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BOBST Announces Its Basic-to-Intermediate Folder-Gluer Operator Training

BOBST has announced its upcoming folder-gluer operator training. Join BOBST for an exclusive basic to intermediate folder-gluer operator training at the BOBST West coast demo center in Santa Fe Springs, CA!

This hands-on training, designed for operators in the folding carton sector, offers a unique opportunity to:
• Master job setups for classic box styles like straight-line, crash-lock bottom, and four-corner boxes.
• Enhance machine knowledge and gain insights into glue and quality control systems.
• Increase production efficiency, maximize running speeds, and reduce setup times.
• Work on real-world jobs with expert guidance from BOBST instructors.
Course Details:
Dates: January 20–24, 2025 (Monday noon to Friday noon)
Location: BOBST West Coast Demo Center, Santa Fe Springs, CA
Fee: $2,800 per participant (discount available for additional participants from the same company)

January 20–24, 2025
BOBST West Coast demo center
Santa Fe Springs, CA 90670

Enrollment is limited, so secure your spot today!

Register Now:
Email: [email protected] (General Questions)
Email: [email protected] (Technical Questions)
Call us at 1-888-226-8800

Unlock your potential with BOBST training and join us in shaping the future of the packaging world! For more information, visit www.bobst.com.

PRINTING United Expo Appoints Vice President

Press release submitted on behalf of PRINTING United Alliance

PRINTING United Alliance, Philadelphia, Pennsylvania, the most comprehensive member-based printing and graphics arts association in North America, announced the appointment of Derrick Nelloms, PMP, as vice president, PRINTING United Expo. With a distinguished career spanning three decades in operational planning, event management, and strategic growth, Nelloms brings a wealth of expertise and a proven track record of delivering exceptional trade show and event experiences to the Alliance team.

In this leadership role, Nelloms will oversee the continued growth and success of the Expo, the industry’s annual premier trade show in North America, as well as assist in the optimization of other key events in the organization’s portfolio. His results-driven approach and dedication to operational excellence will further solidify the Expo’s position as the premier event for the global printing industry.

“Joining the Alliance team is an honor and I am excited for the opportunity to build upon the incredible legacy of PRINTING United Expo,” said Nelloms. “Having spent my career in events and operations, I am eager to work with this talented team to drive continued success, deliver unforgettable experiences, and foster growth across the global printing industry.”

Nelloms Brings Over 30 Years of Experience to the Alliance
Before joining the Alliance, Nelloms spent 18 years as operations managing director at Emerald Expositions where he oversaw the strategy, planning, and execution of flagship events, including GlobalShop, Imprinted Sportswear Show (Impressions), Hospitality Design (HD EXPO), CEDIA, Boutique Design (BDNY), Healthcare Design, Environments for Aging, and Sports Licensing. He was also instrumental in the successful launch of NBACON, leading efforts in budgeting, cost optimization, and vendor relationship management, which consistently enhanced customer experiences and streamlined event operations.

Nelloms’ career also includes a foundational role at the Georgia World Congress Center in Event Operations, where he worked with major event and tradeshow organizers on a range of industry-renowned events, including the World Energy Engineers, CTIA Wireless, Specialty Graphic Imaging Association (SGIA) Expo, International Home Builders, International Woodworking Fair (IWF), MegaFest, Microsoft, Partylite National Conference, Kitchen & Bath Show, Medtrade, Supershow, ESPN GameDay Live, and Supercross BMX Fanfest, to name a few. His work at the Georgia World Congress Center honed his skills in managing complex logistical demands and providing high-touch service for large-scale, multifaceted events.

“Derrick’s leadership, industry expertise, and passion for operational excellence are precisely what we need to continue elevating the Expo,” said Chris Curran, group president, media and events, PRINTING United Alliance. “His deep understanding of event strategy and customer engagement aligns perfectly with our vision to expand the Expo’s reach and impact. We are thrilled to have him on board and cannot wait to see his contributions to the team.”

Nelloms holds a B.B.A. in Finance and Marketing from the University of West Georgia, is a certified Project Management Professional (PMP), and is a member of the International Association of Exhibitions and Events (IAEE).

PRINTING United Expo 2025 will be held October 22-24, 2025, in Orlando, Florida. Visit PRINTINGUnited.com to be notified when online registration opens.

Join the Alliance
For more information about becoming an Alliance member to tap into the industry’s leading resources, training, education, content, and support, visit www.printing.org/membership.
About PRINTING United Alliance
PRINTING United Alliance is the most comprehensive member-based printing and graphic arts association in the United States, comprised of the industry’s vast communities. The Alliance serves industry professionals across market segments with preeminent education and training through iLEARNING+, workshops, events, research, government and legislative representation, safety, and environmental sustainability guidance, as well as resources from our leading media brands – Printing Impressions, Packaging Impressions, Wide-format Impressions, In-plant Impressions, and Apparelist. A division of PRINTING United Alliance, Idealliance is a global leader in standards training and certification for printing and graphic arts operations across the entire industry supply chain.

PRINTING United Alliance also produces the PRINTING United Expo, the most influential days in printing. The expansive display of technology and supplies, education, programming, and services are showcased to the industry at large, and represents all market segments in one easily accessed place. For more information, visit www.printing.org.

GOEBEL IMS Introduces the Automatic Knife Positioning System

Press release submitted on behalf IMS Technologies

GOEBEL IMS, Calcinate BG, Italy – a brand of IMS TECHNOLOGIES – announced a new upgrade to the slitter rewinder: the automatic knife positioning system developed in collaboration with DIENES. This innovative system brings unparalleled precision and efficiency to the RAPID series, well-known in the slitting and winding industry for its exceptional handling of different materials, including paper and light board.

With this upgrade, the RAPID machine sets a new standard for high-performance production, delivering both ease of use and increased operational speed. Engineered to streamline slitting processes, the automatic knife positioning system offers features that cater to the evolving needs of today’s high-speed production lines.

Key Technical Features
• Fully Automated Knife Positioning: A stand-alone control system with dedicated touch panel and “Pick and Place” automation for fast, precise upper knife adjustments.
• High-Performance Capability: Featuring a minimum slitting width of 20 mm and web speeds up to 1,000 m/min, the system is designed to handle high-speed slitting demands with exceptional accuracy.
• DS 4 Shear Knife Holders: With 105 mm diameter knives and quick-change heads, the DS 4 holders incorporate a double vertical stroke guide for increased stability and reliable cuts.

Main Benefits
1. Easy Integration: Designed for seamless integration into existing RAPID equipment, this system reduces setup time and facilitates a smooth transition to advanced automation.
2. Efficient Maintenance: Maintenance is simplified, allowing top knife shaft adjustments without disassembly, reducing downtime and enabling rapid switches between slitting formats.
3. Enhanced Safety: 360° hand protection and minimized overhead work enhance operator safety, reducing risks associated with manual setup.
4. Increased Machine Availability: Offline knife replacements and quick-change heads boost uptime, while automated positioning reduces configuration time, maximizing productivity.
5. Stable and Error-Free Operation: Easy Set integration, touch-panel control, and saved slitting recipes ensure precise, repeatable slitting for consistent, quality results.

Meeting Modern Production Needs
The integration of this automatic knife positioning system marks a significant step forward in efficiency and safety for RAPID users. This upgrade is meticulously designed to support the demands of today’s advanced slitting and winding applications, enhancing not only performance but also operator experience.

For further information on integrating the system with your RAPID machine or to discuss the benefits for your production line, please contact us at
[email protected].

GOEBEL IMS and DIENES continue to drive innovation in the slitting and winding industry, delivering solutions that empower businesses with cutting-edge technology. For more information, visit www.imstechnologies.com.

Metsä Board Introduces QR Code with Recycling Information for All Its Delivery Packaging Materials

Press release submitted on behalf of Metsä Board

Metsä Board, Espoo, Finland, the leading European producer of premium fresh fiber paperboards, has launched a new solution to enhance and simplify the recycling process for packaging materials customers receive as part of Metsä Board product deliveries.

Metsä Board has introduced QR codes on the pallet and reel labels of its products for all volumes delivered to its customers. The QR code directs customers to an intuitive app that provides detailed information on the various packaging materials used to protect the paperboard during the logistics chain. This information will assist customers in determining how each component of the delivery’s packaging should be recycled.

By providing accessible and clear recycling information, the company aims to make it as easy as possible for customers to sort and recycle all the materials they receive with the product deliveries. In addition, customers will be able to reduce the amount of waste sent to landfills and ensure the materials are recycled as part of the local circular economy loop.

“The implementation of the new recycling QR codes on our paperboard deliveries stems from a strong commitment to sustainability and customer convenience,” says Isto Hongisto, Product Safety Specialist at Metsä Board. “Recycling can sometimes be complex, and our goal is to make it as seamless and straightforward as possible for our customers. This initiative will not only save them time, but it will also ensure that the materials used in our deliveries are recycled in an optimal way.”

The new initiative is part of Metsä Board’s ongoing strategic commitment to sustainability and innovation in its operations. The company invites all customers to take advantage of this new feature and contribute to promoting efficient recycling practices within the packaging industry.

The QR codes have been visible on all paperboard deliveries as of November 2024.

Metsä Board is a producer of lightweight and high-quality folding boxboards, food service boards and white kraftliners. The pure fresh fibers we use in our products are a safe, renewable and recyclable resource, that can be traced back to northern forests. We aim to have completely fossil free mills and raw materials by the end of 2030. We promote a culture of diversity, equality and inclusion.

Metsä Board is listed on the Nasdaq Helsinki. In 2023 our sales totaled EUR 1.9 billion, and we have around 2,300 employees. Metsä Board is part of Metsä Group, whose parent company Metsäliitto Cooperation is owned by over 90,000 Finnish forest owners. For more information, visit www.metsagroup.com/metsaboard.

INX Introduces INXhrc RC Expansion for Rigid Packaging

Press release submitted on behalf of INX International Ink Co.

INX International, Schaumburg, Illinois, today announced a brand extension for INXhrc(TM) RC natural-based inks: a new UV/LED dual cure low migration formulation for plastic and foam-based packaging joins the tried-and-true UV curable formulation. Both offer a series of operational, regulatory, and sustainable benefits for brand owners and printers.

INXhrc RC LM is a Nestle-compliant, high-performance ink solution with clean, renewable, and sustainable ingredients used for the printing of low migration applications on rigid container packaging. Designed with high levels of biorenewable content and formulated without VOC solvents, it delivers top-tier print quality and reduces the carbon footprint of packaging materials by up to 30%. With excellent adhesion and color consistency attributes, these inks are food-safe for sensitive packaging applications.

“Consumer expectations,” states Renee Schouten, INX International’s vice president of marketing, “for manufacturer accountability in regards to safety and sustainability continues to increase, so low migration inks are becoming a more important consideration for the packaging industry. This is especially true for the impact of plastic and foam-based rigid containers, so we are replacing petrochemical derived resins with natural and renewable materials.

“These two INXhrc RC formulations offer superior dry offset printing quality of rigid containers or decorative packaging, and help lower your carbon footprint. By keeping consumer safety and the environment in mind, you have regulatory confidence and access to a product using biorenewable, clean ingredients without compromising performance.”

INXhrc RC LM is ideal for nonfood contact surfaces on rigid materials. Verified by a third party laboratory as an eco-friendly alternative to standard UV inks by using ASTM D6866-20 Method B, it meets food safety regulatory compliance measures such as Regulation EC No. 1935-2004. Known as the Framework Regulation, it sets requirements for materials to safeguard human health.

The natural components of INXhrc RC are not derived from food crops, ensuring they are non-allergenic and food-safe. Free of harmful chemicals, they do not contain any nanomaterials, fluorochemicals, fanal pigments, heavy metals or PTFE.

INXhrc RC inks have a history of providing outstanding printing benefits. Its high strength and gloss produce sharp, vibrant colors and eye-catching finishes, and precise color matching with single-pigment bases allow for accurate PMS shade matching. Excellent adhesion and abrasion resistance make for enhanced durability. Superior flow and transfer capabilities also make it ideal for dry offset printing on rigid packaging presses such as VanDam, PolyType, and Kase.

Schouten cited a longtime Michigan based customer who began using INXhrc inks in 2017. A leader in single-use food packaging, they have achieved impressive carbon emissions reductions and strengthened their sustainability goals and environmental responsibilities.

“When Dart Container Corporation made the switch from traditional to natural-based inks with INXhrc, they anticipated a positive effect on their environmental footprint,” explained Schouten. “However, they were surprised by the enhanced ink performance as well.”

Over the course of seven years using INXhrc inks, the world’s largest manufacturer of foam cups and disposable food containers has experienced a major annual decrease of 200 tons of CO2 carbon emissions. Lowering VOC emissions by 75%, Dart created a safer working environment while reducing their environmental impact. They also improved their pressroom performance with better ink mileage, less downtime, and increased production efficiency while maintaining the high print standards they are known for.

Click on the following link to learn more about the Sustainability vision and approach INX takes, including details about the Coloring a Safe and Sustainable Future model, regulatory, quality assurance, and social responsibility measures, and a copy of the 2023 Sustainability report.

About INX International Ink Co.
INX International Ink Co. is the third largest producer of inks in North America, with full-service subsidiaries in Europe and South America and is part of Sakata INX worldwide operations. We offer a complete line of ink and coating solutions technology for commercial, packaging and digital applications. As a leading global manufacturer of inkjet inks, we provide a full palette of digital ink systems, advanced technologies and integrated services. Stay updated on the latest developments and follow INX on LinkedIn, Facebook, and X, or visit our website.

Industry Influencer: Gary Cohen

Gary Cohen is the executive director of RadTech International North America, a trade association devoted to promoting the use and development of ultraviolet (UV) and electron beam (EB) processing as an industrial technique offering energy savings, elimination of pollution, greater productivity, higher yields and the opportunity for improved, new or unique products. The association serves as an international forum and reliable source of education and information for individuals and organizations involved in the use of UV and EB processing or who supply equipment, chemicals or other materials to such users. With a background that includes work at the US International Trade Commission, Cohen is focused on supporting US manufacturing across a wide variety of industries, including print and packaging.

How did your career develop into your involvement with RadTech North America and the UV and EB curing industries?

I was born and raised in the Washington DC area – so, way too many lawyers and lobbyists concerned about politics. I started out at the US International Trade Commission looking at imports to the US that may be unfairly harming US industry. From that time on, my work always has focused on manufacturing, with subsequent positions at the Association for Manufacturing Technology and the Consumer Electronics Association / Consumer Electronics Show. That broad manufacturing perspective, focused on technology users, seemed to be a good fit for RadTech as UV/EB has so many applications across industries.

How do you see the industry embracing global trends, such as the circular economy and sustainability demands from manufacturers, brand owners and consumers?

The UV/EB industry is all in on circular economy and sustainability. In fact, it is members who encouraged us to tag our 2024 biennial event as UV/EB for Sustainable and Responsible Manufacturing. Over the years, our industry had grown a bit frustrated as we always have offered low to no VOC, CO2 and Hazardous Air Pollution solutions, but it was difficult for many companies to make the investment to change their processes. Moving to UV/EB means not just changing equipment, but also much of the process. Many of our members used to say that our real job was “changing mindsets” to get the word out about the various operational benefits of UV/EB that come with a more sustainable process.

What are the biggest challenges the UV, UV LED and EB curing industries are facing? How should the industry respond to successfully grow and thrive?

Understandably, it is hard for many manufacturers to make major changes to their processes. In some instances, companies have been running successfully for generations with their equipment, and change always comes with some perceived level of risk. The challenge of the UV/EB industry is to demonstrate not only the benefits of the technology, but that the technology may be implemented seamlessly
and easily.

As we are seeing federal and state regulations pop up around sustainability, UV/EB sometimes are excluded by regulators as they are not familiar with the technology and/or may have heard some misconceptions. Education is the key opportunity for our industry.

What trends are emerging in design and production that will influence the future of the UV, UV LED and EB curing industry? How do you believe this will affect the printing and packaging industries?

With increased computing power and artificial intelligence (AI) design programs, the ideas we have been talking about for years, such as mass customization, are becoming a reality. This technology is perfect to implement for inkjet, customization, direct to object and special effects. UV/EB offer nearly infinite tuning and precise curing.

Which markets/verticals are growing their use of UV, UV LED and EB curing technologies?

The graphic arts industries are by far the largest segment for UV/EB in North America. UV/EB seems to be accelerating its growth in food packaging and all types of printing, offering safe, sustainable solutions to printers for a range of substrates. That includes metal can decorating and coatings, and coatings and decorations for various flooring and wall covering applications.

While sustainability certainly is a driver to the growth of the technology, the main driver for UV/EB always has been the fact that it is an “enabling” technology, offering enhanced capabilities to print, coat and adhere on a wide range of substrates that may not be practically done in any other way. In addition to the environmental benefits, the hyper-speed (UV/EB cure nearly instantly, in most cases, with products ready for pack and ship immediately), increased capabilities to make new products and the efficiency of the UV/EB processes offer manufacturers real opportunities to benefit their bottom line.

What are your predictions for the UV/EB industry in the next five to 10 years?

I have been in the UV/EB industry for a long time, and part of the reason is because the technology and applications are rapidly evolving, making me very fortunate to be involved with this exciting technology. Big, amazing surprises about new applications and processes almost are a certainty, if the past is any indicator.

If the emphasis on energy savings, CO2 emissions and sustainability continues, the outlook for this technology is very exciting. In many cases, I am not sure there is any better way to meet such enviro-goals while enhancing product and process performance.

Sea Life Poster Journeys into the Future with AI

Edited by Erin La Row, writer, PostPress

An annual project became an award-winning piece of art for the team at Hinderer + Mühlich (H+M), based in Göppingen, Germany, with a US facility in Charlotte, North Carolina. “Sea Life” merged artificial intelligence (AI) with print embellishment to create an eye-catching undersea adventure on paper. The poster, anchored by an embellished sea horse, captivated the judges at the Foil & Specialty Effects Association’s 31st annual Gold Leaf Awards, where the project won Best of Show: Best Use of Foil & Embossing.

Heike Martetschläger, marketing and design manager, said the poster first began as a project to decorate the cover of Verpackungsrundschau, a German packaging magazine. H+M used the opportunity to bring together a team of specialists in each involved area of the project (paper, foil, stamping dies, machinery) to show outstanding embellishment and give inspiration to designers and brand owners. The final cover design then was turned into a large poster. The magazine is not on the market anymore, but H+M continues the tradition of the poster, large and small. Sea Life is the 17th edition of its posters, and the team already is working on number 18.

“In our posters, we incorporate current trends in fashion, design or social trends and transform them into embossed designs,” Martetschläger said. “In doing so, we continually push the limits to showcase the exceptional potential of H+M stamping dies. We also use this project to underline our capacity for innovation and expertise.”

What sets apart Sea Life from the other posters is that its artwork was created using AI. The team used ChatGPT to formulate prompts for MidJourney, a text-to-picture AI tool, to generate imagery. The team wanted to see and experience for itself if there is more than mere functionality to AI – exploring the creative potential of AI. While brainstorming, Wohlgemuth & Company, the design agency behind the poster, suggested taking the AI experience a level higher and starting a collaboration between ChatGPT and MidJourney.

“We used ChatGPT to formulate prompts for MidJourney, swiftly generating around 300 images. Precision in prompt wording proved crucial, guiding the AI to meet our creative vision. Our approach merged fashion, design and jewelry with an underwater theme, prioritizing visual impact over realism,” Martetschläger said.

While Midjourney produced astonishingly realistic results, occasionally it resulted in flaws. “Embracing AI presents an opportunity to learn and innovate, despite occasional quirks like six fingers or peculiar facial features,” Martetschläger added. But with the speed of improvements in AI tools, Martetschläger said she believes the flaws in their process now would be reduced.

With the design determined, the team set out to create the final product. David Bohne, general manager at H+M USA, said, “The poster was designed to combine various visual and tactile styles, such as nanoembossing, microembossing and textured embossing. The big posters were printed on Algro Design Advanced 315 gm while the small poster was made on Algro Design Duo 250 gr – both by Sappi. Details and respective art files for the various foil and embossed elements were meticulously created for H+M to produce the highest quality and precision brass dies for this project, and then stamped and embossed on a Gietz FSA 720 foil stamping press.”

To create the larger Sea Life poster, there was a total of six passes on the Gietz foil stamping press. This included several flat stamp passes of foils, nanoembossing and customized texture in the top Sea Life headline, and a final intricate sculptured embossing of the sea horse. The gems on the sea horse were created with a combination of a clear foil and round embossing.

Art is subjective. The effectiveness of the previous posters depended on the audience – some people related to the design while others didn’t, Martetschläger said, adding there is a lot of interest in the story behind the project and the use of AI to get the design. “Sea Life is one of the designs in recent years that created interest and positive feedback from almost everybody – especially when people get to hold it in their hands,” Martetschläger said. “We even received pictures of customers showing where they had hung it up at their workplaces and their homes.”

Cast and Cure Films from Breit Technologies

By Jeff Peterson, editor-in-chief, PostPress

How Does Cast and Cure Work?

The Cast and Cure process embosses a UV varnish so that it bends light, creating a holographic effect. While Cast and Cure film is temporarily ‘laminated’ to the varnish, UV light is cast through the film, curing the image into the UV varnish. The Cast and Cure film then is lifted off the substrate and rewound for reuse, leaving no film behind. The Cast and Cure material can be embossed with a variety of standard patterns and can support customized designs. It is compatible with clear label, wet label, coated paper, paperboard, film, heat-sensitive material and shrink film.

Cast and Cure creates affordable, sustainable and stunning visual and tactile effects. Since Cast and Cure leaves no material on the substrate, it does not obscure the underlying design. It’s easy to enhance existing designs without creating new artwork. Cast and Cure’s reusability reduces the cost of embellishment and dramatically reduces waste compared to the 1:1 application of other embellishments.

As stated earlier, Cast and Cure is reusable – reducing the cost and waste. With proper use, the films have been reused five or more times for certain applications. Breit Technologies offers dedicated Cast and Cure equipment for both sheet-fed and wide and narrow flexographic presses. There are several machinery options in the marketplace, including digital equipment that can apply Cast and Cure inline, as well as many popular cold foil systems. This flexibility in application methods allows for affordable embellishment regardless of print process or run size.

Applications

Cast and Cure commonly is used to embellish direct marketing pieces, prime labels, paper and flexible packaging, gift wrap, trading cards and other collectibles. Cast and Cure can be used either in spot or flood coat applications without obscuring designs. It typically is chosen in cases where dynamic brand differentiation is required, but cost efficiency and speed-to-shelf are key. It also can be advantageous for shorter-run projects. The subtle light diffraction of UV film casting looks particularly striking on dark or vivid colors; it does not reflect as well on lighter backgrounds. With custom designs, Cast and Cure can provide additional security features for brand protection as well.

Sustainability

Cast and Cure can be reused multiple times, reducing the amount of material waste and the carbon footprint of transportation of both raw materials and finished product. Cast and Cure film also is recyclable, reducing the embellishment waste stream. With UV and EB curing, Cast and Cure embellishment produces no VOCs and significantly reduces energy use in processing. Since no additional material is laminated to the substrate, Cast and Cure embellishment has no impact on the recyclability or compostibility of the product.

Breit Technologies inventories a variety of stock patterns and finishes. This includes 30 standard holographic patterns, scuff resistant matte, soft touch matte, Clear Super Gloss and non-holographic textures, such as brush stroke, canvas, linen and leather effects.

For more information on Breit Technologies’ Cast and Cure films and equipment, visit www.breit-tech.com or call 913.492.8081.

Trading Card Trends 2024

By Jeff Peterson, editor-in-chief, PostPress

The trading card industry continues on a positive trajectory. Just the sporting trading card industry alone expects to reach over $2881.7 million by 2028. The industry was strong before the pandemic, but COVID-19 sparked a resurgence that has continued today and is expected to continue well into the future. Other trends that have sparked growth include NFT (non-fungible tokens) integration that offers a novel digital experience, increases in special editions and autographs, and the overall online marketplace that has facilitated the ease of buying and selling trading cards.

At the core of the design of today’s trading cards is the use of specialty embellishments to help create differentiation and value. The creativity and application of metallics, specialty UV coatings, laminates and other embellishments continue to grow and prosper.

At the recent 2024 Print Embellishment Conference (sponsored by FSEA), one of the panels included a group of experts involved in the production of sporting and gaming trading cards. With the conference taking place in Dallas, Texas, the epicenter for trading card production in the US, the event provided a perfect landscape to bring sources together from different sections of the production process. The panel included Brandon Lesley, Fanatics; Jim Singer, Brodnax 21C Packaging; Stefan Congram, Cartamundi; and Doug Fontana, Xplor Group.

Trading cards (both sports and gaming cards) have seen a new spike in popularity in the last few years. Can you discuss why you believe this has happened, and do you foresee this growth continuing in the future?

Lesley: During the pandemic, people found new ways to spend their time and money, and people really got back into collecting. And, I predict the market will continue to increase and remain steady over the next 10 to 20 years for sure.

Singer: We have been printing and embellishing trading cards for many years. We have moved to cold foiling even base cards that are not the main collectibles. We also have been building up our digital workload and recently added 40″ digital printing and digital embellishment processes to our operation.

Fontana: I believe the pandemic certainly had a huge impact, with people staying at home and looking for hobbies. That clearly was the reason for the spike. We do a great deal of the finishing work on the trading cards, and the innovative ideas are amazing and are keeping the collectors interested.

Congram: We work on the gaming side of trading cards, and the pandemic certainly had a major impact. A lot of people who played board games in the 1990s as kids were bringing the board games back out again. And, coming out of the pandemic, there have been new licenses and new entrants in the gaming market that are sparking even more growth.

Both metallic and coating embellishment technologies continue to dominate the design and production of trading cards. Why do you believe this is the case? What drives the use of specialty effects and embellishments for cards?

Congram: It is the nature of the product itself for both gaming and sports cards. Collectors receive the cards in a sealed pack, and it is all about the chase. It is a treasure hunt. So, the nicer the piece of treasure is, the more valuable that chase card is that you’re looking for. The embellishments elevate the aesthetics of the card of that player and directly drive up the value of the card.

Fontana: Embellishments dominate the card world. It is the appeal and the hunt for the perfect card – a card that someone else doesn’t have. The trading card companies keep asking us to push the limits with specialty effects.

Singer: With new digital embellishment technology, set-up time is very quick and the tooling is zero, so we can provide all types of samples and prototypes and do a lot of innovative things with the cards. This provides the trading card companies additional choices for foils and specialty coatings.

Lesley: Collectors want to feel and touch things. We live in a digital world where everything is disposable. When people buy cards, they keep them. We discuss this with our designers all the time. You are designing something that someone can pass down to their grandchildren, as opposed to marketing materials or a digital asset. Embellishments make a difference because they create emotion for the collector as they go through packs – they are looking for something that really jumps out, as well as the texture and the shininess of it. People want something that makes them feel different as they break open a card pack.

What types of embellishments are you seeing being used on trading cards? Are you seeing growth in any specific type of embellishment technique or process?

Singer: We have invested a great deal in digital embellishment technology for trading cards, opening up new opportunities. We can create an etching effect using the raised polymer over the top of the foil with stunning effects. We also can get very fine line work with foil and spot coatings with our digital embellishment technology. We continue to try to innovate. Recently, we laid down a cold foil on a second surface so you can see through the adhesive to the foil. When you look at it from the front side, it looks like a piece of glass. The sky is the limit because our customers always are asking – what if we do this?

Fontana: We have been seeing a great deal of clear plastic, synthetic paper and other variable stocks. There continues to be R&D on different substrates and embellishments.

Congram: Certainly, different types of paper and substrates are being used. Some of our new games want a specific holographic pattern developed for them that has never been seen before. Three-dimensional holograms are making a comeback, too. I have seen new requests for registered holograms or patterns. The holograms also are important for authentication or anti-counterfeiting.

How has the increase in digital embellishment processes enhanced the growth of digital for larger runs that are done more conventionally with hot or cold foil processes?

Fontana: Digital embellishment technologies have allowed printers and finishers to be extremely creative for those special valuable cards in a pack. The lower-value cards go through embellishment processes as well – usually more traditional foil stamping, UV coating or cold foil. I believe that is where it is. The digital embellishment processes are being used for high-end, difficult-to-find cards in each pack.

Singer: Even more standard cards include cold foil and other processes, so the expectations are higher for every type of card. We, hypothetically, can run a mass volume with our traditional platform and through our digital processes, adding additional embellishments on certain cards. All the processes are working together – conventional processes with digital – creating even cooler, more interesting cards.

What types of changes do you predict for the trading card industry in the future? Do you believe embellishment processes will continue to be an important part of the industry moving forward?

Lesley: In the next three to five years, embellishments will continue to be a very important part of the trading card market – probably the most important part. You have to create value in different ways, and I think you do that through embellishments. Innovations and new processes will continue to happen. We have done more testing in the last year than we have in the previous six years on new processes and ideas and how to use them on cards.

Congram: I believe the complexity of processes will be a given. It’s not going to get simpler. We continue to have requests to make the creativity for our games and cards more exclusive. I predict more short runs and more frequent releases (drops) in the market. However, costs still will be a factor. We will have to find ways to keep costs in line. As the rarity model sort of shifts, and we want to give more people more rare cards, we are going to see the evaluation of production costs more heavily scrutinized.

Metallic Transfer Decorating, the Sustainable Choice for Print & Packaging

By Steven Schnoll, Schnoll Media Consulting

Sustainability is becoming increasingly important for the packaging world, including cartons, labels and more. Sustainability is not just a buzzword but a core part of the packaging industry value chain. Today, consumers, brands, packagers and governmental regulators are heavily focused on the environment and the demand for sustainable packaging solutions.

In the highly competitive retail marketplace, brand owners know that consumer attitudes are vital in purchasing decisions. Creatively designed packaging structures create a First Moment of Truth (FMOT) in purchasing decision-making. For brand organizations to thrive, creating dynamic packaging is paramount. Realizing this, Consumer Packaging Goods (CPGs) manufacturers turn to innovative technologies to help their packaging stand out. This includes metallics and other specialty effects for print that can transform and influence a consumer’s purchase decision.

Sustainability Education

Let’s define the words “repulpability” and “recyclability” regarding paper and packaging. Repulpability refers to the ability to convert paper back into pulp, whereas recyclability generally is about the capability of a substrate to be processed into new paper or paperboard. Repulpability is a critical characteristic of paper products that are intended to be recycled. When recycled, paper is mixed with water and turned into a slurry. The slurry then is screened to remove contaminants, and the resulting pulp is used to make new paper products.

It is a rapidly evolving area where CPGs and consumers are concerned but remain confused about sustainable packaging. Actual sustainability performance will depend on which element is prioritized. Sustainable packaging demands less use of natural resources, making repulpability very important (vs. managing natural resource depletion). Municipal Recycling Facilities (MRFs) also are critical in the packaging supply chain. How they process printed materials with metallic effects is essential to creating a more sustainable future. Packagers and brand companies want to learn from experts about significant research and the efficient and feasible recycling process for metallic transfer processes.

FSEA Studies Recyclability

In 2021, the Foil & Specialty Effects Association (FSEA) sponsored a sustainability study conducted by Georgia Tech’s Renewable Bioproducts Institute to demonstrate that paper and paper boards with foil-stamped metallic transfer foils can be repulped. Georgia Tech researchers tested a 12 pt coated, one-sided card stock with 50% up to 100% metallic transfer coverage. The conclusions:

75% of metallic transfers could be repulped with very low rejects.
The aluminum in the metallic transfer foil could be broken down into small particles and were removed from fibers during screening.
The sample sheet demonstrated similar physical strengths to recycled paper fibers.
It is feasible to repulp the paper that included the metallic transfer foil as it is done in standard recycling settings.

More recently, FSEA has taken a further step and has unveiled its newest study – Recycling of Fiber-Based Materials with Transfer Metallic Decoration. The study was commissioned by FSEA and was conducted by the Van Dyk Technology Center. The testing at Van Dyk, one of North America’s leading providers of comprehensive recycling and sorting systems, included 20 samples of eight different products. The following were the conclusions from the testing:

The eight folding carton and greeting card samples were tested at the Van Dyk Testing Center to mimic various functions found in MRF sorting plants in a laboratory setting.
All eight samples of folding cartons and greeting cards included an estimated 25% up to 75% coverage of transfer metallic decoration.
The summary of the test results for each of the eight fiber-based transfer metallic decorated samples demonstrated that 100% of all samples were sorted to be included in the recycling stream. None of the metallic decorated samples were sorted and destined for landfill.
Brand owners, Print Service Providers (PSPs) and designers have testing conclusions that transfer metallic decoration is most likely being recycled by MRFs.
The test results of the Van Dyk sorting study, with the conclusions from the FSEA Repulping of Foil Decorated Paper study, indicates that fiber-based transfer metallic decorated materials are recyclable and currently are most likely being sorted by MRFs to be included in the recycling stream.

(Both of the above studies/tests are available through FSEA.)

These findings will help packagers meet their sustainability goals without compromising their designs and branding initiatives. Customer expectations constantly are evolving. Consumers want to know that packagers are thinking about the environment as much as trying to make a lasting impression that generates a sale. Forward-thinking brands recognize the significance of ensuring sustainability, and now research clearly illustrates that the repulpability of metallic transfer foils achieves those evolving expectations.

Evolving Brand/Consumer Perspective

In January 2023, the non-profit member-based organization Two Sides commissioned a global survey study of 10,250 people from the independent research company Toluna. Two Sides findings stated that “55% of consumers surveyed prefer paper packaging over plastic.” This is a significant change in attitudes toward printed paper-based packaging. Respondents felt paper packaging is better for the environment than plastic and glass.

In an interview with Ben Markens and Brian Westerlind, who manage the Paperboard Packaging Council, Markens shared “that the ‘bling’ in folding cartons that employ metallic transfer materials creates a great value add for packaging companies selling to brand owners.” Markens pointed out “that while the vast amount of printed folding cartons have no metallic foil decorating, the majority of winners, like high-end beverages and cosmetic packaging (in their recent association competition) utilized foil decorating very effectively.” Markens continued with a significant potential issue for international packagers, “even though US packages are heavily invested in sustainability, the European Union is creating higher standards for sustainability than the United States.”

As brand leaders began to craft sustainability strategies and experiment with different metallic foil applications, they needed answers from suppliers. Diamond Packaging of Rochester, New York, is a leading packaging converter focused on green initiatives. Diamond Packaging realizes its sustainability actions can profoundly impact the industry and the environment. In a recent interview with Eric Longnecker and Dennis Bacchetta, the two made it clear through the Diamond Packaging Greenbox initiative that they are “empowering our brand customers with creative metallic design transfer capabilities that meet or exceed customer expectations for recycling folding cartons.” Diamond Packaging is committed “to focusing on sustainability throughout the entire operation.” They believe the company’s commitment to sustainability in their operation makes them more attractive to CPGs to seek them out as a supplier.

During an interview, Longnecker shared that “examining the scientific impact of foil transfer is an ongoing mission.” Bacchetta stated that 40% of all the folding cartons the company produced for customers utilize metallic foil transfer processes. Diamond Packaging has created a fact sheet called “Decorative Foil by the Numbers,” which takes a closer look at the consumer and environmental issues related to metallic foil in packaging. Its facts include:

The Value of Foils: Perception Research Services did a study in 2004 that showed that decorated foil packaging had an 80% higher appeal and brand awareness. This was supported by an FSEA study that found that foil had a 44% better chance of attracting consumer attention.
Recyclability of Foil: The Georgia Tech and Western Michigan research studies validate this premise.
Literally Splitting Hairs: The aluminum foil layer is less than .05 microns, a fraction of the width of a human hair.
Zone Coverage: Another way to analyze this fact is to take a jumbo roll of foil weighing 440 pounds and covering the length of 2.4 football fields. The amount of foil on that roll weighs 1.043 ounces and measures .66 cubic inches in volume, about the same as the tip of one’s thumb.
Carbon Neutrality of Paperboard: The American Forest and Paper Association and American Wood Council clearly state that paperboard is carbon neutral.

Attracting Consumers

As stated, consumers are focused on brand identification (FMOT). Metallic decorating is an excellent example of creating special effects on printed substrates that attract consumers to a specific brand. The power of using metallic effects, whether hot, cold or digital, is a significant brand identifier and attraction for consumers.

Chris Leary, a US distributor for Gietz and Vinfoil, shared an incredibly detailed presentation designed for packaging and metallic transfer processes. Leary illuminated the value chain for metallic cold foil decorating in this document. The presentation highlighted the value proposition and the “de-inkable and repulpable characteristics.” It also stated, “72% of consumers are influenced by product packaging, and 36% would consider avoiding a brand that isn’t actively trying to recycle packaging.”

Glorious Gaming is a dynamic, growing company producing computer accessories for gamers. Its products are colorful and exotic in their design. Therefore, according to Chris Wilson, the company’s packaging engineer, “We needed packaging that would be ‘eye-catching’ to our potential customers.”

The company did a great deal of research and determined that metallic transfer technologies met its packaging expectations. While its creative designs drive customers to purchase products, Glorious Gaming also wanted to make sure its packaging would be sustainable by being repulpable and recyclable. The FSEA Georgia Tech research built a strong confidence in using metallic foil decorating.

Working Toward the Future

Karen Kromat of Case Paper, a leading distributor of transfer metallic substrates, believes that “metallic substrates present a genuine growth opportunity for the printing industry.” While issues still have to be addressed concerning the plastic adhesive liners that are not recyclable, municipal recycling centers can successfully recycle vast quantities of metalized packaging products. Case Paper is committed to helping make its metalized transfer substrates as sustainable as possible while recognizing that many municipal recycling centers are rejecting plastic adhesives while accepting transfer metallic decorated recycling products.

A sub-committee of FSEA’s Sustainability Committee is working with MRFs to ensure that metallic transfer foil packaging is recycled correctly. The big question in front of the committee and for recycling facilities is ‘where does the decorated packaging material go?’ The goal is to have MRFs carefully test transfer metallic decorated packaging with many organizations to facilitate the best recycling processes. Frank Kelly, ITW ShineMark, sub-committee chair, said, “This is an ongoing process and FSEA is committed to finding workable solutions.” The goal is to increase MRF operations’ efficiency while simultaneously creating more recyclable and repulpable by-products.

Conclusion

FSEA is committed to assisting brand owners, converters, printers and consumers to develop the most dynamic, growth-oriented and exciting metallic transfer decorating methods for the packaging supply chain. Innovation and sustainability in packaging entrepreneurship are core values of everything it does. Helping the the industry design new environmentally friendly business models with dynamic metallic transfer embellishments while fostering entrepreneurial ecosystems around the globe will never be compromised.

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