Beyond Paper

Specialty Media Options

By Cassandra Balentine 0--

Beyond traditional pulp and paper, specialty media options maintain a growing presence in the digital production print space. These include solutions for toner, dry toner, and HP ElectroInk machines, as well as inkjet.

Speciality media options consist of but are not limited to synthetic options designed to resist the heat put out in digitalprinting process. Sometoutstainand tear resistance, while others are thick enough for folding cartons. Additional solutions include peel-and-stick, self-adhesive, magnetic, and even eco-friendly.

Defining Specialty

It's difficult to pigeonhole specialty media into one category. For many, the definition of a specialty substrate is simply any substratethatisnottraditionalpaper. "We define specialty media as unique and innovative problem-solving paper products," adds Steph Oeser, marketingmanager, Relyea.

David Field, GM, specialty paper & film division, Midland Paper, describes specialty media in the digital print space as a substrate specifically formulated, treated, and/orcoatedinsuchawaytobecompatiblewithdigitalprintdevicesinthemarket.

Field sees the definition expanding intoproductsthataddvaluefortheprinter and/orenduser.Thisincludesoptionslike synthetic paper, films, self-adhesive paper, self-adhesivefilms, and pre-converted/preperforatedproducts.

Aaron Bares, productmanager, Nekoosa,addsthatspecialtymediaproductshelp visually communicate a company's messagingoraparticularapplicationlikeretail signageorreusablemenusatarestaurant.

A specialty media is a substrate that enables a printer to stand out in their market...

- Jason Leonard, technical sales manager, digital print, Neenah

':,\ specialty media is a substrate that enablesaprintertostandoutintheirmarket by offering a higher impact message for their client. It should act as a design element in the printed piece and add tactileappeal, intrigue, orpersonalizedbrand identity;' agreesJason Leonard, technical salesmanager, digitalprint, Neenah.

Julie Brannen, director of regional sales and sustainability solutions, Monadnock Paper Mills, feels speciality media either has unique performance characteristicsorahighsustainabilityprofile.

UPM Raflatac refers to specialty media in two categories, shares Kirit Naik, global director, digital printing technologies-oneisbasedon printingcapabilitiesandtheother based on surface appearance. “Print-compatible media requires special ink-receptive coatings for given printing technologies. Conventional printing methods such as flexographic, thermal transfer, and direct thermal printing still require specific ink-receptive coatings, however as well-known printing technologies, most customers refer to it as standard material. In digital printing, surface chemistry becomes more specific for the given print technology,” he explains.

1. Neenahspecializesinpremium,uncoated papers with textures and colors that command attention. 2. GF offers a line of pressure-sensitivevinylmedia.

On the Market

A range of specialty media options are available. Here we highlight a few.

General Formulations (GF) offers a line of pressure-sensitive vinyl media. Its narrow format digital (NFD) offering consists of 14 different constructions. “All 14 have been certified for HP Indigo presses, receiving a three-star rating. GF’s NFD sheets are available in 19x13 and 29.5x20.5 inches, stocked and ready to ship in 200 sheet cartons. We apply a proprietary top coating to make them compatible with Heidelberg, Konica Minolta, Ricoh, and Xerox production digital presses in addition to HP Indigos,” shares Greg Kestler, narrow format digital product manager, GF.

Many of Monadnock Paper Mills’ products are offered with 100 percent post-consumer waste recycled fiber. Its Astrolite PC 100 Velvet is the only coated 100 percent recycled text and cover sheet made in the U.S. and is offered in a 9 pt. postal complaint caliper as well as 150 lb. single-ply cover stock, shares Brannen.

Midland Paper’s Specialty Paper & Film division is a national distributor of specialty media solutions for various print segments such as HP Indigo, dry toner, production inkjet, conventional offset, and wide format inkjet. Midland’s media range includes self-adhesive paper, self-adhesive films, synthetic paper, films, specialty paper, media for windows/walls/floors/doors, die cut labels, pre-converted/die cut media, and magnetized products.

Neenah specializes in premium, uncoated papers with textures and colors. Its portfolio accommodates all print technology, including specially treated papers for liquid toner equipment, such as the HP Indigo as well as its newest launch of production inkjet papers, designed for exceptional performance on production inkjet engines like the Canon VarioPRINT and Prostream.

Nekoosa offers specialty media products used across many industries and applications. The main Nekoosa product of focus is its synthetic waterproof, tearproof, and weather-resistant paper— SYNAPS XM, which is compatible with dry toner and laser copiers.

Relyco provides a variety of specialty media, including durable waterproof synthetics, sustainable weatherproof paper, durable synthetic pre-perforated die cuts, metallics, tear-resistant paper with a synthetic core, pressure seal forms, and ID cards.

UPM offers optimized specialty media for printer technologies from conventional to digital printing.

In Demand

Specialty media options often present functionality and are gaining acceptance and demand.

Bares continues to find great opportunities for short-run synthetic paper and a continued shift away from traditional lamination. For example, he says SYNAPS XM is a great fit for these applications due to it being a polyester sheet that performs consistently with the high heat conditions of dry toner-based print engines.

Leonard sees increased demand for more options in the production inkjet space. “As high-speed inkjet printing has grown, the demand for this technology has pushed printers to diversify and grow their business, ultimately creating a drive for uncoated, textures and colors. We recently launched our new CLASSIC Production Inkjet line to meet this demand. “

Naik believes that as printer technologies improve, conventional media can be used. However, not all printers offer the same capabilities so optimized media is required for specific printers. ”

Kestler points out that over the years, many shops have tried to print synthetics via their offset presses with conventional ink sets only to have unpredictable results. “As more printers and in-plant shops install production digital presses, it allows them to run specialty products—including pressure-sensitive vinyl—knowing that they will have great results.”

Oeser sees an increased demand for durable materials year over year.

Sustainability Considerations

Specialty media is often characterized by durability, this leads to the question of where it fits in terms of sustainability, which is a feature that is in demand for media options.

As a pressure-sensitive manufacturer, GF looks to use recycled components when possible, including the use of FSC release liner base paper and base paper made with pre- and post-consumer waste. “The same goes for certain facestock and polyester liners, utilizing R-PET versus PET is a newer trend,” says Kessler.

With few exceptions, Brannen says Monadnock’s products are recyclable in the curbside mix paper waste bin. “When you need a durable material that has to meet rigorous test standards, it inherently becomes more difficult to recycle curbside,” she offers. “At the very least it is important to make sure that these products are made with responsibly sourced fiber and third-party certified.”

For Neenah, it’s all about being completely fiber based. “Our products are manufactured with certified, responsibly sourced pulp, and our digital offering includes items containing up to 100 percent post-consumer waste. In addition, all our digital papers are recyclable. Choosing paper over plastics and PVCs whenever possible is the goal of most brands. The opportunity lies with making them aware of what is both possible and available for them to select,” offers Leonard.

Bares admits this can be a tricky area to navigate as many specialty, nonpaper-based products are used for key attributes like long-term durability. “I would focus closer on the application it is replacing, which is traditional lamination. Over time, most touch laminated prints like a menu, for example, would need to be reprinted and discarded multiple times before ever needing to reprint the SYNAPS XM product. You also need to consider that many printers nowadays outsource lamination work, and certian specialty media limits the need to send work out. SYNAPS XM is a #7 plastic and that means it falls under the general plastics category. One great advantage of this product is that it is up to 15 percent pre-consumer recycled content.”

Sustainability is everything UPM Raflatac does, according to Naik. “So it does not stop whether we provide conventional or specialty media. We offer more sustainable solutions, covering all components applicable in media such as adhesive, facestock, liner, or total construction. We believe in closing the loop and making the switch and it is applicable to all media we offer,” he shares.

Media Matters

Choosing the right media for the job at hand is essential. “There are countless applications that call for specialty products. The best path is to use the right media for your application,” shares Kestler.

With a knowledge of the customer requirements and the understanding of what is possible with the right media, the potential is limitless for digital print. dps

by Cassandra Balentine

s environmental concerns continue to make headlines, consumers and business owners search for ways to reduce waste and make products more sustainable.

Labels/packaging is one area that can create added waste. However, media providers are diligently working to find solutions.

After a product is purchased, used, and placed in a recycle bin, it is sorted at a material recovery facility before being shredded and chopped into small pieces at a polyethylene terephthalate (PET) reclaimer, shares Dan Riendeau, strategic business unit manager, packaging, FLEXcon Company, Inc.

Some modern label materials are designed to easily debond from the packaging they adhere to, which helps the process of separating recyclables.

Melissa Harton, marketing manager North America, Fedrigoni Self-Adhesives, explains that debonding occurs when a container is processed utilizing a water temperature of 88 degrees Celsius/190 degrees Fahrenheit or higher with an alkaline solution.

“Container pieces receive a warm caustic water bath where the labels wash off and float to the top while the container pieces sink. The container pieces then start their journey to becoming a new container, free from adhesive and label materials,” adds Riendeau.

Above: FLEXcon optiFLEX ecoFOCUS with V-52RE adhesive is a line of white, clear, and silver BOPP films designed to enable better recyclability of PET containers.

Christina Barajas, sustainability manager, Mactac, points out that PET has a density of 1.38, so labels need to be formulated in a way that the adhesive will cleanly remove from the PET container during the wash process at a materials recovery facility and float, so they can be skimmed off and leave behind a clean PET container.

“This sink/float recycling process cleanly separates the label from the container and PET flakes. The PET fragments, now clean and free of residue, can be used in a PET bottle-to-bottle recycling process,” comments Harton.

Debonding Demand

As consumers become more environmentally conscious, they drive demand for eco-friendly packaging.

“In fact, according to research by Trivium Packaging and Boston Consulting Group, 74 percent of consumers are willing to pay more for items in sustainable packaging, and 60 percent say they are less likely to buy a product in harmful packaging. In addition, many consumer brands have committed to the U.S. plastic pact, which addresses key challenges. One commitment is to make 100 percent of plastic packaging reusable, recyclable, or compostable by 2025. This is a lofty goal for most brands as according to the U.S. Plastics (USPP) annual report, only 36 percent of plastic packaging put on the market from USPP activators by weight is reusable, recyclable, or compostable. Their goal is to reach 100 percent by 2025. This is going to require brands to start looking at more options to help enable the recyclability of their PET containers,” offers Riendeau.

“One of the keys to a truly circular system is having enough ‘clean’ material going into the recycling stream to allow for high-quality materials to be made from recycled content on the backend,” agrees Harton.

James Allen Howell, product manager, UPM Raflatac Americas, says because PET plastic packaging is lightweight and economical to manufacture, it is in high demand. “Although PET has the highest recycling rate among plastics, less than half is collected for recycling and the vast majority that is recycled is downcycled because it is not suitable for turning back into bottles or food containers. This can be due to the labels not separating well during the recycling proecss. As more global brands seek recycled content in their packaging materials, label choice becomes critical.”

Due to the increasing focus on sustainability and the need to reduce waste, Harton also sees a growing demand in the packaging industry for debonding of non-recyclable materials from containers before recycling. “When nonrecyclable materials are included in the recycling stream, they contaminate the plastic flakes. Contaminated flakes cannot be used to make products that include post-consumer content.”

There is also increased demand for recycled PET (rPET) versus virgin resin PET in the marketplace. “Having a label solution that will cleanly debond from a PET container is a critical step in the PET recovery process,” comments Barajas.

Consumers expect more from brands when it comes to their overall environmental impact, shares Harton. “Therefore, brands demand more from their label material suppliers, which pushes the industry as a whole to find solutions.”

Certified Solutions

When it comes to sustainable media options, certifications help provide confidence in the process.

One certification is by the Association of Plastic Recyclers (APR) Critical Guidance, which provides recyclability of PET and high density polyethylene (HDPE) offerings.

The APR offers certification of certain label materials that meet its critical guidance protocols. “The APR has also published container labeling guidelines to help ensure recyclability. The Sustainable Packaging Coalition offers brands The How2Recycle Guide to Recyclability, which provides clear messaging on whether a package is recyclable or not,” offers Riendeau.

Barajas notes an increased need for APR Critical Guidance tested solutions for white or clear biaxially-oriented polypropylene (BOPP) offerings.

Barajas says the Mactac PUREfloat offering provides no adhesive residue during the PET washing process.

She explains that this differs from HDPE, where the preferred guidance is for the label to stay on the container, but being recycling compatible, of which Mactac has both hot melt and acrylic APR Critical Guidance HDPE label offerings for its customers.

Fedrigoni Self-Adhesives’ Ri-Move PET products are also certified by the APR. Ri-Move PET’s AR842 adhesive provides debonding of non-recyclable label materials from PET containers, making them recoverable. “APR certification means that plastics using label materials from Fedrigoni Self-Adhesives were subjected to the industrial recycling process. After undergoing the recycling process, the labels were evaluated and certified as compatible with industrial recycling,” comments Harton.

UPM Raflatac’s SmartCircle RW85C Wash off products are recognized by the APR as meeting or exceeding its Critical Guidance testing requirements. Available as clear, white, or silver metalized film face materials, these labeling solutions add sustainability benefit when paired with UPM Raflatac’s PCR liner—featuring up to 90 percent post consumer recycled content.

Finding Success

Common PET labeling applications include bottles, clamshells, health and beauty products, food and beverage packaging, and household goods, notes Barajas.

At this time, Harton says any product in a PET container can successfully utilize its Ri-Move products as they are specifically formulated to cleanly remove from PET containers. The product inside of the container does not impact the ability of the label to be removed during the recycling process.

Riendeau says BOPP is one of the best label materials to use for debonding from PET because it is lighter than water and will float to the surface. “This allows for the label material to be screened off during the reclaim process. Otherwise, it would contaminate the clean rPET flake.”

Alternative Considerations

In addition to media solutions that debond, there are benefits to an alternative method, in-mould labeling.

The idea behind in-mould labeling, according to Louis Rouhaud, global marketing director, Polyart, is to use a label made of the same material as the container itself to have a mono-component container that is easy to recycle. “The concept is to place the label inside the mold at the time of production of the container/bottle. This is an efficient labelling technology as it optimizes the process and energy of forming the bottle/container to affix the label. This also avoids a second energy consuming step of offline labeling.”

Moreover, there is no additional glue required to bond the label to the container, avoiding further contamination and decreasing the quality of the recyclate.

Rouhaud points out that in-mold labels are liner-less, thus avoiding millions of square meters of liner that are most of the time landfilled. “It is a very efficient, and globally sustainable labeling technology.”

Sustainability Gains

Media and adhesive suppliers are working diligently to create sustainable solutions, including debonding label solutions as well as in-mould options.

Rouhaud says the demand for recycled material is high as in some states, like CA, where the law is already requiring that containers contain some recycled material. “This requirement will increase, and by 2030, it will also be a requirement in Europe; and this will keep on rising; to achieve that, we need good quality recyclates, thus organizing recycling loops, harmonizing containers, and generally speaking, designing containers and their labels to be easily recyclable,” he comments. dps