Label handling system

Abstract

 A label handling system in which a face material supported on a carrier is transported through various stages including a die cutting stage (where labels are cut into the face material) and a label separation/application stage at which point the labels are separated from the carrier and applied to a product surface.
In one embodiment the carrier is recyclable for repeated use in the system. In another embodiment, a laminator is used to attach the face material to the carrier and controlled so as to improve the release value of the face material.
In a further embodiment, the die cutting is undertaken prior to attachment of the face material to the carrier preventing damage of the carrier during the cutting process.

Description

[0001] This invention relates to a label handling system. In one aspect the invention relates particularly, but not exclusively, to a recyclable carrier label handling system. In the further aspects the invention relates particularly, but not exclusively, to a system incorporating a continuous carrier release system or recyclable carrier release system.

[0002] Label handling systems are well known in the industry. These systems typically are reel or spool fed systems in which a pressure sensitive laminate is fed through a cutting assembly to a dispenser. The pressure sensitive laminate typically includes a face material layer, an adhesive layer formed on one side of the face material layer, and a liner. The liner typically is coated with a silicone release agent to limit the adhesion of the face material to the liner. The liner permits the face material to be stored on the reel and provides a mechanism for transferring the face material to the product. Printed indicia is typically applied to the pressure sensitive laminate either prior to being wound on the reel, or after being unwound. The pressure sensitive laminate can be cut into labels prior to being wound onto the reel or after being unwound.

[0003] A conventional cutting assembly in a label handling system includes a die and anvil between which the laminate is fed. The die is forced into the laminate material from the face side cutting to form the cut label.

[0004] After cutting, the label is then separated from the liner and the waste laminate material (commonly called the waste matrix) by a dispenser. There are a variety of well known techniques currently in use for dispensing labels onto a product. Typically, the liner feeds the label to a label dispenser, such as a peel plate, which peels the label off of the liner for subsequent application to the product. The liner is then discarded as waste having no further use in the system.

[0005] The primary drawback with this type of system is that the liner must be relatively thick to support and stabilize the face material during die cutting. As such, the liner can be quite expensive, and significant costs are associated with the liner which is typically discarded after the labels have been removed and dispensed.

[0006] In order to reduce the cost associated with the fabrication of a label, a "liner-less" labelling system has recently been developed. This labelling system uses a continuous strip of material that is first formed by imprinting a face material layer with the desired indicia and coating one side with an adhesive. For simplicity, the combination of the face material and adhesive is referred to herein generally as the "face material". If the liner-less face material is to be wound into a reel or spool, then the second side of the face material is typically coated with a silicone release agent. The reel is then supplied to a label handling system for subsequent cutting and application to product.

[0007] However, as discussed below, despite the cost savings associated with the non-requirement of a liner, there are significant costs associated with the fundamental inadequacies of such a system which has meant that the savings are not realised.

[0008] The cutting process for a liner-less labelling system is different than for a conventional laminate. As discussed above, a conventional laminate is die cut from the face side with the liner preventing the adhesive from contacting the anvil. In a liner-less system it is not possible to cut the face material from the face side since the adhesive would cause the face material to stick to the anvil. Instead, the cutting must occur from the adhesive side of the face material. In order to minimize adhesive of the face material to the die cutter, the die is sometimes coated with a non-stick coating. The die is then driven into the face material from the adhesive side. However, this type of die cutter has not proven to be reliable. Also, concerns have been raised over contamination from the non-stick coating around the edges of the adhesive.

[0009] Another problem with this type of die cutting system relates to the difficulties associated with holding the face material during cutting. As discussed above, in order to wind a liner-less face material onto a reel, the non-adhesive side of the face material must be coated with a silicone release agent. When this liner-less face material is subsequently fed into the die cutter, the non-adhesive side of the face material with the silicone release agent is positioned against the anvil. The silicone release agent, however, makes supporting the face material during, cutting difficult. Hence, accuracy and control of the cutting process is significantly impacted. To overcome this problem, these die cutting systems use vacuum anvils to hold the face material during cutting. This results in added expense for the system. However, even with the use of vacuum anvils, it is not uncommon for a label to stick to a die during a cutting operation. When this occurs, the entire operation must be shut down until the label can be removed.

[0010] Also, since a liner is not present to support the face material during cutting, additional pressure and control is required to accurately and consistently cut the face material. However, conventional liner-less label handling systems use die/anvil cradle assemblies that lack the robustness necessary to accurately and consistently cut labels. As a result, uneven loading and die 'bounce' occur often, producing poor cutting of the face material.

[0011] A further deficiency with liner-less systems is that the die cutting process, the choice of face material, and the choice of adhesive are fundamentally interlinked. Due to the fact that a liner is not present to support the face material, the choice of material being cut effects the success of the die cutting process. For example, a rigid face material layer requires less pressure to cut through than a face material made from soft, high caliper material.

[0012] Moreover, the liner-less systems have only been successful to a limited extent on paper material, with much less success on synthetic material. As such, the liner-less labelling system must be precisely tailored to the particular synthetic material being used in order to achieve a reasonable degree of success. Whenever the synthetic material is changed, the liner-less label handling system parameters have to be completely altered so that the system can cope with the cutting and holding requirements of the new material.

[0013] A further problem with conventional liner-less systems is that the process as a whole is not continuous. The handling and dispensing run has to be stopped with any stoppage in the die cut operation so that the face material, which is possibly the most expensive of the materials used in the process, is not wasted.

[0014] The present invention aims to overcome or ameliorate some or all of the above problems by providing a label handling system which can handle effectively liner-less face materials.

[0015] According to one aspect of the present invention there is provided a recyclable carrier label handling system comprising a face material, a carrier, wherein the carrier supports the face material during cutting thereof, and means to remove said face material from said carrier, the carrier being retained for continued use.

[0016] The advantages of the proposed invention are that the carrier may be used again and again thus providing a significant cost saving, while the problems of the liner-less system are substantially decreased due to the fact that during the cutting process the face material is supported by the carrier and, as such, functions similar to a conventional reel fed system.

[0017] In a preferred embodiment of the first aspect of the invention, the face material is liner-less when presented to the label handling system. Preferably, the liner-less face material is coated with a layer of adhesive on one side and is silicone coated on the other side. The silicone coating permits storage and supply of the liner-less face material to be in reel form.

[0018] The use of liner-less face material reduces the costs associated with the presently known system, that of the provision of a liner which is then discarded once the face material is cut and dispensed on to an article.

[0019] In a further preferred embodiment of the first aspect of the invention, the liner-less face material is attached to the carrier prior to the cutting of the face material.

[0020] The liner-less face material is drawn off the reel, preferably by means of a powered unwind system. The liner-less face material is brought into contact with the carrier. The adhesive layer of the face material attaches the face material to the carrier. The combined carrier and face material is then supplied, on demand, to a cutting station. The demand is determined by the status of a label accumulator which in turn supplies a label applicator as required.

[0021] The carrier may take any suitable form and need not be the same width as the face material. It may be wider than the face material, allowing several widths of face material to be carried on a common carrier.

[0022] In a preferred embodiment of the first aspect of the invention, the liner-less face material is laminated to the carrier prior to the cutting of the face material and in this instance the carrier is preferably a flexible release carrier and may be of the type conventionally used as a liner in currently known label handling systems. The carrier is preferably of polyester material such as PET and further preferably has a thickness of approximately 36 micron.

[0023] Alternatively, the carrier may be a lightweight support material, preferably having a thickness of approximately 12-24 microns polyester material.

[0024] Other materials may be substituted for the carrier e.g. polyethylene, a woven or nonwoven textile material paper, rigid or flexible material. The carrier need not be flexible if it is not provided in reel form.

[0025] The carrier may be in the form of a continuous belt, which may be siliconised on one side.

[0026] In the continuous carrier belt embodiment, the carrier is in the form of an endless loop that continuously cycles through the labelling system transferring the liner-less face material through the cutting assembly to the applicator. As with the reel embodiment, the carrier belt is replaced after it has degraded.

[0027] Further preferably, the carrier may be recycled several times and used to support the face material repeatedly. Also, the carrier may be used several times to support the face material during the cutting process. Repeated use of the same carrier, even in the form of a conventional liner can be conducted between 10 to 20 times without loss of integrity.

[0028] Preferably, the carrier is combined with the liner-less face material prior to or during the cutting process. The resultant face material is presented for die cutting in register with the printer label. The method by which the label is die cut is such that the face material is cut without damage to the carrier and the waste matrix can be separated from the face material leaving uniformly spaced labels attached to the carrier.

[0029] Preferably, the reel to reel carrier, in the form of flexible release carrier, is then wound onto a further rewind unit, once the label has been separated from the carrier by said means for removing the face material from the carrier, which may take any suitable form. Said means for removing the face material may include label application means for application of a label onto a surface and may, for example, be a typical pressure sensitive label applicator, such as a beak or peeler plate. The carrier is tensioned around the dispensing portion of the beak causing the label to release from the carrier, and attach to the surface.

[0030] Alternatively, in another embodiment of the invention, the face material is presented to the label handling system while being supported by the carrier, rather than meeting the carrier prior to the cutting process as outlined above.

[0031] As described for the earlier embodiment, the carrier here is a reel-to-reel carrier. Once the face material has been die cut in register with the printed label and once the waste matrix and label have been separated from the carrier, the carrier is then wound onto a further rewind unit. Rewind unit stations are well known in the field of label handling systems and may include a carrier rewind mandrel and drive. Thus, unlike previously known systems, the rewind carrier is available for subsequent re-use as the carrier supply. The rewind carrier mandrel and drive complete with rewound carrier may be rotated to become the carrier supply station, comprising carrier rewind mandrel and drive for subsequent re-use as the carrier supply. This operation is effected when the running carrier supply reel is exhausted. In an alternative embodiment, the carrier is not rewound, but instead is conveyed back to a location in the handling system prior to die cutting for attachment to an upstream portion of continuous liner material.

[0032] This process may be repeated several times until the carrier becomes unusable.

[0033] It is also contemplated that the present invention can be used to create die cut labels which are re-reeled for subsequent application to a product. In this embodiment, the face material is attached to a carrier and die cut as discussed above. The carrier and die cut labels (with or without the waste matrix) is then wound onto a reel using a conventional reeling device. The reeled labels can then be applied to a product using another label handling system and the carrier rewound for future use.

[0034] In a further preferred embodiment of the invention, the carrier can be used to transport the face material through the cutting stage and through to the point of application of the label to a product.

[0035] The face material may meet the carrier prior to or during the cutting stage, so that the face material is die cut in register with the printed label while being supported by the carrier and the face material is then transported by the carrier to the label applicator, where it is separated from the carrier and applied to an article. A typical pressure sensitive label applicator may be used in this regard.

[0036] It is sometimes necessary to "splice" i.e. introduce further material such as face material or carrier material to the label handling system when such face material has run out. This is done without having to stop the running of the label handling system using traditional splicing techniques, i.e. splicing the lead of the supply carrier to the trailing edge, which can be done manually or automatically using conventional splicing tape. In the instance of automatic splicing, the adhesive face of the liner-less face material is used to adhere to and thereby transport the carrier to the tape applicator. When the liner-less or lightweight face material is exhausted, a new reel can be spliced in a similar method as described above using the supply carrier as the transport medium to the tape applicator.

[0037] This operation does not require the label application process to stop as labels are fed from the accumulator whilst the change of reel takes place.

[0038] Traditional splicing techniques are well known to those skilled in the art and will not be described in further detail here.

[0039] To prevent splices having a detrimental affect on the die cutting or label application, the system may further include a mechanism allowing splices to be shuttled through, i.e. bypass, the cutting stage (which, in accordance with convention, may be undertaken at a die cutting station) without the splices being cut.

[0040] The contemplated mechanism would include a suitably positioned sensor that monitors the liner-less face material to detect any splice approaching the die cutting station. The sensor sends a signal to a web feed motion control system when a splice is determined. The web feed motion control system would then control the dwell (non-cutting) of the die cutting operation so as to skip the splice and allowing it to bypass the cutting stage.

[0041] In the instance of splices on the face material, the spliced uncut portion of the face material may be stripped off with the waste matrix leaving an extra wide gap between labels on the web. This is compensated for by a control system incorporated in the label application means, e.g. a label applicator module thus eliminating the risk of misplaced labels on product. Such control systems are well known to those skilled in the art. Splices on the supply carrier do not detrimentally affect label application.

[0042] As above, in a preferred embodiment of the invention, there is provided a splice medium to join the ends of face material or carrier which may be conventional liner material or lightweight liner material.

[0043] In a preferred embodiment of the present invention the system comprises continuous web (face material) feed rather than intermittent web feed, where the face material attached to a carrier is termed a "web". This is preferably done via close cutter frame pitching, a technique well known in the technology of label handling systems and is impossible to achieve on conventional "liner-less" label handling system.

[0044] As discussed above a conventional liner-less system requires extra pressure and control to accurately cut synthetic materials since there is no support for face material to maintain the face material in place during cutting. The present invention incorporates the use of a carrier to support the liner-less material during cutting, thereby permitting the use of a conventional die cutter. This is a major improvement over conventional liner-less systems.

[0045] In a further preferred embodiment of the invention, there is provided an improved die cutter/anvil assembly which is offset such that vertical cuts are progressively made. This reduces the problems associated with having to make horizontal cuts through the length of the face material.

[0046] In further preferred embodiments of the invention, the system may be capable of accepting on-line printing modules, on-line adhesive coating modules and on-line adhesive activation modules, wherein adhesive activation is conducted via heating or chemical means.

[0047] Rather than modules being attached to the label handling system of the present invention, an integral system having one or more of the above modules is anticipated.

[0048] In a further preferred embodiment, the label handling system of the present invention may be incorporated into a known handling system which has a conventional label applicator and is capable of feeding conventional pressure sensitive label stock, wherein the carrier is rewound on a further carrier reel to be used again.

[0049] Alternatively, the present invention is preferably provided as a free standing unit to be used in place of a conventional label handling system.

[0050] In a further aspect of the present invention there is provided a method of operating a label handling system which comprises the steps of:-

(1) supporting label face material using a carrier during cutting of the face material; and

(2) removing face material from the carrier; characterised in that the carrier is retained for continued use.

[0051] In a yet further aspect of the present invention there is provided a label having been manufactured by the above method.

[0052] Another problem associated with the conventional pressure sensitive reel fed labelling systems relates to the dispensing techniques used to apply labels to products. Usually a liner carrying the labels is drawn around a beak, sometimes referred to as a peeler plate, encouraging the label to release from the liner typically in a direction and speed similar to that of the product. There are several influencing factors governing the characteristics of the flight of the label as it is released. Firstly, the flexibility of the face material affects its release characteristics. This flexibility results from the thickness (caliper) of the material so that if the caliper of the face material js reduced to such an extent that the rigidity of the label is lost, then the release characteristic of the label becomes unpredictable resulting in poor application on to the product and loss of accuracy.

[0053] Another factor influencing the release characteristics of the label is the release value of the silicone coating of the carrier. This may be affected by the winding tension in the reel and the length of time the labels are stored under tension. If the silicone release value is high the label may fail to release altogether and remain on the carrier resulting in an unlabelled product.

[0054] The present invention has been made with the above problems in mind.

[0055] According to a yet further aspect of the invention there is provided a label release system comprising a face material, means to temporarily attach the face material to a supporting carrier and a dispenser for application of the face material to a surface.

[0056] In a preferred embodiment of the invention, the means to temporarily attach the face material to a supporting carrier comprises a laminator.

[0057] Preferably the laminator and laminating process are controlled to such an extent that the eventual release of the face material has a low release value which is much lower than with reel wound labels. As a result the dispense characteristics are predictable ensuring consistency of label application.

[0058] In a further preferred embodiment of the invention, the supporting carrier comprises a continuous belt siliconised on one side. Further preferably, the belt is positioned around a beak, or peeler plate which releases the face material from the belt and to a surface such as a product to be labelled.

[0059] In a further embodiment of the present invention, the supporting carrier may be a recyclable carrier and may be wound from reel to reel and re-used as a carrier on one or more (even numerous) occasions.

[0060] In accordance with convention, labels are printed on and then die cut from the face material and these operations may take place while the face material is supported by said carrier.

[0061] In the case where the supporting carrier takes the form of a continuous belt, such a belt can withstand repeated die cutting of the face material. Furthermore, in the case where the support carrier is a recyclable carrier, repeated die cutting of the face material may be conducted until the recyclable carrier can no longer be used.

[0062] In an alternative embodiment of the present invention, the label may then be picked up by a medium in such a manner that the adhesive face is exposed. Preferably, the medium is an intermediate belt or drum.

[0063] Further preferably, the medium may take the form of a vacuum flexible or rigid rotating drum. A negative pressure is developed on at least a portion of the drum causing the label to be suctioned off the carrier and on to the drum. Further preferably, the medium is a continuous belt driven at the same linear speed as the product, the product being the final surface on to which the label is applied. The product is carried in a way that allows its relative position to come into contact with the label, thus resulting in attachment. As a consequence of this preferred feature of the invention, the product is always presented to a label which is fully controlled, regardless of its flexibility or flimsiness.

[0064] Preferably, the release system allows improvement of the wet out characteristics (associated with the application of adhesive onto the label material) of certain types of label construction. This results when using face material supplied wound on siliconised liner having an uneven surface. This characteristic is typically associated with Kraft or Glassine paper liners and results in air entrapment between the product surface and the adhesive coating of the label. The trapped air increases the time it takes for the adhesive to form a smooth layer between product and label after application. This is particularly important in the case of clear synthetic labels on clear labels, as any residual air trapped behind the label may not be acceptable for quality standards. Conventional techniques prefer the use of smooth surface liner, typically polyester to ensure the above does not occur. However, this is an expensive cost penalty on the material construction.

[0065] Accordingly, in a preferred embodiment of the present invention, by transferring the face material from a conventional liner and laminating to a smooth surfaced support carrier, such as a continuous siliconised belt or a recyclable carrier, adhesive flows to form an even surface prior to application of the label resulting in elimination of air entrapment.

[0066] It may be desirable to utilise lightweight liner material: by reducing the caliper of liner, savings can be made in label construction costs. However, in doing so the integrity of the liner can be compromised during die cutting, resulting in web failure as it is drawn around the beak edge. By laminating the face material onto a carrier as described above the lightweight liner plays no part in the die cutting and dispensing processes and can reasonably be employed in the operation.

[0067] One of the advantages of pressure sensitive labels as a decorational medium on products is its security of placement and the inability to remove it without damage. Advantageously, this facility can be used as a means of attaching a substrate to a suitable product which cannot readily be fixed to the product on its own. Examples of this are promotional coupons which require removal from the product for redemption and security tags securely attached to the product in a discreet location.

[0068] In an alternative embodiment of the present invention the system further includes apparatus for attaching a secondary substrate, e.g. a promotional coupon, to the adhesive face of a label cut into the face material which may be pressure sensitive, prior to application on to a product surface.

[0069] The combination of face material and underlying secondary substrate is then die cut and dispensed onto a product. Alternately, the secondary substrate can be dispensed between the cut label and the product as the label is being applied to the product. Those skilled in the art would be capable of incorporating a suitable secondary substrate dispensing device into the present invention without further discussion.

[0070] A further object of the present invention is to provide a label handling system in which the supporting carrier used in the label release system is not at risk of damage during the die cutting process.

[0071] Accordingly, in a yet further aspect of the invention therefore there is provided a label handling system comprising a face material, means to temporarily attach the face material to a supporting carrier and apparatus for die cutting the face material, characterised in that the die cutting operation is undertaken prior to attachment of the face material onto a supporting carrier.

[0072] In a yet further aspect of the invention, there is provided a method for operating a label handling system comprising the steps of:-

1) die cutting label face material, followed by the step of:-

2) temporarily attaching the die cut face material to a supporting carrier.

[0073] The advantages of the system and method are derived from the ability to die cut the face material without risking damage to the carrier, which in the case of a recyclable carrier could seriously compromise its re-usability.

[0074] The cutter diameter and associated drive may be designed as a change part to suit the label length and may have the same pitch as the label on the web.

[0075] In accordance with convention, the repeat on the cutter cylinder may be a function of the label pitch.

[0076] The matrix surrounding the label following die cutting may remain to maintain good register of the label onto the carrier. The matrix may be used to transfer out of the system splices and other faults.

[0077] One advantage of the system and method is that control of the die is less critical as mis-setting will not affect the carrier (it will however affect the cutter life expectancy).

[0078] A continuous loop of supporting carrier may be used rather than reel to reel handling making for simpler carrier handling even to the extent of handling it in a cassette.

[0079] In accordance with conventional practice with the invention, the labels are preferably defined by printing and cutting on the carrier whereby the handling system of the invention may incorporate a printing station combined with or separate from the cutting station, on pre-printed material may be used.

[0080] Specific embodiments will now be described by way of example with reference to the accompanying drawings in which:-

Fig. 1 is a perspective view from one side of a recyclable carrier label handling system according to one form of the invention;

Fig. 2 is a perspective view of one side of a label release system according to one embodiment of the another form of the invention;

Fig. 3 is a side view of the comparison between a conventional lightweight dispenser and a dispenser modified in line with another form of the present invention;

Fig. 4 depicts the use of a vacuum transfer drum to dispense the label to a product according to another form of the invention;

Fig. 5 depicts the use of an intermediate transfer belt to dispense the label to a product according to another form of the invention;

Fig. 6 shows a perspective view of a label release system according to another form of the invention which attaches a secondary substrate to the adhesive face of a pressure sensitive label prior to application onto a product;

Fig. 7 shows the steps of the method of application of a secondary substrate to a face material as depicted in Fig. 6;

Fig. 8 is a side view of one form of label release system according to another form of the invention;

[0081] Referring to Fig. 1 the label handling system comprises a support structure 110 on to which is mounted the various mechanisms making up the label handling system.

[0082] In the specific embodiment described in Fig. 1, the face material 111 is presented to the label handling system 112 supported by a lightweight support liner which is wound on to a lightweight liner take up 114 as the face material is unwound and carries on liner-less along path 115 supported by several rollers 116 along the way. The liner-less face material 113 is then laminated via a laminator 117 onto a carrier material 118 which in this instance is a polyester carrier supplied via a carrier reel 119.

[0083] The web of laminated face material/carrier is then transported upwards along path 120 to a conventional die cutting mechanism 121 comprising an anvil 122 and a die cutter 123. The die cutting mechanism 121 cuts web 150 into a series of spaced labels 152 surrounded by waste matrix 124. The waste matrix 124 of face material is separated from the label/carrier web 125 via a roller 126. The waste matrix 124 is then wound on to a matrix wind up reel 127.

[0084] The label/carrier web 125 is transported to a label accumulator 19 and is then processed on a by-demand basis to the label dispenser 128.

[0085] The label/carrier web 125 is moved along path 129 via several rollers 130 and is dispensed on to article 131 via a pressure sensitive label applicator 132.

[0086] The carrier is then transported back to a carrier wind up reel 133 along path 134 which may be transferred to carrier supply 119 when this has run out, using splicing techniques to introduce the new edge into the laminating/cutting stages without a detrimental effect on the operation of the label handling system.

[0087] The face material may have been presented to the label handling system as a liner-less supply without the necessity of a lightweight support liner.

[0088] Referring to Fig. 2, the face material is supported by a lightweight support liner 250. The support liner 250 is separated from the face material initially and is wound on to a reel 212. The face material alone is then laminated to a continuous belt 213 which is siliconised on side 214. The laminating process is controlled by the laminator 215. The face material, laminated to the continuous belt is then die cut to the shape of the resulting label via a die cutter 216 and anvil 217. The waste matrix 218 is wound on to a reel 219 and removed from the process.

[0089] The continuous belt 213 is strengthened so that repeated die cutting can take place without damage to the belt. The labels 220 which remain laminated to the continuous belt proceed forward via movement of the belt to the peeler plate 221. The peeler plate releases the label from the belt 213 and this is then positioned on a product (not shown). The continuous belt is driven by a drive roller 222.

[0090] Fig. 3 shows the comparison between (a), which shows the unpredictability of a conventional label dispenser and (b) the dispenser of the present invention.

[0091] The face material 311 laminated to a carrier 323, (with an inconsistent release value resulting from the release value of the silicone coating of the carrier) moves towards the peeler plate 324 and the release characterising of the label are unpredictable, so that as the label is presented to the peeler plate 321 this results in inconsistent label application 325.

[0092] Fig. 3(b) shows that controlled lamination onto a carrier 313 of a face material 311, controls the release value of the label so that on presentation to the peeler plate 321 the release value is lower than that associated with reel wound labels such as (a) and as a result the dispenser characteristics are predictable, ensuring consistency of label application, as shown as point 326.

[0093] Fig. 4 shows the use of a vacuum transfer drum 427 as a dispenser for application of a label to a product 428. The labels 420 are transferred from a carrier 413 to a vacuum drum 427 so that the adhesive face 428 of the label 420 is exposed. The vacuum drum 427 is rotated and the product 428 is presented to the exposed adhesive face 428 of the label 420 resulting in attachment.

[0094] Fig. 5 shows an alternative dispenser for application of a label to a product which uses a vacuum transfer belt 529 rather than the vacuum drum of Fig. 4.

[0095] The cut label 520 is conveyed to the transfer belt 529 using the carrier 513. The transfer belt 529 is positioned so that a portion of the transfer belt 529 is adjacent to the carrier 513. The negative pressure produced by the vacuum lifts the labels 520 off of the carrier 513. The transfer belt 529 than conveys the labels 520 to a dispensing location for application to a product 528.

[0096] Referring to Fig. 6, the face material 611 prior to being laminated to the carrier 613 has a substrate 630 presented to the adhesive face 631 of the face material via a substrate applicator 632.

[0097] Fig. 7 shows the steps of the method of application of a secondary substrate to a face material. The face material 730 in reel form 733 is unwound and presented in a controlled manner to the substrate applicator 734 with the adhesive coated face 735 of the face material 733 towards the applicator 734. The substrate, a promotional coupon 736 in reel form is dispensed onto the adhesive face 735 of the face material in register with the label 737. The components 737 and 736 are then laminated at 738 onto a reusable carrier or continuous belt and then die cut at 739 such that the coupon 736 is securely part of the label 737. The matrix 740 is then stripped off and the label either presented directly for application to a product 741 or re-reeled 742 for later use. The result is a secure attachment of the coupon to the product which can only be removed for redemption by tearing off the main label.

[0098] Referring to Fig. 8, the system as specifically described in Figs. 2-7 incorporates a laminating process which is controlled by a laminator 815, however in this system the laminating process follows the die cutting of the label via a die cutter 816 and anvil 817.

[0099] As shown in the drawing, the matrix 818 surrounding the label following die cutting remains to maintain good register of the label 820 onto the carrier, here a continuous belt 813. The waste matrix 818 is then drawn off onto a reel 819. The carrier 813 conveys the label 820 to a peeler plate 821 for dispensing 820 as discussed hereinabove.

[0100] It is of course to be understood that the invention is not intended to be restricted to the details of the above embodiments which are described by way of example only.

Claims

1. A recyclable carrier label handling system comprising a face material, a carrier, wherein the carrier supports the face material during cutting thereof at a die cutting station, and means to remove said face material from said carrier, the carrier being retained for continued use.

2. A recyclable carrier label handling system according to claim 1 in which the face material is liner-less when presented to the label handling system.

3. A recyclable carrier label handling system according to claim 2 in which the liner-less face material is silicone coated on one side.

4. A recyclable carrier label handling system according to claim 1 in which the face material is presented to the system while being supported by the carrier.

5. A recyclable carrier label handling system according to any preceding claim in which the carrier is a reel-to-reel carrier.

6. A recyclable carrier label handling system according to claim 2 or claim 3 in which the carrier is stored in reel form and drawn off such that its path is combined with the liner-less face material prior to or during the cutting thereof.

7. A recyclable carrier label handling system according to claim 1 in which the carrier is a continuous belt.

8. A recyclable carrier label handling system according to any preceding claim in which said means for removing the face material from the carrier, includes label application means for applying a label onto a surface.

9. A recyclable carrier label handling system according to any preceding claim in which the carrier is approximately 36 micron silicone coated PET.

10. A recyclable carrier label handling system according to any of claims 1-8 in which the carrier is approximately 12-24 microns polyester material.

11. A recyclable carrier label handling system according to any preceding claim in which the system further includes a sensor which is operable to detect any splice in the face material approaching the die cutting station, the sensor in communication with a web feed motion control system for controlling the cutting of the face material enabling the spliced material to bypass the cutting stage.

12. A method of operating a recyclable carrier label handling system which comprises the steps of:-

(1) supporting a label face material using a carrier during the cutting of the face material

(2) removing the face material from the carrier, characterised in that the carrier is retained for continued use.

13. A label release system comprising a face material, means to temporarily attach the face material to a supporting carrier and a dispenser for application of the face material to a surface.

14. A label release system according to claim 13 in which the means to temporarily attach the face material to a supporting carrier comprises a laminator.

15. A label release system according to claim 14 in which the laminator and laminating process are controlled so that the release of the face value has a low release value.

16. A label release system according to any of claims 13-15 in which the supporting carrier is a continuous belt, siliconised on one side.

17. A label release system according to any of claims 13-15 in which the carrier is wound from reel to reel.

18. A label release system according to any of claims 13-16 in which an adhesive is applied to the label and the supporting carrier has a smooth surface so that the adhesive flows to form an even surface prior to application of the label onto a surface.

19. A label release system according to any of claims 13-18 in which the system further includes apparatus for attaching a secondary substrate to an adhesive face of a label prior to application of the label onto a product surface.

20. A label handling system comprising a face material, means to temporarily attach the face material to a supporting carrier and apparatus for die cutting the face material, characterised in that the die cutting operation is undertaken prior to attachment of the face material onto a supporting carrier.

21. A method for operating a label handling system comprising the step of:-

(1) die cutting the label face material, followed by the step of:-

(2) temporarily attaching the die cut fact material to a supporting carrier.

22. A label handling system according to claim 20 in which the supporting carrier is in the form of a continuous loop which is handled in a cassette.

Drawing