Laminate is a durable flat sheeting material used in home and industrial furnishings. Lamination is the technique of manufacturing a material in multiple layers, so that the composite material achieves improved strength, stability, sound insulation, appearance or other properties from the use of differing materials. A laminate is a permanently assembled object by heat, pressure, welding, or adhesives.

There are different lamination processes, depending on the type of materials to be laminated. The materials used in laminates can be the same or different, depending on the processes and the object to be laminated.

The manufacturing process of decorative laminates involves the following steps

Impregnating the paper

The process begins by soaking strips of paper in resin. Decorative plastic laminates can be made in different grades or thicknesses, depending on its intended use. There may be from 7-18 layers of paper combined into the final sheet. The bottom layers are kraft paper. It is then run through a "bath tub" or vat containing phenolic resins. The paper for the top layer of the sheet is translucent. This is run through a vat of melamine resin. The layer just beneath the top is the decorative layer.

Drying

The resin-impregnated sheets are then put into a drying chamber to dry up and soak moisture.

Stacking

Now a saturated Kraft paper is placed under each decorative layer. On top of each decorative layer a textured plate is laid, this will prevent the finished laminates from sticking together.

Thermosetting

The layers of paper are then loaded onto a flat-bed hydraulic press for final curing. The press compresses the sandwich of resin-soaked paper at 1,400 psi, while heating it to a high temperature. The heat catalyses a reaction in the resins. Thermosetting converts the paper sheets into one single, rigid laminated sheet.

Finishing

The dry sheet is cut into the desired size and shape. It may also be bonded to a building material such as plywood, flakeboard, fiberboard, or metal. Laminates are most commonly used surface finish for furniture elements, as they provide decorative look in comparatively less price. They also enhance the durability of the furniture as they are scratch resistant and easy to clean.

There are different types of laminates available in the Indian market according to their application.

Types of Laminates Based on Pressure Applied

• High Pressure Laminate (HPL)
• Low Pressure Laminate (LPL)

Types of Laminates Based on Thickness

• Regular Laminate Sheets
• Compact Laminate Sheets

Types of Laminates Based on Usage

• Decorative Laminates
• Industrial Laminates
• Solid Colored Laminates
• Gloss Finished Laminates
• Matt Finished Laminates
• Textured Laminates
• Wood Grain Laminates
• Metal Laminates
• Leather Laminate Sheets
• Fire Rated Laminate
• Anti-Bacterial Laminate
• Outdoor UV Laminates
• Electrostatic Dissipative Laminate

In India The combined worth of the plywood and laminates industry is believed to be to the tune of Rs. 21000 crore per year, with laminates accounting for a share of approximately Rs.3300 crore, and the industry is expected to keep on growing further in the years to come.