TDL-2200 Roll-to-Roll Cold Laminating Machine 10-50 m/min for EVA PE Foam Fabric Bonding

Cold Laminating Foam Lamination Machine with 2000-2200 mm Width and 10-50 m/min Speed for EVA PE Foam Bonding

The TDL-2200 turns a plain foam sheet into a finished composite material. It bonds PU, EVA, PE and EPE foam to fabric, artificial leather, genuine leather, non-woven fabric or mesh at ambient temperature, using a cold adhesive instead of heated rollers. The line works across a 2000–2200 mm width at 10–50 m/min, is driven by an 8 kW motor, measures 7800×2200×2000 mm and weighs 3000 kg. Because the bond is formed without heat, there is no warm-up cycle, no heated roller bank and no thermal load on the foam surface.

This page is written for production managers who need to plan the machine around real material pairs, real shift output and real downstream processes. It covers web handling, adhesive metering, curing and peel testing, throughput planning, line integration, installation, maintenance and the commercial terms. The parameters quoted below come from the TDL-2200 specification. Adhesive type, coat weight and tension settings should always be confirmed with your own foam and facing materials during commissioning.

• ModelTDL-2200
• Laminating MethodCold laminating, no heating
• Laminating Width2000–2200 mm
• Laminating Speed10–50 m/min
• Motor Power8 kW
• Machine Weight3000 kg
• Overall Dimension7800×2200×2000 mm
• CertificationCE

• Cold bonding without heat: the adhesive is applied and pressed at ambient temperature, so there is no warm-up wait, no heated roller bank and no risk of scorching thin foam or glazing a coated fabric.
• 2000–2200 mm working width: the nip spans the full sheet and holds pressure from the operating side to the drive side, which keeps the edges as flat as the centre.
• 10–50 m/min stable line speed: a steady drive keeps the wet adhesive film constant, so the bond does not change from the start of the roll to the end.
• Roll-to-roll web handling: edge guidance and matched tension keep the foam and facing square as they enter the nip, reducing diagonal folds and edge lift.
• Lower running cost: the connected load is an 8 kW motor driving the mechanics; energy is not spent holding rollers or an oven at temperature.
• Repeatable settings: because there is no thermal variable, the nip pressure and metering gap set at the start of the shift repeat from batch to batch.

The machine is a roll-to-roll line. A foam roll and a facing roll are mounted at the infeed, the adhesive is applied, the two webs meet at the nip, and the finished laminate is rewound or cut at the outfeed. The sequence below is the operating cycle used during commissioning and operator training.

1. Load the rolls. Mount the foam roll and the facing roll on their shafts, check the roll direction, and confirm that the splice is flat and clean before threading.
2. Thread and align. Pass both webs through the edge guide, the adhesive station and the nip. Set the web path so both layers enter the nip square to the roller axis.
3. Set tension. Match the tension of the foam and the facing material. A mismatch pulls the laminate out of square and shows up later as a curved edge or a diagonal fold.
4. Apply adhesive. Set the metering gap and start the adhesive feed. Confirm an even film across the full 2000–2200 mm width before production speed is raised.
5. Close the nip and run. Bring the pressure roller down, start the drive and increase to the target line speed. Watch the laminate at the outfeed for the first metres.
6. Rewind or cut. Wind the laminate under controlled tension, or cut it to length for flat stacking. Label the roll with material pair, adhesive batch, line speed and operator.

On a wide laminator, the quality of the finished sheet is decided before the material reaches the nip. Web handling keeps the two layers arriving flat, square and at equal tension. The TDL-2200 frame carries the laminating rollers across the full working width and holds them parallel, which is what keeps nip pressure even from the operating side to the drive side.

The infeed section accepts the foam and facing rolls; the edge guide keeps the facing web tracking in line with the foam; the adhesive station applies the glue film; the nip roller presses the two layers into contact; and the outfeed section rewinds or delivers the laminate to a run-out table. The 7800 mm length gives enough distance between the unwind and the nip for the webs to settle before bonding, which matters on thin facings that curl when unwound.

Because the process is cold, there is no thermal expansion in the rollers during a run. The pressure set at the start of the shift is the pressure at the end of the shift, provided the rollers are clean and the mechanical locks are engaged. That repeatability is the main reason cold lamination holds a stable thickness on long rolls.

Cold lamination moves the quality variable from temperature to adhesive film thickness. Too little adhesive leaves dry patches that lift after curing; too much adhesive creates slip in the nip, squeeze-out at the edges and a laminate that feels wet when it is rewound. The practical control is the metering gap plus the line speed, because both change the wet film weight that reaches the nip.

A workable starting window for a water-based laminating adhesive is 20–60 g/m² wet coat weight, depending on the foam density and the porosity of the facing. Dense EVA and coated leather take the lower end; open-cell PU foam and non-woven take the higher end. These figures are a starting point, not a fixed rule: the correct coat weight is the one that passes your peel test after the recommended cure time.

• Metering gap: sets the wet film thickness. Adjust in small steps and check the film on both edges, not only in the middle.
• Nip pressure: presses the adhesive into both surfaces. It must be even across the width; a low spot on one side shows up as a dull, unbonded strip.
• Line speed: changes the amount of adhesive transferred per metre if the adhesive feed is not linked to speed. Keep speed steady during a roll and adjust the feed when speed changes.

Adhesive selection follows the material pair, not the machine. A water-based PU adhesive that bonds PU foam to cotton works differently on EVA with a coated leather face. Send your material pair to our engineers before the order is fixed and run a trial during commissioning. The trial should include the actual foam grade, the actual facing roll and the adhesive you intend to use in production.

Cold adhesive develops strength over time. The laminate leaving the winder is handleable but not yet at full bond. Plan floor space for the rolls or sheets to rest before the next operation, and do not send a freshly wound roll straight into die-cutting without a first-article check.

A simple approval routine that works on a production floor:

1. Run a 10–20 m sample at the production speed and adhesive setting.
2. Cut three test pieces: one from the operating side, one from the centre and one from the drive side.
3. Condition the samples for the recommended cure time, then run a 180° peel test at a controlled rate.
4. Record the peel result, the failure mode (foam tear, adhesive split or interface lift) and the coat weight for that roll.
5. Keep the record with the production order so that a later complaint can be traced back to the adhesive batch and machine setting.

If the peel test fails, check the failure mode before changing the machine. A foam tear means the bond is stronger than the foam and the setting is already sufficient. An adhesive split means the film is too thin or the two surfaces were not pressed into contact. An interface lift on one edge points to uneven nip pressure or a tension mismatch, not to the adhesive.

The table below shows the combinations the TDL-2200 is normally specified for. It is a planning guide, not a limit: any pair that can be bonded with a cold adhesive and passed through the nip can be trialled.

The TDL-2200 is specified where a foam sheet needs a finished face, a reinforcing layer or a decorative surface. The list below covers the industries that use this width and speed range usually; any pair that passes a peel trial can be added.

• Footwear: shoe lining, collar padding, insole cushioning and sandal uppers where EVA or PU foam is bonded to fabric or artificial leather.
• Garment and interlining: foam laminated to non-woven or knitted fabric for lining, shoulder padding and decorative panels.
• Automotive interior: seat padding, door trim, headliner backing and floor mat base material.
• Furniture and bedding: upholstery laminates, mattress comfort layers and sofa cushion wraps.
• Packaging: PE and EPE foam bonded to film or non-woven for protective packaging and case inserts.
• Care and support products: pressure-relief cushions, seating pads and support cushions built from foam and fabric.
• Construction and insulation: foam bonded to felt or facing for acoustic and thermal panels.

Output is a function of line speed and uptime, not of the motor size. At 10 m/min the line produces 600 m per hour; at 50 m/min it produces 3000 m per hour. Over an eight-hour shift with 80% uptime, that is roughly 3840–19200 m of single-lane laminate. The upper end assumes long rolls, few splices and a material pair that runs without adjustment.

Cost per metre is easier to control than headline speed. It has four parts:

• Adhesive: wet coat weight (g/m²) × working width (m) × adhesive price per kg, divided by 1000. This is usually the dominant variable cost.
• Energy: the connected load is an 8 kW motor. Multiply by your local tariff and divide by metres per hour; the result is a small fraction of the adhesive cost.
• Labour: one operator can run the line; add time for roll changes and adhesive mixing.
• Waste: the first metres after a changeover and any roll that fails the peel check. Reducing changeovers is the fastest way to cut this line.

Cold lamination is the sensible route when the foam is thin or heat-sensitive, when the facing is a coated fabric that glazes under heat, or when the plant wants to avoid a warm-up cycle. Hot and flame processes remain relevant for specific high-speed commodity lines, but they bring energy, safety and material limits that the cold process does not.

The TDL-2200 is a converting step, not a foam-making machine. It sits between sheet preparation and final cutting:

1. Upstream: a splitting or slicing machine produces the foam sheet at the required thickness; the facing material arrives as a roll.
2. Lamination: the TDL-2200 bonds the sheet and the facing into one laminate and rewinds it.
3. Curing: the laminate rests for the adhesive to develop full strength.
4. Downstream: die-cutting, contour cutting, edge trimming, stitching or packaging.

Two integration points deserve attention. First, the width of the upstream sheet should match the 2000–2200 mm working width; an undersized sheet leaves the nip running on one side only and loads the rollers unevenly. Second, the downstream cutting table should be long enough to handle the cured laminate without dragging it across a sharp edge, which can delaminate a corner even when the bond itself is sound.

When the laminator is paired with a CNC contour cutter or a horizontal splitting line, plan the buffer between the two machines around cure time, not around machine speed. A fast laminator feeding a cutter with no cure buffer will push green laminate into the blade and create delamination that is blamed on the adhesive.

Four questions narrow the specification:

• What is the widest sheet you must bond? The working width is 2000–2200 mm. Choose the width around your normal production roll, not around a one-off order.
• What output do you need per shift? Use the 10–50 m/min range and the uptime assumption above. If the required output sits near the upper end of the range, plan for long rolls and quick changeovers.
• Which material pairs will you run? Bring samples. Adhesive choice and coat weight follow the pair, and a trial is the only reliable way to confirm the bond.
• What space and utilities do you have? The machine is 7800 mm long and 3000 kg. It needs a level, load-bearing floor, clearance at both ends for roll loading and laminate removal, and a power supply sized for the 8 kW motor.

Confirm voltage and frequency for your site before the order is fixed. Keep the adhesive storage and mixing area ventilated,