Release liners are an imperative part of a pressure sensitive label. As with facestocks, the liner is seeing numerous trends designed to improve efficiency and quality. Plus, sustainability functions as one of the key trends impacting this growing market.

According to Avery Dennison, the label and package printing industry is demanding increased sustainability and improved coating and adhesive technologies. Of course, thinner liners can serve two roles – sustainability and efficiency. In addition, the market is seeking new solutions for filmic liners.

“There’s a push toward using recycled materials and thinner liners,” explains Angel Harvey, marketing director for Film, Rapid Roll, and Overlaminate Solutions, Avery Dennison. “We’ve now introduced new 90% rPET liner options, which are perfect for pharmaceutical, wine, and spirits applications, further advancing eco-friendly packaging solutions. Thinner liners also allow for more labels per roll, reducing storage needs, transportation costs, and waste, all while improving overall productivity.”

When it comes to coating and adhesive technologies, there are several areas of exploration. First, lower residue coatings provide better adhesive anchorage even with thinner or recycled materials. Secondly, silicone-free, UV-curable, or water-based coatings are becoming more attractive because they help recycling or reduce environmental and safety concerns.

Paper vs. film

While the demand for film has increased significantly over the years, there are pros and cons to using each substrate depending on the application.

Paper liners are excellent for low to medium-speed, automatic applications. They offer great performance on many different dispensing machines and superior diecutting performance due to the  calendaring process. Meanwhile, paper liners are suitable for roll-to-roll applications. Additionally, paper liners can often be printed on the reverse side for batch codes or branding, adding functional value. From a sustainability standpoint, paper’s chain-of-custody certification tracks fibers from forest to end use, ensuring sustainability through traceable sourcing.

Film liners, on the other hand, are made from PET, providing strength and resistance to tearing. They also offer excellent registration for printing and diecutting at high speeds.

“Film liners offer the opportunity for recycling after dispensing,” notes Harvey. “They are more resistant to humidity, reducing curl and ensuring better dispensing at high speeds, as well.”

Film liners excel in high-speed printing, di-cutting, and dispensing machines, maintaining dimensional accuracy and resisting deformation. This can involve curl or humidity issues.  From a stability and durability perspective, film liners are preferred in humid or harsh environments where moisture resistance and durability are critical.

“Films are less likely to tear or break during converting or dispensing, ensuring smooth operations,” explains Harvey. “Film liners also maintain their thickness, width, and registration even at high speeds and varying temperatures, making them reliable for precision applications.

“PET films can also be much thinner than paper liners while remaining strong, reducing material waste and shipping costs,” she adds. “Unlike paper, PET films do not absorb water, preventing curling or swelling in humid conditions. The consistent surface of film liners supports high-quality printing, diecutting, and even laser cutting, too.” 

A changing market

Industry demand for new and improved technologies fuels companies like Avery Dennison, which has invested significant resources into optimizing its substrates. This technology was recently on display at Labelexpo Europe, where Avery Dennison celebrated 90 years of innovation.

“The label market is dynamic and evolving, driven by the need for innovation, efficiency, and sustainability,” remarks Harvey. “In recent years, there has been a notable shift toward thinner liners and recyclable materials, reflecting the industry’s focus on reducing environmental impact and ensuring efficiency for converters. To support  this shift, we’ve introduced our new 90% rPET liner option, which is ideal for pharmaceutical, wine, and spirits applications, offering a sustainable solution without compromising performance.”

The shift toward thinner liners, recyclable materials, and the continued use of filmic liners, particularly PET-based options, has been significant due to their strength and versatility for roll-to-roll applications. “Avery Dennison continues to innovate in coating technology and materials to stay ahead in this evolving market,” adds Harvey.

Overcoming challenges

Sustainability has emerged as a core principle for many throughout the supply chain, from suppliers to brands and end users. While it is a crucial factor for many, it also represents a challenge that suppliers are navigating diligently.

According to Harvey, sustainability and the recycling of release liners remain challenging due to limited global infrastructure and facilities for recycling matrix waste and liners, as well as the variability in materials like paper and plastic, which require specific recycling solutions. In the future, linerless labels will continue to emerge as an option, too.

“Significant progress has been made, though,” states Harvey. “The industry is working to find new end-markets for release liner such as the use of paper liner in the insulation manufacturing process. Also, through the Liner Recycling Initiative, powered by TLMI, the label industry is trying to develop a robust, national-scale, recycling program for paper release liner that connects both small and large end-users that generate release liner to qualified recycling mills.”

Avery Dennison’s AD Circular program is another significant step forward. This initiative connects converters and brands with trusted recycling providers across the US, enabling landfill diversion, improved recycling, and support for circularity.

“In regions like Quakertown, PA, the program is driving change,” says Harvey. “By leveraging our Distribution Center, we collect full truckload quantities of paper and PET liners from label printers and brands – with a minimum drop-off quantity of one filled gaylord box – ensuring they are recycled.”