Shrink sleeve labels have emerged as a transformative solution in the packaging industry. These labels became popular after Tylenol used them for attractive, tamper-evident labelling.
As per a Future Market Insights report, shrink sleeve labels are projected to reach $28.47 billion by 2032, growing at an average rate of 6% per year.
Shrink sleeves are widely used for labelling cans, bottles, and other containers.
In this article, we will look at shrink-sleeve labels in detail. We’ll cover shrink sleeve media, the process of designing and applying these labels and their pros & cons.
Shrink sleeve labels are 360-degree preprinted labels. These are placed around the primary packaging and heated to mould perfectly to the shape of the primary packaging.
These labels are usually printed on plastic or polyester film and commonly applied to aluminium cans, glass, and plastic bottles.
A 360-degree label completely wraps around a product, covering it from all sides. |
Shrink sleeve packaging covers products fully and allows for detailed designs on containers. This method helps companies make eye-catching packaging that draws customers’ attention.
Any attempt to alter or remove shrink sleeve labels is immediately noticeable, making them ideal for tamper-evident packaging. They are also durable and resist abrasion, scratching, and tearing, so the label remains intact and legible for the life of the product.
Shrink sleeve label materials evolved from 1970 to 2024. Early labels used PVC. By 2024, manufacturers switched to PETG and OPS. Common options for shrink sleeve labels include:
Material | Description | Why It Is Used | Additional Information |
|---|---|---|---|
PVC (Polyvinyl Chloride) | PVC is a synthetic plastic polymer which is durable and cost-effective. | PVC is used for shrink sleeves due to its excellent shrinkage properties. PVC ensures a tight and uniform fit around various container shapes. | PVC is also resistant to chemicals and moisture, making it suitable for harsh environmental conditions. It is recyclable and concerns about its environmental impact are being addressed through improved recycling methods. |
PETG (Polyethylene Terephthalate Glycol) | PETG is a clear thermoplastic which has excellent clarity, strength, and impact resistance.
| PETG is favoured for its superior clarity, which allows for vibrant, high-resolution graphics that can enhance the visual appeal of the product.
| PETG is also highly resistant to chemicals and is easy to thermoform, which makes it versatile for shrink sleeve labelling. It is more environmentally friendly compared to other plastics due to its recyclability.
|
OPS (Oriented Polystyrene) | Oriented Polystyrene is a clear, rigid plastic polymer and has excellent clarity and printability. | OPS is a popular choice for applications where cost is a critical factor without compromising on quality and functionality.
| OPS has a lower density compared to other shrink films, which can lead to material savings. It offers good dimensional stability and is easily printable, making it ideal for high-quality label designs. It is also recyclable, but recycling options may be limited because not all recycling facilities can handle recycling OPS. |
There are three primary types of sleeves used for shrink-sleeve labelling:
Shrink sleeve labels offer advantages over traditional labelling methods. Here’s a breakdown of how shrink sleeve labels compare to other methods.
Aspect | Shrink Sleeve Labels | Pressure-Sensitive Labels | In-Mould Labels | Cut-and-Stack Labels |
|---|---|---|---|---|
Coverage | Full 360-degree coverage, including complex shapes. | Do not typically offer full 360-degree coverage. They are applied to specific areas of the container. | Integral to the container | Typically covers only flat surfaces.
|
Application | Applied with heat or steam, conforming to product shape.
| Self-adhesive and easy to apply but may require precise alignment.
| Integrated during the moulding process of the container.
| Applied using glue, requiring precise application.
|
Durability | Highly durable and resistant to moisture, abrasion, and temperature changes. | Moderately durable, may be affected by environmental factors.
| Extremely durable, as the label is part of the container.
| Moderate durability, depending on the adhesive and material used.
|
Design Flexibility | High flexibility in design, accommodating intricate graphics and full-colour images.
| Good design flexibility but limited by the shape and surface area of the product.
| High design flexibility, allowing for complex and vibrant designs.
| Limited design flexibility, usually restricted to simpler designs.
|
Environmental Impact | Available in recyclable materials, reducing environmental footprint. | Can be environmentally friendly if made from recyclable materials, but adhesives can complicate recycling. | Environmentally friendly, as they do not require adhesives and are part of the container, simplifying recycling.
| Varies, but often less eco-friendly due to the use of adhesives and separate application processes. |
Cost | Cost-effective for small runs and highly customisable, but can be more expensive for large-scale production.
| Generally cost-effective, especially for large runs, but costs can increase with complex designs and materials.
| Typically more expensive due to the integration with the container manufacturing process.
| Usually less expensive, but costs can increase for precise application and higher quality labels.
|
Tamper-Evident Options | Provides excellent tamper-evident features, enhancing product security.
| Limited tamper-evident capabilities, often requiring additional features.
| Inherently tamper-evident due to integration with the container. | Limited tamper-evident options, usually requiring additional features. |
Shelf Appeal | High shelf appeal due to vibrant, high-definition graphics and full product coverage, enhancing visibility and attractiveness.
| Good shelf appeal with high-quality prints, but visibility can be limited by the surface area and shape constraints.
| High shelf appeal with vibrant designs that are integral to the product, providing a seamless look.
| Moderate shelf appeal, often limited by simpler designs and the need for glue application, which can affect aesthetics.
|
Shrink sleeve labels are versatile and can be tailored to various product needs. Here are five main types:
Full Body Sleeves: These labels cover the entire product, including the cap, providing complete 360-degree branding. This sleeve maximises the surface area for branding, making it perfect for products with intricate designs and marketing messages. They are ideal for products that need to stand out on the shelf.
Example: A juice bottle with colourful graphics and nutritional information wrapped around the entire bottle.
Partial Sleeves: These cover only a portion of the product, which is perfect for showcasing the product while still offering branding opportunities. Partial sleeves are often used to highlight specific features or benefits of the product without obscuring the container or what’s inside it.
Example: A clear bottle of shampoo with a sleeve covering the middle section, allowing consumers to see the product inside.
Tamper-Evident Bands: These small sleeves are placed over the cap or lid to ensure the product has not been opened or tampered with prior to purchase. These shrink sleeves add an extra layer of security and reassurance for consumers.
Example: A bottle of vitamins with a band around the cap that must be removed before opening.
Combo Packs: These sleeves bundle multiple products together. They are typically used for promotional packs.
Example: Two bottles of conditioner and shampoo wrapped together in a single sleeve for a promotional sale.
Multi-Packs: These are similar to combo packs but are specifically designed to bundle identical products together for bulk purchasing.
Example: A pack of six cans of soda wrapped in a shrink sleeve, providing convenience and easy handling.
Each type of shrink sleeve label serves a unique purpose, helping brands enhance their product’s appeal, ensure safety, and offer convenience to consumers.
Shrink sleeve labels offer numerous benefits, making them popular for various products. Here’s a detailed look at their advantages:
If you only had 3 x 2 inches to showcase your brand while your competitor had three times that much area, whose product would first catch a consumer’s eye? Custom shrink-sleeve labels can wrap around an entire container, providing a 360-degree viewing area. This allows you to display full-colour graphics and more messaging space, making your product stand out. A 3″ x 2″ label cannot compare.
Shrink sleeve labels can help reduce packaging costs. According to Pack Leader USA, shrink sleeves offer a 150% increase in label area for only a 25% price increase compared to traditional pressure-sensitive labels.
Shrink sleeve labels are versatile and can accommodate a variety of container shapes where another labelling would fail. These labels are typically printed in reverse on the inside of a transparent shrink film, protected by 40-70 microns of clear film. This design ensures resistance to scratching and scuffing, reducing the likelihood of damage to distributors and stores during transit.
Previously, shrink-sleeve labels required long runs with a flexographic press. Today, digital presses allow for shorter runs and quicker turnarounds. This technology enables label-by-label variation for promotional campaigns, holiday specials, or flavours within a product line.
Studies have shown that innovative packaging influences buying behaviour, and consumers satisfied with a product’s packaging are likely to purchase it again.
The production of shrink sleeve labels is a multi-step process. This guide outlines each stage, from design to distribution, highlighting material selection, printing methods, and quality control.
The process begins with creating a detailed design for the shrink sleeve. This design must account for the three-dimensional shape of the final product to ensure a proper fit and appearance after shrinking. Prepress work involves preparing the design for printing, which includes adjusting colours, ensuring high resolution, and creating proofs.
The choice of material is critical for shrink sleeves. Common materials include PVC, PETG, OPS, and PLA, each offering different shrink characteristics, clarity, and environmental impacts. The selection depends on the product’s shape, size, and the desired shrinkage rate.
There are four printing processes used for shrink sleeves:
Printing Method | Description | Ideal For |
|---|---|---|
Rotogravure Printing | Known for its high-quality and precise ink application, ideal for large runs and complex designs. | Large runs and intricate designs
|
Flexographic Printing | Versatile and cost-effective, suitable for a variety of materials and medium-sized runs. | Medium-sized runs and versatility |
Digital Printing | Best for short runs and prototypes, allowing for quick changes and personalisation. | Short runs, prototypes, and customisation |
Prepress Work | Preparing the design for printing, including adjusting colours, ensuring high resolution, and creating proofs.
| All printing methods
|
After printing, the flat film is formed into a continuous tube by overlapping and sealing the edges. The seaming process can use adhesives, heat, or ultrasonic methods, ensuring a strong and durable seam that can withstand the shrinking process.
Each sleeve undergoes rigorous inspection to check for print quality, seam integrity, and material consistency. Any defects identified at this stage are corrected before moving on to the next step.
The continuous tube is then cut into individual sleeves according to the required length for each product. This step is critical to ensure that each sleeve will fit perfectly around the product.
The cut sleeves are applied to the products using specialised application machines. These machines ensure the sleeves are placed accurately and securely on the products.
The sleeved products are passed through a heat tunnel where the sleeves shrink to conform tightly to the product’s contours. The heat causes the material to shrink uniformly, creating a smooth and professional finish.
A final quality check ensures that the sleeves have shrunk correctly and that the final product meets all design specifications and quality standards.
Afterwards, the finished products are packaged and prepared for distribution. The proper packaging of products is essential to protect them during transportation and ensure they reach customers in perfect condition.
Challenges | Description |
|---|---|
Material Selection | Choosing the right material (PVC, PETG, OPS, PLA) is crucial for shrink performance and environmental considerations. |
Printing Quality | Ensuring high-quality printing can be difficult, especially for intricate designs and colour accuracy. |
Seaming Issues | Achieving strong and seamless joints without defects is a common challenge in the seaming process. |
Application Precision | Properly aligning and applying sleeves to products requires precision to avoid misalignment and wrinkling. |
Heat Shrinking | Controlling the heat shrinking process to ensure uniform shrinkage without causing distortion or damage to the product.
|
Inspection and Quality Control | Rigorous inspection is needed to identify and rectify defects, which can be time-consuming and costly. |
Environmental Impact | Managing the environmental impact of materials and processes, particularly with non-recyclable materials. |
Cost Management
| Balancing the costs of materials, printing, and production while maintaining high quality.
|
Design Considerations | Designing for shrink sleeves requires understanding how the sleeve will conform to the product’s shape and ensuring the design remains visually appealing after shrinking.
|
Regulatory Compliance
| Adhering to various regulatory requirements for materials, inks, and processes used in shrink sleeve production. |
Shrink sleeve labels are a versatile and effective solution for modern packaging, offering 360-degree coverage and accommodating complex shapes. Despite challenges like material selection and application precision, their benefits in branding, durability, and design flexibility make them essential for enhancing product visibility and consumer appeal.
As the market grows, shrink-sleeve labels will play a key role in packaging strategies.
Shrink sleeve labelling began in Japan in 1960. Fujio Carpentry Shop invented it to provide tamper-evident seals on sake bottles.
The process involves printing on a film, forming it into a tube, seaming, cutting to size, applying to the container, and heat shrinking to fit.
Shrink sleeve labels made from recyclable materials like PETG and PLA are recyclable and, therefore, environmentally friendly.
Customisation options include high-resolution graphics, vibrant colours, metallic finishes, tactile varnishes, and label-by-label variation for promotional campaigns, holiday specials, or different flavours within a product line.
Yes, shrink-sleeve labels are ideal for irregularly shaped containers. Their ability to conform to complex shapes provides full-body coverage and high visual appeal, making them suitable for various product designs.
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