Alternative Liners for Label Applications

presented at the

FINAT Technical Seminar, Barcelona, Plaza Hotel 14 16 March 2001

Technology Adapting to New Demands

by

Dr. Winfried Hamann degussa. Goldschmidt Industrial Specialties Technical Service Release Liner Business
winfried.hamann@de.goldschmidt.com www.tego-rc.de

Based on the evaluations of professional market analysts and our own experience in the market over the years, the global demand for self-adhesive materials will still increase in the years to come. North-America, Europe, and Asia will be the biggest players, with approximately three-quarters of the total release liner consumption. Label manufacturers will remain the top user of release liner materials; they will cover more than 50% of the world production of release liners. Pressure-sensitive self-adhesive materials Looking into the European market for self-adhesive materials, PS labelstock applications are clearly dominating over the feminine hygiene and tape sector. For the label manufacturer, the glassine and super calandered kraft (SCK) liners are the most important release liner for PS materials in roll applications. These substrates are also often used in tape or special applications, whereas in the field of hygiene and building/insulation, these materials are of minor interest.
Self-adhesive Materials (1999) - Europe
Label Hygiene Tape Building/Insulation
65%

14% 4% 7% 10%

Others Glassine / SCK Paper

Source: AWA Alexander Watson Associates BV

The physical/mechanical properties of the glassines and SCKs are tailormade for the various steps of processing: siliconising, adhesive coating, die-cutting, and dispensing. The release properties are important for the converting of the PS laminate and for manual or automatic dispensing. Unacceptable variations in the thickness of the release liner may cause problems during the die-cutting process and the matrix stripping. So, decades of development and optimisation have lead to a high-tech product, which is superfluous after having released the label to its final destination.
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Classical PS self-adhesive laminate on roll

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Paper face stock Pressure sensitive adhesive thermally curing silicone glassine type release liner

Cost Share Therefore, the release components, i.e. silicone and silicone base paper, must not be expensive. Looking at the cost structure of a standard paper label, you will find that more than one third of all material costs is caused by the release base paper.
Cost share of a classical paper laminate (materials)
Release liner substrate Paper face stock

Raw material costs 37% 42% face 80gsm 1 /kg adhesive 1,50 /kg silicone 10 /kg glassine 62 gsm 1,40 /kg ( 37 % of the total laminate 0,08 /m 0,03 /m 0,01 /m 0,07 /m construction)

5% Silicone

16% Adhesive

Therefore, there is an ongoing trend towards lighter basis weight papers. Decades ago, the typical glassine paper for roll labels started at a thickness of 75 g/m. Today, the standard weight for a glassine release liner is 62 g/m. Going to an even lower basis weight could cause problems in processability and converting. There is always a compromise between cost and technical properties. In the past years, when the market for self-adhesive products became more and more competitive and cost-driven, the variety of release liners increased to meet exactly the performance requirements and not to be over3/19

qualified. On the other hand, down-sizing the number of raw materials, simplification of product lists, and focussing on standard products are keywords to stay competitive in the international market. Release Liner Substrates Within the European release liner market, paper substrates continue to account for the bulk demand. SCK paper and glassine are the dominating base substrates with a predicted constant share for the upcoming years. Clay-coated and machine finished papers are used in the label industry for sheet materials, and in hygiene applications. It is said that the demand for this group of base papers will slightly decrease. Poly-coated krafts, which are strong in Asia, will decrease over time, due to the fact that they are composed of two materials and are not easily recyclable.
Materials for Release Liners (1999) - Europe
Glassine / SCK Clay-coated Paper
50%

10% 7% 11%

Other Papers Poly-coated Paper

22%

Film
Source: AWA Alexander Watson Associates BV

Synthetic base release liners are steadily increasing their share in different market segments, particularly in labels, tapes, and hygiene applications. Filmic release liners offer a bundle of new opportunities and a big potential for improvements on the production and converting side, and for new applications. Linerless Pressure Sensitive Materials Some years ago a new idea for pressure sensitive labels was introduced to the traditional label market, linerless labels. This concept was sparked by looking that way pressure sensitive adhesive tapes are manufactured, and
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applying the technique to labels. By adding a release coat directly over the printed label, one would be able to apply adhesive to the backside, wind it into a roll, and dispense it like a tape, all without the need for a separate liner. Linerless labels are printed using conventional methods on narrow web presses, using either thermal sensitive or classical graphic base paper. Curing and adhering the release coating on top of the ink is the key point for this new technology. UV curable silicone acrylates are used successfully for this purpose.
Linerless Labels on roll
paper substrate printed information release coating over print adhesive coating on backside micro-perforation

One of the most obvious and most significant distinctions of linerless labels is that they produce no waste in the application process. For end users, the absence of the silicone coated liner represents savings, adds to inventory space, removes a safety hazard in the plants, and presents an environmental benefit.
Linerless Labels
Pros
no liner - simplified manufacturing process no liner - raw material savings no waste in the application process adds to inventory space

Cons
shape limitations squares and rectanlges investment in new equipment for manufacturing and end-use loss of flexibility due to printing prior siliconising no transport of single labels

One of the limitations of the linerless labels is the shape. Since there is no liner, one label is attached directly to the next; shapes are limited to squares
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or rectangles. Cutting the labels takes place during application; machinery used to apply the labels use various methods of cutting, e.g. scissors or tear bars. Graphical base papers The development of the classical silicone base papers over the past decades has resulted in highly technical and specialised substrates, tailormade for the thermally curable release coatings and the subsequent converting processes. Special focus has been put on the composition of ingredients used in the glassine and clay-coated papers to prevent inhibiting the silicone curing reaction. This is the reason why many of the less expensive machine and cast-coated graphical papers, used as facestock materials, failed as silicone base papers for thermally cured coatings. For the UV curable silicone acrylates, which are not sensitive to potential thermal inhibitors in the paper surface, that does not matter. Curing is not affected by traces of heavy metal compounds, amines, sulfur compounds etc.
Graphical Papers
Pros
low cost compared to classical clay-coated silicone base paper double-side siliconising possible

Cons
changed mechanical-physical properties adjustments of siliconising and converting equipment higher silicone coat weight compared to clay coats lack of experience in siliconising, laminating, and converting

There is a wide variety of graphical papers in the market, normally used for label facestocks. Some of them have the potential to replace the traditional silicone base substrates, although there are differences in the mechanicalphysical properties in comparison to the conventional clay-coats.

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Graphical Papers
Ref. Grammage [g/m] Thickness [m] Tensile strength [N/15mm] MD CD Elongation [%] Smoothness [Bekk-s] Stiffness [mN] MD CD FS BS MD CD IGT [mm] FS Silicone coat weight [g/m] 80 82 85 40 2,9 7,5 600 25 62 35 128 1,1 A 90 72 85 32 2,1 5,5 1100 750 67 45 135 1,4 B 87 73 80 54 2,1 5,5 2200 420 54 32 140 1,6 C 84 80 86 42 1,8 6,5 900 30 72 58 145 1,5

We tried some of these potential substitutes successfully in terms of processibility on our narrow web lab coater. We found that they need approx. 30-50% more silicone than normally used on typical silicone base papers, caused by poor holdout. On the other hand the savings on cost for the alternative paper overcompensate the high silicone coat weight. By using UV curable silicones there is no significant thermal impact during the siliconising process. Rehumidification is not necessary. Of course, the graphical paper must withstand the stress while adhesive coated and converted. These are new areas to be explored and will require unconventional thinking and some commitment, but the rewards will be greater than the effort invested. Again, you will have to break with decades of experience and standard properties of conventional silicone base papers. All parties involved in the process chain will have to demonstrate flexibility and standing power to bring this idea to success. Filmic Release Liners Today, there are already important applications for filmic release liners, which is no surprise because approximately 10% of the total release liner production is on filmic substrates.

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Typical applications for filmic release liners

labels
replacement of glassine liners no-label-look materials

self-adhesive tapes

hygiene tapes (multi-functional) medical applications industrial tapes (double-side coated)

packaging materials

for protection of high gloss surfaces for sticky goods (bitumen, hotmelt)

Although glassine paper is the standard substrate for reel materials in Europe, filmic liners based on polypropylene (PP) and polyester (PET) are competitive alternatives, fuelled by cost and physical properties. In the cosmetic and hygienic fields, the no-label-look has been established as an alternative for direct printing on glass bottles and flacons. The crystal clear appearance of the adhesive coated label demands a glossy and perfect release liner substrate; PP or PET are the ideal candidates for that application. Filmic liners are also preferred in tape applications with high technical requirements, e.g. duo- and triple constructions with double-side release coatings and differential release values. Diaper tapes are a well-known filmic release liner application. In the medical field, super clear PET materials imply a sterile and proper impression; so, PET liners are often used for wound care and other medical products. Polyethylene (PE) and PP films are the favourite substrates for packaging of sticky goods because of their tensile strength and elasticity. Coated with a special adhesive for low adhesion force, LDPE films are often used as protective films for high gloss surfaces in the electronic and automotive industry. During the last five years biaxally oriented polypropylene (boPP) liners have gained more and more importance in the European label industry, replacing part of the dominating glassine papers. Furthermore, the markets for hygiene, building/insulation, and tape applications contribute to the two digit growth of PP liners.

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Polypropylene film for release liners (1999) - Europe

5% 11%

5%

Label Hygiene
40%

Building/Insulation Tape Health/Medical

14%

25%
Source: AWA Alexander Watson Associates BV

Others

The advantages of a PET film over PP are its high optical transparency and the tensile strength. Although it is more expensive than a boPP liner, PET is well established in the label market followed by health and medical applications.
Polyester film for release liners (1999) - Europe
Label Health/Medical
51% 12%

10% 6%

6%

Tape Building/Insulation Covering

15%

Others

Source: AWA Alexander Watson Associates BV

Properties Comparing the properties of paper and synthetic liners, you will see that there are some pros for the filmic substrates, which may help to combat the ongoing pressure on prices and decreasing profits.

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Replacement of paper liner by filmic substrate

some typical properties Paper substrate Tensile strength Transparency Thickness Smoothness Silicone coat weight Die-cuttibility Dimension stability Humidity Recyclability OK limited 40 - 200 g/m smooth - rough 0,8 - 1,5 g/m OK, well known curl, shrinkage sensitive possible Filmic substrate OK crystal clear - opaque 12 - 150 very smooth - rough 0,4 - 1,0 g/m new; challenging shrinkage possible non-sensitive possible

A significant difference between paper and filmic substrates is the lack of experience in processing and handling the synthetic materials. The switch to a new liner material often requires rebuilding technical equipment, and in some cases reconfiguring some aspects of converting devices. Savings A promising approach to reduce the ongoing price pressure could be the replacement of a traditional paper liner. About one third of the cost, of e.g. a PS laminate, is caused by the backing material, as already mentioned.
Cost savings by using filmic release liners
Release liner substrate

Paper face stock

Release liners (raw material) 37% 42% glassine 62 gsm 0,07 boPP 30 0,06 PET 36 0,12 PET 12 0,05 (from entire laminate /m /m /m /m (100%) ( 86%) (171%) ( 71%) 13%)

5% Silicone

16%

By using synthetic release liner materials, it is possible to save a considerable amount of the material cost of a PS laminate. Using 12 PET as a replacement of a 57 glassine paper would be a very challenging effort. In close co-operation with your partners in the manufacturing chain, it should

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be possible to prepare this way of innovation step-by-step for the benefit of all parties involved.
Innovative self-adhesive laminate on roll

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Paper face stock Pressure sensitive adhesive UV/EB curable RC silicone filmic release liner (boPP/PET)

Forward-thinking manufacturers, converters and printers will undertake the hardware investment to run the attractive alternatives because of their focus on long-term return on investment. Radiation Curable Some of the alternative synthetic release liner substrates are sensitive to temperature where the conventional thermal curing silicones would fail because of damage to the liner substrate. For years now, novel, radiation curing silicone systems in the market allow silicone to cure under very mild conditions. These EB and UV curable silicones are best suited for siliconising filmic substrates or thermal sensitive paper materials. In the early 1980s, the idea of radiation curing silicone to form a release coating was a novelty. The first commercial products for release coatings were based on the principal of curing through the acrylate sites. The curing of the acrylate groups was activated by radicals. Already at that time Goldschmidt AG was the driving force for the development of radiation curing technology. Goldschmidt AG was (and still is) a pioneer in this field, having started with its 1st generation of radiation curable TEGO RC Products in 1983.

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Silicone Acrylates With continuous feedback from the market, Goldschmidt AG developed a variety of chemical modifications and improvements over the past sixteen years. After extensive development time and up-scaling these products to standard materials, we were able to improve three important properties:
TEGO RC Silicones - improved 4th Generation

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Better Cure Lower Viscosity Adhesive Compatibility

higher line speed better processibility improved ageing

At the end of 1998, Goldschmidt announced and demonstrated the 4th generation of high performance silicone acrylates with outstanding properties. This latest range of TEGO RC Silicone Acrylates includes the novel products RC 902, RC 715, and RC 709.
Wide range of release values

TEGO RC 902 TEGO RC 715 TEGO RC 706 TEGO TEGO RC 709 RC 711

easy release to controlled release controlled release controlled to tight release controlled to tight release for differentials tight release

A very wide range of release values can be generated by blending different types of RC Silicone Acrylates. In our product range (the new) RC 902 stands for easy release applications, e.g. for typical PSA label laminates. You can increase the release level almost continuously by adding RC 715, RC 706, RC 709, and finally pure RC 711 for tight release applications . Since the introduction of this RC silicone system it has been well accepted by various customers for many different applications. In addition, Gold-

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schmidt has given public proof of the processability and the capability to meet the most demanding requirements for future growth.
Practical Proof

High Speed UV Siliconising (Kroenert / Hamburg) Film-on-Film Laminating (Kroenert / Hamburg) Inline coating at Black Clawson (Fulton / NY)

High Speed Speed of cure is one of the essential keypoints of our RC technology. In contrast to the thermal silicone systems, the maximum cure speed does not depend on the type or the gauge of the substrate to be coated. The reactivity of the RC silicone formulation is the dominating factor for the maximum speed of cure. Using a UV lamp (arc type) with a UV power of 120 W/cm a standard formulation of silicone acrylates, RC 902 and RC 709 can be cured at 200 m/min.
Cure Speed of TEGO RC Products

one 120 W/cm Arc Lamp with 2 % A12 or 15 % PC 750 with min. 30 % RC 711

All blends including RC 902 or RC 709 All blends including RC 715 or RC 706 RC 711 only

200 m/min.

300 m/min.

400 m/min.

Because of higher functionality, and therefore higher release level, the degree of cure of RC 715 and RC 706 is excellent up to 300 m/min per lamp (120 W/cm). Pure RC 711 for very tight release values can be cured as fast as 400 m/min with just one UV lamp. Recently Goldschmidt AG, together with two leading companies in the PSA market, successfully demonstrated the improved properties of the 4th gen13/19

eration of RC Silicone Acrylates to a public audience. In close co-operation with one of the major builders of coating lines, MAX KROENERT GmbH and the innovator of inerted UV curing systems, ELTOSCH GmbH, we coated three different substrates for various self adhesive applications with a standard easy release formulation based on RC 902 at extraordinary high line speeds.
High Speed UV Siliconising
TEGO RC Silicone for Easy Release application

TEGO RC 902 TEGO RC 711 TEGO PC 750

Substrates for siliconising

70 parts 18 parts 15 parts

boPP LDPE clay-coated paper

30 25 80 g/m

UCB Films Nordenia Gronau Cartiere BOSSO

All the substrates were run through the pilot line at 600 m/min without any problems. A state of the art inerted UV unit, built by Eltosch, cured the easy release coating. With just three lamps of 200 W/cm each, we achieved excellent curing and good anchorage on the three release liner materials. We finished the demonstration trials with the boPP responsible LDPE substrate for running at 900 m/min.
High Speed UV Siliconising
Machine parameters

Speed coating width corona treatment

Curing conditions

600 - 900 m/min 1020 mm 3 kW

UV output residual oxygen nitrogen consumption

3 x 200 watts/cm 25 - 45 ppm approx. 300 m/h

The UV output of three arc lamps of 200 W/cm each, was sufficient run at speeds of 900 m/min. Subsequent adhesion values were in the eighties and

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nineties with no smear and no rub-off. Also, inerting was not a problem at that high speed. The nitrogen consumption was approximately 300 m/h.
High Speed UV Siliconising
Some results (LDPE and boPP film) LDPE 25 ctwght subsequent adhesion release (tesa7475/7476) 600 m/min 1,1 g/m LDPE 25 87 % 4 / 42 cN/in ctwght subsequent adhesion release (tesa7475/7476) 600 m/min 0,9 g/m boPP 30 94 % ctwght 6 / 45 cN/in subsequent adhesion release (tesa7475/7476)

900 m/min 1,1 g/m 83 % 6 / 47 cN/in

boPP 30 ctwght subsequent adhesion release (tesa7475/7476)

900 m/min 0,8 g/m 95 % 8 / 56 cN/in

It could be that a line speed of 900 m/min is not of interest for every customer. Nevertheless, the 4th generation of TEGO RC Silicone Acrylates has been proven to be capable of withstanding these extreme conditions. Inerting, which is occasionally still a reason for future customers to hesitate in silicone acrylate chemistry, was fully capable at these high speeds. In the end, this demonstration confirmed that siliconising at moderate speeds and for combined in-line coating silicone acrylates offer a high security level for the processing and the properties of the final product. No-Label-Look In a second trial, we demonstrated that the manufacturing of no-label-look material is not a problem with RC silicones. From market response, it is understood that the shrinkage of the coated release liner during the adhesive drying process is a critical point.

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Film-on-Film Laminating
Release liners: PP films 30-50 (from UCB and Nordenia Gronau)

Face stock material: Adhesive: Adhesive coating: Drying:

PP film 75 (from Nordenia Gronau) acrylic dispersion for plastic face stock, permanent multi-pressure gravure, coat weights 15-18 g/m 4 segments 3 m length, air temp. 70-130C, coating speeds 150 - 200 m/min, residual water < 1% shrinkage < 1%

Therefore, we siliconised some boPP films (30 and 50) with the standard RC formulation for easy release properties. These trials were also performed on the KROENERT Technicum line in Hamburg. Since in-line adhesive coating is not an option on this line, we applied a PS acrylate emulsion in a second pass onto the siliconised filmic release liner. The face stock material for the no-label-look laminate was a transparent 75 PP film. The adhesive was applied onto the release carrier by means of a multi-pressure gravure system (coat weight 15-18 g/m). The drying process of the adhesive took place in four oven segments with a length of 3 meters each at a speed of 100-200 m/min. We optimised the temperature profile of the air flotation dryer to find the best compromise of machine speed, adhesive coat weight, residual humidity, and the shrinkage of the boPP liner. We were successful in producing a clear laminate at 150 m/min. There was no shrinkage of the boPP film at temperatures of up to 135C; which proves that finding the best temperature setting for the adhesive dryer segments is a critical point. It was demonstrated that using solventless RC silicones and known adhesive technology, is a proven way to face and meet the challenging requirements of future products and applications.

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In-Line Coating A further trial that proves practical maturity of UV silicones was demonstrated by tandem coating trials of UV silicones and emulsion acrylics at BLACK CLAWSON Research & Technical Centre in Fulton/NY. Since UV capacity can be added to a coating line at a lower cost than installing an oven makes UV a practical solution for many companies. UV machines take up less space, and require lower capital investment than other curing processes. Fast cure speeds and no post cure of RC silicone acrylates allows a company to design a process with tandem coating in mind
Inline coating trials
Substrate, silicone, adhesive Substrates - release liners - facestock Silicones

three different types, e.g. boPP 30, PET 25 and 36 PET and PP (clear/white) four different formulations, based on RC902, RC711, RC709, and PC750 two permanent acrylic dispersions

Adhesives

The trials were designed to test a range of parameters including release level, adhesives, substrates, and face stock. Substrates for the release liner were three general types, including 30 polypropylene and 25 and 36 polyester. Silicones were chosen to give four different release levels with easy, medium, controlled, and tight release properties. The two supplied adhesives were both clear drying acrylic dispersions. Both polyester and polypropylene (white/clear) were used as face stocks for the trial runs.
Inline coating trials
Trial conditions UV output Speed Coating width Coating heads - silicone - adhesive Coat weights - silicone - adhesive 1 x 240 watts/cm 125 m/min 457 mm differential offset gravure reverse gravure (transfer coating) 0,9 g/m 15 g/m

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One row of FUSION UV bulbs was utilised with the machine speed kept constant at approximately 125 m/min. This speed was limited due to adhesive drying capacity. The silicone coating was done on a three roll offset gravure coating station, and adhesives were applied to the release liner with a reverse gravure coater. The achieved coat weights were approximately 0,9 g/m for the release coating and averaged 15 g/m for the adhesives. To date, the results are very promising; release for all samples remains stable, and there is no interaction between the silicones and the adhesives. The pure transparent synthetic laminates are highly clear and suited for nolabel-look materials. Future In the future, new technologies for siliconising, adhesive coating, converting, and final applications will have a strong impact on the label, tape, and release liner business. It is expected that the pressure on prices will continue and therefore profits will drop. It has been shown at customers and machine manufacturers that UV silicone technology opens the door for using alternative release liners in todays standard PS products. UV silicone technology is capable of saving money by replacing more expensive release liner substrates, and gives access to new applications and additional business.
Outlook and Message

save cost in standard label applications by the use of alternative release liners make use of specific physical properties of filmic substrates for new applications participate in future growth of the attractive alternatives for classical release liners take the challenge and break with conventions to be prepared for the highly competitive label market

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Today, e.g. filmic release liners already have a two digit growth; some companies are on the learning curve for handling and processing alternative backings. In some years from now the substrates themselves and the technologies involved will be further developed and they will be industrial standards with benefits of optimised properties, better technical understanding and know-how, and world-wide experience. Release liner production requirements for label applications are constantly increasing and changing. It is more important than ever before that all players in the production chain, including suppliers of raw materials and final users, work closely together for the benefit of everyone.

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