Best Practices and Common Mistakes with Synthetic Facestock (Polypropylene/Polyester)

Synthetic Facestock (Polypropylene/Polyester) offers great performance, but getting reliable results requires attention to a few practical details. This article covers best practices for storage, printing, adhesive selection, converting, and sustainability, along with common mistakes beginners often make. The goal is to help you avoid costly errors and get consistent, high-quality labels every time.

Start with storage and handling—often an overlooked area

• Store rolls correctly: Keep film rolls in a cool, dry place away from direct sunlight. Ideal storage is in a temperature- and humidity-controlled environment to prevent curl, edge damage, or adhesive degradation.
• Handle gently: Avoid dropping rolls or exposing edges to pressure that can cause micro-cracks or creases which affect print and conversion.

Printing and converting best practices

• Match inks and treatments: Ensure facestock has the right surface treatment (e.g., corona treatment, primer) for your ink system. Water-based inks may need specially coated films; UV-cured inks require compatible primers to prevent adhesion problems.
• Control press settings: Films are less forgiving than paper—monitor tension, nip settings, and drying/curing parameters to avoid wrinkles, blocking, or staining.
• Use appropriate ribbons for thermal transfer: When printing with thermal transfer, select ribbons formulated for synthetic film; resin ribbons generally give the best durability on polyester and certain polypropylene films.
• Test embossing or varnish: Some films can be damaged by heavy lacquer application or aggressive embossing. Pilot tests ensure desired tactile effects without compromising performance.

Adhesive and conversion choices

• Select adhesives for the substrate and environment: Acrylic adhesives are common for synthetics; however, choose permanent, removable, high-shear, or high-temperature formulations depending on end-use. For oily or low-energy surfaces, specialty adhesives or primers may be required.
• Die-cutting and matrix removal: Adjust die depth and cutter geometry to prevent nicked liners or die creep. Synthetics can be springy—tuning cutters avoids dimensional errors and waste.
• Lamination and overlaminates: Use compatible laminates to increase chemical, scuff, and UV resistance. Hot-melt or solvent-based laminations should be compatible with the facestock to avoid distortion or delamination.

Testing and quality control—don’t skip these steps

• Environmental testing: Validate labels under expected conditions: temperature cycles, moisture exposure, chemical contact, and abrasion. Simulated shelf-life or accelerated aging tests help identify failure modes early.
• Adhesion and peel tests: Conduct standard 90° or 180° peel tests and shear tests to confirm adhesive performance on the actual substrate (e.g., plastic bottle, glass, metal).
• Barcode and scanner verification: If labels carry barcodes, validate print contrast and scannability after any finishing process and after environmental exposure.

Common beginner mistakes and how to avoid them

• Assuming one adhesive fits all: Mistake: using the same adhesive for every surface. Fix: specify adhesives based on surface energy and environmental conditions and test on actual substrates.
• Skipping printer trials: Mistake: approving artwork without press trials. Fix: run short press tests to check color, registration, and finish before full runs.
• Neglecting liner compatibility: Mistake: choosing an incompatible liner that delaminates during converting. Fix: confirm liner release properties match die-cutting and dispensing equipment.
• Ignoring recyclability: Mistake: assuming synthetic labels are recyclable. Fix: consult suppliers for mono-material constructions and local recycling guidelines, and consider take-back or waste segregation strategies.

Sustainability practices and disposal guidance

• Ask about mono-material options: Films manufactured and laminated with materials that keep the label construction as a single polymer type improve recycling prospects in some facilities.
• Consider film thickness and lifecycle: Thinner films reduce plastic use while often maintaining needed performance—discuss minimum film thickness with suppliers.
• Label removal and recycling: For packaging that must be recycled as paper, consider facestocks designed to be removable or that separate easily during recycling processes.

Supplier engagement and documentation

• Request technical data sheets (TDS): TDS provides tensile strength, temperature resistance, recommended adhesives, and printability notes. Use these to compare films objectively.
• Obtain samples and run trials: Always request physical samples and run them through your actual production line. What looks fine on paper may behave differently on press or in the field.
• Keep records: Maintain a repository of performance data, failed samples, and test results to reduce repeat issues and speed troubleshooting.

In friendly summary: Synthetic Facestock (Polypropylene/Polyester) unlocks many advantages over paper but requires attentive handling—from storage to print to application. Focus on matching facestock properties to the environmental demands, test adhesives and print processes on your actual substrates, and work closely with suppliers to select films that meet both performance and sustainability goals. Avoid the common traps of one-size-fits-all adhesives and skipping trials, and you’ll get reliable, attractive labels that perform well through their expected life.