CHOOSING THE RIGHT FOUNDATION FOR YOUR LABELS
BY KATIE FORSYTHE
In the labeling and printing industry, the foundation of a label is just as important as the design printed on it. That foundation is called the facestock. Selecting the right facestock is essential for the best performance, durability, compliance, and even brand perception. Different industries—from food and beverage to healthcare, etc—depend on carefully chosen facestocks to meet both functional and regulatory requirements.
A facestock is the base material of a label—the surface where inks, coatings, and adhesives are applied. It plays a key role in determining how well a label prints, how durable it is, and how it performs in its intended environment.
The facestock might be a paper, film, or a specialty material, while the application surface could be plastic, corrugated cardboard, or metal. The two need to be compatible for successful, longlasting label performance.
Label facestocks come in many forms, each offering distinct advantages and limitations. The choice often depends on factors such as cost, durability, appearance, and environmental conditions. Understanding the strengths and weaknesses of each type is the first step in selecting the right foundation for a label. While paper remains the most widely used material, films and specialty facestocks provide solutions for more demanding or unique applications.
Paper is one of the most widely used label materials. It is typically cost-effective, versatile, and easy to print on, making it a common choice for retail, shipping, and logistics labels. There are also several types of paper for a variety of aesthetic needs. However, paper can be less durable in environments where it may encounter moisture, chemicals, or heavy handling.
Film facestocks include materials such as polypropylene (BOPP), polyester (PET), polyethylene (PE), and vinyl. These offer excellent durability, flexibility, and resistance to water, chemicals, and UV exposure. Film is often used in food packaging, personal care products, healthcare labs, and industrial labeling where long-lasting performance is essential.
Some applications call for more specialized materials. Examples include dissolvable or biodegradable facestocks designed for sustainability, tamper-evident materials used for security, or premium finishes like metalized and holographic films that enhance branding and visual appeal.
Selecting the right facestock involves evaluating several factors:
Labels often face challenging conditions, and the environment plays a major role in facestock selection. A paper label may perform well in a dry warehouse or wine cellar, but fail quickly if exposed to moisture, oils, or extreme temperatures. Film facestocks, on the other hand, are designed to withstand harsh elements such as water, chemicals, or prolonged sunlight exposure. Understanding whether a label will be used indoors, outdoors, in a freezer, or in a manufacturing facility helps ensure the chosen facestock can stand up to those conditions.
The surface a label is applied to can impact adhesion and overall performance. Smooth surfaces like glass or plastic may require different facestock and adhesive combinations compared to rough or porous surfaces like corrugated cardboard. For example, flexible film facestocks often pair better with curved or squeezable containers than rigid paper. Matching the facestock to the intended surface helps avoid peeling, bubbling, or premature label failure.
Not all labels are meant to last the same amount of time. A shipping label may only need to remain legible for a few days, whereas a medical device or industrial label may need to last for years without fading or deteriorating. Durability considerations include resistance to abrasion, tearing, and exposure to cleaning agents or environmental stressors. Choosing a facestock with the right level of durability prevents issues such as illegibility or product misidentification.
Different printing technologies interact uniquely with facestocks. Thermal transfer printing, for instance, requires facestocks that can accept a ribbon, while direct thermal facestocks must be heat-sensitive. Digital and inkjet printing may require coated surfaces to ensure vibrant colors and crisp details, while flexographic printing is more versatile. Using an incompatible facestock can lead to smudging, poor ink adhesion, or reduced print quality, making it essential to align the facestock with the intended print method.
Many industries have strict regulatory requirements for labeling, and facestocks must be able to support compliance. In the food industry, for example, FDA-approved materials are required for direct or indirect contact with food packaging. In the chemical industry, labels may need to meet GHS standards for durability and legibility under exposure to hazardous materials. Electrical products often require UL-recognized labels that can withstand heat or abrasion. Choosing a compliant facestock ensures both legal adherence and consumer safety.
The world of label facestocks continues to evolve, influenced by both technology and sustainability efforts. Key trends include:
Sustainable Materials
Development of recyclable, compostable, and reduced-plastic options.
Thinner Materials
Using thinner materials to reduce shipping costs and environmental impact.
Advanced Synthetics
Stronger films engineered for harsh or extreme environments.
Technology Integration
Integration of RFID and NFC technologies for tracking, authentication, and supply chain management.
Labels used in food packaging must hold up against challenging conditions, including refrigeration, freezing, condensation, and handling throughout the supply chain. Paper facestocks often absorb moisture and lose legibility, which makes them unsuitable for these environments. Film facestocks such as polypropylene (BOPP) or polyester (PET) are commonly chosen because they resist water and oils, maintaining print clarity and adhesion. In addition, food packaging labels may need to comply with FDA regulations, making material selection critical not just for performance but also for safety and compliance.
In logistics, labels are constantly applied to boxes, pallets, and shipping containers to identify and track goods. Here, the decision between paper and film facestocks often comes down to cost versus durability. Paper labels are inexpensive and sufficient for short-term needs, such as parcel delivery where the label only needs to last a few days.
However, in long-term storage, outdoor shipping, or high-abrasion environments, synthetic film facestocks provide the durability needed to ensure barcodes remain scannable and information stays legible. This choice directly impacts efficiency in supply chain operations.
Labels used in healthcare settings face some of the most demanding conditions. They often must endure sterilization processes, exposure to chemicals, and frequent handling. For instance, a label on a test tube may need to stay intact during freezing and thawing cycles, while labels on medical devices must remain legible for the lifetime of the product.
Facestock selection in this field also carries regulatory implications, with FDA, ISO, or UL standards often dictating material requirements. Durable synthetic facestocks are typically preferred to ensure compliance, accuracy, and patient safety.
Label facestocks provide the foundation for label performance, durability, and compliance. Understanding the different options — and the factors that guide selection — helps ensure that labels meet the specific needs of their environment and industry. By aligning facestock choice with application requirements, organizations can improve both functionality and overall brand presentation. Reach out to our team of label experts and we will provide the resources you need.
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