Mastering Polymer Fusion Labeling: TIP #1

Jason Brownell : Director of Engineering
Jason Brownell : Director of Engineering

When it comes to applying Fusion Labeling Technology solutions for Olefin-based plastics, few can rival the expertise of Jason Brownell, Director of Engineering at Polyfuze. With over 30 years of hands-on experience, Jason has been instrumental in helping manufacturers worldwide, providing both virtual consultations and on-site training. This blog series distills his wealth of knowledge, offering manufacturers valuable insights into the setup and application of Polymer Fusion Labeling.

The Most Common Mistake in Polymer Fusion Labeling

While Polymer Fusion Labeling can be successfully implemented using standard hot stamp equipment, the number one issue manufacturers face is insufficient heat.This mistake often stems from a misunderstanding of the process, confusing it with similar technologies like hot stamping or heat transfer, which require much lower heat settings and /or faster dwell times.

When manufacturers reach out for support, the troubleshooting process typically begins with reviewing their results through photographs or videos. Jason’s next step is to assess the die material, verifying whether it is made of high-temperature silicone and determining its thickness. If these elements check out, the root cause is usually the machine’s heat setting being too low or the dwell too short.

Understanding the Fusion Process

Unlike hot stamping or heat transfer, Polymer Fusion Labeling requires the plastic label and the plastic part to melt together, achieving a seamless bond. For this to occur, the stamping die face must reach a sufficiently high temperature. Operators often attempt to run their machines at around 350°F, mistakenly aiming for adhesive melting—a method relevant to other labeling technologies but ineffective for Polymer Fusion Labeling.

Steps To Finding A Solution For Automotive Battery Dunnage Labeling To achieve proper fusion, the process demands temperatures significantly higher than those used in traditional methods. For instance, using an 80-durometer high-temperature silicone die, a die face temperature of around 450°F is recommended.

The Importance of Die Material

The choice of die material is critical in Polymer Fusion Labeling. Jason recommends an 80-durometer high-temperature silicone die for optimal heat absorption and recovery between applications. A 60-durometer silicone die, on the other hand, struggles to retain and recover heat, leading to inconsistent results.

For manufacturers using aluminum dies without silicone, adjustments to the machine’s temperature settings are necessary. Aluminum dies typically require a drop in machine temperature by about 100°F, as they conduct heat differently than silicone-based dies.

Considering Ambient and Material Temperatures

Label Plastic Durable Goods The Right Way With Polyfuze fusion label technology. Another factor that impacts the fusion process is the ambient temperature of the facility and the plastic part itself. Parts that are warm when they come out of the mold require shorter dwell times compared to parts pulled from a cold warehouse. Cold parts necessitate longer dwell times for proper fusion.

Additionally, the material’s composition plays a role. For example, talc-filled polypropylene demands slightly longer dwell times than low-density polyethylene due to differences in material properties.

Key Takeaways

  1. Heat Settings: Ensure the machine’s die face temperature is set high enough to achieve fusion (e.g., 450°F at the die for an 80-durometer silicone die).
  2. Die Material: Use an appropriate die material, such as 80-durometer high-temperature silicone, for effective heat transfer and recovery.
  3. Ambient and Material Conditions: Adjust dwell times based on the ambient temperature and the material’s initial temperature or composition.

By understanding and addressing these factors, manufacturers can overcome the most common challenges in Polymer Fusion Labeling and achieve consistent, high-quality results. With insights like these, Jason Brownell continues to lead the way in advancing Fusion Labeling Technology, ensuring manufacturers get the best outcomes from their processes.

Ready to stop the labeling issues? Visit or contact Polyfuze Graphics Corporation and discover how Polymer Fusion Labeling can transform your operations.

About the Author

Jason Brownell

Jason Brownell

Director of Engineering

Marty Mares

Marty Mares

VP Branding & Commercial Development

About the Author

Easy To Apply - Polyfuze Labeling Using the VERSAFLEX System

Easy To Apply Polyfuze Labels - Using Standard Hot Stamp / Heat Transfer Equipment

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