Release Liners - Label and Narrow Web

As the label and package printing industry has grappled with numerous challenges over the past five years, release liners have been front and center in the minds of converters and suppliers. From availability to efficiency to sustainability, the release liner is critical to the function of our industry. The Covid-19 pandemic and the ensuing supply chain disruptions, in addition to numerous mill closures, significantly impacted the release liner marketplace. Historically, however, this has been a stable market.

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“The period from to was marked by significant disruptions,” remarks Ginnie Gandy, sales manager, Release Liner, Channeled Resources Group. “During this time, the surge in demand for release liners, coupled with limited supply, forced customers to take drastic measures. Many overstocked materials as a precaution, accepted sharp price increases due to rising pulp costs and production constraints, and quickly adapted to alternative liner grades when their usual products became unavailable.  

“As of today, US-based manufacturers are increasingly focused on reducing reliance on overseas suppliers, prioritizing domestic production for both base paper and silicone coating,” adds Gandy. “In , the market experienced downward price pressure as demand softened, prompting suppliers to lower prices in a bid to retain or grow
market share.”

“The release liner market is a dynamic and rapidly evolving market, responding to both geopolitical tensions and consumer behavior,” comments Patricia Rodrigo, Industry Group Labels manager and international key account manager, Mondi. “Even though some main markets experienced a decline over the last years due to the high inventory build-up across the supply chain, industry recovery and growth is underway.”

According to AWA Alexander Watson Associates, the largest market segment for release liners is pressure sensitive labelstock. In its AWA Release Liner Market Report , AWA notes that PS labelstock accounts for an estimated 46% of the total global market. The tapes segment follows, with 14%, and the total industrial segment (building and construction, composites, electronics, and more) makes up 12% of the market.

In North America specifically, AWA notes that PS labelstock accounts for 41% of release liner volumes. The second-largest market segment is the industrial segment as a whole, accounting for 18% of the total. This is followed by the tape segment, with 13% of total release liner usage, and the medical segment representing 10% of the market.

AWA, which will soon be launching its newest report in Q1 , states that glassine/SCK papers continue to account for the largest share of release base materials used in North America, representing 39% of the total market. “In North America, SCK or supercalendered papers are the first choice as opposed to glassines, as used in Europe and Asia. These paper grades are followed by clay coated papers, at 16%; polyolefin coated papers at 9%; and other papers, such as MF, MG, and parchment grades, at 9%,” according to AWA. 

Plus, film accounts for 27% of the total North American release liner market, with PE, PP, and PET films accounting for 8%, 4%, and 14%, respectively.

There are still challenges with release liners, though. Joe Zavaglia, development manager, Silicones & Liners, Americas, UPM Raflatac, notes that paper suppliers exiting the release liner market has caused a tightening supply.

As far as other obstacles, much of the focus on release liners has understandably shifted to sustainability. As brands establish lofty goals for protecting the environment, the release liner’s role in waste and recycling has been scrutinized.

“While label liners make up a relatively small part of a total packaging solution, they have a big impact on sustainability,” says Angel Harvey, senior marketing manager, Paper, Avery Dennison. “The label market is dynamic and evolving, driven by the need for innovation, efficiency, and sustainability. In recent years, there has been a notable shift toward thinner liners and recyclable materials, reflecting the industry’s focus on reducing environmental impact and ensuring efficiency for converters.”

According to CRG’s Gandy, there have been numerous initiatives to promote sustainability in this space, including transitioning to thinner caliper papers where feasible; prioritizing recyclability and exploring alternatives to landfill disposal; and moving away from non-recyclable grades, such as poly-coated release liners, in favor of more eco-
friendly options.  

“Sustainability is a key focus for the label market when it comes to release liners, but other industries, like tape, medical, and automotive, have been slower to adopt these practices,” says Gandy. “However, change is gradually occurring, with these markets beginning to follow the label industry’s lead.”

“At Mondi, one specific trend we observed is the shift toward paper-based release liners,” adds Rodrigo. “This trend reflects the rising demand for release liners made from renewable materials that support a circular economy.”

In the future, this market is poised to move past the challenges and disruptions that have been present for the better part of five years. “Looking ahead to , the market appears to be stabilizing, with an ongoing emphasis on domestic production,” explains Gandy. “However, potential tariffs could significantly impact the market dynamics, though the extent of this impact remains uncertain.”

The surge in e-commerce has also influenced the market, increasing the need for high-quality packaging and labeling solutions that balance functionality with sustainability. There are other trends to watch, as well. “The integration of smart technologies, such as RFID and NFC, is also shaping the market, requiring release liners that work seamlessly with digital systems,” comments Rodrigo. “This trend reflects the growing need for high-tech compatibility, and Mondi’s expertise enables the development of materials that meet these specialized requirements.”

Recycling challenges

Release liner recycling/collection has been one of the biggest challenges facing the industry. The silicone on the liner is what poses the greatest challenge when it comes to recycling. 

“Both paper and PET are highly recyclable materials,” states Michael Garretson, manager, Recycling and Circular Solutions, UPM Raflatac. “However, adding a layer of silicone to them limits who can process them and the amount of value that can be derived from the materials.”

“While release liners can be recycled, they must first be separated from other non-paper materials – a process that requires dedicated infrastructure, and funding,” adds CRG’s Gandy. “Unfortunately, most liner users, whether in production or at the end-user stage, lack the resources to effectively separate and collect liner waste. Efforts are underway within the industry to tackle this challenge.”

Logistics are another challenge, notes Garretson. “Because of spent release liner’s limited value, the expense of transporting material from the site of label application to the recycling facility is often greater than the value of the release liner,” he remarks.

“Many release liners are made from multi-material compositions that require specialized facilities, which are geographically dispersed and often at capacity, making large-scale recycling impractical,” adds Mondi’s Rodrigo.

It should be noted, though, that there are significant efforts underway to effect change. Organizations like TLMI and the Liner Recycling Initiative have launched regional pilot programs aimed at identifying recycling mills and establishing best practices for managing liner waste. 

“These programs are designed to support both small and large end users in setting up operational systems for recycling release liner,” says Gandy. “Importantly, any manufacturer generating liner waste can participate in these initiatives.”

CELAB is another such resource. Mondi actively collaborates with CELAB, an industry initiative to build a circular economy for self-adhesive label materials in Europe and the US, aiming to standardize recycling processes and foster a cohesive approach to collection and recycling systems.

“By collaborating closely with industry stakeholders along the value chain, we improved the circularity of material flows in two release liner production sites in Germany and the Netherlands: 95% of the production waste is now used as secondary raw material for other industries, for example for tissue products and construction materials,” says Rodrigo. “This collaboration highlights how value chain partnerships can drive sustainability.”

Plus, the companies themselves are making strides. “Avery Dennison’s AD Circular program is a significant step forward,” explains Harvey. “This initiative connects converters and brands with trusted recycling providers across the US, enabling landfill diversion, improved recycling, and support for circularity. In regions like Napa Valley, CA, and Quakertown, PA, the program is driving change. By leveraging our distribution centers, we collect PET liners from label printers and brands, ensuring they are recycled.”

UPM Raflatac has touted its RafCycle recycling program. “RafCycle is release liner recycling made simple,” says Garretson. “It is one of the many ways UPM Raflatac is working to advance the sustainability of the labeling industry. If you’ve got customers that are interested in recycling their label release liner, RafCycle could be a solution for them. We offer a sustainable, cost-efficient way for converters and brands to recycle release liner waste.”

CRG, meanwhile, is converting release liner by-products into fuel pellets through its partnership with Convergen Energy. 

Paper vs. Film

Filmic liners grew in popularity in usage during much of the supply chain challenges. With supplies normalizing, there are pros and cons for each material when examining release liners.

According to Avery Dennison’s Harvey, paper liners are excellent for low to medium-speed, automatic applications. They also deliver great performance on many different dispensing machines. 

“Paper liners offer superior diecutting performance due to the  calendaring process,” says Harvey. “They are suitable for roll-to-roll applications, and paper’s chain-of-custody certification tracks fibers from forest to end use, ensuring sustainability through traceable sourcing.”

On the filmic side, release liners are made from PET and provide strength and resistance to tearing. “Film liners deliver excellent registration for printing and diecutting at high speeds,” adds Harvey. “Film liners offer the opportunity for recycling after dispensing. Additionally, film liners are more resistant to humidity, reducing curl and ensuring better dispensing at high speeds.”

While there are various considerations, CRG’s Gandy succinctly sums up the choice: “Choose film release liners when you need durability, moisture resistance, and precision but are less concerned about cost and recyclability,” she notes. “Opt for paper release liners when cost and recyclability are priorities and the application does not involve high moisture exposure or require extreme dimensional stability. Each choice depends on the specific needs of your project and environmental considerations.”

The project’s goal is paramount when examining any liner decision. UPM Raflatac will work with converters to ensure they’re getting the right solution for the right application.

“As with any label selection, we must start with the end use or full package in mind, to achieve the desired outcome regarding sustainability, functionality, visual aspect, or efficiencies,” explains Agata Kowalska, director, Consumer Label Solutions, Americas, Markets, UPM Raflatac. “In all uses, film and paper labels are important and have their place. Its performance depends on pairing with the adhesive that is right for the application.”

According to Kowalska, an example might include a no-label look on a PET bottle. This solution would be best achieved with a clear film. Conversely, a unique texture on a wine bottle, or cosmetics packaging where a brand wants to stand out on the shelf, can be better accomplished with specialized papers.

“For a package where you need more flexibility in the label, film would be a clear choice,” adds Kowalska. “Shipping or logistic labels, where the main function of the label is traceability, paper is the industry first choice.”

From a product standpoint, Avery Dennison has 40# SCK, 40# CK, 44# PK, and 40# BG available for converters. There are also a variety of pairings with paper or filmic facestocks, with rPET liners featuring 30% recycled content.  

“We also offer a variety of machine-finished liners that are ideal for manual dispensing, laser applications, or anywhere requiring layflat properties,” adds Harvey.

If you are looking for more details, kindly visit release liner suppliers.

CRG offers a wide range of high-quality release liners tailored to meet diverse needs, including SCK, clay-coated release liners, poly-coated release liners, and barrier-coated release liners. For the sustainability conscious, CRG’s barrier-coated kraft liners have been designed to replace poly-coated kraft liners, offering comparable layflat characteristics with enhanced sustainability.

Mondi has engineered a comprehensive portfolio of paper-based Ever/Liner and film-based Smart/Liner solutions, which allows customers to select the material that best meets their specific requirements. By integrating recycled materials, renewable resources, and new designs, Mondi ensures that its release liners offer a balance of functionality, sustainability, and cost-effectiveness for a wide range of applications.

UPM Raflatac offers most all paper and film liners currently available in the AME market  such as SCK, CCK, glassine, PCK, Nat kraft, and PET. UPM Raflatac also has a robust line of linerless label solutions, with functional adhesive options to meet a range of application needs.

Going linerless?

With sustainability so prominent, many converters have explored the viability of linerless labels. Linerless label constructions feature a facestock and adhesive but no release liner. The facestock is instead treated during manufacturing with a silicone coating. This allows the facestock to protect the adhesive while also ensuring that adhesive releases cleanly
during application.

“Linerless direct thermal labels hold great appeal for categories such as shipping and logistics and food service/quick service restaurants (QSR), and more,” notes Avery Dennison’s Harvey. “Adoptees of the technology enjoy a wide range of benefits.”

Harvey adds that 32% less material is used compared to standard linered products in this process, and with 50% more labels per roll, end users have fewer roll changes. There is, of course, less waste, too.

Linerless labels are a small but rapidly growing segment of the VIP and prime label markets. “Because they eliminate the need for a release liner, they are a more environmentally friendly alternative to traditional pressure sensitive adhesive (PSA) labels,” states CRG’s Gandy. “The fastest adoption of linerless labels has been in quick-service applications, such as food delivery and logistics, where their efficiency and waste reduction are highly valued. However, growth in other VIP and prime label applications has been slower.  As advancements continue in adhesive, silicone, and thermal coating technologies, the adoption of linerless labels is expected to expand.  

While linerless labels have the potential to significantly disrupt the PSA label market, their overall impact on the broader release liner market is likely to be less pronounced. This is because many release liner applications exist outside of the markets that linerless labels primarily target, adds Gandy.

State-of-the-Art Solutions for Custom Release Liners

CRG is redefining what’s possible in the release liner industry by combining cutting-edge technology with a commitment to customization and customer service.

Why Choose CRG?

• Innovative Equipment:

¬ Installed two state-of-the-art wide web coating machines in the past five years, including a five-roll coating head in .

• Custom Solutions for Every Need:

¬ SCK (Super Calendered Kraft), CCK (Clay Coated Kraft), BCK (Barrier Coated Kraft) and PK (Poly Coated Kraft) grades

¬ One- or two-sided coatings available for tailored performance

¬ One-color printing under silicone using water-based inks for added functionality.

• Exceptional Capabilities:

¬ Custom-formulated release coatings

¬ One color print with water-based ink under silicone available

¬ One or two-sided coating

• A Family-Owned Difference:

¬ As a third-generation, family-owned business, CRG blends cutting-edge innovation with personalized, customer-focused service.

What Sets Us Apart?

• Precision: Superior quality control ensures liners meet your exact specifications.

• Dependability: On-time delivery and consistent performance you can trust.

• Agility: CRG’s small, family-owned structure allows for fast decision-making and customized solutions.

Ready to Partner with CRG? Let us create the perfect release liner solution for your business. Learn more about our capabilities at channeledresources.com/siliconized-release-liner/.

This is the third installment of our five-part series called Labels 101: Five Key Elements of Effective Labels. 

Label Liners: Often overlooked but crucial to success

A liner is the paper or film backing that protects the adhesive on the label until it is ready to be applied. While that sounds simple enough, the wrong liner can create lost time, production delays, wasted material and even a failure of adhesion once your label is on the job.

How will your labels be applied?

A key question when selecting a liner is how the label will be applied — by hand or machine.

• Hand-applied labels require a liner that will lay flat without curling yet allow easy manual release, often through a slit back for larger-sized cut sheet labels.
• Machine-dispensed/applied labels are available in two basic types of liners: roll or fan-fold. In either configuration, the demand is for a strong, dimensionally stable liner that will feed smoothly through the auto-dispensing/application equipment without misfeeds, jams or tears.

Liners that do not release easily can lead to poorly applied labels. They also increase the chance of contaminants reaching the adhesive. Both escalate the risk of adhesion failure.

Paper or film?

Once you know how your labels will be applied, choosing the right liner material becomes a simpler decision. Here are the basic properties of each liner type:

• Paper is the most commonly used liner material because it’s usually lower in cost than film. Paper liners typically use a supercalendered (a paper-making process to smooth the paper surface) sheet. The paper is coated with silicone to keep the adhesive from sticking to the liner. Overall, paper is less consistent in thickness than film and can sometimes fracture when die cut. Paper liners are available in a variety of weights, calipers and colors.
• Film liners are more consistent in thickness than paper and more resistant to tearing. This enables more forgiving die cuts and can often avoid feeding jams in machine-dispensed applications. Film is not as reactive to humidity, ensuring less curl and better dispensing at high speeds. Film liners can be opaque or clear and are available in a wide range of weights and calipers.

The right choice between paper and film will depend on your type of adhesive, dispensing method, budget and label size. Consult with your label supplier for the optimal choice.

Personalization and liner printing

There are many important considerations when choosing a liner. Will your label require additional printing with a laser, ink jet or other printer? Labels going through a cut sheet printer must lay flat, feed smoothly and be heat-resistant in the case of laser printers. Continuous roll or fan-fold printers have specific liner requirements. Printing on the back of the liner requires the liner surface to be receptive to ink.

Your application process is critical

No matter the type of liner, how the liner is removed and the label applied is crucial in avoiding a loss of adhesion. The application process should avoid clothing fibers, dust, other particles, skin oils, moisture and chemicals from coming into contact with the label’s adhesive. This requires a consistent and regimented label dispensing methods. A qualified label supplier can suggest ways to improve your application process.

Eco-friendly options

Since the liner requires disposal once the label is applied, choosing a biodegradable liner can be an important consideration. Fortunately, many types of paper and film liners fit the bill.  Some liners can be recycled, but you need to contact your local recycler to confirm that they will accept it. Moreover, some linerless label options exist. Ask your label supplier for specific recommendations and samples.

Making the right choice

Choosing the right liner means your labels will arrive in good condition and be applied correctly with the adhesive intact. The wrong choice of liner can lead to wasted dollars, lost time and even a loss of adhesion, creating costly failures. Yet, the liner is just one part of the formula for creating the right label. 

To learn more about the other key components of an effective label, read these posts in our “Labels 101” series:

Contact us to discuss your requirements of bopp transparent film. Our experienced sales team can help you identify the options that best suit your needs.

• Choosing the Right Substrate
• Choosing the Right Adhesive
• Choosing the Right Ink
• Choosing the Right Laminate