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Adhesive Application on Web Presses Creating Pressure Sensitive Materials Inline

Clark Brown Director of Engineered Products Valco Cincinnati

Label converters can save money, control quality and increase business when

considering adhesive application inline.

Inline adhesive application

– Continuous (floodcoat) application – Intermittent (pattern) application – Spot gluing – Remoistenable – Removable – Pressure sensitive

Adhesive Application

Adhesive types for labels – Solid adhesives

• Hot melt PSA • Acrylic • Fugitive • Hot melt UV curable PSA

– Liquid adhesives

• Waterbased acrylic • Emulsion • Solvent

Adhesive Application

Products which can be manufactured inline utilizing adhesives

– Mailers – Forms – Form-to-label – Inserts – Specialty tapes – Pressure sensitive labels

Adhesive Application

Creating pressure sensitive label stock inline

What is it?

Continuous or intermittent coating of pressure sensitive adhesive (and possibly silicone release) on an in-line web press or coating machine

Creating Pressure Sensitive Label Stock Inline

− Single web (also called liner-less) with a silicone or adhesive coating applied over the printed label and rewound onto itself

− Multi-web presses used for paper to liner is the most common; webs are nipped together and rewound

Why Create pressure sensitive label stock inline?

– Print and Manufacture label stock in one operation

– Reduce costs and control quality – Reduce inventory; just-in-time delivery – Open new markets

Creating Pressure Sensitive Label Stock Inline

• Eliminate/Reduce purchased pre-coated label stock – Print, coat adhesive (and apply silicone), in one pass

for increased added value and cost savings – Cost of adhesive and liner can be less than pre-

coated label stock purchased from supplier – Reduce waste – Reduce stock – Eliminate intermediaries and multiple operations – Use adhesives specifically designed for the product – Just-in-time manufacturing

Creating Pressure Sensitive Label Stock Inline

• Apply adhesive only where required (pattern coating) – This can be done with intermittent application

and/or ‘stripe’ application – Reduces adhesive usage (cost) – ‘Frame’ label to make it easier to remove – Reduce label stock width to only what is

required (partial width, eg. tags, coupons) – Multi-web lamination and printing (specialty

labels)

Creating Pressure Sensitive Label Stock Inline

• Open New Markets and create unique labels – Reverse printing – Print both sides of the web – Reduce label plies – Reduce or eliminate liner (environmentally friendly) – Apply to unique substrates, such as foils, clear films or magnetic backing

Creating Pressure Sensitive Label Stock Inline

Control Your Own Destiny And

Increase Profit Margin!!!

Creating Pressure Sensitive Label Stock Inline

How

Do you create pressure sensitive label stock inline?

Creating Pressure Sensitive Label Stock Inline

1. Determine the type of label(s) to be manufactured.

Examples: – General purpose permanent labels – Clear labels – Removable labels – Re-usable/resealable – Flexible – FDA/direct food contact – Resistance to water and chemicals

Creating Pressure Sensitive Label Stock Inline

2. Based on the type of labels to be manufactured, determine the best machine for the application

Machine Considerations

– New machine or existing machine? – Single or multi-web machine? – What machine speeds are required?

Creating Pressure Sensitive Label Stock Inline

Can a current machine be updated with application equipment to manufacture the product?

Courtesy Mark Andy

Creating Pressure Sensitive Label Stock Inline

Often, an inline coating station can be retrofitted to an existing press without significant upgrades to tension control or web handling. This option allows converters to open new markets with minimal investment, machine modification and operator training.

Although material savings is not as high as when

coating adhesive AND silicone inline, some applications can realize a savings of 20% or higher.

Creating Pressure Sensitive Label Stock Inline

Example: Inline machine with label ‘coupon’ Flood-coat pressure sensitive coated inline

Semi gloss paper label stock: $.25/msi

Paper: $.05/msi Liner: $.13/msi Adhesive: $.05/msi Total: $.23/msi

6 inches

12 inches

Savings: 8%

Creating Pressure Sensitive Label Stock Inline

Example: Inline machine with label ‘coupon’ Pattern-coat pressure sensitive coated inline

Paper: $.05/msi Liner: $.09 (width reduced 33%)

Adhesive: $.01 (reduced 80%)

Total: $.15/msi

4 inches

3 inches

Savings: 40%

Creating Pressure Sensitive Label Stock Inline

Is a complete new machine purchase viable to create new business and new markets?

Courtesy ETI Converting

Creating Pressure Sensitive Label Stock Inline

A new machine investment may be worthwhile for converters specializing in a particular market or product.

While initial investment is much higher, material

savings can be 30% or higher as compared to purchased label stock.

Creating Pressure Sensitive Label Stock Inline

Example: Flood coating, ETI Machine Semi gloss paper label stock: $.25/msi

Full coat pressure sensitive coated inline Semi-gloss paper: $.05/msi Silicone: $.02/msi Liner: $.05/msi Adhesive: $.05/msi Total: $.17/msi

Savings: 32%

Creating Pressure Sensitive Label Stock Inline

3. What is the best application method for the adhesive?

Slot die? Rotary die? Gravure rolls? Reverse rolls? Meyer bar? Spray?

Creating Pressure Sensitive Label Stock Inline

Inline coating station with slot die

Spray applicator

Inline rotary die station

Creating Pressure Sensitive Label Stock Inline

Gravure application system

Reverse roll application system

Creating Pressure Sensitive Label Stock Inline

Common Application Methods

Slot and Rotary Die

Creating Pressure Sensitive Label Stock Inline

Slot die application:

– Easy to install and operate…lowest cost option for existing machine

– Consistent metered adhesive application; completely enclosed

– No cleanup…very low maintenance

– Width of coating is easily changed; matching specific product width, or creating stripes of coated and uncoated areas as required

– Can be designed to handle a broad range of adhesives for various style products

Creating Pressure Sensitive Label Stock Inline

Intermittent slot die applicator

Creating Pressure Sensitive Label Stock Inline

Rotary die application:

– Can be retrofitted to existing machinery

– Ideal for clear to clear applications, transparent labels, adhesive tapes and flexible packaging where a glossy, streak free finish is required.

– Some cleanup… minimal maintenance

– Width of coating can be changed, matching specific product width, however cannot be used for pattern coating.

Creating Pressure Sensitive Label Stock Inline

Rotary die applicator with servo driven bar

Creating Pressure Sensitive Label Stock Inline

Adhesive supply units for extrusion systems

Typical adhesive supply tank

Drum unloader supply unit

Closed delivery path - adhesive is completely sealed from the environment

Creating Pressure Sensitive Label Stock Inline

4. What adhesive is going to be used?

The type of label plays a big part in the adhesive to be used PERFORMANCE - What does the label need to adhere to?

− Metal, paper, plastic, etc. ENVIRONMENTAL - What conditions must the end product withstand?

− Extreme temperature conditions (freezer, hot filled products)

− Chemical and solvent resistance − Water resistance − UV resistance

Creating Pressure Sensitive Label Stock Inline

Creating Pressure Sensitive Label Stock Inline

Courtesy Henkel Adhesives

Creating Pressure Sensitive Label Stock Inline

5.Substrate

– Standard paper-to-label application? – Coating liner or direct application? – Multi-ply label? – Liner-less? – What is the composition and strength requirements of the facestock (paper, film)?

Creating Pressure Sensitive Label Stock Inline

Summary: The keys to creating successful pressure sensitive materials in-line are:

Creating Pressure Sensitive Label Stock Inline

– Determine specific products to be manufactured

– Determine machine and application requirements

– Compare new raw material costs to purchased label stock

– Justify equipment required to run the product(s)

– Keep it simple for the operator to run!

THANK YOU!!!