Printer Labeling and Label Laminating Solutions
All labels are not created equal. The choice of materials and proper manufacture of a label are important factors for successful dispensing during automatic application. What may appear to be a machine malfunction can often be traced to inferior materials or faulty label manufacturing. Purchasing a label that was not manufactured for use with automatic printer applicators can often lead to demise. This document can serve as a guide so that you can be a better educated consumer.
Selecting a vendor to supply labels for your printer applicator is a ``make or break`` decision. Often, the cost justification of a printer applicator is based upon its ability to automate a process, i.e. operate unattended. Therefore, the labels printed in a thermal transfer printer and hand applied may not be the right choice for use in a printer applicator. When hand applying, a person can accommodate ``sub-par`` labels that may not peel well, have weak adhesive, are wound to tight.
Choosing Quality Label Materials
A good label starts with good material. To cut material costs, some manufacturers purchase mill-end paper. As with any ``left-over`` product, mill-end paper lacks consistent quality. For example, it may be uneven, rough and vary in thickness. A rough paper surface will wear the print head prematurely. Inconsistency is the enemy of automation!
The Die-Cutting Process
To give labels their shape and size, they are die-cut and the waste is pulled away. The process involves the use of precision tooling that needs to be constantly maintained. If not maintained, it will affect the depth of the die-cut, making the cut either too deep or too shallow.
Die Cutting Depth
Deep die-cuts will penetrate beyond the adhesive and through the silicone coating on the liner. This leads to two possible failures. First, cutting through the liner will make the liner tear under stress. Since the liner acts as the label ``carrier,`` this can cause the applicator to shut down. It could appear that the printer applicator is tearing the label on sharp edges when in reality the tear is caused b a weak liner.
Secondly, deep die cuts can cause the adhesive to migrate past the silicone and into the liner. When this happens, the adhesive will bond to the liner and will not release from the liner. The result is a label that does not ``strip`` onto the applicator head but rewinds onto the take-up roll.
Shallow die-cuts will cause the adhesive to ``string-out.`` This results in excessive adhesive that oozes out around the label and eventually will ``gum-up`` the printer and applicator mechanisms or attach to the back of the liner causing the label to pre dispense as the roll unwinds.
To compensate for a dull cutting tool, some manufacturers increase the pressure on the die-cutting press beyond the recommended force. A too high pressure will cause the cut to be rough and pushes the adhesive into the liner, subsequently causing the label to not strip properly when dispensed in the printer applicator.
For increased throughput, some manufacturers run the die-cutting machinery and rewinders at very high speeds. This leads to two label failures. First, the high speeds on the machinery will cause the labels to be tightly wound on the core. Tightly wound rolls result in adhesive that is squeezed out onto the label gumming-up the printer and applicator mechanisms. Running the machinery at higher speeds creates a dusty manufacturing environment. Dust on the label can cause a void in the bar code during printing. A void is a small area that did not print. After scanning, a void on the label may give a no-read or false-read condition. This is especially critical with today`s high-density, high-resolution codes.
Identifying Problems - Marker Test
Not every problem can be avoided up front. However, performing this simple test can help identify if the die-cuts are within specification. This test should be performed at the start of every roll and after every splice. To perform the test, use the following procedure.
- Use a water-based felt tip marker. This may be any color. The wider the tip the better.
- Remove three to four labels from the liner.
- With a back and forth motion (covering the width of the web where the labels were taken) lightly wipe the marker across the web.
- Inspect the liner for spots where the ink ha penetrated the paper. A very light line around the perimeter of the label is normal. However, if the lines are dark the die cut is too deep.
The Image-Tek Solution
At Image-Tek, we have spent years developing labeling systems. For us, a system involves everything from the adhesive to the applicator head design to the bearings used in the printer applicator drive mechanism. Each component can be compared to a link in a chain. The weakest link determines the strength. When it comes to the label, we know what can ``make or break`` the application. We use high-precision die-cut presses that run at lower speeds. This allows us to control the process. When choosing the label material or liner, we design and manufacture materials specifically for use in printer applicators. Factors such as weight of the material and adhesive/line release properties are considered carefully and constantly monitored in our extensive laboratory facility. Our cutting tools are placed on a rigid maintenance schedule resulting in consistent quality.
On The Shelf Program
Image-Tek will stock a minimum of one week`s supply of labels. Contact us to receive a fax form to fill out. You will be sent information on how to obtain a ``rush`` order. Image-Tek will ship the normal supply of labels on a weekly or bi-weekly basis to ensure you have an adequate supply.
Benefits of On the Shelf
- allows for JIT planning
- eliminates down-time caused by out-of-stock situations
-reduces inventory costs
- compensates for expanding needs
- does not have to be a ``standard`` product
* Please Note: this is a trial program and Image-Tek is looking for repeat order customers to design this system.
