Value-added labels are the envy of the industry
As Skip Heintzelman writes on page 54, the modern roll label press is a "web-fed converting machine whose primary operation is printing." Some developments over the past six years include combination printing, UV flexo, quick-change presses, short-run digital and narrow web rotogravure.
Equally important to label converters have been the advances in diecutting, including quick-change die stations, micro-perforation, laser systems and flexible magnetic dies.
Almost all of these changes in technology are the result of customer demand. Tarsus Conferences (formerly Cowise) forecasts the market for specialty pressure-sensitive label constructions (form/label combinations, promotional and security) to grow 12 percent in the next year. By working in concert with product manufacturers, label converters are becoming innovators in bringing new products or promotions to market.
Diecutting as a value-added service
Analogous to digital printing, laser diecutting is suited for short-run label converting. "We are not trying to compete with rotary die presses running at 1,000 feet per minute," admits Bill Dinauer, president, LasX Industries, Inc., White Bear Lake, Minn.
Described as a "soft tool," a laser eliminates tool wear, changeover time, fabrication, maintenance and storage, he says. "The idea is zero downtime with immediate changeover plus one laser die station that can perforate, slit, score, through-cut, or kiss-cut with the same tool."
In addition to labels, the LasX system is being used to diecut gaskets, filters, membrane switches, and abrasive materials. The module can retrofit to any existing line or can be integrated as a stand-alone unit.
Zimmer Industries, Inc., Hawthorne, N.J., is no ordinary diemaker. In addition to manufacturing steel rule and flexible dies, it has pioneered microperforations. Its technology can put high-density microteeth on flexible, chemically milled dies to create hidden microperfs and invisible tabbing systems.
The U.S. Bureau of Engraving and Printing is using the technology in-line on Goebel printing presses to convert pressure-sensitive postage stamps in roll form. Previously, when fully diecut, the tightly wound stamp edges would occasionally pop up, exposing the adhesive and mucking up the operation, says Greg Zimmer, owner of Zimmer Industries. Microperforation keeps the stamp edges down, yet allows stamp to separate easily and consistently. "Unless you know these edges where perfed, you probably wouldn't recognize it as such," says Zimmer. The approximately 20x20-in. flexible die used in the postage stamp application can perforate 400 stamps/impression
The technology holds promise. Zimmer Industries has a patent on linerless labels created with micro- perforations, with or without an adhesive. As far as Greg Zimmer is concerned, the stamp is just a point of entry. "We have solved in spades every possible opening problem involving perforated [flexible] packages," he says. Microperforations can facilitate the opening of foil-based packets and make ripping a supermarket produce bag off a roll an easy proposition. Preperforated in-process roll stock and preperforated tapes are also being investigated.
New materials make the difference
New substrates are playing a big role in the creation of innovative label products. At Labelexpo USA 98 it was evident that paper face stocks have become lighter, brighter and offer a better print surface, while the properties of film materials are endless. Innovations in pressure-sensitive adhesives have made the difference for two label converters.
Troy, Ohio-based, 3 Sigma, a manufacturer of adhesive-coated products, supplies innovative removable, repositionable and pattern adhesives to Repacorp's label business in Tipp City, Ohio.
Repacorp's specialty is bar-coding applications. Its Roto Press flexographic press, and others, prints pinfed and fanfolded sheets and rolls up to nine colors with UV coating on a variety of different substrates including gloss papers, polyesters, polypropylenes and tag stock.
Repacorp's blank label program stocks 125 items for thermal-transfer printing. Its service bureau offers thermal-transfer printing, in-line hot stamping and digital thermal-transfer printing. Its Markem (Keene, N.H.) LP8400 digital thermal-transfer press can produce labels in up to four colors, laminate and diecut all in one pass. It also can sequentially bar code the labels.
One unique application is a diecut, with fold, 8-pt tag stock with 3 Sigma's heavy coatweight, pressure-sensitive adhesive. Repacorp's customer thermal-transfer prints a bar code on the label. After affixing it to a box, the top liner is removed, exposing a permanent base stock. Repacorp provides a fold so that the end user can easily tear off the face stock and reposition it elsewhere. The preprinted base stock has the same barcode as the face stock.
Repacorp also uses 3 Sigma's Universal Coupon Film™ for instant redeemable coupons. 3 Sigma's trademarked circle design eliminates the need for a pattern adhesive face stock or designated lift area. It reportedly removes cleanly without leaving an adhesive residue
"3 Sigma is good at specialty items, quick turnaround and they don't require a lot of minimums," notes Tony Heinl, vice president, sales and marketing for Repacorp.
A label and affixing company that focuses its energy on the document side of the business uses 3 Sigma products to produce ID cards and reader impact devices for direct marketing applications. A converter for the trade, American Affixing Div. of American Stenrite, Someville, N.J., affixes labels and other products to business forms, direct mail pieces, carton flats, and converts prime labels for all types of uses.
A dynamic area for the company is ID cards--credit-card size documents used to identify an affiliation with an organization. It converts what it calls "integrated diecut cards" into direct mail forms. Using 3 Sigma's Universal Coupon Film provides the "clean release" that customers seek.
American Affixing uses a seven-color Mark Andy press equipped with a RotoMetric rotary die to convert the 3 Sigma coupon film. President Mike McClain, credits 3 Sigma's predictable release values for the success of the product.
A funky material look also is appealing. Coburn's (Lakewood, N.J.) Diffracto-Lite self-adhesive, metallized plastic film creates "beguiling" light diffraction effects through an intricate array of interlocking geometric prism patterns. It is a polyvinyl chloride (PVC) copolymer, second-surface microembossed, and metallized. A solventless, moisture-resistant, permanent adhesive is standard.
King International, King, N.C., one of the largest sticker manufacturers in the U.S., uses Diffracto-Lite as the base of its popular vending machine decals. "Coburn products have contributed to our success," says president Chris Smith. Exactly the type of partnerships needed in a successful tag and label business.
