Historical Presentation on BOPP Liner for Labels


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AWA Conference Washington D.C. April 2005

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Historical Presentation on BOPP Liner for Labels

  1. 1. From the 1970’s until now BOPP Release Liners Novelprint’s R&D division at our plant in Brazil Import Restrictions = We had to think outside the box We will tell you all about it
  2. 2. History - Novelprint Novelprint was established in 1958 as a cloth label manufacturer. In 1967 Novelprint entered PS label manufacturing
  3. 3. Brazilian Macro Economic Factors In 1973 the first oil shock hit, creating an import substitution policy: • domestic production incentives • importation prohibitve Novelprint sought out alternative solutions. Brazil – 1960’s. Open door economy and importation was permitted. Novelprint imported raw materials and machinery
  4. 4. From the early 1960 ´s to the mid 1970´s, Novelprint imported the highest grade label stock and label applicators Supply Chain 1960´s
  5. 5. Product Quality Equation Novelprint + high quality raw materials and technologies - Import no longer available = What do you do? Settle for what was available OR Develop The Best Not very good Available Supply Chain 1970´s
  6. 6. – Dictionary Definition: de·vel·op·ment      Pronunciation Key  (d-vlp-mnt) n. [syn: growth, growing, maturation, • The act of developing. • A significant event, occurrence, or change. DEVELOPMENT Novelprint’s Solution to the Scenario Determination of the best techniques for applying a new device or process to production of goods or services.
  7. 7. If you can’t import the products, then import the know how. The “PEOPLE FACTOR” Novelprint’s Solution to the Scenario
  8. 8. Cycle of Innovation - Who we are today
  9. 9. Novelprint BOPP Liner R&D Time Line
  10. 10. 1st Machine in South America. Top of the line Flexo at the time. Novelprint BOPP Liner R&D Time Line 1968
  11. 11. Development did not start with nor was restricted to BOPP Novelprint began making rotary dies in 1972 Novelprint BOPP Liner R&D Time Line
  12. 12. Label applicator development began. Initially the machines were semi automatic. Gradually more automatic versions were developed, including a dot matrix inprinter which was one of the first in the world. Step motors were introduced in the 1980’s BOPP Liner Automated Application
  13. 13. Faustel Coater Start up of silicone coating production 1975 Novelprint BOPP Liner R&D Time Line
  14. 14. Novelprint BOPP Liner R&D Time Line o 30 years ago we purchased our first hot melt coater. o 2 years later, we began formulating & producing our own adhesives. o Over the last 3 decades we have developed innumerous special formulations. 1975
  15. 15. Novelprint was the 2nd company worldwide outside Japan to purchase and install a Ko - Pack press. Nowadays we have 5 in operation. 1976 Rotary Letter Press Revolution
  16. 16. The rotary Letterpress process required UV Inks which were not available in Brazil at the time. 1977 Solution: Develop UV Inks “In House” Continued R&D Developments
  17. 17. In 1976 there was 1 unreliable Brazilian Super Calandered Kraft/Glassine supplier for release liners. At the time, NP developed a liner from brown Kraft packaging paper with a primer before silicone coating. These labels did not require automatic application. The How of BOPP Development
  18. 18. The only available BOPP on the Brazilian market was for the cigarette industry. The only available thickness was 30 microns. Polyester was not cost effective for mass production. $$$$$$$ Automatic application became more and more of a demand. That is how we got to BOPP. The CATCH The Catch
  19. 19. The synergy of all of these technologies under one roof lead to a continuous cycle of development.
  20. 20. The arguments presented were: BOPP will not resist to the silicone heat curing It didn’t BOPP liner will not permit die cutting It didn’t BOPP will stretch on the press It did, BOPP will be affected by the press drying process It was BOPP will not be an adequate liner for applicators It wasn´t THE BOPP CHALLENGE When the concept was pitched inside our company, to our clients and to colleagues throughout the world, we became at times less encouraged to go forth with the idea.
  21. 21. It became clear to us at Novelprint, that siliconized BOPP liners were a manufacturing improvement within the label business. In November of 1979 at the TAPPI conference the subject matter revolved around paper liners. At the Q&A session, I inquired about the absence of discussion of BOPP liners. The question was brushed off and the subject matter diverted. At the end of the seminar, both Mr. Chris Watson, the event Co-Chairman and a gentleman from MOBIL approached me and told me that they were working on the same development and we had a fascinating conversation at the time. The Anecdote – 1979 25 years ago: TAPPI Silicone Coating Course, Chicago How funny: 25 years later and BOPP is still a novelty
  22. 22. The “whys” and “hows”of BOPP release liner development has been the result of an evolutionary process. The following slides will show you how we went from the cave to where we are today. Evolutionary Results Developing products before the market is ready to use them is not always an easy task to overcome commercially.
  23. 23. Hard to believe? The initial constructions in the 1980’s, utilized various paper face materials with the 30 micron liner. Evolutionary Results
  24. 24. Later that decade 40 micron BOPP became available on the market. The thicker BOPP material lead us back into the development process where we began developing BOPP face material. Over the next few years, Novelprint began to substitute paper for BOPP face material in label production until it became a preferred construction for standardized products. 40 Micron Evolutionary Results The 30 micron BOPP available in the early 1980’s was just too thin to use as a plastic face materials due to die cutting
  25. 25. Evolutionary Results From Paper to BOPP In the mid 1980´s, customers began migrating from Paper/BOPP constructions to BOPP face 40 micron/ BOPP Liner 40 micron.
  26. 26. From White -to Metalized BOPP Evolutionary Results
  27. 27. Evolutionary Results
  28. 28. Evolutionary Results
  29. 29. 25 years of experience has proven to us BOPP´s various advantages • Quality Benefits • Lower Cost Benefits • Environmental Benefits BOPP BENEFITS
  30. 30. • Quality Benefits – Improved release performance – No paper dust particles on labeling machines – Cleaner products for hygienic or sterile plants – More transparent “No Label look” labels • Lower Cost Benefits – Less costly per MSI than glassine paper – Higher speed labeling and less web breakage – Thinner face materials may be used – Fewer roll changes due to thinner BOPP liner • (more labels per roll ) • Environmental Benefits – BOPP silicone release Liner is recyclable • Buy back price in Brazil US$ .25/lb BOPP BENEFITS 25 years of experience has proven to us BOPP´s various advantages
  31. 31. THE END • To end this presentation – we offer the following video demonstrating the conversion and printing process on one of our presses. • Both liner and face materials are BOPP • Thank you for your attention.
  32. 32. TLMI FINAT