WPR-TAKA Academy

Technical training
Suggestions for the lamination
of PVC profiles

2020
About us
 WPR

WPR is the leading company in the design and

manufacturing of innovative wrapping
machines and completely automatic smart
systems for profiles and panels.
We are present in more than 25 countries in 4
continents.

WPR 3
 1
TAKA
TAKA offers high quality polyurethane HMPUR and polyester
adhesives for interior (furniture) and exterior (windows) application
and other industries such as bookbinding, caravan etc.
2
Three modern advanced production units offer the best production
capacity, perfect timing and highest quality.
TAKA assures the integration of the complete production process from
the raw material to the final product.
3

TAKA 4
 MAJOR SYSTEM
MAYOR SYSTEM SALES
SALESSINCE
SINCE2000
2000
BELGIUM 16

FRANCE 18

SPAIN 21

TURKEY 26

GREAT BRITAIN 38

ROMANIA 38

POLAND 58

GERMANY 71

ITALY 107

RUSSIA 19

CZECH REPUBLIC 20

SLOVAKIA 11

We Are Here 5
WPR / TAKA ACADEMY
Trainings:

Application Control of the Quality control

parameters process
 Personalized teaching programs

Multiple topics

In the classroom or in production

Decades of experience with exstensive

experise

Immediate return on investment

WPR / TAKA ACADEMY 7

 WPR/TAKA gives 360° attention and
support to its customers

WPR/TAKA is the only company

worldwide to combine the design
and performance of wrapping
machinery with a high quality state-
of the art adhesive technology,
resulting in unrivalled application
expertise of the lamination process.

Synergy 8
THE WRAPPING PROCESS
2020

www.wpr.it
www.taka.it
academy@wprtaka.it
 Wrapping means applying various foil types (PVC, PP, PET, ABS/PMMA) onto
(PVC, PP, Aluminium, HPL) profiles.

Wrapping: Definition 10
 1. • PVC, PP, PET, ABS foils in coils

2. • HMPUR + primer

3. • PVC Profile

Wrapping: Materials 11
 COMPOSITION OF FOIL FOR EXTERIOR APPLICATION: WINDOWS&DOORS

• A base PVC layer which is either a solid colour or a printed design.

• a second layer which is a protective transparent layer made of polymethylmethacrylate

(PMMA) which protects the foil by absorbing more than 95% of UV radiation.

Protective trasparent layer (PMMA)

Printing ink

PVC Pigmented base film

Materials: Foil composition 12

 PVC extruded profiles need to be pre-treated with primer
before being wrapped, in order to clean the surface of
lubricants and waxes and to chemically enable the bonding.

Aluminium profiles must be coated with PE (poliester) or

PU (poliurethanic) powder paint.

Materiali: Profiles and panels 13

 According to the European rule: EN 923

Adhesive: non-metallic substance capable of

joining materials by surface attachment
(adhesion) so that the bond obtained
possesses adequate internal strength
(cohesion).
The raw material used to produce adhesives
comes from organic materials described as
resins and polymers with different molecular
weight

Adhesive definition 14
 Support
cohesion

Adhesion

Adhesive
Pattern of the cohesion

bonding process Adhesion

support
cohesion

Pattern of the bonding process – Adhesion vs cohesion 15

 Immediately ( Phisycal Adhesion) After crosslinking (Chemical Adhesion)

FOIL

PROFILE PROFILE PROFILE

Glue cohesion failure Foil cohesion failure Foil cohesion failure

FOIL ✓j ✓j ✓j
PROFILE

FOIL FOIL

PROFILE PROFILE
No glue transfer (Glue stay Transfer of glue (Glue
on foil) completely on profile)

X X
First 5 min after wrapping Days Time
Pattern of the bonding process – Adhesion vs cohesion 16
 Drying and Priming
Glue application heating
2 Profile
4 3 preparation
Wrapping area 1
5
Quality control
6

Wrapping machinery 17
 1. Profile preparation
1.1 Profile cleaning
1.2 Deionization
1.3 Pre-heating
2. Priming
2.1 Wettability
2.2 Primer application
2.3 Types of primer and dosage
3. Drying and heating
3.1 Purpose of the primer
3.2 Drying of the primer
3.3 Heating of the profile
5. Wrapping area
5.1 Open time
5.2 Ideal temperatures at the first pressing roller
5.3 Pressing wheels and air heaters set up
5.4 Initial bond strength
5.5 Temperature after the pressing area
6. Quality control
6.1 Physical and chemical adhesion
6.2 End of the machine
6.3 Lab tests and certification

4. Glue application
4.1 Adhesive definition
4.2 Feeding system
4.3 Adhesive application
4.4 Cleaning of the system
4.5 Viscosity
4.6 Stability
4.7 Temperature and humidity

Table of contents 18
 1
Profile preparation

1.1 Profile cleaning

1.2 Deionization
1.3 Pre-heating

1. Profile preparation 19
 1 Dirt and water on the profile lead to
a wrong application of the primer

Dirt on the profile Water on the profile

1. Profile preparation: 1.1 Priming 20

 1 Elettrostatic charges attract dust
particles to the surface disrupting the
primer applcation

Deionizers

1. Profile preparation: 1.2 Deionizers 21

 When the profile temperature drops below 18°C, it is
necessary to increase it as follows:
1
• MTK and MEK based primer from 18 to 25°C

• Low VOC primer from 25 to 35°C

Profile
✓j Profile
✓j
1. Profile preparation: 1.3 Pre-heating 22
 2
Priming area

2.1 Wettability
2.2 Primer application
2.3 Types of primer and
quantity

2. Priming area 23
What is the purpose of the primer?

The aim of the primer is to increase the wettability of PVC foils and profiles.

The wettability of a liquid is the ability to lie completely

on a flat horizontal surface of a solid. The wettability is
measured in dyne / cm

Surface
energy

24

2. Priming area: 2.1 Wettability 24

 Low wettability
Surface energy of the adhesive

High wettability

Surface energy of the support

2. Priming area: 2.1 Wettability 25

Contact angle

1. Low
Wettability 2. High
Wettability

1. α > 90° the liquid (adhesive) doesn’t wet the surface (e.g. mercury on glass);
2. α < 90° the liquid (adhesive) wets the surface (e.g. water on glass).
α= 0° the liquid completely wets the wall.

Example of 2 PVC foils / PMMA

Surface Surface
Average
Average Energy Energy
Contact Surface Energy
PVC Foil Contact Dispersive Polar
Angle (mN/m)
Angle CH2I2 component component
H2 O
(mN/m) (mN/m)
“Good” 88.2° 43.3° 39.4 37.9 1.5
“Bad” 105.8° 53.5° 32.3 32.3 0.0

2. Priming area: 2.1 Wettability 26

 2
Felt must be correctly positioned following the
geometry of the profile. Is important to cover the
entire surface.

The most common primer application is by FELTS

2. Priming area: 2.1 Primer application 27

 2

Too much
4 3 primer

2 2 1 1

Felt Area with double amount

of primer, the primer here
is applied 4 times
Felt

Profile DO NOT overlap

multiple felts

2. Priming area: 2.1 Primer application 28

 Inflammable solvent based (MEK) 20 - 25 g/m² Very fast
Non flammable solvent based
20 - 25 g/m² Very fast
(Methylene Cloride)
Low or 0% VOC non flammable
6 - 8 g/m² Medium - low
solvent

Primer right dosage is crucial. Low or free VOC primers must be applied with automatic primer
dosing systems. The length of the primer zone on the machine must be dimensioned based on the
type of primer used

TYPE OF PRIMER USED LENGTH OF THE PRIMER ZONE

Traditional primer 1.5 - 2 m
Low/free VOC primer (ecological primer) > 3.5 m

2. Priming area: Types of primer and dosage 29

 171 171M WPN10 WPN3
Application Very good Very good Good Good

Drying Very fast Fast Medium low Medium low

Harmfull
No lable
H361 Suspect of
causing cancer
H373 May cause H225 Highly H314 Causes severe H319 Causes
Hazard statements damage to organs flammable liquid skin irritation and serious eye
through prolonged and vapour eye damage irritation
or repeated
exposure
VOC
0% 30%
(Volatile organic 100% 100%
with NOP without Pyrrolidone
compounds)

2. Priming area: Types of primer and dosage 30

 MANUAL PRIMER DOSAGE

Exact primer dosage cannot be measured.

Large primer waste/overdosage.
NOT SUITABLE FOR LOW VOC PRIMER

AUTOMATIC PRIMER DOSAGE

• AUTOMATIC DOSAGE ACCORDING TO THE SPEED
• SAVING OF PRIMER with consequent ecological advantages
• PRECISE DOSAGE: gr/m2 based on the width to be treated, essential
for the application of new generation ecological primers
• DOUBLE TANK FOR FAST CLEANING OF THE SYSTEM

2. Priming area: Types of primer and dosage 31

 3
Drying and heating area

3.1 Purpose of the primer

3.2 Drying of the primer
3.3 Heating of the profile

3. Drying and heating area 32

 3

The empty space between the last felt and the first air
heater necessary for the primer to penetrate in the
profile depends on the primer used:

MEK and DCM

0,5 m/2-3sec (10-15m/min)

LOW VOC primer

0,8 -1m /5 sec (at 10-15m/min)

3. Drying and heating area: Purpose of the primer 33

 3

BEFORE PRIMER APPLICATION

PROFILE SURFACE

PROFILE AFM picture

3. Drying and heating area: Purpose of the primer 34

 3
The bonding surface increases

AFTER PRIMER APPLICATION

PROFILE SURFACE

PROFILE AFM picture

3. Drying and heating area: 3.1 Purpose of the primer 35

 3
Rifare foto

Primer must be dried correctly to avoid bubbles

appearing after the wrapping process.
This can be achieved by:

• Direct air heaters towards the slot nozzle in

order not to dry the felts.

• Increase the amount of air heaters when

using low VOC primer

3. Drying and heating area: 3.2 Drying of the primer 36

 3

IR lamps should be positioned after

the air heaters before the slot nozzle
so that the profile temperature right
before wrapping reaches 45-55°C

3. Drying and heating area: 3.2 Heating of the profile 37

 3 IR lamps vs hot air blowers

AIR HEATERS

Hot air
Air heaters
heat the
surface
80 % of the heat gets lost within 10 - 20 cm

IR LIGHT

IR lamps
heat
penetrates
into the
profile 80 % of the heat gets lost within 50 - 100 cm

3. Drying and heating area: 3.2 Heating of the profile 38

 4
Glue application

4.1 Adhesive definition

4.2 Melting system
4.3 Adhesive application
4.4 Cleaning of the
system
4.5 Viscosity
4.6 Stability
4.7 Temperature and
humidity

4. Glue application area 39

 HMPUR
Hot Melt PoIyurethane Reactive
o
HMMC
Hot Melt Moisture Curing

4. Glue application area: 4.1 Adhesive definition 40

Taka adhesive production

HMPUR series :
1308.1
1308.2R – .2RF
1308.20 – .20F

NCO-R-NCO + HO-R-OH = Certifed

MDI POLYESTHER Products RAL- GZ 716

4. Glue application area: 4.1 Adhesive definition 41

HMPUR crosslinking inside the warehouse

NCO-R-NCO + H 2O =
TAKA adhesives Enviromental humidity
Final product in the warehouse

4. Glue application area: 4.1 Adhesive definition 42

 4

• Continuous process • Continuous process • Discontinous process

• Melt rate up to 25 kg/h) • Melt rate up to 18 Kg/h • Melt rate from 35 up
• Glue can stay longer in the to 90 kg/h
melter

4. Glue application area: 4.2 Melting systems 43

 4

1 2 3

Turn the cartridge

Insert 5-10-20kg glue cartridges with 4 5 6

the top upwards.

4. Glue application area: 4.3 Adhesive application 44

 4

Melter temperature range : 100 - 140°C

Setting a lower temperature in

the melter and a slighly higher
temperature at the slot nozzle Hose temperature range: 130 - 140°C
increases the stability of the
glue (avoiding skin build up).

Slot nozzle temperature range: 140 - 150°C

4. Glue application area: 4.3 Adhesive application 45

 4

Adhesive application quantity range from 40

g/m2 to 60 g/m2 for both PVC and Aluminium

4. Glue application area: 4.3 Adhesive application 46

How to check the quantity of glue

• Regularly check the quantity of glue applied on the foil, to

verify if the parameters set on the machine are correct. IF
THE MELTER/HOSE ARE DIRTY THE GLUE QUANTITY WILL
DIFFER FROM THE VALUE SET ON THE MACHINE

• Weighing can be done placing a piece of silicon paper on

the profile. Glue doesn’t adhere on silicon paper so it can
easily be peeled off and weighed

• Alternatively use a digital micrometer. Measure the foil

thickness before and after the glue application
50 grams = 50 micron = 0,05 mm)

4. Glue application area: 4.3 Adhesive application 47

 4
Dry lines on the foil

4. Glue application area: 4.4 Cleaning of the system 48

 If filters are clogged all particles between 40-150micron get stuck
4
in the slot nozzle creating lines

120-150
micron filter
TAKA Client
F
production production
500 micron = 0,5mm

Heated
hose Zoom in

40 micron F
filter F
120-150 micron
filter Colla

4. Glue application area: 4.4 Cleaning of the system 50

 4

Glue cured in the melter goes through the pump and

Clean melter
ends up on the profile surface

4. Glue application area: 4.4 Cleaning of the system 51

 4

Glue
Glue

Glue

4. Glue application area: 4.4 Cleaning of the system 52

WITHOUT heating WITH the heating
resistance the glue is resistance the glue
temperature is < 60°C and temperature is above
can’t melt. 100°C and can melt.

4. Glue application area: 4.4 Cleaning of the system 53

The ability of an adhesive to wet depends on its viscosity.
Viscosity is the frictional force of a fluid while passing through an
object.
It ‘s a measure that depends on the characteristics of the fluid and
the temperature in which it resides.
The units are mPa.s (milli Pascal per second). The most common is
the Brookfield rotational viscometer.

The longer the glue stays in the melter the more its
viscosity INCREASES

4. Glue application area: 4.5 Viscosity 54

 Substance Viscosity in mPa.s at 20°C

Petrol 0,65
Water 1,0
Mercurio 1,5
Grapes juice 2-5
Coffee cream 10
Honey 104 (10.000)
Adhesive (HMPUR for wrapping) 20-40.000 ( at 140°C)
Molten polymers 103 – 106 (1.000.000)
Bitumen 108 (100.000.000)
Glass 1023 (100.000.000.000.000.000.000.000)

4. Glue application area: 4.5 Viscosity 55

 Viscosity (cPs)

TAKA glues 120°C 140°C 160°C

1308.1 52000 26000 13000

1308.2R 40000 20000 14000

1308.20 66000 33300 16500

temperature used in production

4. Glue application area: 4.5 Viscosity 56

Stability of TAKA glues @140°C
GLUE 1 GLUE 2
GLUE 1 GLUE 2
TAKA Glue WITHOUT DRY WITHOUT DRY
WITH DRY AIR WITH DRY AIR
AIR AIR

1 day
Optimal cycle: 10 sec of dry air or
nitrogen per minute.

2 days In case of breaks longer than

30min use the melter
temperature“Economy” function
to avoid overheating the glue
3 days

4 days

This goes for TANK MELTERS. Drum melters are sealed improving the stability of the
adhesive

4. Glue application area: 4.6 Stability 57

Stability of TAKA glues @110°C
GLUE 1 GLUE 2
GLUE 1 GLUE 2
TAKA Glue WITHOUT DRY WITHOUT DRY
WITH DRY AIR WITH DRY AIR
AIR AIR

1 day
Optimal cycle: 10 sec of dry air or
nitrogen per minute.

2 days In case of breaks longer than

30min use the melter
temperature“Economy” function
to avoid overheating the glue
3 days

4 days

4. Glue application area: 4.6 Stability 58

 Minimun moisture - % values - in the wrapping department The colder the enviroment the higher
humidity is needed for a timely curing of the
adhesive
Relative humidity in relation to the temperature
70
65
60
Relative humidity (RH %)

55
50
45
RAL-GZ 716 suggests
40
35
30
Min18°C by at least 45% RH
25
20
15
10
5
0
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35

Temperature (°C)

4. Glue application area: 4.7 Temperature and humidity 59

 5

5: Wrapping area

5.1 Open time

5.2 Ideal temperatures at the pressing
roller
5.3 Pressing wheels and air blower set up
5.4 Initial bond strength
5.5 Temperatures after pressing area

5. Rivestimento 60
 A

start

Open Time: It is the time within

which the adhesive, after having
Open time

Finish 1
been applied on the foil, will stick
on the profile.

A A A

5. Wrapping area: 5.1 Open time 61

 A
B

start C
Open time

Open Time: It is the time within

Finish 1
which the adhesive, after having

Finish 2
been applied on the foil, will stick

Finish 3
on the profile.

A
B C

5. Wrapping area: 5.1 Open time 62

 Open Time: It is the time within which the adhesive, after having been applied
on the foil, will stick on the profile.

TEMPERATURE INFLUENCES THIS PARAMETER

Increase speed
50 g/m2 di HMPUR Speed: 10 m/min

Speed: 20 m/min

Speed: 30 m/min

5. Wrapping area: 5.1 Open time 63

 Open Time: It is the time within which the adhesive, after having been applied
on the foil, will stick on the profile

TEMPERATURE INFLUENCES THIS PARAMETER

Increase glue quantity

Speed 15m/min 45 g/m2 glue

50 g/m2 glue

60 g/m2 glue

5. Wrapping area: 5.1 Open time 64

 Open Time: It is the time within which the adhesive, after having been applied
on the foil, will stick on the profile

TEMPERATURE INFLUENCES THIS PARAMETER

Increase the temperature of the profile

Speed 15m/min Profile 40°C

Profile 45°C

Profile a 50°C

5. Wrapping area: 5.1 Open time 65

 45-55°C Good adhesion START

Glue Temperature low limit 40°C

<38-40°C Good initial bond strength

END
(low stickiness)

5. Wrapping area: 5.1 Open time 66

 5 GKFP (RAL 716) guidelines

45°C to 55°C

This temperature range keeps the

glue within its OPEN TIME.

38°C

31°C

5. Wrapping area: 5.2 Ideal temperatures at the pressing roller 67

 5 GKFP (RAL 716) guidelines

45°C to 55°C

This temperature range keeps the

glue within its OPEN TIME.

31°C
57°C

48°C

5. Wrapping area: 5.2 Ideal temperatures at the pressing roller 68

How to use an infrared thermometer Spot size@distance

25@100
50@200
100@400

profile Laser

Reading

X V

5. Wrapping area: 5.2 Ideal temperatures at the pressing roller 69

 X OK Ideal
5. Wrapping area: 5.3 Pressing wheel and air blowers set up 71
 IDEAL

67°C

57°C Keep pressing while

heating

5. Wrapping area: 5.3 Pressing wheel and air blowers set up 72

Glue application

45-55°C Good adhesion

First pressing roller

Keep the pressure

Limit temperature of the glue
40°C
Keep pressing with wheels

<38-40°C initial bond strength

5. Wrapping area: 5.3 Pressing wheel and air blowers set up 73
 5 The correct pressure is essential to enable a good
bond of the glue on the substrate and a good
adhesion all around the geometry of the profile.
The pressure needs to be mantained untill the
temperature drops below 40°C

5. Wrapping area: 5.3 Pressing wheel and air blowers set up 74

 5

Wrong temperature

53°C 46°C

After the last pressing

wheel the profile
temperature is still >
40°C

5. Wrapping area: 5.4 Initial bond strength 76

 5

5. Wrapping area: 5.4 Initial bond strength 77

 5

Air coolers are used to quickly decrease the glue

temperature

5. Wrapping area: 5.4 Initial bond strength 78

 Shop floor: 18°C – 25°C Profile temp. before
Relative humidity: 40% - 70% application of primer
Low-VOC primer: 30-35°C
MEK/DCM: no pre-heating
Foil preheating Profilo temp.
Primer application
30-60°C 18-25°C
MEK: 15-30g/m2
DCM: 20-60g/m2 (fully acclimatized)
Adhesive application Low-VOC: 8g/m2 (+/- 2g/m2)
40-60g/m2
Reaction time/distance:
MEK/DCM: 0.5m / 2-3sec (at 10-15m/min)
Low-VOC: approx 1m / 5sec (at 10-15m/min)
Foil temp. before
pressing roller
Profile run-out 45-55°C
temp. max. 35°C
Profile temp. before pressing
roller 45-55°C

5. Wrapping area: summary 79

 6
6. Quality control

6.1 Physical and

chemical adhesion
6.2 End of the machine
6.3 Lab tests and
certification

6. Quality control 80
Crosslinking reaction of HMPUR

Physical and chemical adhesion

3,5

Above described suggestions ensure: 3

2,5
• 1°THE PHYSICAL ADHESION during the

Force (N/mm)
lamination process 2

1,5

• 2°THE CHEMICAL ADHESION after 1

lamination
0,5

Physical adhesion
0
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80

Time (hours)

6. Quality control: 6.1 Physical and chemical adhesion 81

Crosslinking time of HMPUR at different enviromental conditions

Standard glues
3,5

Limit RAL 716 • Optimal condition for crosslinking: 23°C with

3
50% humidity.
2,5
• Crosslinking time at 15°C with 80% humidity
Peeling (N/mm)

2 is the same as at 23°C with 50%.

15°C a 20%HR
1,5
23°C a 50%HR • Low temperature has a lower impact on the
crosslinking time of FAST curing glues.
1

0,5

0
0 1 2 3 4 5 6 7 8
Time (giorni)

6. Quality control: 6.1 Physical and chemical adhesion 82

Crosslinking time of HMPUR at different enviromental conditions

FAST glues
4

• Optimal condition for crosslinking: 23°C with

3,5
50% humidity.
3
Limit RAL 716
• Crosslinking time at 15°C with 80% humidity
2,5
is the same as at 23°C with 50%.
Peeling (N/mm)

15°C a 20%HR
2
23°C a 50%HR
Colla FAST 15°C a 20%RH
• Low temperature has a lower impact on the
1,5
Colla FAST 23°C a 50%RH crosslinking time of FAST curing glues.
1

0,5

0
0 1 2 3 4 5 6 7 8
Time (days)

6. Quality control: 6.1 Physical and chemical adhesion 83

 Immediately ( Phisycal Adhesion) After crosslinking (Chemical Adhesion)

FOIL

PROFILE PROFILE PROFILE

Glue cohesion failure Foil cohesion failure Foil cohesion failure

FOIL ✓j ✓j ✓j
PROFILE

Final test to be perfomed at the

outfeed of the machine
FOIL FOIL
Check where the glue is
PROFILE PROFILE
No glue transfer (Glue stay Transfer of glue (Glue
on foil) completely on profile)

X X
First 5 min after wrapping Days Time

6. Quality control: 6.2 Machine outfeed 84

6
Wrapping quality test: Peel the foil and check where the glue is

OK NOT OK
GOOD WAIT FOR CHEMICAL REACTION CHECK THE
PARAMETERS ARE OK OF THE GLUE PARAMETERS

Glue transferred on the

Glue on both sides Glue stays on the foil
profile

6. Quality control: 6.2 machine outfeed 85

Peeling test
RAL GZ 716 certification

Peeling -Test at 23°C and

50%RH to be performed
after 72h after
▪ Set a quality standard lamination
▪ Routinely carry out quality checks
▪ Certify only products that fulfill the quality standards
▪ TAKA primers and Hot Melt adhesives are RAL 716
certified
▪ Get your products tested at TAKA labs

Hydrolysis-test 42 days at
70°C and 95% RH

6. Quality control: 6.2 Lab tests and certification 86

Thank you for your kind
attention

academy@wprtaka.it
www.wpr.it