Apparatus and Method for the Provision of Labels

Abstract

A method and apparatus for reuse and/or recycling of liner material layers from a label supply which typically includes the liner material layer and a label supply material in which the labels are formed and from which the labels are subsequently applied to one or more articles. The invention allows the separation and processing and recycling of the liner material layer which, otherwise and conventionally would be treated as waste. The invention allows this to be achieved without the need for the application of any material to the label supply following the formation of the same. The recycling can be in the form of forming the liner material into a raw material for subsequent processing or, alternatively, using the liner material as an adhesive tape or, alternatively, directly reusing the liner material layer as part of another label supply.

Claims

1. A method of processing a labels supply from a location of a formation of a label supply laminate to a remote location at which labels are applied to articles, said method comprising: said label supply laminate formed and including a label supply material layer and a liner material layer on which the label supply material layer is adhered, said liner material layer acting as a carrier for the label supply material layer to a point of separation of the label supply material layer from the liner material layer, and wherein the point of separation is performed at a location intermediate the formation of the label laminate and an application of the labels to the articles.

2. The method according to claim 1 wherein after separation of the liner material layer from the label supply material layer, the label supply material layer is formed into one or more reels of linerless labels for onward movement to a point of application of the labels to the articles.

3. The method according to claim 2 wherein the onward movement of the reels involves transport of the same to the remote location at which the labels are applied to the articles.

4. The method according to claim 1 wherein after the separation of the liner material layer from the label supply material layer, the liner material layer is formed into one or more reels for movement to a recycling facility.

5. The method according to claim 4 wherein the reels of liner material which are formed are of a smaller outer diameter than an outer diameter of the reel on which the label supply laminate is provided to the location of separation of the label supply material layer and liner material layers from said laminate.

6. The method according to claim 1 wherein the location at which the liner material layer is removed from the label supply material layer is at a location at which the labels are printed and/or converted on the label supply material layer

7. The method according to claim 6 wherein once the printing and/or conversion has occurred, the liner material layer is removed from the label supply material layer.

8. The method according to claim 1 wherein the liner material layer includes a release material layer.

9. The method according to claim 6 wherein the label conversion includes an application of protective varnishes and/or anti-release coatings to the label supply material layer to overlie printed images which have been applied.

10. The method according to claim 9 wherein application of the protective varnishes and/or anti-release coating occurs prior to a definition of the labels in the label supply material layer.

11. The method according to claim 6, wherein a cutting module is provided to cut only the label supply material layer to define a final label format and/or form micro-perforations which are to be subsequently separated at the point of application of the label to the article via label applicator apparatus.

12. The method according to claim 1 wherein selvage, print waste and/or matric waste from the label supply material which is left after a definition of the labels in the same, is removed from the label supply material layer separately to the separation of the liner material layer.

13. The method according to claim 1 wherein the liner material layer is progressively stripped from the label supply material layer under tension in a rewinding apparatus.

14-15. (canceled)

16. The method according to claim 1 wherein smaller reels of the separated label supply material layer are formed simultaneously and located side by side with spaces between the same.

17. The method according to claim 1 wherein the separated liner material layer is rewound into a reel.

18. The method according to claim 1 wherein the liner material layer does not reach the location at which the labels are applied to the articles.

19. The method according to claim 1 wherein the label supply material layer is held secure by contact means to support the same during the separation of the liner material layer therefrom.

20. The method according to claim 1 wherein control parameters used to separate the layers are different to those used to allow the separation of a label from the linerless label supply material layer at the point of application to an article.

21. The method according to claim 1 wherein the separated liner material layer is formed into an adhesive tape with on a first surface a coating of release material and, on an opposing surface, a coating of an adhesive material.

22-25. (canceled)

26. A master roll of laminate produced by a laminate manufacturer, said master roll comprising: a label supply material layer which includes a surface for printing thereon, an opposing surface with a layer of adhesive, a liner material layer to which the label supply material layer is initially adhered in the master roll, a release system between the liner material layer and label supply material layer, and wherein said liner material layer and label supply material layer are separable and at least the label supply material layer is formed into a plurality of smaller reels for onward supply to one of more points of application of the labels therefrom to articles.

27. (canceled)

28. The master roll according to claim 26 wherein the separated liner material layer is formed into one or more reels.

29. The master roll according to claim 28 wherein the label supply material layer is slit, printed, released, coated and pre-weakened at a same location as that at which the same is separated from the liner material layer.

30. The master roll according to claim 26 wherein the liner material layer has a surface which is mechanically modified to provide lower surface energy so as to be separable from the adhesive of the label supply material layer at the separation step.

31. The master roll according to claim 26 wherein the liner material layer has a surface which is modified chemically so as to reduce surface energy and release chemistry is removable prior to the recycling of the liner material.

32. Apparatus for processing of a reel of label laminate, said apparatus comprising: a label supply material layer and a liner material layer onto which the label supply material layer is adhered, movement means which allow said liner material layer to act as a carrier for the label supply material layer as the laminate reel is moved to a point of separation of the label supply material layer from the liner material layer and wherein a location of separation of the label supply material layer from the liner material layer is intermediate a location of formation of the laminate and a location of a point of application of the labels defined in the label supply material layer to articles and, at the location of separation, the apparatus includes stripping means to strip the liner material layer from the label supply material layer and for winding and cutting at least the separated label supply material layer into a series of reels of a smaller width than the said laminate reel.

33-40. (canceled)

Description

[0067] Specific embodiments of the invention are now described with reference to the accompanying drawings wherein:

[0068] FIG. 1 illustrates a conventional method for the provision of a laminate and provision of labels to the point of application to articles;

[0069] FIG. 2 illustrates a method in accordance with the invention in one embodiment;

[0070] FIG. 3 illustrate an example of a conversion system and apparatus in accordance with the invention;

[0071] FIG. 4 illustrates a further embodiment of apparatus in accordance with the invention;

[0072] FIG. 5 illustrates the manner in which the different forms of laminates may be created for use in the current invention;

[0073] FIG. 6 illustrates a label defined in the label supply material layer in accordance with one embodiment of the invention;

[0074] FIG. 7 illustrates a label supply in accordance with a first condition in plan in accordance with an embodiment of the invention.

[0075] FIG. 8 illustrates the label supply of FIG. 7 in cross-section along line AA.

[0076] FIG. 9 illustrates an adhesive tape in plan in accordance with one embodiment of the invention.

[0077] FIG. 10 illustrates a cross-section through the adhesive tape of FIG. 9 along line BB;

[0078] FIG. 11 illustrates, in a schematic manner, embodiments of the formation of the label supply of FIG. 7 to the adhesive tape of FIG. 9; and

[0079] FIGS. 12a-d illustrate a further embodiment of a process in accordance with the invention.

[0080] With regard to FIG. 1, there is illustrated a conventional label laminate and this uses the provision of a master roll 2 of laminate which is produced by the laminate manufacturer and is typically of 2 metres or more width and includes a liner material layer which carries thereon, and which has adhered thereto, a label supply material layer.

[0081] The master roll 2 of laminate is then provided with cuts at intervals along its width to form a series of smaller reels 4 of laminate typically of 1 metre outer diameter and these reels are then supplied to a printer and label conversion company location at which the labels are printed on the laminate and then cut again into smaller reels of label laminate 6. Typically, during this process around 10% of the laminate is discarded. These smaller reels 6 are then passed to a “packer” company which then distributes the reels of the laminate to the company location or locations at which the labels are applied to articles to form, typically a retail package and the label supply material layer is conventionally separated from the liner material as the labels are applied to the articles. The liner material, which is now waste, is provided as waste reels 8 which can easily telescope due to the silicone release coating material. The aim is for these to be collected and transported for recycling but, in practice this rarely happens.

[0082] The current invention now overcomes this problem so as to create the significant improvement to the waste material footprint and laminate supply logistics, including also the possibility of new laminate types.

[0083] The first stage of the invention, as shown in FIG. 2, is again to provide a master reel 10 of laminate from the manufacturer and the master reel is cut into smaller reels 12 and supplied to the printer and convertor location and the separation of the label supply material layer from the liner material now occurs at this location. This therefore means that from the printer and convertor location there is provided reels 14 of linerless label supply material to the label application company location or locations. The liner material is now waste at this location and can be made available typically as a reel 16 which is not passed to the label application location but rather can be collected for recycling. It will therefore be appreciated that the size of the reel 16 of the waste liner material is greater and the number of locations at which reels of waste material are located is greatly reduced in comparison to the conventional method and so there is a greater likelihood for the collection and hence recycling of the waste liner material to be performed than in the conventional method.

[0084] The apparatus provided to allow the separation of the liner material from the label supply material layer can take several forms to suit particular requirements. The method introduces the separation of the lining material from the label material across the full width of the reel at the printer convertor location and then rewinding and separation techniques are used to ensure the linerless label supply material layer is secured into reels 14.

[0085] In FIG. 3 the reel 12 is provided at the converter location and face printed and a release coating layer 22 is applied thereto and any linear edge and shape waste of the label supply material is removed 24. An optional cylinder 20 is located at station 26 and this assists in the separation of the label supply material layer 28 to be formed into reels 14 of linerless label supply material for onward supply to the label application location. The separated liner material 30 is reeled to form the liner material waste reel 16. It is also illustrated how the reel 12 is progressively processed to provide the three paths 32, 34,36 of linerless label supply sheet material and each of which is wound to form a respective reel 14.

[0086] The addition of liner separation and winding to a press or offline finishing machine allows the label convertor, when producing conventional labels, to rewind this edge slip waste material separately from the liner material waste. Present methods generally back slit the edge liner and collect this trim with all matrix waste. The optional segment vacuum cylinder 20 as shown in an example of the apparatus in FIGS. 3 and 4 can be used as an alternative path guide for linear and liner material matrix waste removal when producing the linerless or conventional labels in upgraded apparatus. This example allows the transfer of the die cut and face waste stripped web to be controlled by vacuum segments 18 in the rotating cylinder 20 which hold the non-adhesive material by vacuum at certain locations. Thus, in different embodiments, the waste material can be separated from the label supply sheet material before or after the location of the vacuum cylinder. The specific locations at which the vacuum acts can be preset on the cylinder itself or can be defined to suit particular usage requirements, such as by applying tape or other blanking material onto the surface of the cylinder at those locations where the vacuum effect is not required. Thus, the pattern of the vacuum segments on the cylinder can be configured to align with the linear edge and shape label waste pattern of the laminate to ensure no loss of vacuum control of the individual linerless label supply material paths whilst still carried on the liner material. The liner material release surface, which may be exposed by removal of the linear strip waste before this rotating cylinder, is unaffected by the vacuum.

[0087] It is conveniently stripped over a full reel width peel plate before the supported label supply material exits the vacuum segment. This label supply material may retain the linear strip waste now separated at this same cylinder as the linerless label supply material paths are directed toward the reel winding. The method thus frees the linerless label supply material from vacuum control after the vacuum segment and after the full width stripping of the liner material and can be re-wound under the lower reel tension best used for all self-wound linerless label supply material reels.

[0088] These alternative embodiments ensure that the lines of weakening which are created by the micro-perforations in the label supply material layer in order to define the labels are not stressed as the liner material layer is stripped from the label supply material layer using the peel plate or a driven path roller alternative.

[0089] This ensures that the production of label supply material and PS adhesive and the volume of production is still viable.

[0090] FIG. 5 illustrates the manner in which the different forms of laminates may be created for use in the current invention. Laminate 40 is a conventional laminate which includes a label supply material layer of paper or film 42 which meets the required stiffness parameters, a pressure sensitive adhesive 44, a high speed silicone release layer 46 and a liner material layer of paper or film 48.

[0091] In accordance with the invention embodiments of alternate laminates 50 could be used, one of which includes a label supply material layer in the form of a thinner face paper or film 52 and a low coat weight adhesive layer 54 with a liner material layer 58 and a release coating 56 which is particularly suited for recycling purposes.

[0092] The impact of this method supports logistics innovation and potentially means that brands do not have to evaluate and approve new face materials and adhesives in order to adopt the change to linerless labels which frees them of waste and increases their efficiency. It is anticipated that the supply of linerless label supply material to the label application locations should have no significant impact as the majority of production lines can conveniently adapt label applicators to a linerless format whilst running down existing stocks and change artworks in the usual cycle and in a climate of heightened waste concerns, the incentives are significant.

[0093] The change to linerless conversion is far less complex with a printer convertor and does give additional impetus to an industry trend to separate web printing and final converting. The growth of Just in Time digital printing has contributed to overall laminate material savings by faster setups but has not eliminated the generation of liner waste at the point of application of labels to the articles and hence the continued low recycling rates.

[0094] Laminate suppliers are unaffected as a first response to a packer and brands of created PS linerless is a need for the printer to add a waste liner stripping and re-winding it before existing label reel winding systems are to advantageously upgrade this. When completed, the benefits of liner waste collection for enhanced recycling logistics is immediate.

[0095] For the label printer, linerless label supply material conversion is far less complex than the previous options described. The full range of adhesives are supplied as specified to meet all current label applications and most labels are protected by varnish and substitution by a silicone modified release alternative is practical. Die cutting is conventional and has a significant benefit over laminate to linerless as the liner is stripped and is no longer required for label application and so minor damage to the liner will not create quality related waste.

[0096] For the laminate supplier, the fully recovered volume of liner increases the potential to increase the mix of recycled material in the supply to advantage. The inventive methods introduce potential for new laminate constructions which can be produced by the laminate community on their own current assets with minimal investment and which can now be more specially designed for recycling.

[0097] Laminates with reduced face material 52 are provided to exploit the fact that linerless label application methods do not require the stiffness of a conventional label, laminates with the reduced specification of paper release liner can exploit the fact that this liner is now used only as a carrier and the protection of the material facing adhesive, laminates with release functionality changes exploit the fact that release now only relates to stripping the liner from continuous webs of labels, both under controlled tensions.

[0098] In accordance with the invention, the liner and the webs of linerless labels all of which are continuous, are separated under tension which must exceed the release value in the liner release coating. Assistance may be required to ensure that the labels within these webs do not separate under any increased release force.

[0099] Laminates with reduced adhesive coating weights of 12 micrometres or less can exploit the fact that the current degree of protection in die cutting is reduced and the thinner faced materials or the PS linerless labels require less adhesive to be secured to the container or package.

[0100] The substitution of silicone as a release layer coating by, for example, a coating which can be washed off by water prior to final re-pulping of the waste papers aids the recycling process further. Filmic liners without silicone coating using slip agents or alternatives to silicone may be reground and reprocessed conveniently.

[0101] The recycling of liner material is therefore encouraged with the printer/converter now responsible for the waste effectively originated by the laminators and avoids the conventional complex logistics of more than one printer supplying a brand and which is a significant reason why conventionally less than 10% of liner material waste is recycled in well-developed markets. This encourages improvements to the final removal of labels from containers and packages for package recycling.

[0102] As illustrated in FIG. 6 disguised label faced cut patterns of cuts or slits 62 in the label supply material layer 60 which can be provided adjacent or within printed images on the label supply material layer means that the cuts or slits are not readily apparent to the purchaser or user of the article to which the labels are applied. The cuts or slits 62 are imposed to be parallel to the direction of movement 64 only and these cuts are therefore not stressed in label separation from the liner or when the label is applied. The cuts or slits 62 improve wash off processes to allow penetration to the reduced adhesive layer to advantage. Furthermore, the provision of simplified die cutting lines or weakening for the linerless label supply sheet material will encourage brands to exploit the anti-counterfeit feature available by periodic changes to the patterns of micro-perforations between catchpoint format labels. Minor, almost invisible change to these patterns and any surface slits only require die tool changes and the improvements secured by the methods and new laminates will be commercially attractive compared to many anti-counterfeit alternatives.

[0103] Referring now to FIGS. 7 and 8, there is illustrated a label supply 102 in accordance with a first condition in accordance with a further embodiment of the invention.

[0104] The label supply comprises a liner material layer 104 which acts as a liner and has a surface with a release material 106 applied thereto and, on the opposing surface, a layer of adhesive material 108 is applied thereto, or is subsequently applied thereto.

[0105] A label supply material layer 110 is provided in which a plurality of labels 112 are defined, typically at a conversion location by cut lines 114 to form a label matrix as shown and/or the application of printing. The said label supply material layer 110 has an adhesive material 115 and this is applied to the release coating 106 of the liner material layer 104 so as to form the label supply which, typically, is wound into a roll form for transport to the conversion location.

[0106] As shown in FIGS. 9 and 10, the separated liner material layer 104 has the release layer 106 forming the “top” surface and on the opposing surface adhesive material is applied and thereby forms an adhesive tape 122. There is also shown a broken line 121 which indicates that at the stage of separation of the liner material layer 104 the same can be cut along it's length to form two, or more, reduced width adhesive tapes 122,122′ but this step is optional and a decision can be made with regard to the width 123 of the liner material layer 104 and the desired width of the adhesive tape which is to be formed.

[0107] Turning now to FIG. 11 there is illustrated in a schematic manner several options of the process of the current invention. A first stage 116 is to produce the label supply and then a second stage is to convert the label supply typically by cutting and/or printing at stage 118 into the form shown in FIGS. 7 and 8. When the label supply is formed it will typically be formed into a roll for storage and/or transported to the label printer 118 and in one embodiment may already have adhesive material applied thereto and which may be activated to a PS function by the label printer as the liner material layer is processed and slit into typical tape widths of between 20 mm to 70 mm and then formed into reels. It is envisaged that the unwinding of these reels of tapes for subsequent use would be no different from conventional reels of adhesive tapes.

[0108] As an alternative to providing the adhesive on the liner material layer at the laminating stage, the adhesive may be applied at the time of removing the liner material layer from the label supply material layer, typically at or just after the label printing stage, such as, for example, via a hot melt coating apparatus.

[0109] Furthermore, the provision of PP liner material with, for example, a plasma release coating will function as the release from the adhesive.

[0110] Once the tape 122 has been formed there are a number of different options available in accordance with the invention.

[0111] A first option, indicated by broken line 120 is for the adhesive tape 122 to be moved directly to a point of use. The tape, if necessary, can be moved past activation means 124 which are designed to apply heat and/or pressure and/or any other means necessary to activate the adhesive 108 to cause the same to have adhesive characteristics and hence allow the adhesive tape 122 to be applied in the required manner. It should be appreciated that the specific activation means which are used will be dependent upon the particular adhesive used. In this embodiment the activation can take place at or adjacent to the label conversion apparatus 118 or the adhesive tape application apparatus 126 via which strips of the adhesive tape can be separated and applied in a conventional manner to articles. Alternatively, the adhesive layer can be applied to the tape at this stage.

[0112] In an alternative embodiment indicated by broken line 128 the adhesive tape 122 can again be passed to adhesive activation or adhesive application means 124. However rather than apply the tape at this stage the adhesive tape reel is moved to storage 130 and then moved from storage 130 to the adhesive tape application apparatus 126 and applied.

[0113] A third option, indicated by broken line 132 is for the adhesive tape 122 to be wound into a reel at stage 134 and then moved to storage 130 and, once removed from storage for use, the tape 122 is moved past activation means 124 to activate the adhesive layer 108 at that stage and then moved to adhesive tape application apparatus 126 for the application of strips of adhesive therefrom. In whichever embodiment the filmic material used for the liner material layer can be changed to the initial monomers of the material to thereby aid subsequent recycling or reuse of the material. There is therefore provided a cost effective method of recovering the liner material layer. Furthermore, it allows the liner material layer to be economically, and with reduced transport requirements, collected and recovered in relatively large quantities at the location at which the liner material layer is separated from the label material layer, typically at the label convertor location rather than the final label application location, and at which quantities of the liner material would be relatively small and, as a result, uneconomical to collect. This is particularly important with regard to technology which is rapidly emerging that will allow the cost effective recycling of plastics, such as PET, and which will allow, for example, PET liner material to be recovered, depolymerized and then repolymerized to form virgin PET. This will enable a truly circular economy so that in effect the liner material layer will be used over and over again, with only the relatively thin silicone release layer being consumed each time. This solution depends on a cost effective route to recovery of the liner material layer and which is now provided in this invention as the current invention allows recovery of the liner material layer at an intermediate location, such as at the label supply convertor location, which is a much more concentrated location as the converter location typically serves 100+ label application locations, and therefore the level of liner material now removed at the converter location is much greater and the number of recovery locations is much reduced. and makes the prospect of recycling economically viable

[0114] FIGS. 12a-d illustrate a further embodiment of a process for reusing the liner material layer in accordance with the invention.

[0115] In FIG. 12a there is shown the initial printing stage 202 on the reverse face 214 of a clear filmic label supply material layer 206 as currently completed by some label converters in high speed printing units at 1 metre web widths 204. This print process enables the use of metallic inks for high quality decorative effects without the waste associated with conventional foiling techniques. In FIG. 12b the printed label supply material layer 206 is passed from the roller 208 to move the same into a conventional laminate label supply 216 and the conversion is improved over the conventional method by use of a pre-siliconized PET material layer 210 and coating a high speed release silicone 212 on the open face of label supply material layer 206, and coating a clear pressure sensitive 218 on top of the original PET pre-siliconized liner and laminating the liner material layer 210 to the printed face 214 so as to create the laminate label supply 216 ready for die cutting to form conventional labels and which also causes the layer of adhesive to transfer to the face 214 of the label supply material layer.

[0116] This process now uses a repeated reused pre-siliconized PET liner material layer 210, and as a result changes the silicone coating capacity to coat the face of the printed label supply material layer 206 as well as adding the same clear PS adhesive. By this means the process creates the release surface of the final Linerless label and allows the pre-siliconized liner material layer 210 to be removed for reuse as shown in FIG. 12c in which the liner material layer 210 is separated from the label supply material layer 206 at location 220 and the liner material layer 210 is returned to be reused for a new laminate as indicated by arrows 222 at the stage shown in FIG. 12b.

[0117] The die cutting of the conventional labels in the label supply material layer 206 is typically in 500 mm wide webs and hence the original 1 meter wide laminate is slit into two widths 226, 228 at location 224 and moved onto separate reels before the die cutting process and finishing of the conventional labels in typical slitter rewinds.

[0118] FIG. 12d details the linerless label alternative in accordance with the invention and in a new conversion process the original 1 meter wide pre siliconized PET liner material layer 210 is separated for continual reuse and only the label supply material layer 206, now coated with a release layer is slit. Within the new conversion the separated label supply material layer 206 with the adhesive layer thereon is slit to form the two widths 226, 228 and is laminated onto 500 mm wide reels of other reels of reused PET siliconized liner which carries the label supply material layer portions 226, 228 through the die cutting process 230 to impose shape and or micro-perforation patterns before the liner material layer 210 is separated and the now linerless label supply material layer portions 226, 228 are independently wound into reels. This secondary use of a pre-siliconized liner allows similar frequent reuse in the final die cutting process and the new conversion process delivers the efficiency of Linerless labels in high volume markets whilst retaining proven decorative appeal.

[0119] There is therefore provided in accordance with the invention a method and apparatus for the re-use and/or recycling from label supply liner material and which therefore utilises material which otherwise would be treated as waste and to achieve the same without the need for the application of any material to the labels stock following the formation of the same. Furthermore, in terms of recycling, this means that the liner material if used as an adhesive tape and applied to cardboard boxes for example, would be a part of cardboard waste which is classified as packaging waste where European regulations do not restrict movements between countries, as compared to special waste which the liner waste material, if on its own, could be classed as and in which case significant documentation and time is required. The invention also adds the advantage that the liner material does not need to be collected for recycling, as it is “Reused”