Acucote and Discount Labels use their super powers for a complex and successful project.

“This was a true, amazing example of teamwork between the customer, the end user, Acucote and Discount Labels to really pull this off.”
Debbi Ulmer
Marketing Director, Discount Labels

Overview

One day in 1965, Fred Conway, a volunteer fireman in southern Indiana, showed up to a fire and saw that a truck from the wrong company had been summoned. This was in the days before 911 centralized phone dispatch, and each emergency service had its own phone number. It was easy for consumers to make mistakes when numbers had to be memorized or kept handy. Fred saw the need for a label that could be placed on a telephone with room for all the emergency service numbers and with this vision in mind, he created Discount Labels in his basement. As the business grew and labeling opportunities expanded, his son-in-law went on the road in a Winnebago to set up a distributor base across the United States. From these humble beginnings, Discount Labels has grown into one of the country’s largest short-run label printing companies. Purchased by

Cenveo World Limited in 2006, the company manufactures labels in New Albany, IN, employing 500 individuals in a 200,000 square foot facility and utilizing 70 conventional and digital presses and seven ABG Digicon finishers. Discount Labels sells through qualified label resellers (e.g. converters, contract packagers, promotional products companies). Key verticals include the food, beverage, healthcare, automotive, cannabis, beer, wine and spirits sectors.

The Challenge

In April 2018, Discount Labels’ customer Zagwear approached them with a challenging application. They needed to produce several million augmented reality “decals” for one of the world’s largest cereal producers for a promotional tie-in to the “Spider-Man: Into the Spider-Verse” movie. Each decal was individually wrapped and had to withstand insertion into boxes of cereal. Six different designs were created so that consumers could collect a set from various cereals. The lead time was tight, and because the finished label was inserted into cereal boxes the application had to undergo multiple inspections and pass strict FDA requirements. Batch traceability was critical in the event of a recall any time down the line.

DL-Spiderman-Peter2-edit

The Solution

Discount Labels turned to their substrate partner Acucote for help. They needed a construction with a clear flexible facestock and ultra-removable adhesive that could be applied to a variety of surfaces, remove cleanly and then be reapplied to other surfaces. The application also demanded a stiff, printable liner to help with layflat, weight and printability so that the decals wouldn’t be folded or bent in handling. Acucote went to work immediately, modifying the construction’s caliper numerous times by using face sheet and liner changes until they found the perfect weight for their customer’s gravity-feed distribution equipment. This maximized Zagwear’s distribution line speed and prevented
misfeeds.

After close collaboration with Discount Label, testing in-house and with external labs, Acucote delivered a final construction of 5.5 mil matte clear non topcoated (NTC) vinyl with H802 adhesive and an 8-point liner. The label construction conformed with 21 CFR 175.105 (FDA indirect food contact), was Prop 65-compliant and toxicologist-certified to demonstrate that the adhesive was safe for use.

Results

The cereal company launched a very successful campaign, with the Spider-Man decals inserted into approximately 8 million specially-marked boxes of various cereals. They were sold coast-to-coast at 10,000 retailers and the promotion was supported by national television advertisements.

According to Debbi Ulmer, Marketing Director, Discount Labels, “This was a case of all hands on deck. Everyone got involved. It was a true, amazing example of teamwork between our customer, Zagwear; the end user, Acucote; and Discount Labels to really pull this off. It was a huge endeavor and something that we’re very proud of.”

Acucote adds, “Our Application Development Team (ADT) understood the performance characteristics needed by Discount Labels. Our technical team worked with our in-house lab and the customer’s lab to do the testing, provide pre-production samples and quickly deliver a high quality pressure-sensitive construction. The Acucote ADT is composed of seasoned industry technical and applications specialists who support our customers by providing application solutions for the most demanding labeling challenges. Challenges like the one brought to us by Discount Labels.”
Melissa Walsh-Harton
Marketing Communications Manager

Acucote Receives Two Prestigious Safety Awards

Honors reflect a sustainable safety culture at its NC plant

Graham, NC, July 15, 2019 – Acucote, a solutions-oriented pressure-sensitive adhesive coating manufacturer with a 100,000 sq foot plant and 125 employees in Graham, NC, has recently been awarded two top honors for its safety program.

The North Carolina Department of Labor (NCDOL) presented the company with a Gold Award at its annual awards ceremony on June 4. To qualify for any of NCDOL’s annual safety awards, a firm must have zero fatalities during the calendar year and have maintained a safety incidence rate of at least 50 percent below the average for its industry group. The Gold Award is based on days away from work, restricted activity or job transfers as a result of injuries. This is the first time that Acucote has received this highest accolade from NCDOL and recognizes their industry-leading incidence rate of .71.

A WorkSafe Award was also presented to the company on April 29 by Acucote’s Workers Compensation Insurance Carrier – HUB International SE and Accident Fund Insurance Company. This award acknowledges “Continuous Safety Improvement from 2015 – 2019.”

According to John Leath, CEO, “We’re very proud of the awards as they acknowledge the hard work our team has committed to building a sustainable safety program at our facility. But far more important than the awards is the fact that our employees are going home safe and sound each day to their family and friends. We all lose when someone is hurt on the job.”

Amy Trent, Safety Manager, who has been with Acucote for the past two years, conducts weekly safety briefings for all plant employees and has successfully developed processes which encourage proactive reporting of safety concerns. Leath concludes that, “The credit for these awards goes to our Safety Team and the entire Acucote work force due to their efforts to help take care of one another. We have built a culture of trust, awareness and buy-in which enables us to better serve our employees, our customers and the industry.”

 Acucote leaders celebrate Workman’s Compensation award. Pictured L to R: Gene Lauffer, COO; Paul Sanborn, Senior VP of Operations; John Leath, Jr., CEO; Amy Trent, Safety Manager and Barry Brown, HR Director.

Acucote leaders celebrate Workman’s Compensation award. Pictured L to R: Gene Lauffer, COO; Paul Sanborn, Senior VP of Operations; John Leath, Jr., CEO; Amy Trent, Safety Manager and Barry Brown, HR Director.

(L to R) Cherie Berry, NCDOL Labor Commissioner presents Acucote Gold Award 2018 to Amy Trent, Acucote Safety Manager.

(L to R) Cherie Berry, NCDOL Labor Commissioner presents Acucote Gold Award 2018 to Amy Trent, Acucote Safety Manager.

Acucote Expands Pressure-Sensitive Pharmaceutical Label Portfolio

Now offering material for tamper-evident and tight mandrel applications

Graham, NC – Acucote, a solutions-oriented pressure-sensitive adhesive coating manufacturer, has expanded its portfolio with nineteen new pressure-sensitive paper and film constructions specifically designed for the pharmaceutical market.

Pharmaceutical brands demand performance, security and authentication throughout the value chain. Acucote’s six tamper-evident label constructions are ideal for packaging closures and destructible labeling as they leave behind evidence of unauthorized access or alteration and provide brand verification in markets penetrated by counterfeit products. Security enhancements, such as fluorescing adhesives and black light readers, are also available.

Small diameter and injectable device containers are utilized throughout the pharmaceutical industry. Acucote has developed thirteen facestock and adhesive combinations that prevent material lifting and adhere to small diameter curves. For enhanced security, photoluminescence can be added to the adhesive for UV light detection systems. The new Acucote materials are ideal for test tubes, syringes, pharmaceutical labeling, auto injectors, vials and ampoules.

According to Melissa Harton, marketing manager, “The North American pharmaceutical label market is experiencing explosive growth as Baby Boomers age. We’re pleased to expand our portfolio to meet the needs of this fast-growing sector by offering pharma label products compatible with traditional flexo printing and thermal transfer.“

To view the complete Acucote pharma label portfolio visit http://www.acucote.com/pressure-sensitive-products/pharma

Acucote Expands Pressure-Sensitive Portfolio for Durable Labeling on Pigment and Laser Print Systems

Acucote, has expanded its portfolio of durable pressure-sensitive materials that can be printed on pigment and laser systems for chemical and industrial labeling applications.

Acucote is now offering four additional BS5609 Section 2 (label performance) certified film products:

Kimdura® Inkjet Ultra, Kimdura® DualTech, PPG TESLIN® 7 mil face stock and 2.6 mil Matte White Premium Thermal Transfer Polypropylene. All are offered with Acucote adhesive P50, an aggressive acrylic with exceptional durability range (-30F ̴ +250F). The Kimdura and PPG Teslin products are further certified BS5609 Section 3 (print performance) for particularly harsh environments. To obtain BS5609 certification, labels need to withstand a three-month salt water submersion test in the English Channel. BS5609-certified labels are proven to meet the most stringent tests for durability in the industry.

PPG Teslin face stock features static dissipation which reduces potential static discharge when removing label liners (which could potentially ignite chemical and solvent vapors in certain manufacturing environments).

According to Melissa Harton, product manager, digital media, “Converters tell us that specifications for labelstocks are increasingly becoming more stringent in terms of temperature range, environmental resistance, stronger adhesives and better printability. Over the past years, we’ve seen a gradual shift from strictly laser to pigment-based print systems for outdoor and drum labeling. We’re pleased to expand our portfolio to meet the needs of this fast-growing sector by offering products compatible with pigment inkjet, laser and thermal transfer. “

Rounding out the portfolio are materials that can be utilized when BS5609 Section 2 certification is not required, including pigment and laser durable papers, polyesters and vinyls.

Harton concludes, “The label stock supplier partnership with converters is more important than ever before as brands and packaging buyers continue to enforce tougher label performance requirements onto their vendors. Our Application Development Team specializes in creating innovative and effective solutions to serve our customers’ most demanding requirements and recommend solutions in days, not weeks.”

Click here to view the complete Acucote durable label portfolio.

Acucote Inc. upgrades to energy efficient LED lighting

Acucote Inc. continues to make strides towards offsetting adverse effects on the environment by reducing its ecological footprint. Over the past two months, Acucote’s headquarters and manufacturing facility in Graham, NC, invested in lighting upgrades to utilize energy efficient lamps and lighting controls throughout the administrative offices, manufacturing, shipping and exterior areas.

Acucote replaced all lighting fixtures with a combination of interior LED highbays, task and panel lights, and exterior wallpacks and flood lights. Occupancy sensors and dimmers were also installed to further increase energy efficiency. Combined, these upgrades lead to a 67 percent reduction in energy consumption for lighting in the 80,000 square foot facility.

The LED lighting upgrade results in a 469,328 kg decrease in greenhouse gases produced; which is the equivalent of 52,811 gallons of gasoline consumed or 99 fewer cars on the road.

Acucote Inc. expands Specialty Films Line

Now offering Dry Erase and Chalkboard facestocks

Acucote Inc. has extended its line of specialty films to include 2 mil Clear PET Dry Erase Overlaminate, 3.5 mil White Dry Erase Vinyl and 5 mil Black Chalkboard Vinyl. The dry erase overlaminating film is stocked with OL1, a clear permanent adhesive, on a 40# liner. The White Dry Erase Vinyl is available with Acucote’s newest adhesive, UR7, an ultra removable specifically designed for vinyl applications. Both facestocks are treated to accept dry erase markers and are easily cleaned with standard dry erase solutions.

The 5 mil Black Chalkboard Vinyl is offered with a Wall Graphic Removable on a 92# liner. It is treated to accept chalk and is cleaned using an eraser or cloth. This vinyl is perfect for classrooms, dorm rooms, kitchens, offices, playrooms and more.

Films are available at master width x 2,500′ and ship in 4 days or less from North Carolina.

Acucote Inc. launches new website

Improved, user-friendly website launched in early August

Acucote Inc., a supplier of pressure-sensitive labelstocks, launched its new website, www.acucote.com,  in early August. Over the past ten years, Acucote has shifted its focus from being a supplier of strictly commodity products to assisting customers in the development of value-added products and custom pressure-sensitive solutions. The launch of its new interactive website is a continuation of these rebranding efforts.

Visually, the new website is more in line with the company’s brand image and culture. Immediately, visitors to the site will find that ease of navigation was a priority and has been improved.  The site is now dynamic and the screen size will automatically adjust to the device being used including a cell phone, tablet or desktop computer. There is also a new search feature that will allow customers to quickly locate product specific information.

General information is updated regularly on the website and product information is updated daily.

Acucote Inc. passes British Standard BS5609

Compliance confirms durability in marine conditions for white films

Acucote Inc. recently achieved BS5609 Section 2 compliance. This certification includes the evaluation of two film products: Inkjet Kimdura® with P50 permanent acrylic adhesive and 2.6 mil White Premium Thermal Transfer Polypropylene with P50 permanent acrylic adhesive.

Section 2 tests the durability of the label material and adhesive under conditions of marine exposure, temperature variations, weathering and exposure to salt spray and sunlight.

Section 2 compliance is for blank labelstocks and does not include print testing covered under Section 3.

Acucote Inc. provides customized alternative to standard PSA labelstocks

Now offering enhanced security and brand protection solutions

Acucote Inc. has extended its line of frangible, voiding and tamper-evident products to include complete customization. Options for tamper-evident labelstocks have typically included the standard silver and white facestocks with the term “VOID” in a diagonal pattern. Acucote is now providing converters the ability to offer their customers a product that will differentiate them in security packaging.

Acucote’s newest product line, Custom Voiding Facestocks, is flexible in that it allows for the customization of voiding text (company name or virtually any message), the option to PMS color match the facestock, or, if desired, customers can display shapes and logos as the void pattern instead of plain text.

Utilizing a polyester base, this program is available 9.5″ x 5,000′ or by master width at 54″ x 2,500′ (or more). The 9.5″ program has a minimal setup fee of $100, plus MSI cost, for custom text or graphics and our master roll program has a $650 setup fee plus MSI cost. Please note, prices may vary depending on the color selection and/or custom pattern. Duplicate orders do not require additional setup fees. Standard void items with custom colors are also available without a setup fee.

Acucote Inc. adds single-ply IRCs to its line of dry release solutions

Now offering single-ply, single-side and two-sided message IRCs for flexo and digital presses

Acucote introduces its latest Instant Redeemable Coupon (IRC) product line; Diamond-Cote® Single-ply (SP). The single-ply, single-message design converts exactly like standard pressure-sensitive applications – no lamination required. Diamond-Cote® SP minimizes material costs and improves productivity by eliminating the process of delamination and relamination that is typical for converting coupon products.

IRComplete™, Acucote’s most innovative Diamond-Cote® SP solution, is everything you need for a single-ply, two-sided message coupon. As with all Diamond-Cote® SP solutions, the advantage of IRComplete™ is its ability to convert on press exactly like standard pressure-sensitive applications, even with its two-sided messaging capabilities. Compared to other two-sided coupon solutions, this product offers fewer roll changes, faster setup times, improved run speeds, less scrap and it can be produced on a digital press.

Both the IRComplete™ and 55# Semi Gloss Diamond-Cote® SP products are offered No Trim. 2.6 mil Vision Gloss Diamond-Cote® SP, Red Fluorescent Diamond-Cote® SP, Direct Thermal High Speed Diamond-Cote® SP and all purpose Thermal Transfer Diamond-Cote® SP have a MOQ of 2,500′ and are slit to order. All products are offered with AT4505, a permanent all-temperature acrylic adhesive, on a 40# liner. Custom adhesives and liners are available.

Diamond-Cote® SP solutions utilize Acucote’s standard Diamond-Cote® release system. The diamond pattern, a geometric-designed release system, allows for virtually any converted die cut label shape and size to remove cleanly and easily from a variety of substrates. All Diamond-Cote® and Diamond-Cote® SP solutions are ballpoint pen writable.