Manufacturing, Engineering and Technology Manufacturing and Assembly

Laminated Paper And Board Production Techniques Training

SAQA US 110085 | NQF 2 | Credits 15 | Duration 12 Days
From $2,214 per delegate

Description

This course equips learners with the knowledge and skills required to produce laminated paper and board products in a manufacturing environment. It covers the entire production process from material preparation to quality control, ensuring compliance with industry standards and safety regulations.

Learning Outcomes

  • Apply principles of lamination to paper and board substrates using appropriate adhesives and techniques.
  • Demonstrate correct setup and operation of lamination machinery including coating, drying, and finishing equipment.
  • Analyze product specifications and adjust process parameters to achieve required quality and performance.
  • Evaluate laminated products against quality standards using physical and visual inspection methods.
  • Implement safety and environmental procedures relevant to lamination processes and material handling.

Target Audience

Production operators, machine setters, and supervisors in the paper and board converting industry who are responsible for laminated product manufacturing.

Prerequisites

None — open enrollment.

Course Outline

Day 1: Introduction to Laminated Paper and Board Production

Objectives:
• Understand the scope and significance of laminated paper and board in packaging and printing.
• Identify key raw materials and their properties.
• Explain the basic principles of lamination.
• Recognize safety and quality standards in the industry.

Topics:
• Overview of laminated paper and board products.
• Raw materials: paper, board, adhesives, coatings.
• Basic lamination processes: wet, dry, solventless.
• Quality parameters: bond strength, appearance.
• Health, safety, and environmental considerations.
• Industry standards and regulations.

Day 2: Raw Materials and Adhesives

Objectives:
• Describe types of paper and board substrates.
• Compare adhesive types: water-based, solvent-based, hot-melt.
• Explain adhesive selection criteria.
• Discuss storage and handling of materials.

Topics:
• Paper and board grades and specifications.
• Adhesive chemistry and properties.
• Selection criteria for adhesives.
• Material storage and shelf life.
• Quality testing of raw materials.

Day 3: Lamination Processes – Wet and Dry

Objectives:
• Differentiate between wet and dry lamination.
• Describe the steps in wet lamination.
• Describe the steps in dry lamination.
• Identify process parameters and their effects.

Topics:
• Wet lamination process: coating, drying, laminating.
• Dry lamination process: adhesive application, solvent removal, nip.
• Process parameters: temperature, pressure, speed.
• Common defects and troubleshooting.
• Equipment overview: coaters, dryers, laminators.

Day 4: Solventless and Extrusion Lamination

Objectives:
• Explain solventless lamination principles.
• Describe extrusion lamination process.
• Compare advantages and limitations.
• Identify applications for each method.

Topics:
• Solventless lamination: adhesives, mixing, application.
• Extrusion lamination: extruder, die, chill roll.
• Process control and quality.
• Applications: flexible packaging, labels.
• Environmental and safety aspects.

Day 5: Coating and Surface Treatments

Objectives:
• Explain coating techniques for paper and board.
• Describe surface treatments: corona, flame, priming.
• Understand the role of coatings in barrier and printability.
• Identify coating defects.

Topics:
• Coating methods: roll, blade, gravure.
• Coating formulations: waterborne, solventborne, UV.
• Surface treatments for adhesion enhancement.
• Barrier coatings: moisture, oxygen, grease.
• Coating quality and defect analysis.

Day 6: Quality Control and Testing

Objectives:
• List key quality parameters for laminated products.
• Describe testing methods for bond strength, peel, and seal.
• Explain statistical process control (SPC).
• Implement corrective actions.

Topics:
• Quality standards: ASTM, ISO, SANS.
• Testing equipment: peel tester, tensile tester, seal tester.
• In-process and final product testing.
• Statistical process control basics.
• Root cause analysis and corrective actions.

Day 7: Troubleshooting and Defect Analysis

Objectives:
• Identify common lamination defects.
• Analyze causes of defects.
• Implement troubleshooting procedures.
• Optimize process parameters.

Topics:
• Defect types: wrinkles, bubbles, poor adhesion.
• Cause-and-effect analysis.
• Troubleshooting guides.
• Process optimization techniques.
• Case studies.

Day 8: Equipment Maintenance and Safety

Objectives:
• Describe routine maintenance for lamination equipment.
• Explain safety protocols and PPE.
• Identify hazards and risk mitigation.
• Perform basic maintenance checks.

Topics:
• Preventive maintenance schedules.
• Cleaning and lubrication.
• Safety systems: emergency stops, guards.
• Lockout/tagout procedures.
• Fire safety and chemical handling.

Day 9: Environmental and Sustainability Considerations

Objectives:
• Discuss environmental impact of lamination.
• Explain waste reduction and recycling.
• Describe sustainable materials and practices.
• Understand regulatory compliance.

Topics:
• Waste management: scrap, solvents, adhesives.
• Recycling of laminated products.
• Biodegradable and compostable options.
• Environmental regulations (NEMA, etc.).
• Life cycle assessment basics.

Day 10: Advanced Lamination Techniques

Objectives:
• Explore specialty laminations: metallized, holographic.
• Understand multi-layer and high-barrier laminates.
• Describe digital and customized lamination.
• Identify emerging trends.

Topics:
• Metallized and holographic films.
• High-barrier structures: aluminum foil, EVOH.
• Digital printing and lamination integration.
• Smart packaging and active laminates.
• Industry 4.0 in lamination.

Day 11: Production Planning and Optimization

Objectives:
• Plan production runs for efficiency.
• Optimize material usage and reduce waste.
• Apply lean manufacturing principles.
• Manage changeovers and scheduling.

Topics:
• Production planning: order of runs, setup reduction.
• Lean tools: 5S, Kaizen, value stream mapping.
• Waste reduction strategies.
• Scheduling and workflow.
• Key performance indicators (KPIs).

Day 12: Integration and Final Assessment

Objectives:
• Synthesize knowledge from all days.
• Demonstrate practical skills in a simulated production scenario.
• Complete a comprehensive assessment.
• Create an improvement plan for own workplace.

Topics:
• Review of key concepts.
• Simulated production exercise.
• Written and practical assessment.
• Feedback and discussion.
• Action plan for continuous improvement.

Practicals

36 hours of practicals To be conducted online or on-campus or in-house
Overview

Practical sessions are integral to this course as they allow learners to operate lamination equipment, perform quality tests, and troubleshoot defects under supervision. Hands-on experience ensures competence in machine setup, adhesive application, and process control.

Practical Activities
  • Practical 1: Equipment Familiarization and Setup — Learners identify main components of a laminator, perform startup checks, and set up for a wet lamination run. (8h)
  • Practical 2: Lamination Process Operation — Learners run a wet lamination and a dry lamination process, adjusting parameters to achieve target bond strength. (10h)
  • Practical 3: Quality Testing and Defect Analysis — Learners conduct quality tests on laminated samples, identify defects, and propose corrective actions. (8h)
  • Practical 4: Troubleshooting and Maintenance — Learners troubleshoot simulated machine faults and perform routine maintenance tasks. (6h)
  • Practical 5: Production Simulation and Optimization — Learners plan and execute a short production run, optimizing for minimal waste and maximum efficiency. (4h)

Summatives

Each delegate is assessed continuously throughout the course via daily exercises, scored practical assignments, and a final summative test at the end.

Practical Assignments — 30%

Practical assignments are observed and scored against a rubric during the practical sessions. Each delegate's practical mark is averaged into a single 100% score and contributes 30% to the final total.

Daily Exercises — 20%

Every training day ends with a multiple-choice exercise scored out of 100%. The scores from each daily exercise are averaged across the duration of the course to produce a Daily Average mark, which contributes 20% to the final total.

Final Test — 50%

On the last day a final summative test is written. It is a multiple-choice paper with multiple-answer questions: each question may have more than one correct option, and a single wrong selection on a question marks the entire question wrong — no partial credit. The final test is scored out of 100% and contributes 50% to the overall mark.

Final Total
Component Out of Weight
Practical Assignments (rubric-scored) 100% 30%
Daily Average (multiple choice) 100% 20%
Final Test (multi-answer multiple choice) 100% 50%
Final Total 100%

All marks are recorded on the AATICD LMS and visible to each learner under their account.

Certificate

Certificate of Completion

Awarded to delegates who achieve an overall mark of 50% or higher on the Final Total (Practicals 30% + Daily Average 20% + Final Test 50%).

How it works
  • Certificates are auto-generated on the AATICD LMS as soon as the marks pass the 50% threshold.
  • Each certificate is a branded PDF with the delegate's name, the course title, the unit standard ID, NQF level, credits, and the date of issue.
  • You can download or print your certificate from your LMS dashboard at any time after issue — there's no reissue fee and no expiry date.
  • If you scored under 50% you can sit the final test again at the next scheduled session at no extra cost.
Where to find it

Sign in to the LMS, open your dashboard, and your certificates appear under My Certificates. Each entry has a View / Download button and a print option.

Training Discounts

Group discounts apply automatically — the more delegates you enrol, the greater the saving. Discounts are calculated at 3% per 5 delegates, scaling up to 40% off for 100+ delegates.

Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% discount per 5 delegates, up to 40% off for 100+ delegates. Contact us for a custom group quote.

Upcoming Training Sessions
Online training — attend live sessions from anywhere via our virtual classroom.
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Training Discounts
Delegates Discount
5 3% off
10 6% off
15 9% off
20 12% off
25 15% off
30 18% off
50 30% off
75 35% off
100 40% off

3% off per 5 delegates, up to 40% for 100+

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