Last Updated: November 15, 2026 · Salado Commercial Pressroom
Large-Format Lamination
Need 18×24 posters, 24×36 blueprints, or continuous charts encapsulated? Price 1.5–10 mil wide-format roll lamination up to 27" wide in Salado, TX.
Large-format thermal lamination at Lamination Services in Salado, Texas encapsulates press sheets and continuous rolls up to 27 inches wide by any length in 1.5 to 10 mil gloss or low-glare matte—built for 18"×24" charts, 24"×36" blueprints, maps, and industrial machine signage.
Straight answer on 28×40 before you read any further.
How Our Salado Trade Floor Operates
Our roll laminators run 27 inches of web width and any length. That means we cannot laminate a full 28×40 press sheet flat — 28 inches is one inch over our web, and we would rather tell you that now than after your pallet arrives. What we do run is anything up to 27 inches on its short dimension with no limit at all on the long one, which covers cut-down 28×40 components, oversize posters, maps, banners and tabloid placemats.
Salado Pressroom Capability Matrix
| Specification | Salado Pressroom Standard |
|---|---|
| Max width | 27 inches of web |
| Max length | Any length — roll-fed, so length is free |
| Full 28×40 flat sheet | No. One inch over our web width. |
| Film | 1.5 to 10 mil, gloss or matte |
Published Wholesale 5-Mil & Multi-Mil Rate Schedule
| Finished Sheet Size | Common Commercial Use | 100–249 | 250–499 | 500–999 | 1,000–2,499 | 2,500+ Contract |
|---|---|---|---|---|---|---|
| 4.25" × 5.5" | Quarter-sheet credentials, postcards, equipment tags | $0.62 | $0.44 | $0.36 | $0.29 | Roll Contract (~26¢) |
| 5.5" × 8.5" | Half-letter bar menus, cocktail lists, field checklists | $0.84 | $0.61 | $0.49 | $0.41 | Roll Contract (~37¢) |
| 8.5" × 11" | Standard letter restaurant menus, SOP sheets, signage | $1.18 | $0.89 | $0.72 | $0.58 | Roll Contract (~53¢) |
| 8.5" × 14" | Legal-size dinner & wine menus, bilingual instruction cards | $1.44 | $1.08 | $0.87 | $0.71 | Roll Contract (~65¢) |
| 11" × 17" | Tabloid two-page menus, scored bi-folds, shop schematics | $2.05 | $1.54 | $1.24 | $1.01 | Roll Contract (~92¢) |
| 12" × 18" | Oversize digital press sheets, wipe-clean counter placemats | $2.38 | $1.79 | $1.44 | $1.17 | Roll Contract (~$1.06) |
Tip: Click any sheet row above to load that size straight into the live multi-mil calculator.
| Finished Sheet Size | 1.5 Mil (0.78×) | 3.0 Mil (0.88×) | 5.0 Mil (Published) | 7.0 Mil Shield (1.28×) | 10.0 Mil Plaque (1.58×) |
|---|---|---|---|---|---|
| 4.25" × 5.5" (Badge) | ~$0.23 | ~$0.26 | $0.29 | ~$0.37 | ~$0.46 |
| 5.5" × 8.5" (Half-Letter) | ~$0.32 | ~$0.36 | $0.41 | ~$0.52 | ~$0.65 |
| 8.5" × 11" (Letter) | ~$0.45 | ~$0.51 | $0.58 | ~$0.74 | ~$0.92 |
| 8.5" × 14" (Legal Menu) | ~$0.55 | ~$0.62 | $0.71 | ~$0.91 | ~$1.12 |
| 11" × 17" (Tabloid Menu) | ~$0.79 | ~$0.89 | $1.01 | ~$1.29 | ~$1.60 |
| 12" × 18" (Placemat) | ~$0.91 | ~$1.03 | $1.17 | ~$1.50 | ~$1.85 |
Why we are telling you no instead of getting you on the phone
A 28×40 press sheet is 28 inches across its short edge. Our web is 27. Turning it does not help, because the other dimension is 40. There is no orientation in which that sheet fits, and no amount of wanting the job changes it.
The keyword-chasing version of this page would say “large format lamination up to 28×40 — call for details” and let you find out on the loading dock. You would lose a day, we would lose the account, and the only winner would be the search ranking. If you need a full-bleed 28×40 laminated flat, you want a sheet-fed trade house with a 28-inch-plus machine, and we will happily tell you that on the phone too.
What our geometry is genuinely better at
Sheet-fed laminators are bounded in both directions. A roll laminator is bounded in one. That trade is worth understanding, because it flips in our favour the moment a piece gets long.
- Anything up to 27″ on the short dimension with no limit on the long one — a 24×60 banner, a 20×96 wayfinding panel, a fold-out map longer than any press sheet.
- Cut-down components off a 28×40 sheet. Most 28×40 work is trimmed before finishing anyway; send us the cut parts and the width problem disappears.
- Standard oversize trade sizes that sit inside the web: 24×36 posters, 27×40 one-sheets, 12×18 and 11×17 placemats.
- Continuous run-length work where a sheet-fed machine has to load, register and eject every single piece.
Specifying large-format work so it comes back flat
- Leave half an inch of trim on all four sides. So the film never encroaches on printed copy and never hangs off the sheet edge, and so the gripper and side guide stay clean for whatever happens downstream.
- Mind the grain. Paper should feed with the grain running parallel to the rollers.
Read it off the dimension order — 12×18 is long grain and feeds landscape, 18×12 is short grain and feeds portrait. Grain fighting the rollers is the most common cause of a wrinkle down the middle of a large sheet.
- Go heavier on the stock, lighter on the film. Rigidity is cheaper bought from the substrate than from the laminate. A heavy sheet with a thinner film usually costs less and lies flatter than a light sheet under a thick one.
- Laminate both sides on anything big. A large single-sided piece has a sealed rigid face and a bare porous back that keeps reacting to humidity. It will curl toward the laminated side. Two-sided is the fix, and on big formats it is not optional in practice.
Frequently Asked Trade Questions
Can you laminate a 28×40 sheet? Not flat, no. Our web is 27 inches and a 28×40 sheet is 28 inches on its short edge, so it does not fit in either orientation. We can run the cut-down components of that sheet, and we can run anything up to 27 inches wide at unlimited length. If you need the full sheet laminated flat you need a sheet-fed house and we will say so.
What is the largest piece you can laminate? 27 inches wide by any length. The roll laminators do not care how long the piece is, which covers oversize posters, maps, banners and long wayfinding panels that a sheet-fed machine cannot take at all.
Which gauge for a large poster? If it has to fold, 3 mil or less. If it hangs flat and gets handled, 5 mil. If it has to stand up by itself or live somewhere wet, greasy or outdoors, 10 mil. Remember the gauge is per side, so a 5 mil laminate adds 10 mil to the finished thickness.
Do you round corners on large pieces? Yes, and you should ask for it. A heavy substrate under a thick laminate produces genuinely sharp corners at that size. Round corners, hole punch and slitting are included rather than surcharged.
Direct Salado Trade Dispatch
Call (254) 290-6337 and ask for Sam with the flat size. If it fits the web you will get a price; if it does not you will get told, not quoted.
When your press sheets can’t afford a gamble
Don’t burn a client’s live press stack testing heat and tension on an under-pressured roller. Mail 3 printed press sheets to our I-35 Salado, Texas floor (serving Austin, Temple, Waco, and blind-ship accounts in all 50 states) or lock your 58¢–$1.18 wholesale run rate below.
How does Lamination Services run this specification on press?
What does wholesale thermal lamination cost for this specification?
At Lamination Services in Salado, Texas, published 5-mil wholesale lamination starts at $0.29 per 4.25x5.5 card and $0.58 per 8.5x11 letter sheet at 1,000 quantity (with 1.5-mil ~$0.45, 7-mil ~$0.74, and 10-mil ~$0.92), shipping blind nationwide within 48 to 72 business hours.
Can we test 3 printed press sheets in Salado before running our full stack?
Yes—at Lamination Services in Salado, Texas, include 3 marked test sheets with any 500-sheet or heavy 240% TAC digital black shipment (or mail 3 proof sheets in advance). Our crew verifies 100% EVA wet-out, zero silvering, and <=2% spoilage before your live stack touches heat.
P.S. — Don’t Guess on Film Gauge (Test My Rollers Free)
One botched retail pouch job—or one silvered stack of rich-black menus—costs more than three wholesale runs out of Salado.
You don’t have to ship a 1,000-sheet job blind to see how we work. Claim our free unbranded 1.5–10 mil sample deck so your buyer can snap our 7-mil menu shield in their own hands—or mail 3 dark printed sheets to Salado and let me run them free so you can try to peel the edge yourself.
— Sam Belcher · Lamination Services, Inc. · Salado, TX 76571 · (254) 290-6337
Lock your wholesale rate—or grab our unbranded sample deck free.
Don’t guess how 7-mil feels in your buyer’s hand. Lock your calculator rate in writing or have my Salado desk mail our zero-logo sample deck straight to your shop—no call center, no sales pestering.
Free 5-Gauge Sample Deck
Real 1.5, 3, 5, 7 & 10 mil sheets in Crystal Gloss and Satin Matte, 1/8" sealed lip vs. flush cut, and 1/4" round corners—100% unbranded so you close the markup.
3-Sheet Pre-Run Stop-Gate
Include 3 extra dark sheets—or mail 3 test sheets first. We verify zero silvering under angled light before your live stack ever hits the rollers.
Checking roll grain, I-35 Austin/Waco courier drop-off, or rush slots? Call Sam at (254) 290-6337 (Mon–Fri, 8am–5pm CT).