Brand managers and product designers like the look. Colors pop. Products stand out from the competition. Shelf appeal is strong. Clarity and fidelity are described as “outstanding”; images, “razor sharp.” Synthetic substrates print like paper, yet leverage the best properties of plastic.
Durability ratings are high, as are moisture, chemical, tear, scratch and crinkle resistance. Package weights are down in many applications, particularly in-mold labels (IML).
CPCs and their printer partners are charting favorable advances in sustainable footprints. At the same time, they are ramping up their competitive advantage, thanks to the ability to provide containers of unique shapes and sizes.
Defining Synthetics
“Synthetic paper is a white, opaque plastic made from either polypropylene or polyethylene that has been modified with a calcium carbonate coating or clay filler to enhance its dyne level for better ink adhesion and brightness,” explains Jack Smith, Hop Industries.
He continues, “Most synthetic papers are made from resins, which are environmentally friendly and contain no heavy metals, chlorine, phthalates or other carcinogens that are damaging to the environment. Synthetic papers, made from these resins, are 100 percent recyclable and, when incinerated, release less than 0.01 percent of carbon dioxide into the atmosphere.”
Synthetic Composition & Characteristics
Offering a printer’s perspective, Dave Washburn of FTA member Taylor Communications writes, “Synthetic substrates are typically used for most outdoor applications or indoor applications with exposure to a variety of harsh conditions. Most synthetic substrates are clear, metallic or white.” He offers the following classifications:
- Polycarbonate can last for years without fading under extended exposure to UV light while providing resistance to moisture, many chemicals and abrasion. It’s available in matte, gloss and satin. Typically, polycarbonate films used are in the range of 5 mils to 10 mils thick
- Polyester is durable but rigid and can provide two-to-five years of outdoor service. Polyester films are available in a wide range of thicknesses starting at 1 mil
- Vinyl substrates conform well to curves and provide an outdoor service life of seven-plus years. The most commonly used thickness is 4 mil
- Polypropylene is popular for consumer goods like plastic soft drink containers. Lifespan ranges from six months to two years. Polypropylene films are typically less costly on a unit area basis than other films
Market Watch
Industry analyst Markets and Markets reports synthetic paper will be a $386.5 million market by 2020. Current compound annual growth rate (CAGR) is 7 percent. That is expected to remain consistent for the five-year period of 2015 to 2020.
The label segment leads the global synthetic paper market and accounts for a market share of greater than 40 percent. Leading suppliers include Yupo Corp., Arjobex (Polyart), Granwell Products Inc. (Polylith) and Hop Industries.
A majority of those firms have recently introduced new grades of synthetic paper which are lightweight, versatile and recyclable. Marketers stress those traits and indicate the product is essential to responsible packaging and responsible branding.
Driving the use of synthetics in packaging is the need for the labels, cartons, boxes and bottles to play a greater promotional role. Bill Hewitt of Yupo says, “Consumers spend five seconds in front of a store shelf, and you want them to grab your brand. Synthetics are a way to get that package to stand out even more.”
Benefits Broadcast
Granwell maintains, “Synthetic paper is far stronger than conventional paper,” and adds, “The extensive selection of grades, gauges and finishes make it a serious consideration for almost any application.”
The company notes, “Polylith synthetic paper can be printed by flexography, offset, gravure, letterpress, screen and thermal transfer methods. When coated, it can be printed by inkjet, laser and direct thermal processes.”
Among other points, Granwell stresses, “Synthetic papers perform well with guillotining, slitting, die cutting, drilling, perforating, hole punching, grommeting, embossing, foil stamping or folding.”
Arjobex delivers similar claims and deems synthetics as ideal for even the most demanding tag and label applications. “It is easy to convert and can be folded, perforated or die cut. Polyart can be used by all printers and gives the same superb print finish as a matte-coated paper,” the company says.
“Thanks to its coating, Polyart synthetic paper can be printed with all the traditional techniques and gives excellent results in thermal transfer and digital printing on HP Indigo presses and UV inkjet,” Arjobex executives state. “The polyethylene film core makes it resistant to tearing, water, greases and many chemicals. This is why synthetic paper is particularly adapted to all printing jobs which must withstand difficult environments.”
Noting the product is highly effective on large container labels, they cite improved productivity and shorter cycle times as benefits of its use. Why? The coating reduces static, dimensional stability assures even application of the label, and it’s adaptable to a wide range of operating temperatures.
Yupo often speaks to environmental benefits in attracting packagers to the technology. The firm lists them out for the record:
- Replaces paper IML at a total lower cost
- Low waste at all levels of supply chain
- No release liner or label matrix scrap
- Excellent bottle resin savings
- Eliminates need for adhesives and backing materials
- Reduces overall resin weight
Synthetic grades are Category 5 recyclable products, according to Yupo’s environmental statement. “One of the features of synthetic papers is that they enter the waste/recycling streams more slowly than tree-based paper, for the basic reason that they are referred to as ‘durables.’ They’re designed to be long-lasting.”
Alternative Application
The firm credits its IML decoration solution with increasing wall strength for better shape and volume control. Specifically, it says, “Yupo IML grades give printers the freedom of being able to create blow-molded bottles of any design or shape. It allows designers to work with recessed panels, inclines, asymmetrical features and applications like hot foil and fluorescent and metallic inks.
“With IML, the medium becomes part of the blow- or injection-molded bottle, fusing label and container into one adhesive-free, liner-free and fully-recyclable package.” That statement prompts Yupo marketers to decree, “IML is a dynamic solution for replacing pressure sensitive labels.”[perfectpullquote align=”right” cite=”Markets and Markets” link=”http://www.marketsandmarkets.com” color=”#00ffff” class=”” size=””]Synthetic paper will be a $386.5 million market by 2020. CAGR is 7 percent.[/perfectpullquote]
Elaborating on the claim, Yupo reports, “On average, a typical project using pressure sensitive labels would use 2.25-g. of silicone-coated release liner per label. But substitute IML, and you’ll be able to eliminate 42 metric tons of silicone-coated release liner from the waste stream.”
Progress continues. Yupo has recently launched a new technology called Sculpt, which is designed for in-mold labeling. “Imagine a bottle of Hershey’s chocolate syrup,” Bill prompts. “Envision the word ‘Hershey’s’ embossed, and you’ll still be able to put an IML over the top of that bottle and enhance the word.”
In development for two years, Sculpt is a patented technology for ensuring the IML lines up with the embossed image on the package, regardless of the height of the embossed pattern.
The substrate is plastic, resembles paper, behaves accordingly, gets noticed. Many—manufacturers, printers, industry analysts and savvy consumers—say it grabs attention and inspires impulse purchases.
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