MANUFACTURING PROCESS OF CONTAINER LABELS WITH HEAT TRANSFER TECHNOLOGY WITH SEQUENTIAL ALPHANUMERIC IDENTIFICATION CODES APPLIED THEREON

Abstract

The present method relates to a manufacturing process of container labels with heat transfer technology, wherein alphanumeric codes are sequentially applied over, between and/or under the layers of specific inks and varnishes which protect said area of eventual friction and wear to which they are subject during transportation, handling and productive tests.

Claims

1. A process for the manufacturing of container labels with an information data utilizing heat transfer technology for labeling packages by a rotogravue process, said process comprising the steps of: a) application of a wax on a substrate; b) drying the wax; c) application of a protective varnish layer (1D); d) drying the protective varnish layer; e) printing at least one ink layer on the package label, according to a customer's art; f) drying the at least one ink layer; g) application of at least one ink layer having a visualization window on the package label, according to a customer's art; h) drying the at least one ink layer having a blank window; i) application of an adhesive varnish (2D); and j) drying the adhesive varnish layer (2D); wherein a variable information data set is printed before the at least one ink layer having a visualization window, being the variable information data set not covered by the ink of said at least one ink layer.

2. The process according to claim 1, wherein the substrate is in the form of kraft, white or brown paper, with a weight ranging from 35 g/m.sup.2 to 70 g/m.sup.2.

3. The process according to claim 1, wherein the adhesive varnish (2D) comprises a mixture of 50% methyl ethyl ketone (MEK) and 50% ethyl.

4. The process according to claim 1, wherein the protective varnish layer (1D) comprises a mixture of 50% methyl ethyl ketone (MEK) and 50% T-300, wherein T-300 comprises a mixture of 38% ethyl acetate and 62% n-butyl acetate.

5. The process according to claim 1, wherein the printing of information data is performed by a printer using solvent-based ink.

6. The process according to claim 1, wherein the variable information data set comprises a thickness equal to or less than 4 micron.

Description

BRIEF DESCRIPTION OF THE FIGURES

[0029] FIG. 1 represents a container label (R) having a hollow area presenting a sequential alphanumeric information code applied between the layers of inks and varnishes.

[0030] FIG. 2 represents a container label (R) having a hollow area presenting a sequential alphanumeric information code applied under or on the layers of inks and varnishes.

[0031] FIG. 3 represents the overlay scheme of inks and varnishes in a label (R) in the Heat Transfer technology.

DETAILED DESCRIPTION OF THE INVENTION

[0032] The label used in the process of the present invention comprises a substrate having a face printed in rotogravure using solvent-based inks.

[0033] The substrate is available on the market in the form of kraft, white or brown paper, with a weight ranging from 35 g/m2 to 70 g/m2, being subsequently improved with the application of a wax layer with a weight ranging from 1.19 lbs/Ream to 1.57 lbs/Ream, in the rotogravure process prior to the application of inks or varnishes on the substrate.

[0034] The solvent-based ink used is available on the market as inks for rotogravure.

[0035] The solvents used for mixing the inks and varnishes in machines depend on the colors being applied:

[0036] If the color is white, the solvent used is a mixture at 80% ethyl acetate+20% toluene.

[0037] For the other colors, the solvent used will be 100% T-300 (38% ethyl acetate+62% n-butyl acetate).

[0038] The Protective Varnish (1D) consists of a mixture at 50% MEK (methyl ethyl ketone)+50% T-300 (38% ethyl acetate+62% n-butyl acetate).

[0039] The adhesive Varnish (2D) however consists of a mixture at 50% MEK+50% acetate.

[0040] The application area of the alphanumeric code on the label, object of the present invention, comprises printing of sequential data referring to general product information, where it will be arranged, visible to optical identification system that allows the access and recording of information.

[0041] The content of the information data may vary and it is made to order.

[0042] The confidential information data is printed by a printer using solvent-based ink.

[0043] The information data may be applied on, between or under the layers of inks and varnishes applied on the substrate.

[0044] The information data applied on the ink layers receive the application of a protective varnish layer (1D), in order to increase the resistance to friction and to caustic soda test.

[0045] The information data applied between the ink layers require a window on the label, to make it visible after application. The information data are applied to an adhesive varnish layer (2D) and a ink layer (varying the color according to the art ordered). After the application thereof on the adhesive varnish layer and the ink layer, the other inks are applied (varying according to the art defined in the order), these with a window, avoiding overlapping of the other ink layers to the information data already applied. After the application of the other ink layers, the protective varnish (1D) is applied on all art, including information data, in order to increase the resistance to friction and to the caustic soda test.

[0046] The information data applied under the layers of inks and varnishes are inserted on the verse of the label, with the protection of the other layers of inks and varnishes. The application of information data under the layers of inks or varnishes is performed in production line, during the printing or cutting process and/or in the line of label application on the final substrate. The information codes cannot have a thickness exceeding 4 microns, in order to avoid migration and label exposure to abrasion or contamination to the layers of inks and varnishes, affecting the color or finishing of the label.

[0047] The manufacturing process of the container label with the information code can occur in three different ways.

[0048] When the information code is applied on the ink layers on the label, the manufacturing process of the container label comprise the steps of:

a) application of the wax on the substrate;
b) drying this wax;
c) application of the protective varnish layer (1D);
d) drying this varnish layer;
e) printing ink layers on the label, according to customer's art;
f) drying the ink layers;
g) printing the information data after the application of the ink layers;
h) application of the adhesive varnish (2D) on the ink layers and information data; and
i) drying this adhesive varnish layer (2D).

[0049] When the information code is applied between the ink layers on the label, the manufacturing process of the container label comprises the steps of:

a) application of the wax on the substrate;
b) drying this wax;
c) application of the protective varnish layer (1D);
d) drying this varnish layer;
e) printing an ink layer on the label, according to customer's art;
f) drying the ink layer;
g) printing the information data after the application of the ink layer;
h) application of the other ink layers, with visualization window (open in the label) of the information data;
i) drying the overlapping ink layers;
j) application of the adhesive varnish (2D) on the ink layers and information data; and
k) drying this adhesive varnish layer (2D).

[0050] When the code information is applied under the ink layers on the label, the manufacturing process of the container label comprises the steps of:

a) application of the wax on the substrate;
b) drying this wax;
c) application of the protective varnish layer (1D);
d) drying this varnish layer;
e) printing the ink layers on the label, according to customer's art;
f) drying the ink layers;
g) application of the adhesive varnish (2D) on the ink layers and information data;
h) drying this adhesive varnish layer (2D); and
i) printing information data.

[0051] In all three cases, the confidential information is printed on the labels (R), at room temperature, through a process of rotogravure graphic printing process, using solvent-based ink.

[0052] Drying of the ink applied on the label (R), in each of the stations that apply the colors onto the substrate, varies according to the ink used.

[0053] When using solvent-based inks, the ink drying is carried out through an oven whose temperature ranges from 60-70 C. However, depending on the thickness/weight of ink applied on the substrate and printing speed, the drying temperature can be changed.

[0054] The ink application layer varies according to the customer art, the engraving type of the cylinders and tooling used during the application (knives/scraper bladesthe function of which is to make the removal of the excess of inks of the application cylinders and rollersthe function of which is to promote the transfer of inks to the substrate).

[0055] When the engraving is for a flat color, the amount of ink applied is much higher. To gradients, the ink layer is smaller.

[0056] The wax composition that is applied to the substrate is unknown by Technopack, being under the wax supplier's responsibility the development of a composite suitable to rotogravure processes. When it is purchased, it is explained to the supplier the parameter use that it will be willing and normal to this process. Because it is a process already known by the suppliers, such a solution is part of the product portfolio thereof.

Results and Tests

Test of Caustic Soda-Resistance of the Label

Procedure for Execution:

[0057] To prepare the solution, it was used a metal bucket large enough so that the heat transfer label labeled on the bottle was completely submerged. It was added water enough to cover the label of the bottle and the quantity, in liters, of the total added was recorded.

[0058] Then, it was added 4 g of caustic soda (NaOH) per each 1 liter of water used in the test. It's worth emphasizing that the caustic soda should always be added to water, never water to caustic soda. The reversal of this process can lead to abrupt eruptions and consequent burns.

[0059] The solution with the heating iron was heated, maintaining the temperature of 60 C. (5 C.).

[0060] The heating iron was plugged in after being submerged in the solution, into the metal bucket, to preserve the apparatus. The bottles were filled with water so that the water height in the bottle was greater than the height of the solution and placed into the metal bucket with a weight of 2 kg above them to prevent floating.

[0061] The bottles were kept submerged for 30 minutes. During this period, the solution temperature was controlled to rely within the range (60 C.5 C.). After 30 minutes, the bottles were removed and evaluated whether or not it has occurred detachment of the label. If not, the label is approved. If so, it is evaluated whether the affected area (where the label detached) is greater than 1 mm. If so, the label is disapproved.

[0062] The same procedure with the same materials and test settings was conducted for the labels which information code thereof is applied on, between or under the ink layers on the label.

[0063] Materials: For the execution of the test, the following materials were used:

[0064] Metal container;

[0065] Skewer type digital thermometer;

[0066] Loon type water heater;

[0067] Caustic soda solution;

[0068] PET bottle labeled with heat transfer label.

Test Setup:

[0069] Product: PET bottle of 2 liters and 1.5 liters

[0070] Number of samples: 50 of each

[0071] Date of execution: May 23, 2015

[0072] Concentration of the caustic soda solution: 3.5% to 5%

[0073] Temperature of the solution: 60 C.5 C.

[0074] Holding time: 2.5 hours (530 min)

[0075] Ambient light: D65 (Daylight approximation)

Results and Conclusions

[0076] In the three situations, label detachment was not evident after 5 baths of 30 minutes (total of 2.5 hours) of total immersion of the label in the caustic soda solution, even in ruptured areas.

Friction Resistance Test of the Label

[0077] With the aid of a carbon pencil (for writing), without sharpened point, up and down movements were performed in the labeled area, at an angle of approximately 45 to the label. Such movement was performed in the entire label.

[0078] Again, it was evaluated whether or not it has occurred detachment of the label.

[0079] If not, the label is approved. If so, it is evaluated whether the affected area (where the label detached) is greater than 1 mm. If so, the label is disapproved.

[0080] The amount of 5 reps is the default, but the test can be extended to increase the reliability of the tests referred to herein.

[0081] The labels used for container designed according to the present invention showed good results in resistance to both caustic soda and friction, being capable of being used in the packing industry.