Release Liners - Label and Narrow Web

Release liners have become a hot topic in our industry because this pressure sensitive labeling staple can play a big role in a company’s bottom line. And with sustainability trending in a major way, it is no surprise that interest in release liners is greater than ever.

The release liner is a paper, filmic or hybrid paper-plastic film carrier material. The liner is coated on one or both sides with a very thin layer of silicone, and its function is to act as a carrier to protect the adhesive/label until it is applied.

“Release liners are indispensable to carry and protect pressure sensitive adhesive (PSA) products,” explains Andrea Lackner, director of R&D and innovations, Mondi Release Liner. “They are used in a wide variety of industries such as labels, tapes and graphic arts, as well as the hygiene and medical industry.”

As Angel Harvey, senior product manager – variable information and prime paper, Avery Dennison Label and Packaging Materials, notes, the liner serves as a label’s backing before conversion and application, protecting the adhesive during shipment, storage and converting. During the application of the label, the liner is peeled away, and a silicone-based coating on the liner’s side facing the adhesive allows for the liner’s fast and easy removal.  

Functionally, the liner serves as an adhesive carrier, release surface, dieutting base and label transporter, all while preventing oxidation
and contamination.

AWA Alexander Watson Associates, host of the AWA Global Release Liner Industry Conference & Exhibition, has studied this segment extensively. Based on AWA’s data, the global release liner market accounted for 56,748 million square meters in . Asia represents 40% of the market, while North America and Europe comprised 27% apiece.

According to Corey Reardon, president and CEO of AWA, and his team, the global release liner market experienced growth in despite the COVID-19 pandemic. Asia was a significant driver of the segment’s growth, as it contained the spread of the outbreak much earlier. These steps enabled quicker recovery.

“Overall, worldwide annual market growth in was estimated to be 2.7%,” AWA states in its Global Release Liner Annual Review. “Going into , AWA forecasts a growth of 4.0% globally as some market segments recover and others stabilize.

“Worldwide, compound annual volume growth expectations are forecast to be approximately 3.8% for the period -, which is expected to generate an additional estimated 6,790 million square meters of release liner by ,” the report continues.

Multiple materials make up the release liner landscape. Glassine/SCK paper is the predominant material, as it comprises 36% of the global market with 20,377 million square meters. Polyolefin coated paper and clay coated paper account for 16% and 13% of the market, respectively. Meanwhile, PET films are the driver in the filmic space, representing 7,629 million square meters and growing at a rate of 4.5% – the biggest growth rate of all materials. PE films and PP films garnered 6% and 2% of the global market, respectively.

“There are regional differences regarding release liner base, but glassine/SCK papers dominate, representing 36% of worldwide demand,” states AWA. “This is largely driven by their use in the high-volume pressure sensitive label market. Film release base now accounts for 22% of the worldwide total.”

AWA’s research shows that the largest segment for release liners is pressure sensitive labelstock, which accounts for an estimated 48% of the total global market. The tapes segment follows, with 14%, and the total industrial segment (building and construction, composites, electronics, and other industrial) with 12%.

Sustainable impact
Most every product in the label and package printing industry is designed with sustainability in mind, and release liners are no exception. Suppliers are increasingly developing alternative carriers and coatings, as well as products that are designed for recycling like downgauging material.

“The release liner industry is further developing ways to become more sustainable, exploring every aspect of the value chain to see where sustainability improvements of all kinds can be made,” comments Mondi’s Lackner. “We’re creating end-of-life-scenarios and closing the loop for release liners. Looking at the entire value chain is essential. We at Mondi work together with customers and suppliers in order to create a sustainable product and process from the bottom up.”

Avery Dennison has established a pilot program with RoadRunner Recycling for matrix waste recycling to divert waste from landfills in North America. The company also works closely with converters looking to recycle their film and paper liner recycling, helping connect them with recyclers in their area that can support these initiatives.

“Label liners make up a relatively small part of a packaging solution, but they can have a big impact on sustainability,” says Avery Dennison’s Harvey. “As part of our efforts to reduce the environmental impact of labeling and help establish a circular economy, an increasing percentage of our liners and other label materials are responsibly sourced, made with recycled content, use less material and are recyclable.”

Avery Dennison identifies liner selection as a critical part of this process, as well. The company’s thinner liners are produced with fewer fossil fuels, water and energy, resulting in fewer greenhouse gas emissions and less waste. Thinner liners also allow for more labels per roll, reducing transportation and waste along with changeovers, downtime and the space needed for storage. Plus, Harvey adds, rPET liners are made with 30% post-consumer recycled content from PET bottles.

Lackner concedes that the industry still needs to make strides in the liner recycling process. Mondi leans on a special infrastructure to provide collection and sorting streams to address various aspects of matrix and release liner recycling, including analyzing technical issues and promoting the use and creation of recycling networks.

“Currently, release liners are often discarded once the PSA products are used, but technically release liners can be recycled,” adds Lackner. “This requires a recycling infrastructure, which is still being researched and developed. There are technologies in place, but it is all about making sure that they can cover the needs of the industry.”

As Calvin Frost, founder of Channeled Resources Group and longtime L&NW columnist, explains, silicone release liners – both paper and film – are recyclable, with one exception. “The anomaly is polycoated liners,” says Frost. “These liners are used in a variety of applications where stay-flat characteristics are required. Interestingly, because our industry has become more interested in sustainability and reducing non-recyclables from the landfill, we are seeing heavier clay coated liners, which are recyclable, replace polycoated product. They provide the same stay-flat characteristics and are competitive in price.”

However, this begs the question: If liners are recyclable, why aren’t we as an industry recycling more than 7-10% of available liners? “The answer is logistics and packaging,” continues Frost. “These two issues can be solved if the supply chain is willing to commit to following simple practices. There is a third problem, which is more complex, namely education. We need to teach the paper industry that there is value in the fiber, and that silicone is not deleterious to the recycling process. If we focus on solving these three problems – packaging, logistics and education – we have an opportunity to redirect upwards of 400,000 tons per year of spent liner from the landfill into useful applications.”

To further promote recycling in this key area, Mondi joined CELAB (Circular Economy for Labels) in . CELAB is an industry-led initiative founded by companies in the self-adhesive label industry to create greater circularity for its products. By joining this consortium, Mondi will collaborate with partners to facilitate the recycling of release liners.

While sustainable endeavors are critical on the manufacturing level, Mondi has also partnered with its customers to help streamline this process. The company performs research and in-house calculations in order to support customers’ targets, which often include conducting CO2 calculations to fully understand what impact these products have at a comparable level.

“Many customers do appreciate guidance when it comes to understanding how release liners can support the sustainability of their products,” says Lackner. “For example, we can optimize transport costs through the lighter weights of certain papers, improve energy use in production, focus on sustainable procurement or use recycled fiber offerings to reduce the CO2 footprint.”

In , Mondi unveiled a customer-centric EcoSolutions approach, where it works together with customers and partners in the value chain in order to meet their sustainability goals. Mondi developed an agenda specific to its release liner plants to work toward a holistic approach in creating not only sustainable products, but a more sustainable value chain.

“Mondi starts at the beginning, such as getting more sustainable raw materials for products, optimizing logistics, and focusing on local supply chains in order to reduce the carbon footprint of our own production, considering the circularity of the product by looking at recycling options and collection streams, so that products can stay in a circular economy,” Lackner adds.

Liner evolution
Suppliers have engineered a wide range of solutions to optimize the performance and recyclability of release liners.

These products have come a long way to reach their current functionality. According to Channeled Resources, early silicone polymers were silicone gums dispersed in solvent, and this technology was developed in the s.  These dispersions were needed to get silicone diluted or thin enough to be applied with coating technology at that time. 

“Silicones were emulsified and diluted in water in an attempt to move away from solvent dispersion,” explains Tom Ray, technical director, Channeled Resources Group. “In the s ‘solventless’ silicone technology was developed using platinum and rhodium catalyst systems, and multi-roll coating technology was developed to apply thin films of silicone. This was the standard for many years. Recently, polymers have moved to lower viscosity, with the addition of anti-misting additives as coating speeds have increased. Anchorage additives have improved the silicone adhesion to film substrates. And most recently, next generation anchorage additives, coupled with faster crosslink technology, are pushing platinum catalyst levels down for improved cost while retaining good anchorage and cure.”

Avery Dennison’s popular paper liners include 40# SCK, 40#CK, 44#PK and 40# BG. Super calendared liners have proven to be excellent in diecutting, says Harvey, and they’re ypically used for roll-to-roll applications. The 40# SCK and 40#CK liners are optimal for paper facestocks, with 40# BG the ideal choice for film facestocks. Meanwhile, 44#PK has been engineered for both paper and film facestocks.

Avery Dennison’s filmic liners provide a no-label appearance and strength. However, they are not suitable for perfing, punching or fanfolding, and are strictly intended for roll-to-roll. Machine-finished or lay-flat liners are often used on prime and industrial label applications when the labels are sheeted. “PET is the second most common liner material with a growing market share,” says Avery Dennison’s Harvey. “Paper and PET liners can both be paired with paper or filmic facestocks.

“Technology in coatings continues to evolve in a variety of segments, whether that is specialty into high performance applications or into broad coatings utilized in the PSL industry,” adds Harvey. “Avery Dennison continues to look at coating technology, as well as materials used in the release liners, for ways to continually innovate in this space.”

According to Mondi’s Lackner, release liner technology has improved in terms of speed. High-speed coating is one aspect, and other technological developments include double coating heads. These allow for the coating of two sides of a base material in just one machine run, enabling higher operational efficiency.

“High-speed printing further allows the production of customized release liners to meet customers’ requirements,” explains Lackner.

Mondi, which boasts a wide breadth of release liner products, recently launched its EverLiner labelite and EverLiner M R products. EverLiner labelite is a lighter option to standard glassine liners for label applications, with the same thickness of 58 gsm glassine but engineered to a reduced weight of 47 gsm. This results in 20% material savings, the company notes, and its lighter weight allows for optimized transportation.

Meanwhile, EverLiner M R is the first release liner on the market using a recycled base paper, adds Lackner. The machine glazed paper (MG) with 70% FSC-recycled certified content reduces the number of fresh fibers used, and the FSC certification ensures responsible sourcing.  

Mondi has also debuted its NextLiner, which utilizes a recycled base paper with a coating made from renewable resources. “This is the world’s first sustainable polycoated kraft (PCK) paper release liner,” adds Lackner. “Using recycled fibers and renewable materials can have a positive impact on the environmental footprint of NextLiner, used in graphic arts, tapes and other industrial applications.

Going linerless
As release liners continue to improve in terms of performance and recyclability, there is a growing trend toward linerless labels – which undoubtedly influences the liner market. There are benefits and challenges associated with this space, and UPM Raflatac has been quite active in promoting the segment.

For example, UPM Raflatac recently partnered with Toshiba to provide linerless label products to the European market. Through this collaboration, customers of both Toshiba and UPM Raflatac can take advantage of the tested and approved combination of Toshiba’s BV420D-GL linerless printer and UPM Raflatac’s OptiCut linerless label material.

“E-commerce business is requesting flexible, efficient and sustainable solutions,” says Angel de Juan, general manager, Toshiba, Auto ID Europe. “By partnering with UPM Raflatac we are able to offer our European customers a global linerless portfolio, which is a perfect match with our newly launched linerless printer.”

UPM Raflatac has announced the launch of its newly developed Linerless OptiCut product. UPM Raflatac’s in-house-developed adhesive technology used in OptiCut is available for each of the primary direct thermal linerless end-use environments – from retail and logistics to quick service and takeout restaurants. OptiCut minimizes service time and offers customers a linerless product with maximum uptime of printer applicators, fewer reel changes and a crisp barcode on the package, the company says. “We have developed OptiCut in collaboration with our partners across the value chain. Our innovative and sustainable solution is the optimal choice when you are looking for clean cutting performance on the printer combined with excellent adhesion on the package,” says Mauri Suomela, senior vice president, paper laminates, UPM Raflatac.

Linerless innovation is growing at a rapid pace, too. NAStar Inc. has patented TwoFer Shelf Tags, which are back-to-back shelf tags without a liner that use an alternating adhesive and release coated pattern designed for the retail sector. Users can easily pull apart TwoFer Shelf Tags from one another, doubling the label quantity per sheet of material while eliminating liner waste. Plus, TwoFer Twin Signage, with two facestocks and no liner, is the newest member of NAStar’s sustainable TwoFer Linerless Label Solutions product line. This fully recyclable product supports the sustainability goals of its users by having zero liner waste.

“The TwoFer family of products eliminates silicone-coated liners and has two pattern-coated face sheets married together,” explains John Short, marketing director at NAStar, Inc. “The TwoFer Shelf Tags themselves are two paper-based labels constructed together, and they have film-like performance and excel in a variety of retail environments, even in the refrigerator and freezer sections of the store, without curl. When separated, you’re left with two useable, unique shelf tags that are ready to be affixed on the shelf.”

Linerless products can be advantageous, and the adoption of thermal linerless labels offers several advantages. These include more labels per reel, variable label length, less storage space, less weight and bulk for lower transportation costs, and no release liner waste. There are challenges, though.

“Any challenges are mainly related to the limited possible label shapes and the need for specific dispensing devices, which include cutters that can handle exposed adhesives,” notes Mondi’s Lackner. “Linerless solutions can therefore be a valid option for certain defined applications such as retail and weigh-scaling labels, transportation and warehousing, fast food package sealing and more.”

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Release Liners: A Worldwide Special Report

Published: November 01, , By AWA Alexander Watson Associates

Part 1 | Part 2 | Part 3 | Part 4 | Part 5

To view this special report as a PDF, click the link below:

Link to Document

Wanted: A Better Knowledge Base

A leading specialty converter explains why we need more education on release liners.

By Ann Hirst-Smith AWA Alexander Watson Assoc.

Suzanne Zaccone, past president of Tag & Label Manufacturers Institute (TLMI) and president of Graphic Solutions Inc., spoke at the recent North American Release Liner Conference organized by AWA Conferences. Her topic was "Release Liner Applications from a User's Viewpoint," and her message was unequivocal: "Converters are not as educated as they should be regarding liners. And their education, in my opinion, is key to working at solving problems at the converter and end-user level."
Zaccone came to this conclusion following a series of interviews with her own production staff and managers and with about 30 TLMI converter members, in which she asked for input on the challenges they have faced both in converting self-adhesive laminates and in working with their customers, the end-users.
She says, "Even though the liner is thrown away, converters believe it is as critical to the overall performance of the end product as the material and inks that provide the message. Good die-cutting and stripping are heavily dependant upon the ability to cut the face and adhesive cleanly without nicking the surface of the liner. Having a very uniform, dense surface (the anvil effect) to cut against is critical. The release level is also critical to good converting and dispensing, and building good silicone holdout into the liner is paramount. Consistency of release to a converter and an end-user is essential: low release can be as bad as high release."

Sticky Situations
Many problems faced by converters today are the result of their end-user customers' demands for lower-cost labels—and their own efforts to replace high-performance laminates with lower-cost constructions that simply cannot meet the die-cutting and stripping criteria. Such compromises only can be achieved successfully from a good knowledge base—and as far as release liners are concerned, converters do not have that.
Zaccone cited a number of instances of release liner "problems" that resulted in product failure, and in some cases shut down packaging lines for days. Solving the problem on hand can be a challenge in itself, due to the complicated nature of the self-adhesive laminate—it is not always apparent to a converter where the problem lies—and identifying the cause can involve the laminator, release liner supplier, and even their suppliers. It can be a major cost to the converter, since there is a trend toward end-users levying fines on suppliers responsible for downtime on production lines, as well as the cost of reprinting or re-converting the job.
However, this is not the main cause for concern: Large end-user companies have a choice in the labeling or product decoration technologies they employ, and any major or recurring failure in self-adhesive label performance could lead them to switch. Today, there are plenty of alternatives to the "traditional" self-adhesive laminate: direct print, linerless labels, shrink sleeves, and in-mold.
Two of the major technical problems that were highlighted by Zaccone will be familiar to readers: silicone skip (resulting in poor label dispensing from the liner), and its opposite, over-coating of silicone (resulting in label movement on the web, poor converting, and poor dispensing). Several converters no longer specify anything other than polyester liners for high-speed labeling applications; and when, for any reason, polyester liners are unsuitable, converters increasingly are specifying glassine for its enhanced die-cutting, stripping, and application properties compared to super-calendered kraft.
The actual silicone system employed on a liner is also something of a mystery—but essential if a converter is to make an informed decision on the laminate required for a particular application. The attributes of the various systems are completely different—but again, the industry makes it difficult for the converter to compare them, since no two companies use the same testing and measurement methods. Says Zaccone, "The same size, width, angle, and adhesive should be used to test all liners, regardless of supplier. A good plan of attack would be to develop industry standards."

Collaboration and Communication
Zaccone says her company, Graphic Solutions Inc., likes the challenge of "something strange, challenging, or untried," and in addition to self-adhesive labels, converts aluminum nameplates, polycarbonate panels, PCBs, electroluminescent lamps, RFID antennae, and thin and flexible batteries. Many of these are leading-edge technologies, and she says, "the ultimate success of these seemingly different challenges hinges on collaboration and communication." She extrapolates this concept across the whole of the supply chain and emphasizes the need for converters to be able to see "the big picture" in order to do their jobs to their own satisfaction—and that of their customers.
Her message to the self-adhesives industry is clear: "If the silicone liner supplier, adhesive supplier, material supplier, converter, and end-user work closely together, ask a lot of questions, and develop specifications that meet everyone's requirements and abilities, then everyone wins."

Editor's Note: AWA Conferences' first North American release liner conference was held September 9 at the Hyatt Rosemont Hotel in Chicago, IL. The program attracted good attendance and contained something of interest for every level of the value chain. A two-and-a-half day global release liner conference is scheduled for May 1–3, , at Hilton Head, SC.

In this special report:

• Wanted: A Better Knowledge Base
  
• Label Stock Liners: Issues & Trends
• The Market for Release Liners

Label Stock Liners: Issues & Trends

Some pointers from the recent AWA North American Release Liner Conference.

The self-adhesive label stock market is changing in response to the purchasers' increasing demands for product innovation and higher levels of service, without any increase in costs. To maintain profitability, paper and film manufacturers, self-adhesive laminators, and converters are realigning in the face of raw material price increases they cannot pass on and heavy pressure on margins.
Those in the middle of the value chain in the release liner market are experiencing pressures, too, and it is here there will be a major focus for change over the next five years as consolidation—already well established at raw material and silicone coating levels—takes hold. Price pressures are accentuated by the high levels of capacity available in the silicone coating market: In-house coaters currently are using only 55% of capacity, commercial coaters 65%. As state-of-the-art conversion machinery comes onstream, old capacity is not being "retired"—compounding the problem.
At the recent North American Release Liners Conference in Chicago, Corey M. Reardon, principal of AWA Conferences, had strong words of caution to the release liner manufacturers. "In this business environment, the prime need is to drive down costs and not margins in order to maintain a competitive long-term pricing structure that will enable you to remain in business," he said.

Film Liners
Film release liners represent the most dynamic sector of the release liners market today. While polyvinyl chloride, polyester (PET), polypropylene, and polystyrene all are used, it is the PET and polyethylene (PE) films—high-density PE, low-density PE, linear low-density PE—that are showing the greatest growth. The films market is, however, also experiencing overcapacity, the effects of globalization, and changing competitive advantages due to energy costs. While supply/demand balance is forecast for –, the tight resin market is expected to mean higher prices.
Where release liner performance is a critical factor—especially for high-speed label application—films still must remain the ultimate choice. With around 55% of the world's consumption of film release liners concentrated in self-adhesive label stock, they demonstrate exceptional performance characteristics in terms of adhesive coat weight control, the layflat and consistency of the web, print and converting quality, and dispensing properties. Manufacturers of film release liners are expected to continue to develop market-led and research-driven specialty product streams, both for polymer technology and for coating technology. Average annual growth in film liners is 8%–10%.

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Paper Liners
There are still enormous opportunities for paper-based liners. Growth in North America from – showed a compound annual growth rate of 4%, and growth is forecast at between 2% and 4%.
North America's preference for super-calendered kraft (SCK) liners slowly is being eroded by glassines, which offer a more comprehensive range of performance characteristics for high-speed label conversion and application. SCK still remains the cost leader, and any product innovation should not jeopardize that advantage. For lamination to film facestocks, PE-coated krafts represent an alternative to film.

Coating and Converting Issues
As new silicone technologies, coating enhancements, and converting standards develop, release base performance is becoming an increasing focus—whether paper or film. High-speed silicone coating has made misting on the production line a major issue in coating, since it can affect both conversion and dispensing performance adversely.

Release Liner as Packaging Waste
The prospect of classifying release liner as packaging waste is a reality in parts of Europe, and the likelihood is this will impact the North American label market—possibly to the detriment of self-adhesive technology and in favor of other product decoration methods. US-based Channeled Resources, with its increasing base of MaraTech subsidiaries around the world, sets an example to the industry by demonstrating how non-traditional reuse/recycling of release liners can be achieved successfully. The company currently salvages approximately 65% of its waste intake—both paper and films—for reuse, with the balance going to thermal recycling for energy creation.

Market Characteristics
Raw material prices continue to move upward, and competitive pressures increase as the value chain continues to consolidate at all levels. The self-adhesive label market is characterized by a trend toward smaller orders, delivered more quickly so customers can maintain their productivity—whether they are laminators, label converters, or label users. Technical performance of label stocks depends very much on the qualities of the release liner, and the boundaries continually are being pushed back. Facestock improvements have been the focus of self-adhesive laminators in recent years, and present standards probably represent the limit of capabilities in many respects, such as caliper reduction.

Success in Today's Business Climate
Reardon offers advice to players in the market for release liners in this difficult environment: "To be successful, you need to improve your profitability by finding new market growth opportunities. You need to provide added-value materials and services—and take non-added-value complexity out of the supply chain. Demand will continue to grow for performance-oriented materials and, conversely, for the lowest total cost offering the best possible effect. "Don't wait to invest in new technologies. Players who invested earlier—maybe without making money at the beginning—have acquired expertise...and you won't be able to catch up with them."

In this special report:

• Wanted: A Better Knowledge Base
  
• Label Stock Liners: Issues & Trends
• The Market for Release Liners

The Market for Release Liners

A look at North American trends and opportunities in a global context.

by Corey M. Reardon AWA Alexander Watson Assoc.

In the worldwide market for release liners totaled an estimated 24,200 million sq m of silicone-coated papers and films—a lower than expected level of demand. The softening of the US economy during the last quarter of and its impact on the global economy was the main driver. However, there is optimism the US economy may strengthen in and beyond, and the economies in Europe, Asia, and parts of South America—already showing moderate growth—should follow.
Of the five major application categories in the market—label stock, graphic arts, tapes, other self-adhesive, and non-self-adhesive applications—self-adhesive applications account for 89% or 21,538 million sq m worldwide. The other segments—film casting, bakery and food liners, and industrial non-self-adhesive applications—account for the remaining 11% (2,662 million sq m).
In the global market, North America continues to dominate demand, accounting for about 42.6%. Europe takes second place with 31.4%, and Asia Pacific now represents a sizable 22%.

Release Liner Substrates
Overall, substrate demand is dominated by calendered kraft papers, with polyethylene-coated papers in second place, but this generalization is subject to significant regional differences, which (as in Asia Pacific) may be influenced by such basic factors as climate. In North America and Europe, calendered krafts predominate, though each region has its own specific preferences.
North America favors super-calendered kraft (SCK) papers, where Europe prefers glassines. PE-coated papers take the highest share in Asia Pacific (particularly Japan).
Film liners currently achieve a 12% level of penetration both in North America and across the globe and are growing fast, both in self-adhesive and non-self-adhesive application areas.

The North American Market in Detail
Based on the AWA North American Release Liner study published last year, the total North American market for release liners was quantified at 9,719 million sq m of silicone-coated papers and films—across all applications. Worldwide, self-adhesive applications claim the main usage, approximately 89% of the total. Of that total, 45% is in-house silicone coated, driven largely by the label stock and graphic arts segments.
The North American market share of commercial silicone coating companies (55%) will decrease slowly due to the dominance of self-adhesive (in-house coated) applications but will lead in all markets other than label stock and graphic arts materials.
Of release liners used in label stock applications, 80% are produced by in-house silicone coating by major self-adhesive concerns such as Avery Dennison and MACtac. In the highly competitive self-adhesive markets, in-house coating provides a valuable opportunity to minimize costs and increase margins.
There are a number of suppliers of paper release base in North America, including IP, Stora Enso, Westvaco, Wausau-Mosinee, SAPPI, Fraser, and Schoeller.
Some key suppliers for film grades are Saint Gobain, Tredegar Corp., Mitsubishi Polyester Films, DuPont Teijin, UCB, Phoenix Films, and ExxonMobil. Growth in films manufacture has been driven by the requirements of end-users for lower downtime on the packaging/filling line due to liner web breaks, by the relatively low costs of film manufacturing, and by the growth in market segments such as medical, building/ construction, and tapes.
Commercial silicone coaters represent more than half the North American market today, and in a business arena of change, divestment, and acquisition, the top five companies today are Akrosil, CPFilms, Douglas Hanson, Eastern, and Loparex. Of these, only two are global players (Akrosil and Loparex) with production capacity in different regions worldwide.
The supply of silicones in North America is, in contrast to the other raw materials, concentrated among a small number of global suppliers—Dow Corning, GE Silicones, Degussa Goldschmidt, Rhodia Silicones, and Wacker-Chemie.
The changing profile of the industry, at all levels, will lead to higher capacity usage as consolidation, acquisitions, rationalization, and liquidations continue. Undoubtedly, fewer companies will account for a larger share of the business, but there are also good prospects for small specialist suppliers of niche products.
While overall market demand in North America remains buoyant (without enjoying the same growth rates as historically), there has been softening due to economic conditions. Forecast demand continues to rise, and an annual increase of 4% is expected looking forward. This growth is driven by self-adhesive applications.

The Future for Release Liners in North America
The broad range of applications for release liners makes them a relatively secure niche in the world's converting industry. However, demand is softening—especially in the mature markets of North America and Europe—and they no longer can be relied upon to drive real growth, particularly the double-digit or near-double-digit growth seen in the past.
North America is not traditionally a main exporting region in the world for release liners, but there are opportunities for North American producers that are positioned to exploit such export opportunities, particularly in the economically expanding regions of Asia Pacific and South America. Reducing tariff barriers and international trade agreements such as GATT, NAFTA, and ASEAN can contribute to the attractiveness of such business.
In terms of market segments, the ethical and over-the-counter pharmaceutical markets—as well as nutraceuticals, medical disposables, and other medical and quasi-medical devices—are expected to benefit significantly from the demographic shift caused by the aging baby boomer generation—not just in North America but also in Europe.

AWA's in-depth market research in North America has led to projections of a 4% average growth for the release liners industry through , an average that conceals considerable differences in the various market segments, as the chart below shows.
There can be no doubt the market in North America is well-positioned to achieve continuing healthy growth in the medium term, supported by consumer goods' manufacturers demands for more—and more innovative—primary product labels; high growth rates in the building and insulation market and others; and an established and primarily domestic raw materials supply base.

Corey M. Reardon has more than 15 years of management experience in the converting and laminating industry with leading companies such as Rexam and Avery Dennison. Today he is a principal of international market research and consulting firm AWA Alexander Watson Assoc., a company that specializes in supporting the coating, laminating, and converting industries with multiclient and private market studies and industry-specific supply chain conferences. For more information contact AWA at +31 20 676 20 69; This address is being protected from spambots. You need JavaScript enabled to view it. ; awa-bv.com.