200 sheets), this fully-automatic laminator offers major cost savings when compared to traditional pouch laminating or roll laminating used in conjunction with a manual paper trimmer.

Speed

An economy pouch laminator can laminate up to 12″ per minute while a roll laminator laminates 36″ per minute. The ALM3220 has a top laminating speed of 48″ per minute. Pouch laminating doesn’t require trimming after laminating (since laminating pouches are pre-cut), but roll laminating does; for this example, we’ll assume 100 sheets are trimmed per hour. The Fujipla ALM3220 trims projects while they are being laminated, so there is no additional time added to the project in that respect. The total time to produce 1,000 finished sheets by pouch laminating is 15 hours when the pouches are loaded and fed by hand; the speed of lamination is directly affected by the time involved to manually load and center paper into the pouches. Roll laminating production time, which requires hand-feeding the project into the machine and hand-trimming afterwards, takes a total of 14.5 hours to create 1,000 finished sheets. The ALM3220 finishes 1,000 sheets automatically in just 3.13 hours!

Labor Cost

Aside from the physical production time being reduced, the ALM performs all of the required tasks to finish a project all by itself, which eliminates labor cost completely since it can operate unattended.

Other Factors to Consider

When compared to the results of pouch laminating, the finished documents produced by the ALM3320 are superior. Only encapsulation is possible with pouches; they cannot be trimmed to be flush with the edge of a project (since it would come apart over time). Pouches with adhesive designed for toner-based output are limited in size and finish, expensive, and sometimes hard to come by.

Operator fatigue will greatly reduce speed of a project completed with a roll laminator due to the feeding and trimming aspects. The accuracy of trimming can be inconsistent, since it is done by hand. Job sizes of more than 25 sheets are often discouraged due to high labor involvement.

The ALM3220 overcomes all the above mentioned obstacles:

  • No labor is required beyond the initial job set up, which takes less than 5 minutes.
  • It produces a uniform finished stack.
  • The versatility of this machine allows for complete encapsulation, flush cut, or one-sided laminations.

The Fujipla ALM3220 automatic laminator presents not only a great return on investment, but becomes a profit generator for any high-volume work environment that demands high-quality lamination fast!

Laminating Multiple Documents at Once

Trying to cut down both production time and expenses? Consider laminating multiple documents at once by sharing supply surface area.

Laminated Cards

If you have a pouch laminator with a throat measuring at least 9”, you can load multiple pouches side by side in a letter-sized carrier sheet and laminate them together in a single pass. This method is especially convenient when laminating small documents like business cards or luggage tags, since you can easily fit a number of pouches into a carrier sheet. Because you are inserting each document into its own pre-cut laminating pouch, every finished piece will look polished and professional, with identical dimensions and rounded corners.

Placing Multiple Documents in One Pouch

If you have something like a custom-sized strip-shaped document, you may be able to lay the printed material side by side in one larger pouch, then trim them after laminating. However, loading too many documents into one enormous pouch could lead to some problems. Pouch laminating machines are only so capable of pushing air out of a pouch while laminating – if the machine “leap frogs” over too many items in a pouch, a pocket of air can get trapped within the pouch and not all items will get laminated. Placing multiple documents in one pouch can technically save material cost; however, we strongly recommend perusing our wide selection of laminating pouch sizes since one that is pre-cut to the dimensions you need will save you time with clean up later and may in fact be cheaper to purchase than ones with larger dimensions.

Roll Laminating

Roll laminators have rollers with a much larger diameter than those of pouch laminators, which means that they can apply a greater amount of pressure during lamination and can overcome the above mentioned issue. Some roll laminating machines also have the option of a slitter attachment that separates documents as they exit the machine. While the laminator is running, you can insert your documents using the feed table and built-in guides (if present) to ensure consistent placement for easy trimming after lamination.

If you have any technical questions about laminating, ask us within the comment section – we’re happy to answer them for you!

Using a Take-Up Assembly for Pressure-Sensitive Lamination

The take-up assembly on a laminator is used when laminating with pressure sensitive film (also called “cold-process film”). Because pressure-sensitive lamination has a sticky adhesive layer that backs the film, a paper-based release liner is applied to cover the layer of glue and prevent it from adhering prematurely. The supply rollers on the laminator hold the roll film itself, but that release liner has to go somewhere once it is peeled away from the film; keep the discarded liner off the floor (or off your project!) by using a take-up assembly. A take-up roller helps to pull the paper liner away from the film during laminating and neatly collects it for easy disposal.

Take up assemblies either come pre-mounted on a roll laminating machine or are sold separately for installation after purchase. If your firm plans on performing cold-process laminating, be sure to look for a roll laminator that includes a release liner take-up assembly.

If you have any questions about this or another type of laminating machine or process, please ask us within the comment section – we’re happy to help you!

An Overview of Laminating Film Finishes

Laminating film can not only protect a printed document, but it can also add an element of texture to your finished project. The three most common varieties of laminating film textures are:

  • GLOSS – shiny, reflects light; well-suited for most applications, and can be used with dry-erase markers in some instances
  • MATTE – non-reflective; ideal for use in high-light environments and/or to create a “writeable” finish
  • SATIN – reflects some light, in-between gloss and matte

Laminating pouches (which are pre-cut sheets of laminating film fused together on one edge) are most frequently found in either clear (glossy) or matte texture. You can select from laminating sheets that have a clear finish on both sides, matte texture on both sides, or one side of each variety.

Standard laminating film and the majority of PRO lamination film is offered with a clear, glossy finish. PRO film is also available with a matte texture. Premium laminating films such as DIGIKote and pressure-sensitive (cold process) films are available in the full range of textures (gloss, matte, and satin).

If you have a favorite texture that you find works best for your projects or would like advice as to which texture is most suitable for you, please share or ask within the comment section.

A Guide to Understanding Roll Laminating Film Core Sizes

Core size refers to the diameter of a laminating film roll‘s inner cardboard tube. Roll film is most commonly found in 1″, 2.25″ or 3″ core sizes.

Roll laminating film with a 1″ core is often used with machines like the LEDCO Educator or EZ Lam School Budget laminator in educational settings and some smaller print shops. Films with either a 2.25″ or 3″ core are typically used with heavy duty machines like the Royal Sovereign RSH-1151 45″ Wide Format Laminator or LEDCO Signmaster in commercial print shops.

When ordering roll film, do check your machine’s specifications to make sure the mandrel can accommodate the film. If you’re not sure which roll film is appropriate for your machine or project, ask us within the comment section – we’re happy to help you!

Using Letter-Sized Carriers for High-Volume Badge or Bookmark Laminating Projects

Letter-sized cardboard carriers (9-5/8″ x 12-3/16″) for laminating pouches offer a shortcut for high volume laminating projects that involve smaller-sized laminating sheets. Instead of feeding business card- or bookmark-sized laminating pouches into a pouch laminator individually, multiple pouches can be placed within a single letter-sized carrier and subsequently be fed into the machine. The carrier sheet not only spreads heat across its contents, but also cuts down production time significantly.

Each box thermal laminating pouches that we sell includes cardboard carriers; however, if you need additional carriers, we do sell them individually in a variety of sizes – including some that are even larger than letter-size.

Note: Not all pouch laminating machines have enough clearance between rollers to accept both a carrier and a pouch. Be sure to check your machine’s specifications or ask us within the comment section. This shortcut is easily performed using laminators with a throat measuring 9″ or wider.

If you have more questions about laminating or using carriers with your projects, ask us within the comment section – we’ll give you an answer!

Lanyards & Name Badges – Get Attached!

Where do you turn when the classic “Hello, My Name Is” label isn’t strong enough to withstand an event on its own, or when a name tag pinned to a person’s shirt or coat is likely to come off or get lost? An excellent solution is to attach a name badge to a lanyard!

Lanyards and ID Supplies from Lamination Depot

Lanyards can be as simple as plain, round, shoestring-style cords with swivel hook attachments or as elaborate as custom-printed ribbons with specialized clips. Lanyards are worn around an attendee’s neck, allowing the attached badge to hang freely without damaging garments.

For the badge itself, here are some options:

Thermal Laminating Pouches – If you’re planning to make hundreds of tags, thermal laminating pouches are not only the most affordable way to produce your name badges, but they are also the fastest. Laminating pouches are available with pre-punched slots or can be punched before or after lamination using a simple, stapler-style slot puncher. For added durability, you can also add a brass grommet using a hand-held eyelet punching tool.

Self-Laminating (Cold) Pouches – If you’re making a small number of name tags for an event, consider self-laminating pouches. These pouches are also referred to as “cold laminating pouches” because they do not require a thermal pouch laminator to activate. The interior of each pouch has one side coated in adhesive (protected by a release liner prior to use) and one side that is plain clear plastic. Self-laminating pouches can also be punched. We only recommend these pouches for small events because this type of badge takes longer to assemble than those made from thermal laminating pouches and have limited size and thickness varieties available.

Plastic Badge Holders – If tags need to be interchanged for an event, then plastic badge holders are an excellent option. Plastic badge holders come with one open end at the top, allowing paper tags, identification cards, or business cards to slide in and out freely.

Rigid Plastic Badge Holders – This type of badge holder is designed to provide added protection to an already laminated name badge. They can either hang vertically or horizontally and are available in multiple colors. Rigid plastic badge holders can be used multiple times, so they are ideal for use at monthly meetings or sporting events.

If you’re looking to make several name tags, backstage/VIP passes, or credentials for a large event and would like personalized recommendations, feel free to ask us – we’re always happy to help!

Projects on a Roll: A Comparison Between Pouch and Roll Laminating

The mental image that is frequently associated with laminating involves a large machine loaded with rolls of laminating film, into which a project is loaded and exits encapsulated. These roll laminating machines are commonly found in schools and commercial print shops. However, laminating can also be done on a much smaller scale using what are called laminating pouches: pre-cut sheets of laminating film that are sealed on one edge that are then run through a small machine about the size of a household toaster.

When it comes to projects with 13″ as the shorter dimension, one must decide to use either a pouch or roll laminator. Here is how project aspects of laminating using either pouches or rolls compare:

Machine Investment

Pouch laminating is convenient and portable. Pouch laminators often accommodate projects as small as an ID badge or as large as 11″ x 17″, so long as the shorter dimension can fit within the throat of the machine; pouch laminator prices range within hundreds of dollars. Roll laminators can be as small as 12″ or as large as 60″; their prices range within thousands of dollars.

Material Cost

For a project with a minimum dimension of 13″, pouches with the closest shorter dimension would either be too small (12″) or too big (15″). Pouches can be custom made, but do cost a bit more than popular pre-made sizes. Roll laminating film, however, is sold in 27″ widths, which fit two 13″ projects side by side. The total project cost would fluctuate depending on the number of items being laminated at a time and which thickness or texture of film is chosen.

Laminating Speed

Due to their compact nature, pouch laminators have smaller rollers. In order to increase laminating speed, one must select a machine with multiple sets of rollers. For example, a 6-roller machine is much faster than a 2-roller machine. The diameter of a roll laminator’s rollers is much larger than that of a pouch laminator and can laminate feet per minute as opposed to inches.

The Final Touches

Laminating sheets are precisely cut to desired dimensions and the corners are rounded; the only trimming necessary for a project is for whatever is inserted into the pouches; once an item is laminated, it’s finished. Roll film projects not only require trimming, but they also require the corners to be rounded if desired.

If you would still like more information to help you decide which process is more suitable for your project needs, please ask us within the comment section.

Free Luggage Tag Offer

For a limited time, Lamination Depot will make two of your personal business cards into luggage tags for free.

Simply mail us two of your business cards and include a self-addressed, stamped return envelope. We will thermally laminate your business cards in a durable 10 mil luggage tag laminating pouch. We will include two clear luggage loops that will enable you to attach your new luggage tags to your luggage, briefcase, backpack or any item that you want to identify. These professional looking luggage tag laminating pouches will last for years and provide easy identification of your personal items.

To claim your free luggage tags, mail two business cards and a self addressed, stamped return envelope to:

Lamination Depot Inc.
Attn: Free Luggage Tag Offer
1505 E. McFadden Ave.
Santa Ana, CA 92705

One first class postage stamp will be adequate for the return postage.

Allow 14-21 days for processing and receipt of your your new luggage tags compliments of Lamination Depot Inc.

This offer is limited to only two free luggage tags per person. Additional luggage tags may be purchased for $2.50 each plus return shipping.

Customized Front Covers for Bound Documents

Customized binding covers make documents stand out and appear more professional. One of the most frequent and relatively inexpensive ways to achieve this look is to print a design onto the front sheet of the document (on either the same type of stock used for the whole document or something heavier) then add a clear binding cover to protect it. Clear PVC binding covers come in 5, 7, or 10 mil and are offered in a variety of sizes – 8-1/2″ x 11″ covers that are flush with the edges of a standard letter-sized sheet of paper, 8-3/4″ x 11-1/4″ covers with round corners to protect the square corners of letter-sized books, 9″ x 11″ covers to accommodate letter-sized documents that include tab dividers, 8-1/2″ x 14″ covers for legal-sized books, and 11″ x 17″ covers for tabloid-sized (double-letter) books..

An alternative to using a clear PVC cover for a bound document is to laminate the printed design, which eliminates having to flip the clear cover as if it were an additional page in the document. This process can be as simple as inserting the printed page into a laminating pouch and then sealing it with a pouch laminator or encapsulating it using a roll laminator. If you would rather have one side of the cover laminated and the other side exposed (for writing an inscription, etc.), you can laminate the design using nylon “lay flat” laminating film which does not curl after being applied; however, due to the price per roll and investment in the specialized machine, this process is most often used by professional printers and graphic artists.

If you would like a recommendation for a machine or supplies to used to create your custom cover or for another project, please ask us within the comments section – we’re happy to share our knowledge with you and get your project rolling!