Die-Cutting Quality Depends on Pressure-Sensitive Label Face Material Traits

2025-01-13 23:26:50

Good or Bad Die-Cutting Quality: Recognizing the Key Face Material Properties of Pressure-Sensitive Labels!

The quality of die - cutting of pressure - sensitive labels is closely related to many factors, such as the method of die - cutting, the accuracy of the die - cutting equipment, and the compatibility of the die - cutting blades with the materials. Also, there are many types of pressure - sensitive label materials, which are different combinations of various face materials, adhesives, and liner papers, so their die - cutting properties are different.

PART.01 Types of Face Materials
In the pressure-sensitive labeling field, common face materials are paper and film. The cutting principle for paper-based face materials differs slightly from that of film-based ones. Theoretically, die - cutting should cut through the face material and adhesive. But in practice, die - cutting paper - based face materials combines tool cutting and paper breaking. The tool cuts downward and squeezes the paper sideways, causing it to break when stressed. So, the die - cutting accuracy of paper-based face materials is relatively low. When analyzing samples, we often see labels with burrs and tears. This is due to the material's coarse fibers and natural breakage. Considering paper-based face materials' die - cutting characteristics and tool wear, flat - bed die - cutting blades usually have a 52° angle. A larger angle increases material deformation and horizontal separation force, worsening breaks. Some think cutting to two - thirds of the paper thickness is enough, but this can cause waste removal problems and adhesive leakage.
So, it's better to fully cut through the face material and adhesive. Film - based face materials must be completely cut through. They are mostly tough and won't break naturally. The theory of cutting two - thirds doesn't apply here. If not fully cut, waste edges will strip with the label. Die - cutting film - based face materials requires sharp, hard blades with a small angle (30° - 42°). Large - angle blades make die - cutting hard. If the blade isn't sharp, the face material may not cut, but the liner paper might break first. Also, finished labels may have edge flanging and adhesive leakage. In summary, film - based face materials require higher die - cutting accuracy, so the equipment, die - cutting plates, and liner paper must meet certain standards.

PART.02 Face Material Strength
Face material strength relates to its thickness, fiber (resin) structure, and moisture content. In pressure-sensitive label die-cutting, face material strength mostly affects waste removal speed, which concerns production efficiency. Label printers aim for high waste removal speeds. Also, material moisture content affects strength. Higher humidity weakens the material, causing breaks and preventing waste removal.
So, controlling the temperature and humidity of production and storage is crucial. When designing layouts, besides considering graphics, arrange label waste removal size and speed based on material strength through testing. This boosts efficiency and reduces waste.

PART.03 Face Material Thickness
Material thickness affects die - cutting depth. Thicker materials are easier to die - cut. They have a larger die - cutting tolerance and a lower chance of cutting through the liner paper. Thinner materials are more prone to liner paper cuts. An experiment on a flat - bed label die - cutting machine die - cut two face materials with the same liner paper but different weights. The thicker material had normal waste removal, while the thinner one had breaks, liner paper cuts, and label drops. When facing such problems, many label printers often stop and adjust the machine by padding the plate, wasting time and materials. Several factors can cause this. Using rotary die - cutting, reducing the die - cutting area, or employing high - precision equipment can help avoid or reduce this.
So, when die - cutting thin face materials, use high - precision equipment, minimize the die - cutting area (especially for small labels), and use die - cutting plates from professional manufacturers. Also, pay attention to the padding plate's precision.