Selecting the appropriate separation method depends primarily on the type of laminating film being used. Standard BOPP films are ideally suited to Burst Separation, whereas highly tear-resistant materials such as nylon (OPA) and selected PET films require a cutting separator. In practice, this means that commercial printers, publishing houses and manufacturing companies using a wide variety of laminating films for paper finishing and protection need access to both separation technologies..
Developed by ZFP, the DUO System eliminates the need to choose between them. It combines two complete, independent separation systems within a single laminator, allowing the operator to select the most suitable method for the laminating film used in each production run.
Why Was the DUO System Developed?
For many years, laminator users had to choose between the productivity of Burst Separation and the ability to automatically separate tear-resistant laminating films. In most applications, the Burst Separator remains the fastest and most economical solution. However, not all laminating films allow reliable sheet separation by controlled tearing.
The alternative is a Flying Knife Separator, which mechanically cuts the laminating film and therefore enables the separation of virtually all materials used in industrial lamination. This technology has its own practical limitation: its maximum productivity depends on the time required to complete each cutting cycle, which increases as sheet width becomes larger.
In practice, however, this limitation rarely reduces productivity when processing demanding laminating films. Materials such as nylon (OPA), thicker PET films and other speciality laminating films normally require lower laminating speeds for technological reasons. Their greater thickness or specific material properties require a longer contact time with the heated laminating roller to transfer sufficient heat and achieve optimum lamination quality.
It can therefore be assumed that when laminating with demanding films at speeds appropriate for those materials, productivity is not reduced and no production time is lost—the correct technology is simply being used for the application. However, a laminator equipped exclusively with a Flying Knife Separator must also operate at the speed characteristics of that separator when processing standard Burst laminating films.
It was precisely to meet the needs of users who wanted to combine the productivity of Burst Separation with the versatility of Flying Knife technology that ZFP developed the DUO System.
DUO System combining Burst and Flying Knife separation in one laminator
How Does the DUO System Work?
The DUO System combines two independent separation units within a single laminator. Importantly, both separators remain permanently installed and are always ready for operation.
The laminated web passes sequentially through both the Burst Separator and the Flying Knife Separator. Depending on the laminating film used, the operator simply selects the appropriate separation method for the current production job. No machine modification or web re-threading is required.
Each separator retains all of its own characteristics and operating capabilities. The Burst Separator delivers maximum productivity when processing standard BOPP laminating films, while the Flying Knife Separator provides reliable automatic separation of tear-resistant materials such as nylon (OPA), selected PET films and other speciality laminating films.
DUO Is Not a Compromise. It Is Two Complete Separation Technologies in One Laminator.
Most hybrid solutions combine different technologies by compromising their individual capabilities. The DUO System takes a different approach. It integrates two complete, independent separation systems—Burst and Flying Knife—while preserving the full functionality of each. The operator simply selects the separation technology best suited to the laminating film in use, without modifying the machine or compromising separation quality or productivity.
Comparison of Separation Technologies
* When processing films that require mechanical cutting, actual laminating speed is normally limited by technological considerations rather than by the Flying Knife itself.
Benefits of the DUO System
The greatest advantage of the DUO System is the ability to select the separation technology best suited to the laminating film without sacrificing productivity or process quality. The decision no longer has to be made when purchasing the laminator—both technologies are permanently available within the same machine.
In practice, this makes it possible to laminate both standard BOPP films and difficult-to-separate materials such as nylon (OPA), selected PET films and other functional laminating films, without concern that the separation process will unnecessarily slow down or complicate production. Every production job can therefore be planned using the most suitable materials while maintaining predictable production times.
Because both separation systems retain their complete functionality, the DUO System avoids the compromises typically associated with hybrid designs. Both the Burst Separator and the Flying Knife Separator operate with the same capabilities as they do in dedicated machines designed exclusively for one technology.
Where Does the DUO System Deliver the Greatest Benefits?
The DUO System has been developed for manufacturers processing a wide variety of laminating films as part of a diverse production programme. It offers the greatest advantages wherever production frequently requires switching between different separation technologies.
Because Flying Knife productivity is ultimately limited by cutting cycle frequency, the DUO System is primarily intended for laminators with larger sheet widths and higher production speeds. In practical terms, this applies to sheet widths from approximately 740 mm and laminating speeds of around 30 m/min or higher. These conditions are typical of B1-format laminators and machines such as the Jupiter Landscape (740 × 740 mm), where the ability to select the appropriate separation technology maintains high productivity when processing both standard and speciality laminating films.
By contrast, in B3 and B2 laminators—with their narrower sheet widths and typical production speeds of up to 20 m/min—the productivity of the Flying Knife Separator remains fully sufficient, making investment in the DUO System generally unnecessary.
Summary
For many years, laminator users had to choose between the productivity of Burst Separation and the ability to automatically separate tear-resistant laminating films. The DUO System removes this limitation by combining two complete separation technologies within a single laminator.
Instead of compromising between different separation methods, operators can simply select the technology best suited to the laminating film being processed. As a result, a single laminator can efficiently handle both standard BOPP laminating films and materials requiring mechanical cutting, while preserving the full performance of both separation systems.
Related Articles
- Flying Knife Separator – How It Works, Benefits and Applications
- Burst Separator – Operating Principle, Benefits and Applications
- Nylon (OPA) Laminating Films
- How to Choose the Right Laminating Film