Die Cutting in PSA Labels: From Stan Avery’s Innovation to Modern Laser Technology-Part 4

Die Cutting in PSA Labels: From Stan Avery’s Innovation to Modern Laser Technology-Part 4

Storing Magnetic Cylinders and Dies: Best Practices

Proper storage and handling of magnetic cylinders and dies directly impacts their service life and the quality they deliver. These precision tools represent significant capital investments that deserve appropriate care.

Magnetic cylinder storage begins with cleanliness. Before storage, cylinders must be thoroughly cleaned to remove any adhesive residue, ink deposits, or debris. Even microscopic contamination can attract moisture, leading to corrosion that damages the precision-ground surface. A light coating of rust-preventive oil protects the surface, though this must be removed before the cylinder returns to service.

Environmental control is critical. Magnetic cylinders should be stored in a temperature and humidity-controlled environment, ideally between 18-24°C and 40-60% relative humidity. Rapid temperature changes can cause condensation that leads to corrosion. The storage area must be free from magnetic interference sources that could demagnetize the embedded magnets, reducing their holding force. Magnetic cylinders should be ideally stored with protective covers to prevent surface damage, and when not in use for short periods, pressure should be released to maintain precision tolerances. Cylinders should be stored on padded racks or in protective cases with soft linings. The precision-ground surface must not contact hard materials or other cylinders, as even small dents or scratches translate into cutting defects. Cylinders stored vertically minimize bending stress that could compromise roundness tolerances. In India and largely people use open racks to store.

Flexible die storage requires protecting thin, precision-etched steel from damage. Dies should be stored flat, never rolled, as rolling can permanently deform the cutting edges. Individual dies should be separated by protective sheets to prevent edge-to-edge contact that could chip cutting blades. Silicone release paper or polyethylene foam works well for separation.

Organization and identification are equally important. Dies should be clearly labeled with job information, date of manufacture or last use, and any specific setup parameters. This documentation prevents errors during setup and helps track die life and performance. Many converters maintain logbooks recording die usage, and performance notes to optimize die management and predict replacement timing.

Climate control for die storage parallels cylinder requirements. Steel is susceptible to rust, and even stainless-steel alloys used in some dies can corrode under adverse conditions. The storage environment should maintain stable temperature and humidity with adequate air circulation to prevent moisture accumulation.

Handling procedures matter as much as storage conditions. Dies and cylinders should be handled with clean, lint-free gloves to prevent skin oil contamination. Dropping or bumping precision tooling causes damage that may not be immediately visible but will manifest as quality defects during production. Magnetic cylinders should be checked for surface condition and magnetic field strength.

Additional Considerations in PSA Label Production

The pressure-sensitive adhesive label industry encompasses far more than die cutting alone, though die cutting remains a critical converting step that influences every aspect of label performance and quality.

Sustainability has emerged as a dominant concern. The label industry is working toward reduced material consumption through thinner liners, no-liner label technologies, and improved matrix efficiency. Die cutting plays a role through precision cutting that minimizes waste and enables thin liner applications. Some converters report matrix waste percentages below 15% through careful label design optimization and precision die cutting.

Quality control increasingly relies on vision inspection systems working in concert with die cutting stations. Cameras can detect incomplete cuts, die-strike damage, registration errors, and edge quality defects in real-time, triggering automatic press stops before significant waste accumulates. This integration of die cutting with automated quality verification represents a significant advancement over manual inspection.

Automation continues to transform label converting. Automatic die changes, powered by robotic systems or quick-change mechanisms, reduce setup times from 30-45 minutes to under 10 minutes. Automatic job changeover systems, fed by production scheduling software, sequence jobs to minimize die changes and setup time. These technologies are making short-run production increasingly viable, expanding the addressable market for pressure-sensitive labels.

Digital integration connects die cutting with upstream design and prepress systems. Label designs are created with die cutting constraints built-in, ensuring manufacturable shapes and avoiding features that would create matrix removal problems. Digital twin simulations can predict die cutting performance before physical production, reducing trial-and-error during setup and accelerating new product launches.

Future developments in die cutting technology continue to evolve. Research into laser-induced plasma cutting promises speeds approaching mechanical die cutting while maintaining the flexibility of digital systems. Ultrasonic cutting, using high-frequency vibration to assist mechanical blades, shows potential for difficult-to-cut materials. Water jet cutting, common in other industries, is being investigated for specialized label applications.

The pressure-sensitive label industry has traveled an extraordinary distance from Stan Avery’s first self-adhesive label produced in that flower shop loft in 1935. Today’s sophisticated converting lines, producing millions of precisely die-cut labels per day at speeds that would have seemed impossible even a decade ago, stand as testament to continuous innovation and refinement. Yet the fundamental principle remains unchanged—a precision cutting tool separating labels from their backing, enabling the convenience and functionality that pressure-sensitive labels bring to virtually every product we encounter in daily life.

The journey from flatbed presses cutting a few thousand labels per hour to modern rotary systems achieving 300 meters per minute represents not just technological advancement but a transformation in what’s economically and practically possible in product labeling. As laser systems mature, digital workflows integrate, and automation advances, the die cutting component of label converting continues to evolve. The future promises even greater flexibility, faster changeovers, and capabilities we’re only beginning to imagine.

For those of us who have witnessed the Indian label industry’s growth over decades, from its nascent beginnings to becoming a sophisticated, globally competitive sector, the technological journey of die cutting mirrors our own industry’s maturation. The precision, efficiency, and innovation embodied in modern die cutting systems reflect the same qualities that have driven successful label converters to build world-class operations capable of serving the most demanding brands and applications.

Written by Harveer Sahni, Chairman Weldon Celloplast Limited, New Delhi, April, 2026

Die Cutting in PSA Labels: From Stan Avery’s Innovation to Modern Laser Technology-Part 3

Die Cutting in PSA Labels: From Stan Avery’s Innovation to Modern Laser Technology-Part 3

Die Cutting’s Impact on Matrix Removal and Rewinding

The die-cutting process extends beyond simply making cuts in the label material. Subsequent operations, including matrix removal—stripping waste material from finished labels—and rewinding the completed label roll, are directly influenced by the quality and parameters set during die cutting.

Matrix Removal: Challenges and Efficiency

Matrix removal difficulty is closely tied to blade height and cutting depth. When blades cut deeply into the liner, a pronounced score is left, which can make peeling the label easier. However, this can also lead to liner tearing during matrix stripping at high speeds. Balancing ease of label peeling with maintaining matrix integrity requires careful optimization, considering the specific application and production speed requirements.

Matrix removal efficiency depends on producing clean and complete cuts. If the die blade lacks sharpness or the cutting pressure is too low, labels may not separate cleanly from the matrix, resulting in tearing during stripping. Such issues generate waste and slow down production as operators must clear jams.

The shape of the label affects matrix removal as well. Small interior cuts, sharp corners, tight radius corners, and thin connecting strips in the matrix are more susceptible to tearing during stripping if die cutting is not precise. Dies should be designed with matrix removal in mind, sometimes incorporating relief cuts or modified geometries to reinforce the matrix in its most vulnerable areas.

Stripping Tension and Liner Integrity

Stripping tension needs to be carefully managed. If tension is too low, the matrix can bunch or fold, leading to unreliable stripping and potential web breaks. If tension is too high, labels may be pulled partially free from the liner if the kiss cutting depth is shallow, resulting in defects in the finished product.

Liner integrity after kiss cutting has a significant impact on rewinding quality and downstream performance. Liners deeply scored by excessive die penetration are more likely to break during rewinding, especially at the edges where tension is concentrated. This can cause production stops and waste. Even if the liners withstand rewinding, too much die-strike damage may result in failures when the label roll is unwound in applicators.

Edge Quality and Rewinding

Edge quality from die cutting influences how well labels are rewound. Rough or stringy edges can catch on to adjacent wraps as the roll builds, leading to telescoping (uneven roll sides) or starring (radial compression lines visible on the roll face). These defects compromise roll quality and may cause applicator problems when the labels are used.

Rewind tension control must consider the residual stresses introduced during die cutting. Materials stressed during cutting may display different tension characteristics compared to uncut material. Tension compensation is needed as the roll builds to maintain uniform roll density and prevent defects.

Diverse Types of Dies for Specialized Applications

Beyond the use of standard flexible and solid rotary dies, the label industry employs an array of specialized die types to meet the specific requirements of various applications and materials. These alternatives allow converters to address unique production challenges and enhance efficiency in niche scenarios.

Adjustable Dies

Adjustable dies are designed with removable blades, which can be replaced when worn or when different materials need to be processed. While less frequently used in narrow-web label converting, adjustable dies offer valuable flexibility for converters working with a wide variety of substrates, eliminating the need to keep extensive inventories of dies for each material type.

Combination Dies

Combination dies integrate multiple cutting functions into a single tool. For example, a combination die might feature both cutting and creasing blades, enabling the production of folding cartons or multi-panel labels in one pass. Perforation blades may also be included to create tear-off sections or features for easy opening. By consolidating several processes into a single die station, combination dies reduce the number of stations required, shorten setup times, and can improve registration accuracy by completing multiple operations in one controlled step.

Embossing and Debossing Dies

Embossing and debossing dies produce three-dimensional effects in label materials, enhancing visual appeal or providing tactile security features. These dies function through matched male and female patterns and require precise pressure control to ensure consistent depth without damaging the substrate. For embossing applications, magnetic cylinders with enhanced holding force are used to maintain die alignment under the substantial pressures involved.

Hot Stamping Dies

Hot stamping dies are used to transfer metallic or pigmented foils onto labels using heat and pressure. Although they are not cutting tools themselves, hot stamping cylinders are often integrated with die cutting stations for inline processing. These cylinders must manage both accurate temperature control and the mechanical requirements of maintaining the die or foil pattern in precise registration.

Perforation Dies

Perforation dies are engineered to create lines of weakness in materials, facilitating controlled tearing. The blades are precisely spaced, with cutting edges separated by gaps to produce an alternating cut-and-uncut pattern. The ratio of cut to tie length determines the ease of tearing and must be carefully designed for each application and material.

Micro-Perforation Dies

Micro-perforation dies refine the perforation process to produce nearly invisible perforations that still allow clean tearing. These dies are suited for security applications, pharmaceutical labels, and other situations where the perforation must remain hidden until use.

Normal vs. Laser-Hardened Dies

Choosing between standard dies and laser-hardened alternatives is a critical decision for label converters, balancing economic and performance factors.

Standard Dies

Standard dies are made from tool steel, CNC-machined to precise specifications, and heat-treated using conventional methods to achieve hardness levels between 52 and 58 HRC. These dies are reliable and cost-effective for many applications, making them ideal for short runs, prototyping, or processing less abrasive substrates. However, their limitations become apparent during high-volume runs or when converting abrasive materials such as thermal papers, thermal transfer stocks, or certain films. The cutting edge of standard dies gradually wears down and becomes rounded, which requires increased cutting pressure or slower line speeds. Eventually, dies must be re-sharpened or replaced, impacting productivity and increasing costs.

Laser-Hardened Dies

Laser-hardened dies employ focused laser energy to selectively harden the cutting edge, achieving hardness levels of 65-68 HRC, and up to 80 HRC for specialized chrome-coated versions. The laser hardening process creates a shallow, hardened zone at the cutting-edge tip while retaining normal hardness in the rest of the die for flexibility. This selective hardening significantly extends die life, sometimes by two or three times compared to conventional dies, reducing tooling costs per thousand labels produced. The harder edge stays sharper longer, ensuring consistent cutting quality and less frequent die changes or press adjustments. The hardened surface also reduces friction and adhesive buildup, preserving cutting quality and cleanliness. For converting abrasive thermal materials, laser-hardened dies may be the only practical option for achieving satisfactory production runs without constant maintenance.

Economically, laser-hardened dies are favored for high-volume applications. Although their initial cost may be significantly higher, their extended life and reduced downtime offer a compelling return on investment when producing millions of labels. Standard dies remain a better choice for short runs or frequently changing designs, given their lower upfront cost.

Alternative Die Cutting Technologies

While rotary die cutting is the mainstay of label production, alternative technologies are increasingly important for specialized applications and are gaining market share.

Semi-Rotary Die Cutting

Semi-rotary die cutting blends elements of flatbed and rotary systems. The web advances intermittently, while the die rotates. This hybrid mechanism enables fast changeovers and digital registration, making it ideal for digital-flexo hybrid presses where variable data printing is combined with die cutting. Although slower than full rotary systems, semi-rotary die cutting offers flexibility valuable for short runs and custom labels.

Laser Cutting: The Future of Label Die Cutting?

Laser cutting technology has advanced greatly, now serving as a viable alternative to conventional die cutting for many uses. It utilizes a focused laser beam to cut or perforate materials through controlled ablation and vaporization.

CO2 Lasers

CO2 lasers, operating at a 10.6-micron wavelength, are most used for labels, effectively cutting organic materials like paper, PET films, and polypropylene. Fiber lasers, working in the near-infrared spectrum, are gaining popularity for metallized materials and multi-layer constructions.

Laser cutting provides several advantages. Without the need for physical dies, setup times are reduced dramatically, and new patterns can be loaded within seconds. This makes laser cutting ideal for very short runs or custom labels where die costs would otherwise be prohibitive. Digital files allow for rapid design, iterations and customization, supporting personalized packaging and limited-edition products. Laser cutting delivers exceptional precision, enabling features as small as 0.1 mm and positional accuracy measured in microns. Complex shapes, small text, micro perforations, and other demanding features can be executed digitally with consistent quality.

However, laser cutting has limitations that prevent it from taking over high-volume label production. Speed is the primary constraint; even the fastest laser cutters lag behind rotary die cutting in throughput. Complex shapes further slow the process, making laser cutting less attractive for intricate designs despite its precision. Material compatibility also poses challenges. Some materials may release toxic fumes or reflect laser energy, making them difficult to cut. The heat-affected zone around laser cuts can cause discoloration or melting, impacting aesthetics or peel characteristics.

Operating costs for laser systems include high electrical consumption, regular replacement of laser components, and advanced exhaust systems to manage fumes and vaporized material. These costs must be considered when comparing economics to conventional die cutting. Despite these challenges, laser cutting is well-suited for security labels, pharmaceutical serialization, prototyping, and ultra-short runs. Hybrid systems that combine digital printing and laser cutting are expanding options for brand owners seeking customization.

Plotter-Type Die Cutting: Speed and Capabilities

Digital plotter cutting systems use a computer-controlled knife or blade, guided by digital patterns. The cutting head moves along X and Y axes, with blade depth controlling penetration, enabling kiss cutting, through cutting, or creasing. Modern plotter systems can achieve speeds up to 60-80 meters per minute for simple shapes, though complex cutting paths reduce throughput. Their advantage lies in flexibility—job changeovers require only loading a new digital file rather than changing physical tooling.

Plotter systems excel in prototyping and short-run production. Design firms and brand owners can quickly produce physical label samples from digital artwork, accelerating product development. Custom labels in small quantities are economical without traditional die setup costs. Registration capabilities have advanced through camera-based systems that read registration marks, automatically compensating for printing variations and keeping cuts aligned. Some systems can even adjust for material distortion or skew, ensuring precise cutting.

Plotter cutting is compatible with many materials, though extremely stretchy materials may deform rather than cut cleanly, and abrasive materials can accelerate blade wear, requiring frequent replacement and increasing costs. Plotter systems are economically superior for runs below 5,000-10,000 labels, where die costs are the largest expense. As volume rises, slower speeds and higher per-unit costs make rotary die cutting more practical. The crossover point depends on label complexity, material, and die life expectations.

Hybrid workflows that combine digital printing and plotter cutting are enabling new business models, such as print-on-demand label services with no minimum orders or tooling charges. Variable data capabilities allow each label to be unique, supporting serialization, personalization, and limited-edition launches.

Written by Harveer Sahni, Chairman Weldon Celloplast Limited, New Delhi, April 2026

Die Cutting in PSA Labels: From Stan Avery’s Innovation to Modern Laser Technology-Part 1

Die Cutting in PSA Labels: From Stan Avery’s Innovation to Modern Laser Technology-Part 1

The pressure-sensitive adhesive labels industry owes its existence to a struggling clerk working in a loft above a flower shop in downtown Los Angeles. In 1935, Ray Stanton Avery, who went by name Stan, was living in near poverty, residing in a rented chicken coop while working at the Midnight Mission to pay his way through college. What he created with a $100 loan from his fiancée Dorothy Durfee would transform how products are labeled worldwide and launch an industry that today generates billions in revenue.

The Genesis: Stan Avery’s Revolutionary Label

Stan Avery didn’t just invent the self-adhesive label, he invented the entire machinery to produce it. Using parts from a washing machine motor, a sewing machine, and a saber saw, he created and patented the world’s first self-adhesive, die-cut labeling machine. His company, initially named Kum Kleen Products, advertised the ability of these labels to be removed without leaving a mark on merchandise. The first Avery labels were simple, round price stickers meant for gift shops and retailers. In his first six months of operation, sales totaled a modest $1,391. Few could have imagined that this humble beginning would evolve into Avery Dennison, a Fortune 500 corporation with global operations across more than 50 countries and 36,000 employees worldwide.

The innovation Stan Avery brought to market solved a fundamental retail problem. Before pressure-sensitive labels, merchants relied on gummed labels that required moistening with water or paste, a time-consuming and messy process. Avery’s self-adhesive labels eliminated this inconvenience entirely, creating a faster and more practical labeling solution. His vision extended beyond the label itself to include the machinery for precise die-cutting, which would become the foundation of label converting technology.

By 1940, Avery had moved beyond his humble beginnings and officially started selling his products under the brand name Kum Kleen Price Stickers. The company incorporated in 1946 as Avery Adhesive Label Corporation, and in 1990 merged with Dennison Manufacturing to form Avery Dennison. Throughout his career, Stan Avery received 18 patents for his innovations in pressure-sensitive materials and production technologies. His legacy lives on, not just in the company that bears his name, but in every self-adhesive label produced today.

The Evolution of Die Cutting Technology

Die-cutting itself predates Stan Avery’s innovation by nearly a century. The process was invented in the mid-1800s to help the shoemaking industry. Cutting leather soles for shoes by hand was laborious, time-consuming, and expensive. The invention of the die-cutting machine revolutionized cobbler work, allowing shoes to be cut to consistent sizes and shapes rather than crafted individually. This standardization enabled modern shoe sizing as we know it today.

Flatbed Die Cutting: The Foundation

The earliest die-cutting machines used in the label industry were also flatbed presses. These hydraulically operated machines use a steel rule die to “click cut” or punch out die-cut parts by driving the die in a downward motion through the material. The flatbed die-cutting press operates much like a stamp, pressing a flat die onto material that sits on a stationary surface, applying even pressure to cut the material into the desired shape with each strike.

Flatbed dies are used with hydraulic or mechanical presses and other lifting systems to press a die down on a sheet of material. They are particularly suited for heavier materials and thicker substrates, making them less ideal for pressure-sensitive labels but excellent for applications requiring precision cutting of rigid materials. Steel-rule die cutting uses a formed strip of hardened steel set into a slotted plywood die-board, with rubber ejectors aiding part release after the cut.

While flatbed die cutting adapted for labels, offers excellent control over each cut and is ideal for intricate shapes with close tolerances, it operates at a considerably slower pace compared to rotary systems. Typical speeds range from 1,000 to 5,000 cycles per hour, making it suitable for small or mid-sized batches but impractical for high-volume label production. The tooling costs for flatbed dies are significantly lower than rotary alternatives, and the ability to make quick die changes makes them valuable for short-run or prototype jobs.

The Rotary Revolution in Label Converting

The transition from flatbed to rotary die cutting marked a transformative moment in label converting. Rotary die cutting uses a solid cylindrical die that rotates continuously in sync with the web material, paired with an anvil cylinder. The press feeds thin, flexible material, known as web, between these two cylinders. The cutting-edge pinches material against the anvil cylinder, producing clean cuts, perforations, or creases at exceptionally high speeds.

This method revolutionized label production by dramatically increasing throughput. Modern rotary die-cutting systems can reach 10,000 cycles per hour or more, with the fastest machines achieving speeds of 300 meters per minute. The ability to perform inline with printing and other finishing operations means that labels can be printed, die-cut, matrix stripped, and rewound in a single pass, transforming manufacturing efficiency.

A series of gears or servo motors now, force the die to rotate at the same speed as the rest of the press, ensuring that cuts line up precisely with the printing on the material. Rotary presses can incorporate multiple stations that die-cut specific shapes, perform perforations, create creases, or even cut the sheet or web into smaller sections. Some machines use automatic eye registration to ensure cuts and printing align with tolerances measured in fractions of a millimeter, critical for complex label designs and high-quality output.

The economics of rotary die cutting favor high-volume production. While the initial tooling costs are higher than flatbed alternatives, the operational efficiency brings labor expenses down over time. For standardized, repeat orders running into millions of labels, rotary systems offer compelling long-term value and unmatched productivity.

The Magnetic Cylinder Revolution

While the exact inventor and date of the magnetic cylinder for flexible dies are not definitively documented in available industry records, this innovation transformed the economics and flexibility of rotary die cutting. The magnetic cylinder system addressed a fundamental challenge: solid engraved rotary dies were expensive to manufacture, store, and transport, making them cost-prohibitive for short to medium production runs.

Magnetic cylinders are precision-engineered metal cylinders embedded with powerful magnets, either ceramic or neodymium rare earth magnets, on their surface. They are designed to hold flexible dies—thin, etched steel dies—firmly in place during rotary die cutting. The magnets ensure that every square inch of the flexible die remains securely pressed against the precision-ground cylinder surface, preventing any lifting or shifting during high-speed operation.

In 2005, Bunting Magnetics launched the X-treme Magnetic Die-Cutting Cylinder, the first magnetic die-cutting cylinder in the world with total run-out accuracy below 40 millionths of an inch (1 micron). This level of precision was revolutionary, enabling clean cuts even on extremely thin materials like 1-mil stock with less than 1-mil liners, on “no-look” labels, and on synthetic materials that previously posed challenges.

The advantages of magnetic cylinders transformed the label industry. Mounting and removing flexible dies takes just minutes, dramatically reducing downtime during job changeovers, particularly valuable in short-run label printing or multi-SKU packaging environments. The cylinders weigh significantly less than solid rotary dies, reducing operator fatigue, machine wear, and transportation costs. Most importantly, they enabled the use of flexible dies, which cost a fraction of solid engraved cylinders and could be stored flat, saving valuable warehouse space.

Today, magnetic cylinders are available for virtually all types of label presses and converting machinery, from brands like Mark Andy, Gallus, Nilpeter, Omet, Rotoflex, etc. Custom designs accommodate a variety of special applications, making magnetic cylinder systems remarkably versatile.

Flexible Dies: Engineering and Innovation

The development of flexible dies went hand in hand with magnetic cylinder technology. Flexible dies are thin sheets of steel, typically ranging from 0.5mm to 1.5mm in thickness, that wrap around magnetic cylinders and are used for rotary and semi-rotary presses. These dies are produced from specially formulated steel and undergo several sophisticated manufacturing processes.

Manufacturing Process

Production of flexible dies begins with plotting an image directly on the die material. Background material is then removed through chemical etching, and CNC mills create the required cutting or creasing lines with extraordinary precision. The cutting geometry includes profile heights ranging from 0.3mm to 1.5mm and cutting angles that vary based on the material being cut, typically from 30° to 110°.

The manufacturing process includes several optional treatments. Back grinding ensures consistent die thickness. Chemical de-burring smooths edges to prevent damage to the label stock. Most critically, laser hardening and various surface coatings dramatically extend die life and performance.

Die Materials and Surface Treatments

Standard flexible dies are CNC-sharpened and feature smooth polished cutting edges obtained using ultra-fine edge polishing techniques. These universal dies are suitable for all types of self-adhesive and single-material products including paper, PP, PE, PVC, PET, Tyvek, thin films on PET liner material, and other materials that are difficult to cut.

Laser hardening represented a breakthrough in die technology. Companies like Kocher + Beck were the first manufacturers in the world to achieve hardness levels of 65 to 68 HRC through laser hardening technology. This process extends die service life by two to three times longer than conventional dies. The laser hardening increases hardness at the tip of the cutting edge based on the carbon content in the steel, creating exceptional wear resistance while maintaining die flexibility.

For extremely demanding applications, chrome-coated dies offer even greater durability. A thin layer of chromium, typically 0.01mm thick with a hardness of 70-80 HRC, enables extremely high running performance with outstanding wear properties. These dies are particularly suited for abrasive thermal and thermal transfer papers used in longer production runs.

Non-stick coatings represent another important innovation. Special onyx or polymer coatings have no detrimental effect on the cutting-edge angle or sharpness while preventing adhesive and ink deposits on the cutting blades. These coatings are food-safe, FDA-approved, and significantly reduce downtime for die cleaning. The reduced friction and perfect resistance to wear enable maximum running performance with a consistently sharp cutting edge.

To be continued to part-2

Written by Harveer Sahni, Chairman Weldon Celloplast Limited, New Delhi, January 2026

Selecting Digital Label Printing technology

Selecting Digital Label Printing technology

“Change is the only constant in life.” This is an age old saying and it is so true! As we look back in time that has gone by, the evolution in technologies that impact our life is amazing and for the new generations it is difficult to imagine the path traversed by elders.

For example, look at the development in telephony and communications; there was a time when, to get a telephone we had to make a lengthy application with documents plus a hefty deposit and then wait for 3 years to get a telephone. For dialing national or international numbers one had to book a call and experience endless wait to be connected for a 3 minute call. Those who did not have telephone connections had to visit a post office to call relatives in other cities, book a call and wait for their turn until the operator tried to connect them for a call that they had to pre-declare the duration as 3 minutes or 6 minutes. Mobiles have transformed life and we have instant voice and video communication capabilities 24X7 with multiple phones in our pockets. The mobile is perhaps the most impactful technology experienced by us in life so far. In a somewhat similar manner, printing technologies have evolved over hundreds of years to bring changes enabling perfection and colourful meaning to all printed products. A technology that began with carving stone blocks, apply colours and transferring images, evolved to using wooden blocks, metal type sets, letterpress printing, screen Printing to offset printing, a technology that was widely adopted and spread across the world as the most preferred print process. Also evolved flexographic and rotogravure printing. All these technologies had a costly pre-press and make-ready process as also the cost of artworks, plates, print cylinders, etc.

The 1970s saw the beginning of an era that would continue to impact the print industry in a totally different tangent, the digital printing! The technology enabled printing with a command from a computer with press of a button without much of processes that were needed in conventional printing.

It is so much like the changes in mobile phone technology coming about. By 1993 the digital printing technology developed such that the first commercial digital printing press named “Indigo” was produced by Benny Landa in his company with the same name. This transformed the printing world; one could now print personalized short run jobs straight from computer. In 2000-2001, the company Indigo was acquired by Hewlett Packard (HP) and at the time of acquisition Landa had said, “Our vision has always been to lead the printing industry into the digital era and to see Indigo technology pervade the commercial market. Now, a part of HP, that goal is in sight.” Rightly so, the market of digital printing has been registering robust growth. Digital printing technology has been developed by various press manufacturers and is being widely adopted with innovative indulgence.  Label manufacturing is an integral part of print and has also been witnessing growth both in terms of total market as well as in Digital printing of labels. The global market for label printing has been growing steadily in recent times, valuing at $36.98 billion in 2017. As per Smithers Pira the total market of labels is likely to cross 49.9 Billion USD by 2024. According to Finat; 2017 was the first year that, with nearly 300 digital press installations, the volume of newly added digital label presses surpassed that of new conventional label press installed volumes.

While label printers in the western world have been early investors in digital label printing presses yet the Indian printers have been skeptical about the need for this investment in the Indian label production scenario.

The different types of technologies available leave the printers in a confusion as to what is the most appropriate technology that they should invest in. Unlike other conventional printing processes evolution of digital printing has moved into different technical ways of achieving the same goal which is computer to print.
Largely available technologies offered by various manufacturers of digital equipment are as follows;
1.       Dry toner based

2.       Liquid toner based

3.       Inkjet

4.       UV Inkjet

While looking at the selection of digital print process one also needs to decide the finishing of the labels whether they wish to do this inline or offline. Every different short run job maybe of varying shape requiring frequent stops and change of cutting dies.

This substantially reduces press running time and impacts profitability adversely. In such a case it is advisable to finish the labels offline, one offline equipment can free up printing time of multiple presses. Laser die cutting is another option whereby it can handle multiple and frequent job changes without the need for additional dies and machine stoppages, but this calls for a much higher investment in the finishing equipment.  Additionally, one needs to decide with digital, what dpi resolution to go for; does the work need a white ink in one of the printing heads; does the press have an extended color gamut. Press running speeds of all the digital label press technologies vary quite considerably. The printing speed with many short-run job changes is also an important factor for consideration.
Dry Toner based process:

This process is an evolution of the earliest photocopying process known as Xerography invented by Chester Carlson founder of Xerox and converted as Laser printer by Gary Keith Starkweather in 1970s which transformed to digital printing with laser printers also called electrostatic digital printing as we have seen in our offices.

In a laser printer a laser beam runs over an electrically charged drum preparing an electrical image carrying charged areas.  The drum is a cylinder coated with a material that becomes conductive when exposed to light or laser beam. Areas that are not exposed have a high resistance which allows these areas to hold the electrostatic charge necessary for the process. The image then collects the toner and transfers the image to a paper or substrate that is then heated to fuse the image on to it. In traditional xerography the image is formed by reflecting light off an existing document onto the exposed drum which then picks up the toner and transfers the image. Dry toners consist of pigments embedded inside polymer beads. The fusing phase of the electrophotographic process melts the polymer beads to the surface of the paper. These can print on both coated and noncoated papers. Image quality is a complex issue, determined by a combination of hardware, software, consumables and processes. Dry toner is not absorbed by the substrate, it always achieves an optimal optical density as all the ink transferred is adhering on surface. The particle size of the toner has been reduced over the years to achieve fine print results and most equipment are offering prints of 1200 DPI for solids and blends with good color depth and subtle contrasts, ideal to reproduce vibrant images.
Major brands offering dry toner based digital label presses are Xeikon and Konica Minolta.
Liquid Toner based process

Liquid toners also use pigments in polymer beads, but they are dispersed in oil that evaporates during fusing process. Liquid toners are used in digital presses that are typically used for commercial printing on a wide range of coated papers.

Benny Landa an Israeli inventor mentioned above, having to his credit 800 patents produced the first Indigo digital printing press in the early 1990s using liquid toners in a process that was called liquid electrophotography or LEP in his company established in 1977. Landa came to be known as the father of digital printing. The liquid toner used by HP came to be known as ElectroInk, that combines the advantages of electronic printing with the qualities of liquid ink. ElectroInk contains charged pigmented particles in a liquid carrier. The image is created with electrophotographic process on the drum directly from digital data, avoiding the use of any analogue intermediate media. It starts with digitally created pages or print elements containing text, layouts or images. HP Indigo uses a blanket in between to transfer ink from the drum to media. The blanket is heated, melting and blending the ElectroInk particles into a smooth film. This produces an image that is completely defined on the blanket and transferred to the substrate by direct contact. For this reason, it is also referred to as offset digital printing.

Major brand using liquid toner based digital printing process: HP
Inkjet Printing:

Inkjet printing is the oldest of technologies in non-contact printing evolving into digital colour printing commercially. Existing together there are two main inkjet technologies i.e. Continuous Inkjet (CIJ) and drop-on-demand (DOD).

The CIJ method has been in use for ages in which a high-pressure pump directs liquid ink from a reservoir through a gun body and a microscopic nozzle, creating a continuous stream of ink droplets. These droplets are subjected to a varying electrostatic field and then these charged droplets pass through another electrostatic field to deflect them and form characters. The process can be understood by the image reproduced from Wikipedia. The Drop-on-demand (DOD) is divided into thermal DOD and piezoelectric DOD. Most commercial printers use the DOD to print. The large format ones use solvent or water-based inks depending on the equipment and the product. The inks used in digital inkjet label printing presses are water based and formulated with either dyes or pigments. Aqueous inks provide the broadest color gamut and most vivid colors. The water-based inks are inexpensive and may ultimately spell out as the lowest cost print, but some substrates may require specialized coatings as there is an imperative need for the ink droplet to sink straight in and not to smudge or smear. With growing volumes, increased environmental and consumer friendly nature of inks the coated stock prices are likely to become largely affordable making this technology to watch as wider acceptance is envisaged. Such inkjet printers can achieve high resolution of 1600 DPI. Since the start of a new millennium another water-based inkjet technology called Memjet has been evolving. Memjet is used in high speed, full colour printers to give a high-quality print at a very low cost. It uses a fixed print head unlike conventional inkjet printers where the cartridges or head moves back and forth during printing. The Memjet print head is fixed and is of the width of the material it’s printing on enabling edge to edge printing. This way it’s only the material that moves underneath the head as it’s printed.
Major brands using water based digital inkjet printing: Trojan from Astronova, Afina, Colordyne
UV Inkjet Printing

UV inkjet Digital printing is an extension of the inkjet printing that uses ultra-violet light to dry or cure ink. The inks consist mainly of acrylic monomers together with a photo initiator and after printing when exposed to strong UV lamps or in case of specially formulated inks to LED-UV light, the ink is cured by crosslinking.

The ink due to this chemical reaction becomes instantly dried leading to increased printing speeds. The curing process with high power UV exposure for short periods of time (microseconds) allows printing on thermally sensitive substrates like BOPP and PE. Since the ink sits on top of the substrates and neither is dried by evaporation nor by absorption resulting a robust image on a wide range of uncoated substrates. It is the fastest growing sector of digital inkjet printing and more sustainable than conventional printing.
Major brand using digital UV inkjet printing: Canon, Domino, Durst, Epson, Screen, Xeikon

Selecting digital printing equipment for label printing is a complex task depending on the printer’s customer portfolio. It varies on many parameters, like the equipment price, ink price, media cost, media to be printed, consumables cost, speed of machine, resolution required, space and finishing required.

Time is not far when printers will invest in multiple technologies to attain the best of each process and to service a wide array of customers. However to start with the print on demand feature is so very attractive and for short runs it seems to be becoming an absolute necessary at least in case of established printers whose large investments in high end flexo or combination presses gets held up doing shorter runs and taking away valuable production time. Since short run demands from brand owners continue to swell along with need for variable data, it becomes necessary to opt for an offline finishing equipment which does not slow down their printing capabilities.

Most of the leading label press manufacturers have started offering Hybrid machines with combination of Digital and flexo printing capabilities along with decorating and finishing inline. It is not a simple decision to opt for the hybrids.

As mentioned earlier here, it all depends on the portfolio and requirements of individual label printers. It is interesting to note that all hybrid presses with digital capabilities displayed at Labelexpo Europe in September 2019 were fitted with UV inkjet digital presses. Leading press manufacturer who are offering Hybrids of flexo, digital and inline finishing include Gallus, Omet, Mark Andy, Nilpeter and MPS. With environmental concerns, migration of inks and other food or Pharma safety needs, non-waterbased inkjet systems may see more development in future. As of now due to the speed and versatility offered by UV Inkjet coupled with the ability to add additional white and other colours, UV inkjet is the predominantly used technology however investment is high. Therefore, selection of the best suited technology for digital in labels must be as per individual printer’s need and that of their diverse customer mix. It is a competitive time and cost of equipment, cost of consumables and the nature of output is very important to ponder over before finally selecting the first entry into digital.
Written by Harveer Sahni Chairman Weldon Celloplast Limited New Delhi November 2019

Chris Ellison: FINAT President, setting standards in workflow management.

Chris Ellison: FINAT President, setting standards in workflow management.
In an ever-evolving label scenario, the need to produce more efficiently, reduce wastage, shorten downtime, reduce interest and financial stress due to big inventories, reducing manpower and achieving more revenue per asset are necessities that will add to financial health of companies. To achieve the here mentioned imperatives, many companies are increasing the use of digital technologies, automation and artificial intelligence. This not only helps them to be system driven rather than being human driven but also empowers them to add to their bottom lines with peace of mind. Chris Ellison the 20th President of leading global label association FINAT has transformed his company OPM Group, Leeds UK, to be a lean manufacturing one with increasing use of automation and digital MIS system to put in place a workflow that performs efficiently and delivering the desired results. This leaves the management in a comfortable managing environment, their customers happy and results in better relations with all stakeholders including suppliers and customers. A walk through the OPM facility is a delight. There is perfect workflow with no bottle necks or stagnation of materials. A very neat and clean unit where every process leads to the next with aid of an IT enabled workflow and automation. The MIS system has been created by involving the internal team, all suppliers, prepress developers, logistic partners and customers as well. Generally, printers do not share information with their vendors, here the vision of the Ellison family has created a system that makes the unit to work with perfect harmony and the appreciation they get helps in better relations with their customers.
 
In most printing companies the sales force is nowhere in sight and the general perception on the shop floor is that sales people have all the fun travelling and partying with customers. Chris’s vision is to inculcate a sense of togetherness and team work in the entire workforce. Each shift when workers enter the factory, in the first room they get to see behind a glass wall, is the sales force working hard at their desks preparing for yet another gruelling day with customers creating a continuous flow of order. This also instils a sense of bonding as Chris feels that all the workforce needs to feel committed and create success with the inspiration, “Together we will”! Each order that is entered into the system goes through a digital workflow that is available on screens throughout the company and every department can see the progress without any hindrance. From costing, quotation, order approval, pre-press, inventory management, delivering raw materials to presses, finishing, packaging, despatch and invoicing goes on in clockwork precision. All staff, vendors, transporters and customers are hooked on to the system for the information that they are required to access and react to. It is an information highway created for smooth travel of all orders from initiation to delivery. 
 
One cannot see any congregation or unnecessary movement of workers in the factory or over loaded warehouse. A company with 20 million pounds turnover has just 73 employees. Chris says, “implementation of these system has helped us achieve a high turnover of 4 million pounds per asset or per Label press” he further adds that trained and efficient people are scarce to find so they must invest in an IT department and in training people, which is expensive, but it is justified for them to be more efficient. Subscribing to principals of Total Quality Management, all products at OPM are produced to ISO 9001:2015, BRC/IoP Global Standard Food Packaging standards Grade AA and PS9000:2016. They are printed using low migration/ Food Grade Inks. Truly, Chris Ellison as industry leader is setting examples for peers to follow.
 
Jack Ellison and his three partners ran a small engineering company building overprinting machines. His 20 years old son Chris wished to have his own business so started importing Dot Matrix printers from Germany and selling in UK. While in school Chris did not really excel in academics but was very inquisitive about how things worked, enjoyed creativity by changing things and wished to do something different and innovative. After finishing school education, he went on to a technical college to study engineering. He had two brothers and a sister. Both his brothers died due to cancer, one passed away at the age of 34 when Chris was just 15 years and the second at the age of 40 when Chris was 20 years old.  These losses left a void in him and he vowed never to waste a day in his life.
 
One Christmas a person made him a good offer and Chris sold his Dot Matrix business. Mean while one of the partners in his father’s company died in 1986 and discontent started between the partners creating uncertainty. His mother too was diagnosed with cancer at the age of 64 however she passed away much later at the age of 93, just one day after Chris moved his operations to the present facility. His father Jack Ellison could not take the stress at that time, so Chris first took over his father’s share in the business that his father was in with partners and later, since he had the cash from sale of his own business, he bought over rest of the partners. The company had at that time just installed a small Tackiboy label press. Operating out of 1000 square foot factory, 95% of the business was coming from the label press, machine manufacturing was terminated making them primarily a label manufacturing company. 
 
The company was renamed OPM Labels & Packaging group as Chris wished to produce labels and flexible packaging which till date remains their core business. In 1989 OPM bought their first flexo press Propheteer the very first one to be sold into UK. By 1999 OPM flexibles was in place to produce printed films, filmic laminates and sachets. They had by then acquired 6 Nilpeter label presses. As time went by OPM have upgraded their machines by replacing the old ones with new machines. This was done to achieve better efficiency, low wastages and faster production, the number of presses remain; 6 Nilpeters. A seventh Nilpeter is expected to be installed in the last quarter of 2018. About waste management Chris Ellison says “OPM take their environmental responsibility seriously, we are proud to assure our customers that their label products are being produced with as little impact on the environment as possible”. They have recently been awarded their Zero Labels 2 Landfill Certification.
 
OPM is jointly owned by Chris and his wife Susan Ellison. Susan is active in business, looks after the human resource functions, Manage and organise implementation of MIS and Automation systems, Project Managing, R&D alongside with Chris, offers inputs from a design and repro background, takes initiatives for new developments, marketing-Communications and strategic planning. She came to the business with reprographic experience having worked with various companies in the field. Their daughter Charlotte 28 and son Arnold 26 are also working in OPM making it a totally family owned and managed company. 
 
 
Chris feels it is challenging to keep pace with your business as it evolves. One must rely on people and motivate them to grow with your business, the leadership must have the desire, passion and will to take it further and pass it on to his team. Chris and Susan also are involved in a lot of charity work investing time and money in cancer research and aftercare. His elevation in FINAT as president has helped him to get a broader perspective of international label trade. It has helped his expand his knowledge through the global networking platform that FINAT offers. He tries hard to connect with the large spread out membership base and create value for members.
 




The above article is exclusively written for Label and Narrow web magazine USA. This may not be reproduced without permission.
Written by Harveer Sahni, Chairman, Weldon Celloplast Ltd. New Delhi India September 2018
 

Labels on the move-growth in India-2018

Labels on the move-growth in India-2018
Fifty years ago, 80% of India lived in villages.
 
People are moving from villages to cities to experience the modern-day city life as they see on TV and internet. 





 
The scenario has transformed over the years. As a result of ongoing urbanisation, the urban population in India has now grown from 19.4% in 1968 to 33.5% in 2017. The shift has a direct impact on the consumption of household goods, as daily needs in city dwelling are obviously different and more than that in villages. More so due to the impact of a growing rate of literacy level which is the percentage of people aged 15 and above who can read and write having increased to over 72% percent from 40.76% in 1981. People in the working age group 15-64 years has escalated to 66.2%, from a level of 55.4% in the last 50 years. In 2017 the median age of the country, which is half of the people to be younger than this age and other half older, was estimated to be 27.9 years. In a country of 1.32 billion people a growing need for household goods or consumer goods also referred to as FMCG or “fast moving consumer goods” means there is an ever-growing huge demand for labels and packaging that are a part of the consumables they buy.

 

According to a report in The Economic Times dated May 01, 2018, consumer products market grew
13.5% in the Financial year 2018, with eight of 10 leading companies posting double-digit value growth, FMCG being the 4th largest segment of the economy. Online sales of consumer goods is also seeing an enormous rise as number of online users is poised to cross 850 million by 2025. According to a report by marketing research firm “eMarketerOnline” retail sales in India are expected to grow by 31% this year to touch $32.70 billion, led by e-commerce players Flipkart, Amazon India and Paytm Mall. Retail market is estimated to reach US$ 1.1 trillion by 2020, up from US$ 672 billion in 2016 further expected to boost revenues of FMCG companies to 104 billion US Dollars. The data herein mentioned indicates a definite, constant and escalating demand for labels and packaging.

 

 

Indian Label industry has been witnessing challenging time since demonetisation of currency and later due to implementation of GST. While these measures may be beneficial for the industry at large, yet they slowed down the trade impacting margins and revenues. With capacity growth already committed by existing label companies who had already placed orders for new equipment and by those entering the segment in this period, slow down impacted adversely the positive sentiment in label industry. The Label printing and converting equipment was being upgraded globally by machine manufacturers to achieve efficiency in production, reducing wastages, producing to economies of scale and was becoming more expensive. An industry that was used to a quicker ROI (Return on Investment) and better margins found the situation challenging, decided to be cautious and held-back investing decisions. While the economic parameters of growth as mentioned in the earlier part of this article were on the move all the time, a pause or back stepping for two years created a gap that has resulted in now a positive situation whereby new investments to increase capacity are being made. However still, label printers are apprehensive that this sudden indulgence may result in over capacity, promote unhealthy competition resulting in lower margins and make servicing of loans a little difficult. Despite this the positive sentiment in the label industry is evident as those who have excelled are committed to expand and maintain their position.

 

 

Change is the only permanent in a growing scenario, also stagnation leads to deterioration so one has to keep improving, innovating and expanding to remain in reckoning in a vibrant colourful industry. The label industry, much to the discomfort of the existing peers of the industry is seeing a lot of investment from the sheetfed offset printers. The sheet offset industry is used to big time investments in equipment and voluminous sales justifying their lower margins with massive turnovers. They were content with ever growing toplines, yet when the bottom lines needed strengthening labels appears to be a solution. While this would not add much to the top line but would surely contribute positively to their bottom lines. In a conspicuous effort to make their balance sheets look more presentable, it seems the offset printing industry is becoming indulgent in labels. It is for this reason we see label exhibition stalwarts Tarsus targeting the offset printers for their upcoming Labelexpo India. This is much to the discomfort of existing label industry constituents as it would add to the intense competition bringing pressure on already depleting margins in terms of percentage.

 

 

The label demand in India continues to grow and investments in label printing and converting equipment is on the rise. Though not much authentic data is available, yet the author based on experience and time spent in the industry has attempted to reach a reasonable size of the market. There are about 1000 label manufacturing companies in India. These include very small and big plain label, barcode label and product label manufacturers both in roll and sheet, spread all over India. The number of machines that each of these companies possess varies from just one machine to multiple machines, in many cases the machines installed are in double digits. On a very modest estimation if I assume an average of just two machines per label company, the total comes to 2500 label converting machines. The number of rotary machines announced in media in the recent past as installed in India over the years till now by leading label suppliers like Mark Andy, Gallus, Nilpeter, Omet, Bobst, Edale, MPS, Weigang, Orthotec, etc. coupled with those supplied by local manufacturers like Multitec 200 machines, RK label 150 rotary plus 600 flatbeds, Jandu 135, Alliance, Webtech and others, is well over 1500. Now if we add the used machines, the intermittent and other flatbed/rotary options, the figure is definitely over 2500. Working backwards for converting capabilities with realistic downtime, the per capita consumption of labelstocks is well beyond 1 square meter.

 

 

Calculating quantities of label stock manufactured from the number of coaters installed with Labelstock manufacturers we have, according to the author’s personal estimation, Avery Dennison is leading the pack and SMI following, together they account for over 40% of the production in India with almost 48 Crore or 480 million square meters per year. According to Jandu Engineers, who have been the main coater laminator supplier to the unorganised sector, they have till date installed 150 adhesive coating lines in the country. While Jandu asserts that his coaters run at 100 meters per minute but for a realistic estimation their speed with down time has been considered at 50 meters per minute. Added to this is the production coming from numerous Hotmelt coaters installed and together with the stock lots used, the total again justifies the 1 square meter per capita usage. Another evaluation done with base consumption that most in the industry had agreed at 0.25 square meter in the year 2003. Applying a year on year growth rate of just 10%, this year we cross the 1 square meter per capita usage. The estimation is the author’s personal estimation only, many of the industry peers may not agree with the author’s estimation yet it appears that we have come a long way in the last 20 years. The self-adhesive label production and consumption in India all including roll, sheet, stock lots etc. this year seems to have reached a whopping 1.30 billion square meters!!!

 

 

Written by Harveer Sahni Chairman Weldon Celloplast Limited New Delhi India September 2018