gnigakcap lecture 4a

When considering a product label, it's important to have a working knowledge of:

- Brand adherence and creative

- Consumer wants and needs

- Application type

- Product or container material & shape

- Substrate characteristics

- Label to product adhesion requirements

Printer, final output capabilities

- Handling process, including transport, etc.

- Storage, travel and shelf temperatures

Consumer use temperatures

- - Packaging line requirements

- Government Regulations

- Environmental Impact

Label Formats:

Cut and Stack Labeling:

Pressure Sensitive Labeling:

Shrink - Sleeve Labeling

Roll - Fed Labels:

Cut and Stack Labels:

Cut and Stack labels are supplied in stacks or bundles and the label adhesive is applied during the label's application process

Pressure Sensitive Labels:

Pressure sensitive labels have an adhesive backing and are typically supplied on a roll utilizing a liner to allow for release and placement on to the package surface

Roll-Fed Labels:

Roll-Fed labels are supplied on a roll and the label adhesive is applied during the label's application process

.

Shrink Label / Stretch Sleeve Labeling:

Shrink labels are supplied on a roll as tube formed label.

The shrink labels conform to the shape of the container during the label's application process with heat.

The stretch label is also supplied as a tube and is placed and Stretched over the container in the stretch labeling process.

Benefits of Cut and Stack Labeling:

Cut and Stack (C&S): Cost-Effective, typically cheaper option, particularly at very high volumes. Print process large sheets or rolls, that are Cut into the required shapes: either square-cut or die-cut and Stacked into boxes or wrapped.

Additional Cut and Stack Label Considerations:

Most economical label type and allow for long runs.

Variety of printing and decoration options available from a converting perspective.

Variety of materials that can be utilized including both paper and film to allow for wet strength.

Cut and Stack Label Material Options:

Variety of printing and decoration options available from a converting perspective.

Variety of materials that can be utilized including both paper and film.

PAPERS for Cut and Stack Label Applications:

Both Coated One Side (C1S) or Coated Two Sides (C2S) can be utilized for labeling applications.

Paper label Basis Weights:

60lb. Is the most utilized label stock.

55lb label stock can be used to allow for sustainability / cost savings.

70lb. To 80lb. Label stock can be used where more durable labeling applications are required.

Label Material Options - Continued:

Specialty Label Papers:

Metalized Papers, Synthetic Papers, Specialty Papers that have texture to Oil and Grease resistant papers.

Laminated labels:

2 ply - paper/paper or paper/poly and film/film

ADHESIVES for Cut and Stack Label Applications:

Hot Melts.

Cold Adhesives that are typically water based.

Cut and Stack Label Synthetic (Plastic) Material Substrates

Film and Synthetic labels are used today for hot-

filled juices in PET bottles and some water.

• Film & Synthetic cut & stack labels are more

durable than standard paper labels.

• Types of films

• White

• Metallized

• Clear

• Structure is key in its performance for a printer and

on labeling lines

• Typical film utilized for cut & stack is BOPP.

• PE and PET is also used in some cases.

• Film is generally extruded and has a multi layered

structure.

• Types of films

• White

• Metallized

• Clear

Cut and Stack Label Printing Options

Offset:

*Extended Gamut:

*Digital:

* The printing technologies available is

dependent on the label converter

Offset:

• Up to 9 colors.

• Dedicated to Combination runs.

• Finishing including, die-cutting, embossing, foil

stamping and coatings.

*Extended Gamut:

• 7 Color printing process.

• Combination runs.

• Shorter runs with shorter lead time.

*Digital:

• 7 Color.

• Prototypes to Short runs

• Finishing including, die-cutting, embossing, foil

stamping and lamination.

Cut and Stack Label Converting Options:

Die Cutting:

• Standard and Specialty Die Cutting can be utilized by the Label converter.

Embossing:

• The creation of a three-dimensional design on the label substrate using

heat and pressure that reshape the label substrates surface to create the

3D design.

Foil Stamping:

• Stamping is a process in which a hot or cold stamping die is forced down

against the substrate with a marking foil sandwiched in between. The

area where the die meets the paper is where the foil is left behind.

Coating:

• Varnish, UV and Aqueous coatings can be applied both in-line and off-line

Die Cutting:

• Standard and Specialty Die Cutting can be utilized by the Label converter.

Embossing:

• The creation of a three-dimensional design on the label substrate using

heat and pressure that reshape the label substrates surface to create the

3D design.

Foil Stamping:

• Stamping is a process in which a hot or cold stamping die is forced down

against the substrate with a marking foil sandwiched in between. The

area where the die meets the paper is where the foil is left behind.

Coating:

• Varnish, UV and Aqueous coatings can be applied both in-line and off-line

Cut and Stack Promotional Labels:

Peel and Reseal or Peel and Reveal:

• 2 ply cut and stack labels that provide

additional label space.

• Perforated Coupons that can be integrated

into the label design.

• Applications include, Coupons to

Promotions.

Cut and Stack Labeling Options:

Wraparound

Spot

Promotional

Cut and Stack Label Application Considerations:

Cut and Stack labels can be either wrap around in

design or spot label:

• Wrap Around cut and stack labels can utilize hot or cold

adhesives for the lap seal.

• Most spot labels are applied with cold adhesives.

Adhesive selection is driven by the equipment, equipment

speed, the label substrate material and the container that the

label is being applied to.

Other considerations include:

• Label End use.

• Container shape and label placement locations and line speed.

• Environmental considerations including Temperature and

Relative Humidity.

Other considerations for cut and stack label application considerations

• Label End use.

• Container shape and label placement locations and line speed.

• Environmental considerations including Temperature and

Relative Humidity.

Why Cut and Stack

Paper Labels Curl:

• Label Curl can be upward or downward:

• Paper grain and fiber direction.

• Relative Humidity effect on the paper.

• Excessive temperature exposure to paper,

films and coatings.

• Effects of banding, packaging and storage.

Benefits of Pressure Sensitive Labeling

Pressure Sensitive (PSL): Can be used on a greater variety of

substrates and can be customer shaped and sized to many

different types of product containers. Very often referred to as

stickers, based on adhesion.

• A pressurized bond is formed between label and product with.

The less aggressive the adhesive, the easier it is to remove an in-

tact PSL label from the package.

• Additional Pressure Sensitive Label Considerations:

• Pressure sensitive labels are made of several layers of

specialized materials sandwiched together to create a label

that looks good, identifies the product within a package,

additionally, the PS label is designed to last from the

application stages to the consumer experiencing the label

on a given package.

• Additional Pressure Sensitive Label Considerations:

• Pressure sensitive labels are made of several layers of

specialized materials sandwiched together to create a label

that looks good, identifies the product within a package,

additionally, the PS label is designed to last from the

application stages to the consumer experiencing the label

on a given package.

Pressure Sensitive Labeling:

The Benefits of Pressure Sensitive Labeling include:

• Use of high-quality print graphics.

• Film to paper face stocks including clear films to

allow for the "no label look".

• Many finishing and custom die cutting options.

• Can be applied to many container shapes.

• Pressure Sensitive labeling eliminates the need for

cold glue and adhesive application equipment.

• Transfer liners can be Film or Paper based

Pressure Sensitive Labeling Options:

Wraparound

Spot

Specialty

pressure sensitive sandwich ew

Topcoat

printing ink

face stock

adhesive

release coating

liner

Label Liner:

The liner is a critical component of any pressure sensitive label. The liner is the backing paper

that carries the die-cut labels to the applicator and releases the adhesive-backed label onto

the package.

The liner supports the label through manufacturing and use, protects the adhesive until the

label is applied, and provides appropriate label application, either by automatic or mechanical

means.

Liners come in different types to meet specific performance criteria. Typical performance and

quality characteristics include strength, smoothness, density, release level, and stability. Liners

can be made of paper or film.

Label Release Coat:

The release coat is a coating applied to the top surface of the liner. The release coat is

designed to resist the adhesive so that the face stock and adhesive peel away from the liner

smoothly

Label Adhesive

Pressure sensitive labels stick to a surface with light or moderate pressure from a label

applicator.

The amount of pressure needed, the permanence of the label, and the surface the label

adheres to is determined by the adhesive

Adhesive Continued:

Some factors to consider when selecting an adhesive include:

• Permanence:

• Will the label be permanent, or will it be removed at some point?

Note - In some applications, the adhesive can become permanent after a period

of time.

• Residue: If a label is removed, what will be left on the surface?

• Surface: What type of surface will the label adhere to - paper, plastic, metal?

• Texture: Is the surface rough or smooth?

• Temperature: What is the storage temperature of the label? What is the ambient

temperature during label application?

• Environment: Is the environment in which the label must function wet or dry, oily,

dusty, etc.?

Face Stock:

This is the material (Paper, Film etc.) that is used for making self-adhesive labels. It is

the top or "face" of the material from which labels are made. Face stock materials

include plastic films, foils, fabrics and laminates

Label Topcoat:

This is the coating or lamination applied over the face stock to provide physical

protection from abrasion or to enhance some other property of the label.

Topcoats can be used to improve adhesion or legibility of secondary imprints, typically

used for date or lot coding.

Special UV sensitive varnishes or films can also be used, depending on the application.

Label manufacturing, know as label converting, is a process consisting of multiple steps

that include unwinding, printing, laminating, die-cutting, slitting, and rewinding

Pressure Sensitive Label Converting Process:

Converting Process:

In-Line Pressure Sensitive Press Illustration:

The Waste material

being Removed in

the label converting

process is call the

Matrix.

PS Labeling - Added value decoration technologies:

Most Pressure Sensitive label converting is

accomplished with in-line printing utilizing the following

methods:

• Gravure

• Flexo

• Digital.

• Decoration technologies Including:

• Varnishing or Laminating.

• Die Cutting.

• Hot Stamping (Foil).

• Embossing.

• Perforating.

Pressure Sensitive Label Unwind Position Chart:

LOOK AT SLIDE 37 4A!

In working with your Pressure Sensitive label convertor, You must specify the label

unwind position based on the label artwork in relation to the label application system

Pressure Sensitive Label Printing Options:

*Gravure:

• Up to 13 Colors.

• UV, Flexo, Screen and Hot Stamping

• Finishing including, embossing, debossing hot stamping,

laminations and specialty coatings.

*Flexographic:

• 7 to 11 Color printing process.

• UV and water based.

• Finishing including, embossing, debossing hot stamping,

laminations and specialty coatings.

*Digital:

• 7 Color.

• Prototypes to Short runs

• Finishing including, die-cutting, embossing, foil stamping and

lamination.

* This is depending on the label converter

Linerless PS Label Attributes:

• Linerless product is 32% thinner, using less material than

standard linered products.

• Linerless labels offers 50% more labels per roll.

• Linerless labels are available with two adhesives:

• Semi-permanent

• Removable

• Linerless serves a variety of applications, ranging from e-commerce

to fast-food service

What is Direct Thermal Linerless label?

It is a flexible and sustainable alternative to conventional

pressure-sensitive label materials that still offers the same

scanning and traceability properties.

A linerless label is a pre-printed pressure sensitive label that

does not feature liner or backing paper

--------

The labels are wound on a roll and feature a silicone strip applied to

the top, to prevent the adhesive from the underside sticking to the

label below and enabling the label material to release.

• A purpose-built applicator then cuts and applies each linerless label

to product packs at high speed, making linerless a highly efficient

labelling process.

• Linerless is ideal for retail, food and logistics labeling as well as any

other applications where optimal thermal printability and adhesion

combined with a clean cut is required

Conventional PS Label and a Linerless PS Labels:

lineless has no lines inbetween

Roll-Fed Labels

: Clear or white film labels, typically used for water

products, applied to plastic containers.

• Allows for full product wrapping around the mid-section of a typical

plastic water bottle product.

Roll Fed Label Benefits

Partial product wrapped.

• Roll fed labels are a cost-effective labeling option.

• Cost effective at higher Minimum Order Quantities.

• Performs well in water or ice conditions.

• Less gluing required on application lines.

• Improved sustainability options (ease of removing the label

portion of the product waste).

• A roll fed label provides 360 ° shelf presence.

• Roll fed labels can be applied to both straight and shaped wall

containers.

• There are a variety of material and print options for roll fed

labels.

• A roll fed label can eliminate the need for a pre-decorated

container (Eliminate preprinted container inventory)

roll fed labeling options

standard

shrinkable

foam

extended content

Roll - Fed Label Printing Options

Rotogravure:

• Economical for Long Runs.

• Provides excellent opacity

• Allows for the use of specialty inks and finishes.

*Flexographic:

• Economical for short to medium sized runs.

• Lower cost and pre-press time.

• Allows for the use of specialty inks and finishes.

*Digital:

• Can be utilized for Prototyping to short run

production and for sampling.

• Can allow for quick turnaround production

timing.

• No prepress costs.

* This is depending on the label converter

Roll - Fed Label Material Options:

paper

bopp film

mdo shrink film

foam

Roll - Fed Label Printing and Converting Primary Processing Steps:

• Printing.

• Slitting and Rewinding.

Roll - Fed Label Printing and Converting Primary

Printing Options:

• Flexo and Gravure.

• Use of solvent-based inks.

• Use of water based or UV inks

Roll - Fed Label Printing and Converting Primary

Laminations:

• Use of water-based adhesives.

• UV curable adhesives.

• Use of Solventless adhesives (100% solids)

Stretch Sleeve Labeling info

• Stretch sleeve labels are less expensive than shrink sleeve

labels by roughly 30% to 50%.

• There is no need for another process such as a heat tunnel

once the label is applied.

• The downside to stretch sleeve labeling is that the

application rate is typically much slower than shrink sleeve

labeling; typically, less than 150 containers per minute.

• Stretch labeling is ideal for bulk volume containers like one-

quart to one-gallon containers.

Stretch Sleeve Labeling are

ideal for applications where harsh chemicals or fluids can

possibly come into contact with the outer package during the

filling process. Harsh chemicals and fluids are known to interact

with the glue of conventional adhesive labels causing the label to

peel over time.

• If applying stretch sleeve labels post fill, it is ideal to blow dry the

product packaging prior to stretch labeling to eliminate the

potential of trapped moisture or food getting caught under the

label.

• Any food caught under the sleeve label is prone to becoming a

bacteria site. For stretch sleeve labeling, pre-fill package labeling is

recommended

Benefits of Stretch Sleeve Labeling

A stretch sleeve is a one piece 360° closed loop label.

• Flexo printing is utilized for stretch sleeve labels.

• Stretch sleeve labels can use LLDPE Linear low density

polyethylene resin film.

• The stretch sleeve is a continuous tube wrapped on a

roll.

• The stretch sleeve is a label that is opened and stretched

onto the container.

• A stretch sleeve does not use an adhesive and uses the

elasticity of the film.

• Stretch sleeve labels are typically placed on a recessed

panel on the container.

• Can be 100% recycled

Stretch Sleeve Labeling:

Material Options

LLDPE

Printing Capabilities for Sleeve Labeling

A stretch sleeve is a cost effective and provide a large

billboard area to communicate your product's benefits.

Flexographic:

• Up to 8 colors.

• Economical for short to

medium runs

• Low cost and prepress time

needed.

• Ability for quick changeover

at the converter.

• Specialty inks and finished can

be use

Stretch Sleeve Recyclability

standard transportation, no refrigerated truck, smaller carbon footprint

no seaming solution or heat

easier to recycle with density of LLDPE

Stretch Sleeve Label Placement Options

Full Body Panel Sleeve

Hi-Cone Multi-Pack

Super Stretch Sleeve

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Stretch Sleeve Application equipment

A stretch sleeve is applied with specialized

placement equipment.

• The equipment stretches the sleeve and

pulls it over the container.

• The stretch sleeve equipment can be either

Automatic or semi-Automatic in operation

and typically allows for shorter change

over time

What Are Shrink Sleeve Labels?

• Much like roll-fed labels, shrink sleeve labels are a type of

label that wraps completely around a package to offer 360-

degree coverage.

• However, unlike roll-fed labels, the shrink sleeve label is

then heated and shrunk to conform to the unique shape of

the container - best for full cylinder or round shapes.

Therefore, these labels require some amount of machinery.

• Though equipment exists to both apply the sleeve and shrink

the label seamlessly, most times, people will opt to apply the

label sleeve by hand and then utilize equipment only to heat

shrink the sleeve onto the product.

• Requires controlled temperature handling and storage to avoid

partial activation prior to applications

Shrink Sleeve Labeling

• Shrink sleeve labels are ideal for container package labeling where

the product is packed at higher throughput rates, up to 800

containers per minute.

• The sleeve is "dropped" onto the product container either pre or

post fill.

• Applying the shrink sleeve pre-fill provides the advantage of

obtaining a clean container for accurate sleeve application,

eliminates unwanted heat applied to the package product, reduces

scrap and batch loss due to misapplied sleeves and eliminates the

potential of trapped water or food particles behind the sleeve.

• Like stretch sleeve labeling, if applying the shrink sleeve post fill, it is

good practice to dry the container before the sleeve is applied for

smooth sleeve insertion.

• Wet containers can cause the sleeve to not be uniformly applied

impacting the quality of the product appearance once the sleeve

has conformed to the package container.

Benefits of Shrink Sleeve Labeling:

A shrink sleeve provides 360° billboard coverage on

the container.

• A shrink sleeve will allow for tamper evidence to

have increased product security benefits.

• A shrink sleeve can be used for individual and multi-

packs.

• 360-degree graphics.

• Tamper evidence

• Multi-packs

• Scuff resistance

• Great solution for unique shaped containers

• Digital, Flexo and Gravure Print Options

• Foil, tactile & embellishment options

• Sustainability options (supporting PET recycling)

Marty Golden - Lecture 4B

Stretch, Shrink Sleeve & Label Printing Manufacturing Overview

Fall Packaging Manufacturing Course

Shrink Sleeve Labeling Options

• Once the film encounters heat, the label

shrinks and tightly conforms to the shape

of the container.

• Shrink sleeve labels can accommodate

extreme container contour. This flexibility is

applicable to virtually any shape or size

container on a variety of films.

Shrink sleeves provide functional benefits

such as:

• excellent scuff resistance,

• easy detection of tamper evidence.

• consumer-convenient multi-pack

presentation

Types of Shrink Sleeves

• Preform and Neck Bands

Multi-Pack Bands

• Multi-pack bands are utilized to combine multiple

products together into one attractive package

(with a large print surface).

• Common uses for multi-pack bands include:

• Trial Pack Sizes

• Twin Packs

• Value Packs

preform and neck bands

• Preform and Neck Bands are utilized only around the lip, neck or cap

of a container and provide tamper-evident protection for your product.

• Common uses for preform and neck bands include:

• Medicine bottles

• Wine Bottles

• Condiment Containers

Common uses for standard shrink sleeves include:

• Chapstick and Lip Balm Tubes

• Sauce Bottles

• Food Containers

• Coffee and Coffee Creamer Bottles

• Beverage Bottle

Shrink Sleeve Storage

• Maintain warehouse storage temperature below 80° F.

• For OPS 75° F

• Avoid the use of Higher Storage Racks.

• Ship the shrink labels in refrigerated trucks to insure proper

temperature during summer months and in warmer climates.

• Cold storage is good to precondition the material prior to use.

• Avoid double stacking pallets with stretch sleeve materials.

• Do not store in high humidity environments.

• Film not stored can have COF issues in use.

Marty Golden - Lecture 4B

Stretch, Shrink Sleeve & Label Printing Manufacturing Overview

Fall Packaging Manufacturing Course

Shrink Sleeve Label Placement Options:

Full Body

Tamper Bands

Multi-Packs & On Pack

Shrink Sleeve Material

PVC

PEET, PETG

OPS

PLA

OPP (slide 22 of 4B)

Benefits of a White Shrink Sleeve Label:

The white film reduces the need for a printed white

ink coverage or the use of a color bottle.

• From a functionality perspective, the white shrink

label will provide light barrier (UV & visible light) for

to allow for increased product shelf life.

• Will allow for high shrinkage performance for

shaped container use

Shrink Sleeve Label Converting Terminology:

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Thermal Transfer Printing

The Thermal Transfer Printing Process for labeling works by heating individual

pixels (200dpi to 60dpe) on the print head.

• The print head melts the ink and fuses it to the surface of the thermal transfer

label shown above.

• Black and many color ribbons can be utilized.

• Thermal Transfer Labeling utilizes a ribbon (Thermal Ink) that is heat activated to

Fuse the print information on the label surface

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Thermal Transfer Labeling Ribbons:

Wax Ribbons - Works Best for Most Applications

• Wax/Resin Ribbons

• Resin Ribbons- Unmatched Print Quality and Durability

• Resin Ribbons

- Unmatched Print Quality and Durability

• Ideal for Use:

• With all synthetic materials and some top coated labels and tags

• In environments with harsh to extreme exposure to chemicals

• When applications require strong resistance against ultra high

temperatures and harsh outdoor environments

• Wax/Resin Ribbons

• Provides Good Abrasion and Chemical Resistance

• Ideal for Use:

• With top-coated paper and matte synthetic materials

In environments with moderate to harsh exposure

to chemicals and/or abrasion

Wax Ribbons

- Works Best for Most Applications

• Ideal for Use:

• With paper materials

• Where fast print speeds are required (Up to 12 inches per second)

• In environments with little to no exposure to chemicals and/or abrasion

Ink Jet Labeling

Non-Contact printers use a cartridge filled with toner or

liquid ink, which allows them to produce fine-quality

images quickly and quietly. The printer cartridges are

typically recyclable.

• Inkjet printers also form images with tiny dots; they

simply spray small charged droplets of ink from four

nozzles through holes in a matrix at high speed onto

paper.

• It consists of a print cartridge filled with liquid ink and

small nozzles in the form of a matrix.

• However, inkjet printers they are slower than laser

printers.

• An advancement on inkjet technology is the bubble-jet

printer, which uses a type of small heating element which

pushes specially formulated ink through print heads with

128 miniature nozzles.

Laser Labeling Systems:

Laser coding technology is a popular non-contact

option for permanent, high-quality coding. Laser

systems are great for permanent coding of text, time and

date, bar codes, serial numbers and more.

• This technology is an ideal coding alternative where

continuous inkjet (CIJ) printing systems are not

practical

Laser Coding:

• CO2 and Non-CO2 Laser Marking Equipment for Moderate to High-

Speed Applications

• Types of non-impact printers include the laser printer, which

creates images with dots.

• Laser printers are one of the most popular types, as they produce

sharp, crisp images and also provide resolution from 300 dpi to

1200 dpi. They are not only fast, but also quiet.

• Ideal for both simple and complex code requirements on a range

of substrates including paperboard, glass, painted metal, paper

labels, PET and other plastic materials.

• Meets a broad range of applications in many food, beverage,

cosmetics and pharmaceutical operations

Package Labeling Equipment and Coding Methods

Tamp

Wipe-on / Merge

Tamp and Blow

Print and Apply

Blow On

Two panel

Corner Wrap