Label Waste Removal Issues in Adhesive Label Production? A Case Study Provides the Answer!

In the production of adhesive labels and electronic auxiliaries, waste removal issues are common. When waste removal problems arise, it's crucial to consider cost-effective solutions, sometimes implementing multiple approaches simultaneously. This article discusses a real production case to share improvement strategies when dealing with waste removal challenges in adhesive labels product

ion. We hope this can offer valuable insights for those facing similar challenges.

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Adhesive Label Knowledge – Types & Components of Adhesive Labels

Before diving into the specifics of waste removal issues, it’s important to understand the basics of adhesive labels, as well as the different types used in the industry. Whether you are dealing with thermal labels, thermal transfer labels, or direct thermal labels, understanding their composition and uses is essential.

Key Components of Adhesive Labels

Adhesive labels consist of three primary components:

Face Stock

The base material of the label, which can be made of paper, plastic, or synthetic materials like polyester or polypropylene.

Adhesive

The glue that binds the label to surfaces. The adhesive type varies based on application requirements—hot melt adhesive, pressure-sensitive adhesive, etc.

Liner

The backing material that protects the adhesive until the label is applied.

Types of Adhesive Labels

Thermal Labels

Ideal for short-term use, such as receipts and shipping labels.

Thermal Transfer Labels

Used for long-term applications, ideal for product identification, inventory tracking, and shipping.

Direct Thermal Labels

Used for labels printed with direct thermal printers, often for short-term use in environments like shipping and retail.

Case Study – Solving Waste Removal Problems in Paper Label Production

At Sailinglabel, a direct factory supplier of high-quality adhesive labels, we encountered waste removal issues during the production of a kraft paper sealing label. The machine was regularly breaking waste materials during the waste removal process, and manual intervention was required, which significantly increased costs and production time.

Through on-site observation, we identified the following key issue:

Thick adhesive layers: The thick, sticky adhesive was causing the label to re-adhere to the waste material after die-cutting.
Label and waste material adhesion: The waste material was sticking to the finished label, making it difficult to separate, which led to waste material breakage.

Solution – Optimizing Die-Cutting and Waste Removal Process

Step 1: Die-Cutting Pressure Adjustment

The first thing we checked was the die-cutting pressure. Using a ink test method, we applied ink to the die-cut area and observed whether the cut was complete and even. The die-cutting pressure was found to be appropriate, ensuring proper separation of the label and adhesive layer.

Step 2: Adhesive Review

Upon reviewing the material’s Technical Data Sheet (TDS), we found that the hot-melt adhesive used in the kraft paper label had high initial tack and was very active at higher temperatures. This led to significant re-adhesion after die-cutting, resulting in waste material breaking.

Step 3: Modifying the Waste Removal Process

We introduced the following changes to optimize the waste removal process:

Die Cutting Foam Adjustment: We reduced foam padding to only the die-cut areas to avoid unnecessary compression of the waste material, which helped reduce re-adhesion.
Roller Adjustment: The large rollers were replaced with two smaller rollers, focusing pressure only on the waste edges, avoiding contact with the finished label.

Additional Tips for Optimizing Adhesive Label Production

Avoid Sharp Angles in Die-Cut Designs

Die-cutting sharp angles can lead to stress points that make the waste material prone to tearing. It’s recommended to round off corners to at least 0.3mm, reducing the likelihood of waste material tearing.

Minimize Horizontal Die-Cut Orientation

Horizontal die-cutting can make waste material harder to remove because the waste edges will experience more force. Whenever possible, use a vertical die-cut orientation.

Using Small Knife Adjustments

For materials prone to tearing, we can adjust the die-cut design by adding small knives at the waste areas to reduce force in the material’s depth direction.

Sailinglabel – Your Direct Factory Supplier for Adhesive Labels

Sailinglabel is a direct factory supplier of high-quality adhesive labels, including thermal transfer labels, direct thermal labels, and 4x6 thermal fanfold labels. We specialize in manufacturing custom adhesive labels for a variety of industries, including logistics, healthcare, and retail.

Why Choose Sailinglabel?

Direct Factory Pricing: As a direct manufacturer, we offer competitive pricing without the markups from resellers.
Custom Solutions: We offer custom adhesive label solutions tailored to your specific requirements.
High-Quality Materials: We use only high-quality materials to ensure the durability and effectiveness of our labels.

Conclusion

In conclusion, by optimizing the adhesive label production process and considering factors like die-cutting pressure and adhesive characteristics, waste removal challenges can be significantly reduced. Sailinglabel continues to improve its production processes to offer efficient, cost-effective adhesive labeling solutions for businesses worldwide.