PkgT 1210- Module 7

Labeling Systems
Labeling is affixing printed or graphic material onto the package or product. It does not include direct
printing or decorating on the package. Primary purpose of labels is to inform, identify, warn, sell. But
labels serve other purposes as well. They can provide tamper evidence, group multiple products and
close packages. Labels may also take the form of multi-page coupon or instruction books.

In discussing labels, “front” will refer to the outside, non-glued face. “Back” will refer to the container or
glue side of the label. Label “length” will be the dimension of the label in the direction of application. In
the case of roll-fed labels, it will be the length along the roll. Label “width” will be the dimension of the
label perpendicular to the direction of application.

Labels fall into two major categories: flat and sleeve. Flat labels are individual pieces of film, foil, plastic,
paper or composite materials affixed to the product with an adhesive. Sleeve labels are films formed
into a continuous tube and supplied on rolls. Sleeves are cut to length and applied over the package.

Flat Labels Sleeve Labels

Both the flat and sleeve labels can be supplied as a continuous web (roll-fed) or as individual cut labels
(typically referred to as cut-and-stack labels).
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Labeling Systems
FLAT LABELS

Normally, flat labels are die cut into almost any shape, but occasionally, they are butt-cut. Instead of
using the die to cut away waste material, the die simply cuts in between each label. The label extends all
the way to the edge of the web. Most labeling applications require a gap between labels for sensing. If
butt cut labels are used, a registration mark will be required.

Die cut label Butt cut label (green rectangles

illustrate the photoeye marks
between the labels)

Roll-fed labels can be oriented in any of eight positions, called “unwind position,” and numbered 1
through 8. Although there are eight positions, 5 through 8 are seldom used in packaging. Some unwind
charts will show only four positions. This is an industry standard and specifying an unwind position
number should be sufficient but it helps if you could still send this chart to your label suppliers for
consistency.

Unwind Direction refers to the orientation of the labels as they come off the roll. Understanding unwind
orientations is important for label application purposes. If the unwind is incorrect, labels will be applied
to the container on the wrong orientation. This is because not all machines are fed with the labels with
the same orientation, this differ based on the machine requirement.
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Labeling Systems
Take below images for example:

There are four classifications of flat labels, based on the adhesive they use:

1. Pressure sensitive labels (PS Labels)

Labels with pre-applied adhesive that requires no activation. The labels are supplied in roll form
on a backing web, called a liner. The coated paper or plastic film liner allows the label adhesive
to bind with a relatively high shear but relatively low tack strength. This prevents the label from
sliding out of position on the web yet allows it to be easily removed at time of application.

Layers of a PS Label Shear Tack

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Labeling Systems
Shear is the static forces applied in the same plane as the backing while tack is the measure of
how quickly an adhesive bond is formed when two surfaces are brought together with light
pressure. PS labels have high shear but low tack. This prevents the label from sliding out of
position on the web yet allows it to be easily removed at time of application. Due to its low tack,
PS labels require a certain amount of curing time to allow full adhesion to the containers.

Web Material

Web material is important since it is pulled through the labeler, dispensing the label as it goes. If
it does not have sufficiently high tensile strength to withstand the continuous jerking as the
label is dispensed, frequent breakages will occur resulting in lost production. Web could either
be paper or plastic.

Paper-based webs are susceptible to nicking. A small nick in the web will generally cause it to
break. Paper web is usually satisfactory for most applications, especially at lower speeds with
smaller label sizes. Plastic backing webs are stronger and much less susceptible to tearing and
should be used for higher speeds, narrow labels, complex die cuts or other applications where
web breakage might occur.

Nick on the web

Standard Dimensions

The industry standard for roll labels is normally 12-inch outside diameter with a 3-inch core. For
higher speed operations, or where the label is particularly long or thick, larger diameter rolls can
maximize the time between roll changes. 16 and 24-inch rolls may be used but will be heavier
and more difficult to handle. Narrower labels will also be more susceptible to telescoping as the
roll diameter increases.
Roll Industry Standard Dimensions

 12” outside dimensions (OD)

 16” and 24” OD also possible but
use with caution
 3” core
 1/8” gap between labels
 1/16” gap on the sides
 1/8” corner radius
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Labeling Systems
Most pressure-sensitive labels are die cut. They are printed on a continuous film, adhered to the
backing web and a die-cutting machine cuts the label shape. The waste material is then
removed, leaving the label isolated on the web. The industry standard for the gap between
labels is 1/8-inch with the backing web extending 1/16-inch to either side.

Butt cut labels will not have a gap between the labels so some of these dimensions are not
applicable to them.

The PS labeling system consists of the following elements:

1. Web Unwind- where the roll is loaded. It could either be a

free-wheeling hub or driven by a motor
2. Dancer Arm- applies tension to the roll. It could be used
to activate a switch to start the motor unwinding the web
3. Label Sensor- detects the 1/8" gap between labels to alert
the control system to initiate a label stop sequence
4. Peel Plate- a relatively sharp edged metal plate which
separates the label from the backing paper.
5. Drive roller/nip roller- pulls the web backing. A backing
roller normally forces the web against the nip roller to
prevent slippage
6. Takeup Reel/Web Rewind- where the empty web is
collected. It could be driven by a motor rotating at the
same time with the drive roller

2. Heat-activated Labeling
Heat-activated (HA) labels can be paper, foil or film and may be supplied in rolls or pre-cut. If
supplied in roll form, they will be cut at the time of application and will generally need to be
square or rectangular in shape. If pre-cut, they can be square or rectangular but can also be die
cut into complex shapes. HA labels, like PS labels have the adhesive pre-applied, but the
adhesive is dry (non-sticky) and is activated by exposure to heat.

The HA label dispensing system for roll labels is similar to the PS system. However, at the end, as
the label is removed from the backing, it is picked up by a pad and is held by a vacuum. The pad
is heated, activating the adhesive, before it is stuck to the container.

3. Cold glue labeling

Cold or wet adhesive labeling system apply the adhesive to the label or the container at the
point of label application unlike with PS and HA labels where they have pre-applied adhesives.
Cold glue is supplied in liquid form and adheres as it dries and/or is absorbed into the product
and label. Cold glue is often used where complete label adhesion is required unlike with hot
melt adhesive where it is applied only in strips.
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Labeling Systems
Cold-glue systems begin with a reservoir of glue. Glue is pumped from the reservoir and flooded
over the glue application roller to assure complete coverage. A doctor blade scrapes off the
excess glue, leaving a thin film. Excess glue drains back to the reservoir where it is recirculated.
The glue may then be transferred from the roller to either the product or the label.

Adhesive

Glue application without doctor blade Glue application with doctor blade

4. Hot-melt Labeling
Hot melt is more common where the label can be applied with a few beads or strips of adhesive,
such as on canned products. If the label is removed, one can see two vertical strips or vertical
lines of dots of glue hold the label in place. The first glue strip holds the end of the label to the
can. The second vertical strip of glue adheres the label overlap. The advantage of using two
vertical strips is that glue consumption is greatly reduced. A disadvantage is that the label is only
fastened to the product at a single point. If the label tears, it may fall completely off the
product. Hot melt glue in the form of pellets or pillows is melted in a hot vat and then applied to
the labels and containers through a nozzle or gun much like how a glue gun works.

Sample hot melt glue Hot melt Cold glue

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Labeling Systems
Flat Label Application

Label position consistency depends on atleast three factors:

1. Label dispensing- The timer for the drive should be adjusted accurately so the label position on
the peeler plate is enough to be picked up by the bottle. The photoeye sensor will guide the web
to consistent label-stop position.
2. Presentation of the container- Container must be presented to the labeling machine in proper
orientation. It is critical that the bottle be absolutely still, relative to the conveyor at the point of
initial label application. Use of top hold bars, star wheels, guide rails, and other appropriate line
loading mechanisms is important to ensure consistent presentation of the container to the label.
Be sure that they are not too tight or loose. If adjusted too tightly, they will squeeze the bottle,
deforming it. When this happens, the label will not roll on smoothly. As always, smooth
conveying is necessary to reduce container presentation consistency.
3. Variation of the container- Bottle walls must also be consistently flat. However, due to
improper cooling in the molding process, this can cause little bulging or dents on the bottle wall
surface which may be unnoticeable but affects labeling quality. Generally, bottles are best
labeled when full to avoid this.

Whenever necessary, provide tolerance for label placement as labeling machines are mechanical
systems and labeling inconsistency is not uncommon. These inconsistencies can be a source of
disagreement between the mechanic and QC so tolerances and specifications should be set early on
prior mass production.

Labeling Problems Troubleshooting

7. Smooth conveying to avoid bottle

jiggling, aligned properly and moving at
appropriate speed
8. Properly aligned web. Unwind and
takeup roll must be of the same size
9. Guide belts are of the correct gap,
parallel to each other, too tight will
deform the bottle
10. Roll tension is appropriate

Other than this, ensure that adhesive, label, and product combination is correct and label is stored in a
controlled environment as adhesive must not be prematurely activated or lose its effectiveness.

PS labels must be wound on their rolls with a consistent degree of tension. If they are wound too tight,
the label glue can be forced out from under the labels.
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Labeling Systems
SLEEVE LABELS

Sleeve labels are plastic shrink labels formed into tubes which conform to the shape of the bottle upon
exposure to heat. The sleeve is placed and oriented onto the container and is conveyed to a tunnel
where heat is applied, shrinking the label to the container. The tunnel is either using hot air or steam to
heat the label. Shrink labels must be sized so that they will slip easily over the container.

Commonly, HDPE bottles use a hot air tunnel while PET bottles use a steam tunnel. This is because PET
bottles are less heat resistant hence, steam is used with lower temperature.

Shrink sleeves are previously dominated by PVC but due to environmental issues it is being replaced by
PET.

Sleeve labels must be stored in controlled environments to avoid premature shrinking. The same thing
with flat labeling, tolerance setting is important for alignment throughout the process. Common issues
with shrink labeling is usually a cause of improper heating of the label. Cold spots on the container can
cause mapping on the label due to temperature inconsistency throughout the container surface.
Wrinkles is caused by not enough heat while warping may be caused by too much heat.

Temperature is the most critical parameter in shrink labeling so it is important to conduct trials before
mass production to identify the correct conveyor speed and temperature settings. When there’s too
much heat, the temperature could be reduced or the conveyor speed could be increased to reduce the
dwell time. On the other hand, if uncooked label is the problem, conveyor speed could be reduced or
the temperature could be increased.

Wrinkles caused Warping Mapping caused

by not enough caused by too by cold spots on
heat much heat the bottle

Shrink labeling for cut and stack sleeve labels- https://youtu.be/OIJWjZ11imk

Shrink labeling for roll form sleeve labels- https://youtu.be/EgXjSK3Tgig