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The Most Common Harsh Environment Barcode Labels
Most Common Harsh Environment Barcode Labels
No matter what goods you buy, all commercial products have a common denominator: labels.
That sticky piece of paper attached to the jar of your favorite moisturizer or that flimsy wrapper clinging around your bottled water may seem insignificant at first but labels are essential for many reasons. They usually contain all the information you need to know about the product, such as product information, expiration and manufacturing dates, product composition or content, and so on.
All labels are essential, but there is one more crucial than others. Barcode labels contain a wealth of information between those black lines. As with any product, barcodes are important for manufacturing equipment, helping manufacturers gather all the information they need when troubleshooting, upgrading, or fixing a machine.
Unlike most commercial labels, manufacturing barcode labels are not meant to come off quickly. However, no two machines are alike, and an ordinary label might not withstand the harsh environmental requirement of some machines.
Because of this, creating a barcode label specific to the machine’s environmental requirements and characteristics is critical. A good harsh environment barcode label will remain intact for many decades.
The Importance of a Durable Barcode Label
Whatever industry you’re in, labels play an integral role in every phase of a standard business procedure. Listed below are some reasons why investing in a durable barcode label is critical.
- Inventory Traceability: One of the most important uses for a barcode is inventory traceability. This involves being able to track products throughout the supply chain from manufacture to sale. This is important for quality control and safety purposes. If there’s a problem with a product, a barcode label can help you trace its batch and identify the component supplier.
- Risk management: In addition to quality control, barcodes are also crucial for managing risk. When products are recalled, companies need to quickly identify which products are affected and pull them from shelves. This process is made much easier and faster with durable barcodes.
- Regulatory Requirements: In many industries, there are regulatory requirements for traceability and product identification. This is especially true in the food and beverage industry, where there are strict guidelines for labeling and packaging. Failing to include a lasting label could put you at significant risk and leave you with hefty penalty fines.
- Cost-effectiveness: If you have to constantly replace labels because they are coming off or becoming unreadable, the expenses will add up in the long run. Investing in a good quality label will save you money by reducing the need for replacements.
The Barcode Label Manufacturing Process
Many things can happen when a barcode label is not crafted to fit a machine. The ink used to print the barcode could evaporate, the barcode label could come off unexpectedly, or someone could remove the label easily. Durable barcode labels are made with these risks in mind.
Label Parts and Components
The label manufacturing process is composed of many intricate processes that vary among manufacturers. However, most barcode label manufacturing follows a general structure made up of five simple components.
- Release Liner: A release liner is a piece of silicone sheet to which a label is attached prior to its use. This maintains the adhesiveness of the label and ensures the label will stick to the machine for a long time.
- Adhesive: Above the release liner is the adhesive layer. Barcode labels use various types of adhesives, depending on their use and the machine’s material and environmental needs. Understanding this is critical to ensure manufacturers use the appropriate adhesive for their barcode labels.
- Base Stock: A layer above the adhesive is the base stock layer. This is where the barcode and other texts are printed. The paper used to print the base stock also varies depending on the machine’s nature and intended use.
- Print Image: Once the base stock is printed, the image that goes along with the barcode is also printed using various techniques. Some printing methods manufacturers employ are direct thermal and transfer thermal printing.
- Lamination or Covering: The topmost layer of a durable barcode label is the laminated covering or other protective coverings, such as a varnish or a plastic protector. The thickness and materials used to finish the barcode label vary similarly to other components.
Customization is key when creating heavy-duty labels. Manufacturers must ensure that all components complement each other and are made to withstand the harsh environmental requirements of the machine.
Adhesives Used for Harsh Environment Labels
Moisture is the number one culprit of label breakdown. Some machines are maintained at cold temperatures where precipitation is most likely to occur. These little droplets in the air could seep in between the device and the label and degrade the adhesive keeping the label intact on the machine.
Permanent Adhesives
Permanent adhesives, as the name suggests, are intended to stick on the machine for an extended time or until the machine starts deteriorating. Most permanent adhesives are made to resist moisture in the air. A permanent adhesive is often used for medical devices and food-processing machines and in materials such as wood, plastic, or glass.
Removable Adhesives
On the other hand, some machines need to be frequently maintained or updated. In these cases, using a permanent adhesive might do more harm than good as it could damage the engine when removed.
For these machines, manufacturers use removable adhesives that are not as strong as permanent adhesives. A good quality removable adhesive will leave no residue when removed and will not damage the machine’s surface.
High-Tack Adhesives
High-tack adhesives are a type of permanent adhesive used on machines that experience high temperatures. These adhesives have higher heat resistance and can be used on heat-based devices such as furnaces, ovens, and boilers. This extremely powerful adhesive is also used on irregular surfaces.
Different Types of Barcode Label Materials
The material used for the label must also be able to withstand extreme temperatures, humidity, and other harsh conditions. Different materials are used to create long-lasting barcode labels depending on the machine’s needs.
Paper Barcode Labels
Paper labels are the most common type of barcode label. Paper labels are often used for general indoor purposes and could be made using direct thermal or transfer thermal printing. These barcode labels are ideal for machines or products not requiring extreme durability as they are smooth and relatively easy to remove.
You will often see paper barcode labels when you purchase individual machine parts because, unlike the machines themselves, these parts do not need to be as long-lasting, and they are replaceable.
Because of the paper label’s fragility and quick wear-and-tear, it’s not recommended to be used on products or machines that experience a lot of movement, contact, or friction.
Polypropylene Barcode Labels
Polypropylene, or PP for short, is a type of plastic frequently used to make food containers, bottle caps, and pipes. This material is also used to create durable barcode labels as it is moisture-resistant and can withstand high temperatures compared to paper labels.
Most polypropylene-based labels are weather, scratch, chemical, and oil-resistant. This property of polypropylene makes it an ideal barcode label material for products or machines that will be exposed to harsh outdoor conditions or a lot of movement and contact.
Despite polypropylene’s strong resistance to harsh elements, it is not entirely waterproof. Exposing this material to extreme humidity or water pressure could cause the label to peel off and the ink to degrade. You will often encounter this material on retail shelves and electronics.
Polyester Barcode Labels
Polyester, or PET for short, is a type of plastic frequently used to create food and beverage containers and electronics. A PET-based barcode label is the most durable option out there.
Polyester labels can withstand abrasion, chemicals, moisture, and extreme temperatures. They are also UV-resistant, making them ideal for outdoor use.
PET-based barcodes also produce high-quality prints, making it easier for scanners to read the barcode. This is important as a barcode that is difficult to read will adversely impact the overall operational and inventory process.
Despite their many advantages, PET-based labels are also the most expensive option. This material is often used on high-end products that require extended longevity, such as motors, actuators, valves, pumps, and other critical machine parts.
Barcode Label Printing
The method used to print the barcode is equally as important as the label material itself. A high-quality material requires a high-quality printing process to ensure optimal durability and readability. Different manufacturers use a wide variety of printing methods, but the two most common ones are thermal transfer and direct thermal printing.
Direct Thermal Printing
Direct thermal printing uses heat to print images onto paper. This type of printing doesn’t require a printer ribbon, making it more affordable than thermal transfer.
Despite being more economical, direct thermal printing has several disadvantages. One is that the printed image will fade over time when exposed to extreme light or heat. The other is that the labels produced are not as durable as those made using thermal transfer printing.
This type of label is often used for short-term purposes such as proof of delivery, parking permits, and visitor passes.
Thermal Transfer Printing
Thermal transfer printing uses heat to transfer ink from wax or resin-coated ribbon onto the label material. This type of printing produces high-quality, durable labels that can withstand extreme conditions.
However, this method is more expensive than direct thermal printing as it requires the use of a printer ribbon. This type of label is often used for long-term purposes such as asset tracking, product identification, and barcoding.
Barcode Labels for Harsh Environment
Now that we have uncovered the different aspects of a barcode label, it’s time to delve into the different types of labels frequently used in harsh environments.
Heavy Duty Industrial Labels
Heavy-duty industrial labels are made using various materials such as polyester, vinyl, and nylon. These labels are built to withstand abrasion, chemicals, moisture, and extreme temperatures.
This type of label is often used in the automotive and aerospace industries where products are exposed to harsh outdoor conditions or a lot of movement and contact. Heavy-duty industrial labels are made with unbreakable surface adhesion to ensure that the label will stay in place no matter what.
Examples of high-quality and heavy-duty industrial labels are J45 DTL – Freezer/AT/CT, B-7515 High-Strength Adhesive, and J-46 PolyProp-AT.
- J45 DTL – Freezer/AT/CT: This label uses a polyester-paper material that can withstand extreme temperatures (-20°F to 120°F). It also has an acrylic adhesive that can stick to surfaces in both freezing and hot temperatures.
- B-7515 High-Strength Adhesive: This label uses a polypropylene material that can withstand abrasion, chemicals, and extreme temperatures. It also has an acrylic adhesive that can stick to surfaces in both freezing and hot temperatures.
- J-46 PolyProp-AT: This label uses a coated polypropylene material that can withstand extreme temperatures and harsh abrasion. PolyProp-AT also uses an “All Temperature Acrylic” adhesive that can stick to surfaces in both freezing and hot temperatures.
Heat-Resistant Barcode Labels
Heat-resistant barcode labels are made using materials that can withstand extremely high temperatures. These labels are often used in machines with high heat, such as manufacturing equipment, ovens, and furnaces.
An excellent example of a high-quality heat-resistant barcode label is the Z Supreme 2000T. The Z Supreme 2000T is made of high-temperature and permanent acrylic adhesive. This heat-resistance label can withstand temperatures up to 700°F and has a service temperature range of -40°F to 700°F.
Another excellent example of a heat-resistance barcode label is the extra high-temperature (XHT) aluminum barcode label. XHT aluminum labels can resist temperatures up to 1200°F. These labels are often used in aerospace and military applications. It is estimated that XHT aluminum labels can maintain high-quality readability for over 20 years.
Cold Temperature Resistant Labels
Cold temperature-resistant labels are often made with propylene and aluminum, and these materials can withstand freezing temperatures and are often used in food storage and medical applications. In the previous sections, we mentioned a great cold-temperature-resistant barcode label: the J45 DTL – Freezer/AT/CT.
Metalphoto® aluminum durable barcode labels are another excellent example of a cold-temperature resistant label. Metalphoto’s barcode label’s anodized aluminum substrates are designed to withstand exposure to salt spray, UV rays, and abrasion. This element provides additional protection to the label, making it last as long as the machine’s life span.
Another excellent example of a cold-resistant barcode label is the Teflon on an aluminum barcode label. These labels can withstand freezing temperatures and chemical exposure. If you’re looking for a barcode label that can resist extreme cold and harsh chemicals, Teflon on aluminum is the way to go.
Hazardous Material Identification Label
When looking for a hazardous material identification label, it is crucial to find a label that is durable and can withstand harsh chemicals. Polyester and polypropylene are two excellent materials that can resist most industrial chemicals.
An excellent example of a hazardous material identification label is the Q09 cryopolypropylene barcode label. The Q09 cryopolypropylene barcode label is made of a white polypropylene material that can withstand harsh chemical and radiation exposures. This barcode label contains a permanent emulsion acrylic adhesive that can hold up in both hot and cold temperatures.
Weather Resistant Labels
If you’re looking for a barcode label that can withstand unpredictable weather conditions, finding a label that is waterproof, UV resistant, and can resist extreme temperatures is vital. Most barcode labels we mentioned in this blog are ideal for weather-resistant applications. However, we will mention a few barcode labels that are specifically designed for outdoor use, such as the Duratran S Permanent Label. This moisture-resistant label is perfect for outdoor applications exposed to harsh weather conditions.
The Duratran S Permanent Label is made up of polypropylene that can resist UV rays, abrasion, and extreme temperatures. This label also uses a permanent acrylic adhesive that can stick to surfaces in both hot and cold temperatures.
Choosing the Right Type of Barcode Label for Your Needs
Choosing the best barcode label material starts with understanding the needs of your application. Once you know what type of environment your barcode label will be exposed to, finding a durable label material that can resist these conditions is much easier.
Below are the three most common applications of a heavy-duty barcode label.
Warehouse Labels
Warehouses are high-traffic workplaces. There are forklifts, pallets, and other machines constantly moving around, which can cause wear and tear on your barcode labels. If your barcode labels are not durable, they will quickly become unreadable, leading to critical operational errors.
It is essential to find labels made of durable materials such as polyester, polypropylene, or aluminum to ensure that your warehouse barcode labels can withstand the constant warehouse traffic.
These materials can resist tearing, abrasion, and extreme temperatures, which makes them ideal for warehouse applications.
Asset Labels
Another typical barcode placement in a workplace or commercial establishment is company assets. Company assets refer to any physical property that is owned by a business, such as office equipment, furniture, computers, and tools.
Asset barcode labels must be durable because they are constantly exposed to different conditions. For example, if your company assets are outdoors, it is essential to find weather-resistant labels that can withstand sunlight, rain, snow, and other harsh weather conditions.
On the other hand, if your company assets are indoors, it is still essential to find durable asset labels that can resist abrasion and extreme temperatures.
One material that is ideal for both indoor and outdoor asset applications is polyester. Polyester is a strong synthetic material that can resist tearing, abrasion, and most chemicals.
Calibration Labels
Hospitals and pharmaceutical companies rely on strict inventory procedures to ensure that their products are safe and effective. Part of these inventory procedures is keeping track of when each item was last calibrated.
Calibration labels are barcodes placed on items that need to be regularly calibrated, such as medical equipment and tools. To ensure accuracy and prevent errors, it is essential to find calibration labels that are made of durable materials. Calibration labels must stick on items for an extended time to avoid accidental removal.
Cautions Made To Stick
Everything around you is plastered with a label, the computer you’re working on, the yogurt you picked out from your refrigerator, or the bottle of water you’re drinking. We often take labels for granted, but these thin pieces of paper or plastic play a vital role in our everyday lives.
Barcode labels are significant in businesses and commercial establishments as they provide a way to ensure product quality and production efficiency.
If you’re looking for a durable barcode label manufacturer, we recommend checking out our selection of heavy-duty barcode labels. Our labels are made of high-quality materials that can resist abrasion, UV rays, and extreme temperatures.
Contact us now or request a free quote to learn more about our services.