The invention relates to a method for manufacturing a transdermal patch from a drug-containing web that minimizes waste. The web is a layered composite that includes at least a backing layer and a drug-in-adhesive layer and a first strippable release liner. The web is kiss-cut along intersecting cut lines at least down to the depth of the liner, generally defining the extent of individual transdermal patches. The intersections of the cut lines define small zones that are punched out of the web in a generally star shape. The portions of the web above the liner are peeled away from the liner and transferred to a faster moving second liner so that the patches are now further spaced apart from one another. This second liner is then cut to provide transdermal patches that are mounted to release liners that are substantially broader in extent than the patches themselves.
