Composite Laminated Film: Structure Design and Material Selection

Composite laminated film is built as a stack of layers rather than chosen as a single material. Each layer has one job, and structure design is the process of assigning those jobs deliberately. See the full specification on the Composite Laminated Film product page.

The three layer roles

Common structures include PET/AL/PE, PET/VMPET/PE and BOPP/VMCPP. The sequence matters as much as the materials.

Selecting the barrier layer

Barrier selection follows the product, not the artwork.

• Hygroscopic powders and granules need a foil core or a metallized layer to hold moisture out.
• Light-sensitive formulations need an opaque or metallized layer to block light and UV.
• Products with adequate stability margin can use a lighter structure and save cost.

Selecting the seal layer

The seal layer decides how the pack runs on the line.

• PE seals across a wide temperature window and is the general-purpose choice.
• CPP seals at lower temperature, which suits high line speeds and BOPP/VMCPP structures.
• Seal strength and peel behaviour should always be verified on the customer's own equipment.

Selecting the print layer

• PET gives stiffness and print definition, and is the usual outer layer.
• BOPP is lighter and is often paired with a VMCPP barrier and seal layer.

What we verify before supply

• Solvent residue, tested by gas chromatography after lamination
• Heat seal strength, tested with tensile testing per structure
• Coefficient of friction on both faces, to protect line feeding
• Reference layer densities: PET 1.40, AL 2.70, PE 0.92, CPP 0.90-0.91, VMPET 1.40, BOPP 0.90-0.93 g/cm³

Production environment

Printing, dry lamination and curing are managed as critical process steps in a D-class (100,000 class) cleanroom, with raw and auxiliary materials cleaned before entering the area.

A structure selection checklist

• Define the product's sensitivity first: moisture, oxygen or light.
• Choose the pack format: sachet, strip pack, pouch, wrapper or single-serve.
• Assign the barrier layer and confirm it against the sensitivity you defined.
• Assign the seal layer and check the sealing window against your line speed.
• Choose the print layer against the artwork and the ink system.
• Ask for seal strength, residue and friction data before commercial ordering.
• Run a line trial at production speed.

Next steps

Structures are designed per project rather than selected from a fixed list, and total thickness and width are customised to the format. Send us the product type, the format and the target shelf life through Contact Us, or review Composite Laminated Film for the specification.