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Mastering Polymer Fusion Labeling: TIP #1
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.
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
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
- 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).
- Die Material: Use an appropriate die material, such as 80-durometer high-temperature silicone, for effective heat transfer and recovery.
- 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
Director of Engineering
Marty Mares
VP Branding & Commercial Development