Device and method for supplying label

Abstract

To provide a method and a device for reuse and / or recycling of a label supply liner material.SOLUTION: Separation, treatment, and recycling of a liner material layer that is to be treated as a waste matter are enabled. In this invention, these can be achieved without application of any kind of materials to a label supply followed by its formation. In one embodiment, recycling can be performed in a form of forming a liner material 30 into a raw material for subsequent treatments, or alternatively, a form of using the liner material as an adhesive tape, or alternatively, a form of directly reusing a liner material layer as a part of another label supply.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The subject of the present invention is the provision of an apparatus and method that allows reels of label supply material to be supplied to locations where labels are applied to articles, the supply being initially formed at a lamination location and supplied from a laminate producer location as a laminate combination of label supply material layers, adhesive, release coating and liner or backing material layers, then passed to a label printer and converting facility location, and then on to one or more locations for application of the labels to articles. [Background technology]

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

[0003] The use of pressure-sensitive labels is well known, and labels are currently typically applied by peeling the label from a silicone-coated liner material layer at the location where the label is to be applied to an article, or just before the label is to be applied to the article. Once the label is peeled from the liner material layer, the liner material layer represents a complex waste stream of small, variable-width reels located in multiple locations, making their collection and subsequent transportation to waste recycling sites difficult and expensive. As a result, millions of tons of liner material waste have been and are estimated to continue to be sent to landfills. Considering that the supply of this laminate, including the label supply material layer and the liner material layer, is a truly global industry with variable consumption rates ranging from 10 square meters per person per year in developed countries to less than 1 square meter per person in less developed countries, the supply of laminate tends to be handled by relatively large multinational manufacturers, and is relatively large-scale, with machines typically used there that are 2 meters wide and produce laminate at 1,000 meters per minute from master reels of that width.

[0004] The industry recognizes the need to reduce its waste footprint, and while recycling of waste liner materials in the form of glassine and kraft paper is possible, the presence of silicone as a release layer in the liner material makes recycling more difficult, as the silicone acts as a contaminant. Nevertheless, even in developed markets, it is estimated that less than 10% of annual liner material waste is recovered, and although new liner materials containing recycled content are being produced, the continued demand for virgin fiber remains the most significant. The liner material layer of the laminate also needs to have a relatively high tensile strength to enable high-speed, high-frequency application of labels, for example, up to 1,000 labels per minute with stop-start control.

[0005] Thus, although efforts have been made to recycle liner material, the practical application of known recycling methods is quite low, due at least in part to the relatively complex logistics associated with recovering the liner material and transporting it to a location where it can then be recycled.

[0006] A further problem is that because the liner material layer is removed from the label supply material layer at the end user's location, i.e., where the label is applied to an article, and the laminate of the label supply material layer and the liner material layer is provided at that point as a relatively small sized reel, it can be seen that removal of the liner material layer results in a large number of relatively small sized reels of waste liner material, and that these are generated at multiple locations. It has therefore proven particularly difficult to collect and transport multiple small reels from multiple different locations to a centralized recycling location in an economically viable manner, and therefore it has been found that in most cases the waste reels are not sent back for recycling at the recycling location.

[0007] An increasingly attractive alternative is to provide reels of linerless label sheet material, i.e., reels that are not provided with any layer of liner material at any stage. However, while the ability to apply this type of label is proven, it is based on using printing and converting methods that are relatively complex for label printers and / or converter companies, and therefore, although linerless labels allow packagers to produce more labels per reel, reducing raw material use and shipping costs overall, this alone will not, at least in the short term, meet growing label demand or significantly reduce waste.

[0008] The manufacturing industry for such products can be broadly divided into the production of labels provided for decoration and information in association with individual items, and the production of labels used in logistics where variable information is usually printed when the packaging is completed.

[0009] For the latter application, significant development of linerless alternatives has occurred over the years, driven by individual converters taking advantage of advances in direct thermal paper. Typically, 400-mm-wide reels of thermal paper are processed at 150 meters per minute. Converters apply a silicone release layer and a hot-melt pressure-sensitive adhesive layer, then slit and rewind the paper into finished reels, with current maximum production volumes reaching 75 mm wide reels. The development of suitable label application equipment for use in product packaging and handling, typically at line speeds of 50 cases per minute, has accelerated the demand for linerless labels in this sector, attracting global laminating manufacturers to supply "self-rewinding" linerless direct thermal master reels that converters can then cut into smaller reels. The production capacity of these major laminating manufacturers is essential to meet demand, and this development demonstrates that pressure-sensitive labels can be applied without waste liner.

[0010] In the field of decorative and / or informational labeling, individual articles in the form of containers such as bottles are typically labeled at much higher speeds; for example, clear-on-clear printed labels are applied to glass beer bottles at speeds of 1,000 per minute. While packaging line speeds can be variable, all current pressure-sensitive label applications require a high-strength liner material layer to handle the stresses of stop / start acceleration. To meet these speed and precision demands, the industry has developed high-speed release silicone coatings that are sufficiently rigid to reliably separate the label from the liner. The label is separated from the silicone liner material layer by a release plate or beak, with only the liner material layer under tension.

[0011] For the application of large volume beverage and water bottles, major application machinery manufacturers have developed full-wrap labeling with hot melt application and high-speed cutting to apply these labels to the containers. This is a different technology, but has the same requirements compared to individual patch labeling. This has allowed for the development of very thin, cavitated film wraps for roll-fed adhesive-backed labels that can only be used for full-wrap labeling.

[0012] The use of linerless labels has been developed by the applicant, for example with reference to GB 2185426, which uses a pattern of tiny perforations imposed by a printer or in an application machine to define the join between adjacent labels in a label material supply, allowing several shapings of labels. This is now a proven technology and is used, for example, in demanding high speed beer bottle labelling, so the pressure sensitive label supply industry is being challenged to produce large volumes of linerless decorative and informational labels.

[0013] In the process of forming conventional decorative and informational labels, they are typically printed by applying ink to the outer surface of a label material layer, followed by applying a pressure-sensitive layer to the inner surface, then placing a silicone release layer between the adhesive and the liner material layer, and then forming micro-perforations and / or cut features in a die-cutting or tearing station. Direct coating and die-cutting present technical challenges that lead to these specialized machines, primarily due to the use of reusable process silicone liners. Linear matrix waste is generated along with the features, and the results of the die-cutting process are inspected if the linear matrix is ​​not successfully peeled to ensure that the die-cutting process has formed high-quality micro-perforation cuts and seams.

[0014] Alternatively, label printers may employ a laminate-to-linerless option, in which the label printer transfers a clear film liner to the printed surface to decorate the surface and protect the image before die-cutting, and to provide release for the final self-winding reel of linerless labels. However, this alternative requires specialized conversion investment and can only work with clear liner materials, and while these developments are important, they do not solve the enormous challenges the industry faces regarding liner material waste and the tightening waste laws that are 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 may itself be expensive, and in some cases certain components of the waste liner material may not be recyclable, and therefore the waste liner material cannot be recycled unless its components are separated. Summary of the Invention [Problem to be solved by the invention]

[0016] There is therefore a need to be able to improve the feasibility and attractiveness of recycling liner waste, which, in addition to providing clear environmental benefits, allows those benefits to be obtained in an economically viable manner. [Means for solving the problem]

[0017] The object of the present method and apparatus is to enable and improve the efficient recycling of liner material from original laminate label supplies. A further object is to enable waste collection to be accomplished in a manner that allows larger volumes of waste to be provided for collection at one location, thus reducing the number of locations where waste may need to be collected, improving sustainability and waste volume reduction. A further object is to generate sufficient waste at one location to allow recycling of the waste liner material to occur at the same location, thereby avoiding the need for transport of the waste prior to recycling.

[0018] A further object is to further advance environmental benefits by providing improved return of waste liner material for recycling by allowing reels of liner material to be adapted for specific applications without going through a shredding and recycling stage.

[0019] In a first aspect of the present invention, there is provided a method of processing a label supply from a location where a label supply laminate is formed to a remote location where a label is applied to an article, the formed label supply laminate comprising a layer of label supply material and a layer of liner material to which the layer of label supply material is adhered, the liner material layer acting as a carrier for the layer of label supply material until a point at which the layer of label supply material is separated from the liner material layer, the point of separation being located at a location intermediate the location at which the label laminate is formed and the location at which the article is applied to the label.

[0020] In one embodiment, after separating the layer of liner material from the layer of label supply material, the label supply is formed into one or more reels of linerless labels for onward transport to an application point.

[0021] In one embodiment, after separating the liner material layer from the label supply material layer, the liner material layer is formed into one or more reels for transport to a recycling facility. In one embodiment, the printer may stop printing to remove a completed reel of linerless label material layer, but may then continue to produce additional labels of the same or new label images from the same original master reel of laminate, and rewind substantially all of its liner material layers from the master roll onto one reel of waste liner material for collection.

[0022] In one embodiment, said reel of layer of label supply material being formed has an outer diameter that is smaller than the outer diameter of the reel on which the laminate is provided where the label supply and liner material separate.

[0023] In one embodiment, the location where the liner material is removed from the label material is the location in the label supply where the labels are printed and / or converted, and once printing and / or converting has occurred, the layer of liner material is removed from the layer of label supply material and the layer of label supply material is wound onto a new reel for forward feeding and subsequent application to an item.

[0024] In one embodiment, subsequent supply of the reel of layer of label supply material involves transporting the reel to another location where the label is applied to an item.

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

[0026] In one embodiment, during the label converting stage, a protective varnish and / or peel-resistant coating is applied to the layer of label supply material, typically over the applied printed image, prior to defining the label in the layer of label supply material by die-cutting, slitting, etc. In one embodiment, the application of one or more coating layers can be performed in a printing press or a separate label reel finisher.

[0027] In one embodiment, a cutting module, such as a die tool or rotary slitter, is provided to cut only the layer of label supply material to define the final label format and / or to create micro-perforations that are subsequently separated at the point of application of the label to an article via a label application device.

[0028] In one embodiment, the label converter peels the marginal edge print waste and / or matrix waste from the layer of label supply material remaining after a defined portion of the label has been removed, as a separation step relative to the full width removal step of the liner material layer, which is gradually peeled from the layer of label supply material, typically under tension in an unwinding device. In one embodiment, the removal occurs along a line extending substantially parallel to the longitudinal axis of the reel of laminate.

[0029] In one embodiment, a peeler plate or transfer pulley is provided and separate, now linerless, smaller reels of label supply material layers are simultaneously formed and arranged side by side with spaces between them typically resulting from the removal of linear surface material waste.

[0030] Typically, the now waste liner material layer is rewound onto a reel for convenient transport for recycling, and therefore, in accordance with 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 remote location.

[0031] In one embodiment, the lanes or paths of linerless labels are carried by the liner material until the liner material is peeled or separated therefrom, which may be assisted by a plasma-coated drive pulley operating on the adhesive side of the labels or a suitable nip assembly at a speed and tension that creates the necessary force to achieve separation from the liner material in succession before individual reels of the self-winding linerless label supply are completed. These completed reels are wound with minimal tension, eliminating the risk of adhesive leaking from the ends of these reels.

[0032] In one embodiment, the linerless label supply having the lines of weakness formed thereon is supported during separation from the liner. In one embodiment, the surface of the linerless label supply material layer is securely held by a vacuum segment of a contact means, which in one embodiment may typically be a rotating cylinder operating at a web speed determined by the conversion. In one embodiment, the vacuum is selectively interrupted at the outer surface of the cylinder, thereby allowing the liner material layer to be similarly not held or controlled, but peeled under tension by a peel plate or driven path pulley while the surface of the label supply material layer is supported, ensuring that the lines of weakness in the linerless label supply material layer are not under tension as the liner material layer is peeled away.

[0033] In one embodiment, the label is defined by die cutting or otherwise forming fine perforations in the layer of label supply material, and in one embodiment the amount of material cut is 75% of the total width of the label contour; it may also be possible to further increase the percentage of cut by separating the liner material from the layer of label supply material as described herein in accordance with the present invention, thereby facilitating alternative means of application of the label to an 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 to ensure that a label supply material layer of adequate tensile strength is released. In one embodiment, the liner material includes a release coating that is more easily recycled than silicone release coatings. In one embodiment, the release coating is a water-soluble coating that can be subsequently removed or washed off the liner material to further enhance ease of recycling of the liner material.

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

[0036] Peel force measurements using a relatively high stripping speed of the liner material from the label supply sheet material are typically >50 m / min, whereas slow speed peel is a force measurement using a relatively slow strip of 0.3 meters / min. A 45 gsm glassine liner has a Tensile Strength MD (kN / m) of 4.5, a 58 gsm liner with a 51 micron caliper has a Tensile Strength MD (kN / m) of 6.4, and most paper liners are in this range.

[0037] In one aspect of the invention, which can be used in combination with or independently of these aforementioned features, the label supply sheet material on which the labels are defined has a pattern of surface incisions on said labels that are aligned in the same direction as the labels are fed to the articles to be affixed.

[0038] Typically, the surface incisions facilitate accelerated removal of the label from the article to which it was previously affixed, most typically as part of a subsequent recycling process for the article / label combination. In one embodiment, the surface incisions allow penetration of a removal solution to allow washing of the adhesive from the label, thereby improving the rate of label removal. Thus, these incisions are typically provided in the final label simultaneously with or after die-cutting of lines of weakness into the label supply material layers, and in some cases are not provided in the original label supply material delivered to the printer by the laminate manufacturer.

[0039] In one embodiment, a water-based or alternative liquid flushing procedure is used in recycling the item. In one embodiment, the incision is disguised or hidden by alignment 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 so that the fully recovered liner can be fully reprocessed into the original wide web format required for laminate production.

[0041] In one embodiment, a label supply layer is provided in which the seams of the micro-perforations within the lines of weakness vary, and / or the surface label cut pattern provides a counterfeit-deterrent pattern variation that, in one embodiment, is only apparent 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 for the surface of the label supply material layer, and a low affinity for the liner material layer.

[0043] In one embodiment, the separated layers of liner material are formed into an adhesive tape having a coating of release material on a first side and a coating of adhesive material on an opposite side.

[0044] In a further aspect of the present invention, there is provided a master roll of laminate produced by a laminate manufacturer, the master roll comprising a label supply layer having a side for printing thereon and an opposite side having a layer of adhesive, a liner layer to which the label supply layer is initially adhered within the master roll, and a peel system between the liner layer and the label supply layer, wherein the liner layer and the label supply layer are separable, and at least the label supply layer is formed into a plurality of smaller reels for onward feeding to one of more points from which labels are applied to articles.

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

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

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

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

[0049] In another embodiment, a paper or film liner material is provided whose surface has been chemically modified to lower its surface energy and make it releasable. Preferably, the modification is such that the liner material is considered to be uncontaminated or have only minor contamination, and can be recycled into potential downstream use streams.

[0050] In a further embodiment, liner materials are provided that are papers or films that have been treated with release chemicals that can be removed prior to recycling, increasing the number of options for which liner materials can be usefully added.

[0051] In one embodiment, the release coating is of a type that can be washed off or otherwise removed, such as by mechanical abrasion, such as milling, before recycling.

[0052] In a further aspect of the present invention, there is provided an apparatus for processing a label laminate comprising a layer of label supply material and a layer of liner material to which said label supply is adhered, the apparatus comprising: moving means for enabling said liner material to act as a carrier for the label supply as the laminate is moved to a point at which the label supply is separated from the liner material, the point at which the label supply is separated from the liner material being intermediate between the formation of the label laminate and the point at which a label secured to the layer of label supply material is applied to an article; and peeling means for peeling the liner material from the layer of label supply material and winding and cutting at least the layer of label supply material onto a series of reels having a width smaller than the reel from which the laminate is supplied.

[0053] In one embodiment, after separation, only the labels defined within the layer of label supply material are reeled to the point of application to an article.

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

[0055] In one embodiment, the adhesive is made sticky by an activation step.

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

[0057] In a further aspect of the present invention, there is provided an apparatus for forming adhesive tape, said apparatus comprising means for forming a label supply comprising a layer of liner material and a layer of label supply material having one or more labels defined thereon and having an adhesive on a surface thereof and applied to a release material applied to a surface of the liner material layer, said apparatus comprising means for separating the layer of liner material from the layer of label supply material to form the layer of label supply material into a linerless label supply from which the labels may then be separated, means for winding the separated layer of liner material onto one or more reels, and means for applying and / or activating an adhesive to a surface of the separated layer of liner material to form it into a reel of adhesive tape.

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

[0059] In one embodiment, the means for applying adhesive is arranged to non-activatably apply the adhesive to the layer of liner material before the label supply is formed.

[0060] In an alternative embodiment, the means for applying adhesive is arranged so that adhesive is applied to the surface of the layer of liner material after the layer of liner material has been separated from the layer of label supply.

[0061] Typically, means are provided for applying a coating of adhesive to the label supply layer or backing layer to form the adhesive tape supply.

[0062] In one embodiment, there is further provided an apparatus for applying labels from a linerless label supply, said apparatus comprising means for removing said one or more labels and applying them to one or more articles.

[0063] In one embodiment, therefore, the capability is provided for recovery of the liner material at the label supply converter to allow it to be recycled, typically chemically, back into the original monomer.

[0064] In a further aspect of the present invention, there is provided a method for forming an adhesive tape from a layer of liner material that has previously been used in combination with a layer of label supply material to form a label supply, the method comprising the steps of applying a coating of release material to the layer of liner material, applying a layer of label supply material to the release material, and passing the label supply to a converting device to enable printing and / or formation of labels on the layer of label supply material, the layer of liner material being removed from the layer of label supply material that has been passed to a label application device, the separated layer of liner material having adhesive applied to a surface thereof to form it into an adhesive tape.

[0065] In one embodiment, the method includes cutting the liner sheet material into strips and / or winding the liner sheet material onto a reel.

[0066] The present invention therefore allows for the efficient collection and recycling of liner materials and other waste materials.

[0067] Specific embodiments of the present invention will now be described with reference to the accompanying drawings. [Brief explanation of the drawings]

[0068] [Figure 1] 1 illustrates a conventional method for providing a laminate and label to the point of application to an article. [Figure 2] 1 illustrates a method according to the present invention in one embodiment. [Figure 3] 1 illustrates an example of a conversion system and device according to the present invention. [Figure 4] 3 shows a further embodiment of the device according to the invention; [Figure 5] The methods by which different forms of laminates can be made for use in the present invention are shown. [Figure 6] 1 illustrates a label defined on a layer of label supply material according to one embodiment of the present invention. [Figure 7] 1 shows a plan view of a label supply in a first state according to an embodiment of the invention; [Figure 8] The label supply of Figure 7 is shown in cross section along line AA. [Figure 9] 1 shows a plan view of an adhesive tape according to one embodiment of the present invention; [Figure 10] 10 shows a cross section of the adhesive tape of FIG. 9 along line BB. [Figure 11] 10 shows a schematic representation of an embodiment of the formation of the label supply of FIG. 7 to the adhesive tape of FIG. 9; [Figure 12a] 1 illustrates a further embodiment of the process according to the present invention. [Figure 12b] 1 illustrates a further embodiment of the process according to the present invention. [Figure 12c] 1 illustrates a further embodiment of the process according to the present invention. [Figure 12d] 1 illustrates a further embodiment of the process according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0069] Referring to Figure 1, a conventional label laminate is illustrated which is produced by a laminate manufacturer and uses a provision of a master roll 2 of laminate which is typically 2 meters or more wide and which carries a layer of label supply material and includes a layer of liner material to which the layer of label supply material is attached.

[0070] The master roll of laminate 2 is then cut at intervals along its width to form a series of smaller reels 4 of laminate, typically one meter in outer diameter; these reels are then fed to printers and label converting companies, where labels are printed onto the laminate and then cut again into smaller reels 6 of label laminate. Typically, about 10% of the laminate is wasted during this process. These smaller reels 6 are then passed to "packaging" companies, which distribute the reels of laminate to one or more of their locations where labels are applied to articles, typically forming retail packages; the label supply layer is traditionally separated from the liner material when the label is applied to the article. The currently waste liner material is provided as waste reels 8, easily stretchable thanks to a silicone release coating. The intent is to have them collected and shipped for recycling, although in practice this rarely occurs.

[0071] The present invention overcomes this problem to significantly improve waste footprint and laminate supply logistics, including the possibility of new laminate types.

[0072] As shown in FIG. 2, the first step of the present invention is again to provide a master reel 10 of laminate from the manufacturer, which is cut into smaller reels 12 and delivered to a printer and converter location, with the separation of the label supply layers from the liner material occurring at this point. This therefore means that a reel 14 of linerless label supply material is delivered from the printer and converter location to one or more labeling company locations. The liner material is waste at this point and is typically available as a reel 16 that can be collected for recycling rather than being delivered to the labeling location. It will thus be appreciated that, compared to conventional methods, the size of the waste liner material reel 16 is larger, the number of locations where the waste reels are placed is significantly reduced, and therefore the likelihood of collection, and therefore recycling, of the waste liner material is higher than with conventional methods.

[0073] The apparatus provided to enable separation of the liner material from the layer of label supply material can take several forms to suit particular requirements. This method involves separating the liner material from the label material across the full width of the reel at the printer converter, and then using an unwinding and separation technique to securely fasten the layer of linerless label supply material within the reel 14.

[0074] In Figure 3, reel 12 is fed to a converter station, surface printed, has a release coating layer 22 applied thereto, and any linear edges and shaped waste of label supply material are removed 24. An optional cylinder 20 is positioned at station 26, which assists in separating the label supply material layers 28 that are formed into linerless label supply material reel 14 for onward movement to a label application station. The separated liner material 30 is reeled to form liner material waste reel 16. Also shown is how reel 12 is progressively processed to provide three passes 32, 34, 36 of linerless label supply sheet material, each of which is wound up to form a respective reel 14.

[0075] When producing conventional labels, adding liner separation and rewinding to a press or offline finisher allows the label converter to rewind this edge slip waste separately from the liner waste. This method typically involves back-slitting the edge liner and recovering this trim along with all the matrix waste. An optional segmented vacuum cylinder 20, as shown in the example apparatus of Figures 3 and 4, can be used as an alternative path guide for removing the linear and liner matrix waste when producing linerless or conventional labels with an upgraded apparatus. In this example, the transport of the die-cut and area waste strip web can be controlled by vacuum segments 18 within the rotating cylinder 20, which hold the non-adhesive material in specific locations through vacuum. Thus, in different embodiments, the waste can be separated from the label supply sheet material before or after the location of the vacuum cylinder. The specific location where the vacuum is applied can be preset on the cylinder itself or can be tailored to specific usage requirements, such as by applying tape or other blanking material to the face of the cylinder in areas where the vacuum effect is not desired. In this way, the pattern of vacuum segments on the cylinder can be configured to match the linear edge and shape label waste pattern of the laminate, preventing loss of vacuum control of individual linerless label supply material paths while still being supported by the liner material. The liner material release surface that may be exposed by removing linear strip waste in front of this rotating cylinder is not affected by the vacuum.

[0076] It is conveniently peeled off with a full-reel-width peeler plate before the supported label supply exits the vacuum segment. The label supply can retain the now-separated linear strip waste on this same cylinder as the linerless label supply path is directed toward reel take-up. In this way, after the vacuum segment and full-width stripping of the liner material, the method allows the linerless label supply to be released from vacuum control and rewound under the low reel tension optimally used for all self-winding linerless label supply reels.

[0077] These alternative embodiments ensure that the lines of weakness created by the micro-perforations in the label supply material layer to define the label are not stressed when the liner material layer is peeled from the label supply material layer using a peel plate or driven path roller alternative.

[0078] This ensures that production and yield of label supplies and PS adhesives remains viable.

[0079] 5 illustrates how different forms of laminates can be manufactured for use in the present invention. Laminate 40 is a conventional laminate including a label supply material layer of paper or film 42 meeting the required stiffness parameters, a pressure sensitive adhesive 44, a high speed silicone release layer 46, and a liner material layer of paper or film 48.

[0080] Alternative laminate 50 embodiments may be used in accordance with the present invention, one of which has a label supply material layer in the form of a thinner face paper or film 52, a low coat weight adhesive layer 54, a liner material layer 58 and a release coating 56 that are particularly suitable for recycling purposes.

[0081] The impact of this approach supports logistics innovation and potentially means brands do not need to evaluate and approve new facings and adhesives to adopt the waste-free, efficiency-enhancing change to linerless labels. Because the majority of production lines can conveniently adapt their labeling equipment to the linerless format while using up existing inventory and changing artwork on a regular cycle, it is expected that the supply of linerless label supplies to labeling locations should not have a significant impact, and in a climate of heightened waste concerns, the incentive is significant.

[0082] The change to linerless converting is much simpler for printer converters and adds further impetus to the industry trend of separating web printing from final converting. The growth of just-in-time digital printing has contributed to overall lamination savings through faster set-up, but has not eliminated the generation of liner waste at the point of label application to items, and therefore continues to result in low recycling rates.

[0083] Laminate suppliers are unaffected as packagers and brands created PS linerless as their initial response, requiring printers to add waste liner stripping and rewinding before upgrading existing label reel systems to this advantageous feature. Once complete, the benefits of liner waste collection for enhanced recycling logistics will be immediate.

[0084] For label printers, converting to linerless label supplies is much simpler than the previous options described. A full range of adhesives is specified and supplied to meet all current label applications, and most labels are protected by varnish, making replacement with silicone-modified release alternatives practical. A major advantage of going from laminate to linerless is that die cutting remains conventional, and the liner is peeled off and no longer needed for label application, so minor damage to the liner does not generate quality-related waste.

[0085] For laminate suppliers, the fully recovered amount of liner increases the possibility of advantageously increasing the mix of recycled materials in the supply. The method of the present invention introduces the possibility of new laminate structures that the laminate community can manufacture with their own current assets with minimal investment, and which can now be more specifically designed for recycling.

[0086] Laminates with reduced facings 52 are provided to take advantage of the fact that linerless labeling methods do not require the rigidity of conventional labels, laminates with reduced specifications of a paper release liner can take advantage of the fact that this liner is now used only as protection for the carrier and adhesive facing materials, and laminates with modifications to the release function take advantage of the fact that release now involves only peeling the liner from the continuous web of labels, both under controlled tension.

[0087] In accordance with the present invention, the webs of liner and linerless labels are all continuous and are separated under tension that must exceed the release value of the liner release coating. Assistance may be required to ensure that the labels within these webs do not separate under the increased release force.

[0088] Laminates with reduced adhesive coating weights of 12 microns or less can take advantage of the fact that the current degree of protection in die cutting is reduced and thinner facing materials or PS linerless labels require less adhesive to be secured to the container or package.

[0089] Replacing silicone as a release layer coating with one that can be washed away with water before the final repulping of waste paper, for example, further aids the recycling process. Film liners without silicone coatings, using slip agents or silicone substitutes, can be conveniently reground and reprocessed. This facilitates liner recycling by allowing printer / converters to efficiently account for waste generated by laminators, avoiding the traditionally complex logistics of multiple printers supplying a single brand—a key reason why less than 10% of liner waste is traditionally recycled in developed markets. This also encourages improvements in the eventual removal of labels from containers and packages for packaging recycling.

[0090] As shown in FIG. 6 , the deceptive label surface cut pattern of cuts or slits 62 in the label supply material layer 60, which can be provided adjacent to or within the printed image of the label supply material layer, means that the cuts or slits are not readily apparent to the purchaser or user of the item to which the label is applied. The cuts or slits 62 are imposed to be parallel only to the direction of travel 64, and therefore are not stressed when the label separates from the liner or when the label is applied. The cuts or slits 62 improve the washout process to favor reduced adhesive layer penetration. Furthermore, the provision of simplified die-cut lines or weakening to the linerless label supply sheet material encourages brands to take advantage of the anti-counterfeiting features available through periodic changes to the micro-perforation patterns between catchpoint format labels. Minor, nearly invisible changes to these patterns and any surface slits require only die tooling changes, making the improvements ensured by the method and new laminate commercially attractive compared to many anti-counterfeiting alternatives.

[0091] 7 and 8, there is shown a label supply 102 in a first state according to a further embodiment of the present invention.

[0092] The label supply includes a layer of liner material 104 that functions as a liner, with the liner material layer 104 having one side coated with a release material 106 and an opposite side to which a layer of adhesive material 108 has been applied or will later be applied.

[0093] A layer of label supply material 110 is provided in which a plurality of labels 112 are defined by cut lines 114, typically at a converting location, to form a label matrix as shown, and / or have printing applied. The layer of label supply material 110 has an adhesive 115 that is applied to the release coating 106 of the layer of liner material 104 to form a label supply that is typically wound into a roll for transport to the converting location.

[0094] 9 and 10, the separated liner material layer 104 has a release layer 106 forming the "top" surface and an adhesive material applied to the opposite surface, thereby forming an adhesive tape 122. Also, dashed lines 121 are shown indicating that, at the stage of separation of the liner material layer 104, it may be cut along its length to form two or more adhesive tapes 122, 122' of reduced width, although this step is optional and can be determined by the relationship between the width 123 of the liner material layer 104 and the desired width of the adhesive tape to be formed.

[0095] Turning now to Figure 11, several process options of the present invention are shown schematically. The first step 116 is to manufacture the label supply, and then the second step is to convert the label supply into the form shown in Figures 7 and 8, typically by cutting and / or printing, at step 118. Once the label supply is formed, it is typically formed into a roll for storage and / or transported to a label printer 118, and in one embodiment may already have adhesive applied thereto, which is activated for PS functionality by the label printer when the liner material layer is processed, and may be slit into typical tape widths of between 20 mm and 70 mm, and then formed into reels. It is envisioned that unwinding these reels of tape for subsequent use would be no different than reels of conventional adhesive tape.

[0096] As an alternative to providing the liner material layer with adhesive at the lamination stage, the adhesive can be applied when the liner material layer is removed from the label supply material layer, typically at the label printing stage or immediately thereafter, such as via a hot melt coating device.

[0097] Additionally, providing a PP liner material with, for example, a plasma release coating will act as a release from the adhesive.

[0098] Once the tape 122 is formed, there are many different options available to the present invention.

[0099] The first option, indicated by dashed line 120, is for moving the adhesive tape 122 directly to the point of use. The tape can be moved past an activation means 124, if necessary, designed to apply heat and / or pressure and / or any other means necessary to activate the adhesive 108 so that it has adhesive properties and thus the adhesive tape 122 can be applied in the required manner. It will be understood that the particular activation means used will depend on the particular adhesive being used. In this embodiment, activation occurs at or adjacent to the label converting machine 118 or an adhesive tape application machine 126, through which strips of adhesive tape can be separated and applied to items in the conventional manner. Alternatively, an adhesive layer can be applied to the tape at this stage.

[0100] In an alternative embodiment, indicated by dashed line 128, the adhesive tape 122 can be passed again to the adhesive activation or application means 124. However, rather than applying the tape at this stage, the adhesive tape reel is moved to a storage section 130 and then moved from the storage section 130 to the adhesive tape application device 126 for application.

[0101] A third option, indicated by dashed line 132, is for the adhesive tape 122 to be wound onto a reel at stage 134 and then moved to storage 130; upon removal from storage for use, the tape 122 is moved past activation means 124 to activate the adhesive layer 108 at that stage, and then moved to an adhesive tape application device 126 to apply a strip of adhesive therefrom. In either embodiment, the film-like material used in the liner material layer can be converted to the initial monomer of the material, thereby supporting subsequent recycling or reuse of the material. This therefore provides a cost-effective method for recovering the liner material layer. Furthermore, this allows the liner material layer to be collected and recovered economically and in relatively large quantities with reduced transportation requirements at the location where it is separated from the label material layer, typically at a label converter rather than at the final label application location, and where the amount of liner material is relatively small and therefore collection would be uneconomical. This is particularly important in light of rapidly emerging technologies that enable cost-effective recycling of plastics such as PET, for example, by recovering, depolymerizing, and then repolymerizing PET liner material to form virgin PET. This allows for a truly circular economy, whereby the liner material layer is essentially reused multiple times, with only the relatively thin silicone release layer being consumed each time. This solution relies on a cost-effective route for recovering the liner material layer, which is provided herein in the present invention. This is because the present invention allows for the recovery of the liner material layer at intermediate locations, such as label supply converter stations, which are much more concentrated because they typically serve over 100 label application stations; therefore, the level of liner material removed at the converter station is much higher, the number of collection stations is significantly reduced, and the prospect of recycling becomes economically viable.

[0102] 12a-12d illustrate a further embodiment of a process for recycling a layer of liner material according to the present invention.

[0103] In Figure 12a, an initial printing stage 202 for the back surface 214 of a transparent film-like label supply layer 206 is shown, currently completed by several label converters in a high-speed printing unit with a one-meter web width 204. This printing process allows for the use of metallic inks for high-quality decorative effects without the waste associated with conventional foiling techniques. In Figure 12b, the printed label supply layer 206 is passed from roller 208 to transfer it to a conventional laminate label supply 216. The conversion is improved over conventional methods by the use of a pre-siliconized PET material layer 210 and the coating of a fast-release silicone 212 on the open surface of the label supply layer 206, coating a clear pressure-sensitive agent 218 onto the original PET pre-siliconized liner, and laminating the liner material layer 210 to the printing surface 214, creating a laminate label supply 216 ready to be die-cut to form a conventional label, which also transfers a layer of adhesive to the surface 214 of the label supply layer.

[0104] Here, the process uses a repeatedly reused pre-siliconized PET liner material layer 210, thereby modifying the silicone coating capacity to coat the surface of the printed label supply material layer 206, and adding the same clear PS adhesive. By this means, the process creates a release surface for the final linerless label, allowing the pre-siliconized liner material layer 210 to be removed as shown in Figure 12c, where the liner material layer 210 is separated from the label supply material layer 206 at location 220 and returned for reuse in a new laminate as shown by arrow 222 at the stage shown in Figure 12b.

[0105] Conventional label die cutting in the label supply layer 206 is typically on a 500mm wide web, so the original 1m wide laminate is slit into two widths 226, 228 at location 224 and moved to separate reels before the conventional label die cutting process and finishing in a typical slitter rewind.

[0106] 12d details an alternative linerless label according to the present invention, in which the original 1-meter-wide pre-siliconized PET liner material layer 210 is separated for continued reuse, and only the release-layer-coated label supply material layer 206 is slit. In the new conversion, the separated label supply material layer 206, with its adhesive layer thereon, is slit to form two widths 226, 228 and laminated to another 500 mm-wide reel of reused PET siliconized liner bearing label supply material layer portions 226, 228. The liner material layer 210 is then separated and passed through a die-cutting process 230 to impart a shape and / or a micro-perforation pattern before the linerless label supply material layer portions 226, 228 are independently wound onto the reel. This secondary use of the pre-siliconized liner allows for similar frequent reuse in the final die-cutting process, and the new conversion process achieves the efficiency of linerless labels in a mass market while retaining their proven decorative appeal.

[0107] Thus, the present invention provides a method and apparatus for the reuse and / or recycling of label supply liner material, which utilizes materials that would normally be treated as waste and achieves the same without the need to apply any material to the label stock after its formation. Furthermore, from a recycling perspective, this means that if the liner material were used as adhesive tape and applied to, for example, a cardboard box, it could become part of the cardboard waste, which is classified as packaging waste, the movement of which is not restricted by European regulations, compared to the liner waste itself, which would be classified as special waste, requiring significant paperwork and time. The present invention also has the added benefit that, because the liner material is "reused," it does not need to be collected for recycling.

Claims

1. 1. A method of processing a label supply from a location where a label supply laminate is formed to a remote location where a label is applied to an article, the formed label supply laminate including a layer of label supply material and a layer of liner material to which the layer of label supply material is adhered, the layer of liner material acting as a carrier for the layer of label supply material until a point at which the layer of label supply material is separated from the layer of liner material, the point at which separation is located at a location intermediate the location at which the label laminate is formed and the location at which the label is applied to an article.

2. 10. The method of claim 1, wherein after separating the layer of liner material from the layer of label supply material, the layer of label supply material is formed into one or more reels of linerless labels for onward movement to a point of application of the labels to the articles.

3. 3. The method of claim 2, wherein the forward movement of the reel includes transporting the reel to the remote location where the label is applied to the article.

4. 4. The method of claim 1, wherein after separating the layer of liner material from the layer of label supply material, the layer of liner material is formed into one or more reels for transport to a recycling facility.

5. 5. The method of claim 4, wherein the reel of liner material formed has an outer diameter that is smaller than the outer diameter of the reel on which the laminate is provided at the location of the separation of the layer of label supply material and the layer of liner material from the laminate.

6. The method of any one of claims 1 to 5, wherein the location where the layer of liner material is removed from the label material is the location on the layer of label supply material where the label is printed and / or converted.

7. 7. The method of claim 6, wherein once the printing and / or converting has occurred, the layer of liner material is removed from the layer of label supply material.

8. The method of any one of claims 1 to 7, wherein the liner material layer comprises a release material layer.

9. 7. The method of claim 6, wherein the label converting includes applying a protective varnish and / or a peel-resistant coating to the layer of label supply material overlying the applied printed image.

10. 10. The method of claim 9, wherein the application of the varnish and / or peel-resistant coating occurs before the establishment of the label on the layer of label supply material.

11. 11. The method of claim 6, 9 or 10, 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 that are subsequently separated at the point of application of the label to the article via a label application machine.

12. 12. The method according to any one of claims 1 to 11, wherein, apart from separating the layer of liner material, edges, printing waste and / or matrix waste from the label supply material remaining after defining the labels on the label supply material are removed from the layer of label supply material.

13. A method according to any one of claims 1 to 12, wherein the layer of liner material is gradually peeled from the layer of label supply material under tension in an unwinding device.

14. 14. The method of claim 13, wherein the removal occurs along an axis running substantially parallel to the longitudinal axis of the reel of laminate.

15. 15. The method of claim 14, wherein a stripping plate or a transfer pulley is provided.

16. A method according to any one of the preceding claims, wherein the smaller reels of separated layers of label supply material are formed simultaneously and placed side by side with spaces between them.

17. The method of any one of claims 1 to 16, wherein the separated layer of liner material is rewound onto a reel.

18. A method according to any preceding claim, wherein the layer of liner material does not extend to the location where the label is applied to the article.

19. A method according to any one of the preceding claims, wherein the layer of label supply material is held securely by contact means that supports the layer of label supply material during separation of the layer of liner material from the layer of label supply material.

20. 20. The method of any one of claims 1 to 19, wherein the control parameters used to separate the layers are different from the parameters used to enable separation of the label from the layer of linerless label supply material at the point of application to the article.

21. 21. The method of any one of claims 1 to 20, wherein the separated liner material layer is formed into an adhesive tape having a coating of release material on a first side and a coating of adhesive material on an opposite side.

22. 22. The method of claim 21, wherein the adhesive is made tacky by an activation step.

23. A layer of label supply material having a label defined therein, the label having a pattern of surface incisions aligned in the same direction as the label is to be applied to an article.

24. 24. The layer of label supply material of claim 23, wherein the surface incisions facilitate accelerated removal of the label from an article to which it was previously applied.

25. 25. A layer of label supply material according to claim 23 or 24, wherein the incisions are aligned with artwork images printed on the labels.

26. A master roll of laminate manufactured by a laminate manufacturer, comprising: a label supply layer including a surface for printing and an opposite surface having a layer of adhesive; a liner material layer to which the label supply layer is initially adhered within the master roll; and a peel system between the liner material layer and the label supply layer, wherein the liner material layer and the label supply layer are separable, and at least the label supply layer is formed into a plurality of smaller reels for onward feeding therefrom to one of more points for applying labels to articles.

27. 27. The master roll of claim 26, wherein the width of the master roll is at least 2 meters.

28. 28. The master roll of claim 27, wherein the separated layers of liner material are formed into one or more reels.

29. 30. The master roll of claim 28, wherein the layer of label supply material is slit, printed, peeled, coated, and pre-weakened at the same locations where it is separated from the layer of liner material.

30. 30. A master roll according to any one of claims 26 to 29, wherein the liner material layer has a surface that has been mechanically modified to provide a lower surface energy so that it is separable from the adhesive of the label supply material layer in a separation step.

31. 31. A master roll according to any one of claims 26 to 30, wherein the liner material layer has a surface that has been chemically modified to reduce its surface energy, and release chemicals are removable before recycling the liner material.

32. 1. An apparatus for processing reels 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, the apparatus comprising: a moving means for enabling the layer of liner material to act as a carrier for the layer of label supply material as the laminating reel is moved to a point at which the layer of label supply material is separated from the layer of liner material, the point at which the layer of label supply material is separated from the layer of liner material being intermediate between a point at which the label laminate is formed and a point at which a label defined on the layer of label supply material is applied to an article; and a peeling means for peeling the layer of liner material from the layer of label supply material at the point of separation and winding and cutting at least the separated layer of label supply material onto a series of reels having a width smaller than that of the laminating reel.

33. 33. The apparatus of claim 32, wherein only separated reels of label supply material are delivered to the point of application to the article.

34. 1. An apparatus for forming adhesive tape, the apparatus comprising: means for forming a label supply comprising a layer of liner material; and a layer of label supply material having one or more labels defined thereon, the label having an adhesive on a surface thereof, the label having an adhesive on a release material applied to a surface thereof, the apparatus comprising means for separating the layer of liner material from the layer of label supply material to form the layer of label supply material into a linerless label supply from which labels may subsequently be separated; means for winding the separated layer of liner material onto one or more reels; and means for applying and / or activating an adhesive to a surface of the separated layer of liner material to form the separated layer of liner material into a reel of adhesive tape.

35. 35. The device of claim 34, wherein the adhesive is disposed on a side of the liner material layer opposite to the side on which the release material is applied.

36. 36. The apparatus of claim 35, wherein the means for applying adhesive is arranged to non-activatably apply adhesive to the layer of liner material before the label supply is formed.

37. 36. The apparatus of claim 35, wherein the means for applying the adhesive is positioned so that the adhesive is applied to a surface of the layer of liner material after the layer of liner material is separated from the layer of label supply and before forming the reel.

38. 38. The apparatus of any one of claims 34 to 37, further comprising apparatus for applying the labels from the separated linerless label supply, the apparatus comprising means for removing the one or more labels and applying the labels to one or more articles.

39. 1. A method for forming an adhesive tape from a layer of liner material that has previously been used in combination with a layer of label supply material to form a label supply, the method comprising the steps of applying a coating of release material to the layer of liner material, applying the layer of label supply material to the release material, and passing the label supply to a converting device to enable printing and / or forming of labels on the layer of label supply material, wherein the layer of liner material is removed from the layer of label supply material passed to a label application device, and the separated layer of liner material includes an adhesive applied to a surface to form the separated layer of liner material into an adhesive tape.

40. 40. The method of claim 39, wherein the method includes cutting the layer of liner material into a plurality of strips and / or winding the layer of liner material onto a reel.

Images