Common Problems and Solutions with PET Release Liners in Die-Cutting

As a professional supplier of plastics and related services, Alfa Chemistry offers a wide range of plastic materials including various PET release liners. PET release liners are a fundamental auxiliary material, and their performance directly impacts production efficiency and product quality. To help our clients navigate common challenges, we've compiled an in-depth analysis of frequently encountered issues with PET release liners during die-cutting processes, along with practical solutions.

Problem 1: Abnormal Peeling Noise and Partial Reverse Adhesion

After laminating double-sided tape to the PET release liner, a sharp sound may occur during peeling, and parts of the adhesive may peel back with the liner (reverse adhesion).

Solution:

This issue typically stems from excessive or uneven release force caused by inconsistent silicone coating. To resolve this, choose PET release liners with well-controlled and uniform coating thickness. Strict quality control during production is essential to maintain consistency and eliminate peeling anomalies.

Problem 2: Reverse Peeling (Incomplete Separation)

The material that should be released remains adhered to the liner, causing reverse peeling and disrupting downstream assembly.

Solution:

Reverse peeling results from poor matching of release force or degraded release layer performance over time. There are two key reasons:

• Inconsistent production leading to variable release force across batches.
• Release coating lacking weather resistance, which degrades after storage.

To address this, select PET liners with stable release properties, excellent aging resistance, and ensure suppliers implement rigorous quality inspections and advanced process controls.

Problem 3: Inability to Separate Tape After Storage

After die-cutting and storage, the adhesive tape cannot be separated from the release liner.

Solution:

This is often caused by uneven or incomplete silicone coating, where certain areas lack release agent, resulting in full adhesion. To prevent this, use high-precision coated PET liners with 100% surface coverage. This is especially crucial in rotary die-cutting, which demands exceptional uniformity.

Environmental Impact and Biodegradation

The release liner feels greasy or exhibits very low release force, potentially leading to silicone transfer or liner delamination.

Solution:

The greasy texture may come from the type of release agent used. Some greasy-feeling liners have excellent coating uniformity and low residual adhesion, which is desirable. However, others indicate poor silicone anchorage, causing the coating to peel off.

Conduct peel strength and migration tests to distinguish between high-performance formulations and subpar coatings. Select well-anchored silicone systems for reliable and durable release behavior.

Problem 5: Static Electricity and Dust Attraction

Static buildup occurs during rewinding, attracting dust and contaminants, especially in clean environments like electronics or optical manufacturing.

Solution:

While mechanical solutions like ionizing bars help, chemical anti-static treatments offer long-term protection. Use anti-static PET release liners or operate in cleanrooms with ESD control. For high-spec applications, opt for liners designed specifically to reduce electrostatic discharge and dust contamination.

Related Products

PET Release Liner

PET Embossed Release Liner

PET Fluorosilicone Release Liner

PET Carwrapping Release Liner

As a trusted supplier of plastic materials, Alfa Chemistry delivers diverse PET release liner solutions engineered for high performance across various industries. We are committed to providing consistent quality, technical support, and application-specific customization to meet your production needs. For technical specifications and consultation, please feel free to contact us.