1. VITS Systems GmbH Impregnation Lines For Laminate Products
Part 1 The Melamine Paper Impregnating Process

2. Impregnation is the saturation of a basic substrate
What Is Impregnation ?
Impregnation is the saturation of a basic substrate
Examples of impregnation are:
Fibre Glass Mat Impregnated with Epoxy Resin for the printed circuit boards
Woven Cloth for reinforced fabric
Paper for Car Filter elements
Woven Nylon for weather protective clothing
Decorative and Kraft Paper for the Laminates Industry

3. Why Paper ? Readily available in roll form Fibrous structure
Can be easily impregnated
Available in different widths and strengths
Can be produced in various different colours as a raw material
Can be printed into high quality décors

4. Difference Between Impregnating and Coating
Medium is applied to the outside surface of the substrate
Avoids coating medium seeping into the core of the substrate
Impregnation:
Medium is applied to the inside or core of the substrate

5. The Impregnation Process
Where the raw materials are brought together
Success of Final Pressed Product Depends on:
Raw material to Impregnation Line
Impregnation Machines
Impregnating Process parameters
Intermediate Products
Press and its Raw materials (Board)
Press Process Parameters
Many Different Influences on Final Product Quality !

6. Products of Impregnation
Intermediate Papers Films for
Low Pressure Direct lamination onto Boards (LPL)
Single Opening Press
Continuous Double Belt Press
High Pressure Processing into Multi Layered laminates (HPL & CPL)
Multi Opening Press

7. High Pressure Products
Particle Board Laminated CPL or HPL e.g. Kitchen Work Surfaces, Fire Resistant Surfaces
HDF/MDF Laminated with CPL e.g. Laminate Flooring (Special Overlay)
MDF or Particle Board Laminated with HPL e.g. Cubicle Walls, Wall Cladding
Thick Laminates (Self Supporting) e.g. Partition Walls

8. High Pressure Products
Example of a Typical 0.8 mm Laminate
(typical kitchen work surface)
HPL
Overlay Paper 120 gsm Final Weight
Décor Paper 190 gsm Final Weight
4 Kraft Papers 215 gsm Final Weight
CPL
Overlay Paper 120 gsm Final Weight
Décor Paper 190 gsm Final Weight
3 Kraft Papers 285gsm Final Weight

9. Low Pressure Products
Particle Board Laminated with Melamine Foils without Overlay e.g. Kitchen & Bathroom Furniture Carcass
HDF without Overlay e.g. Furniture Back Panel
MDF/HDF with Overlay e.g. Laminated Flooring
MDF with or without Overlay e.g. Furniture Fronts, Horizontal Surfaces
Decor Paper 190 gsm Final Weight
MDF Board 15 to 22 mm
Balance Paper 180 to 300 gsm Final Weight
Overlay Paper 120 gsm Final Weight
Typical Board Make Up

10. Flooring Products (see also Part 2)
High Pressure Flooring Product (CPL/HPL)
Mel. Balance Paper 180 – 300 gsm Final Weight
Abrasive Resistant Overlay Paper 120 gsm Final Weight
Decor Paper 190 gsm Final Weight
Carrier Board (Particle Board/MDF)
2 Kraft Papers 280 gsm Final Weight
Low Pressure Flooring Product (LPL)
Decor Paper 170 – 190 gsm Final Weight
HDF Board 12 mm
Balance Paper 180 – 300 gsm Final Weight
Abrasive Resistant Overlay Paper; either pre-loaded with Al2O3 or coated with Al2O3 during impregnation (ARP) gsm

11. The Machines - Melamine Impregnation
Typical Types of Melamine Impregnating Machines:
1 stage Melamine Machines:
Pure Melamine (MF) Products (Overlay, Al2O3 Overlay)
CPL / HPL Decorative Products
CPL / HPL / MFC Overlay
LP Backer
Production Speeds 25 to 50 metres per min
2 stage Melamine Machines:
Urea and Melamine (UF/MF) Products
MFC Decorative Products
All Products from 1 stage machine
Production Speeds 25 to 75 metres per min

12. The Standard Two Stage Melamine Impregnating Line