Highest Quality

Quality Procedures

General

• Unlike many label converters, we never run our presses at full speed or anywhere near it. When you do, quality suffers. We define maximum press speeds and our press operators adhere to these rules.
• We have a press operator and one or two helpers working together. Many converters will have the press operator run the press and bulk pack the product both at the same time to cut costs. Our press operator’s number one job is to monitor quality; the best way to do that is to have someone else handle the packaging.
• We affix a sequential number to every bulk carton of custom products we produce. We pull a sample from each carton and affix the same number to that sample. We then attach these samples to the corresponding mill roll tag and archive these samples for 12 months. Thus, if there is a problem, we have retained samples from every carton so that we can check.
• We have 100% operator accountability. The Press Operators, who are responsible for all facets of quality, initial each roll tag, thereby creating an audit trail and fostering accountability.
• We have complete employee accountability throughout every process. From order entry to our final quality control check in our Shipping Department, we know who was responsible for each step.
• Explicit quality control procedures are written for every major piece of business we manage. The employees responsible receive training as it relates to each specific account’s needs.
• Every custom carton we produce has a production date on it. We strictly adhere to a first-in-first-out procedure of rotating all customer inventory. This important issue can easily be overlooked by other manufacturers who maintain a continuous supply of customer inventory on their floors.
• We offer expert telephone/on-site consulting services to help solve whatever label-related challenges your customers may have. Our technical expertise in sheets and pin feed labels is unrivaled.
• Generally, we run splice-free rolls. However, some products are not available in a splice-free format and it’s critical that all roll splices be removed from the finished product. All rolls are inspected before going on press and mill splices are carefully marked and monitored to ensure removal from the finished product. Our presses are all equipped with mill splice detector alarms.
• Waste ladders are removed cleanly by specially engineered vacuum removal systems. This is very important as breaks in waste ladders can lead to small pieces of broken ladder stuck to the face sheet, which can cause two sheets to stick together and create a printer jam.
• As a rule, we run grain-long laser sheets (sheeting at 11”) which is what the major printer manufacturers recommend for optimum label feed performance. Some converters run grain-short (sheeting at 8.5”). Running grain long requires 23% more press time. We do not take shortcuts, we do it right.
• If, however, an end user is feeding 8.5” x 11” sheets into their printer using the 11” edge of the sheet as the gripper edge, they should be using grain-short sheets. This allows the sheets to navigate the roller path more easily within the printer while lessening the chance of sheet jams.
• We can run “photo” quality gloss papers without scratching the face sheet. This is not possible unless your equipment has been specially configured for this purpose.
• When we run 8.5” x 11” laser sheets, single or double stream, we run oversized rolls and strip waste from both sides to ensure web widths remain exactly 8-1/2”. This is critical to consistent performance in high-speed laser printers, even though doing so adds 1.2 to 2.9% to our material costs. Many converters do not run oversized rolls. The problem is that mill tolerances on roll material are +/- 1/32”, so rarely will they get exact 8.5” wide finished sheets. In addition, sheets not run from oversized rolls are more subject to adhesive ooze generated from the manufacturing process. Adhesive ooze can cause printer jams. If it accumulates in the printer path, it can also lead to toner adhesion problems and/or fuser damage.
• Oversized sheets can bind in printer trays and cause jams. Undersized sheets will be subject to print alignment variations and potential feeding problems.
• Dies, slitting blades and all nip and idler rollers must be cleaned often to remove accumulated adhesive and other residue. Adhesive left on tooling or rollers will accumulate on sheets and contribute to printer jams. Residue can also emboss sheets and put a dent in the sheets, which can affect toner adhesion.
• We can alter silicone release values to suit your needs. Smaller labels can sometimes pre-dispense if they are subject to certain conditions. We can also help to prevent pre-dispensing issues by adding very small ties to the construction which, when removed, are barely visible.
• Care must be taken to watch for slippery liners caused by excessive “silicone bleed,” or mill variations, which can change the coefficient of friction and contribute to jams in friction feed printer trays.
• Prolonged temperature or humidity extremes while raw material is in transit can adversely impact label converting performance. Care must be taken to acclimate rolls prior to converting and/or final use.
• Static electricity in sheets can sometimes be a problem. In addition to the standard static removal bars that most presses come equipped with, we also have custom built units that blow high volume ionized air onto the finished sheets and remove all static. Sheets with static in them can stick together and cause printer jams.

Die Cuts

• We do die stain tests to help ensure that variations in liner caliper, or depth of cutting rule, do not adversely affect the die cut and/or cause liner cut through. Slight mill variations in liner caliper are normal. Every mill has acceptable tolerances defined. If liner caliper varies beyond the norm, you may have a problem unless you first identify it, make adjustments, or worse case, pull the roll and return it to the mill.
• We have die pressure gauges on every press to ensure die pressures remain consistent from side to side and from one press run to another. Many label converters do not use them. They adjust pressures blindly by hand and only do a visual inspection.
• As you run a job, the die heats up and expands. This expansion can add up to 300 lbs. of additional cutting pressure. Unless you have gauges, you cannot accurately monitor and make adjustments to compensate for this.
• We maintain written die histories on high-volume formats including date, footage run and die pressure used. This defines exactly what die pressure we need to start with when next running the job. This ensures perfect results. It also clearly defines when a die is reaching the end of its useful life.
• In most cases, when die pressure goes over 1000 lbs., we retire the die and replace it with a new one. We do not wait for it to go bad during a press run. Some dies we retire even sooner.
• While running, we continuously test for clean die cuts. Any fiber residue as you remove a label can cause the label to tear and dies must then be replaced.
• Flexible magnetic dies are expensive. As a result, some converters run them to death. Over time dies develop low spots as they wear down. When this happens, some converters will resort to an inexpensive fix to lengthen die life: they spray paint the underside of the die to compensate for the low spot. This is a short-term fix that does not cut evenly.
• Several problems can then occur. The slightest “cut through” into the liner compromises the integrity of the liner and will contribute to curl and feeding issues. It also creates problems when removing the face sheet: the liner will tear and then stick to the adhesive on the face sheet. This temporary fix also doesn’t remain consistent. It wears down quickly; so your cuts are not consistent from roll to roll. When the cuts go bad, it’s a good bet that it’s not caught immediately and that not all the bad material gets removed and discarded.
• We maintain brand new backup dies in inventory for large accounts or for common die sizes. Thus, when a die needs to be replaced, we just mount a brand new die.
• Dull dies and/or adhesive accumulation on the die cavities will contribute to “die pull”: a condition whereby the die-cut labels are ever so slightly pulled away from the silicone liner. It can contribute to pre-dispensing, or puckering, which will increase the propensity for printer jams. A sharp die makes a narrow cut, while a dull die makes a wider cut and pushes the edges of the face sheet further apart than a sharp die. The condition of your die must be closely monitored; once it starts to get dull it must be replaced. In addition, dies must be cleaned as necessary to remove adhesive residue, as this too can contribute to “die pull.”
• Upon mounting a new die and before converting any labels, we proof the dimensions carefully to ensure they meet your exact specifications. We do not assume our die manufacturer got the dimensions correct.
• Monitoring certain materials for die spread, the space between the die cut label and the surrounding matrix, is important. Too much web tension, shrinkage of the liner or face sheet, or an imbalance between the liner and face sheet tension can contribute to adhesive ooze which can cause sheets to stick together and jam in the printer.
• We use male/female shear punch units for hole-punching laser sheets. A male/female shear punching system costs $30,000 and up. To punch with a die only requires an investment of $300 to $500. Die punching is much more likely to leave hanging chads and/or loose chads with finished product, which will interfere with laser imaging. With a dedicated male/ female shear punch unit, chads are vacuumed out through the lower female punch below the web. In addition, as individual punches wear out, we can replace them for less than $10.00 per set. As a die wears out, the entire die must be replaced.

Perforations / Slitting

• Lineal slitting wheels, bearings, sheeting blades, and perforation blades must all be monitored closely and replaced at the first signs of wear. Dull blades will contribute to adhesive ooze, paper dust, uneven edges and perforations that do not tear properly or produce “tenting” perforations. Paper dust inhibits a scanner’s ability to read bar codes on high-speed conveyor systems. If bad enough, it can shut a conveyor system down by backing up the reject conveyor spur.
• In some cases, the only way to eliminate a tenting perforation is to iron it. We have this capability.
• When perforation cuts bleed off the lead edge of sheeted products, broken perforations can cause paper jams. We have the ability on any lineal perforation to leave a small gap between the perforation and the lead and tail edges of the sheet. Most converters can only offer lineal perforation wheels, which cannot accomplish this.

Testing

• We have a state-of-the-art tensile testing device. It measures the tear strength of a 1” section of perforated material. It is used to ensure that perforation strength remains consistent. It also ensures that perforation strength from left to right is consistent. This same device is also used to test release values between a liner and a face sheet by measuring the effort required to delaminate them. Too easy of a release and labels can pre-dispense in your printer; too stiff of a release and labels will tear or lock up as you try to remove them.
• We have a state-of-the-art Starrett electronic indicator which allows us to measure the caliper of a liner or face sheet down to 0.00005” resolution.
• We use ASTM standard F2217-02 for quantifying Adhesive coat weights. Adhesive coat weights within spec are critical to good label performance. Too much adhesive can contribute to adhesive ooze problems; not enough adhesive can cause labels to fall off the substrate they are applied to.

Adhesive

• Freezer adhesives are soft by nature and thus are more prone to oozing than other adhesives. The more sheets you run, the more likely this can become a problem. Press components must be cleaned more frequently.
• We have adhesives to meet every need. Just because an adhesive has a minimum application temperature of -20ºF does not mean it will stick to ice cream sleeves. Add frozen condensation (frost) to them and adhesion becomes even more challenging. We have the best freezer “acrylic adhesive” made for laser printers on the market. It’s been tried, tested, and proven by some of the country’s largest grocery distribution companies.
• Recycled corrugated is becoming more and more prevalent, as well as fibrous cartons from overseas. Both substrates often prove challenging for consistent adhesion. We have the perfect acrylic adhesives for both.
• Plastic composite mailers are gaining in popularity with Internet-based consumer goods companies, especially clothing retailers. We have the perfect adhesives for these applications. Acrylic adhesives that work as well as Hot melts.

Curl

• On sheeted products we inspect every new roll as it first starts coming off the stacker conveyor for a machine direction curl, tubing curl or corner-to-corner curls.
• When we encounter a severe tubing or corner-to-corner curl, we pull the roll and watch the remaining rolls on that master. If we are unable to rectify the problem, we return the bad material to the vendor.
• Machine direction curls are corrected on the press by using a custom-built bidirectional breaker bar that is electronically adjustable on the fly. Having the ability to immediately make pressure adjustments is critical to obtaining satisfactory results. Most breaker bars are static or manually adjusted and thus cannot immediately compensate and correct the increased memory curl present as your roll empties and nears the core where memory curl is the most severe.
• Whenever possible, we run sheeted jobs on 15,000’ rolls with approximately 40” outer diameters. Many converters run standard-size 10,000’ rolls. A smaller roll is easier for operators to handle. A 15,000’ roll weighs 50% more and is difficult to maneuver. Why does this matter? A 15,000’ roll has a larger outer diameter and will yield a 33% higher number of sheets with less of an inherent propensity to curl in a machine direction.
• When necessary, we have the ability to manage Relative Humidity in our factory. We have Humidistats to measure & control RH levels. When relative humidity is very low or very high, sheets will curl unless you have the ability to control humidity levels.
• Laser face sheets and liners must have balanced moisture levels. Depending on the time of year, ideal relative humidity levels are generally between 35-45%.
• Siliconized liner and porous face sheets shed and gain moisture at different rates. A moisture imbalance between the two will cause the sheets to curl. When sheets are manufactured, they go through several drying and re-moisturizing processes. Raw rolls must be properly stored and converting environments controlled to prevent undue moisture gain or loss.

Packaging

• Our procedures for packaging are far superior to most other converters. Packaging is a critical component to maintaining the lay-flat characteristics of laser sheets. Good packaging is also critical for ensuring the edges of sheets do not get damaged or creased in any way.
• We have custom interior dispenser boxes. All outer cartons are custom-made so that the contents exactly fill the carton. We don’t under or overfill cartons; perfectly sized and filled cartons help to keep sheets flat.
• We use protective outer cartons. We package two cartons of 1000 sheets inside a larger outer carton**. This cuts UPS Ground shipping charges by up to 26%. Also, sheets are better protected from damage in transit.
• We use sophisticated Shanklin automated shrink-wrapping systems. Their output capacity is extremely fast and they wrap “retail quality” packages.
• We offer color-coded content labels for large shipments with multiple lots. We can label all 4 sides of a skid with 8.5” x 11” shipping labels and highlight special instructions in bold lettering on highly visible fluorescent color labels.
• We offer EAN 128 bar-coded skid labels. On large programs, we can add barcodes to every carton content label.
• We can use ECT 40 and ECT 44 corrugated cartons when necessary to further protect against the rigors of UPS or Fed Ex parcel shipping.

Shipping

• Every outgoing shipment is checked by a second person prior to release to ensure that everything has been done properly. From carton count, stretch film skid wrapping, shipping labels, packing lists, to the quality of the skid, we ensure everything gets done right the first time.
• Skids can be further secured by the addition of full sheets of chipboard between tiers, heavy duty chipboard corner/edge protectors, and banding with 5/8” plastic strapping.
• Custom-size cartons and skids can be made to meet any requirements you might have.
• Plastic skids are available for overseas shipments.
• When loading product on wooden skids, we always make sure no nails are protruding from the skids. Nail heads will pierce the bottom cartons and damage the finished product.

Fan-Folded Labels

• On fan-folded products, finished goods are continuously monitored to ensure we do not incur pad leans and/or saw tooth piles.
• If fan-folded product requires splicing, we apply our splicing tape across the full web and perfectly remove all tape from the line hole punches.
• When possible, we do not splice on fan-fold perforations. We splice perforations between rows of labels in the middle of a fan-folded segment. This ensures the splice will not cause the web to trip as it is refolding.
• When possible, we run fan-folded products on 15,000’ splice-free rolls. This allows us to provide fewer breaks in cartons. We do everything possible to minimize the number of cartons with breaks.
• Cartons with “breaks” are clearly labeled so that end users are aware ahead of time.
• We constantly monitor the perforation strength of all fan-fold and body perforations. We adjust or replace blades as necessary.
• Paper stretch is monitored on pin feed fan-folded continuous products by using a “throw length gauge” to ensure press web tensions are correctly adjusted.
• Side to side and lineal hole punch register is constantly monitored and adjusted as necessary to ensure perfectly correct alignment.
• We guarantee web width to be +/- 1/64”. This ensures line hole margins and pinhole punching are both perfectly positioned.
• Whenever required, full cross web perforations have ties bleeding off both edges of the web to help minimize paper jams due to ripped perforations.
• Perforation blades and male/female punches are replaced at the first signs of wear to prevent excess paper dust.

Conclusion

• Colonial Label Systems ONLY SELLS TO THE TRADE. Your trade protection is guaranteed. Everything we ship goes in our dealer’s name.
• Your business is very important to us. If there is ever a problem of any sort, we stand 100% behind what we do. If it means crediting back a large order...done. We not only want your business, but more importantly, we will do whatever it takes to keep it.