Linerless Labels: An Evolving Technology

Although many people think that linerless technology is a new trend, in reality it has been around for 35 years. In 1980, the first linerless labeller called the Monoweb was developed by Turpin Engineering in the UK. In 1990, Ravenwood introduced sleeve labels for the fresh meat pack container. Early in the 2000s, Catchpoint and ETI Converting helped pave the way for linerless technology with development of inline printing and coating technologies. Today other players are offering products and services because linerless is here to stay.

All this was brought about by issues concerning release liner wastage. As everyone in the industry is well aware, release liners only act as a carrier and once the pressure-sensitive (p-s) label is applied to a container, the liner is thrown away. Fifty-two billion square meters of release liners are being landfilled each year, which is enormous. Major brands such as L'Oreal, P&G, Unilever, Coca-Cola, and many others have taken the bull by the horns and have requested greener technologies from their major label printers.

Last month at the TLMI Technical Conference, one of the seminars was entitled "Thin is in." Testing of thinner p-s face material, as well as thinner release liners are now major topics of discussion between brand owners and label printers. What was five years ago a standard clear-on-clear pressure-sensitive construction 2-mil BOPP over a 1.2-mil PET release liner, has been modified to a 1.6-mil BOPP over a 0.92-mil PET and even down to a 0.75-mil (18 micron) PET release liner. Thin is in and this is a good way to reduce your packaging costs.

Linerless technology will provide additional packaging cost savings by reducing release liner wastage. Linerless makes sense—more labels per roll, less roll changes, lower weight, lower transportation costs, and better warehousing. Unfortunately, some label printers are very reluctant to change. This will evolve in time, however, as the supply chain feels the pressure from brand owners who are leading the way and requiring that greener technologies be investigated.

Early adoption

Several market segments have committed to make the switch to linerless. Generally, these primary markets are ones that are the most exposed to very competitive pricing.

One of the market segments that has changed over from p-s labels to linerless labels, is the print-and-apply, direct-thermal labels industry. What was a 4˝ x 6˝ direct thermal label is now a linerless direct thermal tape. Companies such as Arca, Etiquettes Labels Ltd, Alltech, and many others have introduced linerless print-and-apply labeling equipment. The direct thermal face material is printed and converted into a tape format. With the help of an eye mark or just calculating the length of the label, the tape gets dispensed and cut with a blade, eliminating the use of release liners. The label is approximately 35 percent less expensive versus a conventional p-s label and will hold 35 percent more labels per roll.

Another market segment that has started to move to linerless is the scale label industry. Again, it's all related to price and having more labels per roll. Companies such as Digi, Bizerba and several others have introduced linerless scale labels. Major retail stores has started to make the switch.

We also see the changes in direct thermal table-top printers, as well as handheld and belt-type thermal printers; which provide more labels per roll and at a lower cost. In the last few years, Zebra, Datamax, and Intermec have introduced a new line of linerless direct thermal printers.

One unexpected situation is a shift to linerless in countries that are less industrialized and where most of the labels are applied by hand. Prior to the linerless technology, fieldworkers were leaving the release liners on the ground which contaminated the soil. Today, there has been a changeover to a perforated roll of linerless tape.

Another trend that we see in the linerless market is the supply of labels on a reusable release liner. The labels are being printed and diecut onto a heavy-duty PET liner with the matrix being removed. The rolls are shipped to the customer and after the labels are applied on the container, the reusable liner is rewound and sent back to the label printer to be reused several times. This reduces substantially the use of a one-time throw-away release liner.

Evolving technology

Linerless has a lot of advantages but, unfortunately it has been limited in terms of label application, so whoever wanted to convert to linerless needed to change their labeling equipment. In addition, up until two years ago, linerless labels were limited to a certain size and shape. Today, this technology has evolved and sizes as well as label shapes are no longer a constraint. Two years ago, an offline linerless adaptor was introduced to the market which was retrofitted to existing p-s labeling equipment. This eliminates the shape and size constraint, as well as the capital investment needed to purchase a brand new linerless labeler. This new technology advancement opens the doors to new linerless applications.

Overall, the linerless market is emerging and is increasingly being used. Label printers have been printing and diecutting the same way for the last 50 years and it is difficult for them to change something they have been doing for so long. But linerless technology is an opportunity. Label printers who have adopted the technology see the real potential in offering their existing customers or new potential customers a standard solution, as well an innovative linerless solution. It is a great door opener.

About the author—Yves Lafontaine is VP of marketing for ETI Converting. pP