Minimum Size Multi-layer Label

Successfully Produced Japan’s Smallest Multi-layer Label at φ22mm

We developed the smallest multilayer label. Here we explain the production process and the testing results in detail.

Challenge

Up to now, our company has produced multilayer labels ranging from φ23 mm to φ35 mm for client projects. However, there had been no clear standard for how small we could actually go. To address this, we conducted our own experimental verification to test the limit of the minimum producible size.

The results confirmed that φ22 mm is the smallest size at which we can maintain stable printing and processing accuracy without compromising usability or the functionality of the multilayer structure. This demonstrates that multilayer labels can now be realized at an even smaller scale than before.

This achievement opens up new possibilities for product packaging that requires multiple layers of information within a limited space, as well as for applications on compact containers. It also establishes a new benchmark that highlights our technical expertise, which we will continue to apply in future proposals.

Impressions from the Production

One of the main focuses of this verification was how compactly the folded leaflet inside the multilayer label could be assembled. In multilayer labels, the finishing size is largely determined by how much the “accordion fold” stroke length can be minimized. Through repeated prototypes, we confirmed that the minimum stroke for folding was 18 mm, and it was not possible to reduce the finished dimension any further.

In addition, when the number of folds increased, the adhesive strength holding the leaflet in place was no longer sufficient, causing the leaflet to open on its own. As a result, we concluded that the maximum stable structure is a four-fold configuration (eight pages in total, front and back).

It is also necessary to secure adhesive sections on both sides, each requiring 2 mm of width. Therefore, the actual minimum finished size is calculated as 18 mm (folded section) + 2 mm + 2 mm = 22 mm.

Through this experiment, we were able to clarify not only the “minimum size” of a multilayer label but also the “structural folding limit.” These findings now serve as important benchmarks for future design and proposals.

Detailed specifications

Material	Yupo 80μ(solvent-based strong adhesive) + Coated Paper 73kg + PET25 (extra transparent) Gloss Laminate
Dimensions	φ22 mm
Printing Method	Upper layer: Offset printing（8 pages） Lower layer: Relief printing（1 page）
Number of Colors	1 color (K100%)
Processing	Multilayer processing 9pages total
Finish	25 pieces/1 sheet
Mass Production Lead Time	From 13 business days (excluding weekends and holidays)

For more information, please see Multilingual Labels | Convenient Labels for Export.

Produced by: Kojima Label Printing Co., Ltd.

Our company is one of the few specialized printing firms in Japan with expertise in producing multilayer labels. With advanced processing technology that allows multiple pages to be incorporated into a single label, we make it possible to include a large amount of information even in limited space. We have extensive experience across various industries, including pharmaceuticals, cosmetics, and food, and we take pride in delivering high quality with short lead times.

We also provide support from the planning stage, proposing optimal label designs tailored to the characteristics of each product and brand. If you have any requests or challenges related to multilayer labels, please feel free to contact us. As a trusted partner, we are committed to turning your vision into reality and providing the best possible solutions.