Surface Toughness,
Print Integrity.
Scratches, rub-off, and scuff marks during handling, filling, and transport compromise brand image and product information. StarColor provides abrasion-resistant inks and overprint varnishes engineered to withstand the toughest conditions β from distribution to retail shelf.
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Common scratch & rub failures and their cost
Ink rub-off / scuffing
Ink transfers to adjacent surfaces during handling, filling or transport. Obvious on white or clear areas.
Scratches & surface marks
Mechanical abrasion from guide rollers, conveyors, or stacking leaves visible scratches on print.
Poor stack / pallet resistance
Ink scuffs or blocks when printed surfaces are stacked under weight or during shrink-wrapping.
π¬ Root cause diagnosis: abrasion factors
π§ͺ Ink Film Properties
- Low crosslink density β soft film
- Insufficient slip / wax additives
- Poor surface hardness (pencil < H)
- Under-cured or over-dried film
π Process & Handling
- Guide roller pressure / alignment
- Conveyor belt abrasion
- Stacking pressure and vibration
- Shrink-wrap friction
π Substrate Contribution
- Rough surface profile
- Coating porosity
- Low surface energy (PE/PP)
- Ink penetration depth
β¬οΈ Free Sutherland rub test and surface hardness measurement available.
β StarColor scratch & rub resistant solutions
From tough, crosslinked ink films to protective overprint varnishes, we offer a complete portfolio to meet your abrasion resistance requirements β from ASTM D5264 Sutherland rub to TABER abrasion.
| Solution | Recommended Series | Abrasion resistance features |
|---|---|---|
| Abrasion-resistant flexo ink | SCAR2000 series | High crosslink density, wax-enhanced, Sutherland rub > 200 cycles |
| Scuff-resistant UV ink | UVAR series | High surface hardness (2H+), excellent scuff resistance, low migration |
| Overprint varnish (gloss) | HY8100 series | Protective gloss coating, Sutherland rub > 300 cycles |
| Overprint varnish (matte) | HY8200 series | Matte finish with scratch resistance, ideal for labels |
| High-durability gravure ink | SCAR5000 series | Solvent-based, high solids, TABER abrasion > 100 cycles |
| Water-based tactile varnish | HY8400 series | Combines tactile feel with excellent rub resistance |
π Abrasion testing methods
π Sutherland rub test
ASTM D5264 β measures ink rub resistance using a weighted block and reciprocating motion. We test up to 500 cycles with standard or custom weights.
βοΈ Pencil hardness
ASTM D3363 β evaluates surface hardness. Target H-2H for most packaging, 3H+ for high-durability applications.
π TABER abrasion
ASTM D4060 β rotating abrasive wheels measure weight loss or visual damage. Used for heavy-duty packaging and industrial applications.
π We provide free rub testing for your printed samples β including Sutherland rub, pencil hardness, and TABER abrasion analysis.
𧴠Case Study: Label Converter β Rub-off on Beverage Labels
The Challenge
A major beverage brand reported ink rub-off on their pressure-sensitive labels after filling, packaging, and transport. The issue was most visible on dark-colored labels where scuff marks exposed white substrate beneath, ruining the premium appearance. The brand had received multiple retailer complaints and was threatening to withdraw business.
The label converter's internal Sutherland rub testing showed failure at only 50 cycles β well below the brand's specification of 150+ cycles. The converter had already tried increasing UV lamp power and reducing line speed, but neither improved rub resistance significantly.
The Diagnosis
StarColor's technical team conducted a complete analysis of the label production process and identified two root causes:
- Low crosslink density β The existing UV ink formulation lacked sufficient reactive monomers and oligomers, resulting in a soft, under-cured film that easily abraded
- Insufficient slip additives β The ink contained no wax or slip agents to reduce surface friction, allowing labels to scuff against each other and against conveyor surfaces during filling and transport
The Solution
StarColor implemented a two-part protective system:
| Component | Function |
|---|---|
| UV-AR Series Ink | Enhanced crosslinking chemistry + optimized slip/wax additive package |
| OPV-G Gloss Varnish | Protective overprint layer for additional scuff and abrasion resistance |
The UV-AR series achieved 2H pencil hardness, while the OPV added an extra protective barrier. Together, they created a dual-defense system against abrasion.
The Results
| Metric | Before | After |
|---|---|---|
| Sutherland rub test | 50 cycles | 350 cycles |
| Pencil hardness | HB | 2H |
| Customer claims | 8β10/month | Zero |
Business Impact:
β
Brand renewed contract with converter and expanded label portfolio
β
Eliminated customer claims β saving an estimated $120,000+ annually in returns and reprints
β
Converter used the UV-AR + OPV solution as a selling point to win 3 new beverage accounts
"We went from 50 to 350 rub cycles. StarColor didn't just fix the problem β they gave us a competitive advantage."
β Quality Manager, Label Converter
π Scratch & rub resistance best practices checklist
Improve the durability of your printed packaging:
- Test your current ink with Sutherland rub (ASTM D5264) to establish a baseline
- Measure pencil hardness β soft films (< H) will scratch easily
- Ensure proper cure for UV inks β under-cured films are soft and rub off
- Add slip/wax additives to reduce coefficient of friction
- Consider an overprint varnish (OPV) for critical applications
- Check your production line for mechanical abrasion points β guide rollers, conveyors, stacker wheels
Frequently asked questions β Scratch & Rub Resistance
β What is a good Sutherland rub result for food packaging?
Most food packaging requires >100 cycles without visible rub-off. For premium brands and high-abrasion applications, we target >200 cycles with our AR series.
β Can I add scratch resistance to existing inks?
Yes β we offer additives (wax dispersions and crosslinkers) that can be added to your existing ink. However, performance is best when formulated at the manufacturing stage.
β What's the difference between OPV and ink additives for rub resistance?
OPV (overprint varnish) provides a protective outer layer on top of the ink. Ink additives (waxes, slip agents) are incorporated into the ink film itself. Both can be used together for maximum protection.
β Do you test samples for free?
Yes. We provide free Sutherland rub testing, pencil hardness measurement, and abrasion analysis on your printed samples β no charge for initial evaluation.
Inks that stand up to scratches and rubs.
Request a free abrasion test, Sutherland rub analysis, or formulation consultation β we'll help you achieve the durability your packaging needs.