Understanding Material Performance, Processing Requirements, and Lamination Techniques

Self-adhesive labels—also called pressure-sensitive labels or instant labels—are widely used across packaging, logistics, pharmaceuticals, electronics, and consumer goods. These labels are created by coating paper, film, or specialty face stock with adhesive and pairing it with silicone-coated backing paper. After printing and die-cutting, they become the finished labels used on countless products.

In this article, we will explore the key printing and processing characteristics of self-adhesive label materials and provide a detailed explanation of the two major lamination methods used in label production.

I. Printing and Processing Characteristics of Self-Adhesive Labels

The performance of self-adhesive labels during printing, die-cutting, and application depends on multiple material factors. Understanding these characteristics helps ensure high-speed production and consistent label quality.

1. Uniformity and Strength of Backing Paper & Face Stock

The thickness consistency and structural strength of the face stock and backing paper significantly impact:

  • Printing smoothness
  • Die-cutting uniformity
  • Waste matrix removal speed
  • Risk of edge breakage during production

Poor material quality reduces machine speed and increases defect rates, making material selection a critical step.

2. Adhesive & Silicone Coating Amounts Affect Peel Force

Adhesive and silicone oil coatings directly influence peel force, which determines:

  • Waste removal stability
  • Machine running speed
  • Label dispensing performance
  • Adhesive seepage at material edges

Choosing materials with appropriate coating weight ensures smooth production and prevents issues such as glue overflow or unstable release.

3. Face Stock Surface Properties Affect Print Quality

Critical surface characteristics include:

  • Gloss level
  • Color consistency
  • Density uniformity

These factors determine ink absorption, color accuracy, and print consistency across batches.
Additionally, poor coating strength may produce excessive paper dust, affecting print clarity and equipment cleanliness.

4. Material Flatness & Rewinding Tension Uniformity

Whether sheets or rolls, material flatness influences:

  • Feeding accuracy
  • Printing registration
  • Rewinding quality
  • Adhesive seepage and roll deformation

For roll materials, proper winding tension ensures smooth operation and prevents registration errors.

II. Why Lamination is Used for Self-Adhesive Labels

Lamination adds a protective film layer—commonly transparent PP film—to enhance:

  • Waterproof performance
  • Corrosion resistance
  • Scratch resistance
  • Overall durability
  • 3D visual appearance

Although PET and PVC films can also be used, they are less common due to higher cost.
Today, UV varnish often replaces lamination for paper roll labels as a more cost-effective finishing option.

III. Two Lamination Methods for Self-Adhesive Labels

Self-adhesive label lamination is generally divided into single-sheet lamination and roll-to-roll lamination. Each method suits different production equipment and application needs.

1. Single-Sheet Lamination (Sheet-Fed Lamination)

This method involves laminating a transparent PP film onto sheet-fed labels.

Process Overview:

  1. Adhesive is applied to PP film on a laminating machine.
  2. Solvent is evaporated through a drying device.
  3. The PP film is bonded to printed sheets at the lamination station.
  4. A heated roller applies pressure to complete the lamination.

This method is suitable for:

  • High-end packaging
  • Premium labels
  • Small to medium production runs

2. Roll-Type Lamination (Roll-to-Roll Lamination)

Used mainly in label printing machines.

Process Principles:

  • The lamination process works opposite to traditional backing paper-coated films.
  • Linerless lamination films (backing paper-free) use the material’s low surface tension to prevent adhesive residue when peeled.
  • PP film with low surface tension re-rolls smoothly and replaces traditional release liners.

Advantages include:

Understanding the printing characteristics, material requirements, and lamination methods of self-adhesive labels is essential for achieving high-quality, efficient label production. Whether you are producing premium packaging labels, logistics labels, or durable industrial labels, choosing the right materials and lamination technique ensures:

  • Stable machine performance
  • Consistent print quality
  • Strong label durability
  • Enhanced end-use performance