Lamination refers to the process of bonding a transparent plastic film to printed box paper through heat, pressure, or both. This finishing technique enhances surface protection, increases gloss, and strengthens durability. As a post-printing process, lamination has become widely adopted in custom packaging because it effectively extends the lifespan of boxes, improves scratch resistance, and elevates overall visual appeal.
For the best results, lamination requires packaging materials with smooth, clean surfaces and consistent thickness. Substrates such as white cardboard and coated paper are ideal because they offer strong fold resistance and allow the film to adhere evenly.
Common Lamination Materials
1.BOPP Film
BOPP (Oriented Polypropylene) film is an economical and highly transparent option. However, it is prone to static electricity and therefore best suited for short-term promotional packaging or other low-cost applications. It is not recommended for high-temperature or outdoor environments.
2. PET Film
PET (Polyester) film is food-grade safe and commonly used in fast-food and ready-to-eat packaging. While it offers excellent durability and clarity, its cost is higher, and it should not be used in applications requiring high material stretchability.
3. PVC Film
PVC film is flexible and easy to apply, making it suitable for shrink wrapping or curved-surface lamination. However, its poor environmental friendliness and inability to meet food-contact standards significantly limit its usage.
Types of Lamination
1. Gloss Lamination
Gloss lamination in custom packing boxes features a shiny, highly reflective surface that enhances color vibrancy and delivers strong visual impact.
2. Matte Lamination
Mate lamination provides a soft, non-reflective finish with a premium and understated appearance. Often used for custom luxury, cosmetics, and high-end retail packaging.
3. Soft-Touch Lamination
Soft-touch lamination is a subtype of matte lamination, offering the same non-glare look on the box surface but with a velvety, tactile surface. Ideal for premium brands seeking a refined, sensory experience.
| Category | Gloss Lamination | Matte Lamination | Soft-touch Lamination |
|---|---|---|---|
| Touch & Feel | Smooth and glossy; slick surface with a shiny texture. | Slightly coarse with a non-reflective, matte touch. | Velvety, silky, and ultra-smooth texture; premium tactile experience. |
| Printing Protection | Protects against scratches, dirt, and abrasion; increases surface durability. | Better fingerprint resistance and improved anti-scratch performance. | Offers excellent resistance to fingerprints and scuffs while adding a tactile layer. |
| Visual Appearance | High-gloss, reflective finish that boosts color brightness and visual impact. | Soft, muted, and elegant appearance with a low-glare finish. | Deep matte appearance with a sophisticated, luxurious look; enhances brand perception. |
| Box Applications | Cosmetic boxes, promotional packaging, colorful retail boxes requiring strong visual shine. | Luxury boxes, minimalist packaging, boutique boxes, and premium product boxes. | High-end gift boxes, luxury brand packaging, electronics boxes, fragrance boxes, and exclusive limited-edition packaging. |
Challenges Facing Lamination in Packaging
As consumer expectations rise and environmental awareness grows worldwide, traditional lamination technologies are under increasing scrutiny. Although lamination remains popular for its protective and aesthetic functions, several issues are influencing its decline in certain markets.
1. Pollution During the Lamination Process
Many manufacturers—especially in developing regions—still rely on solvent-based lamination adhesives containing benzene, alcohols, and other volatile chemicals. These substances pose health risks to operators, create strong odors, and increase fire hazards due to high flammability.
2. Lamination Residue on Finished Products
Chemical residues from adhesives do not fully evaporate immediately after lamination. This means the finished packaging may carry odors or harmful substances, potentially affecting consumers—especially in applications involving cigarettes, alcohol, or food.
3. Limited Recyclability
Currently, laminated paper is difficult to recycle efficiently. The plastic layer must be separated from the paper fibers, which requires specialized equipment and increases the cost of recycling.
4. Production Challenges
Single-side lamination can cause warping or curling, while double-side lamination can complicate die-cutting and post-press operations. Shrinkage differences between film and paper also affect stability.
5. Lower Productivity and Higher Cost
Since lamination speed is limited by film tension and machine capability, it is generally slower and more costly than varnishing or coating processes.
Alternative Methods of Lamination
To balance visual appeal, cost efficiency, and protective performance, brands can also combine multiple finishing techniques. A full-area varnish can be applied first to ensure an overall smooth touch and improved environmental performance. Then, selective lamination or spot UV can be added to the logo or key graphics to enhance depth, highlight focal areas, and increase surface durability. This hybrid approach not only creates a strong visual centerpiece but also keeps production costs under control—making it a smart finishing strategy for modern custom packaging.
As a dedicated packaging manufacturer, we provide a full range of finishing options from lamination and UV to varnishing, embossing, and specialty textures. It allows you to customize every detail of your box. With advanced equipment and strict quality control, we help global brands create packaging that is both beautiful and production-ready. If you are looking for reliable finishing solutions, our team is here to support your next project.
