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
History - Novelprint
Novelprint was established in 1958 as a cloth label manufacturer. In 1967 Novelprint entered PS label manufacturing
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
From the early 1960´s to the mid 1970´s, Novelprint imported the highest grade label stock and label applicators
Supply Chain 1960´s
Product Quality EquationNovelprint + 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
– 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.
If you can’t import the products, then import the know how.
The “PEOPLE FACTOR”
Novelprint’s Solution to the Scenario
Cycle of Innovation - Who we are today
Novelprint BOPP Liner R&D Time Line
1st Machine in South America. Top of the line Flexo at the time.
Novelprint BOPP Liner R&D Time Line
1968
Development did not start with nor was restricted to BOPP
Novelprint began making rotary dies in 1972
Novelprint BOPP Liner R&D Time Line
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
Faustel Coater
Start up of silicone coating production
1975
Novelprint BOPP Liner R&D Time Line
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
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
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
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
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
The synergy of all of these technologies under one roof lead to a continuous cycle of development.
The arguments presented were:
BOPP will not resist to the silicone heat curingIt didn’t
BOPP liner will not permit die cuttingIt didn’t
BOPP will stretch on the pressIt did,
BOPP will be affected by the press drying processIt was
BOPP will not be an adequate liner for applicatorsIt 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.
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
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.
Hard to believe?
The initial constructions in the 1980’s, utilized various paper face materials with the 30 micron liner.
Evolutionary Results
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 early1980’s was just too thin to use as a plastic
face materials due to die cutting
Evolutionary Results
From Paper to BOPP
In the mid 1980´s, customers beganmigrating from Paper/BOPP constructions toBOPP face 40 micron/ BOPP Liner 40 micron.
From White - to Metalized BOPP
Evolutionary Results
Evolutionary Results
Evolutionary Results
25 years of experience has proven to us BOPP´s various advantages
• Quality Benefits
• Lower Cost Benefits
• Environmental Benefits
BOPP BENEFITS
• 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 BENEFITS25 years of experience has proven to us BOPP´s
various advantages
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.
TLMI FINAT