4 Ply Laminates (Paper/PE/Alu.Foil/PE)
Paper / PE / aluminium foil / PE laminates for powders and ORS.
Plain paper is insufficient for medicinal and food product packing because of poor barrier properties, low heat sealability and strength. For that reason it is impregnated with additives or, more commonly, laminated with aluminium and plastic to improve its functional properties for commercial packing lines.
One of the most popular paper laminates used in packing pharmaceutical powders, ORS and similar dry products is the Paper-PE-Foil-PE construction, popularly known as 4-ply laminate. The foil content of the laminate gives the required barrier property, while the extruded PE gives flexibility to the laminate and enables reliable heat sealing.
The outer paper face supports a natural pack look and print presentation. Inner PE provides the seal and product-contact surface. Together the four plies protect the fill through transit, warehouse storage and consumer use. Exact paper GSM, foil micron, PE coat weights and print are confirmed as per the agreed contract with the customer.
- Foil core for the moisture, gas and light barrier plain paper lacks
- Extruded PE for flexibility and heat sealability
- Paper outer face for print and a familiar pack appearance
- Stronger, more functional than uncoated paper for medicinal packing
- Suited to powder and ORS sachet / pouch converting
DB Packaging parameters & tolerances.
General product specification. Final values are confirmed against the customer contract and batch documentation.
DB Packaging manufactures and supplies 4-ply laminates in the Paper / PE / Alu.Foil / PE structure for pharmaceutical powders, ORS and related dry products. Plain paper alone lacks barrier, heat sealability and strength for medicinal packing; this laminate upgrades those functions in one commercial web. Final product specifications are made as per the agreed contract with the customer.
Four-ply laminate: paper / polyethylene / aluminium foil / polyethylene. Paper GSM, foil micron and PE coat or film weights are selected for fill type, puncture risk and seal strength. A typical pharmaceutical powder or ORS brief uses a printable paper face, a foil barrier core and a PE sealant suited to FFS or pouch sealing.
Plain paper is insufficient for medicinal and food product packing because of poor barrier properties, low heat sealability and strength. It is therefore impregnated with additives or laminated with aluminium and plastic so the pack can protect the product and run on automatic sealing equipment.
One of the most popular paper laminates for pharmaceutical powders, ORS and similar fills is Paper-PE-Foil-PE, popularly known as 4-ply laminate. Foil supplies the barrier; extruded PE supplies flexibility and the seal performance that converters need on sachet and pouch lines.
Paper carries print and the outer look of the pack. Intermediate PE helps build and flex the structure. Aluminium foil provides the required barrier against moisture, gases and light. The inner PE is the sealing medium and product-contact face.
Layer Construction & Function
| Layer | Typical Thickness | Function |
|---|---|---|
| Paper (outer) | As specified (GSM basis) | Print surface and familiar paper pack appearance; adds stiffness to the web. |
| PE (build layer) | As specified | Extruded or laminated PE that improves flexibility and bonds the structure toward the foil. |
| Aluminium foil | As specified | Provides the required barrier property against moisture, gases and light. |
| PE (inner sealant) | As specified | Heat-seal medium and immediate contact layer with the packed material. |
Foil content sets barrier performance. Extruded PE content sets flexibility and seal behaviour. Both are balanced against product abrasiveness, sachet size and line speed.
Process Notes
- Supplied as printed or plain roll stock for sachet / pouch converting, or as finished pouches where agreed.
- Paper face carries brand and regulatory print when artwork is approved for the structure.
- Seal on the inner PE face using temperature, pressure and dwell matched to the PE grade.
- Protect reels from moisture uptake in the paper face and from crush that can crease the foil.
- Qualify barrier and seal performance against the filled powder or ORS product on the actual packing line.
Layer Functions
| Layer | Position in Stack | Primary Contribution |
|---|---|---|
| Paper | Outer ply | Print 路 pack appearance 路 web stiffness |
| PE (build) | Second ply | Flexibility 路 structural build |
| Alu.Foil | Third ply | Required barrier property |
| PE (sealant) | Inner ply | Heat seal 路 product contact |
Key Performance Values
Configuration
4-ply laminate is supplied in reel form for automatic packing, and can be converted into sachets or pouches. Width, OD, print and pack style are matched to the customer line.
| Product form | Paper / PE / aluminium foil / PE laminate reels, and pouches where specified. |
| Structure | Paper (print) / PE (build & flex) / Alu.Foil (barrier) / PE (seal & contact). |
| Plain or printed to customer-approved text, layout and shade on the paper face. | |
| Core | Material options: (a) Plastic (b) Cardboard. Core ID typically 76 mm. Core length equals web width. |
| Reel / Web Width | Slit to FFS or pouch-machine width requirements agreed at order stage. |
| Identification | Each reel or pouch lot identified with specification, net weight or count, operator reference and date of manufacture as applicable. |
| Packing | Reels and pouches packed to protect paper, foil and seal faces in transit. Outer markings as per shipment documentation. |
| Quality release | Supplies accompanied by test documentation covering observed values of agreed parameters for the batch. |
Recommended Operating Conditions
- SealingHeat seal on inner PE face 路 set-points per PE grade & machine
- Machine fitSachet FFS 路 pouching lines 路 laminate converters
- HandlingKeep paper dry 路 avoid foil crease / puncture
Related products
Specify your 4 ply laminates (paper/pe/alu.foil/pe) requirement.
Annual volumes, target markets and barrier requirements. Our team will respond within 16 business hours.