How labels are manufactured

The concept of linerless labelling has been around for a very long time. When you receive a parcel that has sticky tape with a logo or a message on, this is the basic concept. Simply take the idea of a plain strip of sticky tape and interface that with a thermal transfer printer, marry this to an applicator head. Voilla a linerless label applicator.

What are self adhesive labels made of?

A standard label comprise of at least 3 layers.


Backing Paper

Being the first layer this is specifically designed with a silicone coating to allow adhesive to stick to it but not permanently.  This allows the label to be removed from the backing when required.  If being used with an automatic label applicator this material must also be strong and not have any damaged edges.

Adhesive

This layer is vital to ensure the label itself will adhere to the surface it is to be applied.

Many differnet types of adhesive can be used depending on the final application surface and the desired longevity.

Label Material

Available in many different materials, this must be matched to the task required of the label.

Top Coat 

An optional top coat can be laminated over the label to ensure durability.

How are self adhesive labels manufactured?


Jumbo Roll

First the base label material is manufactured into large jumbo rolls.

Each roll will be made of a specific backing paper, adhesive and label material.

Cutting and printing

The jumbo roll is then run through a label press.  This large machine will take a jumbo roll of material and using special die’s and printing plates convert the large roll of material into the desired size and pre print of a label.

Die’s and printing plates

For every size of label a die would need to be manufactured to make a cutout on the jumbo roll.  This die will include the width height and repeat of the labels in both horizontal and vertical directions.  As these are being cut into the jumbo material they will also be slit to the appropriate size.

How are linerless labels manufactured?

Now we have established how standard labels are made, we can now explain how linerless labels are manufactured. Lets start by looking at the layers.

Linerless labels can have either two or three layers:-

Layer 1 Adhesive

This is required to ensure the label sticks to the final application surface.

Layer 2 Label Material

Normally manufactured using a polypropylene material this provides thermal transfer printers with an amazing print quality definintion when compared to standard paper labels,

Layer 3 Silicon Coating

Some linerless label material have a coating of silicon on the facestock.  This coating is designed to prevent the adhesive sticking to the facestock when rolled up. This is a neccesary requirement when using standard paper material otherwise the adhesive would be absorbed by the paper material and would not peel apart.

Our linerless material is a smooth plastic base whereby the adhesive cannot seep into the fibres of the material and therefore no silicon coating is required saving time and money at the manufacturing side and bringing these cost savings to the end user.

To use a linerless material with no silicon requires a specially built applicator that can hendle such media just like our linerless label applicator range.

Our linerless product only has 2 layers

How does linerless label technology work?

The end result of The end result of the linerless label manufacturing process is best described as a large roll of sticky tape. This continuous roll of label material is installed into an applicator design specifically for this type of media called a linerless label applicator.


This machine will normally include a thermal transfer printer to print any data onto the linerless material, a cutter to cut the material after it has been printed and an application head of some form to apply the printed label to a product.


Why use a linerless label Applicator?

Up to 30% savings on cost of label material when compared to standard labels.

Due to the greatly reduced overheads in the manufacture of the linerless material and the reduction in media dimension and weight, linerless labelling can boast savings of upto 30% on standard label material.

Larger capacity rolls reduce logistic costs and decreases downtimeThe average roll length for our applicators using standard labels with a 78mm core is 421 metres.  By removing the backing paper with the linerless material we can achieve 900 metres per roll.


Friendly to the environment

The elimination of backing paper means that there is no backing paper waste to dispose of that normally ends up in landfill. This also means the total media weight is less in comparison to standard labels therefore reducing shipping costs.

To make recycling even easier our linerless label material can be recycled along with most plastic outer wrappers. This ensures that when applied to an outer the whole material can be recycled without the need to remove the label first.

Having the linerless material specifcally made for thermal transfer creates print quality that is far superior to that of  a standard label. For barcoding this increases the ansi grade rating of the printed code and improves the crispness of all text.

Superior print quality over standard paper labels

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