Automating Production of Extended Content (Multi Layer) Labels

A profitable niche market for the flexo printer is printing extended
content labels. Doing this job is made easy with the Servo 3000
In-feed and Register System. Extended content labels, also called expanded content or multi layer labels, are necessary for many products such as medical products, pharmaceuticals, insecticides, herbicides, and various chemicals which require a degree of caution in handling. The final product consists of layers of labels that peel back cleanly with no adhesive residue to a hinge in order for the customer to read each page. The layers then reseal cleanly.

Besides their use for relaying complicated instructions or warnings to the customer extended content labels can be used for promotional reasons as well. For example, food product labels can include recipes. Sweepstakes promotions are another use and multi layer labels can be used to provide the same information in several languages or to offer coupons to buyers.

Making a Hard Job Easy with the Servo 3000

Making extended content labels can be a tough job but it need not be. In the traditional process the press operator has to register the colors on two webs simultaneously and then register both webs together. Set-up waste and running waste are high while press speeds are low. The number of colors that a press can print will be divided by the number of labels printed, typically two at a time. The Servo 3000 automates this tough job. The number of press colors available is the usual because the top layer is pre-printed. The Servo 3000 allows the pre-printed layer to be laminated automatically in register to the base layer.

Five steps to extended content labels with the Servo 3000:

• Print the first layer. Press speed is only limited by drying as there is no dye cutting or stripping of matrix. The top layer can even be printed on a different press.
• Make ready the base layer. Put the top layer roll on a lamination tower and web it through the Servo 3000. The two layers can be put together by using a clear laminate or by printing adhesive on the base layer. The nip point where the two webs come together can be a mid-feed nip, or a die station may be used.
• Use the Servo 3000 to adjust the top layer to be in register to the base layer.
• Once set the Servo 3000 will automatically hold that position.
• Laminate, die cut and strip as normal.

No further equipment is needed for this process. Once the Servo 3000 has registered the web of the first print run the subsequent run can be at full press speed. The Servo 3000 reduces material waste and makes an old flexo press fun like new. It makes printing extended content labels more efficient and profitable.