by Melissa Donovan
Label media used in digital printing includes paper and film for face stock options, with sub-categories underneath. Determining which to choose can be daunting for a print provider whether they are novice or experienced in the art of label printing. A good rule of thumb is to ask questions. Specifically to the customer purchasing the labels. Where will it be used? What level of durability is required? How long will the label be functioning? Generating the most information possible can be a huge help in determining the right material.
Above: A label printed on Wausau Coated Products (W032316) Twill Natural Cloth.
Plenty to Choose
Plenty of options are available in terms of media for digital label printing. The trick is finding the perfect fit.
Manufacturers are constantly expanding their label media portfolios in response to customer demand.
“We are always exploring and expanding the media choices for our digital printing customers. The customer drives everything we do and they are always asking us ‘what if’ we could print on ‘fill in the blank.’ The options are endless and range from basic semi-gloss papers and films to extravagant wood veneers, leather, cotton, and even textile cloths,” explains Adam Frey, director, North American roll sales, Wausau Coated Products.
“With today’s advancements in printing technology, the possibilities are nearly limitless. From basic paper labels, such as shipping labels printed on a desktop laser printer, to sophisticated RFID or high-security labels printed on a roll HP Indigo Press, the variety of label media is as diverse as the methods used to print them,” explains Greg Kestler, product manager – narrow format digital/offset, General Formulations.
“In digital label printing, a variety of substrate options are available to suit different needs and applications. These include paper-based materials, synthetic films, and specialty substrates. Paper is a common choice for cost-effective, short-term labels, while synthetic films like polypropylene (PP) and polyester offer durability and resistance to moisture, chemicals, and the environment,” notes Amy Donato, global strategic marketing director, Teslin products, PPG.
Dividing into categories, first there are paper face stocks. These include standard white papers like uncoated offset, matte litho, semi-gloss, and gloss, says Kestler. Also available, specialty paper face stocks such as fluorescents, Astrobrights, brown kraft, bright and dull silver and gold laminated foils, 8 pt. tag, latex-impregnated paper, and Ryan-satin cloth, he lists.
Film face stocks are another option. Popular choices are vinyl, polyester, and PP. “These films are available in white or clear, and gloss or matte finishes. Polyester is also available in metalized versions, offering silver and gold in bright, matte, or brushed finishes. Unique materials like Teslin, Tyvek, and Tedlar can be adhesive-coated and printed digitally,” suggests Kestler.
“Specialty substrates like PPG Teslin label material combine the best of both worlds—offering the printability of paper with the durability of a film. Teslin substrate, for example, is particularly known for its broad print compatibility and excellent adhesion properties, making it ideal for demanding applications such as security labels and durable goods labeling,” shares Donato.
Beyond the face stock adhesive, options for adhesives are varied—and necessary. This is because, according to Kestler, there is such a wide array of surfaces labels are applied to, with different purposes served for each application.
“There are tinted adhesives to prevent show-through and specialized adhesives for easy removal, each tailored to different applications, whether it’s a name badge, a store window, or a painted wall. Even the type of paint on the wall can require a different adhesive. Low-energy surfaces, like powder-coated metal or Rubbermaid containers, present unique challenges for label adhesion. There are also adhesives designed for freezer temperatures, high humidity, or even submersion in water. Tamper-evident labels have their own specific adhesive requirements,” shares Kestler.
New to Labels
What do those new to label production need to know?
Understand the basics of substrate selection, printing technology, and surface application requirements. “The substrate you choose needs to align with the intended use of the label—whether it is for consumer goods, industrial products, or security applications. Also consider factors like durability, environmental resistance, and printability,” shares Donato.
Label needs are specific to the client. “When a client requests a permanent label, they should be prepared to answer several important questions. For example, what types of labels will you be producing? Will you need a range of label materials? Will this device be used exclusively for printing labels, or will it handle other materials as well?,” advises Kestler.
“When selecting media for digital label printing, it’s essential to consider factors like the label’s intended use, environmental exposure, and the surface it will adhere to. Understanding your go-to-market strategy or your client’s needs is the first step in choosing the right label media and adhesive,” says Kestler.
To learn about the right substrate and print technology for the job, Frey encourages novice label producers to “leverage industry resources, including vendors and colleagues, to gain a solid understanding of printing technologies, adhesives, applicators, paper or film types, and essential questions to ask your customers.”
“Don’t be afraid to ask for product selection assistance. If provided with the right print method and field application information, we can often help you select the right label product quickly and easily. And if one isn’t available that is the right mix and match of adhesive, face stock, and print receptivity, we can often work to mix and match products and customize a product that is specific to your needs,” shares a representative from Tekra.
Print Technology
Considerations need to be made in terms of print technology when choosing media for digital label printing.
Identifying a print technology’s limitations and strengths is an opportunity to discover new solutions. “The options are only growing for digital printing engines that are available and learning where those technologies excel versus others is a big part of realizing success,” says Frey.
“Many lower to mid-range digital print platforms, which often use toner or inkjet systems, may have limitations on the types of label materials they can handle,” shares Kestler.
Donato agrees. “When choosing media for digital label printing, it’s crucial to consider the compatibility of the substrate with your printing technology.”
The representative from Tekra provides this example. A print provider is looking to purchase a narrow web UV inkjet printer, but it mostly runs polycarbonate labels. “Polycarbonate rolls don’t always come in 5,000-foot lengths, which is often desired to maximize the printer’s output abilities. Therefore, splices will appear in the roll. Splices are an option, but not typically recommended, as they can cause jamming or printhead strikes. If you primarily run papers or polyesters, which commonly come in longer rolls, splices are less likely to be needed, and a narrow web UV label printer may be the best option for your efficiencies and output.”
Again, it’s important to keep the customer’s wants and needs in mind. Asking questions like how they want to receive their labels—roll, multiple labels per sheet, or as individual labels? Also, inquiring about durability requirements and if the labels will need to be protected from scratching or scuffing is a good discussion to have, according to Kestler.
Many times the answers to these questions will lead to deciding between a printer’s feed type—roll or sheet fed—and the best type for the job at hand.
“The choice between these often depends on the volume and format of the labels being printed. Roll-fed systems are typically used for high-volume, continuous printing, while sheet-fed systems are more common in lower volume printing, and typically digital printers. Consider a label stock that is available in both sheet and roll formats, providing flexibility for different production needs and ensuring smooth feeding in various printing environments,” advises Donato.
Difficulties Abound
With the variety of substrates available, it can be tough to identify the right combination of media, adhesive, and ink for the job. To that end, print providers often look for a substrate that is compatible with the highest number of print technologies.
Kestler says one of the biggest challenges is that most printers want to print on the widest range of label materials. If this is the case, it’s important to partner with a distributor that provides in-stock, ready-to-print media with quick turnaround times for small quantities.
Pairing the chosen label substrate with the correct printer is another challenge print providers face.
“Incompatible media can lead to poor adhesion, issues with ink adhering to the surface, or inadequate durability, which compromises the label’s performance,” explains Donato.
To combat this, Donato suggests using a label stock designed to be versatile across various printing platforms. “As an example, Teslin label stock’s microporous structure absorbs ink and toner effectively, ensuring vibrant colors and sharp details, regardless of the print technology. Additionally, Teslin substrate’s static resistance and conformability help reduce print defects, making it a preferred choice for high-quality, durable labels.”
Meeting customer requirements can be difficult. “Make sure that your choice of a digital print engine and its capabilities align with your customers’ needs and wants for those labels you are producing for them. Understanding what matters most for your customer will help you align with the combination of the right media and digital print process to meet their expectations,” admits Frey.
Another challenge is identifying a label that offers superior durability and environmental resistance—when the application dictates it. “It’s important to select an option with the ability to withstand harsh conditions without compromising print quality in challenging labeling applications. This ensures that labels remain functional and legible throughout their lifecycle,” advises Donato.
Ask Questions
Variety isn’t always the best, as it can lead to overwhelming decisions about which media is well suited for a label project. And when the incorrect substrate is chosen—the results aren’t ideal.
That’s why to ensure success, it is worth having an open conversation with your customer about where and how the label will be used. Ask as many questions as possible to help determine the best label media for the job.
Nov2024, DPS Magazine
