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What You Need to Know About Waterborne Acrylic Linerless Label Adhesives

Find out why you should consider waterborne acrylic pressure sensitive adhesives (PSAs) for linerless label manufacturing, how to implement them in your production and ways the right supplier can make it easy to accomplish.

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If you’re manufacturing linerless labels, you likely have been utilizing hot melt pressure sensitive adhesives (PSAs) as your linerless label adhesive technology. However, you may not know that waterborne acrylic PSAs also can be used for linerless label applications, too. Learn why this technology may be a good fit for your linerless label manufacturing needs, how to implement them and how the right supplier can help.

Why Waterborne Acrylic PSAs are Compatible for Linerless Labels

Based on an acrylic polymer structure, waterborne acrylic PSAs remain tacky when dried and form a quick bond to substrates including paper, corrugate, plastic, metal, glass and textile substrates when pressure is applied. Common applications that utilize linerless labels with waterborne acrylic PSA technology include:

• Logistics packaging
• Cold temperature and freezer-grade packaging

All-Temperature Performance

Waterborne acrylic PSAs provide stable adhesion across temperatures, including hot, humid conditions or freezer-grade levels down to 0°F (-17°C). This is due to their:

• Chemical structure: Waterborne acrylic PSAs are made of polymers with high thermal stability, making them more resistant to heat-related degradation. This helps a linerless label adhesive maintain adhesion in hot climates.
• Flexibility: The acrylic-based formulation can include specific monomers or additives to enhance flexibility for either high or low temperatures. The flexible strength helps waterborne acrylic PSAs protect against contraction or expansion for consistent adhesion.

If you are looking for a linerless label adhesive that can endure shipping in tropical or humid climates, a waterborne acrylic PSA may provide higher performance over a hot melt PSA. This is because a hot melt PSA’s thermoplastic component can soften or melt at elevated temperatures and lose adhesion; as a result, the linerless label could slide off the end-use application if it’s under extreme heat or humidity conditions. Further, a hot melt PSA’s thermoplastic property may contract at low temperatures when used on a linerless label for freezer-grade packaging, leading to reduced surface adhesion. Therefore, you may want to consider a waterborne acrylic PSA technology instead as it will not lose adhesion in low temperatures.

Compatibility With Silicone Release Coatings

Without a release liner, it’s critical for linerless label adhesives to offer compatibility with the silicone release coating so that the label can still come off the roll cleanly. Waterborne acrylic PSAs can be helpful in addressing this because they offer:

• Controlled tack: A waterborne acrylic PSA formulated with a controlled tack allows it to provide the necessary adhesion strength to stay in place on a roll while still releasing cleanly from the silicone release coating without leaving residue behind. This also helps ensure that a printed design on the label is clear and not impacted by any adhesive residue.
• Low surface energy interaction: Silicone release coatings may have low surface energy (LSE), which can cause challenges with proper adhesion. However, waterborne acrylic PSA coat weights can be designed to accommodate LSE silicone release coatings, helping to ensure consistent adhesion that is still capable of releasing off the roll.

It's also important to test the end-use performance of your chosen silicone release coating with a waterborne acrylic PSA. A supplier with expertise on linerless label construction and testing capabilities can help you save valuable time and resources, as they can determine how these label layers work together effectively while also reducing complexities in your supply chain to manufacture linerless labels.

Consider using UV silicone release coatings with a waterborne acrylic PSA. UV silicone release coatings are formulated for use on flexographic equipment with paper, film and foil substrates. Printed with wax-free aqueous, solvent, or UV inks, this topcoat is intended for use as a basecoat for a release coating in linerless labels, helping to remove the label from a roll seamlessly with no residue left behind.

Processing Efficiencies

As a solvent-free technology, waterborne acrylic PSAs help you increase your processing speeds by:

Reducing production steps: Without the need to burn off solvents, you do not have to utilize a thermal oxidizer or specialized storage and ventilation that may require additional processing steps.

• Facilitating easy application and clean up: Waterborne acrylic PSAs can be easily wiped off if there are any spills or excess adhesive during the application process. This helps reduce downtime and enables a neat application.
• Increasing cost efficiencies: It's also important to note that waterborne acrylic PSAs are more cost effective compared to microspheres. Rather than purchasing microspheres as an additive for removability to a linerless label adhesive formulation, a PSA that is 100% acrylic will provide both the adhesive strength and tack levels needed for clean removability, helping you save on costs and simplify logistics.

How to Implement Linerless Labels Into Your Production

It is worth considering ways you can implement linerless labels into your manufacturing, especially if you already have the coating equipment for both hot melt PSAs and waterborne acrylic PSAs. With the adhesive equipment in place, you should then focus on your capabilities for the silicone release coating:

• If you currently purchase silicone and place it on facestock, you simply need to adapt your production steps for linerless label manufacturing. You already have the equipment and materials.
• If you currently purchase pre-siliconized release liner, you simply need to purchase pre-siliconized paper that will be the facestock instead of the liner. Your adhesive will go on the other side of the pre-siliconized paper for linerless labels rather than a separate facestock with linered labels.

Either way, you'll take the same next steps to manufacture linerless labels. You can read about those next steps here.

How Bostik Can Help With Your Waterborne Acrylic PSAs For Linerless Labels

With the market’s most complete and integrated PSA portfolio, Bostik has the knowledge and support capabilities that allow you to rely on us as your one-stop-shop supplier for your linerless label construction needs. Designed to help you address end-use applications with high and low temperatures, Bostik manufactures waterborne acrylic PSAs for linerless label adhesives that allow you to form quick, strong bonds with equipment you already own. Additionally, we can also provide silicone release coatings with our PureRad™ solutions to help your linerless label layers work together effectively.

When you work with Bostik, you’ll receive:

• Customized Solutions: Whether you are new to manufacturing linerless labels or looking for new innovative methods, Bostik can help you eliminate the release liner with both waterborne acrylic or hot melt PSA formulations depending on your specific application needs.
• Technical Support: Our team of experts will assist you throughout the entire process in determining whether waterborne acrylic PSAs are right for your linerless label needs. We’ll help you understand how the formulation will work with other label layers to meet your specifications, customizing formulations to meet application and printer requirements. This involves testing samples and providing recommendations according to what is suitable with your equipment.
• Troubleshooting: We’ll support you through any processing setbacks with suggestions on what may be causing issues and how to improve efficiencies. We’ll also work with you on how to optimize your lines to reduce issue likelihood going forward.

Are you interested in learning how waterborne acrylic PSAs can play a role in your linerless label manufacturing? Contact a Bostik expert to learn how we can make it easy to incorporate this PSA technology into your processes.

Other Relevant Content:

3 Reasons You Need the Right Waterborne Acrylic PSAs for Labels

How to Choose the Right Linerless Label Adhesive

How to Incorporate Linerless Labels Into Your Production Lines

Going Above, Below and In-Between the Label

See also

Back to all articles Overcome Shipping Label Challenges with PSAs  How to Minimize Performance Issues When Coating Hot Melt PSAs Why You Should Use Durable Labels Over Other Options 

A Guide to Understanding Release Liners in Manufacturing

Release liners are an often overlooked but crucial component in various manufacturing processes. These specially designed materials serve as a protective barrier, preventing adhesion during production and ensuring high-quality end products. In industries such as rubber, automotive, and packaging, the right release liner can significantly impact efficiency and product performance. 

In this guide, we will explore the fundamentals of release liners, their types, applications, and why choosing a trusted supplier like OTEGO is essential for maximizing productivity and maintaining product quality.

What Are Release Liners?

At their core, release liners are thin layers of material designed to carry adhesive substances until they are ready to be applied. They provide a temporary barrier between adhesives and other surfaces, ensuring that the adhesive remains functional and uncontaminated during storage, transportation, or processing. 

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The non-stick coating applied to the surface of release liners can be made from various materials, with silicone being the most common due to its excellent non-stick properties. Alternative silicone-release coatings like polyethylene or wax are used for different applications, particularly when silicone is either too costly or not needed for the job. The choice of liner depends on the requirements of the specific manufacturing process, including the type of adhesive used, environmental conditions, and the demands of the final product. 

How Release Liners Work

Release liners are designed to be peeled off easily, exposing the adhesive surface when it’s ready to be applied. In many manufacturing scenarios, the adhesive product (such as tape, stickers, or medical patches) is laminated to the release liner during production. The liner protects the adhesive from dirt, moisture, and damage, preserving its quality until it reaches the final application stage. 

Because these liners are designed to be non-stick, they can prevent costly errors in manufacturing. For example, adhesives may get stuck prematurely during a production run, leading to waste, delays, and poor product quality. Release liners ensure that adhesives stay intact until the moment they need to be applied, offering precision and control. 

Common Types of Release Liners

Release liners come in various types, each suited for specific needs. Here’s a more in-depth look at the most commonly used kinds: 

1. Paper-Based Release Liners
These liners are typically made from standard or specialized paper and are coated with materials like silicone or wax to create a non-stick surface. Silicone release papers are widely used in applications that do not require extreme durability or heat resistance. They are often found in consumer products like self-adhesive labels, tapes, and packaging. Though cost-effective, they may not stand up to the wear and tear of more demanding industrial applications.

2. Film-Based Release Liners
These liners use polyester (PET), polyethylene (PE), or other films made of plastic material as the base material. The use of films provides increased strength, flexibility, and resistance to environmental factors such as heat and moisture. Film-based release liners are essential in high-performance environments like electronics and automotive manufacturing, where precision and durability are key. They also allow for tighter tolerances in terms of thickness and performance, which is often critical in high-tech industries.

3. Single-Sided vs. Double-Sided Release Liners

• Single-sided liners have a coating on only one side, which is enough for simple adhesive applications. These are commonly used in everyday products like stickers, labels, or consumer packaging.
• Double-sided liners, meanwhile, have non-stick coatings on both sides. They are often used in complex manufacturing processes where both surfaces of the liner need to be adhesive-free. For instance, in multi-layered electronic components, a double-sided liner can keep different layers from bonding prematurely.

4. Perforated Release Liners
These liners feature small perforations to allow for easy tearing or dispensing. They are frequently used in packaging applications where rapid processing and dispensing are necessary, such as roll labels or tapes. Perforated liners are also used in processes where precision cuts are needed, as the perforations guide where the liner should tear or peel away. In some applications, just a little pressure is required to separate the liner from the adhesive surface.

Uses of Release Liners in Manufacturing

Release liners have become essential across a wide range of industries. Their role in protecting adhesives and facilitating clean, precise applications makes them indispensable for many production processes. Here’s a closer look at how different sectors utilize release liners: 

1. Tire and Rubber Manufacturing

Release liners are commonly used in the production of tires and other rubber products. In processes like rubber calendaring or extrusion, the liner acts as a barrier that prevents rubber compounds from sticking to machinery or unwanted surfaces. They ensure smooth handling, protect the rubber’s adhesive layer, and help maintain product quality during vulcanization or molding. 

2. Composite Materials

In industries like aerospace, automotive, and construction, release liners are used with composite materials such as carbon fiber or fiberglass. These composites are often pre-impregnated with resin, and release liners keep them from sticking together during storage or handling. The liners are removed right before the composite is applied to molds or structures, ensuring accurate positioning and preventing contamination. 

3. Adhesive Tape and Sealants

Industrial-grade tapes, sealants, and other adhesive-backed materials also use release liners to protect their adhesive sides until they are ready for application. In heavy-duty applications like construction, automotive assembly, and industrial maintenance, release liners prevent adhesives from sticking to unwanted surfaces, ensuring a clean and accurate bond when applied. 

4. Protective Films and Coatings

Release liners are essential in manufacturing protective films and coatings for industrial equipment, machinery, and electronics. These films are often applied to surfaces to shield them from scratches, dust, or corrosion. The liners protect the adhesive layer of the film during storage or transport and ensure it’s clean and effective when applied to surfaces. 

5. Roofing and Insulation Materials

In construction and building materials, release liners are widely used with adhesive roofing membranes, waterproofing materials, and insulation products. These liners protect the adhesives in the materials from environmental exposure and premature bonding, ensuring easy and effective application on construction sites. 

6. Conveyor Belts and Rubber Profiles

Release liners are used in the production of conveyor belts and rubber profiles for industrial use. During the manufacturing process, the liner prevents the rubber or adhesive from sticking to equipment, ensuring smooth production and protecting the product’s quality until it’s applied or assembled. 

In all of these industrial applications, release liners help streamline manufacturing processes, reduce waste, and maintain the integrity of the materials being produced, ensuring clean, efficient production. 

Choosing the Right Release Liner for Your Application

Selecting the best release liner involves considering several factors, such as:

• Adhesive Compatibility: Not all liners work well with every adhesive. Silicone-release liners, for example, are the best choice for high-performance adhesives that require heat resistance and durability.

• Environmental Conditions: For applications exposed to high temperatures, moisture, or chemicals, film-based liners with heat-resistant properties are often necessary.

• Ease of Use: The release force (how easily the liner can be removed) is an important consideration. Some applications require easy peel-off, while others may need a liner that holds firmly until the right moment.

• Cost Considerations: For everyday applications like labels or consumer packaging, paper-based liners are often a cost-effective solution. However, for high-tech or industrial uses, film-based liners, though more expensive, offer better performance and longevity.

FAQs on Release Liners

Selecting the best release liner involves considering several factors, such as: 

What is the purpose of a release liner?

A release liner serves as a protective backing for adhesives, keeping them intact and uncontaminated until they’re ready for use. Its non-stick surface ensures that the adhesive doesn’t bond to unintended surfaces or objects during production, storage, or transport. The liner also helps in the easy application of adhesives by peeling off smoothly when the adhesive is ready to be applied. 

What can I use as a release liner?

Various materials can be used as release liners depending on the specific application. Common materials include paper-based liners with a silicone coating, plastic films like polyethylene or polyester, and even wax-coated paper. The choice of release liner depends on factors like the type of adhesive, environmental conditions, and whether the application requires flexibility, durability, or resistance to moisture or heat. 

What material is used for tape-release liners?

Tape-release liners are often made from materials like silicone-release paper or plastic films such as polyethylene or polyester (PET). Silicone is the most common coating because it offers excellent non-stick properties and can withstand high temperatures, making it ideal for tape applications. Film-based liners are preferred when durability, moisture resistance, or flexibility are essential for the application. 

OTEGO – World-leading Supplier of Release Liners in Manufacturing

Selecting the best release liner involves considering several factors, such as: 

Release liners may seem like a small part of the manufacturing process, but their role is crucial across many industries. Whether it’s protecting adhesives for medical devices, helping assemble electronics, or ensuring precision in the aerospace and automotive sectors, release liners keep things running smoothly. Understanding the different types of release liners and their applications will help manufacturers choose the right product for their needs, improving efficiency, reducing waste, and ensuring product quality. 

Selecting the right release liner is essential for improving quality and productivity in manufacturing. At OTEGO, we bring over 50 years of expertise in technical release liners, particularly for the tire and rubber industries. Our liners, made from fabrics, films, or coated materials, are trusted by international manufacturers and designed to reduce rubber waste, minimize downtime, and enhance efficiency. 

We focus on Total Cost of Ownership (TCO) and deliver solutions that provide long-term value. With a commitment to sustainability and innovation, OTEGO ensures you get high-performance, environmentally friendly products tailored to your needs. 

Ready to enhance your manufacturing process? Contact us today to learn more about our high-quality release liners and how we can support your business! 

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