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The Evolution Of Fusion Labeling For Polyolefin Plastic

The Evolution Of Fusion Labeling For Polyolefin Plastic

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Many people in the plastic industry have never heard of fusion labeling. And for many of those who have heard of it, they really don’t understand it. Why? Because at first glance, fusion labeling resembles other methods like heat transfers, decals or in mold labels.

But since the early 1980’s only one company has produced and continues to develop the world’s only labeling technology that literally fuses into Low Surface Energy (LSE) polyolefin plastic like polyethylene and polypropylene. That company is Mold in Graphic Systems (MIGS). Among dozens of innovative products, MIGS are the exclusive producers and distributors of the Polyfuze Graphic. 

What Makes Fusion Labeling Different?

All MIGS technologies are built around a similar architecture; pigmented polymers which use heat to fuse into polyolefin plastic. Below is a short history that lead to the company’s latest innovation:

Mold-In Graphics (circa 1983): This unique labeling technology started in the world of rotomolding. As the mold heated up, graphic labels and resin fused together to become a single part.

Mold-On Graphics (1997): Mold-In Graphics evolved into a post-molding application for rotomolders that required operators to apply a “mold-on” graphic to the surface of a part, then use a flame-gun to reach a surface temperature that would allow the fusion process to occur between polymer label and polyolefin part.

Polyfuze (2014): The next evolution of MIGS technology was a break-through called Polyfuze. Instead of single “mold-in” or “mold-on” graphics on sheets, MIGS provides their unique pigmented polymer labels on rolls that are threaded onto a standard hot-stamp machine. Polyolefin parts could then be labeled rapidly in order to keep up with the demands of injection molding production environments. This post-mold decorating process greatly improved production speed, but it also greatly reduced, and in some cases, virtually eliminating scrap caused during the labeling process.

VersaFlex (2019): Never resting on their laurels, the Research & Development team at Mold in Graphic Systems have once again created another breakthrough with the VersaFlex Labeling System. Beyond rolls of Polyfuze Graphics being applied to parts on standard hot stamp machines, VersaFlex labels are specially formulated to work as part of a new and innovative application system. At first glance this system resembles a pad print machine. Further investigation however, shows the pad printing “loaf’ has been replaced by a flexible die developed and produced by MIGS. This unit serves as an assembly which transfers heat to activate the fusion process between polyolefin parts and Polyfuze labels. Once completed the two are melded together permanently forever.  

Why You Should Consider Fusion Labeling?

As illustrated above, Mold In Graphic Systems has continued to raise the bar during the past 36 years. Now, with the invention of a system such as VersaFlex, any company labeling LSE plastics such as polyethylene and polypropylene owes it to themselves to ask three questions,

“What if the safety / warning labels I’m currently using fail?”
“What if failed safety / warning labels on my products, expose consumers to danger or injury?”
“If my product causes injury to a consumer, could that expose my company to litigation?”

And for anyone answering yes to any of the above questions, there is one more question to ask,

“What if Label Failure Could Be Avoided All Together, Guaranteed?”