Paper vs. Polycarbonate Labels: How to Choose the Right One

Choosing a label is a specification decision: paper, polycarbonate and decals must suit the product, equipment or package. Since 1996, Pro-Pak Associates in Kennett Square has helped engineers and buyers match materials to the surface, environment and budget.

When paper labels are the right fit

Roll of blank paper labels, die-cut on a liner

Paper labels

Paper is usually the most economical choice when a product or packaging label will live indoors, stay reasonably dry and see limited abrasion. Typical uses include branding and instructions, shipping and carton labels, barcodes, and lot or date information.

Paper is not inherently waterproof or chemical resistant. Moisture, oils, solvents, heavy handling and prolonged sunlight can scuff the surface, fade the ink or break down the stock, unless the label is coated or laminated. If the graphic has to last on equipment, in a wash-down area or outdoors, paper is usually not the first material to specify.

When polycarbonate labels are the better choice

Printed control-panel overlay with legends, indicator lights and a selector knob

Polycarbonate labels

Polycarbonate is a tough plastic film used for durable labels, nameplates and control-panel overlays. Specify it when the graphic has to stay readable for the life of the product or equipment, not just through shipping and shelf display. A common advantage is subsurface printing: the ink can sit behind the film, so the film itself protects the graphic from abrasion, chemicals and repeated cleaning. Typical uses include rating and serial plates, warning labels, equipment identification, and operator overlays that see oils, solvents, cleaners, abrasion or outdoor light. Polycarbonate costs more than paper. That difference is usually justified when an unreadable label creates a service, safety or identification problem, not for a shipper label or a carton brand.

Where decals fit

Warning decals applied to an equipment housing

Decals

Decals sit between paper labels and polycarbonate nameplates in many projects. They are typically a flexible film, often vinyl, with a pressure-sensitive adhesive, used for permanent or semi-permanent graphics on products, equipment and packaging. Choose a decal when you need more durability than paper and the graphic has to conform to a curved, large or irregular surface. Performance depends on the film, the adhesive and the finishing. A permanent adhesive is meant to stay put; a removable construction is meant to come off later without damaging the surface. Specify those details around the actual surface and the intended life of the graphic.

How to choose

1. End use and exposure.

Indoor packaging, outdoor equipment, oils, chemicals, abrasion, UV and cleaning each point to a different construction.

2. Surface.

The stock and adhesive have to bond to corrugated, plastic, painted metal, glass, wood or a finished package.

3. Service life.

Shipping and shelf life are one requirement; the life of a piece of equipment is another.

4. Appearance and budget.

A paper label, a flexible decal and a polycarbonate overlay present differently. Start with the performance you need, then choose the most economical material that meets it.

Labels as Part of the Package

Pro-Pak also designs and supplies thermoformed trays, clamshells and blisters, foam inserts, and poly bags, so the package, card and label can be coordinated together.

Paper vs. polycarbonate vs. decals

Paper labels

Best for: indoor product, carton and shipping labels; Durability: good indoors, more with coating or lamination; Chemical/abrasion: limited unless coated; UV/outdoor: limited; Cost: lowest; Form: flexible sheet or roll.

Polycarbonate labels

Best for: nameplates, overlays, warning and equipment labels; Durability: high, film protects subsurface graphics; Chemical/abrasion: strong against many oils, solvents and cleaners; UV/outdoor: better suited with the right inks; Cost: highest; Form: tough film, plate or overlay.

Decals

Best for: large, curved or irregular graphics; Durability: depends on film and adhesive; Chemical/abrasion: choose construction for exposure; UV/outdoor: use outdoor-rated film and ink; Cost: varies; Form: flexible adhesive film.

Frequently asked questions

Answers to common questions about choosing paper, polycarbonate and decal constructions.

Choose polycarbonate when the label must stay readable through handling, cleaning, chemicals, abrasion or outdoor light, or when you need a nameplate or overlay that stays with the equipment. Use paper for branding, shipping or product identification in a milder environment.

A decal is usually a flexible film graphic, often over a larger or contoured area. A paper or polycarbonate label is often a more defined identification or instruction piece. We help you choose based on the application.

Yes. They can be specified for metal, plastic, wood, glass, cardboard and other common surfaces. Include the surface and end use so the adhesive and construction can be matched to the job.

The product or package, surface, environment, expected life, size, and the artwork or copy the label must carry. From there we design and supply a construction that fits the application.

Ready to specify a label?

Tell us what you're labeling and where it will be used.
Explore Custom LabelsContact Us