Shrink continues to grow! Use of Shrink-sleeve labeling is poised to grow at a compound annual growth rate (CAGR) of 5.2% until 2025.*  It’s a cost-effective way to decorate complex shaped packagin, and utilizes the full 360° of the container.  Shrink-sleeves add a lot of shelf impact to brand packaging.

So what are the trends in the world of shrink-sleeves?  Here are some things our experts have identified as potential drivers of shrink-sleeve appeal in the near future.

Eye “CANdy”

Take a closer look at some of the canned beers and premium sodas on the market.  You’ll notice a good number that appear direct printed but are actually decorated with shrink-sleeves.  Small to mid-size companies often cannot afford the cost of buying large stocks of pre-printed cans, given the high minimum quantity requirements. Because of this, many are opting to purchase smaller volumes of blank cans and decorate them with shrink-sleeves. In addition to being an economical packaging option, shrink-sleeves provide some versatility in decoration. Blank cans decorated with sleeves allow smaller companies to easily switch between brands or varieties. And the shelf-appeal of sleeved cans is turning heads.

Looking Good – Naturally!

As the technology advances, sustainable shrink materials like PLA will become more prevalent and cost-effective.  PLA (Poly-lactic Acid) is a corn-based material, so it comes from a renewable resource and decreases dependence on petroleum-based raw materials.  It is also compostable, so these labels don’t end life as solid waste in a landfill.

Upside-down Is In

Shrink-sleeves are a great decoration option for those liquid products that’ve turned the package on its head – think Heinz Ketchup and all manner of shampoo and conditioner products. It’s not only a practical way to deliver liquid products, but also an eye-catching package presentation.  More products will undoubtedly migrate to this top-down package configuration to take advantage of gravity, and shrink-sleeves will most-likely be the decoration of choice for many.

Health & Wellness

There are a LOT of healthy food and drink choices on the market, and new ones are appearing every day. These products need a good deal of space to make their nutritional claims and to list their dietary benefits. And let’s not forget the ingredient and other regulatory information required in this sector. Shrink-sleeves provide a lot of package real estate on which to print all of this, along with the branding and consumer appeals that marketing demands.  If you need more room, think shrink!

There’s a Cover Up!

Beverage companies struggle at times with pre-printed can and bottle inventory which has become obsolete for any number of reasons. A recent trend has seen these companies turn to shrink-sleeves to ‘cover-up’ the existing decoration and outdated verbiage.  Rather than having to discard obsolete packaging and swallow the loss, the cans or bottles get new life with shrink-sleeve decoration.

Let the experts at AWT tell you more about shrink-sleeves and how you can add some pop to your packaging.

*Research and Markets (www.researchandmarkets.com)

Managing a business provides a lot of things to worry over.  There’s the continual pressure to meet short delivery deadlines; the fretting over cost increases; and the concern for the overall health of the business, to name just a few. Carrying large finished goods or component inventories has its own unique set of business issues to keep you up at night. Managing inventory can tax an organization in a number of ways, and steal time and effort which could be better used toward building the business.

Cash-to-Cash

If you are not familiar with the term ‘cash-to-cash’, it is quite simply the time interval between the point a product is paid for, and the time payment is received from your customer for the goods delivered.  A company’s ‘cash-to-cash’ situation is negatively impacted when paying for production runs of items that are shipped to you and placed in your inventory.  Payment is made either when the product is shipped or in accordance with the credit terms established.  In the case of an overseas supplier, the product may not be delivered for weeks.  Factor in the time it takes to transport the goods from the entry port; convert the final product; deliver it to the end customer; and finally receive payment and you’ve tied up a lot of money with no return potentially for months instead of weeks.

Consider these additional drawbacks to holding inventory:

• Physical space within an organization’s facility needs to be dedicated to store standing inventories. This space may be better served as production area.
• Internally-managed inventory requires a lot more employee time and effort to administer than Supplier Managed Inventory.

Supplier Managed Inventory (SMI) can remove some of these worries!

A SMI program is not going to solve ALL your business problems, but it can improve cash-flow and reduce the number of things you need to focus on.  Quite simply, SMI relieves businesses of the burdens associated with ordering and managing large inventories.  A typical SMI program calculates an organization’s total finished goods quantity requirements on a part by part basis over a set time-frame, and then determines a schedule for the production and delivery of smaller quantities of those items at established intervals.

A well designed and managed SMI program has many benefits, including but not limited to the following:

• Next day delivery of parts included in the SMI inventory.
• Driving out the costs associated with standing inventory, like administration, over-ordering and product/part obsolescence
• Reduction of the total cost of ownership (TCO), encompassing the acquisition; transport; storage; financial accounting; and labor devoted to the oversight of large standing inventories
• Improved cash-flow – Qualified businesses do not pay for inventory until it is shipped to them.
• The supplier has more efficient production options – In the case of a label printer, for example, similar size labels can be produced together in a production run. This can further enhance cost savings to the customer

Labels, Packaging and SMI go Hand-in-Hand

Label and package printing are areas where end users can readily benefit from SMI programs. Graphics and text on labels and packaging are constantly changing.  When shorter production runs are occurring at set intervals, these changes can be made at a point where little or no existing inventory is deemed obsolete by the altered graphics or text copy.

SMI programs are custom-tailored to each specific business, according to that business’s particular operational usage patterns. The goal is to go from ordering large amounts of inventory a few times a year based on longer business cycles, to a scenario where smaller amounts are delivered on a ‘just-in-time’ schedule at more frequent intervals. Whether that is semi-monthly, monthly, or weekly all depends on how the business will be best served.  Automation ‘triggers’ can be set to alert customers when inventory on hand is low, or to automatically order more of the depleted stock.

There’s a lot more to SMI and the benefits it can provide any business which currently carries large standing inventories. We at AWT Labels & Packaging would appreciate an opportunity to evaluate your current inventory model, and demonstrate the benefits an of an SMI program.  We’ve become an industry leader in deploying SMI programs for our own customers unique labeling and packaging strategies, and we’re currently managing over 50 such programs. We’re ‘experts’ in giving you fewer things to worry about, and giving you back time and resources you can invest in more valuable pursuits.

Packaging is having some fun lately. Nowhere is that more evident than in the Beer, Wine and Spirits sector.  Among the growing number of craft producers in these markets are companies fearlessly breaking the mold when it comes to branding, marketing and traditional rules for what goes on a label.  Just look at some of the names on craft beers lately and you’ll get the idea. Brands like “Robohop” and “Geriatric Hipster Club” are just a couple, the likes of which you would have never seen or heard of even 15 years ago. So it should come as no surprise these brands want a unique package to go along with their personal style.

Here’s the skinny on what’s hot when it comes to decorating packaging in this arena:

What’s New is Old.., Looking

Appearing old and established is definitely a trend in this sector.  Many of these brands are choosing specialty paper stocks to provide a weathered or ‘distressed’ look.  Rough finishes are being used to add a tactile aspect to the label, further enhancing consumers’ experience with the package.  Specialty label stocks, inks and coatings are all ways to pull off this effect. Vintage and established is the intended message, and the look is a little more subdued and laid back.

Glossy Is Good

At the other end of the spectrum are those brands that want to shout at you from the shelf. They’re looking for attention and a glossier finish on the label is one way to get it. Brands are employing shiny film stocks or high-gloss coatings on paper in eye-catching ways.  For instance, high-gloss coatings can be applied to specific areas of the label, in-line while printing, to enhance certain graphics or text elements. The contrast between coated and non-coated areas of the label can add a dramatic aesthetic.

Let’s Get Digital!

Digital printing can be employed to create a different design for a set number of labels within a brand. Each bottle in a six-pack of beer, for instance, could have its own look.  Personalization is also possible using digital; think batch numbers for brews and spirits packaging, or regionally-based designs for nationally distributed brands.  The goal is to make a more personal connection with individual consumers.  Digitally printed shrink-sleeves are being used by craft brewers to decorate generic cans in order to mimic the look of a big brand.

Seeking Clarity

Some bottled brands want the product to do the talking.  Super-thin clear film stocks provide the ‘no label look’ many distilled spirits brands are looking for. If you’ve noticed the top shelf vodkas on the market recently you’ll get an idea of what we mean.  The clear films of today are so imperceptible it appears all the brand graphics were directly printed to these bottles.  Many of these brands are choosing distinctive-looking bottles for their product, and they want a label that will complement that custom look and feel.

Environmentally Responsible

Many brands in this sector are run by a new generation of entrepreneurs who are committed to operating in a socially-responsible manner.  When it comes to packaging, they are choosing options which align with these values. Paper and film stocks composed of post-consumer recycled materials are a natural in this arena. So are label materials which are thinner and have the ability to be recycled themselves.  New materials coming online promise to be either compostable or biodegradable.  As this material technology advances it will become a larger part of the packaging strategy.

We understand every product has individual needs. Consider these five trends as general, “scratch-the-surface” guidelines for your projects. We don’t guess about what is working in today’s market – we utilize over 40 years of experience as experts in packaging. We would be happy to take a look at your specific project needs and map out a full strategy for your upcoming product line. Call 612-706-3700 today or drop us a note here at marketing@awtlabelpack.com for a free consultation.

Whether you’re walking the floor at an industry trade show, or sitting face-to-face with a high-level decision maker from a large retailer, the topic of sustainable packaging will be discussed as the “go-green” initiative is gaining momentum.

With mounting pressure from consumers, and the fear of future government regulations or outright bans of certain packaging, large CPG companies are committing more than ever to sustainability, even going as far as to set specific compliance dates.  Many of these companies have ‘2025 initiatives’ with stated goals for sustainability by year 2025.

In the 2018 Sustainable Packaging Study conducted by Packaging Digest, 75% of respondents said they believe increasing recycling rates will alleviate environmental concerns around plastic packaging.  And they’re not alone.

Brands are pushing their supply chain partners to “go green” more than ever before.  Therefore it is important to understand how the market is changing.

Plastic Recycling Process

One of the most common and perplexing questions heard is “Why can’t we recycle the packaging we have today?”  The answer is not as simple as it may seem.  The majority of flexible packaging is made with multi-material films and the ability to recycle these multi-material films comes down to a few factors:

1. Can the plastic resins that make up the materials be recycled?
2. If so, how can they be gathered and sorted in a cost effective manner?
3. Are there second life uses and/or demand for the mixed recycled resins which are cost effective and widely used?

Unfortunately, today’s recycling climate is not equipped to effectively push multi-material packaging through the recycling stream.  Therefore, a large percentage of multi-material plastics are not being recycled and are instead ending up in landfills or the world’s oceans at an alarming rate.

Plastic ‘Islands’ in the world’s oceans

This brings us to the question: “What is the next best option?”

The endgame for packaging suppliers and their customers would be a fully recyclable or compost-friendly material.  However, the current offering of compost-friendly plastic films results in particles of micro-plastics, with no added nutrient value to a compost mound.  Additionally, the packaging industry simply isn’t there yet with respect to feasible options for shelf life barriers, printing and converting capabilities, and the ability to effectively collect and dispose of these materials on a state level, let alone a national one.

Plastic Recycling Streams

The ultimate solution will be a single polymer, recycle-ready material.  There have been significant advancements in recent years to offer a single material option which not only satisfies shelf-life barrier requirements and print/package format requirements, but can also be effectively pushed through the recycling stream at a global level.

The flexible packaging market is in the midst of an important transformation that cannot be ignored without falling short of market needs and sustainability goals.  Brands must stay tuned in, or risk falling behind with their customers.  If you are interested in incorporating recycle-ready films into your packaging, contact the experts at AWT Labels & Packaging.

Achieving a perfect label application to a complex package can be challenging, especially for larger labels that cover more package real estate. This application scenario was no exception.

There were two bottle sizes: 70 and 128 oz.  Both were experiencing the same issues. Multiple factors came into play to hamper the application process, some known and some to be discovered.

The problem: Wrinkling and lifting of the labels

During the application trials, label performance issues appeared immediately.  The labels were wrinkling and lifting away from the package.  The AWT team’s initial diagnosis pointed toward a label that was too large to conform to the complex shape of the bottle.  So AWT Prepress proposed and designed a smaller die outline, logically thinking the smaller label would work better for this package.  And in the next round of application testing the new label did alleviate the wrinkling issue as predicted, but the lifting problem was still occurring.  Once again the AWT team was in search of an answer.

Getting to a solution

Experience and some clues during the trials led to the thought that the plastic bottles may not have been treated to remove mold release agents. Further investigation revealed the bottles were provided by the customer, and that the customer had purchased the bottles from a packaging broker/distributor.  Upon learning this, AWT engaged Fasson – the manufacturer of the material being used for the PS labels. Fasson was asked to analyze the bottles and provide findings that may shed light on the stubborn lifting problem.

Fasson came back with an answer that was the key to solving the issue. Fasson’s analysis found that the bottles were not flame-treated, the most likely cause of the lifting problem.  They also had a solution involving a new face-stock material and different adhesive formula.

Subsequent application trials with the new material/adhesive combination went smoothly, and the issues of wrinkling and lifting were eliminated.

Lessons learned

This project was a learning opportunity in many ways:

• Complex package shapes present design challenges for large label applications
• Smaller labels can be employed to complex shapes to reduce the chances of wrinkling
• Label lifting may not always be caused by shape complexity – in this case it was the package surface that posed the issue
• It is important to know the source of plastic packaging and whether or not the package has been treated to remove mold release agents
• A sound relationship between supplier and customer is vital to working together to solve issues. In this case it was a strong relationship between AWT and the end customer as well as AWT and supplier partner Fasson.

At AWT Labels & Packaging, we’re dedicated to providing the most cost-effective, environmentally-friendly option for your flexible packaging (and label) printing needs. Contact the Experts at AWT to get started on your next project.

When it comes to labels and flexible packaging, the cost of the part is a small component of the Total Applied Cost (TAC) of the part. Budget owners should consider several elements of what it costs to get the product accurately labeled, packaged and routed to the shipping dock.   Hopefully, this blog will give you some perspective of what makes up TAC.

Total Applied Cost is an important consideration to determine true cost! 

TAC is far more than the actual cost of the label or flexible packaging part.  We condensed TAC to nine categories of cost besides the actual cost of the part. All these cost elements (in the numerator) usually interest the budget owner of the production facility and impact downtime, efficiency and ultimately the net run speed of the production line.   Further, these costs should be added to the extended cost of the label or flexible packaging part.

Costs easily overlooked include obsolete inventory and excess inventory. Typical root causes for obsolescence include: component or ingredient changes, regulatory compliance changes, brand redesign, or the product is just not selling like forecasted.  You can spot excess inventory in the warehouse by using the “white glove” test.  Simply slip on an inexpensive pair of disposable white gloves and take a stroll through your label storage room.  Slide your finger across the top of the label cartons and notice the darkness of the dust on your finger: the darker the glove, the higher probability of excess inventory/obsolescence.  These parts should be scrapped and added to extended costs in the numerator.  No reason to hang onto it and pay for storage space.

Finally, don’t overlook how “quantity” impacts TAC unit cost…True unit cost is based on quantity used NOT quantity ordered.  You could easily understate the real TAC by using Quantity ordered in the denominator.  Closely managing inventory levels will pay big dividends and have a significant positive impact on reducing real TAC.

A relevant story that makes the point about the importance of Total Applied Cost is an automotive aftermarket company who makes and distributes remanufactured automobile power steering units.  The units themselves were labeled with a high end PET label/resin TTR ribbon combo and moved down the assembly line to the packaging area where another paper thermal transfer label was generated for the shipping carton. Due to a number of reasons, including poor communication, there were a number of mix-ups of the finished units.  This caused both shadetree mechanics and auto repair shop personnel serious  heartburn, major league frustration, especially when the Chevy power steering unit they were about to install turned out to be for a Ford!   You can only imagine the cost of restocking/replacing products and customer dissatisfaction!

After careful analysis by the assembly plant, the solution to the problem was to redesign/implement the label at triple the cost.   Yep, 3 x’s the cost of the previous label!  Both the actual power steering hard goods label and the shipping carton label were made out of PET and printed on one TTR label, with a split liner. That allowed the shipping label to remain adhered to the unit, removed, and applied to the shipping carton as the re-manufactured unit was inserted into the carton.  When this solution was presented to the ‘purchasing agent’, a person whose yearly review was based on cost reduction of their commodities, the quick answer was that no, a tripling of label costs was absolutely not acceptable.  When the proposed solution was presented to the Operations Manager however, he took a look at it, thought about it for about 60 seconds, and asked how long it would take to implement it and whether he could pay a rush charge to get it done more quickly.  Mislabeled power steering units dropped almost to zero once the program was dialed in.  Even though the actual label cost tripled, when factoring in the cost of mislabeling, receiving returns and quick replacement shipping costs, the new label design was far less when considering the Total Applied Cost.

So don’t forget to consider that it’s not just the unit cost of the label or flexible packaging part but the Total Applied Cost of the quantity used.  It can make a big difference to the organization!

Special acknowledgment to former AWT employee Dave Olson who contributed to some of the concepts in this blog.

It’s no secret that the use of flexible packaging is on the rise.  According to numbers generated by a Harris Poll chartered by the Flexible Packaging Association, 26 percent of all brands have increased their usage of flexible packaging in the past five years, and 31 percent intend to increase their flexible packaging usage in the next five years¹. Not only does flexible packaging cost less for manufacturers to produce and ship, but it also offers significant environmental advantages over its rigid counterpart.

You’ve probably noticed that just about every aisle in the grocery store now sells a pouched or bagged version of a product like soups, coffee, and cleaning products were once only sold in a rigid package. However, what you might not have (intentionally) noticed is the amount of design detail that goes into the flexible packaging your food comes in. You see, brand owners know that they have less than 1/3 of a second to influence your decision-making. This means their product needs to immediately grab your visual attention, inspiring you to pick their product off the shelf and look at it.

Keep your eyes out for these flexible packaging trends and see if they inspire you to put a product in your cart:

Soft Touch/Velvet/Matte

One of the hottest trends out there right now is soft touch matte coatings. The second a consumer picks up a product and has a pleasing tactile experience, they are one step closer to making a purchasing decision. After all, a velvety-feeling coffee pouch is a great subliminal complement to the velvety flavor of the coffee.

You will often see a matte look in products that want to be associated with unprocessed, natural, earthy goodness. Often times, the less shiny or frilly the package, the higher the presumption that  its contents are natural and pure.

Matte coatings are also targeted to be easy on the eyes. As the population gets older, the bright lights of display cases cause reflections that make labels difficult to see.  Matte surfaces will give a brand an advantage over glossy surfaces.

Thermochromatic Coatings

Merging technology with functionality, thermochromatic coatings change color based on temperature, indicating if the product is being stored and served at the correct temperature. This is becoming increasingly popular among beer cans, iced tea labels, microwave foods and more.

Spot/Gloss Varnish

Often used to highlight graphics of the product, its benefits, company logo, a Spot/Gloss varnish is a subtle and visually appealing way to draw attention to a specific area on the package.

The flexible packaging market is ever-evolving with exciting new trends. To discuss incorporating these trends (or explore others!) into your next project, contact the Experts at AWT Labels & Packaging.

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https://www.packagingstrategies.com/articles/90259-packaging-outlook-2018-flexible-packaging-overview
https://www.target.com/p/folgers-1850-black-gold-dark-roast-whole-bean-coffee-12oz/-/A-53228747
https://drinkhacker.com/2008/05/15/coors-lights-cold-activated-bottle

Personal care is on the rise and, let’s be honest, everyone has different needs when it comes to choosing their products. However, while achieving the holy grail of differentiation is great, if you want to tell your potential customers anything, you have to get their attention first.

This is where packaging can make or break you.

Today, you might get five seconds to make an impression with a buyer – if you’re lucky. This is not necessarily a bad thing. Consumer choice creates the opening in the market. With so many options, however, it is easy for your product to get lost in the sea of solutions. Whether your product is being picked up in a physical retail location or discovered through social media, packaging is going to be one of the first ways your customer comes into contact with your brand.

We are here to help. Here are five trends in the personal care packaging space that will help your products to thrive and connect with the people you were meant to serve.

Leave Some Space

Give your packaging design some room to breathe by leaving some clean space. Bold, bright colors can have their best effect when given room to express themselves. Clean white packaging can also be given a subtle touch of quality with various coatings. Whether it is the entire package or just the label, soft-touch matte varnish not only delivers a striking look, it also elevates the tactile feel of your product.

If your packaging has enough space, you can also include product see-through windows. This is a beautiful aesthetic option that promotes product transparency – and giving any potential customer an inside look before they purchase might just be the deciding factor.

Stay Sustainable

Customers are more environmentally aware than ever. The good news is that using more eco-friendly materials and delivery systems in your packaging makes sense across the board. Showing your stance on the environment and your company’s commitment to the big picture impact of commerce can strengthen the connection with your customers. Using flexible rather than rigid packaging is also more economical in terms of shipping and storage costs – rigid packaging takes up more room per unit on the truck and in warehouses. Over time, these savings can make a huge positive impact on your business as well as the environment.

Convenience is Key

When designing your packaging, you must always consider the user experience. What is the best way to discover and interact with your product? Flexible packaging options are gaining traction thanks to the convenience they provide. Pouches are easier to store and use than bottles. Wipes are emerging because as a more convenient, on-the-go option for beauty products that were once thought to be used only at home. Resealable labels on flexible packaging can help to ensure a seamless customer experience. AWT’s team of experts can help you to sort out these finer details to ensure the ultimate user experience.

Customize It

Another great way to surprise and delight customers is to personalize your packaging. This works with new releases, relaunching older products, refreshing products, or timing a release around a specific event relevant to your customers. Add scratch and sniff scent labels to refresh classic products or glow in the dark stickers for a special event. We can guide you towards high-quality comprehensive flexo label printing or digital label printing with a faster turnaround. It really comes down to your project goals and timeline.

Go Vintage

With all the sleek options on the shelves today, a touch of retro is a great way to connect with your audience. Think slightly more detailed designs and alternate color palette options. Nostalgic elements can resonate with your customer no matter how long your brand has existed. Adding a vintage look to a customized special edition is an excellent way to combine two packaging trends for maximum impact.

We understand that every product has individual needs. Consider these five trends as general, scratch-the-surface guidelines for your projects. We don’t guess about what is working in today’s market – we utilize over 40 years of experience as experts in packaging. We would be happy to take a look at your specific project needs and map out a full strategy for your upcoming product line. Call 612-706-3700 today or drop us a note here at marketing@awtlabelpack.com for a free consultation.

Considering shrink sleeves for your product?  We’re here to help! Check out these advantages of shrink sleeves and easy tips to get your project started on the right foot.

Advantages to Shrink Sleeves

1. Visual Appeal.  Since shrink sleeves conform to complex or unique bottles and containers, their 360 degree graphic display offers increased opportunity for product recognition. The vibrant graphics generate high shelf impact, encouraging shoppers to pick up and examine the product. The second the customer picks up the product to explore the details, they are are more likely to purchase the product. Drupa notes that that at least a third of product decision-making is based on packaging, along with personal preferences. This means that sometimes packaging can be just as important as the product inside.
2. Protection from Elements. Believe it or not, the artwork is actually printed on the inside of the film.  This allows the external layers to protect the graphics from friction, which can cause scratches to the artwork. The graphic protection makes shrink sleeves a great choice for products that are subjected to heavy moisture environments and/or humidity.  The next time you look in your refrigerator or shower, you might be surprised by how many of the items in there are shrink sleeved!
3. Easy to integrate a Tamper Evident seal. Full shrink sleeve can provide a tamper evident seal over closure with a vertical or horizontal perforation for easy opening. This reassures the customer that the product has not been opened.

Images courtesy of Karville Beyond Converting

Before you get started on your project, determine:

1. 1. Size. What is the circumference and height of your container?
   2. Colors. How many colors will you be printing?
   3. Application. Will the shrink sleeve be applied automatically or manually? What form of heat (radiant, steam, IR) will be used to shrink the sleeve to the container? Knowing this will help determine the proper material for the sleeve.
   4. Unique considerations. Share a physical sample of the container with your shrink sleeve converter. A physical sample will help the converter determine the material type needed, identify any unique container characteristics, and/or any special treatment needed to ensure the sleeve properly “hugs” the container.

AWT has 10 color print capability using flexographic presses, offering competitive pricing for large volume runs. Our digital presses offer competitive pricing for variable printing, small SKUs, and require no plates. Contact AWT to discuss your project specifications and get started!

Everyone wants to live in a sustainable world.  This includes being environmentally responsible in our work every day.

In the flexible packaging industry, most of the sustainability efforts tend to focus on materials.   Designers and researchers are always searching for materials that come from renewable sources, are reusable in some way, can be easily recycled, or are compostable and/or biodegradable.  A great deal of effort is also concentrated on reducing the overall amount of packaging by down gauging as well as eliminating layers and environmentally unfavorable materials.

While these efforts are all beneficial, an often overlooked opportunity for sustainability in flexible packaging is the manufacturing process itself.  To manufacture flexible packaging in the most sustainable manner possible, one can utilize solvent-free adhesive lamination technology, also known as solventless lamination.  The laminating adhesive used in this process is a two-component polyurethane.  These two components must be mixed together in the appropriate way to form a useful adhesive that will bond the material layers to each other, forming a flexible packaging substrate.  The manufacturers of these adhesive components control the viscosity properties of the final product in such a way that solvents are not required to maintain the material as a liquid; hence, solvent-free.

How It Works

Solventless lamination technology utilizes a computer controlled Meter, Mix, Dispense Unit (MMDU) that continuously measures a precise amount of each component, then mixes and dispenses small amounts of the solvent-free adhesive into the laminating equipment.  This differs from the traditional lamination method in which large batches, up to 55 gallons at a time, of adhesives are premixed for the manufacturing process; this can lead to excess waste.

The MMDU dispenses the adhesive into a laminating machine specifically designed to run this type of adhesive.  The laminator applies the adhesive and combines the two layers of materials to form the flexible packaging lamination.  Since there’s no solvent to drive out of the adhesive, no overhead ovens are required for drying the adhesive.  The two materials are combined, wound into a roll, and the adhesive is allowed to crosslink (or cure) for a specified amount of time before moving to the next manufacturing stage.

This lamination technology is far more sustainable than the traditional adhesive lamination methods for three very important reasons:

1. Reduced Waste. Only the amount of adhesive needed at the time of lamination is mixed and dispensed. Since the adhesive is mixed continuously, there’s no excess and very little waste.  When the lamination equipment is stopped, the adhesive mixing also stops thus, drastically reducing adhesive waste.
2. Energy Savings. Since there’s no solvent that needs to be driven out of the adhesive there’s no need for an overhead drying oven. The result is a significant energy savings in natural gas.  Additional energy savings include reduced electricity usage since there’s no need for large blower motors to circulate the hot air inside drying ovens.  There are further natural gas savings because the solvent-laden air doesn’t need be passed through a secondary thermal oxidation process to destroy the solvents before the air is released to the atmosphere.
3. Lower Material Usage. Solvent-free adhesives tend to use lower coating weights when compared to other adhesive lamination techniques, again resulting in fewer pounds of materials used for the same amount of packaging.

The solvent-free adhesive lamination technology is a highly sustainable manufacturing method due the benefits of drastically reduced waste, lower material usage, and large energy savings.  The large reductions in energy usage can be related directly to significant reductions in the release of carbon compounds to the atmosphere.

This is an example of just one of the many technologies that are available in the manufacturing process to improve sustainability, while still producing useful and safe flexible packaging structures. To learn more, contact your local AWT Representative at http://www.awtlabelpack.com/contact/