Understanding the Differences: Wet vs Thermal Lamination Techniques

In the world of print finishing, lamination is the go-to solution for enhancing the durability, appearance, and functionality of printed materials.  But when considering Wet vs Thermal Lamination, the difference can have a significant impact on both the production process and final product.  Whether you’re a print buyer, designer, or production manager, understanding the nuances of these two lamination methods can help you make smarter, more cost-effective decisions.

What is Lamination?

Lamination is the process of applying a thin plastic film to the surface of printed materials to protect them from wear and tear, moisture, and contaminants.  It also adds aesthetic value through gloss, matt, soft-touch, or textured finishes.

There are several techniques to achieve this, but two of the most widely used methods are wet lamination and thermal lamination.

Wet Lamination: An Overview

How It Works

Wet lamination involves applying a liquid adhesive to the lamination film, which is then cooled and reheated before being pressed onto the printed sheet or substrate. The film is then pressed onto the printed sheet under heat and pressure, bonding the layers together.  After lamination, the sheets require time to dry or cure, depending on the adhesive used.

Key Characteristics

• Adhesive-based: Uses solvent or water-based glues.
• Slower process: Requires drying time and additional handling.
• Superior bond strength: Especially useful for high-volume production and packaging, used with additional additives.

Applications

• High volume runs
• Labels and folding cartons
• High-volume and luxury packaging
• Industrial or food-grade packaging that requires strong, lasting adhesion
• Business cards
• Menus and restaurant materials
• Brochures and flyers
• Point-of-sale displays
• Book covers

Pros

• Excellent bond to a variety of substrates
• Can be used with films that are not heat-activated
• Often results in higher clarity and surface smoothness

Cons

• Requires more complex equipment
• Needs a curing/drying stage
• Longer setup and cleanup times
• More sensitive to humidity and environmental factors

Thermal Lamination:  An Overview

How It Works

Thermal lamination uses a pre-coated film with a heat-activated adhesive.  The film and printed material are fed through heated rollers, melting the adhesive and bonding the film to the paper or board.

Key Characteristics

• Adhesive is built into the film
• Fast and clean process
• Ideal for on-demand and short-run printing

Applications

• Book covers
• Business cards
• Menus and restaurant materials
• Brochures and flyers
• Point-of-sale displays
• Labels and folding cartons
• Luxury packaging
• Industrial or food-grade packaging that requires strong, lasting adhesion

Pros

• Quicker turnaround times
• Cleaner application with less mess
• Fewer consumables needed (no separate adhesive)
• Simpler operation for in-house use

Cons

• Slightly weaker bond than wet lamination on certain surfaces
• More prone to delamination under extreme bending or exposure to moisture.
• Slightly limited compatibility with very high ink coverage or UV coatings

 Head-to-Head Comparison

At Gif Products, we supply a wide range of lamination films suitable for both wet and thermal techniques, offering flexibility, quality, and performance to suit any job.

Need Expert Advice?

Whether you’re setting up an in-house lamination system or looking for the best film for a specific job, our team is here to help.  Get in touch with us and let us guide you to the perfect solution.