By Matthew Stevenson Polyfuze / Mold In Graphic Systems
Safety Labeling Standards
From the late 1970’s to present, Consumer Safety has become the driving force behind safety labeling standards that test everything from label construction and adhesion, to chemical and environmental durability as warning/informative labels have become more prominently used on durable goods products made for a variety of industries.
Much of that drive has been a result of the U.S. Consumer Product Safety Commission (CPSC).
Founded in 1972, their mission is to “protect the public from unreasonable risks of serious injury or death from thousands of types of consumer products under the agency’s jurisdiction. The CPSC is committed to protecting consumers and families from products that pose a fire, electrical, chemical, or mechanical hazard or can injure children.”
Some examples of the first safety label standards:
1978: First UL 969 Standard for Marking and Labeling Systems written. UL 969 is the self described “de-facto safety label standard” that firmly illustrates the UL mission statement by providing direction to manufacturers using adhesive-based or In-Mold labels for use as permanent nameplates or markers in their products.
1979: ANSI Z535 Committee on Safety Signs and Colors formed. ANSI’s mission is “to enhance both the global competitiveness of U.S. business and the U.S. quality of life by promoting and facilitating voluntary consensus standards and conformity assessment systems, and safeguarding their integrity.” 1991: ANSI Z535.4 Standard for Product Safety Signs and Labels written. Language within the standard mandates “permanent” labeling to warn against specific hazards and accident prevention to industries like PowerSports and Outdoor Power Equipment.
In addition to the organizations listed, there are additional safety standards from organizations like ASTM, ANSI, OSHA, FINAT, ISO, NHTSA and more, that continue to oversee the protocols for manufacturing of durable goods products within children’s products, automotive, waste/recycling and consumer durable goods products just to name a few.
Name a product within any industry and there’s a very good chance that a standard is written for it with guidance on permanent safety and warning labeling.
Definition of Permanent
Permanent: [ pur-muh-nuhnt ] adjective – existing perpetually; everlasting, especially without significant change.
A great example is used within the ANSI Z535.4 safety standard, specifically sections 4 and 10 shown below. First published in 1991, the language describing permanent has not changed now for over 30 years.
Pressure sensitive adhesive labels (PSA’s) are the most prominent and well-known labeling system in the world which is why they have been the label choice for durable goods products made from metal and other types of materials. So it comes as no surprise the phrase “permanent labeling” has become synonymous with pressure sensitive adhesive labels. Yet the real question is, are they really permanent?
Unfortunately, manufacturers and original equipment manufacturers (OEMs) who believe they are acquiring permanent safety/warning labels for their LSE polyolefin plastic durable goods are actually getting labels that were engineered and tested for high surface energy metals and composites.
Knowing that even the most aggressive adhesives are susceptible to easy removal through mechanical or chemical means, the PSA industry “loosely defined” permanent adhesive based labels to a measurable result outside of the true definition. For manufactures, OEMs, or anyone seeking permanent safety/warning labels for their LSE polyolefin plastics, the term “permanent labeling” has been disguised and the PSA industry is misleading.
Labeling Durable Goods
Product Highlight: High Chairs
Because of durability and the ease to sanitize, infant high chairs are commonly made from nonporous molded plastic, polyethylene, and polypropylene. This is just one example of many durable good products made from LSE polyolefin plastic.
(ASTM) first approved and published ASTM F404 Standard Consumer Safety Specification for high chairs in 1975. ASTM has since revised the standard over the past 5 years including requirements for visibility and permanency of labels among other things. The most recent mandatory version, ASTM F404-18a, required certified compliancy by June 19, 2019 and states the following about permanent labeling.
ASTM F404-18a then references ASTM D3359 Standard Test Methods For Measuring Adhesion By Tape Test as a test for label permanency.
Yet ASTM D3359 specifically states that it cannot be used with plastic as seen below.
Remember! Safety and warning labels are only effective in keeping consumers safe and manufacturers / OEM’s free from litigious risk if they remain in place for the life use of LSE polyolefin!
Steel, Aluminum and Glass Part 1
“Permanent labeling” has always been a term synonymous with pressure sensitive adhesive labels. Since pressure sensitive adhesive labels are considered “permanent” when achieving a peel strength of two pounds or more from stainless steel (per GPI’s latest edition of its Industry Standards and Practices Manual for Product Identification), it’s important to understand why stainless steel, aluminum and glass were initiated as standard substrates for testing purposes.
In 1956, George Grossman founded the company Q-Lab to serve paint and coatings customers a consistent, reproduceable test surface. George wanted to ensure if a coating failed during testing, it was because of “bad paint, not a contaminated test surface.”
By the early 1990s, the Sherwin-Williams Company had published research on metal panels tested according to an alternating schedule of exposure in a fluorescent UV weathering test chamber (Q-Lab QUV® tester). Their work led to the development of ASTM D5894 used throughout the petrochemical industry today.
Q-Lab, along with other test panel manufacturers, provide R&D and 3rd party laboratories steel, aluminum and glass test panels to minimize the variability of paints, adhesives and more during testing.
For PSA testing, using standardized steel, aluminum and glass test panels was a natural fit and has been ever since. But what about PSA testing on LSE plastic panels?
To minimize variation in testing, stainless steel, aluminum and glass are specified test panels not only for coatings and paints, but adhesives and adhesive based labels as well.
Surface Energy?
A technical yet rarely discussed topic is Surface Energy, the molecular force of attraction between two unlike materials (adhesive & substrate) that determines adhesion and is measured in energy units called dynes/cm.
The first version of ASTM D6252 Standard Test Method for Peel Adhesion of Pressure-Sensitive Label Stocks was written back in 1998. Along with the 2019 revision, it has been used to verify whether adhesive based labels achieve two pounds or more of peel strength from stainless steel to be called “permanent.”
A great real-world example of low vs. high surface energy you’ve probably experienced is the difference a good waxing does for your car. Before waxing, your car has a higher surface energy than rain causing the
water to easily wet out over the surface. A fresh coat of wax lowers surface energy below the rain causing
water to bead and run off freely. Keeping it simple, remember this point: High Surface Energy attracts adhesion, Low Surface Energy REJECTS it!
Referencing the facts above, LSE Polyethylene and Polypropylene are only a few dynes/cm away from Teflon®, one of the most non-stick surfaces known to man. They are however many dynes/cm away from stainless steel. Therefore, “permanent” pressure sensitive adhesive labels achieving an initial two pounds or more of peel strength from stainless steel (700-1100 dyne/cm surface energy) are going to have different results when applied to LSE polyolefin plastics like Polyethylene or Polypropylene at only (31 & 30 dynes/cm surface energy).
LSE Polyolefin Plastics
Today, LSE polyolefin plastics have replaced steel as the primary material of choice for durable goods. But keep in mind most safety standards were written during the time period when pressure sensitive adhesive labels were being applied to steel and other high surface energy materials.
One reason for the switch from steel to LSE polyolefin plastics was the reduction of manufacturing parts needed for final assembly of products. Hundreds of steel parts were reduced to a small handful of polyethylene parts which allowed manufacturers and OEM’s to eliminate secondary operations and lower the cost of manufacturing and products significantly. In addition, Industrial Designers and Engineers have chosen these plastics, specifically, for their ability to stand up against chemicals, harsh environments and heavy impacts while lasting 3 years or more, the normal life expectancy for most durable goods products. As manufacturers and OEM’s in the Automotive industry strive for safer and more fuel-efficient cars, using LSE polyolefin plastics is also becoming more and more prevalent as it’s estimated that a 10% reduction in a vehicles weight equates to a 5-7% increase in fuel economy. Features such as lowering interior noise and vibrations in vehicle manufacturing only adds to the many other benefits of using LSE polyolefins plastics.
In 2015, LSE Polyolefin plastics such as LDPE, LLDPE, HDPE & Polypropylene made up roughly 55% of global plastics demand for both durable goods and packaging products. Who knows what that figure is today?
In 2018, global production of polypropylene hit 55.9 million metric tons at a value of $97.4 billion U.S. Dollars and is poised to grow at a rate of 5.84% annually. Polyethylene production hit 99.6 million metric tons at a value of $164 billion U.S. Dollars and is poised to grow at a rate of 3.78% annually!
Steel, Aluminum and Glass Part 2
Durable goods manufacturers and OEM’s looking to label LSE polyolefin plastics permanently can do a quick Google search for “permanent labels for LSE polyolefin” that will land a list of label suppliers that market and sell special formulated adhesives and label constructions that will supposedly bond and adhere permanently to LSE polyolefin plastics.
Based on the marketing language used, anyone looking for a permanent solution would be led to believe that viable chemical and environmental testing had in fact been conducted on labels applied to LSE
polyolefin test panels verifying permanence.
As durable goods converted from metals to LSE polyolefin plastics during the mid 1990’s, safety labeling standards had already been in place for quite some time. Because adhesive based labeling fell within the same general testing scope as coatings, paints and adhesives, using steel, aluminum and glass panels for standardized testing was established with no real reason to change. Previously existing safety standards reference testing guidelines as the criteria to follow. Below are a few ASTM testing guidelines for adhesion.
1. ASTM D903 – 98 Peel or Stripping Strength of Adhesive Bonds
2. ASTM D6252 – 98 Standard Test Method for Peel Adhesion of Pressure-Sensitive Label Stocks at 90° Angle.
3. ASTM D6862-11 Standard Test Method for 90° Peel Resistance of Adhesives
4. ASTM D3330 / D3330M – 2004 Test Method for 180° Peel Adhesion of Pressure-Sensitive Tape
(Ref: ASTM A666 Preparation of Steel)
Today, the only testing conducted on actual LSE polyolefin panels Industrial Designers and Engineers will see for labels marketed for use on LSE polyolefin durable goods is “Peel Adhesion.” This portion of data sheets shows pressure sensitive adhesive labels applied to various substrates and then peeled by an apparatus after a prescribed dwell time, usually 24, 48 and 72 hours. The results are then measured and recorded.
The second portion of data sheets is more crucial to actual durability and permanency of pressure sensitive labeling but veers from the application method mentioned above. Instead of various substrates, labels are applied to only stainless steel, aluminum or glass and then exposed to chemical and environmental inputs for a prescibed period. The test does not include application of the label to other surfaces of interest like LSE polyolefin plastics for which the label is marketed for in the first place.
Fact Check
The National Association of Graphic and Product Identification Manufacturers Industry Standards and
Practices Manual for Product Identification states, “it is important to identify the substrate to which a PSA (Pressure Sensitive Label) will be applied. Is it plastic, i.e., high or low density polyethylene, polypropylene, polycarbonate etc., or is it metal? Is it painted, lacquered or coated in any way? PSA’s exhibit different bonding characteristics on different surfaces.”
3 Facts about PSA’s:
1. PSA suppliers are marketing and selling PSA’s as “permanent“ for use on LSE polyolefin durable goods. Thus, they’ve identified and marketed the substrates to which their PSA’s will be applied to as referenced above.
2. Data sheets that display and market conclusive information about “permanent“ PSA labels for use on LSE polyolefin durable goods, provide no data on chemical and environmental testing conducted on LSE polyolefin plastics as there’s no formal testing requirement to do so.
3. Days, weeks, months and years of real world exposures to chemicals, UV and other environmental inputs proves that PSA labels neither bond nor adhere permanently to LSE polyolefin durable goods over
extended periods of time.
Fine print disclaimers for “Product Performance and Suitability“ are usually found at the bottom of data sheets. Such language proves the 3 facts about PSAs shown above, placing the burden of discovery on
manufacturers and OEMs.
PSA Label Supplier Example
“All of the descriptive information, the typical performance data, and recommendations for the use of said products shall be used only as a guide and do not reflect the specification or specification range for any particular property of the product. Furnishing such information is merely an attempt to assist you after you have indicated your contemplated use and shall in no event constitute a warranty of any kind by said company. All purchasers of said products shall be responsible for independently determining the suitability of the material for the purpose for which it is purchased. No distributor, salesman, or representative of said company is authorized to give any warranty, guaranty, or make any representation in addition or contrary to the above.”
ML/IMD Printed Inserts
In-Mold Labels (IML)and In Mold Decorating (IMD) came into the spotlight in early 2000 when engineers began using them for durable goods products in the injection molding industry. Robotics and automation are the driving force behind IML’s and IMD’s being used today. IML and IMD printed inserts are constructed of a treated semi-compatible layer which is then printed with screen, rotogravure, offset or digital inks. A final clearcoat or laminated polymer over layer finishes the construction. Although they are considered permanent in many applications, even IML/IMD printed inserts have their limitations when used in conjunction with LSE polyolefin substrates. On page 9 of Fall 2010 SPE Injection Molding Division’s newsletter, it was stated that “The most appropriate sheet or film materials for printed inserts are those with higher surface energy that will allow stronger and more consistent ink bonding. These include polycarbonate, PET, acrylic, ABS, PVC, and PS. However, success with some lower surface energy materials, as well as those that are self-lubricating, is limited due to interfilm adhesion issues. With proper pretreatment, PP and PE have also been successfully used in the inmold process.”
With the expanding use of LSE polyolefins by manufacturers and OEM’s as their material of choice for durable goods within industries such as automotive, durable goods, food, beverage, supply chain, agriculture, medical, outdoor power equipment, recreational sports, powersports, waste, recycling and sanitary, it’s crucial that chemical and environmental testing be conducted on labels attached to actual LSE polyolefin panels and data collected, whether PSA, IML/IMD or any other type, particularly when it comes to the extent of permanent safety/warning labeling that must either meet or exceed the standards that regulate them. This will ensure a future of safety and warning labeling that provides customers proper use instructions and hazards associated with the durable goods products they buy while simultaneously keeping manufacturers and OEM’s free from litigious risk for the life-use
Why Polyfuze?
In 1983, Michael Stevenson began the company Mold In Graphic Systems® (MIGS®) after spending 8 years of development inventing the world’s first and only Mold In Graphic® label to replace failing pressure sensitive adhesive labels used in rotationally molded LSE polyolefin plastics.
Over 30 years and thousands of customers later, MIGS supplies 100% LSE polyolefin compatible labels that permanently meld Brand names, logos and safety/warning information directly into rotomolded kayaks,
coolers, traffic bollards and thousands of other products used throughout the world.
In 2012, as an offshoot of Mold In Graphic Systems® Brand, Polyfuze® Graphics Corporation was created to supply 100% LSE polyolefin compatible labels to manufacturers and OEM’s within the injection molding industry. Polyfuze labels are tailored to permanently meld Brand names, logos, and safety/warning information directly into LSE polyolefin plastic durable goods until their end of life use. This claim is backed by testing conducted on Polyfuze labels applied to LSE polyolefin plastic panels (Test Data Reports available upon request) and guaranteed by Polyfuze’s Lifetime Guarantee. Polyfuze has also invented its VersaFlex system allowing application of the same permanent LSE polyolefin compatible labels to injection, blow, thermoformed & rotomolded LSE polyolefin durable goods.
When end of life comes to an LSE polyolefin durable good and it’s time to recycle, Polyfuze® labels are 100% recyclable, just like the LSE polyolefin plastics they’re seamlessly fused to.
Polyfuze Has Three Goals To Accomplish:
Goal #1. Securing your trust and belief in our labeling products & service.
Polyfuzes permanent Brand and Logo labels will give you a ROI on your Brand Image for the durable goods you produce until their end of life. Something no other label supplier provides, we back Polyfuze labels with a lifetime guarantee.
Goal #2. Polyfuze permanent Safety/Warning labels serve a threefold purpose you and your customers can trust in.
1. First purpose is keeping consumers safe and informed when using LSE polyolefin durable goods until the products end-of-life.
2.Keeping manufacturers and OEM’s of LSE polyolefin durable goods safe from litigious risk caused by label failures.
3. Helping manufacturers and OEM’s comply with their labeling market codes and regulations to meet
actual “permanent” criteria written within safety label standards.
Goal #3. We call this our selfish goal.
Being your partner of choice when it comes to providing your LSE polyolefin plastic labeling needs.
For more information, please contact Jason Brownell at jasonbrownell@polyfuze.com
