In-depth Demand Report | Disassembling Custom Adhesive Solutions

When using pressure-sensitive adhesive (PSA) materials in labels, various issues may arise during printing, application, and storage.  Below are the most common problems and their corresponding solutions.

1.  Printing Issues

Problems:

● Ink adhesion issues: The ink may not adhere well to the surface of the label, leading to smudging or fading.

● Slow drying time: Certain PSA materials, especially those with glossy or coated surfaces, may slow down ink drying.

● Color shift or inconsistency: Different surface coatings and ink absorption rates can lead to color variations.

Solutions:

✅ Use UV or solvent-based inks designed for PSA materials to improve adhesion and drying speed.

✅ Conduct surface treatment (e.g., corona treatment or primer coating) to enhance ink adhesion.

✅ Use color calibration techniques to maintain color consistency.

2.  Adhesion and Bonding Issues

Problems:

● Poor initial tack: The label does not adhere well immediately after application.

● Label lifting or peeling: The edges of the label may lift, especially on curved surfaces or rough materials.

● Incompatibility with certain surfaces: PSA labels may not stick well to low-energy surfaces like plastic, powder-coated metals, or silicone-treated surfaces.

Solutions:

✅ Choose the correct adhesive type (e.g., permanent, removable, high-tack) based on the application surface.

✅ Increase pressure during application to improve bonding strength.

✅ Use adhesion promoters or primers for challenging surfaces.

3.  Label Curling and Warping

Problems:

● Curling during application: The edges or corners of the label lift before or after application.

● Warping over time: The label may deform due to temperature or humidity changes.

Solutions:

✅ Use dimensional-stable materials that resist temperature and humidity fluctuations.

✅ Store PSA labels in a temperature-controlled and humidity-controlled environment.

✅ Ensure proper release liner tension during label dispensing to avoid excessive curling.

4.  Die-Cutting and Processing Issues

Problems:

● Labels tearing or not cutting cleanly: The adhesive may ooze out, affecting the die-cutting process.

● Release liner breakage: Thin or weak liners may break during high-speed dispensing.

● Difficulty in label dispensing: Labels may not release smoothly from the liner.

Solutions:

✅ Use die-cutting blades designed for PSA materials to ensure clean cuts.

✅ Select a proper liner material that is compatible with the label dispensing process.

✅ Store labels in a dry environment to prevent adhesive migration and liner issues.

5.  Temperature and Environmental Issues

Problems:

● Label falls off in extreme temperatures: Some adhesives lose their bonding strength in hot or cold conditions.

● Adhesive failure in humid conditions: Moisture can reduce adhesion, leading to peeling or bubbling.

Solutions:

✅ Select temperature-resistant adhesives for extreme conditions (e.g., freezer-grade adhesives for cold environments).

✅ Choose moisture-resistant adhesives for humid conditions.

✅ Store labels in controlled environments before application to ensure optimal performance.

6.  Surface Contamination and Compatibility Issues

Problems:

● Oil, dust, or moisture on the surface reduces adhesion.

● Adhesive reacts with certain surfaces, leading to label discoloration or residue.

Solutions:

✅ Clean the surface with alcohol or a suitable solvent before applying the label.

✅ Use low-residue adhesives if the label needs to be removed cleanly.

✅ Test the adhesive on the surface before large-scale production to ensure compatibility.

7.  Regulatory and Compliance Issues

Problems:

● Food safety concerns: Labels used on food packaging must meet regulatory standards.

● Recycling and sustainability issues: Some adhesives may hinder the recyclability of packaging materials.

Solutions:

✅ Use FDA- or EU-compliant adhesives for food packaging applications.

✅ Choose eco-friendly, recyclable, or biodegradable PSA materials to meet sustainability goals.

1.  Printing Issues

Problems:

● Poor ink absorption, leading to slow drying and smudging.

● Uneven color distribution and blurry images.

● Poor ink adhesion, especially with UV printing.

Solutions:

✅ Use fast-drying inks or UV-curable inks and adjust printing pressure accordingly.

✅ Opt for low-viscosity inks to improve print uniformity.

✅ Perform surface treatments such as corona treatment or priming to enhance ink adhesion.

2.  Die-Cutting and Waste Removal Issues

Problems:

● Cast coated paper is brittle, making it prone to cracking or chipping during die-cutting.

● Difficult waste removal, reducing production efficiency.

● Uneven cutting edges, leading to labels peeling off or rough edges.

Solutions:

✅ Use sharp die-cutting blades to improve precision and minimize edge cracking.

✅ Adjust die-cutting pressure to prevent paper breakage.

✅ Modify the waste removal process by widening waste edges or optimizing the cutting layout.

3.  Adhesion Problems

Problems:

● The glossy surface makes it difficult for adhesives to bond properly.

● Labels may curl or lose adhesion over time.

● Adhesive performance weakens in cold or humid environments.

Solutions:

✅ Choose high-tack adhesives specifically designed for cast coated paper.

✅ Ensure labels are fully dry before storage to prevent adhesive degradation.

✅ Use suitable release liners (e.g., glassine or PET) to prevent curling.

4.  Water and Abrasion Resistance

Problems:

● Exposure to moisture can cause bubbling or coating detachment.

● Labels are prone to scratching or wear over time.

Solutions:

✅ Select waterproof cast coated paper or apply an additional water-resistant coating.

✅ Use scratch-resistant coatings or lamination to enhance durability.

✅ Apply UV varnish for extra abrasion resistance.

5.  Warping Due to Temperature and Humidity Changes

Problems:

● Paper deforms when exposed to moisture, affecting label application.

● High temperatures can soften the coating, reducing adhesion quality.

Solutions:

✅ Store in a controlled environment (recommended: 20-25°C, 40-60% humidity).

✅ Avoid prolonged exposure to heat or humidity during transport.

✅ Use thicker or composite materials for better stability.

6.  Environmental and Regulatory Compliance

Problems:

● Some coatings may not comply with environmental regulations, affecting exports.

● Cast coated paper is less recyclable, increasing sustainability concerns.

Solutions:

✅ Choose materials that meet ROHS, REACH, or other regulatory requirements.

✅ Use eco-friendly water-based coatings to minimize chemical impact.

✅ Opt for recyclable or biodegradable label materials to align with sustainability goals.

Issue 1: Uneven Shrinking or Wrinkles

● Cause: Improper heat distribution in the shrink tunnel or incorrect shrink film selection.

✅ Solution: Adjust the heat settings, optimize airflow, and use the correct film type based on shrink percentage requirements.

Issue 2: Film Peeling Off After Application

● Cause: Poor adhesive selection or excessive humidity during storage.

✅ Solution: Use a suitable adhesive and store the shrink films in a controlled environment to prevent moisture-related issues.

Issue 3: Ink Smudging or Poor Print Quality

● Cause: Incompatible printing inks or incorrect drying temperature.

✅ Solution: Choose high-quality printing inks compatible with PETG or PVC and optimize drying temperature settings.

Issue 4: Shrink Film Cracking or Brittleness

● Cause: Low-quality material or extreme cold storage conditions.

✅ Solution: Use high-grade PETG films for better flexibility and store materials at recommended temperatures.

When using metallized paper for label production, several common issues may arise. Below is a list of potential problems and corresponding solutions:

1. Printing Issues

Problems:

● Poor ink adhesion: The smooth metallized surface makes it difficult for regular inks to adhere, leading to ink peeling or blurring.

● Slow drying speed: The metallized layer reduces ink absorption and evaporation, causing longer drying times and lower production efficiency.

● Low color reproduction accuracy: The reflective nature of the metallized surface can affect color presentation, leading to deviations in print color.

Solutions:

✅ Use specialized inks (such as UV or water-based inks) to improve adhesion and drying speed.

✅ Apply corona treatment or pre-coating to increase surface energy and improve ink adhesion.

✅ Use a white base layer or adjust color management settings to compensate for the reflective effect.

2. Coating and Surface Treatment Issues

Problems:

● Poor adhesion of UV varnish or lamination: The low surface energy of the metallized paper may cause coatings or varnish layers to peel off.

● Low surface tension: This can affect ink, coating, and adhesive performance, leading to poor processing results.

Solutions:

✅ Use corona treatment or pre-coating layers to increase surface energy, improving the adhesion of UV varnish, lamination, or top coatings.

✅ Choose specially formulated UV varnish or water-based coatings designed for metallized paper.

✅ Store the paper in a dry environment to prevent moisture from affecting the metallized layer.

3. Die-cutting and Processing Issues

Problems:

● Edge cracking or aluminum layer peeling: The metallized layer may detach during die-cutting, affecting the label’s appearance.

● Aluminum layer separation after cutting: The metallized coating may peel off when the label is bent or folded, reducing product quality.

Solutions:

✅ Use high-quality die-cutting blades and optimize pressure settings to prevent cracking or peeling.

✅ Choose flexible metallized paper to enhance adhesion and resistance to folding.

✅ Adjust the die-cutting angle to minimize direct impact on the metallized layer, reducing peeling risks.

4. Adhesion Issues

Problems:

● Weak adhesive bonding: The metallized layer can interfere with glue adhesion, making labels difficult to stick.

● Bubbles or detachment: Adhesives may form bubbles or fail in high humidity or high-temperature environments.

Solutions:

✅ Use adhesives specifically designed for metallized surfaces, such as high-adhesion solvent-based adhesives.

✅ Apply a primer or coating layer to enhance the adhesive’s bonding ability.

✅ Control humidity levels to prevent moisture absorption, which could impact adhesion performance.

5. Durability and Storage Issues

Problems:

● Moisture absorption and warping: Metallized paper has higher moisture sensitivity, leading to deformation when improperly stored.

● Poor heat resistance: High temperatures may cause oxidation or discoloration of the metallized layer.

Solutions:

✅ Store in a dry and temperature-controlled environment (recommended humidity < 50%, temperature 20-25°C).

✅ Use moisture-proof packaging to prevent humidity damage during storage and transportation.

✅ Avoid direct sunlight and high temperatures to prevent oxidation or discoloration of the metallized layer.

6. Environmental and Regulatory Issues

Problems:

● Difficult to recycle: Some metallized papers are harder to recycle due to the presence of the aluminum layer.

● Food safety concerns: Some metallized coatings may not comply with food packaging regulations.

Solutions:

✅ Choose eco-friendly and recyclable metallized paper, such as water-based coated metallized paper.

✅ Ensure compliance with FDA, EU, and other food safety standards, especially for food packaging labels.

✅ Reduce the use of solvent-based chemicals in production and adopt environmentally friendly coating technologies to lower pollution risks.

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