Device and method for providing labels

Abstract

The invention to which this application relates is a method and apparatus for reusing and / or recycling a layer of liner material (30) from a label supply, which generally includes a layer of liner material and a label supply material (28) from which labels are formed and subsequently applied to one or more articles. The invention allows the separation, processing and recycling of layers of liner material that would otherwise be traditionally considered waste. The invention allows this to be achieved without the need to apply any material to the label supply after the labels are formed. In one embodiment, the recycling can be in the form of forming the liner material into raw material for subsequent processing, or, using the liner material as a tape, or, directly reusing the liner material layer as part of another label supply.

Description

Technical Field

[0001] The subject matter of the present invention is to provide an apparatus and method which permits the provision of rolls of label supply material to locations where labels are applied to articles, the supply material being initially formed at a lamination location and provided from a laminate production location as a laminated composition of a layer of label supply material, an adhesive, a release coating and a layer of liner or backing material, and then being transferred to locations of label printers and converting facilities and then on to said one or more locations where labels are applied to articles. Background Art

[0002] The present invention is particularly, although not necessarily exclusively, directed to providing linerless pressure sensitive (PS) labels formed from suitable sheet materials. The initial laminate provided typically comprises a layer of liner or backing material adhered to a layer of label supply material and is transported in this form until the liner or backing material layer is separated from the layer of label supply material, typically at the same location where the linerless label is applied to an article. Once the liner or backing material layer is separated from the layer of label supply material, the liner or backing material layer is waste material.

[0003] The use of pressure sensitive labels is well known and currently the labels are usually applied by releasing them from a silicone coated liner material layer, said release usually being carried out at the location where the label is applied to the article and at the time or shortly before the label is applied to the article. Once the label is released from the liner material layer, the liner material layer represents a complex waste stream, i.e. small rolls of different widths located in multiple locations, which makes it difficult and expensive to collect and transport them to waste recovery locations. As a result, it is estimated that millions of tons of liner material waste are discarded to landfills and this situation will continue. If it is considered that the supply of such laminates consisting of a label supply material layer and a liner material layer is a truly global industry with different consumption rates, such as 10 square meters per capita per year in developed countries and less than 1 square meter per capita in less developed countries, then the supply of laminates tends to be carried out by relatively large multinational manufacturers and on a relatively large scale, usually using a 2 meter wide machine, producing a master roll of laminate of this width at a speed of 1000 meters per minute.

[0004] While the industry has recognised the need to reduce its waste footprint, and recycling of discarded liner materials in the form of cellophane and kraft paper is possible, the presence of silicone as a release layer in liner materials makes recycling more difficult as silicone is a pollutant. Despite this, it is estimated that even in developed markets less than 10% of liner material waste produced each year is recycled, and while new liner material production includes recycled content, the continued need for virgin fibre remains paramount. The liner material layer of the laminate must also have a relatively high tensile strength to enable high speed, high frequency label application, for example, up to 1,000 labels per minute in a stop-start controlled manner.

[0005] Thus, while efforts have been made to recycle liner materials, actual implementation rates of known recycling methods are very low, due at least in part to the relatively complex logistics involved in recovering the liner material and transporting it to a location where it can be recycled.

[0006] Another problem is that, because the liner material layer is removed from the label supply material layer at the end user (i.e., where the label is applied to the article), at which location the laminate of the label supply material layer and the liner material layer is provided in relatively small rolls, a large number of relatively small waste liner material rolls are generated when the liner material layer is removed, and it is understood that these rolls are generated at multiple locations. It is therefore particularly difficult to collect and transport the multiple small rolls from a large number of different locations to a centralized recycling location in an economically feasible manner, and therefore it has been found that in most cases these waste material rolls are never returned to the recycling location for recycling.

[0007] An increasingly attractive alternative is to provide rolls of linerless label sheet material, i.e. rolls without any liner material layer at any stage. However, while the ability to apply this type of label has been demonstrated, it is based on the use of printing and converting methods that are relatively complex for label printers and / or converter companies to use, and therefore, at least in the short term, this approach alone will not be able to meet the growing demand for labels and significantly reduce waste, although linerless labels do allow packagers to produce more labels per roll and overall reduce the use of raw materials and reduce transportation costs.

[0008] The manufacturing industry for this type of product can be roughly divided into two categories, one is the manufacturers of labels that provide decoration and information related to individual items, and the other is the manufacturers of labels used in logistics, where variable information is usually printed when the outer packaging is completed.

[0009] In the latter use, significant development of linerless alternatives has taken place over the years through individual converting machines (converters) taking advantage of advances in direct thermal paper. Typically, a 400mm wide roll of thermal paper is processed at speeds of 150m / min, with the converter applying a silicone release layer and a hot melt pressure sensitive adhesive layer before slitting and rewinding into finished rolls, with the largest volume product currently being 75mm wide rolls. The development of label application machines suitable for goods packaging and shipping has increased, with line speeds of 50 cases per minute typical, and as a result, the demand for linerless labels in this area has accelerated, attracting laminate producers worldwide to offer ‘self-wrap’ linerless direct thermal master rolls for the converters to cut into smaller rolls. The capability of these master laminators has been critical to meeting demand, and this development has demonstrated that pressure sensitive labels can be used without a waste liner.

[0010] In the area of ​​decorative and / or informational labeling, individual items in container form, such as bottles, are often labeled at higher speeds, for example, clear printed labels are applied to glass beer bottles at speeds of 1,000 per minute. Packaging line speeds may vary, but in all current pressure-sensitive labeling applications, a high-strength liner material layer is required to meet the pressures of stop / start acceleration. The industry has developed high-speed release silicone coatings that ensure that the label is separated from the liner with sufficient hardness to meet these requirements for speed and accuracy. The label is separated from the silicone liner material layer at the peel plate or beak, and only the liner material layer is subjected to tension.

[0011] In high-volume beverage and water bottle applications, major applicator (application) machine producers have developed wraparound labeling, which uses hot melt adhesive application and high-speed cutting when these labels are applied to the container. Although this is a different technology, it is equally demanding compared to individual patch labeling. This has led to the development of very thin and cavitated film cover materials for roll-to-roll labels that can only be used with wraparound labeling.

[0012] The use of linerless labels was developed by the present applicant with reference to, for example, patent GB 2185426, which uses a microporous pattern applied by a printer or applicator to define the joints between adjacent labels in the label material supply and allow some shaping of the labels. As this has been technically proven and used in, for example, demanding high-speed beer bottle label application, the pressure sensitive label supply industry is faced with the challenge of mass producing linerless, decorative and informational labels.

[0013] In the traditional process of forming decorative and information labels, it is usually printed by applying ink to the outer surface of the label material layer, and then applying a pressure-sensitive layer to the inner surface, and then a silicone release layer is set between the adhesive and liner material layers. In addition, micro-holes and / or cut shapes are formed in the die-cutting or slitting station. Mainly due to the use of process silicone liners that can be used multiple times, direct coating and die-cutting pose technical challenges for these special machines. Linear matrix waste produces various shapes. In order to confirm that the die-cutting process has produced high-quality micro-hole cuts and knots, if the linear matrix has not been successfully released, the die-cutting process results should be checked.

[0014] As an alternative, label printers can now adopt a lamination to linerless solution, where the label printer now decorates the surface and transfers a clear film liner to the printed surface before die-cutting to protect the image and provide release in the final linerless label self-roll. However, this alternative requires a specialist conversion investment and can only be operated with clear liner materials. Although these developments are important, they do not address the huge challenges facing the industry in terms of liner material waste and the increasing waste legislation that is being introduced.

[0015] Another potential problem with waste liner material being returned for recycling is that the material must go through a specific recycling or waste treatment process, which itself can be expensive, and in some cases certain components of the waste liner material cannot be recycled, resulting in the waste liner material being unable to be recycled unless those components are separated.

[0016] There is therefore a need to be able to increase the feasibility and attractiveness of recycling liner waste materials in a way that, in addition to providing clear environmental benefits, can also achieve these benefits in an economically viable manner. Summary of the invention

[0017] One object of the present method and apparatus (device) is to enable and improve the efficiency of recycling liner material from a virgin laminate label supply. Another object is to allow the collection of waste material to be achieved in a manner that allows a greater amount of waste material to be provided for collection at one location, thereby reducing the number of locations where waste material may need to be collected to improve sustainability and reduce the amount of waste. Another object is to allow sufficient amounts of waste material to be generated at a single location so that the waste liner material can be recycled at the same location, thereby avoiding the need for any transportation of the waste material prior to recycling.

[0018] Another object is to further facilitate the environmental benefits of providing improved return recycling of waste liner materials by allowing rolls of liner material to be tailored for specific uses without having to go through shredding and recycling stages.

[0019] In a first aspect of the present invention, there is provided a method for processing a label supply from a forming location of a label supply laminate to a remote location where the label is applied to an article, wherein the label supply laminate is formed and includes a label supply material layer and a lining material layer, wherein the label supply material layer is adhered to the lining material layer, and the lining material layer serves as a carrier of the label supply material layer until a separation location (separation point) of the label supply material layer from the lining material layer, wherein the separation location is achieved at a location between forming the label laminate and applying the label to an article.

[0020] In one embodiment, after the liner material layer is separated from the label supply material layer, the label supply is formed into one or more linerless label rolls for onward transportation to an application location (application point).

[0021] In one embodiment, after the liner material layer is separated from the label supply material layer, the liner material layer is formed into one or more rolls for shipment to a recycling facility. In one embodiment, the printing press (printer) can stop printing to remove the finished roll of linerless label material layer and then continue to produce more of the same or new label images from the original master roll of the same laminate, in effect rewinding (rewinding) all of the liner material layer from the master roll into a roll of waste liner material for collection.

[0022] In one embodiment, the roll of label supply material layer is formed to have a smaller outer diameter than the roll providing the laminate to the separation location of the label supply and liner material.

[0023] In one embodiment, the location where the liner material is removed from the label material is the location where the label is printed and / or converted in the label supply material. Once printing and / or converting occurs, the liner material layer is removed from the label supply material layer, and the label supply material layer is rolled into a new roll for continued supply and subsequent application to an article.

[0024] In one embodiment, subsequent supply of the roll of layers of label supply material involves transporting it to another location where labels are applied to articles.

[0025] In one embodiment, the layer of liner material includes a release layer, and in one embodiment, the release layer is a silicone material.

[0026] In one embodiment, during the label converting stage, a protective varnish and / or anti-release coating is applied to a layer of label supply material, typically over a printed image that has been applied prior to defining labels in a layer of label supply material, such as by die cutting or slitting. In one embodiment, application of one or more coatings may be performed during the printing process or in a separate label web finishing machine.

[0027] In one embodiment, a cutting module (such as a die tool or a rotary slitter) is provided to cut only the label supply material layer to define the final label format (form) and / or form micropores that will be separated when the label is subsequently applied to an article by a label applicator device.

[0028] In one embodiment, the label converter strips the edge print waste and / or matrix waste from the label supply material layer, which waste is removed after the label is defined in a stage independent of the removal stage of the full width liner material layer, and the full width liner material layer is gradually stripped from the label supply material layer, usually under tension in a rewinding device. In one embodiment, the removal is performed along a line substantially parallel to the longitudinal axis of the laminate web.

[0029] In one embodiment, a peel plate or transfer pulley (plow) is provided and smaller rolls of separated, now linerless layers of label supply material are formed simultaneously and generally placed in a row with spaces created in between due to the removal of liner (linear) face stock waste.

[0030] Typically, the now waste liner material layer is rewound into rolls for transport for recycling, so according to the present invention, the liner material layer does not reach the location where the label is applied to the article, which in one embodiment may be a geographically separate location.

[0031] In one embodiment, the path or passage of linerless labels is carried by the liner material until the liner material is peeled or separated therefrom, which may be assisted by a plasma coated drive pulley running on the adhesive side of the label or a suitable nip assembly at a speed and tension that produces the required force to continuously achieve separation from the liner material before each roll of the self-winding linerless label supply is completed. These completed rolls are wound under minimal tension to eliminate the risk of adhesive leakage at the edges of these rolls.

[0032] In one embodiment, the linerless label supply having the line of weakness formed therein is supported as it is separated from the liner. In one embodiment, the surface of the linerless label supply material layer is held in place by a vacuum section of a contact device, which in one embodiment may be a rotating drum that is generally operated at a web speed determined by the conversion. In one embodiment, the vacuum is selectively blocked at the outer surface of the drum so that the liner material layer is not similarly held or controlled and is peeled under tension from a peel plate or drive path pulley while the surface of the label supply material layer is supported, thereby ensuring that no tension is applied to the line of weakness of the linerless label supply material layer when the liner material layer is peeled.

[0033] In one embodiment, the label is defined by die cutting or otherwise forming micro-holes in the label supply material layer. In one embodiment, the amount of material cut is 75% of the total width of the label profile. By separating the liner material from the label supply material layer as described in the present invention, the percentage of cutting will be further increased, thereby facilitating alternative means of applying the label to the article, such as by vacuum pad transfer.

[0034] In one embodiment, the liner material layer used is a paper-based liner with reduced tensile strength, and ensures the release of a label supply material layer with sufficient tensile strength. In one embodiment, the liner material includes a release coating that is more easily recycled than a silicone release coating. In one embodiment, the release coating is a water-soluble coating that can be subsequently removed or washed off from the liner material to further improve the convenience of liner material recycling.

[0035] Typically, the control parameters used to separate a pressure sensitive label from a conventional liner material and apply it to an article are different than the control parameters required to separate a layer of label supply material under tension from a recyclable liner material.

[0036] The release force measurement of the liner material from the label supply sheet material using a relatively high peel speed is typically >50 m / min, while slow release is a force measurement using a relatively slow peel speed of 0.3 m / min. The tensile strength of a 45gsm fiberglass liner is MD (kN / m) 4.5, the tensile strength of a 58gsm at 51 microns is 6.4, and most paper liners are also in this range.

[0037] In one aspect of the invention, which may be used in conjunction with or independently of the above features, a label supply sheet material having defined labels has a pattern of surface cuts on said labels which are aligned in the same direction in which the labels are fed to the articles to be applied.

[0038] Typically, the surface cutouts help speed up the removal of labels from previously labeled articles, most typically as part of a subsequent recycling process for the article and label combination. In one embodiment, the surface cutouts allow entry of a removal liquid to wash the adhesive from the label, thereby increasing the speed of label removal. Thus, these cutouts are typically provided in the layer of label supply material simultaneously with or after the weakened die cut line in the finished label, and may not be provided in the original label supply material delivered to the printer by the laminator.

[0039] In one embodiment, a water-based or alternative liquid cleaning process is used in the recycling of the item. In one embodiment, the cutout is camouflaged or masked by aligning with an artwork image on the label.

[0040] In one embodiment, the liner material is a film liner coated with a non-silicone release material to allow the fully recycled liner to be fully reprocessed into the original wide roll form required for laminate production.

[0041] In one embodiment, a label supply material layer is provided wherein the microperforation tie (pattern) within the weakened line is varied, and / or the surface label cutting pattern provides a security pattern variation which, in one embodiment, is only visible under a magnified view of the applied label.

[0042] In one embodiment, the adhesive used in the label supply material layer has a relatively high cohesive strength and a relatively strong affinity to the surface of the label supply material layer, but a lower affinity to the liner material layer.

[0043] In one embodiment, the separate layer of liner material is formed as a tape having a coating of release material on a first surface thereof and a coating of adhesive material on an opposing surface.

[0044] In another aspect of the present invention, a master roll of laminate produced by a laminate manufacturing machine (manufacturer) is provided, which includes: a label supply material layer, the label supply material layer including a surface for printing thereon and an opposing surface with an adhesive layer; a lining material layer, in the master roll, the label supply material layer is initially adhered to the lining material layer; and a release system between the lining material layer and the label supply material layer, wherein the lining material layer and the label supply material layer are separable, at least the label supply material layer is formed into multiple smaller rolls so as to continue to be supplied to one or more application points for applying labels to articles.

[0045] In one embodiment, the width of the master roll is at least 2 meters.

[0046] Typically, the separated layers of liner material are recovered and recycled into useful material and, in one embodiment, are formed into rolls of such material.

[0047] Typically, the master roll is slit, printed, release coated and pre-weakened, such as by die cutting, at the same location where separation of the liner material layer and the label supply material layer occurs.

[0048] In another embodiment, the surface of the liner material, which may be paper or film, is mechanically modified to provide a relatively low surface energy, thereby enabling separation from the adhesive in a separation step without damaging the laminate. In this method, the liner is not chemically modified and can be directly recycled into the production of new liners or more useful products.

[0049] In another embodiment, a paper or film liner material is provided, the surface of which is chemically modified to reduce its surface energy so that it can be peeled off. Preferably, this modification can make the liner material considered to be non-contaminated, or slightly contaminated, so that it can be recycled into a potential subsequent use stream.

[0050] In another embodiment, a paper or film liner material is provided that has been treated with a release chemical that can be removed prior to recycling to increase the number of options to which the liner material can be effectively added.

[0051] In one embodiment, the release coating material is of a type that allows it to be washed off or otherwise removed, such as by mechanical abrasion (eg, grinding), prior to recycling.

[0052] In another aspect of the present invention, there is provided an apparatus (device) for processing a label laminate, the label laminate comprising a label supply material layer and a lining material layer, the label supply body being adhered to the lining material layer; a moving device, which allows the lining material to serve as a carrier of the label supply body when the laminate is moved to a separation location of the label supply body and the lining material, wherein the separation location of the label supply body and the lining material is between a formation location of the label laminate and a location where a label defined in the label supply material layer is applied to an article; and a separating device, which comprises a peeling device, which is used to peel the lining material off the label supply material layer and at least wind and cut the label supply material layer into a series of rolls having a width smaller than that of the roll supplying the laminate.

[0053] In one embodiment, after separation, only the labels defined in the layer of label supply material are supplied in a roll to the site for application to the article.

[0054] In another aspect of the present invention, there is provided an adhesive tape comprising at least one layer of sheet material (sheet layer) having a coating of release material on a first surface and a coating of adhesive material on an opposite surface.

[0055] In one embodiment, the adhesive material is rendered tacky by an activation stage.

[0056] In one embodiment, in a first mode, the layer of sheet material is formed from liner material previously provided as part of a label supply. Typically, the layer of sheet material will therefore previously have had a label supply layer applied onto the release coating to form a label supply. In one embodiment, the label supply layer has a plurality of labels defined along a linear axis, the label supply layer being removed from the layer of sheet material to form a linerless label supply, and in a subsequent stage, the labels are sequentially separated from a leading edge of the linerless label supply.

[0057] In another aspect of the present invention, a device for forming tape is provided, the device comprising a device for forming a label supply body, the label supply body comprising a lining material layer, a label supply material layer, one or more labels being defined in the label supply material layer, and having an adhesive on its surface, the adhesive being applied to a release material, the release material being applied to the surface of the lining material layer, the device comprising a device for separating the lining material layer from the label supply material layer to form the label supply material layer into a linerless label supply body, from which labels can subsequently be separated, and wherein the following device is provided, the device rolling the separated lining material layer into one or more rolls and applying and / or activating adhesive on the surface of the separated lining material layer so as to form it into a tape roll.

[0058] In one embodiment, the adhesive is located on the surface of the liner material layer opposite the surface to which the release material is applied.

[0059] In one embodiment, the means for applying adhesive is arranged to apply the adhesive to the layer of liner material in a non-activated manner prior to formation of the label supply.

[0060] In another embodiment, the means for applying adhesive is arranged to apply the adhesive to the surface of the liner material layer after the liner material layer has been separated from the label supply layer.

[0061] Typically, a label supply or backing layer arrangement is provided to apply an adhesive coating to form the tape supply.

[0062] In one embodiment, there is further provided an apparatus for applying labels from a supply of linerless labels, wherein the apparatus includes means for removing the one or more labels for application to one or more articles.

[0063] Thus, in one embodiment, the ability to recycle the liner material at the label supply converter is provided so that the liner material can be recycled, typically chemically, to virgin monomers.

[0064] In another aspect of the present invention, a method for forming a tape from a liner material layer previously used with a label supply material layer to form a label supply body is provided; the method includes the following steps: applying a release material coating on the liner material layer, applying a label supply material layer on the release material, passing the label supply body to a conversion device for printing and / or forming labels on the label supply material layer, and wherein the liner material layer is removed from the label supply material layer passed to the label applying device, and the separated liner material layer includes an adhesive material applied to the surface to form it into a tape.

[0065] In one embodiment, the method comprises the steps of cutting the liner sheet material into strips and / or rolling the liner sheet material into rolls.

[0066] Therefore, the present invention can effectively collect and recycle liner materials and other waste materials. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Specific embodiments of the present invention will now be described with reference to the accompanying drawings, in which:

[0068] Figure 1 A conventional method of providing a laminate and providing a label to a location for application to an article is shown;

[0069] Figure 2 A method according to the present invention is shown in one embodiment;

[0070] Figure 3 An example of a conversion system and apparatus according to the present invention is shown;

[0071] Figure 4 Another embodiment of the device according to the invention is shown;

[0072] Figure 5 Shows the way in which different forms of laminates can be created for use with the present invention;

[0073] Figure 6 shows a label defined in a layer of label supply material according to one embodiment of the present invention;

[0074] Figure 7 A flat label supply according to a first condition according to one embodiment of the present invention is shown;

[0075] Figure 8 Shows Figure 7 A cross-sectional view of the label supply body along line AA;

[0076] Fig. 9 shows a plan view of an adhesive tape according to one embodiment of the present invention;

[0077] Fig.10 Shows the Fig. 9 A cross-sectional view of the tape;

[0078] Fig.11 Shown schematically Figure 7 The label supply body is formed as Fig. 9 Embodiments of the adhesive tape; and

[0079] Fig.12a -d shows another embodiment of the process according to the invention. DETAILED DESCRIPTION

[0080] about Figure 1 , a conventional label laminate is shown which uses a laminate master roll 2 produced by a laminate manufacturer, which is typically 2 meters or more in width and includes a liner material layer with a label supply material layer carried and adhered thereto.

[0081] The main roll of laminate 2 is then cut at intervals along its width to form a series of smaller rolls of laminate 4, typically 1 meter in outer diameter, which are then supplied to a printing press (printer) and label converting company location where labels are printed on the laminate and then cut again into smaller rolls of label laminate 6. Generally, about 10% of the laminate is discarded during this process. These smaller rolls 6 are then sent to a "packaging" company, which distributes the rolled laminate to one or more company locations where labels are applied to items to form a typical retail package, with the label supply material layer typically separating from the liner material when the label is applied to the item. The liner material (now waste) is provided in the form of a waste roll 8, which can be easily retracted due to the silicone release coating material. The intention is to collect and transport these liner materials for recycling (recycling), but in practice this is difficult to happen.

[0082] The present invention now overcomes this problem, thereby achieving significant improvements in waste material footprint and laminate supply logistics, including the possibility of new laminate types.

[0083] The first stage of the present invention, as Figure 2As shown, a master roll 10 of laminate is again provided from the manufacturer, the master roll is cut into smaller rolls 12 and supplied to the printer and converter (converter) location where the separation of the label supply material layer from the liner material now takes place. This therefore means that a roll 14 of linerless label supply material is provided from the printer and converter location to the label application (application) company location. The liner material is now waste at this location and can typically be provided in the form of a roll 16 which is not passed to the label application location but can be collected for recycling. It can be appreciated, therefore, that the size of the roll 16 of waste liner material is larger and the number of locations where the waste material roll is located is greatly reduced compared to conventional methods, so that collection and recycling of the waste liner material is more likely than with conventional methods.

[0084] The means provided for separating the liner material from the label supply material layer can take a variety of forms to suit specific requirements. The method involves separating the liner material from the label material along the entire width of the roll at the printer converter position, and then using rewinding (rewinding) and separation techniques to ensure that the linerless label supply material layer is fixed in the roll 14.

[0085] exist Figure 3 In the figure, the roll 12 is provided to the conversion machine position and surface printed, a release coating (release) layer 22 is applied thereto, and any linear (straight) edges and shape waste material 24 of the label supply material are removed. An optional roller (cylinder) 20 is located at the station 26, which helps to separate the label supply material layer 28 to form the roll 14 of linerless label supply material so that it can be continuously supplied to the label application position. The separated liner material 30 is rolled up to form the liner material waste roll 16. The figure also illustrates how the roll 12 is progressively processed to provide three paths 32, 34, 36 of linerless label supply sheet material, wherein the sheet material on each path is rolled up to form a corresponding roll 14.

[0086] Adding liner separation and winding capabilities to a printing press or off-line finishing machine would allow the label converter to rewind this edge waste material separately from the liner waste when producing conventional labels. The current method is usually to reverse cut the edge liner and collect this trimmings with all the matrix waste. Figure 3 and Figure 4As shown in one example of the apparatus in FIG. 1 , an optional segmented vacuum drum 20 can be used as an alternative path guide for removing matrix waste of linear and liner materials when producing linerless or conventional labels in the upgraded apparatus. This example allows the transfer of the web stripped of die-cut and face waste to be controlled by the vacuum segments 18 in the rotating drum 20, which grasp the non-adhesive material by vacuum at certain locations. Thus, in different embodiments, the waste material can be separated from the label supply sheet material before or after the location of the vacuum drum. The specific location of vacuum action can be preset on the drum itself or determined according to specific usage requirements, such as applying tape or other blank material to the surface of the drum at those locations where vacuum action is not required. Thus, the pattern of vacuum segments on the drum can be configured to coincide (align) with the linear edge of the laminate and the shape label waste pattern to ensure that vacuum control of the respective linerless label supply material path is not lost while the liner material is still carried. The release surface of the liner material (which may be exposed by removing the linear strip waste before this rotating drum) is not affected by the vacuum.

[0087] Before the supported label supply material leaves the vacuum section, it is conveniently stripped on the stripper plate across the full web width. As the path of the linerless label supply material is directed toward web winding, such label supply material can retain the linear ribbon waste now separated on this same roller. Thus, the method frees the linerless label supply material from vacuum control after the vacuum section and the full width of the liner material is stripped and can be rewound at the lower web tension that is optimally used by all self-winding linerless label supply material rolls.

[0088] These alternative embodiments ensure that when the liner material layer is peeled from the label supply material layer using a peel plate or alternative drive path rollers, no stress is applied to the weakened lines created by the micro-perforations in the label supply material layer to define the label.

[0089] This ensures that the production and production volume of label supply materials and PS glue remain feasible.

[0090] Figure 5 The laminate 40 is a conventional laminate comprising a paper or film layer 42 of label supply material meeting the desired stiffness parameters, a pressure sensitive adhesive 44, a high speed silicone release layer 46 and a paper or film layer 48 of liner material.

[0091] According to an embodiment of the present invention, a spare laminate 50 may be used, one of which includes a label supply material layer in the form of a thinner face paper or film 52 and a low coating weight adhesive layer 54 and a liner material layer 58 and a release coating 56, which is particularly suitable for recycling purposes.

[0092] The impact of this approach supports logistical innovation and has the potential to mean that brand owners do not have to evaluate and approve new facestocks and adhesives in order to switch to linerless labels, which frees them from waste and improves efficiency. It can be expected that there should be no significant impact on the supply of linerless label supply materials to label application locations, as most production lines can easily adapt label applicators to linerless format while depleting existing inventory and changing product (artworks) within the usual cycle. With waste issues becoming a growing problem, this incentive is very important.

[0093] Changing to linerless conversions is far less complex than press converters and does provide additional impetus to the industry trend toward separating web printing and final converting. The development of just-in-time digital printing has facilitated overall laminate savings through faster setups, but has not eliminated liner waste generated when applying labels to articles, so recycling rates remain low.

[0094] Laminate suppliers are not affected and the first response of packagers and brands creating PS linerless is to require printers to add waste liner stripping and rewinding before the existing label roll winding system to profitably upgrade it. When this is done, the benefit of liner waste collection for enhanced recycling logistics is immediate.

[0095] For label printers, the conversion of linerless label supply materials is far less complex than the options previously described. A full range of adhesives is supplied as specified to meet all current label applications, and most labels are varnish protected and alternatives with silicone modified releases are also practical. Die cutting is conventional, and linerless materials have a distinct advantage over laminates in that the liner is peeled away and no longer required for label application, so minor damage to the liner does not result in quality-related waste.

[0096] For laminate suppliers, the amount of fully recycled innerliners increases the potential to increase the recycled material mix in the supply. The method of the present invention opens up the potential for new laminate structures that laminate groups can produce on their own existing assets with minimal investment, and these laminates can now be more specifically designed for recycling.

[0097] Laminates with reduced face stock 52 are provided to take advantage of the fact that linerless label application methods do not require the stiffness of traditional labels, laminates with reduced paper release (release) liner specifications can take advantage of the fact that the liner now serves only as a carrier and protective facing material to the adhesive, and laminates with a change in release functionality can take advantage of the fact that release now only involves peeling the liner from a continuous label roll, both under controlled tension.

[0098] According to the present invention, continuous webs of liner and linerless labels separate under tension that must exceed the release value in the liner release coating. It may be necessary to provide assistance to ensure that the labels in these webs do not separate under any increased release force.

[0099] Laminates with reduced adhesive coat weights of 12 microns or less can take advantage of the fact that currently there is a reduced degree of protection in die cutting, and thinner facestock or PS linerless labels require less adhesive to secure to the container or package.

[0100] Replacing silicone as a release layer coating with a coating that can be washed off with water before the final re-pulping of the waste paper, for example, can further assist the recycling process. Silicone-free film liners using slip agents or silicone substitutes can be easily reground and reprocessed. As a result, the recycling of liner materials is encouraged, and printers / converters are now responsible for efficiently handling the waste generated by laminators, avoiding the traditional complex logistics of supplying brands from more than one printer, which is an important reason why the traditional recycling rate of liner material waste is less than 10% in developed markets. This encourages improvements in the final removal of labels from containers and packaging for packaging recycling.

[0101] like Figure 6 As shown, a camouflaged label face cutting pattern of cuts or slits 62 in the label supply material layer 60 can be provided near or within the printed image on the label supply material layer, which means that the cuts or slits are not obvious to the purchaser or user of the item to which the label is applied. The cuts or slits 62 are parallel only to the direction of movement 64, so these cuts are not subjected to pressure when the label is separated from the liner or when the label is applied. The cuts or slits 62 improve the cleaning process to enable it to penetrate into the reduced adhesive layer. In addition, providing a simplified die cut line or weakening the linerless label supply sheet will encourage brand owners to use regularly changing micro-hole patterns between joint-type labels to achieve anti-counterfeiting functions. Minor, almost invisible changes to these patterns and any surface slits only require changes to the mold tooling, and the improvements ensured by these methods and new laminates will be more commercially attractive than many anti-counterfeiting alternatives.

[0102] Reference now Figure 7 and Figure 8 , the figure illustrates a label supply 102 under a first condition according to another embodiment of the present invention.

[0103] The label supply comprises a layer of liner material 104 as a liner, a surface of which is coated with a release material 106, and a layer of adhesive material 108 is applied to the opposing surface, or is subsequently applied thereon.

[0104] A label supply material layer 110 is provided, with a plurality of labels 112 defined therein, typically formed at a converting location into a label matrix and / or printed application as shown by cut lines 114. The label supply material layer 110 has an adhesive material 115 applied to the release coating 106 of the liner material layer 104 to form a label supply that is typically rolled into a roll for transport to a converting location.

[0105] like Fig. 9 and Fig.10 As shown, the separated liner material layer 104 has a release layer 106 forming a "top" surface, and an adhesive material is applied to the opposite surface to form a tape 122. The figure also shows a break line 121, which indicates that at the stage of separating the liner material layer 104, it can be cut along its length to form two or more tapes 122, 122' of reduced width, but this step is optional and can be determined according to the width 123 of the liner material layer 104 and the ideal width of the tape to be formed.

[0106] Now turn to Fig.11 , which schematically shows several options for the process of the present invention. The first stage 116 is to produce the label supply, and the second stage is to convert the label supply into a label by cutting and / or printing at stage 118. Figure 7 and Figure 8 When the label supply is formed, it will typically be formed into a roll for storage and / or shipment to a label printer 118, which in one embodiment may already have an adhesive material applied thereto, and the label printer may activate the PS function as the liner material layer is processed and cut into typical tape widths of 20 mm to 70 mm and then formed into rolls. It is contemplated that the unwinding of these rolls for subsequent use is no different than a conventional roll of tape.

[0107] As an alternative to providing the adhesive on the liner material layer at the lamination stage, the adhesive may be applied when the liner material layer is removed from the label supply material layer, typically at or just after the label printing stage, for example by a hot melt coating device.

[0108] Furthermore, providing the PP liner material with, for example, a plasma release coating will act to release it from the adhesive.

[0109] Once the tape 122 is formed, there are many different options according to the present invention.

[0110] The first option represented by the broken line 120 is to move the tape 122 directly to the place of use. If necessary, the tape can be moved through an activation device 124, which is designed to apply heat and / or pressure and / or any other necessary means to activate the adhesive 108 to give it adhesive properties so that the tape 122 can be applied in the desired manner. It should be understood that the specific activation means used will depend on the specific adhesive used. In this embodiment, the activation can be carried out at or near the label conversion device 118 or the tape application device 126, by which the tape strips can be separated and applied to the article in a conventional manner. In addition, an adhesive layer can also be applied to the tape at this stage.

[0111] In another embodiment indicated by broken line 128, tape 122 may again be passed to adhesive activation or adhesive application device 124. However, rather than applying the tape at this stage, the tape roll is moved to reservoir 130 and then from reservoir 130 to adhesive tape application device 126 and applied.

[0112] A third option indicated by the broken line 132 is that the tape 122 is rolled into a roll at stage 134 and then moved to the storage 130, from which, once taken out for use, the tape 122 is moved through the activation device 124 so as to activate the adhesive layer 108 at this stage and then moved to the tape application device 126 so as to apply a strip of adhesive therefrom. In any one embodiment, the film material used for the liner material layer can be changed to the original monomer of the material, thereby facilitating the subsequent recycling or reuse of the material. Therefore, a cost-effective method for recycling the liner material layer is provided. In addition, it allows the liner material layer to be economically collected and recycled in a relatively large amount (with reduced transportation requirements) at the location where the liner material layer is separated from the label material layer (usually at the location of the label converter, rather than the final label application location), while at the final label application location, the amount of liner material is relatively small and therefore, collection is uneconomical. This is particularly important with regard to the rapidly emerging technology that will make recycling of plastics such as PET cost effective and will allow PET liner materials to be recovered, depolymerized and then repolymerized to form virgin PET. This will enable a true circular economy whereby in effect the liner material layer will be used over and over again with only the relatively thin silicone release layer being consumed each time. This solution depends on a cost effective route to recover the liner material layer which the present invention now provides as it allows the liner material layer to be recovered at an intermediate location such as at a label supply converter location which is a more centralized location as converter locations typically serve over 100 label application locations and therefore the level of liner material removed at the converter location is now much greater, the number of recycling locations is greatly reduced and the prospect of recycling is made economically viable.

[0113] Fig.12a -d shows another embodiment of the process for reusing the lining material layer according to the present invention.

[0114] exist Fig.12a In the figure, the initial printing stage 202 is shown on the back side 214 of a transparent film label supply material layer 206, which is currently completed by some label converters on a high speed printing unit with a 1 meter web width 204. This printing process can use metallic inks to achieve high quality decorative effects without the waste associated with traditional lamination techniques. Figure 12b In the process, the printed label supply material layer 206 passes from a roller 208 so as to be transferred into a conventional laminated label supply body 216, and the conversion is improved compared to conventional methods by using a pre-siliconized PET material layer 210 and applying a high speed release silicone 212 on the open face of the label supply material layer 206, and applying a clear pressure sensitive adhesive 218 on top of the original PET pre-siliconized liner and laminating the liner material layer 210 to the printed face 214, thereby forming a laminated label supply body 216 that can be used for die cutting to form conventional labels, which also causes the adhesive layer to be transferred to the face 214 of the label supply material layer.

[0115] The process now uses a reused pre-siliconized PET liner material layer 210 and therefore changes the capacity of the silicone coating to coat the surface of the printed label supply material layer 206, as well as adding the same clear PS adhesive. In this way, the process creates a release surface for the final linerless label and allows the pre-siliconized liner material layer 210 to be removed for reuse, such as Fig.12c As shown, the liner material layer 210 is separated from the label supply material layer 206 at position 220, and the liner material layer 210 is returned to be reused in a new laminate, such as Figure 12b The stages are shown as indicated by arrow 222 .

[0116] Die cutting of conventional labels in the label supply material layer 206 is typically done in 500 mm wide rolls, so the original 1 meter wide laminate is cut into two widths 226, 228 at position 224 and moved to separate rolls prior to the die cutting process in a typical slitter rewind and finishing of conventional labels.

[0117] Fig.12dDetailing the linerless label replacement according to the present invention, in the new converting process, the original 1 meter wide pre-siliconized PET liner material layer 210 is separated for continued reuse and only the label supply material layer 206, now coated with a release layer, is slit. In the new converting process, the separated label supply material layer 206 and the adhesive layer thereon are slit to form two widths 226, 228 and laminated to a 500 mm wide roll of other reused PET siliconized liner, which passes the label supply material layer portions 226, 228 through a die cutting process 230 to apply a shape and or micro-perforated pattern before the liner material layer 210 is separated and the now linerless label supply material layer portions 226, 228 are independently rolled into rolls. This secondary use of the pre-siliconized liner allows frequent reuse in the final die cutting process, and the new converting process provides the efficiency of linerless labels in the high-volume market while retaining the proven decorative appeal.

[0118] Thus, according to the present invention there is provided a method and apparatus for reusing and / or recycling label supply liner material, thus utilising material which would otherwise be considered waste and requiring no material to be applied to the label stock after formation. Furthermore, in terms of recycling this means that the liner material, if used as a tape and applied to, for example, a cardboard box, will form part of the cardboard waste, being classed as packaging waste in the absence of restrictions on movement between countries under European legislation, in contrast to the liner waste material, if used on its own, which would likely be classed as special waste, in which case considerable documentation and time would be required. The present invention also has the added advantage that the liner material does not need to be collected for recycling as it is "re-used".

Claims

1. A method of processing a label supply from a location where a label supply laminate is formed to a remote location where labels are applied to articles, the label supply laminate being formed and comprising a label supply material layer and a liner material layer to which the label supply material layer is adhered, the liner material layer acting as a carrier for the label supply material layer until the labels are printed and / or transferred to the location where the label supply material layer is separated from the liner material layer between the location where the label supply laminate is formed and the point where the labels are applied to articles, and after the printing and / or transfer occurs and when the liner material layer is separated from the label supply material layer, forming the label supply material layer into one or more linerless label rolls for continued movement to the point where the labels are applied to articles; and the separated liner material layers are formed into one or more rolls for movement to a recycling facility, wherein The control parameters for separating the liner material layer from the label supply material layer are different from the control parameters for allowing the label to be separated from the linerless label supply material layer at the point of application to the article; wherein the label supply material layer is firmly fixed by a contact device so as to support the label supply material layer during separation of the liner material layer from the label supply material layer; and wherein one side of the surface of the linerless label supply material layer is fixed by the vacuum section of the contact device and the vacuum is selectively blocked so that the liner material layer is not held or controlled and is peeled under the tension of the peel plate or drive path pulley, while the surface of the label supply material layer is supported but no tension is applied to the weakening line of the linerless label supply material layer.

2. The method according to claim 1, wherein: Continued movement of the roll involves transporting it to said remote location where labels are applied to articles.

3. The method according to claim 1, wherein: The roll of liner material is formed to have an outer diameter which is smaller than the outer diameter of the roll which provides the label supply laminate to the position where the label supply material layer and the liner material layer are separated from the label supply laminate.

4. The method according to any one of claims 1 to 3, wherein: The location where the liner material layer is removed from the label supply material layer is where labels are printed and / or converted on the label supply material layer.

5. The method according to claim 4, wherein: Once the printing and / or converting has taken place, the layer of liner material is removed from the layer of label supply material.

6. The method according to any one of claims 1 to 3, wherein: The lining material layer includes a release material layer.

7. The method according to claim 4, wherein: The converting of labels includes applying a protective varnish and / or anti-release coating to the label supply material layer to cover the printed image that has been applied.

8. The method according to claim 7, wherein: The application of the varnish and / or anti-release coating occurs prior to defining the label in the layer of label supply material.

9. The method according to claim 4, wherein: A cutting module is provided to cut only the layer of label supply material to define the final label format and / or to form micro-perforations which will be separated at the point of subsequent application of the label to an article by a label applicator apparatus.

10. The method according to any one of claims 1 to 3, wherein: Offcuts, print waste and / or matrix waste from the layer of label supply material which is removed from the layer of label supply material independently of the layer of liner material is what is left after defining the label.

11. The method according to any one of claims 1 to 3, wherein: The liner material layer is gradually peeled off from the label supply material layer under tension in a rewinding device.

12. The method according to claim 11, wherein: The peeling is performed along an axis extending substantially parallel to the longitudinal axis of the web of label supply laminate.

13. The method according to claim 12, wherein: A stripper plate or a transfer pulley is provided.

14. The method according to any one of claims 1 to 3, wherein: Smaller rolls of separate layers of label supply material are formed simultaneously and are placed side by side with spaces between them.

15. The method according to any one of claims 1 to 3, wherein: The separated layers of liner material are rewound into rolls.

16. The method according to any one of claims 1 to 3, wherein: The layer of liner material does not reach the point where the label is applied to the article.

17. Apparatus for handling a roll of label laminate comprising a layer of label supply material and a layer of liner material to which the layer of label supply material is adhered; A moving device, when the label laminate roll is moved to a position where labels are printed and / or converted onto the label supply material layer, the moving device allows the liner material layer to serve as a carrier for the label supply material layer, and the point at which the label supply material layer is separated from the liner material layer is between the position where the label laminate is formed and the point at which the label defined in the label supply material layer is applied to the article; and wherein, after the printing and / or conversion occurs and in the separation position, the device includes a peeling device, which is used to peel the liner material layer from the label supply material layer and at least wind and cut the separated label supply material layer into a series of linerless label rolls having a width less than that of the label laminate roll so as to continue to move to the position where the label laminate is formed. a point at which a label is applied to an article; and the separated liner material layer is formed into one or more rolls for movement to a recycling facility, wherein the control parameters for separating the liner material layer from the label supply material layer are different from the control parameters for allowing the label to be separated from the linerless label supply material layer at the point of application to the article; and wherein the apparatus includes a contact device at the separation position, the contact device being used to secure the surface of the label supply material layer by a vacuum section of the contact device, and the vacuum being selectively blocked so that the liner material layer is not held or controlled and is stripped under the tension of a stripping plate or drive path pulley, while the surface of the label supply material layer is supported but no tension is applied to the weakening line of the linerless label supply material layer.

18. The apparatus according to claim 17, wherein: Only separate rolls of label supply material are supplied to the point of application to the article.

Images