• Automated labeling requires more precision than manually application.
• Labels have to be exactly to spec to work reliably in automated labeling systems without causing downtime, loss, and rework. 
• Release and liner behavior, adhesive timing, and label construction all become important factors in automated labeling systems.
• Automated labeling processes and their labels should be designed together.
• Common mistakes like testing with temporary labels, designing labels after the automated process is finalized, or selecting label materials before thinking about your system are all easy to avoid.
• There are five easy steps you can take to successfully design and implement automated labeling.
• The stakes are higher when automated labeling happens in a regulated environment.
• You should seek expert help when designing or implementing an automated labeling process and/or if you’re experiencing intermittent problems with your labels. 

Automated labeling requires precision

Humans are amazingly adaptable at tasks,  including putting labels onto surfaces. Our dexterity, our responsiveness to small changes in label size or stickiness or thickness means that we can get most labels to stick to the thing they’re supposed to stick to. 

Not so with automated labeling. 

Why labels that have worked fail in automated labeling processes

Automated labeling machines are not adaptable. They are designed to repeat a certain action within a certain set of specs reliably and quickly many, many times every day. That means the labels you feed into them have to be exactly the same and exactly aligned to the requirements of your particular machine. And it explains why standard labels that performed fine when applied by hand suddenly fail when fed into an automatic labeling machine. 

What suddenly matters in automated labeling 

Look at it this way: if you’re applying labels by hand, they’re a consumable. But once you switch to automated labeling, your labels become a mechanical component of the system. That means your labels have to be just as precise and reliable as the other parts of the system if it’s all going to run smoothly.

Release and liner behavior

Unlike the human hand that can pull harder or softer to peel a label off its liner, automated labeling has tight release force tolerances that make liner construction matter far more than it does in manual application settings. Peel angle, speed, liner stiffness, and release consistency all affect whether a label feeds smoothly or begins to chatter, snap, or mis-register. 

Adhesive timing

In manual applications, the question is: will this label stick. In automatic labeling, the question becomes: will it stick at this speed, pressure, and dwell time. Initial tack, wet-out timing, temperature, humidity, and any prior sterilization or environmental exposure can change the answer to that question from yes to no in an instant. 

Label construction

Small variances in label construction aren’t a stumbling block for manual application, but they are amplified in automated labeling situations. Facestock caliber impacts registration. Curl memory affects edge lift and placement. Die cut consistency affects pick-and-place accuracy. 

Automated labeling processes need to be designed in tandem with labels

Achieving automated labeling success isn’t a chicken or egg situation. It’s a chicken AND egg situation. Here at CleanMark, we’ve been helping companies switch to automated labeling (and rework failed attempts at moving to automated labeling) for a lot of years. 

The biggest lesson we’ve learned? Successful automated labeling comes from designing and testing your labels and process together.

Since labels are an integral mechanical component of any automated labeling system, it makes sense that you’d run into problems if you design without them in mind. Applicators, placement methods, line speeds, and container geometry are all affected by and affect label construction and performance. 

Also, most companies don’t have an automated labeling expert in-house when they first decide to automate. Bringing on a strong label partner, like CleanMark, early on means you have a partner to advise you on common missteps and short-cuts to success.

Common automated labeling mistakes

Speaking of those common missteps, here are a few we see often that lead to delays, rework and unexpected downtime. But, you can easily dodge them if you know what to avoid. 

Selecting label material before your automated labeling process is fully designed

Our label design team carefully chooses every component of your label to conform to the requirements of your automated labeling process. If you don’t know what that process is yet, then you’re choosing label materials blindly, which never leads to a good result.

Validating your automated labeling system using surrogate or temporary labels

Remember when we said automated labeling requires precision? If you test using surrogate or temporary labels, you don’t know for sure that your permanent labels will meet the tight tolerances required by automated labeling systems. If it turns out they don’t, then you’re stuck reworking either the labels or your system.

Testing at bench conditions rather than production speeds

As line speed increases, your release window shrinks, which challenges your automated label system much more. Testing at production speed lets you know for sure if your labels can print, release, and adhere consistently as they’ll need to day in and day out during regular manufacturing. 

Assuming material approval equals system readiness

There’s a reason we do lab testing, environmental testing, and then in-situ testing with our customers. It’s because the real world is always just a little different than artificially constructed testing environments. Finding the right material is a big step toward success, but you can’t know your system is truly ready until your label has successfully run through a production speed test in your facility. 

The right way to automate labeling

We’ve called out the ways companies get automated labeling wrong, but what steps do you need to take to get it right? Follow these high-level steps, and you’ll reduce the risk of a new system and be on your way to efficiency-boosting, reliable automated labeling.

1. Understand your goals — What do you need your automated labeling system to do? What does success look like? This can be very basic, but orienting yourself early on leads to quicker design and implementation.
2. Involve a label expert early — Finding a label partner experienced with label construction and automated labeling process helps avoid mistakes (like those above) and lets you step away from the technical details to focus more on your larger business goals. 
3. Design your labels and automated labeling system together — When you take into account the strengths and inherent limitations of all of your process components, including labels, during the design phase, you’ll end up with an optimized solution and fewer surprises. 
4. Consider all label components — Just as your automated labeling is a system, so is each individual label. Make sure your label partner has an experienced material science team and access to the latest adhesives, facestocks, liners, and coatings to ensure you get the highest-functioning label possible. 
5. Test at production speeds and conditions — Once you’ve completed the design of your automated labeling system and labels, test them together at production speeds and conditions to ensure there are no surprises. 

The stakes are higher in regulated and high-reliability environments

The reliability of an automated labeling system is key in any manufacturing operation, but especially so in regulated and high-reliability environments. In these scenarios, labeling failures aren’t just cosmetic, they can jeopardize your customers’ safety and put you at risk of noncompliance.

• Batch delays — faulty labels must be checked and/or reworked
• Validation complications — missing, misapplied, or illegible prevent validation
• Supply interruptions — incorrect or missing labels impede supply chain tracking
• Compliance risk — faulty or failed applications can go afoul of mandatory traceability and safety requirements

Is it time for you to talk to CleanMark?

We’re always happy to chat with you about labels, whether you’re ready to make an order or not. It’s our passion! But, there are some key times when we recommend reaching out so we can support your label needs. 

If you’re doing or considering doing one of the following, schedule a consultation with us and we’ll walk you through the process.

• Transitioning from manual to semi-automated or automated labeling
• Designing or validating an automated labeling process
• Seeing intermittent issues in your automated labeling process 

In the meantime, if you’re looking for some more info on how we design labels for automated labeling systems, visit our technical services page on label automation.

The post How automated labeling changes your label needs appeared first on CleanMarkLabels.

Great ideas for manufacturing improvement come from people in all sorts of roles: quality leaders, operations manager, procurement specialists, all the way up to executive leaders. The sticking point is that many of these people haven’t ever been called to lead the change management process before.  And, if you don’t have experience building internal consensus, you’re going to have trouble getting your great improvement idea across the finish line.

We hear these kind of complaints all the time from customers working their way through internal approval processes:

• “It should be simple, but we’re stuck in analysis paralysis.”
• “Every department has a say, but nobody is driving decisions forward.”
• “We keep revisiting decisions without moving forward.”

This 5-step guide to taming the change management process gives you concrete, no-nonsense guidance for taking your idea from conception to implementation by building strong internal consensus. Let’s get to the nitty gritty! 

Step 1: Identify and strategically engage stakeholders

A successful change management process always involves identifying key stakeholders and engaging them strategically at the right moments. Here are some questions to ask yourself when you’re identifying stakeholders?

• Who will make the final decision? 
• Who will advise the decision maker(s)?
• Who is impacted by the current problem?
• Who will benefit from the proposed change? 
• Who has veto power?

As you look for these people, keep in mind that the change management process often involves stakeholders from across the company, not just in your department. You’ll want to consider that your stakeholders could be in quality assurance, operations, procurement, regulatory affairs, engineering and R&D, or executive leadership. 

And, each stakeholder’s role, both in the organization and in the change management process, affects when and how you should talk to them. You’ll want to think about their context in the company, when they’ll likely play the largest role in the process, and what information they might find most compelling.

Initiating one-on-one conversations with key stakeholders before group discussions to privately address concerns, build rapport, and identify potential support or resistance. And, it puts you in the strongest position to provide everyone with information tailored to their unique concerns at the right time in the process.

Step 2: Clearly define the problem and solution

Clarity and detail are essential elements of a successful change management process. Initiatives commonly fail because the problem and/or solution is perceived differently by each stakeholder or simply misunderstood. So how do you avoid that issue? With concrete, detailed explanations that address shared concerns and goals. 

First, avoid broad, vague statements: 

 “Our labeling system isn’t reliable.” 

Instead, choose details that define the concrete parameters of the problem and its impact: 

“Our team spends significant time correcting labeling errors, resulting in increased regulatory compliance risks and delaying critical production schedules by up to 15%.”

And set clear expectations for the benefits of your proposed solution:

“CleanMark labels are customized for our label applicator machine and production environment, so they will apply and adhere reliably, reducing compliance risk and eliminating production delays due to labeling errors.”

Quantifiable details (like additional cost or production delays) are objective indicators that all teams can rely on to make strong decisions. When you’re choosing which data points to include in your description of the problem and solution, make sure to include information that speaks to all departments that will be part of the final decision. Here are a few to consider:

• Regulatory compliance and audit readiness
• Operational efficiency
• Product quality and integrity
• Cost control and resource optimization
• Competitive advantage and market responsiveness

Step 3: Anticipate and address objections proactively

No one ever made their best case for change while caught off guard. Be proactive about objection response. Put yourself in the shoes of the stakeholders you identified in Step 1. What might they be concerned about? Why? What evidence can you provide to put their minds at ease? And then make sure you have answers — and the documentation to back them up — at the ready. 

Here are some examples:

Notice that in each of these responses, there’s an offer for detailed information to back up the claim that your proposed change will improve the situation from their specific point of view. And remember, relying on concrete, robust data and thorough documentation ( rather than subjective opinions) strengthens your position significantly.

Step 4: Guide the decision-making process

An effective change management process isn’t just about presenting solutions — it involves guiding teams toward collective, well-informed decisions. That means not just providing information, but facilitating productive conversation and ultimately building consensus. 

Here are some approaches many our our customers have found effective:

Comparative analysis matrices

Comparative analysis matrices are valuable tools for clearly outlining and contrasting the current versus proposed scenarios. These matrices help stakeholders visually understand the benefits, risks, costs, and trade-offs associated with each option, enabling more informed, objective decision-making.

Risk-benefit summaries

Risk-benefit summaries provide concise, clear documentation highlighting the potential impacts, opportunities, and consequences of each proposed change. These summaries focus on actionable data, allowing stakeholders to easily assess and balance potential benefits against any identified risks, ensuring transparent and informed decision-making.

Interactive Q&A sessions

Interactive question-and-answer sessions directly engage stakeholders, providing a platform for open dialogue, addressing concerns, and clarifying uncertainties. These sessions help build alignment, reduce misconceptions, and strengthen commitment to the agreed-upon solution by actively involving stakeholders in the decision-making process.

Implementation pilots

Conducting controlled tests or trial runs of the proposed changes provides practical, real-world evidence of effectiveness, enabling stakeholders to validate outcomes and build confidence in broader implementation plans. This approach helps manage risk, demonstrate feasibility, and secure broader organizational buy-in.

Remember, the objective of the change management process is to build clarity, mitigate risks, and secure unified commitment across all stakeholders.

Step 5: Document decisions and ensure follow-up

Effective change management includes maintaining clear documentation, following up on commitments promptly, and ensuring accountability so that decisions lead to tangible actions.

After any meetings, group or individual, send clear follow-up communications detailing:

• Confirmed actions and next steps
• Assigned responsibilities and owners
• Specific timelines and milestones
• Resources and support required from each department

Regular follow-up sessions reinforce accountability, demonstrate progress, prevent stagnation, and maintain momentum.

Need support implementing your change management process?
CleanMark specializes in helping manufacturing leaders implement custom labeling solutions through structured, proven change management processes. We support our customers from solution design to internal approval, implementation, and beyond.

Ready to get your great labeling idea across the finish line? Schedule a consultation with us and one of our team members will walk you through our comprehensive support.

The post 5 steps to tame the change management process appeared first on CleanMarkLabels.

Read on to learn why your process improvement is going off the rails and how to get on the fast track to implementing your smartest initiatives.

Misalignment kills manufacturing process improvement

You’ve identified a smarter way to do things. Maybe that’s an upgrade to traceability protocols, a new label material, or a new sterilization protocol. On paper, it’s a no-brainer. But moving from proposal to implementation is rarely that simple.

In many regulated manufacturing environments (like BioTech and pharma), process improvement isn’t blocked by technical flaws. It’s blocked by internal friction and misunderstandings.

• Siloed priorities — Manufacturing operations cares about efficiency. QA focuses on compliance. Procurement is driven by cost. Without shared priorities, even simple changes can trigger misalignment.
• Information gaps — Leadership may only see the top-line cost. Engineering may not see the compliance benefit. When team leaders are making decisions based on incomplete information, the easiest answer is no.
• Regulatory caution — Even minor changes can raise concerns about revalidation or audit exposure. Without clear documentation, teams often default to the status quo.
• Unclear ownership — Who’s responsible for pushing an improvement through? In many companies, process improvement is everyone’s job — which often means it’s no one’s job.
  

When these blockers are present, even the most promising manufacturing process improvement can sit idle. But there are ways to clear the path.

We help you build a case for process improvement that your entire organization can support

Companies that successfully implement manufacturing process improvements have a clear approach to internal alignment. And when it comes to CleanMark’s customers, we’re a big part of their plan.

We’ve worked with manufacturers across BioTech, pharma, semiconductors, and other highly regulated sectors to design and implement new labeling solutions that improve the efficiency and effectiveness of their manufacturing processes. And we understand that driving process improvements isn’t just about finding the right solution — it’s about building the case in a way your entire organization can support.

Here’s how we help our customers gain consensus around manufacturing process improvements:

Technical data that answers stakeholder questions before they’re asked

We provide the kind of evidence your team needs to feel confident — validation summaries, durability test results, application guidance, and more.

Tailored communications for every stakeholder group

Need a compliance summary for QA? A cost-benefit breakdown for procurement? A change impact outline for operations? We help you tell the story in the right language for each decision-maker.

Support for internal conversations and team presentations

We’ve supported dozens of process improvement initiatives through the internal review process. We’ll join calls, present findings, or help clarify technical concerns — whatever helps keep your project moving forward.

Case study — cryogenic labels

Let’s take a look at a real-world example to see what our support can look like in action.

The challenge

A packaging engineer at a global biotech company needed to improve labeling for cryogenic vials — a high-risk process with tight compliance requirements. CleanMark identified the right solution quickly, but getting it approved required a complex internal approval process. 

The engineer faced questions from QA about long-term adhesion, skepticism from procurement about switching vendors, and requests from regulatory for validation data. He feared the improvement process was stalled for good. 

The CleanMark solution

We understand that approval processes are complex because each stakeholder has unique insight into potential impacts — both positive and negative — that a process change could have on overall operations. We respect that, and we set out not to side-step internal checks, but rather to support our customers as they move through them to feel confident that implementing our solution will be a win for the company. 

In this case, we provided use-case-specific adhesion test results at cryogenic temperatures and co-created a compliance brief that mapped directly to QA and regulatory concerns. We also joined a call with procurement to explain technical requirements and lifecycle cost savings.

The result? Approval in just two weeks — and the new labeling system was validated and in place by the end of the month.

Case studies >> Learn more about how we’ve helped customers succeed 

Ready to see your manufacturing process improvements in action?

Let’s be honest: pushing for process improvements can be lonely.  We’re here to make it easier to  be the one who moves things forward. We know you’re not just trying to solve a problem. You’re trying to create a more reliable process. A more compliant operation. A smarter way of working. That only happens when people say yes. And we can help you get there.

Let’s talk. CleanMark is here to support you not just with custom labels — but with the clarity and coordination needed to bring real improvements to life. Schedule a consultation here.

The post Need help getting your manufacturing process improvement across the finish line? appeared first on CleanMarkLabels.

To do this successfully, it might appear that your labels need to be fully preprinted during production. And sometimes that is the case — but not always. There are a lot of use cases where information needs to be added to a label in the moment. Quality control labels, QR code labels for tracking, and sterility indicators, for example, are helpful because they convey up-to-date  information like date, time, batch number, inspector initials, and other information that just can’t be preprinted. 

Thermal printing labels give you the best of both worlds. They can be preprinted with evergreen information and then easily re-printed on site to add process-specific information. And, they’re durable enough for even the harshest environments. 

What are thermal printing labels?

When we talk about thermal printing, we’re really talking about two types of printing — direct thermal printing and thermal transfer printing. Both offer high precision and durability, making them  ideal for industries with strict durability and legibility requirements, but each has its own unique advantages and disadvantages as well.

In direct thermal printing, the label material itself is heat-sensitive, meaning no ink or ribbon is required. When the printer applies heat, the label darkens in specific areas to form the desired text or image. This method is simple, cost-effective, has high chemical resistance and can handle smaller text sizes, but the labels are more prone to fading over time, especially when exposed to heat, light, or friction.

Thermal transfer printing, on the other hand, uses a heated ribbon to transfer ink onto the label, resulting in a more durable and long-lasting print. This method can be used on a wider variety of materials, including synthetic labels (like polyimide labels and their alternatives), which are resistant to heat, chemicals, and abrasion. Thermal transfer printable labels are commonly used in environments where labels need to endure harsh conditions, such as in semiconductor manufacturing, pharmaceuticals, or automotive industries, making it a versatile choice for high-tech applications.

Fully preprinted labels don’t fit every scenario

There’s a place for fully preprinted labels: primarily in situations where large-volume consistency is a priority. Product or packaging labels that are the same for each unit and need to be uniform across large quantities, for example, are an obvious choice for full preprinting. It’s lower cost and more consistent. 

But there are the limitations we mentioned at the beginning of this article. Fully preprinted labels just can’t accommodate information that changes frequently or unexpectedly, like inspections, serial numbers, and tracking codes. Additionally, preprinted labels can become a financial burden if your processes or product change. Rather than updating labels on the fly, you waste any labels already in stock and have to wait for new labels to be produced and shipped.

Blank thermal printing labels also have pros and cons

The other extreme is a blank thermal printable label that you fully print on site. This too, has some advantages.

• Full customization on demand — Whether it’s a regulatory update that changes labeling requirements or product variations that call for new information on labels, real-time customization is crucial. Onsite thermal printing enables businesses to quickly and easily adapt their labels to meet these changes. 
• Minimized waste — Fully onsite printing allows you to print only what is needed, when it is needed. So no label stock is wasted if you change directions.

These advantages are valuable, but full on-site printing has its downsides too. 

• Decreased efficiency — On-site printing is slower than factory preprinting of information that’s the same across all labels. What might seem like an insignificant amount of additional time spent printing an individual label adds up to serious slowdowns over thousands or hundreds of thousands of labels.
• Inconsistency — Labels printed on-site are inherently less uniform than factory printed labels because of environmental and user differences from print batch to print batch. 

Partially blank thermal printing labels are the sweet spot

Using thermal printing labels that are partially preprinted during production with blank spaces left for on-site printing of more transient information is the best of all worlds. Here are five key ways they save you time and resources:

1. Save time

Partially preprinted thermal labels save valuable time by allowing companies to print static elements, such as company logos, branding, or regulatory information, in advance, which is faster per label than on-site printing.

2. Track variable data

One of the key advantages of partially blank thermal printing labels is the ability to customize variable data onsite. Information such as batch numbers, dates, and barcodes can be adjusted in real-time, allowing companies to track products and maintain accurate records throughout the production process. 

3. Increase consistency

By preprinting static elements like logos and branding, companies can ensure that the brand and compliance-related information on their labels remains consistent across all product lines. 

4. Reduce errors

Partially printed thermal labels significantly reduce the risk of errors in the labeling process. When static information — such as regulatory symbols or company details — is preprinted, there’s less room for mistakes, especially in fast-paced or complex production environments where mislabeling can lead to costly recalls or compliance issues. 

5. Eliminate label failure

By using partially preprinted thermal labels that are specifically designed for durability and resistance, companies can ensure that essential information remains intact and legible even in harsh environments. 

The role of thermal printing labels in your industry

Not every industry needs the durability and flexibility of thermal printing labels that can be customized on site, but it’s essential in high-tech fields where environmental and process requirements are complex and precise. 

Semiconductor manufacturing

The components used in semiconductors are intricate, and many are exposed to high temperatures during the manufacturing process. Labels must withstand these harsh conditions without compromising clarity or durability. Thermal printing labels completed onsite enable semiconductor manufacturers to create specialized labels on demand that are resistant to heat and abrasion, while also being small and detailed enough to fit onto tiny, complex components. This level of precision is essential for accurate tracking and identification throughout the production process, particularly in environments where even minor errors can lead to costly downtime or defects.

Pharmaceutical and biotech industries

Thermal printing labels completed onsite allow companies in the pharma and biotech industries to print labels in real-time, ensuring they can meet regulatory demands and adjust information as needed. Expiration dates, batch numbers, and specific testing information, for example, can be updated on the fly, which is especially important for ensuring traceability and maintaining the chain of custody in clinical trials or drug manufacturing. The ability to print variable data onsite also helps pharmaceutical companies respond quickly to regulatory updates, avoiding delays and ensuring compliance with the latest guidelines.

Automotive industry

From engines to electronic components, automotive parts are often exposed to extreme heat, chemicals, and mechanical stress. Thermal printing labels completed onsite allow automotive manufacturers to create durable, heat-resistant labels that remain legible and intact throughout the production process and beyond. Additionally, the industry’s need for variable data labeling — such as serial numbers, part identification, and manufacturing dates — can be met efficiently through onsite printing, ensuring that each part is accurately tracked from assembly to final inspection.

Food and beverage sector

Thermal printing labels completed onsite provide food and beverage manufacturers the ability to quickly update labels in response to changing product lines or regulatory requirements, ensuring that information remains accurate and compliant. This flexibility is crucial in an industry where product life cycles are short, and labeling errors can result in costly recalls or health risks, and the durability of thermal printing labels allows them to remain legible through the cold storage and mechanical abrasion often present in food and beverage processing.

Oil and gas industry

The oil and gas industry operates in some of the most harsh environmental conditions, where equipment and labels must withstand exposure to extreme temperatures, chemicals, and rough handling. Labels on pipelines, equipment, and storage containers must be durable, legible, and up-to-date to ensure safety and compliance. Thermal printing labels completed on site allow companies to produce customized labels that are resistant to these tough conditions, with materials that are designed to endure long-term outdoor exposure and physical wear. 

How to choose the right thermal printing label for your needs

Really, the right thermal printing label isn’t something you choose. It’s something you design.

There are a lot of variables that must come together in just the right combination for a label to work efficiently and reliably in your research, manufacturing, or processing environment. And the only way to make sure that combination is exactly right is to use a custom label designed by labeling experts in your industry.

CleanMark has 40 years of experience providing labeling solutions to high-tech industries that are just as innovative as the products our customers are producing. Our experienced label-engineers work with you to understand the specific needs of your use-case, then they design a label tailored to your unique needs.

Ready to up your process efficiency with custom thermal printing labels? Schedule a consultation with one of our label engineers today. 

The post 5 ways thermal printing labels save you time and resources appeared first on CleanMarkLabels.

Choosing the right label for your label applicator machine

The use and environmental requirements of your label and the type of label applicator machine you’re using both influence which label is right for you. If you’re a pharmaceutical company producing vaccines that require cold chain storage and shipping, you’re going to need a very different label than if you’re an auto manufacturer whose labels need to withstand harsh daily use. 

Below, you’ll find some top-level factors to consider when choosing the right label for your label applicator machine. But in reality, the best way to ensure that you have the perfect label for your process is to have one custom-engineered (more on that later). 

Liners

The liner is the backbone of any label construction and can make or break the efficiency of a label applicator machine. The liner material should be both durable and flexible. While paper liners are common, film liners often perform better because of their enhanced strength and ability to withstand higher application speeds without tearing. 

A good release coating, typically silicone, ensures that labels peel off smoothly without tearing or leaving residue. Thickness is another consideration. Thinner liners can increase the number of labels per roll, reducing downtime for roll changes, but only if  they’re  compatible with the applicator machine. Otherwise, you can end up with jams and improper feeding. 

Adhesives

The adhesive used in label construction is crucial for ensuring the label sticks properly to the intended surface once it’s processed through the label applicator machine. 

Surface texture, cleanliness, and composition can all affect adhesive choice. Surface energy also affects how well the adhesive bonds. High surface energy materials, like metals and glass, typically provide better adhesion, while low surface energy materials, like some plastics, may require special adhesives.

Beyond that, you’ll also want to consider whether you want the label to be permanent, removable, or repositionable. Permanent adhesives are ideal for long-term applications, while removable adhesives are suitable for temporary labeling. The initial tack, or the adhesive’s ability to stick to the surface immediately upon contact, should be high enough to prevent label lift during application but not so high that it causes issues with repositioning if needed. Final adhesion must be strong enough to ensure long-term adherence to the substrate.

It’s also important to consider temperature conditions and choose an adhesive that will form a strong bond under real-use conditions. Labels that must perform under high-heat conditions or in refrigerator, freezer, cryogenic, or dry-ice environments all should be designed with speciality adhesives that will perform reliably under those extreme circumstances.

Facestock

The facestock is the visible part of the label. It too, should be carefully selected to meet all of the environmental and usage needs of your unique processes and to ensure compatibility with the label applicator machine. Paper, polyester, polypropylene, and vinyl are all common facestock materials. You’ll also want to take factors like durability and printability into consideration. 

Understanding if you’ll want your labels to be 100 percent pre-printed or if you’ll want to add all or some of the information on site is essential to choosing the right label. Regardless of which of these printing options you choose, you’ll want to make sure the facestock supports a high print quality (especially important for barcodes) and excellent ink adhesion. 

Additionally, the facestock might need to be resistant to abrasion, chemicals, moisture, or UV light depending on the application.

Peel values

Peel value refers to the force required to remove the label from the liner, which is a critical parameter for label applicator machines. Peel values should be optimized to allow easy peeling by the label applicator machine without tearing the label or liner. These values are typically tested at a specified angle and speed to ensure consistency and facilitate smooth operation during high-speed labeling.

Release values

Release value measures the force needed to separate the facestock from the liner and is crucial for high-speed labeling applications. Consistent release values prevent label applicator machine misfeeds and jams. The balance must be such that labels do not prematurely detach during handling but still release easily during application, maintaining efficiency and accuracy.

Label applicator machine pitfalls

So what if you don’t get your labels exactly right? The consequences of a small design error can be massive operationally. 

Jams

Incompatible liner thickness or materials can cause jams or misfeeds in the label applicator machine, leading to downtime and reduced productivity. Ensuring that the liner’s thickness and material are compatible with the applicator machine is crucial to maintaining smooth operation and avoiding costly interruptions.

Tearing or mis-peels

Incorrect peel values can result in labels tearing or not peeling off the liner properly, causing interruptions and potential damage to the labels. Accurate peel values are essential for ensuring that labels separate cleanly from the liner when processed through the label applicator machine.

Sticking and misalignment

Without measures to minimize static electricity, labels can stick together or misalign, leading to misapplication and wastage. Effective static control is necessary to prevent labels from clinging to each other or misaligning as they’re processed through the label applicator machine.

Adhesive failure

Choosing the wrong adhesive type or one that is not suitable for the application temperature can result in labels not sticking properly to the surface, causing them to fall off. Conversely, too strong an adhesive can make repositioning difficult and cause damage to the labeled surface or the label itself when adjustments are needed. If the adhesive is not compatible with the surface material, it can result in poor adhesion or even damage the surface, especially with delicate or low-surface-energy materials.

Smudging and fading

Selecting an inappropriate facestock can lead to issues with print quality, such as smudging or fading, which can affect the readability of barcodes and other critical information. Labels may not withstand environmental conditions if the facestock material is not chosen correctly, leading to fading, tearing, or degradation when exposed to moisture, chemicals, or UV light.

Custom labels ensure label applicator machine success

If it seems like there are a lot of factors to consider when choosing labels for your applicator machine, it’s because there are. And, the sensitivity level across each feature is so high that getting just one wrong could jeopardize the functionality of your labels. 

The answer is custom-engineered labels. When you work with a labeling partner — like CleanMark — that has worked in your industry for years and understand the nuances of ensuring smooth operation of your label applicator machine, you take the headache out of optimizing your label application process. 

And, if you partner with CleanMark, you have a long-term partner who will be there to help you optimize your processes now and in the future. Ready to get started? Schedule a consultation with one of our label engineers today.

The post Which label is right for your label applicator machine? appeared first on CleanMarkLabels.

What is polyimide and why is it used for labels?

Polyimide is a high-performance polymer known for its exceptional heat resistance, durability, and chemical stability, making it a go-to material for labels in extreme conditions. These labels can endure temperatures up to 932°F (500°C) without degrading, which is crucial in applications like automotive manufacturing, food and beverage production, and oil and gas processing, where exposure to high heat is routine. 

The downside of polyimide labels

Polyimide labels handle heat and chemical exposure well, but there are drawbacks, the most notable being their high cost. This expense stems from the complex manufacturing process of polyimide films. The raw materials used in polyimide production are also more expensive than those for other label materials, which contributes to the overall higher cost. Additionally, polyimide labels are a specialty product that often isn’t produced in cost-lowering, large-scale runs.

Why a polyimide alternative might be the right choice for you

Given the high cost of polyimide, it makes sense to explore whether there’s a better alternative for your use case. If your specific application doesn’t require the extreme heat resistance or chemical stability that polyimide provides, for example, odds are you would be better off with a lower-cost alternative. Polyester, aluminum, polyamide (nylon), and polycarbonate all offer varying levels of durability and heat tolerance but come at a lower cost, making them more budget-friendly for applications that don’t demand the highest performance levels. By choosing an alternative to polyimide labels, companies can optimize performance while significantly reducing expenses. 

Polyester as an alternative for polyimide labels

Polyester labels are a versatile and cost-effective alternative to polyimide labels. They offer several benefits, making them a popular choice for many applications:

• Durability and resistance: Polyester labels provide excellent durability, tear resistance, chemical resistance, and moisture resistance, similar to polyimide labels.
• Temperature tolerance: These labels can withstand high temperatures up to 500°F (260°C) for short durations, making them suitable for many high-heat environments.
• Abrasion resistance: Polyester labels offer very high abrasion resistance and can last over three years in outdoor conditions.
• Variety of finishes: Polyester labels are available in various finishes, including matte, gloss, clear, and silver, providing flexibility in aesthetic choices.
• Cost effectiveness: Particularly for larger volumes, polyester labels are more cost-effective than polyimide labels, making them an economical choice for many businesses.

Aluminum as an alternative for polyimide labels

Aluminum labels are known for their extreme durability and are well-suited for harsh environments:

• Durability and resistance: Aluminum labels are extremely durable and resistant to chemicals, abrasion, and high temperatures.
• High-temperature tolerance: These labels can withstand temperatures up to 800°F (427°C), making them ideal for use in the most demanding industrial settings.
• Industrial and outdoor use: Aluminum label durability and resistance make them suitable for harsh industrial environments and outdoor applications.
• Aesthetic appeal: Aluminum labels provide a premium, metallic look and feel, adding a touch of quality to any product.
• Cost comparison: While more expensive than polyester, aluminum labels are still less costly than polyimide labels, offering a balance between cost and performance.

Polyamide (nylon) as an alternative for polyimide labels

Polyamide labels, commonly known as nylon labels, are another alternative offering good performance at a moderate cost:

• Durability and resistance: Nylon labels offer good durability and chemical resistance.
• Temperature tolerance: These labels can withstand temperatures up to 250°F (121°C), making them suitable for a range of industrial applications.
• Cost effectiveness: Nylon labels are less expensive than polyimide labels but more costly than polyester, providing a mid-range option for those looking for a balance of performance and cost.
• Versatility: Suitable for many industrial and outdoor applications, nylon labels provide a reliable solution where moderate heat resistance is required.

Polycarbonate as an alternative for polyimide labels

Polycarbonate labels are known for their excellent impact resistance and are a strong contender in environments requiring durable labeling solutions:

• Durability and resistance: Polycarbonate labels offer excellent impact resistance, temperature resistance up to 280°F (138°C), and chemical resistance.
• Cost comparison: They are more expensive than polyester labels but less costly than polyimide, making them a good middle-ground option.
• Application suitability: Suitable for various industrial applications, polycarbonate labels are ideal where both durability and heat resistance are necessary.

Are there situations where polyimide labels are the best solution?

It’s important to note, that while polyimide labels alternatives are the best cost-effective solution for many situations, there are circumstances in which the higher performance of polyimide labels is non-negotiable. 

This is particularly true in industries such as aerospace, semiconductor, and advanced manufacturing. In the production of printed circuit boards (PCBs), for instance, polyimide labels can withstand the intense heat of solder reflow processes, where temperatures can reach up to 500°F (260°C) or higher. In such settings, other materials would fail, compromising the readability of barcodes or tracking information, which could lead to production delays, quality issues, or safety risks.

Similarly, in aerospace applications, components may be subjected to extreme temperature fluctuations, from the freezing cold of high altitudes to the heat generated by engines or exhaust systems. Polyimide labels maintain their legibility and structural integrity throughout these cycles, ensuring that essential information, like serial numbers or maintenance records, remains visible for safety inspections and compliance. 

In these specialized environments, the upfront investment in polyimide is justified by its ability to provide consistent, reliable performance where other materials would fall short. The peace of mind that comes from knowing labels will remain secure and legible in even the harshest conditions makes polyimide labels the best choice for applications where extreme precision, safety, and regulatory compliance are non-negotiable.

Having a label expert at hand makes the decision easier

Choosing between polyimide labels and their alternatives is a nuanced decision — one better made with an industry-savvy label expert at your side. And facestock isn’t the only factor when choosing labels for process-specific applications.

You’ll need to consider adhesive, printability, size and shape, thickness, chemical resistance, temperature resistance, sterility, cleanroom compatibility and so many other factors. The reality is, it’s just not possible to find an off-the-shelf label that meets every single one of your operational criteria. True optimization call for a custom-engineered label, and that means finding the right labeling partner. 

That’s where we come in. CleanMark’s team of industry-experienced labeling experts investigates your specific use case, designs a custom-engineered label that fits every aspect of your requirements, and then we produce your labels faster than anyone else in the labeling industry. 

Schedule a consultation today, and we’ll help you decide if polyimide or another label material is the right choice for you.

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