When Adhesion Fails,
We Find Out Why.
Poor ink adhesion leads to delamination, peeling, and rejected batches. StarColor provides diagnostic support and tailored ink systems that bond permanently to challenging substrates โ from untreated films to high-speed lamination lines.
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Common adhesion failure symptoms & hidden costs
Ink lifts on tape test
Cross-cut tape test shows >15% removal โ batches rejected.
Delamination after lamination
Ink layer separates from adhesive or film during curing/storage.
Peeling on filling lines
Labels or printed areas peel off during product filling or transport.
๐ Root cause diagnosis: 3M framework
๐ Material (Substrate)
- Low surface energy (PE/PP <38 dynes/cm)
- Surface contamination (slip agents, dust, oil)
- Moisture or oxidized corona treatment
โ๏ธ Machine (Process)
- Insufficient corona/flame treatment
- Under-curing or over-drying
- High printing speed / low anilox volume
๐งช Medium (Ink/Coating)
- Ink-substrate mismatch
- Expired ink or wrong additive ratio
- Poor wetting or low resin tack
โฌ๏ธ Not sure where to start? Contact our team for free sample testing & diagnosis.
โ StarColor adhesion-optimized ink series
Each substrate requires a specific resin and additive package. Our technical team selects the right formulation based on your surface energy, post-printing process (lamination, retort, deep-freeze), and end-use requirements.
| Substrate | Recommended Series | Key Adhesion Features |
|---|---|---|
| PE (HDPE, LDPE,LLDPE) | SC2000(water-based) | The surface dyne level needs to be corona-treated to 38 dyn/cm. |
| PP (cast, BOPP, CPP) | SC2000 series | The surface dyne level needs to be corona-treated to 38 dyn/cm. |
| PET | SC2000 series | The surface dyne level needs to be corona-treated to 44 dyn/cm. |
| Aluminum foil | SC2000 series | The surface dyne level needs to be corona-treated to 50 dyn/cm. |
| Tyvekยฎ / medical non-woven | SC3000 series | The surface dyne level needs to be corona-treated to 40 dyn/cm. |
| Coated / kraft paper | SC1000 series | Fast penetration, no flaking, FDA indirect food contact |
๐ Adhesion testing methods you can use today
Cross-cut tape test
ASTM D3359 โ cut grid, apply tape, peel. Rating 0B (total loss) to 5B (0% peel). Food/medical packaging requires โฅ4B.
Rub & scuff resistance
ASTM D5264 โ Sutherland rub tester. Indirectly indicates ink anchorage on films.
MEK double rubs
ASTM D4752 โ solvent rub test to check cure / crosslinking density. Low rubs โ poor adhesion.
๐ We provide free test method SOPs and can evaluate your samples in our lab โ no charge for initial diagnosis.
๐ญ Case Study: Flexible Packaging Converter โ PE Film Adhesion Failure
The Challenge
A Southeast Asian flexible packaging converter experienced 15% batch rejection on surface-printed PE pouches due to intermittent ink adhesion failure. The issue appeared inconsistently โ some batches passed tape testing, others failed โ making production planning impossible. The brand owner was threatening to move the business.
The Diagnosis
StarColor's on-site investigation identified two root causes:
- Surface energy decay โ The high-slip PE film contained migratory slip agents (erucamide) that bloomed to the surface over time. Compounded by warehouse temperature fluctuations, surface energy had dropped to 34 dynes/cm โ well below the โฅ38 dynes/cm required for reliable adhesion.
- Ink-substrate mismatch โ The existing water-based ink had insufficient wetting on the low-energy surface and lacked slip agent resistance, resulting in inconsistent adhesion (2Bโ3B cross-cut rating).
The Solution
StarColor implemented a three-part solution:
| Component | Action |
|---|---|
| Corona Treatment | Adjusted treater output to achieve โฅ40 dynes at print station |
| Ink System | Switched to SC2000 series โ formulated with slip agent-resistant resin system |
| Process Optimization | Reduced viscosity by 8%; adjusted drying profile for improved film formation |
The Results
| Metric | Before | After |
|---|---|---|
| Surface energy | 34 dynes/cm | 40+ dynes/cm |
| Cross-cut adhesion | 2Bโ3B | 5B (0% peel) |
| Rejection rate | 15% | <0.5% |
| Line speed | 280 m/min | 313 m/min (+12%) |
Business Impact:
โ
Annual savings: $180,000+ from reduced reprints and waste
โ
Brand owner renewed contract for 2 additional years
โ
Converter won 2 new flexible packaging accounts
โ
Zero customer complaints since implementation
"StarColor didn't just sell us ink โ they diagnosed our entire process and fixed the root cause. The SC2000 series has been running flawlessly for six months."
โ Production Manager
๐ Adhesion troubleshooting best practices
Quick checklist before you call a specialist:
- Measure substrate surface energy (dyne pens) โ target >38 dynes for most films
- Check corona treatment freshness (decays over time, especially in humid storage)
- Verify ink drying/curing parameters โ under-cured ink has poor internal strength
- Test with alternative ink series to isolate substrate vs. ink issue
- Run adhesion tests after 24h aging โ some failures appear after full cure
Frequently asked questions โ Adhesion failures
โ Why does my ink peel off PE film even after corona treatment?
Corona treatment decays within hours to days depending on storage. Measure actual surface energy (dynes) right before printing. Also, some PE grades contain migrating slip agents that block adhesion.
โ What is the acceptable cross-cut test rating for food packaging?
Most food and medical packaging require 4B or 5B (<5% removal). Our WB-PE Bond and UV-LM series consistently achieve 5B on properly treated films.
โ Can you help if my substrate surface energy is too low (๏ผ36 dynes)?
Yes. We offer primerless low-surface-energy inks for PP, PE and some treated papers. Contact our lab with your substrate sample for a free test.
โ Does StarColor provide on-site adhesion troubleshooting?
Absolutely. Our technical team can visit your plant to measure surface energy, review drying parameters, and recommend adjustments or alternative ink systems.
Adhesion-optimized inks that stay where they're printed
Request a free surface energy test, sample swatches, or a technical consultation to diagnose the root cause of your adhesion issues.