The drinks industry’s move away from traditional self-adhesive labelling to OPP (oriented polypropylene) alternatives has been fast-tracked by Brexit and Covid-related supply chain issues. Here, Steve Bradley, UK sales director for AVE UK, explains why 2021 was the year that so many finally made the switch.
SELF-adhesive labelling has been a mainstay of soft drinks packaging for many years. However, 2021 has seen end-users reach a tipping point as the issues that affected supply chains across so many industries also negatively impacted the self-adhesive labelling sector.
A perfect storm of increased red tape, border hold-ups and rising import costs because of Brexit, combined with onerous Covid-19 protocols, drastically impacted the supply chain. This resulted in a sharp rise in the cost of component materials, making self-adhesive labelling an unaffordable option for many drinks manufacturers.
Cost savings
This unprecedented supply chain landscape provided the catalyst needed to upgrade beverage labelling lines across the UK and accelerated many drinks manufacturers’ purchasing decisions. With lower component costs, OPP labellers were already a cheaper alternative than self-adhesive models, but in 2021 they proved an even more attractive proposition – the cost of labelling a soft drinks bottle with OPP technology is now, on average, three times less expensive than a self-adhesive option.
Sustainability gains
As well as the cost savings to be made, OPP labelling also brings considerable sustainability benefits. This is because, unlike self-adhesive labels, OPP labels are produced on a reel with no backing paper. Not only does this mean a lower carbon footprint in the manufacturing process but it also cuts the volume of waste created by the end-user. And, of course, OPP machines support the use of recyclable labelling materials. In addition, accurate control helps end-users minimise wastage further. For example, available in rotary or linear configuration from 3,000-70,000 bottles per hour, the Z-Italia roll-fed OPP labeller supplied by AVE UK applies plastic, recyclable or paper wrap-around labels from a reel onto cylindrical or shaped containers, either empty or full.
The servo motor in the labelling unit accurately controls the stretching of the film, which is unwound, cut and transferred onto the container using vacuum technology. Precision control ensures only the exact amount of material required is unwound, further reducing waste. Similarly, the stainless-steel glue roll distributes glue onto the edges of the labels and ensures only the minimum amount of glue is used.
Increased productivity
Perhaps the greatest benefit of OPP labelling, however, is the impressive productivity gains it can deliver compared with self-adhesive alternatives. Each self-adhesive reel contains, on average, 5,000 labels; in comparison, the lack of backing paper means each OPP reel can hold 20,000-25,000 labels. And as they are completely automated, OPP labellers require no manual reel change. On a 20,000 bottles-per-hour line, production would need to stop every 15 minutes to accommodate the changeover of the self-adhesive labelling reel. With a twin-feed OPP labeller, there is no requirement to stop the line.
Flexible production
Finally, the twin-feed design of OPP labellers like the Z-Italia range from AVE also supports production flexibility. Ideal for applications such as beverage, mineral water, food and milk production, as well as in the chemical industry, the double reel support is operated by servo motors that allow the end-user to process a wide range of materials of varying quality and thickness.
Furthermore, if the size or type of label needs to be altered to accommodate a product changeover, this can be actioned while the original label is still being applied; the first reel can continue operating while the second is being switched, ensuring total flexibility without requiring production to be stopped.
Offering clear productivity, sustainability, flexibility and profitability benefits, it is clear UK beverage producers have much to gain by switching from self-adhesive to OPP alternatives.
