Extrusion Coating & Lamination

04
EXTRUSION COATING
& LAMINATION
TECHNICAL GUIDE
Front Cover
Pellet geometry and pellet quality can have a significant effect
on material flow and the efficiency of feeding polyethylene into
an extruder. Qenos measures pellet quality using a pellet shape
and size distribution analyser, a device that photographs around
10,000 pellets in 4 minutes, digitally analyses the images and
generates a report on pellet quality.
Qenos, the Qenos brandmark, Alkathene, Alkatuff, Alkamax,
Alkadyne and Alkatane are trade marks of Qenos Pty Ltd.
EXTRUSION
COATING AND
LAMINATION
4 EXTRUSION COATING AND LAMINATION
TABLE OF CONTENTS
INTRODUCTION 4
GRADE SELECTION FOR EXTRUSION COATING
EXTRUSION COATING PROCESS TECHNOLOGY
The Extrusion Coating Process
The Extruder
The Die
The Air Gap
Nip Assembly and Chill Roll
Edge Trimming
Reeling and Wind-up Equipment
Coextrusion 7
EFFECT OF PROCESSING CONDITIONS ON PROPERTIES
Melt Temperature
Coating Weight, Neck-in and Drawdown
ADHESION 9
The Nature of Adhesion
Oxidation of the Polyethylene
10
Preheating the Substrate
10
Factors Affecting Adhesion
10
Use of Primers
11
Electrical Surface Treatment
12
Ozone Treatment or Ozonisation
12
PROPERTIES OF EXTRUSION-COATED LAMINATES
13
Frictional Properties
13
Heat Sealing
13
Barrier Properties
14
Food Contact Odour and Taint
14
Printing and Gluing
15
ALKATUFF FOR EXTRUSION COATING
15
Introduction 15
Draw Resonance
15
Other Coating Characteristics
16
APPENDIX 1 TYPICAL LAMINATED FILMS
17
APPENDIX 2 EXTRUSION COATING TROUBLESHOOTING GUIDE
18
BIBLIOGRAPHY/FURTHER READING
20
Qenos Technical Guides
EXTRUSION COATING AND LAMINATION 4
INTRODUCTION
With the increasing trend towards more sophisticated
packaging and industrial materials, laminated and
composite flexible structures are being widely used for
many applications. By combining the unique barrier,
sealability and structural properties of several different
substrates, a composite laminate is realised with the
characteristics required for specialised packaging
and industrial applications. Extrusion coating is one
of the processes used to produce a large range of thin
multilayer structures.
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in writing in relation to the contents of this publication is given in good faith and is believed by Qenos to be as accurate and up-to-date as possible.
The information is offered solely for your information and is not all-inclusive. The user should conduct its own investigations and satisfy itself as to
whether the information is relevant to the users requirements. The user should not rely upon the information in any way. The information shall not
be construed as representations of any outcome. Qenos expressly disclaims liability for any loss, damage, or injury (including any loss arising out of
negligence) directly or indirectly suffered or incurred as a result of or related to anyone using or relying on any of the information, except to the
extent Qenos is unable to exclude such liability under any relevant legislation. Freedom from patent rights must not be assumed.
INTRODUCTION
GRADE SELECTION FOR EXTRUSION COATING
Extrusion coating is one of the processes used to produce

alarge range of thin multilayer structures. In the extrusion
coating of polyethylene, a molten web of extruded polymer
is applied as a thin coating onto a substrate which is
passing continuously through a nip-roll assembly (see
Figure 2). In extrusion lamination, the molten polymer is
applied as an adhesive layer between two substrates to
form a laminated structure. The substrate may be paper,
paper board, polyester film, polypropylene film, aluminium
foil, woven fabric, etc.
Alkathene LDPE grades are characterised mainly by their

melt flow index (MFI) and density. The way in which these
parameters affect the physical and chemical properties
of the polyethylene is described in detail in the publication:
General Properties.
Low density polyethylene (LDPE) is especially suitable

for use in the extrusion coating process and is applied
to a wide variety of substrates as indicated in Appendix 1.
A major application is in the coating of board for milk
and fruit juice cartons, as an LDPE/board/LDPE or LDPE/
board/adhesive/aluminium foil/LDPE laminate (the
latter for aseptic packaging). Other applications include
specialised laminates for liquid and food packaging,
and industrial and building uses.
Note for convenience, the term Melt Flow Index or MFI is

defined as the melt flow of polymer extrudate in g/10 min
when subjected to a load of 2.16 kg otherwise referred
to as MI2.
In general the MFI of Alkathene LDPE extrusion coating
polymers is in the range 4 to 12 g/10 min and the density
around 0.918 to 0.924 g/cm3. The choice of the appropriate
grade for a particular extrusion coating application is
invariably a compromise between a number of conflicting
requirements with regard to processing performance and
laminate properties. Figure 1 indicates the influence of MFI
and density on these various properties.
The polyethylene coating provides increased tear

resistance, scuff resistance, a heat sealable surface,
resistance against chemicals, grease resistance, and
a good barrier against water and various gases.
Because of processing challenges, linear low density
polyethylene (LLDPE) has had only limited application
inextrusion coating and lamination and this is amplified
inasection at the end of this publication (see pg. 15).
However, its superior mechanical properties and sealability
would be beneficial in many laminate structures.
Figure 1: Influence of MFI and Density of Low Density

Polyethylene on Processability and Laminate Properties
For example, good processability (drawdown) is obtained
using a high MFI polymer but this is at the expense of
neck-in performance during the extrusion coating process.
Good flexibility is achieved using low density polymer but
higher density is required for good heat and oil resistance
and superior barrier properties.
Some of the effects of MFI and density on the extrusion

coating performance and laminate properties are
described in more detail later in this publication.
The properties of the finished laminate will depend not
only on the grade of Alkathene LDPE resin selected but
alsoon the substrate and the extrusion conditions used.
EXTRUSION COATING PROCESS TECHNOLOGY

The Extrusion Coating Process
In the extrusion coating process, polyethylene is melted
under heat and pressure in an extruder and the molten
polymer is extruded through a slit die as a thin web. This
web, at high temperature, is drawn down and coated onto
a flexible substrate in a nip-roll assembly formed by a
water-cooled chill roll and a rubber-covered pressure roll.
The substrate to be coated is fed continuously from an
unwind reel over the rubber pressure roll into the nip where
the laminate is formed by pressing the two layers together.
The laminate is rapidly cooled by the chill roll and is taken
up by a wind-up mechanism.
A schematic drawing of a typical extrusion coating line is
shown in Figure 2.
Figure 2: Typical Extrusion Coating Line for a

Paper/Polyethylene Laminate
The Extruder
The purpose of the extruder is to deliver uniformly
heated homogeneous melt to the die, at an acceptable
temperature and rate. The general principles for the
extrusion of Alkathene LDPE resins are described in the
publication: Extrusion.
For extrusion coating, a single screw extruder is generally
preferred with a screw length to diameter ratio of greater
than 25:1. To facilitate die and extruder adjustment
(especially for start-up and shut-down procedures), it is
best to mount the extruder so that it can be moved away
from the lamination and reeling equipment.
Good mixing of the melted polyethylene is essential if
a good coating film with no defects or blemishes is to be
obtained. Defects which may be apparent as a result of
a non-homogeneous melt include:
Pinholes
tiny holes in the coating surface
Voids
small holes in the coating matrix
Lace curtains
large voids giving the coating the

appearance of lace this is often due
to moisture or volatiles in the polymer
Streaks
thin bands in the coating extending

in the machine direction and showing
thicker and thinner areas of coating
Die lines
lines in the coating in the machine

direction, often caused by
contamination or oxidised particles
in the die
Gels
round or elongated clear spots which

are raised so that they can be felt
Oxidised particles
yellow-brown specks
Applesauce or
Orange peel
rough, wavy appearance in the

coating, reminiscent of applesauce
or orange peel
All of the above defects are either detrimental to the

appearance of the coating or damaging to the mechanical
and barrier properties. Voids and lace curtains will result
in a totally unacceptable product.
Pinholes will make the coating permeable to grease,
chemicals, moisture, gases and vapours. Streaks, gels,
oxidised particles or applesauce affect the coatings
appearance and may indicate some form of contamination
or inadequate operating conditions.
The Die
The slit die used in extrusion coating is normally centre
fed, particularly when the die is wide; however, an end-fed
design may also be used. The two main types of dies are
the coat-hanger die and the T-slot manifold die.
The prime objective in an extrusion coating slit die is to
have the melt leaving the die at constant velocity across
the full width. When a centre-fed die is used the uniformity
of the delivery rate across the die can be controlled by
restricting the flow in the shorter flow-paths, or by
maintaining the temperature at the die extremities 5 to
10C higher than that at die centre. However, the latter
does not always produce the best quality film.
working speed range, must be large enough to significantly

reduce the temperature of the laminate during its brief
period of contact.
The temperature of the chill roll should be kept at
approximately 15 to 30C; if it increases to 55 to 60C or
higher, the polyethylene may stick to the chill roll, causing
partial delamination between the coated web and the
substrate, or even web breakage.
Uniformity of flow is preferably achieved by contouring

the internal die dimensions or by adjustable choke bars.
Adjustable die lips give maximum adaptability of the die
when in use. Adjustable deckle rods inserted at each end of
the die permit adjustment of the effective width of the die.
The Air Gap

The air gap, or draw distance, between the die lips and the
nip to chill roll contact point is one of the most important
areas in terms of the polymers coating performance. In the
air gap, some of the properties of the laminate are most
affected by extrusion conditions. It is here that the molten
web is drawn down and necks-in (see pg. 8) and oxidation
takes place.
A large gap may cause premature cooling of the melt,
increasing its viscosity which in turn may lead to poor
adhesion to the substrate. However, if the air gap is too
small then this can also result in a deterioration of adhesion
strength. V-shaped dies allow the die lips to approach close
to the nip, thus minimising the amount of cooling and
improving the control over the degree of adhesion.
Nip Assembly and Chill Roll

The nip (see Figure 3) is formed by the steel chill roll and
therubber-covered pressure roll. The chill roll is usually
chromium-plated and highly polished, although matte
and mirror pocket surface finishes are sometimes used.
It is designed to remove the maximum amount of heat
from the polyethylene, and its construction is usually
based on a double-shell arrangement with built-in spiral
baffles to ensure effective and regular cooling. The cooling
medium is water, circulated from a separate storage
tank in which it can be maintained at a set temperature.
It is essential to provide sufficient water to ensure
effective temperature control at the surface of the roll.
The diameter of the roll, which is determined by the
6
Figure 3: Typical Extrusion Coating Nip Roll Assembly

The rubber pressure roll is usually made from silicone
rubber but neoprene rubber can also be used. The
requirements of the pressure roll include that it needs to
have good resistance to heat-ageing and work-hardening.
The roll is actuated by air cylinders to exert an even
pressure against the steel chill roll. It is also desirable
to have provisions for continuous cooling of the surface
of the pressure roll by having a water-cooled backing roll
(see Figure 2).
The position of the nip is usually adjustable relative to the
die. To obtain maximum adhesion the nip should be set to
ensure that the molten polyethylene meets the substrate
just before the chill roll exerts its cooling effect.
Edge Trimming
It is not possible to coat the molten web to the same width
as the substrate, due to two different effects which modify
the edges of the web. One of these effects is known as edge
weave. The other is the thickening at the edges of
the web to form an edge-bead. This is a consequence of the
necking-in of the web between the die and the nip. To
overcome these faults it is necessary to remove edge trim
(consisting of polyethylene and/or substrate) continuously
by means of slitting knives.
When a neoprene pressure roll is used the polyethylene
cannot be applied beyond the edge of the substrate
because it sticks to the neoprene. Polytetrafluoroethylene
(PTFE) adhesive tape is often applied around the ends
of the pressure roll to prevent sticking of the molten
polyethylene, to improve the service life of the rubber
covering and to allow extrusion of a wider web.
With a silicone-rubber pressure roll, the molten polyethylene
has a lower tendency to stick, particularly if the roll is cooled
by contact with a water-cooled chill roll. This allows the
polyethylene to be applied beyond the full width of the
substrate, so that only the excess needs to be trimmed.
Reeling and Wind-up Equipment

Equipment for the high-speed handling of reels of paper
and other substrates is usually highly specialised and not
designed to handle a range of materials. Static eliminators
are always incorporated to dissipate any build-up of
electrical charge. Information on reeling equipment is
best obtained from the machinery suppliers.
Since the coating line must run continuously, flying-splice
unwinds and rewinds are usually installed to permit
automatic reel changes at full production speed.
Coextrusion
Coextrusion is often used in combination with extrusion
coating/lamination. In coextrusion two or more layers of
different polymers are extruded simultaneously through
a single die. The major benefit of coextrusion is that some
of the separate laminating steps required to produce a
complex multilayer laminate can be combined into one
stepin the process.
There are two main types of coextrusion dies. The most
popular is the feedblock die where several melt streams
fed from separate extruders join within the die and are
extruded as one web. With this die type, more than two
different polymers can be extruded but their viscosities
must be carefully matched. With the dual slit die, two

extruders feed two separate channels in the die block
and the two extruded webs meet at the nip where they
are pressed onto the substrates. This die type is not
widely used.
Coextrusion offers the possibilities of extruding a thin layer
of an adhesion-promoting polymer or a tie layer, such as an
ionomer or ethylene-acrylic acid copolymer, in combination
with polyethylene. Tie-layers are generally used to bond
two dissimilar materials (e.g. polyethylene and aluminium
foil) together and to improve the adhesion. For many
laminates, this may eliminate the need for chemical
priming or other pre-treatments of the substrate.
Another application is the coextrusion of two polyethylene
layers, one at a relatively high temperature to promote
oxidation and adhesion to the substrate, the second
extruded at a much lower temperature to give a top
coating layer with better heat sealability and an acceptable
odour level.
EFFECT OF PROCESSING CONDITIONS

ON PROPERTIES
Melt Temperature
The exact conditions required to achieve optimum product
quality will vary from one unit to another. However, coating
weight uniformity, adhesion strength, and overall quality are
largely dependent on the melt temperature and its uniformity.
The melt temperature used varies according to the
substrate being coated, customer requirements regarding
desired properties, and the equipment. Temperatures can
be between 265 and 330C but 300 to 320C are typical.
Properties such as gloss and clarity improve with increasing
operating temperatures. However, if the temperature is too
high, the melt exiting the die may be too fluid for coating.
It may also be difficult to cool and windup, and excessive
oxidation may occur. Oxidation is a prerequisite for good
adhesion, but can lead to inferior heat sealing and the
possibility of odour and taint problems.
High temperatures can also lead to fairly rapid degradation
of the polyethylene, especially in the extruder and die
system if the process is stopped for longer than a few
minutes. If thermal degradation is allowed to occur, the flow
of the polymer will be adversely affected and undesirable
defects and blemishes will appear in the coating. Shutdown and start-up procedures are therefore very critical.
Low melt temperatures on the other hand may give the

polyethylene coating better frictional properties and allow
heat sealing at greater speeds (shorter dwell time) and
at slightly lower temperatures. This may be at the expense
of adhesion.
Fluctuating or non-uniform melt temperatures may result
in irregular coating gauge, uneven width, variable clarity
and gloss, wrinkles in the finished roll, pinholes and
other defects.
Coating Weight, Neck-in and Drawdown

The thickness of the coating is usually expressed in terms
of the surface coverage or coating weight (see Table 1).
Coating weights range from as low as 8 to 10 g/m2 for
packaging films and up to 50 to 100 g/m2 for certain heavy
duty cartons and fabric coatings. The coating weight is
determined by the line speed (chill roll speed) and the
extruder output rate. Line speeds usually range from 100 to
600 m/min but can be much higher for special applications.
Table 1: Surface Coverage for Polyethylene Coatings
using a 0.920 g/cm3 Density LDPE
Surface Coverage
Thickness m
g/m2
m2/kg
10
9.2
108
25
23.0
43
50
46.0
22
Associated with coating weight are two important

properties of the extruded web, neck-in and drawdown.
Neck-in is the reduction in width of the molten film web
which occurs as it leaves the die. It is measured as half
the difference between the width of the coating at the nip
and the width of the die, as indicated in Figure 4. Neck-in
is caused by surface tension and melt elastic effects in
the immediate vicinity of the die exit.
Drawdown refers to the ability of the polymer to
coat evenly down to very low coating weights without
breakage. It involves the reduction in thickness of the
molten polyethylene after leaving the die and before
contacting the substrate. It is a limiting factor in the
maximum line speed obtainable.
Figure 4: Neck-in During Extrusion Coating

It is important that extrusion coating grades of
polyethylene have good drawdown, particularly if low
coating weights are to be obtained without causing
tear-offs and voids. Neck-in should be minimal to reduce
trimming and obtain the maximum useable width of the
laminate.
Neck-in and drawdown are a function of MFI and melt
temperature. As shown in Figure 5, the maximum line
speed(drawdown) increases with increasing MFI but
neck-in performance gets worse. The choice of a coating
polymer is thus a compromise between drawdown and
neck-in performance. Most extrusion coating polyethylenes
have an MFI in the range 4 to 12 g/10 min.
Other factors also play a role in determining neck-in
performance and maximum drawdown. These are as
follows:
Line speed. Neck-in values decrease with increasing
line speed (see Figure 6).
Processing temperature. Neck-in increases and
drawdown improves with increasing melt temperature
(see Figure 7).
Air Gap. Large air gaps give better drawdown but worse
neck-in (see Figure 8).
Polymer swelling ratio. (defined as the initial thickness
of the polymer melt exiting the die over the die gap).
Neck-in decreases but drawdown is worse as the swelling
ratio increases.
Figure 5: Variation of Drawdown and Neck-in Performance

for Alkathene LDPE Resins of Different MFI
Figure 8: Typical Effect of Air Gap Distance on Neck-in
Edge tearing occasionally occurs during extrusion coating,
and this is an indication that web breakage is imminent.
Edge tearing can affect the width of the coating. It can
be caused by cold die ends or a high draw ratio. Using
a narrower die gap, increasing the coating weight (by
decreasing the line speed or increasing the extruder output)
or raising the temperature at the ends of the die can assist
in overcoming this problem.
ADHESION
The Nature of Adhesion
Figure 6: Effect of Line Speed on Neck-in for Several
Alkathene LDPE Grades of Different MFI
Good adhesion is usually the key requirement in extrusion

coating. A coating which does not adhere to the substrate
or which can be easily peeled off is worthless.
The nature of the adhesion between polyethylene and
the substrate is either physical (mechanical) or chemical,
depending on the type of substrate involved (i.e. porous
or non-porous).
Polyethylene coatings can form a mechanical bond with
porous substrates (such as kraft paper or cloth) as the
polymer is able to flow into the pores of the substrate. The
two surfaces physically lock together and can be difficult
to separate. Most smooth, non-porous substrates such
as metal foils or plastic films have less physical means of
adhering to the coating. They tend to resist adhesion, and
the substrate and coating must be chemically bonded.
Figure 7: Effect of Processing Temperature on Neck-in
The adhesion between the polyethylene and the substrate

is measured by the peel strength, which is the force
required to peel a strip of the laminate apart when tested
ina tensile machine.
Oxidation of the Polyethylene
Factors Affecting Adhesion
To obtain a chemical bond between the coating and

non-porous substrates, oxidation of the polyethylene
surface is necessary. Such oxidation requires a high melt
temperature and an adequate draw-down distance (or air
gap) between the die and the chill roll nip. The air gap is
needed simply to give adequate time for oxidation to occur.
However, an excessive air gap will allow cooling of the melt,
which will impair adhesion. Oxidation also plays a minor
role in coating porous substrates.
The adhesion of the polyethylene coating to the substrate

depends upon a number of factors, including:
The recommended time in the air gap (TIAG) for

polyethylene is between approximately 80-120 ms. It may
be less for some porous substrates, or where very good
adhesion is not required. TIAG can be calculated using the
following equation.
Polymer flow properties (MFI). Higher MFI polyethylenes,

with their lower viscosity, adhere better to porous
substrates than lower MFI grades (see Figure 10).
Time in the Air Gap (TIAG) = 60 x air gap (mm)

line speed (m/min)
The air gap can be adjusted by raising or lowering the
extruder or the nip roll assembly.
Any factor which reduces the amount of oxidation of the
hotpolyethylene web reduces its chemical adhesion to
the substrate. These factors include: low melt temperature,
small air gap, high coating speed and low coating weights.
The nature of the substrate. This has been discussed

earlier in relation to porous and non-porous substrates.
Melt temperature. Adhesion improves as the melt
temperature is increased, as shown in Figure 9.
Chill roll temperature. Too low a chill roll temperature will
impair adhesion. Increasing the temperature of the chill
roll will help overcome quick cooling.
Nip roll pressure. Low nip roll pressure will cause poor
adhesion, but increasing the pressure above a critical
level gives no extra benefit (see Figure 11).
The air gap. A larger air gap allows more oxidation of the
surface, thus promoting adhesion, as discussed earlier
(see Figure 12).
Coating speed and coating weight. Low coating speed
and high coating weight tend to promote adhesion
because more time is available for oxidation to occur (see
Figure 13). As thinner coatings are extruded, they cool
more in the air gap and adhesion may become poorer.
Fourier Transform Infrared (FTIR) examination of polyethylene

materials has been shown to be a reliable technique to
assess the degree of oxidation of polyethylene. The amount
of oxidation can be measured by the Carbonyl Index, which
is the ratio of the absorbance of a selected carbonyl peak
(1,700-1,750 cm-1) to that of a reference peak of the polymer.
Preheating the Substrate

The preheating of porous materials, like kraft paper, cloth
or woven fabrics, helps adhesion. The surface becomes
more receptive to the molten polymer by being dried and
warmed. Preheating the surface of non-porous substrates
such as metal foil or glossy paper will also help remove
moisture as well as lubricants, thus promoting adhesion.
However, preheating affects only the substrate surface; it
does not really penetrate into the web because of the very
short heating duration. Wet, porous substrates are rarely
dried by preheating. Such substrates should be oven-dried
before being used in the extrusion coater.
Figure 9: Effect of Melt Temperature and Ozone

Treatment on Adhesion of Extrusion-Coated LDPE
to Aluminium Foil
Preheating can be achieved by passing the substrate over

aheated steel drum (at approximately 175 to 190C). Gas
flames or radiant heaters are also used. Flame treating with
an oxidising flame will assist adhesion by oxidising the
substrate surface and creating adhesion-promoting groups.
10
Figure 10: Effect of MFI on Adhesion of Extrusion-Coated

LDPE to Porous Substrates
Figure 13: Typical Effect of Coating Weight on Adhesion

ofExtrusion-Coated LDPE to Aluminium Foil (60 m/min,
307C)
Figure 11: Effect of Nip Pressure on Adhesion of ExtrusionCoated LDPE to Porous and Non-Porous Substrates
Coating experiments carried out with kraft paper have

shown that the lower the coating weight, the higher the
melt temperature required to obtain good adhesion;
conversely, the higher the coating weight, the lower the
required melt temperature.
Use of Primers
It is difficult to obtain good adhesion between polyethylene
and a number of common substrates without first treating or
priming the substrate surface. Primers are chemicals which
when applied as a discrete layer to the substrate surface
provide a chemical affinity between the extruded web and
the substrate and hence lead to better adhesion. Substrates
which often require priming before coating are aluminium
foil, polyester and oriented and cast polypropylene films.
Many papers and paper boards are primed to achieve
maximum line speeds at low coating weights.
Figure 12: Effect of Air Gap on Adhesion of ExtrusionCoated LDPE to Non-Porous Substrates
In-line priming is the most economical method, as this

avoids additional unwind and rewind steps. Figure 14 shows
a schematic drawing of an in-line priming station. Effective
priming may also reduce the required melt temperature.
11
Primers can be solvent- or water-based and either curing

(reactive) or non-curing systems. There is no universal
primer; primer selection is specific to a particular
application and the final use of the laminated material.
Electrical Surface Treatment

Corona discharge treatment enhances the adhesion of
polyethylene to non-porous substrates. The treatment
is applied to the substrate prior to its entry into the nip.
Corona discharge treatment is particularly effective
with plastic films such as polyester and polyamide films,
oriented and cast polypropylene, and to a lesser extent
aluminium foils. It also has a beneficial effect with
paper substrates.
Ozone Treatment or Ozonisation

Ozone treatment is a technique sometimes used to
accelerate the oxidation of the polyethylene web,
especially with high speed coating lines where natural
oxidation is limited by the short time of the web in the air
gap. A stream of ozone-rich air from an ozone generator is
directed via an applicator slit onto the hot web just before
it enters the nip. The ozone, being a very strong oxidising
agent, creates polar groups on the polyethylene surface,
and very effectively improves the adhesion. The effect is
illustrated in Figure 9. Ozone treatment is mostly used in
combination with either or both corona treatment and
chemical priming.
The benefits of ozone treatment are:
Figure 14: Schematic Drawing of Typical Priming Station
Improved adhesion
The most common priming systems are:
Opportunity to reduce melt temperatures and hence

reduce the possibility of odour issues
Polyurethanes
excellent with aluminium foil

and plastic, very good with paper
Polyethylene imine
excellent with plastic films,

very good with paper
Polyvinylidene chloride
excellent with paper and

plastic film
Ethylene-acrylic acid
copolymer and ionomer
excellent with paper and

aluminium foil
The curing polyurethane systems generally offer the widest

range of adhesion and the best resistance to heat, moisture
and chemicals. The other primers all suffer limited
resistance to these environments.
12
Opportunity to run at higher line speeds, thus reducing

production costs
Opportunity to run lower air gaps whilst improving melt
stability and neck-in performance
Improved heat seal characteristics
In other words, ozone treatment improves adhesion and
minimises the negative effects associated with excessive
oxidation such as odour/taint, chill roll sticking and poor
heat sealing.
It should be noted that ozone is a toxic gas at high
concentrations. The web area should be enclosed and an
adequate ventilation system installed to remove the ozone
after contact with the web.
PROPERTIES OF EXTRUSION-COATED
LAMINATES
Frictional Properties
One of the important final properties of the coated
laminate is the ease with which it will slide or slip over
another surface, i.e. its coefficient of friction (COF).
A similar property is blocking, which is the tendency of
adjacent surfaces in intimate contact to stick to each
other, making separation difficult.
The COF and blocking of the coated polyethylene surface
are affected by such factors as coating temperature, chill
roll temperature, chill roll surface finish, overtreatment
during corona discharge treatment, and of course, the
presence or absence of slip and antiblocking additives in
the polyethylene.
Heat Sealing
Polymer density, MFI, film thickness and sealing conditions
all affect the sealability and the strength of the heat
seal bond.
Density controls the minimum temperature at which
sealing takes place and the amount of heat required to
meltthe polymer. Melting properties can be determined
by Differential Scanning Calorimetry (DSC) on different
grades, as shown in Figure 15. Density also has a minor
influence on the ultimate heat seal strength. However, it
should be noted that the density of the coating can be
significantly affected by thermal history (rate of cooling)
as dictated by the line speed and the chill roll temperature.
The use of different chill roll finishes allows the texture

of the coating to be varied. There a three types of chill
roll finish:
A matte finish, which results in a rough surface on
the polyethylene, a relatively low gloss, and a low COF
(high slip).
A highly polished mirror finish, which gives a very glossy
coating and increases the COF.
A mirror pocket finish, which induces some roughness
on the surface and a low COF like that obtained with
the matte roll, but with higher gloss like that from the
mirror roll.
Figure 15: Melting Point and Heat of Fusion for

AlkatheneLDPE Extrusion Coating Polymers.
(Determined by Differential Scanning Calorimetry)
The COF decreases as the polymer density increases. It

is relatively unaffected by the air gap distance but may
decrease slightly at low melt temperatures. A high coating
temperature and a highly polished chill roll can contribute
to blocking. Increased chill roll temperature will increase
slip and decrease blocking.
The polymer MFI and the film thickness are the principal
factors influencing the heat seal strength, as illustrated in
Figure 16.
If a coated substrate is to have a glossy coating on both

sides, then the use of a slip additive might be considered.
The slip additive blooms to the surface and significantly
reduces the COF. The effects of the additive on the taint
of the product must be reviewed as part of the decision
making process.
The strength of the seal while still hot is important

particularly with high speed automatic filling and
packaging machines, where the product is introduced into
the package almost immediately after the seal has been
formed. For instance, many paper board laminate seals
are under tension, with the tendency to reopen when the
sealing pressure is released. Sufficient melt strength is
required to ensure that the seal remains intact until it
cools. The hot tack strength is one measure of a polymers
performance in situations such as this. A strong bond over
as wide a temperature range as possible is indicative of
good performance.
Alkathene LDPE extrusion coating grades have good hot
tack properties which are illustrated in Figure 17.
13
Excessive oxidation of the polyethylene surface can lead

to difficult heat sealing. Such oxidation may occur in the
air gap between the die and the nip, or during corona
discharge treatment. However, some oxidation is necessary
to promote bonding to non-porous substrates.
Barrier Properties
An important function of any laminate is to provide a barrier
against a variety of gases, vapours or liquids. Polyethylene
generally provides a good to excellent barrier to such
materials and the performance will usually improve as the
density increases and the MFI decreases.
Improved barrier properties are also achieved as the
coating weight is increased. However, it is often more
satisfactory to incorporate in the laminate a material with
a much lower intrinsic permeability, such as polyester
film, polyvinylidene chloride film or aluminium foil. In such
laminates the polyethylene can still provide one or more
of the following functions:
Tear or puncture resistance
Adhesive layer between two other films
Heat sealability
Figure 16: Relationship between MFI Values, Heat Seal

Strength and Sealing Temperature
Table 2 illustrates typical gas water vapour transmission

rates through various 25 micron packaging films. Further
information about the permeability of films is given in the
publication: General Properties.
Food Contact Odour and Taint

Alkathene LDPE extrusion coating polymers are suitable
for use as polymer coatings in contact with foodstuffs.
They meet the requirements set down by the US Food and
Drug Administration (FDA) 21 CFR 177.1520 (c) 2.1 and the
Australian Standard AS2070- Plastics Materials for Food
Contact Use.
Alkathene LDPE extrusion coating polymers have been
usedover many years to give coatings of very low odour
andtaint; they are components of laminates used to
package a wide variety of foodstuffs including milk, fruit
juices, dried soups, etc.
Figure 17: Typical Hot Tack Strength Characteristics of

Alkathene LDPE Extrusion Coating Polymers.
Odour and taint are often caused by additives in the

polymer or by excessive oxidation of the polymer at the
hightemperatures used for extrusion coating. Alkathene
LDPE extrusion coating polymers are additive free. If
optimal processing temperatures are applied for these
polymers, then the problems from excess oxidation should
not arise. However, tolerances are fairly tight and should be
closely monitored at all times.
There is no apparent relationship between odour or taint
of the coating and parameters such as density and MFI.
14
Table 2: Relative Gas and Water Vapour Transmission Rates of Polyethylene and Other Packaging Films
Gas Transmission Rate
(for 25 micron film at 20C, 1 atm)
(cm3/m2, 24 h)
O2
N2
CO2
Water Vapour
Transmission Rate
(for 25 micron film
at 38C, 90% RH.)
(g /m2, 24 h)
Polyethylene
LDPE (0.920 g/cm3)
8500
3000
38000
18
Polyethylene
HDPE (0.960 g/cm3)
3000
650
9000
12000
6200
45000
70
Surlyn ionomer
6500
6500
30
Polypropylene Biaxially oriented
1900
500
5500
Film
Ethylene Vinyl Acetate

EVA Copolymer (18% VA)
Polypropylene PVdC coated BOPP
16
30
4200
750
10000
12
Polyethylene Terephthalate (PET)
60
15
250
25
Biaxially oriented nylon
20
180
Polyvinylidene Chloride (PVDC)
15
50
3.5
Ethylene Vinyl Alcohol* EVAL-E
1.8
0.15
Polypropylene, cast
* Moisture dependent
Printing and Gluing
Excellent sealability
If polyethylene-coated surfaces are to be printed with

inks or glued by an adhesive, a degree of oxidation of the
polymer surface is necessary to cause the ink or adhesive
to adhere. The oxidation can be obtained either by suitable
adjustment of the air gap or preferably by using corona
discharge treatment. Treating is best carried out in-line in
order to minimise handling of the coated rolls.
Excellent hot tack performance
Polymers containing slip or antiblock additives must be

treated in-line before the additive has time to bloom to
the surface of the coating.
ALKATUFF LLDPE FOR EXTRUSION COATING

Introduction
Linear low density polyethylene (LLDPE) is generally not
suitable for use in the extrusion coating process. LLDPE
has poorer processability in the extrusion coating process
due to its intrinsic rheological behaviour. However,
many of the properties of LLDPE would be beneficial for
extrusion-coated products, and these benefits are likely to
be achieved through the use of blends of LDPE and LLDPE.
Compared with LDPE of equivalent MFI and density, the
superior properties of LLDPE include:
Superior tear resistance

Greater abrasion resistance
Improved adhesion onto aluminium and polyester
Slightly lower water vapour transmission rate
Higher softening point and heat resistance
Higher drawdown, lower gauges possible
Draw Resonance
The main reason for the limited use of LLDPE in extrusion
coating is the problem of draw resonance which occurs
during the extrusion coating process above a critical flow
rate. Draw resonance is a surging or sustained cyclic
pulsation in the dimensions of the extruded web occurring
between the die and the nip. It can result in wide variations
in the coating thickness and the coating width, and
consequently can cause a major deterioration in the
product quality.
Draw resonance typically occurs with linear polymers
because of their non-strain-hardening (or strain-thinning)
characteristics in extensional flow. Conventional LDPE
polymers like Alkathene show an increase in extensional
viscosity with deformation and any disturbances in the flow,
15
such as an instantaneous thinning, tend to be self

restricting and stabilising. With LLDPE polymers like
Alkatuff, the extensional viscosity shows a much reduced
tendency to strain-harden and any disturbances will
propagate and create instabilities, which in the case of
extrusion coating is the phenomenon of draw resonance.
This difference in behaviour during extensional flow
between Alkathene LDPE and Alkatuff LLDPE polymers is
a consequence of the narrow molecular weight distribution
and linear (no long chain branching) molecular structure
in Alkatuff LLDPE compared with a wider molecular weight
distribution and significant long chain branching with
Alkathene LDPE.
Further information about the rheological differences
between Alkathene LDPE and Alkatuff LLDPE is given in
the publication: General Properties.
Draw resonance can be reduced by extruding at higher melt
temperatures, and at higher output rates and lower
drawdown speeds (to give a lower drawdown ratio and
thicker coatings).
16
Other Coating Characteristics

The extrusion of Alkatuff LLDPE grades is more challenging
than with Alkathene LDPE grades because of their higher
shear viscosity at extrusion shear rates. This means that
more extrusion power is required, greater melt
temperatures and pressures are developed, and as a
consequence, output rates may be limited. Special screw
designs and dies with wider gaps are recommended.
Further information is given in the publication: Extrusion.
Alkatuff LLDPE products have lower melt elasticity (and die
swell) than Alkathene LDPE products and this is a serious
limitation in extrusion coating, where high melt elasticity
is a requirement for low neck-in performance. Accordingly,
LLDPE polymers give high neck-in results. On the other
hand, because of the lower extensional viscosity and melt
strength of Alkatuff LLDPE products, its drawdown is
excellent, thus allowing lower coating thicknesses.
APPENDIX 1 TYPICAL LAMINATED FILMS

Construction
Benefits
Application
PE/kraft
Strong, water-proof, heat sealable, low cost with

excellent moisture resistance.
From heavy to light duty packaging.
PE/kraft/PE /kraft/
PE/kraft
Strong, water and moisture proof, chemical

resistant, good gas barrier properties.
Heavy duty packaging only (fertilizer, fodder,

cement, agricultural and industrial chemicals,
sugar, salt and grains).
PE/high quality paper
Moisture proof, low cost and heat sealable.

Good printing surface.
Light duty packaging. Simple moisture proof

packaging for pharmaceuticals, moistureabsorbing foods and ready-to-serve foods.
PE/glassine
Moisture-proof, good oil and chemical resistance,

semi- transparent and heat sealable.
Light duty packaging for oiled foods,

pharmaceuticals, candies and machine parts.
PE/Al foil
Excellent moisture barrier, gas barrier, UV light

barrier, outstanding fragrance preservation and
heat sealable.
Light duty packaging for pharmaceuticals,

candies, photo film packaging, industrial parts
and machine parts.
PE/Al foil/high
quality paper,
PE/Al foil/kraft,
Al foil/PE/Al foil,
PE/high quality
paper/Al foil.
Perfect moisture and gas barrier, chemical

resistance, heat sealable, light shading
and adaptable for automatic fill packaging.
Good printing surface.
Light packaging for moisture-absorbing foods,

detergent, candies, photo sensitive paper, photo
films, spices and food additives.
PE/Cast
polypropylene
PE/Oriented
polypropylene
Heat and oil resistance, moisture barrier, water

proof, see-through and heat sealable.
Light packaging for pharmaceuticals, candies,

oiled foods, moisture absorbing foods, table salt,
sugar, seasoned foods, preserved foods and
medical supplies.
PE/polycarbonate
Outstanding heat and oil resistance, moisture

and water proof, outstanding for low temperature
properties, see- through, excellent gas barrier
and heat sealable.
Light packaging for seasoned foods, preserved

foods, frozen foods. Also used in gas-fillpackaging and vacuum packaging for heat
sterilisation.
PE/polyester
High strength, water proof, moisture proof, gas

barrier properties, outstanding low temperature
properties, see- through and heat sealable.
Light packaging for seasoned goods, preserved

foods, processed meat, frozen foods, medical
supplies and ready-to-serve foods. Also used for
vacuum packaging for heat sterilisation and
gas-fill packaging.
Used in frozen foods, agricultural and fishery

products and other foods.
17
APPENDIX 2 EXTRUSION COATING TROUBLESHOOTING GUIDE

Problem / Issue
Cause(s)
Potential Solution(s) /Action(s)
Adhesion
Low melt temperature
Increase the melt temperature to help oxidise the surface and prevent
premature cooling
Increase back pressure in the extruder
Apple sauce
Air gap too low
Increase the air gap to get adequate oxidation of the surface
Line speed too high
Decrease the line speed to allow additional time in the air gap for
oxidation of the surface
Substrate surface untreated
Pre-treat substrate (such as corona treatment, flame treatment and

ozonation) or add a chemical primer to improve wettability
Pre-treatment ineffective
Inspect treatment method, adjust treatment settings as required,

ensure primer coverage is adequate and drying time is sufficient
Sticking to chill roll
Decrease the chill roll temperature
Low nip roll pressure
Increase the pressure of nip rolls, ensure pressure is evenly distributed
Air gap too high
Decrease the air gap to avoid premature cooling
Low chill roll temperature
Increase the temperature of the chill roll to help overcome

quick cooling
High melt temperature
Decrease the melt temperature to avoid thermal degradation,

decrease back pressure in extruder
Surface active additives (e.g. slip)
Modify the additive package
Inadequate resin selection
Ensure resin is compatible with substrate, lower viscosity

(high melt index) resins adhere better to porous substrates
Decrease the melt temperature
Inadequate mixing or poor

melt quality
Increase the back pressure of the extruder and use finer screen packs
Interfacial instability in coextrusion
Check flow properties of resins
Contamination
Ensure adequate purging time and cleaning of transfer lines

Check resin for any foreign material
Die Lip Build-Up
Additives
Decrease the melt temperature to avoid thermal degradation
Melt scraping against die lip
Machine the die lip

Change angle at which the melt contacts the chill roll
Excessive resin shear
Lower output
Increase the die lip temperature
Increase the die gap
Draw Resonance
High draw ratio
Decrease the die gap

Increase the coating weight
Edge Tear
Melt strength of polymer is too low
Select higher melt strength resin
High draw ratio
Decrease the die gap

18
Low melt temperature
Increase the melt temperature
Incorrect deckle settings
Decrease the off-set between internal deckle settings
Inadequate die design
Seek advice from manufacturer
Problem / Issue
Cause(s)
Potential Solution(s) /Action(s)
Edge Tear
continued
Melt strength of polymer is too high
Select lower melt strength resin
Splicing
Reverse splice direction, seek advice from machine manufacturer
Melt index too low for coating weight Use higher melt index resin
Gauge bands
Gels and voids
Decrease the melt temperature to increase melt viscosity
Dirty die
Clean the die to remove any build-up of material
Variation in temperature control
Check the temperature zones are running correctly and use flat
temperature profile
Inadequate die set-up
Adjust the die bolts accordingly
Poor melt quality
Moisture
Check raw materials for moisture (e.g. resin and substrate)

Ensure storage conditions are dry
Degradation of polymer

Check temperature zones are running correctly
Contamination
Ensure adequate purging time and cleaning of transfer lines

Check resin for any foreign material
Neck-in
Inadequate mixing
Dirty die
Clean the die to remove any build-up of material
High melt temperatures
High draw ratio
Decrease the air gap

Odour/Taint
Pinholes
Sealability
Surging
Melt strength of polymer is too low
Select higher melt strength resin
Decrease the melt temperature to reduce thermal degradation
Air gap too high
Decrease the air gap to reduce the time for oxidation of the surface
Additives
Substrate roughness
Use flame treatment on the substrate
Low coating weight
Dirty or damaged idler rollers
Inspect and clean the idler rollers or replace if necessary
Excessive tension
Decrease the tension accordingly
Decrease the melt temperature to reduce thermal degradation
Air gap too high
Decrease the air gap to reduce the time for oxidation of the surface
Additives (e.g. slip)
Modify the additive package as some additives may bloom

to the surface and contaminate the seal
Inadequate sealing conditions
Increase the sealing temperature or dwell time
Contamination
Clean the chill roll surface and limit handling of coating surface
Inadequate resin selection
Use higher melt index resin
Excessive corona treatment
Check treatment level and adjust if necessary
Inadequate screw design
Seek advice from manufacturer, increase back pressure in extruder
Inconsistent hopper feeding
Decrease the temperature at the feed zone to stop bridging
Disclaimer
The proposed solutions in this guide are based on conditions that are typically encountered in the manufacture of products from polyethylene.
Other variables or constraints may impact the ability of the user to apply these solutions. Qenos also refers the user to the disclaimer at the
beginning of this document.
19
BIBLIOGRAPHY/FURTHER READING
1. Bezigian, T.; Extrusion Coating Manual (4th Ed.), TAPPI Press, 1999.
2. Gregory, B. H.; Extrusion Coating: A Process Manual, Trafford Publishing, 2007.
3. Rolando, T. E.; Flexible Packaging Adhesives, Coatings and Processes, Volume 11, iSmithers Rapra Publishing, 2000.
4. Kouda, S.; Prediction of Processability at Extrusion Coating for Low-Density Polyethylenes, J. Polym Eng Sci, 48,
1094, 2008.
5. Sollogoub, C.; Montmitonnet, P.; Demay, Y.; Agassant, J. F.; Deparis, P.; Origin of the Bubble Defect in the Extrusion Coating
Process, J. Polym Eng Sci, 51, 347, 2011.
6. Hammond, F. M.; Hansen M. H.; Improving aluminum adhesion and heat seal performance of LDPE and LLDPE extrusion
coating resins, Tappi J., 74, 232, 1991.
7. Wagner, J. R. Jr; Handbook of Troubleshooting Plastic Processes: A Practical Guide, John Wiley and Sons, 2012.
8. Frey, K. R.; Optimising Time in the Air Gap in Extrusion Coating for Improved Adhesion, TAPPI Place Conference, 2012.
9. Ferrari, D.; Extrusion Coating Resins Troubleshooting, TAPPI PLC Conference, 2000.
Issued July 2015.
20
Polyethylene Technical Guide Series
01
GENERAL
PROPERTIES
05
INJECTION
MOULDING
TECHNICAL GUIDE
TECHNICAL GUIDE
02
06
EXTRUSION
TECHNICAL GUIDE
ROTATIONAL
MOULDING
TECHNICAL GUIDE
03
FILM EXTRUSION
AND CONVERSION
07
PIPE AND TUBING

EXTRUSION
TECHNICAL GUIDE
TECHNICAL GUIDE
04
EXTRUSION COATING
& LAMINATION
08
POLYETHYLENE
BLOW MOULDING
TECHNICAL GUIDE
TECHNICAL GUIDE
Qenos Pty Ltd

471 Kororoit Creek Rd
Altona Victoria 3018 Australia
Phone 1800 063 573
Fax 1800 638 981
ABN 62 054 196 771
qenos.com

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What is the extrusion coating process?

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How do processing conditions affect the properties of extrusion coated products?

04

4 EXTRUSION COATING AND LAMINATION

EXTRUSION COATING PROCESS TECHNOLOGY

The Extrusion Coating Process

The Air Gap

Nip Assembly and Chill Roll

Reeling and Wind-up Equipment

Coating Weight, Neck-in and Drawdown

Oxidation of the Polyethylene

Preheating the Substrate

Factors Affecting Adhesion

Electrical Surface Treatment

Ozone Treatment or Ozonisation

PROPERTIES OF EXTRUSION-COATED LAMINATES

Food Contact Odour and Taint

Printing and Gluing

ALKATUFF FOR EXTRUSION COATING

Other Coating Characteristics

APPENDIX 1 TYPICAL LAMINATED FILMS

APPENDIX 2 EXTRUSION COATING TROUBLESHOOTING GUIDE

Qenos Technical Guides

EXTRUSION COATING AND LAMINATION 4

Qenos Technical Guides

4 EXTRUSION COATING AND LAMINATION

GRADE SELECTION FOR EXTRUSION COATING

Extrusion coating is one of the processes used to produce

Alkathene LDPE grades are characterised mainly by their

Low density polyethylene (LDPE) is especially suitable

Note for convenience, the term Melt Flow Index or MFI is

The polyethylene coating provides increased tear

Figure 1: Influence of MFI and Density of Low Density

Qenos Technical Guides

EXTRUSION COATING AND LAMINATION 4

Some of the effects of MFI and density on the extrusion

EXTRUSION COATING PROCESS TECHNOLOGY

Figure 2: Typical Extrusion Coating Line for a

Qenos Technical Guides

tiny holes in the coating surface

small holes in the coating matrix

large voids giving the coating the

thin bands in the coating extending

lines in the coating in the machine

round or elongated clear spots which

rough, wavy appearance in the

All of the above defects are either detrimental to the

4 EXTRUSION COATING AND LAMINATION

working speed range, must be large enough to significantly

Uniformity of flow is preferably achieved by contouring

The Air Gap

Nip Assembly and Chill Roll

Figure 3: Typical Extrusion Coating Nip Roll Assembly

Qenos Technical Guides

EXTRUSION COATING AND LAMINATION 4

Reeling and Wind-up Equipment