Avery® 900 Super Cast

Avery® 900 Super Cast
(April 2014)
Avery Dennison Instructional Bulletin 4.06
Processing Tips for Avery® DOL™ Films
This bulletin provides recommendations for the application of Avery DOL clear digital overlaminate films to
provide additional abrasion and weathering resistance to digitally printed images. The procedure for applying
premask, packaging and converting films is also covered. It is also imperative that you understand, and practice
the proper safety and operating procedures recommended by the manufacturer of your laminator.
Overlaminating printed images with transparent overlaminate films is a necessary step to provide maximum
performance and durability of finished graphics. Overlamination provides gloss, matte, satin, colour depth,
durability and graphic protection.
Laminating and Premasking Equipment
To properly apply Avery DOL films, and approved premask, a manual or automatic lamination machine will be
required. The information contained in this bulletin provides an overview of the use of Avery DOL films with the
proper equipment. For specific information regarding equipment, follow the manufacturer's instructions or
consult with the manufacturer's technical service department.
Laminator Set-Up Tools
In addition to the set-up procedures and tools recommended by the laminator manufacturer, it is recommended
that the nip pressure and ‘footprint’ of the laminator be monitored. The equipment needs to be located on a level
surface and the rollers should be checked to ensure they are both also level.
Nip Impression Paper
Nip impression paper is a wax transfer paper used to determine the evenness of the nip ‘footprint’ across the
width of the laminating rolls. If the footprint is inconsistent (too heavy on the edges, too heavy in the middle, or
too heavy on one side), poor adhesion of the overlaminate, or wrinkles may occur.
Alternatively, an inexpensive nip impression paper can be made by printing three solid black images on plain
paper in a xerographic copier or printer. The laminator rolls must be hot to perform this test. Mark the strips left,
right, and middle and insert the sheets into their respective positions between the top and bottom heated rolls.
Close the nip momentarily (about 10 seconds). Remove the sheets and examine the consistency of the
impression across the width of the laminator. If necessary, adjust or repair the laminator according to the
manufacturer's instructions.
Prior to Laminating
Prior to beginning lamination, ensure the following:
The rollers of the laminator are clean and not damaged.
The rollers are parallel to each other.
The rollers are set at the correct temperature and pressure.
The material is laminated in the centre of the laminator, in case the materials are narrower than
the laminator.
To operate the laminator, the following settings are recommended:
Avery Dennison Instructional Bulletin 4.06 – Processing Tips for Avery® DOL™ Films
DOL Range vs. Settings
DOL 1000 / 1100
DOL 2000 / 2100
DOL 3300 / 3400 / 3500
DOL 4300
DOL 5900 / 6000 / 6100
Roller temperature
50-70 psi
0 - 2.5 m/min
20-35 C
Always set the lamination tension of the overlaminate and the printed substrate in such a way that they
are laminated flat but without stretching, the correct setting should have no tension across the web.
Improper tension adjustment is the major cause for wrinkles and possible delaminating. This is caused
by the tension difference of the laminate and media.
Note: Increased roller temperatures in combination with higher winding tension could lead to unwanted
elongation of the film and image. Winding tension therefore should be carefully monitored and kept at an
appropriate level.
For specific settings on the laminator, please consult the technical manual from the original supplier of
the laminator.
The following general recommendations apply to overlaminating Avery digital print media with Avery DOL clear
overlaminate films. For specific instructions relating to equipment operation when overlaminating, please refer
to the instructions provided by the laminator manufacturer.
1. The use of heat is not recommended when overlaminating with Avery DOL clear overlaminating films.
Should heat be required in the overlamination process, do not exceed 35°C on the top or bottom roll.
2. To overlaminate printed Avery digital media roll-to-roll, mount the printed film on the bottom roll unwind and
follow laminator manufacturer recommendations for unwinding from the bottom shaft.
Pull the printed film through the front nip (image side up). Continue pulling the web evenly through the back
pull rolls. Close the back pull roll nip and apply 50-70 PSI (350-490 kPa).
3. Mount the Avery DOL clear overlaminate film on the top unwind and web according to the laminator
manufacturer recommendations. Pull the release liner away from the overlaminate film and adhesive.
Attach the liner to the upper rewind shaft to accumulate the delaminated liner. Pull the overlaminate film
evenly through the front nip until the web is wrinkle free with even tension across the web. Close the front
nip and adjust the pressure to 50 PSI (350 kPa). Start running the laminator at 1.0 FPM (0.3 m/min). Cut
away the overlaminate film and adhesive before it reaches the back nip.
4. As the overlaminated film passes through the back roll nip, inspect the web for signs of wrinkling, waviness,
bubbles, etc. If problems are evident, stop and correct them before proceeding. Once the overlaminated
film looks good, increase the speed to 4 FPM (1.2 m/min.).
NOTE: Overlaminated graphics are less flexible than typical pressure sensitive film constructions.
For best results, feed the overlaminated graphics onto a flat table and cut into sheets.
5. To hand feed printed sheets into the laminator, web the Avery DOL overlaminate as instructed in this
section. Use a length of release liner beneath the print to protect the bottom roll from contacting the
adhesive. The liner can also be used as a leader to begin sheet feeding.
Avery Dennison Instructional Bulletin 4.06 – Processing Tips for Avery® DOL™ Films
6. Once the Avery DOL overlaminate has passed through the front nip, close the front nip and adjust the
pressure to 50 PSI (350 kPa). Start running the laminator at a speed of 1.0 FPM (0.3 m/min). Cut away the
non-laminated clear film between front and back nips.
7. When the Avery DOL overlaminate is feeding evenly, begin feeding printed sheets into the nip, taking care
to align the sheets evenly with the overlaminate. Increase the running speed as desired. Adjust the
overlaminate unwind brake to maintain the minimum tension required to keep the overlaminate free from
wrinkles. As the sheets exit the back pull roll nip, cut between the sheets.
8. For graphics to be applied by hand (not roll laminated onto a board surface), such as vehicle graphics,
window graphics, etc., a premask is recommended to protect the graphic from damage during handling and
Application Tapes (Premasks)
Application tapes are self-wound specialised paper (or plastic) pressure sensitive tapes with an adhesive on one
side. It is applied to the front of graphics before applying the graphics to the substrate. The application tape
aids in the successful production, handling, and protection of a graphic during application.
An application tape has a lower adhesion to the film than the film has to the substrate; this is why it is
easier to remove from the film.
Application Tape may also be referred to as ‘premask’ or ‘pre-spacing tape’.
Application Tape Selection
The type of application tape required depends on the type of graphic being produced, ink used and overprint
clear coat used.
Recommended application tape for Avery pressure sensitive films
(Adhesion Level)
Low Tack
Medium Tack
High Tack
Recommended Premask
American Biltrite 6760
R-Tape 4700
American Biltrite 6782
R-Tape 4760
Recommended Premask
American Biltrite 6882 (for UV Inks)
R-Tape 4700
American Biltrite 6782 (for Solvent Inks)
R-Tape 4760
American Biltrite 6792 (for Solvent Inks)
American Biltrite 6892 (for UV Inks)
R-Tape 4775
 Four-color process printed decals may require heat lamination to prevent tunneling of application tape.
 It is recommended to allow the premasked graphic to dwell for a minimum of 3 hours before applying the
finished graphic.
Generally it is not necessary to use an application tape on film that is 100 micron or thicker, or for any film that
has an overlaminate film applied. However, an application tape does prevent stretching and protects the graphic
during handling and application.
After applying the application tape, avoid exposing the graphic to sunlight except during application. Sunlight, or
UV light, can cause the tape to permanently bond to the film.
Avery Dennison Instructional Bulletin 4.06 – Processing Tips for Avery® DOL™ Films
Finished graphics should be wound face out with a minimum inner diameter of 15cm. Keeping the inner
diameter at 15cm or larger will prevent the graphic from tunneling.
The following table describes a number of common problems encountered in image transfer and overlamination,
along with possible causes and solutions:
Wrinkles in film going
into nip
Mottle or air bubbles in
overlaminated graphic
Possible Cause
Tension too low
Increase unwind brake setting on affected web.
Uneven feeding of webs
Cut webs and re-thread according to steps
Reduce unwind brake setting momentarily and
then increase to bring tension back up.
Increase pressure.
Uneven tension
across web
Not enough pressure
at nip
Running too fast
Uneven footprint in nip
Mottle in adhesive coat
Reduce speed in 0.5 FPM (0.15 m/min)
Check graphic  if mottle has consistent repeat in
roll direction or is heavier on one side, problem
may be in laminator set-up or laminator rolls.
Refer to instruction manual or contact laminator
Check mottle pattern  if consistent across
web or decreases in repeat as roll unwinds,
problem may be adhesive related. Try slower
speed, higher pressure, or add heat
(no more than 38°C).
For further information, contact your local Avery Graphics representative.
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