“In this world, you get what you pay for.”
— Kurt Vonnegut

(from the novel Cat’s Cradle)

Every digital print shop needs at least one laminator. But a laminator is a tricky thing to buy. They are available with a myriad of options and features. It’s difficult to know which ones are necessary, which ones would be nice to have and which features will be of little use. Since everybody’s applications are different, it’s impossible to have one answer to fit all needs.

Of course the easy solution is to buy the flagship model that has all the bells and whistles, but it might not be the most financially viable solution. I recently spoke with a couple of experts to about the issue. Let’s see what they have to say.

Laminator’s Features

Jerry Hill is the Vice President of New Market Business Development for Drytac Corporation. Here’s how Jerry lays out the problem, and the options and choices:

“By definition, entry-level laminators target first-time business owners who are primarily concerned with disbursing payroll and paying taxes. These units have just enough moving parts to function. Fast-forward into the future and owners will start to concentrate on improving yields and create efficiencies for better profit margins. This takes both capital investment and discernment of laminator features to a higher degree.

“An interesting case study to share: I once had a sign maker come up to me at a trade show and yell at me for not selling him an upgraded laminator. In just a few short months, his business had tripled. He was upset because his entry-level laminator required two operators, whereas with the upgraded unit he would have been able to process the same workload with a single person.

“Some key differences between the two options relate to the overall quality of the laminator. For instance, a higher- quality laminator will come with full side cases and the stand will not be separate. This leads to better rigidity in the frame. The rollers—crucial components in the system—have a larger diameter that helps correct wrinkles and aids with heat evenness. In most cases, the concealed parts are different, such as the lifting mechanisms, electronic components, and even the casters.

“Accessories are also nice to have and should be considered. One of the best features is the presence of extra supply and take-up rollers, which will allow for full roll-to-roll lamination. Another excellent feature is heated or heat-assist rollers that help with adhesive flow and cure silvering. A calibrated pressure measurement device allows for repeatability. There are also ease-of-use features worth noting, such as a tilting in-feed table and a paper guide. A wider nip opening will not limit your ability for mounting to thicker substrates.”

A Laminator for the Long Run

Next, I spoke with Frank Romanello, a spokesman for Rolinx Performance Products, a company that sells the Kala brand of laminators, which are famous for their ease of use. Here’s what Frank has to say on the topic: 

“Among other things, a laminator should be user friendly while consistently producing perfect results. In our approach, a laminator is meant to last for more than 15 years. When investing in a laminator, the evolution of the print shop business should be considered and the decision should not be based solely on a specific application to meet a special request at a particular time. Doing so usually leads one to buy only on price and almost always results in a short-term laminator, not one that’s in for the long run.

“In our range, we pay particular attention to the characteristic design elements of the rollers. They are the central component of the machine that guarantees a high-quality output for a long period of time. The diameter of the roller is important, but should not be the only deciding factor. The grade of steel and the coating process of the silicone rubber are also crucial for this purpose.  

“Laminating can be a challenge because if the print is wasted by this process, it has to be reprinted. This is often the case with inexpensive laminators where operators cannot run long batches of work or repeat the same adjustments later due to a lack of calibration devices. As a result of a bad experience, users can get intimidated and turned off by lamination process.

“We offer a unique patented Auto Calibration System which assures absolute roller parallelism and consistent pressure throughout the entire width of the rollers, up to 83" wide. This feature eliminates skewing and requires no supervision when processing long runs (up to 100 yards) of graphics roll-to-roll.  Just web the media through, attach it to the rear take up reel and let it run. Unlike other laminators that require a technician or a technically capable person to spend hours of trial and error perfecting the right setup for every use, our Auto Calibration System does it for you in less than three minutes. 

“The Kala laminators also feature a one-piece welded steel chassis securing the entire assembly. Chassis stiffness is what separates high quality laminators from less expensive units that are prone to torque/twist when placed on uneven surfaces. This affects the pressure at the nip and the overall performance/output quality.” 

“The top line models will produce top results for a long time, but often a less expensive unit will meet a printer’s current needs. However, if business improves or changes, the buyer might wish they had the increased flexibility that the more expensive models offer. The trick is to find a balance that will work for present and future needs without breaking the bank.”