Presentation on theme: "Pressure Sensitive Labels 101"— Presentation transcript:
1 Pressure Sensitive Labels 101 Global VenturePressure Sensitive Labels 101
2 Contents 1 Construction of the Pressure Sensitive Label 2 Components of the Pressure Sensitive LabelLinersRelease SystemsFacestockAdhesives3Selecting Pressure Sensitive Stock4The Global Venture Process5Review / Q&A
3 Chapter 1 1 Construction of the Pressure Sensitive Label Paper Making ProcessParts of the Label
4 Paper Making Process - Simplified Drying&Roller Press ProcessPulp Productionby adding chemicalsRemoval of barkChippingTimber
5 Start with a release liner Building a LaminateStart with a release linerRelease CoatingRelease Liner
6 Apply Adhesive to Release Coated Liner Applying AdhesiveApply Adhesive to Release Coated LinerAt The Back EndAdhesiveRelease CoatingRelease Liner
7 Why is adhesive coated on the liner? Minimize heat exposure to FacestockReduces the web path that the facestock has to travelImprove consistency of adhesive / release bondIndustry norm to transfer coat adhesive
8 Top Coat & Primer Coating At The Front EndTopcoat or Print Receptive CoatingFacestockPrimer or Barrier Coating
9 The Finished Pressure Sensitive Label Top CoatorPrint Receptive CoatingFacestockPrimer or Barrier CoatingAdhesiveRelease CoatingRelease Liner
10 Chapter 2 2 Components of the Pressure Sensitive Label Liners Release SystemsFacestockAdhesives
11 in Determining Release of Product Liner RequirementsSmoothFiber & Contaminant FreeConsistent (Web is flat)RobustDistortion Free (Curl)Minimum ElongationHigh Heat ResistanceHigh Tear StrengthFunctionalGood Release Coverage & AnchorageEconomicalStatic ResistanceDie-Cut ResistanceDimensionally StableConsistent Caliper#1 Factorin Determining Release of Product
12 Super Calendered Kraft Liner ChoicesPolycoated Kraft(44 PP or 44 PK)Natural or Brown Kraft(NK or BK)Super Calendered Kraft(SCK)SpecialtyPolyester(PET)Glassine
14 Release Systems Choosing Release Systems High speed dispensing requires lowInitiation and average releaseChoosing Release SystemsConformable face stocks such asFilms need low release valuesHand application, multi-stepConverting, and piggy backConstruction tend to have higherRelease values
15 Paper Facestock Cellulose Fiber: Basic Building Block Fillers: Clay, TiO2, Silica, CaCO3Increase StiffnessAffects Porosity and AbsorbencyIncreases Brightness and OpacitySurface Sizings/Coatings: Starches, BindersImproves StrengthAffects WettabilityAffects Holdout and AbsorbencyImproves Smoothness
16 Direct Thermal Vs. Thermal Transfer Short-Term ApplicationsWhen Printing: Ribbons are not required, image is directly printed on material.Mostly Black & White PrintingNot as crisp as Thermal TransferLabels darken subjected to heat and sunlightVery Popular in the Food Service Industry & Indoor ApplicationsLower cost of Printing on Direct Thermal since ribbon is not requiredCommon applications include: shipping labels, including compliance labels; receipts; pick tickets; coupons; event tickets; citations and parking tickets; name tags; visitor passes; and more.Thermal TransferWhen Printing: Requires the use of a carbon ribbon which gets transferred to a substrate via heat.Paper can be printed with variety of colored RibbonsVery crisp and durable; excellent for high-density barcodes and longevity labels.Common applications include: product identification; circuit board tracking; permanent identification; sample and file tracking; asset tagging; inventory identification; certification labels such as UL/CSA; laboratory specimens; cold storage and freezers; and outdoor applications.
17 Laminated Foil / Metalized Papers Facestock Paper facestock baseAdditional coatings applied to face and back sideProvides additional smoothness for less distortion of foil / metalizationThin foil laminated to face or aluminum applied via vaporization in vacuumAcrylic top coat to supply an adequate print surface
18 Film Facestock FILM FILM Film Facestock Ingredients Monomer: Basic Building Block typically derived from petroleumStrength (Back-Bone)Basic Properties of FilmFiller: Clay, TiO2, Silica, CaCO3Increase Stiffness, Brittleness, and OpacityAffects Porosity, Gloss, and AbsorbencyCoatings, Co extrusion Layers (Topcoats, Primers, Skin Layers, Tie Layers)Increase Wettability (Surface Energy)Improves Smoothness
19 Special Composites or Blends Facestock FILMSaturated PapersSaturated with latex to improve strength and moisture resistanceSynthetic PapersFilms that print or function like paper with film durabilityMulti-film/paper laminatesPaper/film/paper provides tear-resistance
20 Pressure Sensitive Adhesives Basic Building-BlocksTypes AvailableRubber / AcrylicHow They Get CoatedSolvent / Hot Melt / EmulsionHow They FunctionPermanent / Removable / Application
21 Rubber Adhesives Pro’s / Con’s STRENGTHSWEAKNESSESEconomicalGood AvailabilityGood Quick StickGood Moisture ResistanceWell EstablishedAmber in ColorDegrades When Exposed to UV LightShorter Shelf LifePoor Solvent ResistanceNarrower Temperature Range
22 Acrylic Adhesives Pro’s / Con’s STRENGTHSWEAKNESSESGood UV ResistanceBroad Temperature PerformanceGood Stripping QualitiesClear in ColorLonger Shelf LifeGenerally More Expensive than RBMay Require TackifiersMay Turn White When Exposed to Moisture
23 Adhesive Properties PROPERTIES Rubber Based Acrylic UV Stability Poor – FairGood - ExcellentAging StabilityFair - GoodDie CuttingWide Web ConvertingInitial AdhesionMedium - HighLow - MediumUlt. AdhesionMediumHighQuick-TackCohesive StrengthClarityPoor - FairPlease note these are generalities, there is an extremely wide ranges of performance in rubber and acrylic adhesives.
24 Adhesive UsageAcrylic Vs. RubberACRYLIC69%RUBBER31%
25 Coating Method for Adhesives 123HOT MELTSOLVENTEMULSION
26 Solvent Adhesive Advantages / Disadvantages Allows Crosslinking for StrengthHigh Temperature ResistanceGood Water ResistanceWell EstablishedEPA RegulationsResidual SolventsPotential Poor Solvent ResistanceRubber-Based are Amber ColoredPotentially DangerousHigh Cost
27 Emulsion Adhesive Advantages / Disadvantages Initially Less AggressiveLimited Water ResistanceTackifiers needed for Quick TackModerate CostFew EPA ConcernsExcellent ConvertingBroad Temperature RangeGood ClarityMany Formulations
28 Hot Melt Adhesive Advantages / Disadvantages Poor Temperature ResistanceLimited Adhesive Performance RangeFair ConvertingAmber Color if Rubber-BasedFew EPA ConcernsHigh Quick TackEconomicalNormally Good Adhesion to Most Plastics
30 Basic Adhesive Performance Intended for Life-Cycle of end-use product. The adhesive is characterized by a relatively high ultimate adhesion to a wide variety of surfaces.Open Time: How long before it becomes permanent.Repositionability: How long you can remove and re-apply.Tamper Evident: Either facestock distorts or leaves adhesive residue (evidence).PERMANENTADHESIVEREMOVABLEIntended for applications requiring removal of the label intact .No residue or ghosting when removed.Short expected life-cycle.The adhesive is characterized by low ultimate adhesion.
31 Adhesive Categories ADHESIVE COLD TEMPERATURE FREEZER GENERAL PURPOSE ALLTEMPERATUREADHESIVEPHARMACEUTICALHIGH TACKSPECIALTY
32 General Purpose & Cold Temperature Adhesives Applications Designed for Ordinary ApplicationsGood ConvertingGENERAL PURPOSE“House” AdhesiveBalances Price Vs. PerformanceApplications Below 40 FCOLD TEMPERATURE (FREEZER)Formulated for Adhesion at Low TemperaturesMaintain Tack at Low TemperaturesTends to soften with Temperature rise
33 All Temperature & High Tack Adhesives Applications Designed to Cover Normal to Freezer ApplicationsALLTEMPERATUREDescent ConvertingSometimes the “House” AdhesiveHigher Price for Wider PerformanceSoft Adhesive / Easy FlowingHIGH TACKHeavy Coat WeightOoze Converting / Shipping / Storage Issues
36 Selecting a Pressure Sensitive Stock What Type of Pressure Sensitive Laminate Do I Need?FunctionEnvironmentalIssuesPrintingImagingNeedsReleaseSystemDesignFacestockEnvironmentsAdhesivePerformanceLinerSelectionEconomics
37 Selecting a Pressure Sensitive Stock FacePrimary ConsiderationEDPVIPLinerSecondary ConsiderationAdhesiveTertiary ConsiderationNote: Different Markets have Different DriversFacePrimary ConsiderationPRIMELABELAdhesiveSecondary ConsiderationLinerTertiary ConsiderationLinerPrimary ConsiderationGENERALLABELINGAdhesiveSecondary ConsiderationFaceTertiary Consideration
38 Label Converters Criteria Finding the Sweet SpotAESTHETICSTHE COMPROMISEFUNCTION&PERFORMANCEPRICE
39 Eliminate Mistakes, Ask The Right Questions Describe the ApplicationIs this a new application?Any previous problems with the application?Have samples of past or current labels?What does final label need to look like?What is the substrate - material, texture, shape?What is the expected label lifetime?Does the label need to be permanent or removable ?What are the application conditions, temperatures, service ranges, etc…?How is the label applied, auto or hand?How will the labels be stored and how long?What should they cost ?What are the typical order sizes and estimated yearly volume?What is inside the package to be labeled (possible migration issues)?How will the labels be supplied - rolls or sheets?Will the end-user be doing any printing - TT, Laser printer, etc.?Any demanding end-use conditions or operations - sheet fed printer, auto insert, closure label, etc...?
42 The Global Venture Process Phase 1Global Venture Enters OrderGlobal Venture enters order according to Customer SpecificationsEnables Global Venture to asses pricing, inventory of products, and time of completion
43 The Global Venture Process Phase 2Materials & Die OrderedGlobal Venture has an Extensive in-house inventory of Dies and Pressure Sensitive StockIf Stock is unavailable, Special Material and Dies are ordered
44 The Global Venture Process What is a Die?A cutting tool which is cylindrical in nature. Sharpened steel blades are bent and formed around the outer surface of the cylinder to the pattern to be cut.Blades are held in position with high density plywood.Blade thickness typically runs between .056 and .112 inches.Fold lines, scores, and perf cuts can all be made.
45 The Global Venture Process Phase 3Submitting ArtworkState-of-the-art, graphic software is utilized to ensure labels print exactly as requested.Utilize one of our many die layouts to design your artwork
46 The Global Venture Process Preparing your ArtworkBleedDetermined by adding 0.125" to the width and length dimensions (2" x 3" label would need to have the art board set at 2.125" x 3.125"). This is important because there can be slight shifts in alignment when the labels are die cut. Shifts of up to 1/16" may occur and are within acceptable industry standards.BordersBorders bleeding off of a label need to be at least " in thickness and meet the bleed edge.LABEL
47 The Global Venture Process Preparing your ArtworkFontsSubmitting a file that is not flattened (files other than jpeg, tiff, bmp), change all text to outlines or embed the fonts into the file.The minimum printable font size for black text on a light background is 5pt and for color is 7 pt.File FormatPreferred format is PDF.Use the "Press Quality" preset, convert your text to outlines, make sure there is no color conversion, and make sure that there is no down sampling of the images (unless above 800dpi).Formats we accept are: .eps, .ps, .ai, .psd, .jpg, .tiff, & .pdf
48 The Global Venture Process Preparing your ArtworkColorsAssign Pantone or Process color(s) to your artwork.Ensures accurate representation of your logo/art when matched at the press.Please note: The color you see on your computer screen isn't necessarily what color will print because monitors can adjust the color contrastsResolutionMinimum resolution is 300 dpi & Maximum resolution is 800 dpi. We encourage our customers to submit files that have a higher resolution. This makes dramatic improvements in quality especially when there is text on the label.
49 The Global Venture Process Proofs Submitted for ReviewPhase 4Communication is vital to achieve Success in Final Proof of Label
50 The Global Venture Process Designing Plates ProcessPhase 5Laser engraved Photopolymer platesDirect laser engraving of Flexo Photopolymer plates (which fit over a cylinder).Utilized in wide array of presses, including narrow and wide (up to 61.5 inches wide), and mid-web flexo presses (up to inches wide).Fully Digital Process - Filmless.No integral ablation mask.High-powered carbon dioxide laser head burns away, or ablates, unwanted material. The aim is to form sharp, relief images with steep, smooth edges to give a high standard of process color reproduction.A short water wash and dry cycle follows.
51 The Global Venture Process Phase 6ProductionTechnologically advanced flexographic presses—the most cost-effective method of manufacturing and printing high-quality, pressure-sensitive labels.Flexographically designs in up to ten colorsExceptional photographic quality, using water-based, UV flexo, or a combination of UV flexo and UV rotary screen printing.Presses accommodate all of standard and specialty label materials, including papers, films, foils, and vinyl's.
52 The Global Venture Process How does the Flexographic Press Work?Flexo-Plate - Creating a positive mirrored master of the required image as a 3D Relief in a rubber or polymer materialMeasured amount of ink is deposited upon the surface of the printing plate (or printing cylinder) using an engraved anilox roll whose texture holds a specific amount of ink.Print surface then rotates, contacting the print material which transfers the ink.Large Dryers are utilized to dry the ink onto the paperPerforation, Slits, etc…stageRelief is removed, outcome is the Matrix and Final LabelFinal Labels are rolled for rewinding
53 The Global Venture Process Slitting & RewindingPurpose:Rewinding: Customer requests for direction of labels for there manufacturing plants.Slitting: Utilizing sharp blades to cut larger quantities of rolled labels to smaller rolled quantity rolled labels.Variations:Rewind DirectionQuantity of LabelsCore size
54 The Global Venture Process Rewinding Directions & Standard Core SizesStandard Label Core Inside Diameters:944”, .995”, 1.015”, 1.025”, 1.075”, 1.122”, 1.500”, 1.820”, 2.000”, 2.015”, 2.285”, 2.535”, 2.750”, 3.015”, 3.025”, 3.032”, 3.040" & 6.035”Lengths range from .25” to 12”
55 The Global Venture Process Phase 7Order ShippedExcellent Vendor relations, enabling cost-effective shipping methods
57 What have we learned?What are the parts of a Pressure Sensitive Label?In reference to liners; what is the number one factor in determining release of product?What is the main difference between Thermal Transfer & Direct Thermal Facestock?Name three strengths and three weaknesses of Acrylic and Rubber adhesives?What is the difference between Permanent and Removable Adhesive Labels?What are the different types of adhesive usage?How do you find the “Sweet-Spot” when determining your label needs?What is the purpose of a die?What format of artwork does Global Venture accept? (i.e. colors, file, resolution?)How many different ways can a label be re-wound?What are some choices in sizes of label cores?What are the three main questions you need to ask to make your label just right!
58 Answers Weaknesses Weaknesses Top Coat, Facestock, Primer Coating, Adhesive, Release Coating, & Release LinerFunctionalThermal Transfer is printed with a ribbon and Direct Thermal is ribbonlessAcrylicStrengthsGood UV ResistanceBroad Temperature RangesLonger Shelf LifeRubberEconomicalMoisture ResistanceGood AvailabilityPermanent Labels is for one-time application only. Removable can be re-applied numerous times.All Temperature, Cold Temperature, Pharmaceutical, High Tack, General Purpose and SpecialtyWeaknessesExpensiveMay turn white when exposed to moistureMay require tactifiersWeaknessesDegrades when exposed to UVShorter Shelf LifeNarrow Temperature Range
59 Answers Continued…By Compromising a little for Aesthetics, Price, Function & Performance.A cutting tool with sharp blades utilize to cut out the labelArt Files:Preferred Format - PDFMinimum Resolution – 300 DPIEnough Bleeding / Border spacePreferably Pantone Color InformationFont – Black (minimum-5pt) Color (minimum – 7pt)A Label can be re-wound 8 waysSample Core sizes –944”, .995”, 1.015”, 1.025”, 1.075”, 1.122”, 1.500”, 1.820”, 2.000”, 2.015”, 2.285”, 2.535”, 2.750”, 3.015”, 3.025”, 3.032”, 3.040" & 6.035”THE ANSWER IS THERE ISN’T ANY, ASK AS MANY QUESTIONS TO GET THE JOB DONE RIGHT!