Single Sided Repulpable Light Blue Die-Cuts — Butterfly Shape Paster Tabs for Flying Splices
The one component that secures the top layer before the flying splice — preventing flapping that fails the web.
A flying splice on an offline coater or super calender does not fail at the splicing tape. It fails at the preparation. When the top layer of the new paper reel is not securely held flat against the reel body during the run-up phase, it flaps under the aerodynamic forces of the accelerating web — and a flapping top layer at the moment of splice creates a mis-splice, a web break, and lost production. The butterfly-shaped paster tab is the single component engineered to prevent exactly this failure: it secures the top layer in the specific geometry recommended for the TUB profile reel presentation, with high bonding strength that holds flat through the full run-up to splice speed.Pioneer Tapes manufactures and supplies single sided repulpable light blue die-cuts in butterfly shape — also known in the paper industry as paster tabs or butterfly tabs — for securing the top layer of medium and heavy weight paper reels during the run-up to flying splices on offline coaters and super calenders. Made from a printable white kraft paper carrier coated light blue, coated with synthetic resin water-soluble adhesive, and protected by a silicone-coated white paper liner, these tabs are tailor-made for the application and very easy to handle on the production floor.
As a Pune-based paper industry tape manufacturer with pan-India supply capability, we supply these specialist die-cuts to paper mills, offline coating plants, and super calender operations that require a reliable, repulpable paster tab as part of their flying splice preparation programme. Today, we're proud to support a wide range of multinational companies with our solutions.
What are Repulpable Light Blue Butterfly Die-Cuts?
Pioneer's butterfly die-cuts are constructed from a printable white kraft paper carrier (coated in light blue for identification, keeping it consistent with the light blue colour convention used across Pioneer's repulpable paper mill tape range), coated with synthetic resin water-soluble adhesive on one face, and protected by a silicone-coated white paper liner. The butterfly shape is specifically engineered and recommended for securing the top layer of paper with the 'TUB' profile — the reel preparation format used on offline coaters and super calenders — where the wings of the butterfly shape provide controlled adhesion points that hold the top layer flat without restricting the clean separation of the tab at the moment of splice.
The single-sided configuration is deliberate and functional: the tab bonds on one face to the paper reel's top layer, while the uncoated carrier face can be used for identification marking, batch coding, or operator notes if required — the printable white kraft paper construction enables this. The confirmed product properties position these tabs as:
- Particularly suitable for: Securing the top layer of medium/heavy paper reels during the run-up to splicing tape at offline coaters and super calenders.
- Specifically recommended for: Securing the top layer of paper with the 'TUB' profile — the standard reel end presentation format on these machines.
- Tailor-made application: Very easy to handle — the die-cut shape and silicone-paper liner combination allows operators to peel and apply the tab quickly and accurately during splice preparation without specialist tools or training.
- High bonding strength: Prevents flapping during paper web flying splices in the offline coater — the tab holds the top layer flat through the full run-up to splice speed.
We supply these butterfly die-cuts in standard sizes suited to offline coater and super calender reel preparation, and can discuss custom size requirements with your splicing process team.
Key Features
- Butterfly Shape — Purpose-Designed for TUB Profile Reel Preparation: The butterfly shape is not a generic die-cut form — it is specifically recommended for securing the top layer of paper with the TUB profile used on offline coaters and super calenders. The wing geometry of the butterfly provides the correct adhesion point distribution for this reel preparation format, holding the top layer flat across the appropriate contact area while allowing clean separation at the splice moment.
- High Bonding Strength — Prevents Flapping During Run-Up: The synthetic resin water-soluble adhesive provides high bonding strength confirmed to prevent the top layer flapping during paper web flying splices in the offline coater. Flapping of the top layer during the run-up to splice speed is the mechanism that causes mis-splices and web breaks at the splice point — the tab's bonding strength eliminates this risk.
- Single-Sided Adhesive — Tab Bonds to Top Layer Only: The single-sided construction means the adhesive bonds the tab to the top paper layer while the uncoated carrier face remains free — allowing the tab to function as a securing hold-down without creating an unwanted bond between the top layer and the reel body beneath it.
- Printable White Kraft Paper Carrier — Light Blue Identification: The carrier is made from printable white kraft paper, coated light blue for instant visual identification consistent with the light blue colour convention used across the Pioneer repulpable paper mill range. The printable carrier allows batch coding, date marking, or other operator notation to be applied directly to the tab if required.
- Water-Soluble Adhesive — Fully Repulpable: The synthetic resin water-soluble adhesive disperses completely in the pulping process — both the carrier and the adhesive are repulpable, ensuring the butterfly tab introduces no contamination into the fibre stream when the spliced paper is recycled or repulped downstream.
- Silicone-Coated White Paper Liner for Clean Application: The silicone-coated white paper liner protects the adhesive face until the tab is applied, then peels away cleanly — allowing operators to handle, position, and apply the tab quickly and precisely on the reel floor without adhesive contact during handling.
- Tailor-Made — Very Easy to Handle on the Production Floor: Confirmed as a tailor-made application that is very easy to handle — the pre-cut butterfly shape and easy-peel liner combination allows rapid, accurate application during splice preparation without operator training in complex technique.
- Consistent with the Light Blue Repulpable Range Convention: The light blue colour coding maintains visual consistency with Pioneer's repulpable light blue tissue tape used for the actual flying splice — allowing machine-floor operators to distinguish the paster tab from the splicing tape at a glance, supporting organised and error-free splice preparation.
Applications of Repulpable Light Blue Butterfly Die-Cuts
The primary confirmed application is securing the top layer of medium and heavy weight paper reels during the run-up to flying splices on offline coating plants. In a flying splice on an offline coater, the new reel is brought up to running speed while the expiring reel is still feeding the web. The top layer of the new reel must be held absolutely flat and secure during this acceleration phase — any lifting or flapping of the top layer creates a mis-splice when the splice tape makes contact.
The butterfly tab is applied during splice preparation as follows:
• Step 1 — Reel preparation: The splicing tape is applied to the new reel in the TUB profile configuration, ready for the splice. The top layer of paper is folded back to expose the splicing tape and then returned to its flat position over the reel.
• Step 2 — Tab application: The butterfly die-cut liner is peeled and the tab is applied across the top layer in the position specified for the TUB profile, with the butterfly wings providing adhesion points that hold the top layer flat against the reel.
• Step 3 — Run-up: The new reel is accelerated to match the running web speed. The butterfly tab holds the top layer flat through the full run-up phase, preventing flapping under the aerodynamic forces of the accelerating web.
• Step 4 — Splice and separation: At the moment of splice, the splicing tape bonds the new reel to the running web. The butterfly tab separates cleanly from the reel as the splice completes, and the tab is carried into the web — where it will eventually enter the pulping process and disperse without contaminating the fibre.
Flying Splice Preparation — Top Layer Securing on Super Calenders
Super calenders applying pressure and gloss finishing to paper webs use flying splices for reel changes and require the same top layer securing function as offline coaters. The butterfly tab is confirmed as particularly suitable for offline coaters and super calenders — the two primary paper machine types where this preparation format applies.
Medium & Heavy Weight Paper Reel Changes
The tabs are confirmed as particularly suitable for securing the top layer of medium and heavy weight paper reels. On heavier paper grades, the aerodynamic forces on the top layer during run-up are greater — making the high bonding strength of the butterfly tab more critical than for lighter paper grades where the top layer is less susceptible to lifting.
Repulpable Splice Preparation Programme
Within a complete repulpable splicing system, the butterfly tab works alongside Pioneer's repulpable light blue tissue tape and other repulpable splicing tapes — providing the top layer securing function that the double-sided splicing tape cannot perform (the splicing tape bonds between the two reel surfaces, while the butterfly tab holds the top layer down before the splice). Used together as a system, all components are repulpable, maintaining full fibre-stream compatibility through the complete splice preparation process.
Who Uses Pioneer Repulpable Butterfly Die-Cuts?
Offline coating plant operators running flying splice systems on medium and heavy weight coated paper grades are the primary users of these butterfly tabs — using them as the top layer securing component in their TUB profile splice preparation process.
Super Calender Operations
Super calender operations applying calendar finishing to paper webs use butterfly tabs for the same top layer securing function in their flying splice reel change preparation.
Newsprint & Paper Processing Mills
Paper mills and processing facilities running flying splice systems on their winding and converting lines use butterfly tabs as part of their broader repulpable splicing tape programme — maintaining a fully repulpable, fibre-compatible splice preparation system across the facility.
Sustainability & Recycled Fibre Operations
Mills and converting plants operating formal fibre recovery and sustainability programmes use repulpable butterfly tabs specifically to ensure that every component of the splice preparation system — including the paster tab — is fibre-compatible and disperses cleanly in the repulping process without introducing non-paper contamination.
Technical Specifications
| Parameter | Specification |
| Product Form | Single-Sided Die-Cut (label/tab format) |
| Shape | Butterfly / Paster Tab — specifically engineered for TUB profile reel preparation |
| Carrier Material | Printable White Kraft Paper (coated light blue for identification) |
| Carrier Configuration | Single-Sided — adhesive on one face; printable uncoated reverse face |
| Adhesive Type | Synthetic Resin, Water-Soluble (repulpable) |
| Release Liner | Silicone-Coated White Paper — peels cleanly during application |
| Repulpability | Fully repulpable — carrier and adhesive disperse during pulping |
| Colour | Light Blue (consistent with Pioneer repulpable range identification convention) |
| Printability | Printable carrier — supports batch coding, date marking, operator notation |
| Primary Machine Type | Offline coaters and super calenders (flying splice equipped) |
| Paper Weight Application | Medium and heavy weight paper reels |
| Key Performance Property | High bonding strength prevents top layer flapping during flying splice run-up |
| Standard Size | Contact Pioneer's team for standard butterfly tab dimensions |
| Shelf Life | 12 months (stored at 20–25°C / 50% RH, away from direct sunlight) |
Why Choose Pioneer Tapes?
- Purpose-Designed Butterfly Shape — Not a Generic Die-Cut: The butterfly shape is the result of a confirmed, specific engineering recommendation for the TUB profile reel preparation used on offline coaters and super calenders. This is not a generic rectangular tab adapted for splice preparation — it is a shape designed for this application, providing the correct wing geometry for effective top layer securing in the TUB configuration.
- Complete Repulpable Paper Mill Tape Programme: Pioneer supplies the complete repulpable tape programme for paper mills and coating plants: repulpable tissue tape, repulpable light blue tissue tape, repulpable splicing tape, and these butterfly die-cut tabs. The butterfly tabs work as a system component alongside Pioneer's splicing tapes — maintaining full fibre-stream compatibility across every element of the splice preparation process.
- Light Blue Identification — Programme Visual Consistency: The light blue colour coding of the butterfly tabs maintains visual consistency with Pioneer's repulpable light blue tissue tape used for the actual flying splice — allowing machine-floor operators to manage the two components as a recognisable system with clear visual identification of each element.
- Printable Carrier for Process Management: The printable white kraft paper carrier allows mills to apply batch codes, production dates, or identifying information directly to the tab — supporting traceability and process management requirements without requiring separate labelling components.
- Pune-Based Manufacturer, Pan-India Supply: Manufacturing in Pune with nationwide supply capability gives Pioneer Tapes shorter lead times for Maharashtra-region paper and printing operations, and dependable delivery for coating plants and mills across other states.
- Consistent Die-Cut Quality — Identical Geometry Across Every Pack: The butterfly tab's function depends on precise, consistent shape — tabs that vary in wing geometry between batches create inconsistent top layer adhesion during splice preparation. Pioneer's controlled die-cutting process ensures identical butterfly geometry across every tab in every delivery.
- Trusted by Multinational Companies: Today, we're proud to support a wide range of multinational companies with our solutions — including offline coating plants, super calender operations, and paper mills that depend on reliable, repulpable splice preparation components for continuous, high-speed paper production.
Frequently Asked Questions
Repulpable light blue butterfly die-cuts — paster tabs — are used to secure the top layer of medium and heavy weight paper reels during the run-up to flying splices on offline coaters and super calenders. They hold the top paper layer flat against the reel body during the reel acceleration phase, preventing it from lifting and flapping before the splice is triggered. A flapping top layer at the moment of splice creates a mis-splice and web break; the butterfly tab eliminates this risk by holding the top layer securely through the full run-up to splice speed.
The TUB profile is the specific reel end preparation format used on offline coaters and super calenders, where the paper top layer is folded back to expose the splicing tape and then returned to a flat position over the reel end ready for the splice. The butterfly shape is specifically recommended for securing the top layer in this TUB configuration — the wing geometry of the butterfly provides adhesion contact points at the correct positions on the top layer to hold it flat and secure through the run-up phase without creating excessive adhesion that would prevent clean separation at the moment of splice.
The butterfly die-cut tab and the splicing tape perform different functions in the same flying splice process. The splicing tape (double-sided) is the component that actually joins the new reel to the running web — it is the adhesive bond that creates the splice. The butterfly tab is a preparation component that secures the top layer of the new reel flat against the reel body during the run-up phase before the splice happens. Both components are used together in the same splice preparation process: the splicing tape creates the splice, the butterfly tab prevents the failure mode that stops the splice from working correctly.
Single-sided adhesive is correct for this application because the tab only needs to bond on one face — to the top layer of the paper reel — to perform its top layer securing function. If the tab were double-sided, the second adhesive face would create an unwanted bond between the top layer and the reel body underneath it, which would prevent the top layer from releasing cleanly at the moment of splice. The single-sided construction bonds the tab to the top layer only, holding it flat against the reel while leaving the interface between the top layer and the reel body free to separate as the splice occurs.
Q5. Are these butterfly tabs repulpable, or do they need to be removed before the paper is repulped?
Fully repulpable. Both the printable white kraft paper carrier and the synthetic resin water-soluble adhesive are formulated to disperse completely in the pulping process. The butterfly tab does not need to be located and removed before the spliced paper enters the repulping or recycling process — it disperses into the fibre stream without contaminating the recovered paper pulp. This is the same fundamental repulpable property that characterises all products in Pioneer's repulpable paper mill tape range.
Yes. The carrier is specifically described as made from printable white kraft paper — confirming that batch codes, production dates, reel identifiers, or operator notation can be applied directly to the tab's uncoated carrier face. This printability supports traceability and process management requirements without requiring separate labelling. Contact Pioneer's team to discuss printing options and minimum order quantities for pre-printed tabs.
Yes. Pioneer Tapes supplies repulpable light blue butterfly die-cuts in bulk to offline coating plants, super calender operations, newsprint mills, and paper processing facilities across India. Bulk supply is managed with consistent die-cut geometry and adhesive performance across every delivery batch, dedicated account support, and scheduling to fit your production programme requirements. Contact Pioneer's team with your machine type, reel width, and volume requirements to discuss the appropriate tab size and supply arrangement.
Eliminate Top Layer Flapping from Your Flying Splice Process.
Tell us about your machine type, paper grade, reel width, and current splice preparation method. Pioneer Tapes will confirm whether the repulpable light blue butterfly die-cut is the right paster tab for your offline coater or super calender operation, and arrange samples before you commit to a bulk supply.
Butterfly shape for TUB profile. Light blue for identification. Printable carrier. Water-soluble adhesive. Fully repulpable. High bonding strength. The complete paster tab component for your repulpable splice preparation system.
Contact Pioneer Tapes today — request samples, get a bulk quote, or speak with our paper industry specialists.
Pioneer Tapes | Pune, Maharashtra, India | Industrial Adhesive Tape Manufacturer & Supplier
Tell us about your machine type, paper grade, reel width, and current splice preparation method. Pioneer Tapes will confirm whether the repulpable light blue butterfly die-cut is the right paster tab for your offline coater or super calender operation, and arrange samples before you commit to a bulk supply.
Butterfly shape for TUB profile. Light blue for identification. Printable carrier. Water-soluble adhesive. Fully repulpable. High bonding strength. The complete paster tab component for your repulpable splice preparation system.
Contact Pioneer Tapes today — request samples, get a bulk quote, or speak with our paper industry specialists.
Pioneer Tapes | Pune, Maharashtra, India | Industrial Adhesive Tape Manufacturer & Supplier
