Monolayer Roll Fed Labels - Do More with Less

Monolayer Roll Fed Labels Do More with Less!

Dear reader, We know that sustainability trends are leading the packaging industry, everyone is striving to comply with recycling standards to close the loop for a ‘Circular Economy’. Although, the more complicated the packaging design, the lower the chance of it being recycled. On the following pages you’ll read how monolayer roll fed labels (MLRFL) could be the answer to this problem. We understand that cost savings are an important factor for customers, something that MLRF labels could also help within the beverage industry. You will want to take a closer look to find out why.

We want to show you everything you need to know about this solution so you can determine if it would be good to convert your projects to monolayer. In this magazine, we highlight roll fed labels from the perspective of monolayer roll fed, not laminated. We go into detail on how we produce monolayer labels differently than what’s out there today.

We go over the challenges, application considerations for MLRF and how we help you throughout the process. Our goal is for you to have a label that successfully passes through your distribution network.

Thank you and enjoy the read!

The MCC Beverage Team

In this issue 3

What is Monolayer Roll Fed

4

MLRFL VS Laminated labels

5

Sustainability in Action

7

Technical Specialist Offering

9

Success Stories

Visit our website www.mcclabel.com to discover more on how our premium label solutions can meet your needs.

“Monolayer Roll Fed Labels. Do More with Less!” is a publication of Multi-Color Corporation.

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Copyright © by MCC. All rights reserved. The content of this document, including all copy, images, and attachment(s) are property of MCC and should be treated as confidential. It cannot be shared with or forwarded to third parties and cannot be published without MCC’s prior permission. If you have any questions regarding the use of this document, please email marketing@mcclabel.com.

What is Monolayer Roll Fed A Roll Fed Label is a label made of a single or double ply of polymer film (BOPP/PVC/PET) that is rolled against the core to create a reel of labels and released in continuous roll then applied to various primary containers. The labels are cut to size and attached to the container with an adhesive. Also known as a wrap around label.

In the USA and Canada, roll fed labels are made with a laminated construction. However this is not the norm elsewhere in the world. For example in Europe, monolayer is used as a standard. Monolayer construction uses less overall material and processes than laminated ones.

The monolayer labels offer several benefits compared with standard 2-ply roll fed constructions. The benefits

include increased sustainability through reduced raw material usage, cost savings and enhanced operational efficiencies and, just as important, monolayer labels have increased opportunities for embellishments.

Sustainable solution The monolayer film is more sustainable because it uses less overall material than laminated labels. Reducing the amount of raw material is one of the most impactful

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ways to reduce the label’s footprint. Not only are you producing a label that uses less material, but you also keep costs and resources from entering the supply chain upstream and downstream. In addition, these monolayer labels still meet the strict requirements for PET bottle recycling.

More labels per roll provides more storage space Operational efficiency is enhanced because the thinner film allows for more labels per roll. This creates fewer roll changes on application equipment and more labels per reel, pallet, warehouse racks and trucks. Storage space is also optimized because you need less space to store a larger number of labels. Longer run time reduces the number of reel changes per shift, day and year.

MLRFL constructions: MLRFL VS Laminated labels Now let’s go deeper into the battle between MCC MLRFL versus yesterday’s laminated labels, since the difference is not only an assumption of its name (monolayer), but that it entails all its construction. Let’s review some attributes of these labels in the table below.

Monolayer labels comparison to Laminated labels

MLRFL

LRFL

Comparison attributes

Single

Multiple

True surface embellishments (scent, tactile)

✓

✗

High gloss

✓

✗

Matte finish

✓

✗

Spot embellishment

✓

✗

Inks adhesion resistance (alkaline/acidic) Wash Off or Retain inks

✓

✗

Material cost savings/polymer avoidance

✓

✗

More labels per reel/pallet/truck/rack

✓

✗

Longer run time between reel changes

✓

✗

Better carbon footprint (less trucks delivering same amount)

✓

✗

Laminating equipment avoidance

✓

✗

None

✗

Label curl We are proud to say that MCC is leading the change by having zero in line laminators for RFL.

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Sustainability in Action Packaging trends are increasingly dominated by sustainability.

Consumers want products to be more environmentally friendly.

61%

of millennials are likely to pay more for eco-friendly or sustainable products(1) according to Global Web Index

+ 54%

of CPG Market Growth from 2015-2019 were from Sustainabilitymarketed products(2)

From this, we can conclude that sustainability is no longer a trend, but the new norm. It is what we’ve got to be cognizant of as suppliers and as manufacturers to give the consumers what they want, to give them a sustainable solution.

MCC as an industry leader in sustainable label solutions wants to ensure that we have the ability to give you label options and solutions that will not prevent it from being recycled, reusable or compostable, embellished or used for functional promotions. Therefore, we proudly share that all our monolayer labels are tested and approved by the APR, confirming that we have met the Critical Guidance requirements for recycling.

Monolayer options: • Roll Fed Labels constructed with high yield white cavitated (typical surface print with over print varnish OVP). We do that for Sparkling /Still/ HF products.

7.1x faster

growth of sustainability-marketed products than conventionally marketed products(2)

• Clear polypropylene- BOPP (either surface or reverse print/ OPV) We typically do that for Still Products, but it can also be done for hydration products.

• Labels constructed with BOPP ROSO (Roll on shrink on) can be either Surface or Reverse printed, we can do that in clear, and we can do that in opaque.

This solution was recently awarded APR recognition.

More than efficiency, it’s a sustainable perspective We have already seen monolayer as an improvement to efficiency, knowing that it allows for more labels per reel, more per pallet, more on the truck, and the material gives more performance and results in a longer execution time between reel changes.

But now let’s go deeper when it comes to sustainability. Obviously, it has a reduced carbon footprint. We are using less polymer. We are using fewer trucks to deliver the same base material. We are using

(1) http://www.novotaste.com/top-five-beverage-packaging-trends-2021-foodbev-media/ (2) Information Resources Inc. / NYU Stern POS Data 6/15 – 6/20 5

fewer trucks to deliver the same or more labels to you, so we are reducing that resource expenditure altogether.

There are sustainability metrics associated with all the upstream and downstream talking points with production. This is a useful exercise we offer to our customers to go through a couple of critical sizes or types or all those brand size equations, so you can understand what the value is beyond the initial monetary piece. It will have some intrinsic monetary value, but it’s not the cost of goods directly, but internal monetary benefits.

When you start looking at the overall savings, not just from a cost perspective, but yields for space and sustainability as well, you’ll notice that it can be quite significant. Read some real cases: • The reduction of the number of trucks, in some cases we have reduced by up to 60 trucks, then we have taken 60 trucks off the road for a brand.

That’s a combination of incoming and outgoing trucks because we are bringing fewer trucks, we are sending fewer trucks with the same amount of material or more there.

• Regarding avoiding polymers from the carbon footprint, in some instances they have saved 30,000 to 40,000 pounds = 13.6 to 18.1 metric tons of polymer for an annual basis.

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We can do these complete calculations taking into account the considerations of: how many lines are running; of those lines how many are manual? Splices, are you setting up the splice? Are you stopping the line?

Are you making the cut in the existing reel? Are you inserting the new reel, pulling the label through as in typical older Trines or B&H or non-automatic splicers?

We can sit down with you and take a deep dive to your specifications and get some real-world numbers that are indicative of savings.

Technical Specialist Offering Knowing the characteristics of monolayer roll fed labels and their differences compared to laminated ones, it is important to take into account that these have some application considerations, whether for CSD bottles or non-carb, still products.

Monolayer roll fed labels are tested and used in high speed labelers, such as: SACMI, Sidel, Krones, Trine, PE Labelers, B&H. There are many variables that we must take into consideration. Not only do we look at your labels from the viewpoint of printing and slitting your labels as monolayer. We will collaborate with your manufacturing team(s) to understand the equipment (age, condition, adhesive, environmental considerations) to ensure a successful launch.

MLRFL on CSD (Carbonated Soft Drinks) bottles application considerations As more and more companies are light weighting their preforms/ bottles the result is… expansion, it happens: using the right glue selection/application amount is critical for success with CSD products.

When you have a thinner material, make sure to adjust your glue rollers just enough to make up for that compensation of the material thickness differences to get the correct pattern. Now, you have the correct amount of adhesive on the label and bottle.

Other areas to consider when making the conversion to Monolayer labels are: • Empty/filled labeling • Warmers • Stack (compression) • Transportation (hyper agitation) A common example we run into is when a brand will ship their bottles a couple hundred miles to a distribution point or store. They are transported in trucks that reach up to 120 degrees + in the summer, resulting in the expansion of the PET containers with an extremely carbonated product.

• Scuff testing and appropriate real-world contact/ abrasion Unfortunately, we can never have a coding as strong as lamination when surface printing, but we

can build that label to overcome the scuff testing in the appropriate real-world contact and abrasion.

There are contact points that we must consider. Our team identifies the contact points and completes the scuff testing to ensure the label we produce doesn’t scratch on contact with the rails, other products, or touch points in secondary/ tertiary equipment.

• Age/condition and diversity of equipment The age, condition and machine type are the equipment properties that need to be considered.

We work together with your plants maintenance teams/ equipment to make a label that will run successfully though your machine.

Static happens regardless • This is everyone’s culprit for cooler/dryer month issues typical of Sept- March (geographically dependent).

• Static mitigation is necessary for both laminated and monolayer labels.

• A thinner label is more susceptible to static by its weight reduction.

• Anti-static additives can be applied via inks/ OPV. Laminated labels can’t do this due to their construction, but regardless, the plants are responsible for static mitigation on their lines. It’s the same for the wide web thin shrink films printed or clear. This is the same for roll fed labels.

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MLRFL on non-carb still application considerations • Proper glue selection/Application amount This is something that you need to consider. It could be as simple as a label removal or an operator reviewing glue checks. Our team will work with your glue suppliers on the appropriate amount of glue needed to hold the label.

• Delamination as a label peel is not a valid glue pattern or application amount testing method.

✓ Acceptable glue pattern and application

✗ Poor application and bad pattern

Technical Implementation Guide

Application assistance Our technical service team knows the best practices for the application of our monolayer labels.

We understand working with MLRFL is a change, as it runs differently from common laminated labels.

We share our knowledge of this process with you so you can learn what is good and bad, along with all the specification to make your labels work effectively.

You can find all this information in our Technical Implementation Guide (TIG).

MLRFL Technical Implementation Guide We develop the Technical Implementation Guides with your engineers based on the plant testing that we do and the machine type you use.

Our teams create a one to two-page document with that data to uncover key technical scenarios. An example could be what parameter needs changed on the input screen of the control panel to give your operational team enough troubleshooting information to continue to run at that desired speed. All relevant adaptations and findings are based on the time from the labeler manufacturer.

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Place the TIG on the labeler

We recommend placing the TIG on the labeler.

This provides the operator with the information needed to solve any problems that might occur. This is important because when changing sizes, you are not only changing the product, but multiple change parts.

However, we work with you on the machines during the testing phase to see what issues might arise and figure out how to fix them and capture these on the TIG’s.

It’s important to go through the TIG with the operators.

You will find the key learnings on how to run monolayer roll fed labels versus laminated labels.

Below are some examples of what you can find in the TIG: • GMP – Potential adjustments – Sick Eye label potentiometer “Sick Eye spot for LUM” considerations • GMP – Vacuum Systems • Label brushers/wipers & knives considerations • GMP – Static & label “End-of-Roll” detection considerations

Topo Chico mineral water is a tradition in Mexico and has quietly gained thousands of followers in the United States. Bottled for more than 125 years in Monterrey, Nuevo León, it has become a brand that over time, has remained in people’s preference.

Topo Chico is supplied as a glass bottle and a PET bottle. For PET bottles, a wrap-around roll fed label is used, which is of transparent construction. This label was initially developed in a laminated structure of two layers of polypropylene with a total thickness of 40 microns, but in search of environmental responsibility, savings and better performance, a monolayer polypropylene film construction label was developed.

MCC developed the monolayer structure in conjunction with Envases Universales. A material of a thickness was used that could meet the standards of application speed and quality.

The challenges The main objective was to reduce the use of materials and to have savings compared to the two-layer laminated structure, but there were also other considerations. They needed a label that could run

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Success Stories

Monolayer construction results in savings at an application rate of up to 37,500 bottles per hour without warping, that applied correctly, and with minimal changes in operating conditions. Since it is a highly carbonated beverage, it was also a challenge to ensure that the label stays adhered during possible bottle expansion and during the transport to the point of sale.

The results The result was a reduction of 6.5% in terms of material and saving of 4% in the sale price of the label compared to the bilayer laminate.

In addition, it is a more sustainable solution since the yield is increased by at least 5% in terms of m2 per Kg, eliminating the lamination process in the manufacture of the label and the use of adhesives. An additional benefit in terms of quality is that the curling problems encountered with the laminated label were eliminated.

We achieved this label, thanks to the fact that during the development we were selecting the appropriate materials (films and inks), as well as being on the floor with the labeler operators with our technical service team to achieve a good implementation without sacrificing application speeds.”

Armando García, Manager of Research and Development and ST, MCC Monterrey

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Success Stories

Great brands making great changes Arca Continental’s mission is to generate maximum value for its customers, associates, communities and stockholders, satisfying its consumers’ expectations at all times with the highest quality products and services.

As Coca-Cola is one of the brands handled by Arca Continental and the most popular soft drink in history, the demand is very high and therefore the volume of production is equally high, sometimes with urgent orders.

Therefore, the brand set itself the objective of obtaining cost savings and trying to reduce delivery times in the face of urgent requirements. The solution was the migration of the BOPP label volume from a bilaminate structure to a monolayer structure used in non-returnable PET bottles for the national market, Mexico.

MCC Monterrey has been a strategic partner of Arca Continental for many years, so the company chose them as responsible for this transition. According to Arca Continental’s team, MCC has shown them a high level of confidence in the performance of their labels on their products.

This was not an easy conversion for Arca Continental, as it presented some challenges.

First, they had to adapt the labeling equipment of the different operations of their non-returnable PET container business partners that delivered the already labeled bottle. In addition to having two commercial partners for non-returnable PET bottles in sync with MCC, they themselves had a variety of labeling equipment that had to be adjusted in order to use the labels with a monolayer structure.

Another concern was having optimal performance under drastic environmental conditions (temperature

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and percentage of humidity) in territories throughout the north of Mexico, such as the state of Sonora, Chihuahua, Sinaloa, Durango, among others.

Despite the difficulties, this undoubtedly had a positive impact. The main result was economic savings, as well as the improvement in delivery times before emergencies, by cutting the availability of labels between 48 and 72 hours.

MCC met the customer’s expectations by supplying a monolayer label with the required quality and having managed to “connect” with the brand’s non-returnable PET packaging commercial partners to maintain the correct application of each of the labels.

“

MCC’s greatest support was the technical service to be able to classify the tests in each of our operations to be able to use the monolayer label.”

Arca Continental

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3 Reasons To Get In Touch With Our Monolayer Experts Around The Globe

1

We guide you through every step of the process.

2

Talk about the look and feel possibilities to really make the difference on shelf.

3

Work together for smooth integration and ongoing technical support.

Our Monolayer expert Noel Stewart, Innovation Manager at MCC Contact: marketing@mcclabel.com

Visit our website www.mcclabel.com to discover more on how our premium label solutions can meet your needs.