Label Anatomy
The main components of a label are the facestock, adhesive and liner.
Think of the facestock as the printed label. This can be made up of various papers, films or even vinyl depending on the eventual label use. For instance, laser-printed labels will use a different facestock than thermal printed labels.
The adhesive makes the label stick and a label may use rubber or acrylic products. The right adhesive will ensure that the label continues to perform once applied. For example, rubber adhesives may not work well when exposed to UV or chemicals.
The liner keeps your labels from sticking together and can be made with paper or film, with different release coatings depending on how the label is eventually going to be applied. For example, labels applied with high speed automation would use a different liner than labels that are applied by hand.
In addition to these three layers, there are options for a variety of topcoats, primers or embellishments.
Luckily, when you work with DLS, we make it easy for you to find the right label, with all the right components for your customers.
Die Cutting Types and Basics
Ever wonder how labels get their shape? Whether a label is a simple circle, a rectangle with rounded corners or a complex logo cutout, the shape is cut during printing or conversion using a process called die cutting. Die cutting can either be accomplished using a pre-made die and a press, or digitally using a laser.
A die is a special metal cutter that has been created to match the desired shape of the label. Think of a die as a very shallow cookie cutter. The die physically cuts into the label as it is passed through the die cutter, creating the correct size and shape. Depending on the design of the label, the die can cut all the way through to create individual labels, or it can just “kiss” the label, leaving the liner behind.
These dies can be made up of a flat sheet of metal that is pressed onto the labels using a flatbed press, or the die can be made of a thin, flexible sheet of metal that is mounted onto a cylinder that rolls over the labels.
Laser die cutting is newer technology that utilizes a high-speed laser to follow the die lines to shape the label. Laser die cutting allows you to create complicated label shapes, without the additional time and potential expense of creating a physical die.
There are advantages and disadvantages to using either a physical die or laser die cutting. There are also other considerations that should be looked at when creating a shaped label such as whether the shape will make it difficult to apply the label. Contact DLS anytime and we will help you determine the shape and die cut method that works best for your customer’s labels.
Variable Printing
You’ve probably gotten a piece of direct mail that is meant to look like it was printed just for you, perhaps including your name in the salutation. This type of personalization is accomplished with variable data printing. Unlike traditional printing where each printed piece is exactly the same, variable data printing is a digital print technique that uses information from a database to change text or graphics so that each finished piece can be unique.
This powerful print tool goes far beyond replacing a customer name though. With variable data printing, it is possible to swap one or several elements including color, images, text, data or even the complete design. Digital printing makes variable printing possible because the image is redrawn for each print.
Variable printing can be used for a wide variety of label uses including consecutive numbering, barcodes, regional packaging, A/B testing, personalized products, customer tracking, serialization and more.
Consider changing things up for your customer’s labels with variable printing. Contact DLS for more information or ideas.
Laser Die Cutting
The principle of the laser dates back to 1917, when Albert Einstein first described the theory of stimulated emission. There is some controversy over who actually invented the laser, but lasers were first used for cutting industrial parts in the mid 1960s. Since then, lasers have made their way into the printing world, with their use especially taking off with the growth of digital printing and laser die cutting.
Laser die cutting is a process that uses a high-speed laser to accurately and efficiently cut materials into custom shapes. Instead of using a physical die to cut a label, a laser traces a die line that is included in the print file – essentially “burning” or cutting the substrate and leaving a smooth, precise cut. Laser die cutting can be used to cut labels of almost any shape, including complex shapes. It can also be used to create perforation, crease/score lines and etching. Because there is no need to create a physical die, laser die cutting saves time and money. It is also extremely flexible since there is no need to change out dies between jobs. It is a cost-effective alternative for short label runs and prototype labels.
Contact DLS to learn more about all of our die cut options.
Variable Printing for Labels
You’ve probably gotten a piece of direct mail that is meant to look like it was printed just for you, perhaps including your name in the salutation. This type of personalization is accomplished with variable data printing. Unlike traditional printing where each printed piece is exactly the same, variable data printing is a digital print technique that uses information from a database to change text or graphics so that each finished piece can be unique.
This powerful print tool goes far beyond replacing a customer name though. With variable data printing, it is possible to swap one or several elements including color, images, text, data or even the complete design. Digital printing makes variable printing possible because the image is redrawn for each print.
Variable printing can be used for a wide variety of label uses including consecutive numbering, barcodes, regional packaging, A/B testing, personalized products, customer tracking, serialization and more.
Consider changing things up for your customer’s labels with variable printing. Contact DLS for more information or ideas.
HP Indigo Label Printing Process
HP Indigo is known for exceptional print quality. But what makes it different from other digital printing? The secret lies in HP’s proprietary Liquid Electrophotography (LEP) process. LEP uses HP ElectroInk, a special liquid ink that is electrically charged to control its placement onto a photoconductor plate.
The image is transferred from the photoconductor plate to a heated blanket, where the image dries completely into a very thin ink layer. The complete image is then transferred onto the media. Because the rubbery blanket conforms to the topography of the substrate, the image mirrors the texture and shine of the label stock. Also, because the image is completely created and dried on the blanket, it is possible to have a very high print resolution and quality regardless of the media.
Contact DLS to see how your customers can benefit from HP Indigo label printing.
Cold Foils
Brands that are looking for a way to help their product stand out will often add metallic foils to their labels. One of the most economical ways to add foil to a label is with cold foil printing. Cold foil is an inline process where a UV-curable adhesive is “printed” onto the label surface where the foil is desired. Foil is pressed onto the adhesive, and the excess foil is stripped away from the areas without adhesive—leaving behind the foil design. The labels then run through an ultra-violet light to cure the adhesive. After the foil is applied, varnish or laminate can be added to the label for added durability.
Cold foil is available in a wide variety of colors and even patterns, including holographic options. Cold foil works best on smooth facestock, and is perfect for films. Unlike hot foil options, that rely on heat for foil application, cold foil is also a good choice for heat sensitive substrates. An additional benefit of cold foil vs. hot foil is that with cold foil, there is no need to create a die. This makes the process faster and more economical.
Contact DLS to help your customers create a wow factor with foil on their labels.
Label Registration
Do you know what those crosshairs are on a printing proof (or bottom of your cereal box)? These are registration marks. In printing, registration (or register) relates to the importance of precision alignment and placement. When printing something with more than one color, each color will be printed separately by the printing press. For example, with four color flexographic printing, each ink color (cyan, magenta, yellow and black) is applied with a separate plate. These four colors are then applied one after the other on a printing press. By overlapping each other on the paper, they combine to create a full-color image. Proper alignment, or registration of these layers is critical for a sharp image. If one of these layers isn’t properly registered, colors may blend, images may be fuzzy, there may be gaps between colors or color halos will appear on the edge of graphics. Although registration most often refers to the alignment of colors, accurate registration is equally important for die cutting, as well as effects such as spot varnishing or foil application.
Almost every print method is subject to slight registration shift during the printing and cutting process. The registration of printed pieces is affected not only by the initial settings on the production equipment, but also by any movement of the paper as it runs through the equipment. Maintaining proper registration requires a skilled press operator. He or she will monitor the job to make sure it is properly aligned. For some print jobs, there are also adjustments that can be made during the design and prepress process to help alleviate potential registration problems.
Trust DLS to keep your customers’ labels aligned.
Aqueous Inkjet Label Printing
Aqueous Inkjet printing is a type of digital printing that utilizes a water-based ink or dye. In this process, very tiny drops of ink are sprayed onto a substrate to create graphic and font images. The image is air dried, often with some heat added to adhere the image to the label stock. This means the face stock needs to be receptive to ink. This is accomplished by either purchasing coated material from the raw material manufacturer or having the label converter apply a primer during the manufacturing process. Often, the image will then be varnished or laminated to provide an additional level of protection and durability. Not all papers and films are compatible with aqueous printing.
Contact DLS for your Aqueous inkjet printing needs.
Avoiding Static Electricity
Cold, dry winters often lead to extra static electricity. And let’s be honest, who hasn’t taken advantage of this static to playfully shock a pet or significant other? But for label printing, static electricity can actually be a year-round problem.
Some of the issues caused by excess static electricity include: machinery jams, substrates sticking together, dust contamination and incorrect ink placement. And of course, there is always the problem of shocks to employees. While these shocks are usually more annoying than harmful, there are cases where these types of shocks, or sparks caused by static can be dangerous.
Label printers can utilize a number of tools to help decrease static electricity. These include humidifiers or static eliminator tools that neutralize the ions that cause static electricity. One of the simplest static elimination devices is actually copper tinsel. A piece of copper tinsel, or garland, is grounded and placed close to static laden machinery. The tiny points of the copper strands interact with the static field to form a static neutralizing cloud enveloping the targeted area and eliminating the static electric charges.
If you take part in either an in-person or virtual tour of one of our DLS facilities, keep an eye out for these shiny static neutralizers.
Spectrodensitometer for Color Matching
When it comes to color matching, there are several methods to make sure that label color is correct. There is the option of a visual inspection, but this depends on the vision of the operator performing the inspection. So, it can be subjective. To truly test for accurate color, printers utilize tools like a spectrodensitometer. Essentially, a spectrodensitometer combines the functions of a densitometer and a spectrophotometer.
Densitometers detect color density by measuring light reflected back from a print sample. A densitometer can detect how dark or light the sample is, letting a printer know if ink levels should be adjusted. However, a densitometer doesn’t measure how color is seen. To measure the accuracy of color, especially non-spot colors, a printer would use a spectrophotometer.
A spectrophotometer measures reflected or transmitted light at many points. This results in a spectral curve. Because each color has a unique spectral curve, it can accurately identify the sample color for accurate color matching. By utilizing both types of measurements, a spectrodensitometer can determine the density and the color of the sample – helping to ensure accurate, consistent color production.
For label customers who need precise color matching, tools like the spectrodensitometer are key. Contact DLS for help matching your customer’s label colors.
Retroreflective Label Material
How does a retroreflective label work? Retroflective labels provide improved visibility in low light and over further distances. The secret is the reflective beads or material that are imbedded into the label. These beads are specially shaped to reflect light directly back at the source, regardless of the angle at which the light comes from. This is unlike a normal reflective material that would diffuse the reflected light. It is the directly reflected light that allows for better visibility and long-range scanning of a retroreflective label.
To better explain this, imagine a billiard ball. If you bounce a billiard ball off the table from any angle other than straight on, the ball will bounce off at an opposite angle, not back where it came from. If the edge of the pool table was made with retroreflective material, that ball would come straight back. Not particularly helpful in billiards, but very effective when dealing with light and labels.
Contact DLS for your customer’s retroreflective labels.
UV Ink
What does an outdoor label and a composite filled cavity have in common? UV curing. With UV curing, a liquid or resin is quickly “dried” or cured with exposure to ultraviolet or UV light. Think of the little blue light that your dentist uses as part of the filling process.
UV printing utilizes special inks that contains monomers and oligomers, as well as a photointitiator. After the ink is applied on the press, specialized UV lights follow closely behind. When the ink is exposed to the UV light, the photoinitiator undergoes a chemical reaction that causes it to bond with the monomers and oligomers to create a tough polymer. The result is that the liquid ink instantly hardens, or cures.
Once cured, UV inks are incredibly durable with a high degree of moisture, scratch and chemical resistance, as well as better fade resistance compared to traditional inks. When it is cured immediately, the ink does not have a chance to spread, or absorb into the substrate. This leads to crisp, detailed printing. Because the ink doesn’t have to soak into the substrate, it can also be used on a wider variety of non-absorbent materials such as vinyl, glass, wood or metal. Additional benefits include low VOC production and lower energy requirements - making it a more environmentally friendly option.
Contact DLS to see if our UV print capabilities will work for your customer’s labels.
Active v. Passive RFID
What’s the difference between active and passive RFID? It’s all about the power. At it’s most basic, passive RFID tags do not contain an internal power source, while active RFID tags do.
With no power source, a passive tag’s energy is drawn from the radio-frequency waves that originate from the RFID reader. The tag does not transmit until it is powered by these radio waves. Passive RFID tags are relatively inexpensive and are widely used in supply chain businesses such as warehouses, or major retailers such as Walmart.
Active RFID tags use an internal battery to continually broadcast their signal. They can be read from farther away and at faster speeds – and are usually the type of RFID used in applications such as toll road transmitters. They are also more expensive than passive RFID tags.
Contact DLS for your customer’s RFID label needs.