2017 May/June

Loose Leaf Stays Relevant

June 14, 2017

by Melissa Larson, contributing writer, PostPress

Custom-shaped telescoping box designed for a unique promotional job. Created by Trends Presentation Products.

As recently as the ’90s, most of the collective knowledge of American companies – not to mention procedures, records, presentations and the like – were kept in stacks of three-ring binders. Today, with so much of that content residing on PCs, in data centers and cloud storage, there is a steadily shrinking market for printed binders.

Still, today’s custom binders are able to create an effective tool for business-to-business or business-to-consumer marketing. Digital printing and finishing techniques, low minimum orders, fast turnaround and a custom look with unique decoration mean that marketers can get exactly what they want, and get it fast. That goes for not only binders, but sales kits, tote boxes, packaging, etc.

Savvy corporations also know there are instances – for example, when handling legal and financial documents – where storing information electronically can introduce the possibility of the sensitive information being compromised.

Also, a printed document can sometimes be more easily shared if marketers wish to disseminate information to a large group of people at the same time. And custom binders and other information kits are the perfect takeaway from a meeting or presentation.

So how can custom loose leaf manufacturers fight off obsolescence and make the most of their capabilities and the advantages of a printed binder?

Consolidation: a fact of life

Cadillac Presentation Solutions created this e-flute box, which holds badges and lanyards framed by water-jet foam with a pocket for cards and a hub to hold a DVD.As the commodity loose leaf houses consolidate or close, the leaders seem to be those companies that embraced new technology early and quickly expanded their product offerings.

“The best outcome of change is that slowly the generic commodity and stagnant manufacturers have stepped aside, allowing the vibrant and viable producers to spread their wings,” said Kurt Streng, president, Cadillac Looseleaf Products, Troy, Michigan.

Cadillac is an established supplier of digital and wide format printing, as well as CAD cutting for prototype and short-run production. Cadillac also offers custom fabric and textile swatching, which utilizes the company’s bindery resources, as most swatch boards are packaged in a binder or box.

“There has been a lot of consolidation in the industry over the last few years and it’s still happening now,” commented David Inman, sales and marketing manager, Trends Presentation Products, Washington, Missouri. “Through all the changes going on out there, we have remained a strong supplier of turned-edge products.”

“Turned-edge” is the term used to describe premium or high-quality book binding. It also can be used to describe products on which cover materials are wrapped and turned around the board edge, producing a smooth, finished look.

Trends Presentation Products was also one of the first to enter the digital market. According to Inman, the company purchased its first Xeikon digital press in 1999. The company has since upgraded and replaced its digital press three separate times. This not only has provided the wide format printing needed for the larger capacity ring binders and packaging items, but it also made them competitive for smaller custom orders.

“Of course, we also have had to adapt over the years,” Inman continued. “We are running leaner than ever before, but we have been very fortunate to sustain good business through it all. We may be a little more selective on what types of projects we take on, but for the most part we haven’t had to change much.”

Custom finishing techniques

A seminar in a box was produced by Cadillac Presentation Solutions incorporating a magnetic closure, a bolted-in handle and custom-cut, high-density foam to secure the contents.

As the photos throughout this piece make clear, the custom binders available today bear little resemblance to the primary color, vinyl-over-chipboard binders common in the past. Instead, they sport custom materials, full-bleed photography, foil highlights, custom hinging and other postpress techniques.

For those customers who may not know exactly what they want, competent binder/loose leaf manufacturers can offer design help and recommendations to make the piece truly unique – whether that includes graphics recommendations, a variety of paper types and weights, complementary hardware options, or whether to include pockets.

While suppliers acknowledge the overall binder pie is shrinking, they emphasize they are surviving by delivering a high-quality product, in smaller quantities, to meet tight deadlines. To do that, they’re using digital printing, turned-edge construction and up-to-date finishing techniques.

“Our ability to diecut, screen print, foil stamp and deboss items in-house also provides our customers a convenient opportunity to create that unique item they are looking for,” said Inman. “We also can print and laminate wide format digitally. This becomes important when producing the larger digital turned-edge tote boxes, ring binders, sales kits and promotional boxes. All these items have become a big part of our business. It’s all about customization and unique decoration now.”

“Digital printing and finishing has complemented our growth and helped us run traditional finishing at the speed of digital,” said Streng. “As quantities are getting lower, and budgets bigger, we can deliver precisely the product the customer wants to represent their brand.”

Speed of turnaround

Loose leaf manufacturers that have invested in digital printing and new finishing technologies can offer customers a big advantage: speed. For instance, the Trends website offers digitally printed Fast Impression binders with 4-color process on the company’s Xeikon printer for a price the company says is half the cost of offset printing – and shipping – in three days.

“Speed on job turnarounds is also becoming the priority when awarding jobs – above price, quality and service. Today’s access to information is almost instantly available, and the speed of doing business is becoming just as fast. Customers want their products fast. Those that can meet those demands often have an edge.”

In the long run, Inman expressed hope that the turnaround speed aspect of his company’s offerings serves as an incentive for marketers to buy from American companies, closer to home. He also hopes that turnaround speed will balance the tendency for customers to go to overseas suppliers to save a few cents on each binder.

Conclusion

Custom turned-edge slipcase and ring binder set from Trends Presentation Products.

When asked their assessment of the market 3 to 5 years in the future, Streng and Inman made it clear they feel their companies are responsible for their own destinies.

“We see a continued growth in the custom market,” said Streng. “Quantities are getting lower and budgets bigger to deliver precisely the product the customer wants to represent their brand. For us, market share and diversity has grown. There are days in the shop you wouldn’t believe there was a decline in the binder business.”

Trends, one of the few binder manufacturers that does not sell direct or use an online website to sell directly, makes use of resellers and must take those relationships into account.

Said Inman, “We need to decide how we can continue to grow in a shrinking market. We have positioned ourselves well by choosing to enter the digital market early on, but now our outreach is becoming limited. As the digital age of sharing information increases, and more and more use the cloud for data storage, fewer resellers are wanting to sell our items. We’ll need to continue to find creative ways to promote and push out our products.”

Cross-Training Benefits Next Generation of Employees

For many commercial printers and finishers, a looming concern is finding qualified employees. As David Inman of Trends Presentation Products commented, “We have been very fortunate to retain many of our employees over the years. We are now entering a point where many are beginning retirement. Most of our employees have been here for 20-plus years. This has always been a huge advantage for us. Our internal systems and checkpoints on quality control and accuracy have correlated directly to the quality of staff we’ve been lucky to have. Hiring and replacing these employees will be our next big challenge.”

It’s not as though interested prospects can’t find a place to take a course on, for instance, digital or 4-color printing. Whether through community college courses, online courses or in-person industrial training, such opportunities exist. But does that give prospective printers the kind of training that allows them to step into a real-world manufacturing environment? Not necessarily.

Trends has elected not to leave that to chance. “We are trying to cross-train our new employees in different areas of the plant as we begin replacing some of our retirees,” he said. Cross-training not only will allow the company to retain these valuable employees, but also contribute to productivity.

“It not only allows us, as a company, to run and operate a little leaner (being able to shift staff around to different areas as needed), but it also allows the employee to learn multiple functions of the plant, keeping them motivated as well,” Inman concluded. It’s hard to find young, motivated workers that want to do manufacturing work these days. They want to learn and try new things. Allowing and providing some flexibility in the workplace has helped us, and them.”

Paper and Print: Sustainable and Essential

June 14, 2017

by Phil Riebel, president, Two Sides North America, Inc.

What is Two Sides?

Two Sides is an industry-funded nonprofit that has carved out a presence as a familiar advocate for the sustainability of print on paper. Since its beginnings in the UK in 2008, Two Sides has grown to be present in five continents and several countries. More than 1,000 companies from across the print, paper and related industries support Two Sides, including such major industry players as Canon, Konica Minolta, Domtar, International Paper and many more.

Making progress in the battle against anti-paper claims

One of the key initiatives of Two Sides is an anti-greenwash campaign that challenges corporations when they make misleading environmental claims about print and paper to promote electronic services, such as e-billing, i.e. “go green – go paperless, save trees.”

To date, the campaign has resulted in more than 160 companies removing their anti-paper claims, including several Fortune 100 US corporations, such as AT&T, Capital One, Wells Fargo, HSBC and Sprint. “One of the benefits of anti-greenwashing campaign has been the opportunity to reflect on how we communicate our efforts,” stated Sprint’s Director of IT Care & Billing Services Business Management Alan Anglyn. “This caused us to review Sprint’s messaging about electronic media across multiple touch points.”

The main reasons for challenging the claims are the following:

Most of the marketing claims made are vague and unsubstantiated and do not meet country-specific environmental marketing guidelines, such as those of the US Federal Trade Commission (FTC).¹
The life-cycle environmental impact of electronic transactions, including the vast infrastructure needed, manufacturing of components, energy use, waste disposal and more, is far from negligible² and not properly considered by companies making the anti-paper claims.
Print on paper has unique environmental characteristics compared to electronics. It originates from a renewable resource – trees grown in responsibly managed forests in Europe, North America and many other countries. It is recyclable and is the most recycled commodity in many developed regions of the world, often with recovery rates exceeding 65 percent.
Marketing messages like “save trees” create a false impression that forests are a finite resource instead of a renewable resource that is continuously replenished using sustainable forest management practices in many countries. For example, over the last 60 years, the volume of trees growing on US forestland increased by 58 percent.³
The claims are damaging to local economies and threaten jobs. For example, in the US alone, a total of 7.5 million jobs (6 percent of total US jobs) that generate $1.4 trillion in sales revenue (4.6 percent of US total output) depend on the US mailing industry, which includes paper production, printing production, related suppliers, graphic design and the handling and distribution of mail.⁴

The campaign has resulted in major changes in marketing messages and, as such, millions of consumers throughout the world are less exposed to anti-paper and anti-print slogans.

Consumer surveys in the US^5,6 and UK⁷ also reveal that many people feel misled by “go paperless, go green” environmental claims. For example:

87 percent of adult Americans agree that “the main reason companies want to shift customers to electronic delivery formats is to save money, not to be environmentally responsible.”
80 percent did not think it was appropriate for companies to cite environmentalism when it is not their real motive.
More than 70 percent believe that print and paper are a sustainable way of communicating when produced and used responsibly.
50 percent or more of respondents don’t believe, feel misled or question “go paperless, go green” claims.

People want to have a choice…and a paper option

Switching to digital is not always welcomed by consumers, and many wish to retain the flexibility of paper-based, postal and electronic communications. Research shows that paper still has a place today, and many people want to be able to choose their preferences and even prefer print over electronic communications.⁸

Even today, not everyone is computer-savvy or has access to a computer. For example, access to a reliable internet connection depends on many factors, such as age, education and location. As many as 30 percent of Americans are not online, including 65 percent of seniors who don’t own computers.⁹ Forcing people to go paperless or pay added fees for paper bills and statements disenfranchises a significant part of the population. US consumer surveys show that 89 percent believe that “shifting customers/clients to online only documents disadvantages some groups, such as the elderly, disabled, low income and poorly educated.”¹⁰

Even those with computers seem to prefer paper for many tasks. US consumer surveys^11,12 found that most people prefer reading print on paper compared to screens and want to retain a paper option. For example:

88 percent believe that they understand and can retain or use information better when they read print on paper. Reading on screen shows lower preference, with the lowest being 41 percent indicating that mobiles and smartphones were useful for understanding and retaining information.
When given a choice, 81 percent of respondents indicated that they prefer to read print on paper. These percentages drop to 39 percent for screens, laptops and PCs, 30 percent for e-readers and 22 percent for mobiles or smartphones.
64 percent say they would not choose a company that did not offer a paper bill option.
50 percent read their bills and statements received both electronically and by postal mail; only 15 percent read bills that they receive by email only. Finally, 91 percent say they are unwilling to pay for paper bills.

Corporations that are eliminating paper-based options are passing printing costs to consumers given that 34 percent of respondents are “home printers” with 20 percent printing up to 20 percent of their bills and 8 percent printing between 80 and 100 percent of their bills. Respondents said that printed documents are easier to read (74 percent), better for storage and archiving (56 percent), more secure (55 percent) and less likely to be lost (47 percent).¹³

Consumers value the physical mail piece as a recordkeeping tool and reminder to pay.¹⁴ An integrated marketing strategy that includes both print and online components spans preferences and generations, allowing everyone to get the message.

Phil Riebel is president of Two Sides North America and has more than 30 years of international experience acquired in senior management positions in industry and consulting related to the forest products industry.

References

1. U.S. Federal Trade Commission, 2013. Environmental marketing guidelines.

2. Arnfalk, P. 2010. Analyzing the ICT – Paper interplay and its environmental implications.

3. USDA Forest Service, 2012. Forest Inventory Analysis.

4. EMA, 2015. 2015 Job Study.

5. Two Sides, 2013. Most US consumers want the option to receive paper bills and statement.

6. EMA, 2014. Highlights of EMA nationwide survey.

7. Two Sides, 2013. Paper bills and statements – A real necessity in a digital world.

8. Two Sides, 2013. Most US consumers want the option to receive paper bills and statement.

9. U.S. Department of Commerce, 2011.

10. EMA, 2014. Highlights of EMA nationwide survey.

11. Two Sides, 2013. Most US consumers want the option to receive paper bills and statement.

12. Two Sides, 2015. Reading from paper or reading from screens – What do consumers prefer?

13. Two Sides, 2013. Most US consumers want the option to receive paper bills and statement.

14. US Postal Service, Office of the Inspector General, 2015. Will the check be in the mail? An examination of paper and electronic transactional mail.

Global Study: Most People Highly Value Paper and Print

Consumer survey results on global attitudes toward paper and print, as well as toward corporate environmental claims promoting digital over paper-based communications, indicate a clear preference for print on paper across all countries and regions analyzed. For more information, visit www.twosidesna.org.

Most people still need and prefer paper for many day-to-day activities. Organizations should fully investigate the implications of switching from paper to digital.

Q&A: Perfect Binding – Traditional EVA vs. PUR Adhesive

June 14, 2017

by Brittany Willes, editor, PostPress

Perfect binding and PUR binding – they’re essentially the same process, aren’t they? Actually, no. PUR binding refers to a method of perfect binding that has become increasingly popular in the last few years. As with traditional perfect binding, a book’s pages and cover are glued together at the spine while the three remaining sides are trimmed to give them the classic “perfect” edges. However, there are a few notable differences between the two methods.

With decades of industry experience, Eckhart & Company, Inc., Indianapolis, Indiana, is more than familiar with the challenges faced by printers and binders looking for the most effective method for binding a given project. When it comes to deciding between traditional perfect and PUR binding, Chris Eckhart, president of Eckhart & Co., offered the following information:

How is PUR different from perfect binding?

For sure there are differences between the two binding methods, even if it doesn’t appear that way at first glance. It all comes down to the adhesive used during the binding process. The biggest difference between PUR and perfect binding is that traditional perfect relies on ethylene vinyl acetate (EVA) adhesives, while PUR makes use of polyurethane reactive (PUR) adhesive.

Book spines that make use of PUR are prepared in much the same way as a traditional EVA-bound book, utilizing a variety of notching, roughing/equalizing heads in order to create fiber. The adhesive then will bond with these fibers during the curing process. The properties of PUR adhesive are designed in such a way that they draw moisture out of the air as part of the curing process. The amount of paper fibers also is reduced with PUR.

Why opt for PUR instead of EVA binding?

One of the biggest advantages of PUR is that it offers significantly increased binding strength. Once the adhesive has set, page pull tests are often up to 50 percent stronger than with books that use EVA glue. It also offers greater aging stability, is impervious to print ink oil migration and is capable of bonding to coated and cross-grained stock. Furthermore, PUR is extremely durable. This is particularly helpful in that it is not susceptible to issues brought on by extreme temperatures, like traditional perfect binding can be.

As with conventional hot melt glues, the initial bond in PUR is formed as it cools and solidifies. Unlike conventional hot melts, PUR contains reactive components (isocyanate groups), which cure in the presence of humidity and form a strong elastomeric film. Furthermore, while EVA’s properties allow it to be reactivated with heat, the film produced by PUR cannot be re-melted and is insoluble to most solvents. Thus, EVA binding exposed to extreme heat is able to melt, while a PUR binding will remain in its solid state. Typically, PUR has a heat resistance of 350°F peel failure, compared with 165°F to 200°F for quality EVA. Extremely cold temperatures provide additional problems for EVA, mainly that it is subject to cracking and brittleness. Again, because PUR cannot be reactivated, it is in no danger of cracking. Typical cold crack for PUR measured at -20°F vs. 30°F for EVA.

How does PUR achieve its flexibility?

As mentioned earlier, once the adhesive is set, it is extremely difficult to pull pages from a PUR-bound book. The adhesive cannot be reactivated, giving it increased durability. This might seem like it would make the binding less flexible, but that’s not the case.

PUR uses a much thinner application of adhesive than compared with EVA (10 to 12ml vs. 25 to 35ml per EVA). This thinner application of adhesive, along with its reactive properties, is what gives PUR its flexibility. In testing, PUR has extremely high flex-test values, often in excess of 1,000 flexes. It is this flexibility that allows also for greater lay-flat characteristics. When applied properly, PUR’s lay-flat ability is comparable to that of true Otabind. Additionally, a thinner application frequently will improve performance and result in improved “mileage” over time. With less adhesive on the spine, there is less distortion of shape and cleaner overall appearance.

What are some challenges associated with PUR binding?

PUR is applied using an open roller pot system and, while this system does have advantages – such as better accessibility for operators and providing greater consistency of application with thicker books – it also can be costly in terms of maintenance and cleaning.

The one-pot system requires a longer cleanup process than traditional EVA systems. The pot must be drained and the adhesive allowed to cure overnight before the pot can be reheated and any remaining adhesive removed. The adhesive pot may require recoating as often as once every three years. The system also allows for greater amounts of glue spoilage.

When it comes to maintaining a one-pot system, it’s best to check with the equipment manufacturer for guidance on best practices. The technology does exist to apply (essentially spray) PUR onto the binding edge using slot-nozzle technology. This technology has advantages and disadvantages – the biggest advantage being the cleanup is not nearly as extensive as it is with an open pot system.

Are there times when PUR adhesive is not preferable to EVA?

In almost every situation, PUR is better than EVA. There is one exception, however: If a book block is being bound or prepared for case binding, the spine can’t be rounded in the casing-in process if PUR is used. In this situation, EVA has a tad bit more roundability/flexibility.

PostPress would like to thank Chris Eckhart, Eckhart & Co., and Matt Worley, BC Adhesives, for their assistance with this article. Eckhart & Co. has spent decades providing the printing industry with bookbinding and custom information packaging. Based in Franklin, Wisconsin, BC Adhesives combines its technical expertise with ongoing, proactive support to ensure its customers are utilizing the most efficient consumption practices to help customers maximize the efficiency of each application.

Shifting from Populism to Pragmatism

June 14, 2017

by Chris Kuehl, managing director, Armada Corporate Intelligence

The Trump campaign was a mystery from the very beginning. Pundits did not give this effort much of a chance and assumed that it would fade as soon as voters started to make real choices. Obviously, this didn’t happen. The problem for many analysts was that Trump had no real track record as far as politics or governance were concerned. It was not all that clear what he would do once in office, and positions tended to shift as the campaign demanded.

This was a populist insurgency – driven by voter anger and frustration – as opposed to a distinct set of policy prescriptions. The people who surrounded Trump were generally just as new to governing as Trump. The assumption was that the Trump team would evolve over time, but nobody really had a sense as to how this would take place. Now that evolution has started to take shape, and it seems that pragmatism slowly is overtaking populism. This will doubtless be frustrating for some of those core supporters who assumed government would be fundamentally altered, but this transition has been welcomed in the business community and has added somewhat to the confidence levels that had been noted at the start of Trump’s term.

One of the key differences between the campaign and the presidency thus far is that the advisers have changed – at least, some of them. The emerging inner circle is far more corporate – and business – oriented than was the inner circle during the race. The voices catching the ear of the president are pursuing a far less radical agenda and look a great deal more like the traditional base of the GOP. They have been far less antagonistic toward trade and far more supportive of agreements such as NAFTA. There has been a reversal as far as support for NATO and the Export-Import Bank, and suddenly there has been far less criticism of China and even Mexico. This doesn’t mean that all the populist messages have been abandoned, and many likely will remain part of the White House strategy, but when it comes to the day-to-day of governing, there is more reliance on those who have been around longer – and with that comes more trust in the overall business community.

Three areas that have changed more radically than others include China policy, position on NATO and what to do with NAFTA and overall trade policy. Throughout the campaign, China was positioned as enemy number one. The country was held responsible for the decline of manufacturing jobs and the loss of US competitiveness and now would be dealt with severely. China was going to be labeled as a currency manipulator, and the US would impose everything from tariffs to legal restrictions to blunt exports from China. Today, most of those policies have been abandoned, and China has returned to its former status as partial ally. The fact is that China is vastly important to the US business community and is needed to put the brakes on North Korea. The Chinese never assumed the rhetoric was real and patiently waited for Trump to come around. With the advice of his team, Trump has returned to the positions the US pursued toward China under Obama, Bush and before.

The relationship between China and the US has always been complex, as each country needs the other – and deeply resents that dependence at times. Both China and the US have their nationalists who resent the impact of the other country. The US resents the import surge that has driven many manufacturers out or forced them to relocate. The Chinese resent their dependence on the US to buy these products and chafe at the demands made by US buyers. The Chinese would like nothing more than to ignore the US in pursuit of its regional ambitions, but the Chinese are in no position to ignore the country that buys $350 billion of the country’s exports. For those who are counting, that is almost a quarter of the total Chinese GDP.

A second major change is seen regarding NATO. During the campaign, Trump asserted the alliance was obsolete and that the US should no longer finance it. The policy was connected to the assertion that Europe had not being paying its fair share and owed the US money. This position was roundly criticized in Europe and stressed relations with several key US allies. That stance now has been softened, and NATO is back in the good graces of the US. It was made apparent by Trump’s military advisers that the US could not do what it wanted in the rest of the world without the support of these allies, and the criticism has been replaced by praise.

NATO no longer is focused on the threat from the USSR. Its mission is far more complex, and troops have been engaged in every US conflict of the last 20 or 30 years. Its role in Afghanistan, Iraq and Syria can’t be overlooked, and it has been engaged in Libya, Ukraine and many other hot spots. The generals who now advise Trump have urged a far more cooperative tone.

The third major shift has involved trade policy. The Trump of the campaign trail was a classic populist, supportive of an isolationist stance that was based on strict protectionism. That stance has been changing by the day, as there has been more reliance on pro-trade advisers as well as congressional leaders who favor expanded trade. The promised changes to NAFTA are now likely to be minor, and the White House position on the Ex-Im Bank has shifted toward support. The US seems willing to pursue trade pacts again, but more attention will be paid to the economic implications than to the political motivations. The bottom line is that many are making the case that the US benefits from free trade more than most nations – after all, exports account for 14 percent of the total GDP of the country.

Trade pacts that were far more political than economic in nature have been dismissed – as was the case with the Trans Pacific Partnership. But, pacts like NAFTA have been looked at more closely to realize what they have meant for the US. The fact is that every trade agreement will have provisions that benefit the US and provisions that benefit the other trade partner. It doesn’t hurt that the US is looking to ensure that more provisions favor America, but a full-fledged protectionist approach is now off the table.

Chris Kuehl is managing director of Armada Corporate Intelligence. Founded by Keith Prather and Chris Kuehl in January 2001, Armada began as a competitive intelligence firm, grounded in the discipline of gathering, analyzing and disseminating intelligence. Today, Armada executives function as trusted strategic advisers to business executives, merging fundamental roots in corporate intelligence gathering, economic forecasting and strategy development. Armada focuses on the market forces bearing down on organizations. For more information, visit www.armada-intel.com.

A Symphony in Color by J.S. McCarthy

June 14, 2017

by Lara Copeland, assistant editor, PostPress

J.S. McCarthy’s self-promotion 2017 calendar has received much praise from its customers. Additionally, it is being recognized through industry awards as well.

Attending a live symphonic performance is a cultural experience people from all walks of life have enjoyed for centuries. This musical concert often evokes thoughts of sophistication and class as dramatic, red curtains hide an orchestral ensemble that will tantalize the senses of all in attendance. Rich, all-encompassing sounds of the combined instruments arouse emotions as symphony-goers anticipate the ebb and flow of the music – surging and commanding one moment and delicate and fleeting the next. The combined talents of the nearly 100 musicians offer an inspiring and meaningful shared experience. J.S. McCarthy, headquartered in Augusta, Maine, has taken the experience of a classic symphony and transformed it into the 2017 J.S. McCarthy Printers calendar – A Symphony in Color – showcasing a compilation of the talents of its craftspeople and highlighting its printing capabilities and most-requested finishing techniques.

J.S. McCarthy is one of New England’s oldest and largest sheet-fed printing operations. A thriving business for more than 60 years, the company is constantly pursuing advanced technology to remain competitive in the marketplace. With a wide array of capabilities beyond its printing presses – from perfect binding, diecutting, embossing and foiling to packaging, fulfillment and mailing – its tagline, “one source, one solution” rings true to its broad and diverse customer base spread throughout the country.

Each year, J.S. McCarthy creates a marketing piece to showcase its capabilities for its customers. Michael Tardiff, director of communications at the company, partners with his mother, Patty Tardiff, special projects, and Sue Bourdon of Bourdon and Company, a designer who has worked with J.S. McCarthy for many years, to create the design for the annual promotional project. When the design team holds its first meeting for the calendar, they brainstorm several ideas and consider what the design will look like and what it will represent. They are looking for that “spark” of genius as they explore different universal themes each year to reach their extensive customer base.

“We are doing work with designers from a multitude of industries – health care companies and colleges to name a couple – so we try to find something that has appeal to a large range of people while also highlighting our capabilities,” Tardiff explained. This year, they wanted to emphasize coatings and different inks, foil and diecutting, while also providing a sensory experience. After contemplating various options, the team decided to use the symphonic theme to create a multifaceted sensory experience.

From the diecut, scored, folded and glued by hand (due to the musical insert) cover to the 12-page calendar, J.S. McCarthy endeavored to replicate the symphonic experience, using not only visual representations but also sound. The entire capacity folder that holds the calendar is intended to resemble the red curtains that adorn theaters and separate the audience from the back stage. “We wanted the audience to feel like they were opening up the curtain of a symphony,” Tardiff stated. On the front panel is a sculpted and embossed sign that reads “2017” and appears to hang from the top of the cover. On the top half of its backside is another 3×4 area flat-stamped in gold foil that reads “A Symphony in Color.” Inscribed on the bottom half is a description of the theme – a poetic acknowledgement of the shared beauty between music and color.

Opening the inside panel activates a sound chip that plays Beethoven’s 5th symphony, captivating the audience’s attention with its riveting four-note introduction. “We chose that particular song for its suspenseful draw and classical appeal,” Tardiff specified. Pockets on the inside serve a similar purpose by including thumbnails to give the audience a preview of what’s to come without spoiling the details completely.

The capacity folder presented a few challenges for the design team – but nothing that they considered insurmountable. In recent years, J.S. McCarthy fashioned what Tardiff called a “traditional” calendar – with one sheet per two months. This year, the company moved away from this traditional style, opting for a format that would allow them to experiment with different foil, embossing and coating techniques.

To meet their design expectations, the team used its HUV Straight Komori and its HUV Perfecting Komori. The capacity folder that holds the calendar was printed on a 14pt Carolina White stock and coated inline. UV-curable inks were used for the cover in a 7 over 6 HUV process with a double hit of black on one side. Lastly, Velcro dots were used on the inside to secure the calendar within the folded wrap.

J.S. McCarthy won Gold in the “Best Use of Foil Stamping & Embossing – Self-Promotion” category during the Foil & Specialty Effects Association’s 24th annual FSEA Gold Leaf Awards competition.The main attraction, a 12-page calendar with wire-O binding and a hanger, features one month per page. Each page depicts different processes in an appropriately themed musical picture for the specified month. The days of the week, in all but one month, run horizontally in bold across a faded musical bar. In a sidebar on the left of each calendar grid, the design team decided to include a brief description of that page’s production, as well as a small-scale version of the previous and next months’ calendar.

“We tried to find processes that are popular with our clients and show different ways to do those, and if we have a new process – maybe a new coating – we tried to incorporate it into the calendar,” Tardiff said.

The elaborately designed November page is one example of a relatively new process for J.S. McCarthy. With a focus on percussion instruments, several drums are depicted, with one snare drum pictured in the front. To obtain this look, designers started with a metallic stock and then printed on an 8-color offset press. The first pass on press included 4-color process and two hits of white opaque ink in strategic areas of the calendar grid. It was also gloss UV-coated inline. A second pass included a spot dull varnish on the grid portion of the calendar page. The combination of the translucent inks over the drum set and reversed-out silver in specific areas gives a unique and distinguished finish to the entire page. To complete the look the design team envisioned, the page was topped off with a sculpted embossing pass to highlight the gold drum set. Patty Tardiff explained, “As the beat went on, so did the sculpted emboss to soften the edges of this heavy metal month.”

The February calendar page showcases several of J.S. McCarthy’s capabilities. The featured clarinet, shown tucked away in its case, was first printed with a pass of metallic silver ink. “We felt Metallic Spectrum would highlight the design without losing the antique finish on the clarinet parts,” Patty articulated. The second pass included a reticulating UV coating that creates a spot gloss on the clarinet parts and a dull varnish in the other areas of the image. The second pass also included a spot aqueous soft-touch coating on the inside portion of the clarinet case. Lastly, the metallic silver-inked clarinet parts and the wording “February” were sculpted embossed to accent the beautiful calendar page. “Going a step further, we felt the sculpted emboss would enhance the image and add yet another tactile element to the unique inks and coatings used,” said Patty.

May might be the most outstanding of them all. “It is truly exquisite with the rough texture of brick, elegant shine on the piano and smooth velvety curtain,” Bourdon commented. The first pass included seven stations on the Komori where the piano and brick background were printed in 4-color, and then a gloss UV coating was used to highlight the piano, with the surrounding brick and flooring being coated with a dull UV. The curtains on the outside of the image were spot-coated with an aqueous soft-touch. The next pass included a peacock-blue metallic flat stamp on the wording “May,” the days of the week, and highlighted specific dates – the 14th for Mother’s Day and the 29th for Memorial Day. “The foil in a contrasting color added a subtle touch of elegance to the “grand” setting,” Patty noted. The last pass was an embossing/debossing of the background brick and windows that the design team included to add dimension to the architecture.

With any great feat, great challenges are expected. One production hurdle the company faces each year is finding time to process something for self-promotion during its busy season. “Our busy time is July 4 through the end of the year, and it’s a challenge to process something for yourself when you’ve got a majority of your customer work going through,” Tardiff explained. To overcome this obstacle, designers strive to get it on press as early as possible – with everything ready by June or July. Squeezing it in around customers’ work can be difficult, but he admits that customers come first. “We have to make sacrifices to make sure we are prioritizing correctly.”

The main attraction is a 12-page calendar with wire-O binding and a hanger, features one month per page. Each page depicts different processes in an appropriately themed musical picture for the specified month.

Fortunately, the sacrifices seem to be well worth it thus far. Tardiff shared that this has been one of J.S. McCarthy’s best received years. “We always get calls the first few weeks when people are looking at our calendar, so that’s not unusual,” he continued. “But this year it seems like every month when a calendar page turns, I’m getting emails forwarded from sales representatives saying ‘I just changed my calendar and this month is my favorite.'”

The company is seeing plenty of engagement this year – more so than what it has seen in years past. Tardiff said this is exactly what the design team was aiming to accomplish when it changed the way it communicated its capabilities with its customers. In the past, J.S. McCarthy sent out monthly mailings with production notes that accompanied the new month. This ensured that contact with the customers was maintained throughout the year. Now, however, Tardiff says that “doing it the traditional way – the calendar is really speaking for itself.” Most of all, he is pleased that customers are responding.

J.S. McCarthy’s self-promotion 2017 calendar has received much praise from its customers. Additionally, it is being recognized through industry awards as well. Winning the Gold for “Best Use of Foil Stamping & Embossing – Self-Promotion” during the Foil & Specialty Effects Association’s 24th annual FSEA Gold Leaf Awards competition this year left the entire J.S. McCarthy team feeling honored. “None of this would be possible without the amazing craftspeople we have here, and it’s nice to see our hard work recognized,” Tardiff disclosed. The calendar was then awarded “Best of Show” at the FSEA Awards Reception that took place during the recent IADD•FSEA Odyssey in Schaumburg, Illinois, an award selected from all the Gold winners in 36 categories. Feeling inspired, Tardiff concluded, “we are going to keep innovating and doing more and being better.”

Tech Watch: The Matrix from Vivid Laminating

June 14, 2017

by Lara Copeland, assistant editor, PostPress

The Matrix series is from Vivid Laminating Technologies Ltd., Coalville, England.

Specialty effects is a popular trend in short- to medium-run digital printing. The Matrix series from Vivid Laminating Technologies Ltd., Coalville, England, features multifunctionality to do foiling, holographic effects and spot UV effects that are easy to apply without costly dies or setups.

“For many years, luxury packaging with special-effect foils and finishes was only available to the biggest and most successful companies,” explained Jon Gasperini, vice president North American sales. “However, today these effects are within reach for even the smallest boutique business.” The same holds true for many other special and unique effects such as labels with glitter holographic lettering, foiled wedding invitations, variable data mailers and rainbow holographic security print for event ticketing. Printers of all sizes can offer their customers these products and produce them in house with quick turn time.

The Matrix can be used for short-run variable data foil fusing using DataBind FuseEffects® thermal transfer foils. Thermal transfer foiling can be applied to any digitally printed stock using the Matrix. Foiling can be done direct on coated stock, on specially treated soft-touch matte laminate or on printable glossy laminate, allowing low-cost creative designs for business cards, invitations, direct mail, brochures and more.

Vivid’s Matrix also brings lamination in house, giving a company control over timing and quality of output when finishing a job. With an easy-to-use multilingual digital control panel, the user can quickly set up for small runs or accommodate large runs. The Matrix can conservatively run 750 (12×18″) single-sided cover sheets per hour and with all types of laminating film. Average cost to run a 12×18″ sheet can be as low as 2.5 cents for single-sided gloss, or the popular silky or soft-touch mattes will average about 11 cents a sheet. “Bringing lamination and foiling in house saves time and money, while also creating the opportunity to deliver additional custom products,” Scott Diamond, manager lamination sales and service, commented.

The Matrix also has a self-registering gate that ensures proper and consistent spacing of sheets, maintaining underlap for single-sided laminating or a consistent gap if doing a two-sided sheet. In conjunction with the automated burster, the laminator delivers a consistent output for the next step of production – be it creasing, folding or cutting.

Several options are available when doing smaller singled-sided sheets. A film trimmer allows the user to slit down a roll if only working with a wider roll, and a take-up mandrel is available for doing variable spot foiling using DataBind FuseEffects® thermal transfer foil. An auto feeder also is available, mounting directly on the feed table, as is a rotary blade cutter for cutting thicker materials that won’t burst inline.

“We have seen our customers achieve new levels of success when they realize not only are they saving time and money by laminating in house but also are increasing profits by offering these new specialty effect products to customers directly,” said Gasperini.

Technical Details

The Vivid Matrix is available in two sizes: the MX-370, which can accommodate 1″ film and a 17″ sheet width; and the MX-530, which can accommodate 20″ film and a 22″ sheet width. All the MX series machines are manufactured with a large, chromed-steel heated roller offering a quick warm-up time of 10 minutes. The metal roller solves difficult output issues when running hard-to-laminate digital prints by applying direct heat and pressure simultaneously, allowing laminating at a lower temperature in conjunction with the pressure of the pneumatic roller to run faster. Both systems are available with manual or pneumatic roller pressure, single-sided or double-sided, and with a heated bottom roller and lower supply mandrel.

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