Multi layer Labels, Making Them Easy Without Limits...

A product label’s size is often restricted by the physical size of the product itself, but what if the label needs to tell a much larger story? The benefit of multi layer labels is that it solves the need for more content space. Multi layer labels peel back cleanly with no adhesive residue to a hinge, exposing more layers for content. The label can then be resealed.

You see these commonly on pharmaceutical and medical labels where regulations require product information remain intact with the product. Food labels can add recipes. They are also used to promote sweepstakes, give multilingual information, introduce new products, and for coupons.

Traditional processes used to make these labels have inherent problems and limitations compared to using the Servo 3000 process. There is a high level of difficulty. The press operator has to register the colors on two webs simultaneously and then register both webs together. Set-up waste and running waste are high while press speeds are low.

The limitations are the number of colors that can be used. A typical press may have six to eight print stations. These must be split among the number of printed panels, resulting in a few colors per panel.

Using the Servo 3000 is more efficient through the use of automation. The number of press colors automatically double because the top layer is pre-printed. The Servo 3000 allows the pre-printed layer to automatically be laminated in register to the base layer.

The benefits are the operator is only registering one web at a time while the Servo 3000 performs the complex task.
Set-up waste and running waste are low while press speeds are high. Even though the top layer is pre-printed, the total press time may be lower due to increased press speeds. Even greater efficiencies are realized when considering reduced material waste.

The steps in making multi-layer labels using the Servo 3000 are simple and efficient. The top layer is printed first. The press speed is only limited by drying since there is no diecutting or matrix stripping in this step. The top layer may even be printed on another press.

Make ready the base layer. Put the top layer roll on a lamination tower and web it through the Servo 3000. The two layers can be put together by using a clear laminate or by printing adhesive on the base layer. The nip point where the two webs come together can be a mid-feed nip, or a die station may be used.

Use the Servo 3000 to adjust the top layer to be in register to the base layer. Once set the Servo 3000 will automatically hold that position. Diecut and stripe as normal; it’s just that easy.

Another factor when comparing these processes is that the traditional process requires additional equipment to accommodate the second web. The extra equipment is only used when making multi-layer labels. The Servo 3000 can be used on every job to improve press register and lower material waste, but that is the subject for the next newsletter.