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      Print Decorating, Binding and Finishing

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        2018 Nov/Dec

        Trends Presentation Products Reaches New Heights with Wine Box

        December 28, 2018

        by Lara Copeland, contributing editor
        PostPress

        High above the Sonoma valley, a nearly 300-acre winery is spread across the western slope of the Mayacamas Mountain Range in California. Here, distinctive wines are crafted to represent the unique appeal of the property. Recently, the winery needed a high-end wine box to launch its new wine branding. For this job, Trends Presentation Products, Washington, Missouri, was called upon to create a sophisticated box to hold a bottle of wine as well as promotional material for the product.

        Trends makes most of its boxes by hand, so “we tend to cater to the higher-end specialty boxes that run under 3,000 quantity per order,” David Inman, sales manager at Trends, explained. The winery wanted the packaging to represent luxury and elegance. The order quantity was set for 2,000 boxes, and the project took six months from start to finish – this includes everything from the initial quote, sampling materials, testing various prototypes, all the way through to the final production.

        The 16.5×5.5″ box and lid are covered on the outside with a synthetic leather material called Alpha Aston Brown from Ecological Fibers. Inman relayed that this was not a stock color, and the material had to be brought in from overseas. “This particular material foil stamped very well,” he said. The inside collar material was made from Metal X Hammered Copper from Neenah. “The color of the material matched API’s copper foil that was used to foil stamp on the lid,” he added.

        Each wine box, hand-wrapped and assembled, was constructed out of 100 pt. chipboard. The lid and the base both were diecut and then taped together before wrapping the box in the custom material. The piece of foam on the interior also was diecut and then glued inside the box and covered in a black cloth material. This is what cradled the wine bottle.

        “It provided a nice presentation when the lid was removed, and the wine bottle was displayed,” Inman said. The inside of the lid showcased a wrapped and diecut French panel designed to hold an envelope containing product information. The envelope fit snugly in the diecut area underneath the lid and could be removed easily by a ribbon pull.

        The winery’s logo is a hexadecagon (16-sided polygon) made of uppercase letter Rs. “This graphic design was created by the customer with Trends’ own graphic artist coordinating the best layout of the graphics on the box,” Inman said.

        Once the concept and final sizes were determined, Trends created and supplied the art templates for the project. The box involved three positioned stampings, with one position on the lid foil stamped with the metallic copper foil and two blind deboss positions on the side of the box, according to Inman.

        “Since the customer really wanted a deboss look and feel, we had to do the stamping after the material was wrapped around the box,” he said. This required a special fixture to be used inside the box to hold it in place when debossing the logos onto the box. A Franklin press model #8200 had just enough capacity to complete all the stamping.

        Once the concept and design of the box were set, the staff at Trends ran with it. “We have a great crew here at Trends that really works hard to ensure that quality is kept consistently throughout the project,” Inman stressed. Even when facing the task of stamping the logos on the box, the team came together and rose to the challenge.

        “Because there were three positions to hit, and we had to do the stamping after construction of the box, there was little room for error throughout the stamping process,” he confirmed. Essentially, the entire cost of the box was in before stamping, so the team had to guarantee each hit was done correctly. To do this, they created and used a fixture that was placed inside the box when stamping the blind deboss logos on the sides of the box. From there, Inman said it took time and patience to ensure each hit was centered properly and left a good impression.

        “There was a total of 6,000 separate hits on the 2,000-quantity order,” he explained.

        Inman said the project was a huge success: “We ended up shipping 22 skids out to California – each wine box was packed in its own shipping carton to ensure maximum protection.”

        Most importantly, everything was delivered on time and made it safely.

        “There is no better feeling – after completing a big project and all is paid, made and delivered – knowing the customer was thrilled with the end result,” Inman exclaimed. He said this energizes the whole team and reinforces the company’s commitment to supplying top-quality products.

        The 3 P’s to Becoming an Engaged Healthcare Consumer

        December 28, 2018

        by Dr. Josh Luke, faculty member
        University of Southern California’s Sol Price School of Public Policy

        It is common for businesses or start-up made a major purchase only to find out later they overspent significantly. How often are they making this same mistake with healthcare? Moreover, it’s likely that employees are making this mistake every day, yet they may not even know they have an option. Unless the organization takes ownership of educating its workforce, it’s likely employees will continue to overspend. And remember, if they are overspending their own money, multiply that by three or four times for its financial impact on the company. For example, a simple surgery can cost the company $30,000 to $40,000 more if the employee does not choose a center of excellence.

        It’s very common that one hospital will charge 60% more for the same procedure as a competing hospital, often located directly across the street. To confuse this process even further, the same doctor will operate at either of these hospitals? This is what happens when people are led to believe “insurance will pay for it.” These are the six words that killed American healthcare.

        Insurance will not pay for it

        When buying a new car, do customers compare features and price? When buying a house, do they shop neighborhoods, school districts and number of bedrooms? Of course they do. Why don’t they do the same when it comes to personal health? Why are Americans afraid to ask a doctor for a second opinion – or even an alternative – when a high-cost procedure is recommended?

        Well, the short answer is that they have been led to believe that insurance will cover the costs, so it’s not important. They don’t monitor which facility they choose, and they don’t question recommended procedures. But that’s dead wrong. Each time an employee chooses a higher-cost provider, that cost is added in some form to the following year’s premium cost to the company – which, in turn, is passed on to the employees. Year after year. It’s inflation by design! Not the company’s design, but by the hospitals, insurers and pharma companies (among others) that benefit from constantly increasing prices.

        Become an EHC

        It is critical that individuals become engaged healthcare consumers (EHCs) How? Start by focusing on the three P’s: plan, prevent and personalize. Create a strategy that focuses on preventive care, as well as personalized care.

        P #1 – Have a plan: The first P is to take control of individual health by creating a healthy living plan. That plan includes dietary goals as well as fitness and lifestyle habits. Also, for those who suffer from a condition or chronic disease that impacts their health, their plan should include specialized steps to specifically address those needs as well. Plans also should include several personalized and preventive medicine steps.

        Update the plan at least annually, but daily monitoring and tracking of diet and fitness habits are critical in shaping this plan as well. There are plenty of tools available via mobile phone applications to track both diet and fitness. Also, research mobile applications available to support management efforts for any chronic diseases, such as diabetes or hypertension.

        P #2 – Personalized medicine tactics: A number of personalized medicine tactics should be considered, including DNA testing and genome sequencing, as well as functional and integrative medicine tactics. The more people can learn about how their body differs from others, how their body metabolizes medication and food, and how their body reacts in general to different foods, exercises and lifestyle habits, the healthier they will be. Implement these tactics into the plan!

        P #3 – Preventive medicine tactics: The second key component of the plan is to utilize the tools, resources and technology available to assist in monitoring and improving health. From checking blood pressure to diabetic management to tracking exercise and dietary consumption, a healthy living plan is the first step in practicing preventive medicine tactics. It’s only a matter of years now before science will identify the exact medication that is best for each condition based on personal metabolism, known as polygenic risk scoring. At present, medicine is well on its way to that level of personalization, so utilize the tools currently available.

        To date, there has been little evidence suggesting any link between price and quality in healthcare. In fact, those doctors who engage in the discussion about fair pricing often are getting higher quality scores than the high-cost provider. The doctors and facilities that offer lower pricing and higher quality are known as centers of excellence, often referred to as within the narrow network. Once beginning the journey to becoming an engaged healthcare consumer, continue by shopping for healthcare centers of excellence. This will save significant dollars for both employees and employers.

        So, while corporate America has finally stepped up to lead the charge against hyperinflation in American healthcare, individuals can do their part by becoming engaged healthcare consumers. The tactics listed above are a simple start down the EHC path.

        Dr. Josh Luke is a celebrated speaker, award-winning futurist, a faculty member at the University of Southern California’s Sol Price School of Public Policy and the author of Health – Wealth: 9 Steps to Financial Recovery. Drawing on his experiences as a hospital CEO, Dr. Luke delivers engaging and entertaining keynotes that teach audiences simple concepts on how individuals and companies can save thousands on healthcare. For more information, visit www.DrJoshLuke.com.

        The 2019 Print and Packaging Outlook

        December 28, 2018

        by Dr. Ronnie H. Davis, senior vice president and chief economist
        Printing Industries of America

        With 2018 rapidly coming to an end, printers and suppliers are turning their attention to 2019. The Printing Industries of America (PIA) provides its outlook for the 2019 economy and print markets with a focus on the following:

        • An update on current macroeconomic conditions and outlook for next year
        • Current print market conditions
        • 2019 print markets

        Current macroeconomic conditions

        The American economy was operating in high gear as of the third quarter of 2018. Signs of strength abound:

        • Second-quarter gross domestic product (GDP) increased at a very robust pace of 4.2% on an annual basis.
        • Core inflation continues at a low rate, although it is heating up.
        • Consumer and business confidence remain very strong.
        • Business profits are high, driven by strong domestic and global sales, plus deregulation and lower corporate taxes.
        • Employment is growing, and the unemployment rate is extremely low, pushing up wages.
        • Stock prices and home prices are growing.

        The 4.1% growth pace for the economy for the second quarter ranks as the highest mark out of the last 10 quarters going back to 2016. The current economic expansion started all the way back in June 2009, a phenomenal 112 months of sustained growth. This makes this expansion the second longest in 164 years of record keeping by the National Bureau of Economic Research, the official scorer of the economy. The only longer expansion was from 1991 to 2001, which commenced a discussion about the “new normal” and an end to the business cycle. Unfortunately, the Great Recession of 2007 to 2009 put an end to that belief.

        PIA’s economic outlook for 2019

        Will the strong economy continue into 2019? In our view, the economy will most likely continue on a pace of robust, above-trend growth of around 3% in 2019. However, as always, economic forecasting is fraught with uncertainty. As usual, we offer two other entirely possible 2019 economic scenarios:

        • A “slowing but growing” trend line, with GDP retreating back to around 2% growth.
        • A 2019 recession with total GDP down around 1.5%.

        Other outcomes are possible, including higher growth or a more serious recession or any hybrid combination of the three scenarios. The likelihood of the three scenarios is a 50% chance for robust growth, 20% chance of slowing growth and 30% chance for a recession. Note, that we have increased the likelihood of recession from last year’s outlook from 25% to 30%. In our view, the likelihood will increase even more in 2020 if we get through 2019 without one.

        Strong growth: This most likely scenario is a continuation of the recent uptick in economic growth. The two key drivers of this prospect are already in place – deregulation and the cut in corporate taxes. Both increase the competitiveness of the US economy and raise the equilibrium annual growth rate by around 0.5 to 1%. So far, the economy has been able to accelerate to this pace by an elastic response in labor force participation and a return to more “animal spirits” (instincts) in business investment.

        Recession: Historically, most recessions are caused by two primary reasons – external shocks, such as oil shortages or a financial crisis, or excess exuberance leading to over-investment that finally results in cutbacks and downsizing. A variation of the second cause is simply the recovery dying of old age as new investment opportunities decline. A case can be made for either of these arising next year or in 2020.

        At the present time the downside risks that could lead to a recession include:

        1. Trade restrictions or barriers that slow down the US/global economy.
        2. Labor shortages restrict growth, coupled with immigration restrictions (total number, quantity and quality, age). In the case of immigrants – will there be a substitute or complement to US labor supply?
        3. Bottlenecks – particularly in transportation.
        4. Costs and price pressures. Both are inherent in the growing economy and are also a result of possible missteps by the Federal Reserve as it unwinds the bond-buying push of the last few years.
        5. Interest rates ramp up from inflation, and increases in deficit crowd out private investment.
        6. Other wild card issues.

        Slower growth: A slowing but growing economy would be a return to the economic trajectory of the past few years. The likely cause of this path is some combination of the six downside risks listed above. Just two or three of those in combination may not be enough to tip the economy into recession but certainly could shave a full point from the robust growth scenario and leave us with sluggish growth.

        Current print markets

        At the current time, print markets are robust, although, as always, they remain competitive. Generally, there are six key reasons why print and printers have largely been healthy over the last few years.

        1. Print has hit its sweet spot in the mature recovery phase of the economy.
        2. Most of the severe displacement of print by digital media is now behind us.
        3. Labels, wrappers and packaging print serve as an anchor on print sales, as it generally tracks very closely with the overall economy.
        4. Recently print marketing and promotion – particularly direct mail – has demonstrated its effectiveness as a premium marketing and promotional medium.
        5. Even the print sector most impacted by digital media – informational and editorial print (books, newspapers and magazines) – has been doing relatively well lately.
        6. Printers themselves have adjusted their business models to take account of new industry trends and realities.

        On a nominal basis, print markets are growing around 1 to 2% at present. In total, the economic footprint for US print markets is very large:

        • Approximately $170 billion in annual sales
        • Over 800,000 employees
        • Around 42,000 establishments

        Printers’ profits are also generally healthy, based on historical trends. The most recent metric from PIA’s Ratios program shows profits as a percent of sales at 2.7%.

        PIA’s print outlook for 2019

        • So how will the three 2019 economic scenarios impact print?
        • In the most likely robust-growth scenario (50% likelihood), overall print shipments increase by 2% or more next year. In terms of industry profitability, the average printer’s profit rate would likely increase by about 0.5% over trend to around 3.5% of sales.
        • The recession scenario (up to 30% likelihood) would reduce total print and print-related shipments by around 2 to 4% next year. The typical printer’s profits would dip significantly into negative territory until the recovery is underway.
        • The slowing-but-growing scenario (20% likelihood) would result in stable or slightly growing overall print sales in 2019. In this scenario, printers’ profits dip slightly to around 2.5% of sales.

        Printers’ profits: Printers’ profits will trend by significantly different paths, depending on the economic scenarios. In the robust-growth scenario, profits would jump significantly to historic highs of 3.4% of sales in 2018 and 3.5% of sales in 2019. If the economy falls into a recession, 2018 printers’ profits would be wiped out and turned into losses for both 2018 and 2019. In the trend scenario, profits would remain at 3% of sales for both 2018 and 2019.

        Outlook by print processes: The current trends regarding print processes will continue in all three economic and print market scenarios. Three print processes that will grow relatively fastest over the next one to two years include: inkjet – both wide-format and production, wide-format – particularly digital and inkjet, and digital toner-based.

        Outlook by print market segments: The current trends for specific print market segments also will likely carry over to next year in all three scenarios. Five specific print market segments will likely grow at a relatively higher rate than other sectors: packaging and specialty packaging, labels and wrappers, signage, direct mail and point-of-purchase.

        In conclusion, most indicators point to a strong economy and healthy print markets next year. However, as always, printers and suppliers need to keep grounded and be ready to take advantage of the opportunities while at the same time looking out for the challenges.

        Dr. Ronnie H. Davis is the Senior Vice President and Chief Economist of the Printing Industries of America. The PIA strives to enhance the growth, efficiency, and profitability of its members through advocacy, education, research, technical information and cost-saving resources. www.printing.org

        Evaluate Your Company’s 401(k) for Optimal Success

        December 28, 2018

        by Joseph P. Trybula, CFP®, AIF
        Printers 401k

        Employers face a daunting challenge: attracting and retaining the right talent necessary to drive their businesses forward. At the same time, they likely feel a responsibility to help employees reach retirement financially prepared. A 401(k) plan can help manage both of these goals.

        Keeping an eye on the latest trends and tactics in the 401(k) arena is one way that employers can offer a competitive plan. Below is insight across a wide variety of companies and industries on contributions, investments, fees and fiduciary responsibilities that can help in evaluating individual companies’ plans.

        Contributions

        How many employees are contributing?

        • In 2017, 79.3% of participants made contributions to their plans, up from 78.5% in the prior year. If their plan participation rate is less than overall or similar industry benchmarks, then companies should review their plan design options and develop a strategy to increase participation. If your plan exceeds benchmarks, consider what features might drive even higher participation.
        • 74% of organizations offer a matching contribution to participant accounts – with an average contribution/deferral rate among active participants of 7%. Plans that offer an employer contribution are more attractive to both prospective and existing employees, which helps recruiting and retention efforts. Matching Benchmarks: Based on first 6% of salary contributed:
          • More than 100% match: 7.9%
          • 100% match: 12.1%
          • 51-99% match: 33.8%
          • 50% match: 22.1%
          • Less than 50% match: 17.5%
        • 41% of plans now automatically enroll eligible employees. Automatic enrollment may be the most direct way to increase plan participation. It also may help extend participation among more junior employees that might otherwise fail to enroll.
        • Why is plan participation important? Each year, 401(k) plans must pass a series of compliance tests to ensure that the company owners and key personnel are not benefitting disproportionately compared to lower-paid employees. To pass these tests, plan metrics must fall within certain mathematical limits.

        If a company happens to receive failing results, they may need to act quickly to take corrective action to maintain the tax-qualified status of their plan. These actions may include making taxable distributions to highly compensated employees (HCEs) or making additional employer contributions for other employees.

        Investments

        Just where is the money going?

        • Plans offered an average of 22.8 investment options to participants, with participants holding an average of 5.7 investment options within their plans. This number has remained relatively steady over the past three years.
        • 92% of plans offered mutual funds, and 71% of plans offered domestic equity index options.

        Fees

        What are participants actually paying in fees?

        • 82% of plans annually review administrative costs and fees
        • 63% calculated the actual fees the plan paid to its adviser
        • 39% of companies have between 76 and 150 basis points as the average asset-weighted expense ratio of all investment options in the plan.
        • The average plan is wasting 25 basis points of participants’ money per year and some are wasting in excess of 1%.

        As a plan fiduciary, employers have a responsibility to ensure that the services provided to the plan are necessary and that the cost of those services is reasonable. To fulfill that important duty, employers need to make sure they understand the types of fees charged for their plan.

        Fiduciary

        • 37% of plans state their plan adviser is a fiduciary to their plan.

        Selecting an investment professional to help with retirement plans is an important fiduciary matter – it’s crucial to understand the types of professionals available and how to choose the best one.

        • 28% of plans did not have an investment committee.

        No one likes to go it alone, especially when “it” is the oversight of an employer-sponsored retirement plan.

        The fiduciary rules, regulations and the responsibilities to employees can be enormous burdens. Employers want to be in compliance, and they want to provide a plan that meets the goals and objectives set forth so employees can adequately prepare for the future.

        Keep in mind the Employee Retirement Income Security Act’s (ERISA) original intent for retirement plans was for plans to be run by experts. Delegating administration and investment responsibility to outside experts insulates a plan sponsor from both liability and responsibility. The delegation of administrative and investment fiduciary duties to fiduciaries that accept them in writing can offer real value and peace of mind for plan sponsors.

        The Printers 401k® Success by Design Program is a collaboration of 401(k) specialists who assume specific fiduciary duties for plans. The solution is designed to fulfill fiduciary obligations, allowing employers to continue serving as the plan sponsor without the liability and responsibility. Participants see reduced risk and work, lowered liability and plan cost, and improved plan operations and investments. Learn more at www.printers401k.com.

        Foil Cheat Sheet Puts Decorating Options in Your Hand

        December 28, 2018

        by Melissa Larson, contributing writer
        PostPress

        It’s hard to make use of a finishing option if you don’t know it’s available. A significant new graphics resource for the printing and decorating industries has professionals and creatives asking each other, “Do you have the Foil Cheat Sheet?”

        The Foil Cheat Sheet originated as a joint project between the Foil & Specialty Effects Association (FSEA), and online graphics hub PaperSpecs.

        “This project was inspired by the countless times I’ve mentioned digital foiling in presentations or conversations at design conferences, such as HOW Design Live and Adobe MAX, only to discover that no one had any idea what I was talking about,” said Sabine Lenz, principal at design firm PaperSpecs, who spearheaded the project, along with FSEA.

        “To me it was vital that creatives have an overview of their foiling options – especially the short-run ones provided by digital; something that they could turn to as a reference time and time again,” she added.

        Limited edition

        To provide designers and others with real-world examples of these techniques, PaperSpecs, in collaboration with FSEA and Orlando-based printer and finisher SunDance (FSEA member), produced a limited-edition print version of the Foil Cheat Sheet for distribution to select audiences. This 6″x9″ coil-bound collector’s item features a wraparound cover, and interior pages that actually use some of the same digital foiling options discussed inside, as well as soft-touch lamination and French folds.

        PostPress asked Lenz what makes this guide better than anything else currently out there. “There are ample references for hot foiling, of course, and some cold foil ones,” she said. “But when it comes to digital foiling with the ever-increasing options available, there really was a need to see all the benefits and limitations of each system laid out side-by-side. To the best of my knowledge, this has never existed before. It’s certainly never been done this clearly.”

        Jeff Peterson, FSEA’s executive director, agreed. “When Sabine Lenz and PaperSpecs approached us about partnering on the project, it was really a no-brainer. We have continued to get a lot of questions about all the newer, digital foil technologies and where they fit in with more traditional foil stamping and even cold foiling.”

        FSEA worked closely with PaperSpecs to put together the text for the Foil Cheat Sheet and outline the advantages and disadvantages of each type of metallic foil process.

        What’s inside

        The Cheat Sheet contains a section detailing and illustrating each of the following techniques and materials:

        Hot Foil Stamping
        Cold Foil Transfer
        Digital Foiling
        Toner Digital Foil
        Varnish Digital Foil
        Foil Substrates

        For each, the guide lists available providers, colors available, run lengths, maximum sheet sizes, paper options (coated or uncoated), advantages and disadvantages.

        For instance, for Varnish Digital Foil, the guide offers the following information:

        Provider: Varies from 40+ to more than 100 print service providers (PSPs) depending on press used.
        Colors: From metallic gold and silver to unlimited.
        Run Length: Small to medium.
        Advantages: No dies, plates or film required, so a good option for shorter runs; and the ability to use foil for personalization. Adding clear polymer on top of the foil gives that extra tactile (embossed-like) feel.
        Disadvantages: Not as feasible for larger-size foil areas, and limitations on paper stocks and foil colors. Polymer-based foiling is not commonly overprinted—the foil color you choose is the color you get.

        At the back of the piece is a foldout chart comparing all techniques side by side. We asked Lenz for an example of how a graphic designer or PSP might use the piece to plan a project.

        “For those times when printers just need to cut to the chase and compare all the various types of foiling at once, we included a handy fold-out chart at the back,” she explained. “With one glance printers can see which techniques are overprintable, what colors are possible, and the maximum sheet size the different foil options will accommodate, among other vital pieces of information.

        “With budget always being a concern, a vital piece here is the recommended print runs. Many print customers are not aware that, thanks to digital foiling options, they can run as few as one or 10 or 100 pieces. On the other end of the spectrum there is cold foil transfer, which makes economic sense for much larger print runs – but again, many customers are not aware of their options,” she said.

        How did they print that?

        Kandi Johansmeyer of SunDance walked PostPress through the process of printing and finishing the Cheat Sheet, with all the decorating techniques used.

        • The 4-color was printed on an HP Indigo 7 series.
        • All pages were then laminated with a soft-touch lamination.
        • Some of the pages were then run on a Heidelberg Versafire CV, a digital press with special-effect colors.
        • These were then run through the laminator, where toner reactive foil was applied.
        • Other pages in the guide were run on SunDance’s MGI JETvarnish 3D digital print enhancement system. They were then run though a laminator with digital UV reactive foil.

        FSEA will be gearing up for a second, larger print and foil run of the Foil Cheat Sheet. The goal is to make it available to FSEA members and others in the industry and provide a real tool to help everyone from designers and end users to printers and finishers.

        “We worked extremely hard with FSEA members, PaperSpecs and others involved in the metallic foil industry to create the Foil Cheat Sheet and make it as user friendly as possible,” explained Peterson. FSEA will provide an opportunity for its members and others to order quantities of the Foil Cheat Sheet as soon as January 2019. Peterson said that FSEA will continue to update members and others on the progress of a new run of the Foil Cheat Sheet.

        “While the book’s high production values and foiling prevent us from offering a copy to absolutely everybody who wants one, we’ve made all the information contained within its pages available to all in the form of a free PDF available for download,” said Lenz. PaperSpecs reaches over 18,000 designers and print service providers through its website, emails and webinars.

        When asked about industry reaction to the piece thus far, Lenz commented: “We have only shared the piece with select audiences at PRINT 18 and a number of design influencers, and the response has been amazing. We are receiving requests for larger quantities, so they can be shared within agencies and PSPs. Many, even in the print industry, were not aware of the possibilities. Our goal at PaperSpecs has always been to explain things as simply as possible while providing the crucial information needed.”

        A free download is available at www.foilcheatsheet.com. More information on ordering a print/foil version of the Foil Cheat Sheet will be available soon on the FSEA website at www.fsea.com.

        Understanding UV LED Curing

        December 28, 2018

        by Paul Mills, contributing writer

        One of the growing areas in UV coatings and printing is the growth of UV LED curing – a technology that offers great advantages. PostPress reached out to a long time consultant and expert in the field, Paul Mills, senior editor of the UV LED Curing Community website, to answer a few questions on the technology.

        Q. What are some of the main benefits LED curing offers over more conventional UV curing?

        Some of the advantages of LEDs (light emitting diodes) come from the “D” part, or diode aspects of emitting light. Semiconductors have replaced older technologies in so many areas. Old radios with vacuum tubes that burned out were replaced by transistor radios. TV sets with cathode ray tubes that were bulky, needed time to warm up and often had shrinking images as they deteriorated have been replaced by high-def LED screens. Even the incandescent light bulb, with its fragile filaments, has been replaced by robust LED lights.

        For UV curing, LEDs are now replacing quartz tubes that rely on small drops of mercury to generate UV light. Mercury technology requires high voltages, generates large amounts of heat and the mercury emissions can be dangerous to worker health and safety if not properly handled. Mercury lamps, particularly the popular arc lamp variety, degrade every time the lamp is turned on and off. It takes a good deal of engineering to manufacture an arc lamp with very uniform output, and they require routine maintenance.

        By contrast, LEDs are highly reliable, producing consistent output over extremely long time periods. They use less energy, produce less heat and the longer wavelength LEDs are relatively benign light sources. And, because they are solid-state light sources, they can be turned on and off nearly instantaneously with no degradation.

        Q. There are a lot of decorative coatings out there today, such as raised profile UVs, textured UVs and glitter UV. Is LED the best choice for drying these types of specialty coatings?

        It’s not so much the LED itself that makes it any more, or less, suitable for curing a specialty coating. From the coating’s point of view, the light source is a black box that emits photons, and molecules are pretty egalitarian when it comes to their photons. However, there are aspects of LED light sources that make it easier to control the photons. For instance, where mercury emits a broad spectrum, with multiple peaks of light spanning from 200 to over 400 nanometers, LEDs are like lasers in that they emit a strong peak of light at very specific wavelengths. This potentially allows chemists to perform some tricks when curing with LEDs. Also, since LEDs are tiny and an array can be put in spaces as small as those between inkjet heads, LEDs can “freeze” inks, keeping the ink dots from growing in size, or a process called “pinning”.

        But it would be dishonest to say that every ink and press manufacturer is taking advantage of these capabilities. In fact, only a handful of leading suppliers are really tapped into the inherent advantages of LED. Many suppliers are just trying to substitute LEDs for arc lamps and treating the LED as a semiconductor version of a mercury light source. In that case, traditional light sources might even perform better, since the existing chemistry has been developed around mercury-based technology.

        As competition for LED technology ramps up, firms that want to create more value with curing technology will embrace the unique aspects of LED to cure coatings with unique colors, textures and special effects.

        Q. Is there a difference between installing a new LED system and converting a mercury-based system to LEDs?

        If space aliens visited earth and had no prior knowledge of UV lamps, then adopting to LED would seem like a simple decision. But old habits die hard. An economist might call it switching cost, a physicist might call it inertia and a psychologist a habit. Changing paradigms is hard. For example, consider the tools and techniques used to measure UV lamp performance. With mercury lamps, broadband radiometers were the proper tool, since the mercury spectra are so broad. But a broadband radiometer can’t be used to measure a 395 nm LED and result in accurate measurements. That led to a lot of confusion about the claims of various manufacturers. Companies have now developed new devices tailored to measure these new light sources. So, for UV neophytes, the LED path may actually be easier than to those who have a long history with conventional UV curing who will have to make more adjustments.

        Q. Is LED the answer to all curing/drying applications for coatings? When is more conventional UV curing still a better or, as good as, choice?

        Someday most, if not all, applications will move toward LED curing technologies. But not yet.

        Until now, there has been some rationale for sticking with arc lamps. LED sources were relatively expensive, particularly for larger curing footprints. Bu that gap has narrowed considerably, and in some cases LED can be less costly. LED capability has been correlated with output power, or irradiance. Years ago LED sources were 50 to 100 milliwatts. Today, 20 watt units are commonplace. These higher power units overcome many of the hurdles regarding cure speed, depth of cure and distance from the lamp to the substrate.

        Finally, as alluded to above, advances in chemistry, which have been frustratingly slow, are beginning to emerge that will enable more LED applications. So, if arc lamps were to go away today, there would still be users with applications that would be stuck without an LED solution. In another five years there will likely be few curing applications that won’t be able to convert to LED, and the advantages of LED will make mercury lamps an obsolete technology down the road.

        However, today the least desirable candidates for LED, and, thus, most well suited applications for conventional lamps, include: 1.) larger cure surfaces that are expensive to cure with LED arrays, 2.) coatings that require hard, scratch- and mar-resistant surfaces and 3.) surfaces with contours and profiles that present greater variability in distance from the part to the light source.

        Q. What’s next in the future of LED curing?

        The developments in the near future will be in two areas. First, LEDs are pushing the envelope to shorter and shorter wavelengths. These efforts are being driven more by germicidal/disinfection/food safety applications, but there will be clear spillover effects that will enable mixed-diode arrays to cure more coatings with harder surface properties than ever. One result of these developments will be the solid-state analog of the mercury arc lamp. This will mean losing some of the advantages of early LED sources, such as safer emission spectra. However, this is most likely inevitable.

        The second area of development is in more LED specific chemistry that takes advantage of the novel characteristics of LEDs, such as special effects coatings that can be produced by high-speed strobing of the light source, or coatings that take advantage of the narrow wavelength spectra of LED sources. For example, coatings with light stabilizers that combat the deleterious effects of sunlight can be cured with LED sources whose emissions are not absorbed by the light stabilizer itself.

        Paul Mills is the senior editor of the UV LED Community website. The site is a free, educational resource for UV LED chemistry (inks, coatings and adhesives), light sources, LED printing presses, and other UV LED related supplies and applications. The UV LED Community is operated by RadTech North America. Learn more at www.uvledcommunity.org

        Association News

        December 28, 2018

        Nearly 80 percent of Exhibit Space Sold for Odyssey Expo 2019

        FSEA and IADD are well under way preparing for Odyssey Expo 2019, with nearly 80% of available space already sold for the 10th edition of the biennial event. Odyssey Expo will be held May 1 – 3, 2019, at the Cobb Galleria Centre, Atlanta, Georgia.

        Exhibit space is filling fast as suppliers from across the industry reserve booths and make machinery commitments for the TechshopTM. Techshop simulates a working production shop floor where technical sessions are taught on-press throughout the three-day event. Odyssey Expo 2019 has confirmed the exhibit space from virtually all of the leading suppliers of both FSEA and IADD. The Odyssey Expo website (www.OdysseyExpo.org) includes a map of the exhibit floor and a current list of exhibitors.

        “We are very excited about having the Odyssey Expo in Atlanta next year,” stated Jeff Peterson, FSEA executive director. “Exhibit sales are going very well, and we already have many commitments for machinery on the show floor.”

        Several special events are planned for the week of the Odyssey Expo. The FSEA Gold Leaf Awards celebration will take place on the second evening of the Odyssey, May 2, and the PIAG, headquartered in Atlanta, is planning a reception the first evening of Odyssey, May 1. IADD also is working with several of its members and exhibitors on other special events. FSEA and IADD will share more information on these events as it becomes available.

        For more information on Odyssey Expo, visit www.OdysseyExpo.org to see the new website and more details on the event. Hotel information is available on the website. Registration and complete programming information will be available by February 1, 2019.

        Spoilage Survey Report Published September 1

        Foil & Specialty Effects Association

        Recently, FSEA asked its members to answer a series of 12 questions designed to investigate a major cost center for trade finishing companies and binderies – spoilage.

        Questions in this survey were designed to help the association provide benchmarks to its members on the percentage of spoilage incurred and the actions finishers/binders have taken to help decrease spoilage rates.

        When calculating spoilage for this survey, members were asked to provide information on a per sheet basis, based on the number of sheets that are unusable because of mistakes, jams, registration problems, stops and starts on a machine, etc. It did include what is calculated for makeready and set-up of the machine.

        The survey addresses issues such as average material spoilage rate per job, whether or not a tracking system exists for spoilage in the respondents’ facilities and what programs had been effective in reducing spoilage rates. Key findings indicate: 1) an increase in spoilage due to digital printing and/or shorter run lengths and 2) the importance of employee training on proper equipment usage as a tactic for reducing spoilage rates.

        The full survey results are now available on the Member Only section of the FSEA website at www.fsea.com. FSEA members can log on with their password to receive it. If there are further questions on the survey, email jeff@fsea.com.

        Binding & Loose Leaf Division of FSEA Holds Breakfast at PRINT 18

        FSEA sponsored a breakfast at PRINT 18 in Chicago this past October. The event was planned to help introduce the new Binding & Loose Leaf Division. Chris Eckhart, president of Eckhart & Company and bindery division representative on the FSEA Board of Directors, and Jeff Peterson, FSEA executive director, discussed some of the benefits that have been put in place for the new division and answered questions from those who attended.

        “We have already signed up over 10 new FSEA members under the newly formed division,” explained Peterson. “We believe there is a natural fit to get trade binderies, loose leaf manufacturers and suppliers involved with FSEA and set up specific benefits for the division as well.”

        To learn more, visit www.fsea.com and click the link to the Binding & Loose Leaf Division page on the right side of the homepage.

        Start Collecting Your Best Work!

        FSEA Gold Leaf Awards

        FSEA has the new entry forms available online for its 26th Annual Gold Leaf Awards competition. FSEA urges its members and others in the industry to start collecting their best work from the past few months to enter. Winners will be announced at a the Gold Leaf Awards Celebration during the upcoming Odyssey Expo, May 1 – 3, in Atlanta, Georgia.

        This is a great way for companies to gain recognition for creative work and bring pride to their organization for the great work their team performs every day. The categories have been updated again and include foil stamping, embossing, cold foil, digital foil and coatings, specialty UV coatings, special diecuts, and more.

        Gold Leaf Award winners also will be highlighted in promotional materials and industry magazines, including PostPress, Brand Experience and Folding Carton Industry magazines. Winners also will be displayed during the Odyssey Expo event and in the Showcase of Packaging area during PACK EXPO 2019 next fall in Las Vegas.

        To download the entry form (use a separate form for each entry) and for further details, visit www.fsea.com and click on the Awards link.

        PRINT 18 Specialty Printing, Post-Press & Finishing Technology Recognition

        December 28, 2018

        by Katy Ibsen, managing editor
        PostPress

        At PRINT 18, APTech celebrated the inaugural Red Hot Technology recognition program, an opportunity for companies to highlight their “red hot” products.

        “The program was created to provide a place where the PRINT attendee base, primarily print service providers, can easily discover the newest products and services on display. It’s a way for OEMs in the industry to put a spotlight on what’s new in their ever-expanding product mix,” said Julie Schafer, APTech’s association vice president, program and community development, and organizer of the Red Hot Tech program. “Programs like this benefit both printing industry practitioners and their suppliers and are part of the Association for PRINT Technologies’ dedication to support the entire commercial print value chain.”

        To be recognized, products must align into one of 12 categories, including postpress, with a product that came to market within the last 12 months. A Red Hot Technology evaluation team then reviews each entry and supporting documentation to verify it meets the program criteria. Products are not in competition within each category; rather any new product meeting the program criteria is eligible for recognition as Red Hot Technology.

        “This is an especially important distinction for software products, because modern software development is ongoing and often year-to-year updates are significant. We think that those products can be as deserving of recognition and brought to the attention of attendees as something just brought to market,” added Schafer.

        Under the Specialty Printing, Post-Press & Finishing category, several products were recognized. PostPress visited with several of those that fit into the postpress/finishing category to learn more about recently released products and technologies.

        Learn more at: www.printtechnologies.org/events/print18/red-hot-tech/red-hot-tech-recipients/

        MGI USA – JETvarnish 3D Image Editor Software Application

        The MGI JETvarnish 3D Image Editor allows unlimited prototyping, modification, personalization and customization of CMYK print files right at the workstation. So, no need for time-consuming, costly and laborious back and forth exchanges with prepress departments and supply chain (i.e. broker/print buyer/agency/brand/end-user). For trade finishers and packaging/label printers, this is absolutely revolutionary because they are dependent on other firms for image creation. The Image Editor is integrated with a Job Cost Calculator and the OptiFoil Management System so printers and finishers know how much foil and varnish will be used before bidding, pricing and negotiating jobs. This also helps to manage operations such as job and staff scheduling, as well as supply procurement. The OptiFoil software automatically manages the foil roll application process to minimize unnecessary waste.

        The MGI JETVarnish 3D Series of digital inkjet print enhancement presses are standalone postpress finishing solutions (taking in offset, digital and flexo output). The Image Editor allows the “capture” of sheets and rolls so print embellishments can be created and produced, even without a CMYK print file or registration marks because it can create an entirely new file and assorted varnish and foil embellishment file layers – a first in the industry.

        The Image Editor comes loaded with more than 50 free pre-formatted 3D textures to use as a starter library, and users can add an unlimited number of new styles.

        The touchscreen interface of graphical design and intuitive print file management tools gives press operators the ability to create and modify new, decorative special effects with no prior graphic design experience or training necessary. This is a powerful vehicle for creativity and adding value to print jobs, thereby increasing profitability as well. The software can even be downloaded to desktops and networks, so design work and prototyping activities can be created remotely.

        Nobelus – LuxeFilms Rainbow Holografik Metalized printable laminate and Streams of Light Holografik

        The LuxeFilms Rainbow Holografik Metalized printable laminate film features a smooth, subtle brilliantly metallic holographic surface, ready to be printed. The effect is an engaging visual display of light and color that provides a striking impact and is ideal for surface printing to enhance high-end graphics. Rainbow Holografik Metalized film boasts a 40″ seamless pattern, allowing for full press sheet use.

        The Rainbow Holografik Metalized film adheres to most substrates and can be printed with conventional offset and UV offset inks while performing in postpress applications such as diecutting, folding, gluing, foil stamping and spot UV finishes. Rainbow Holografik Metalized film is an excellent substrate for folding cartons, labels, book covers and point-of-purchase (POP) displays.

        LuxeFilms Streams of Light Holografik is a special clear overlaminate film featuring a distinctive light band pattern. The effect is an engaging and seamless visual display of light and color that draws attention to and highlights the graphic elements of the printed piece. Streams of Light Holografik boasts a seamless pattern so the eye cannot detect the pattern repetition.

        As a PET thermal overlaminate film, Streams of Light Holografik adheres like standard lamination to most print substrates and performs well in postpress applications such as diecutting, folding, gluing, stamping and spot UV finishes. This makes it an excellent finish for folding cartons, labels, tickets and tags that need anti-counterfeit protection, POP displays and much more.

        Standard Finishing Systems – Standard Horizon StitchLiner Mark III

        The Standard Horizon StitchLiner Mark III has been equipped with the latest in automation technology, including true end-to-end support for variable thickness production, a key innovation for personalized and short run work. The system is designed to meet the evolving requirements of the market and improve on previous technology. Users value the machine’s tools that minimize changeover time and maximize efficiency.

        Read more about the Standard Horizon StitchLiner Mark III in Tech Watch on page 25.

        Streamfeeder – BW Integrated Systems – P1250 Tip-On Feeder

        The P-1250 Tip-On Feeder offers highly accurate and precise placement with on the run fine tuning. Its small footprint can be easily integrated into existing equipment such as folder-gluers, vacuum bases, mail tables, conveyors, etc. It is also available as a turnkey system. The feeder includes a state-of-the-art servo drive and motor, along with an Allen Bradley HMI to make set-up fast and easy via user-friendly menus.

        The P1250 Tip-On Feeder can feed a wide variety of products including plastic cards, coupons, promotional products, magnets, notepads, calendars and others.

        Tecnau – Stack 5250

        Featuring the double-cutting cutter c52, Tecnau’s Stack 5250 accommodates the broad range of papers and heavy ink coverages characteristic of the demanding applications migrating to digital inkjet printing

        Handling delicate graphic arts work at speeds up to 656 fpm requires a stable web of paper with minimal touchpoints. The taut-web Stack 5250 holds the web securely, minimizing friction on the printed surface. Stack 5250’s Stacker s50 module produces 1-up, 2-up, 2-up merged or 3-up stacks, featuring a patented “gripper” technology for reliable, damage-free handling of high-value print. North/south job offsetting ensures high-speed operation even for consecutive small set/book-block jobs.

        Stack 5250 features next generation controls for compatibility with the “Internet of Things” (IoT). The system includes natural-language error reporting on the user screen and onboard diagnostics to help keep the system up and running. IoT options are being introduced for remote monitoring and diagnostics, automatic software updates and preventive maintenance aids.

        Xerox Corporation – customized envelope feeder and conveyor for the Xerox Versant Press

        With no fuser change required, the Versant Press can run envelopes continuously and can run standard production sheets to 26″ posters on any type of media. The Xerox Versant envelope feeder and conveyor makes printing and finishing envelopes (a task once impossible to run on a digital production press) as efficient and simple as a standard print job, ensuring continuous, uninterrupted envelope production and unloading.

        The customized Envelope Feeder offers a top-loading friction feeder that feeds the press from the bottom of the stack to ensure reloads don’t stop or slow the press, resulting in extended, uninterrupted runs. For the first time, this feeder enables a Production Digital Press with ease of use and flexibility to run all types and sizes of envelopes.

        To keep the press running, a conveyor unloads envelopes from the output tray. This elegantly designed ensemble is an affordable game changer, enabling printers to migrate smaller offset envelope runs profitably to digital, while delivering matched print quality for the envelope and contents.

        This solution would allow for more than 5,000 envelopes an hour, with operator intervention limited to dropping stock into the chute feeder, with a conveyer that will automatically unload printed envelopes. Simple size adjustment and reliable operation makes for a great addition to any Xerox Versant Press.

        PUR or EVA – What is the Best Adhesive Option?

        December 28, 2018

        Information provided by Duplo USA Corporation and BC Adhesives

        It can be tough for binderies to decide which adhesive to use in their manufacturing process. The industry seems to be very comfortable with ethylene-vinyl acetate (EVA) since it’s been around for so long, but as polyurethane reactive (PUR) becomes more popular, it is important to know the differences between the two.

        Each has different qualities that might make it the correct option for different types of books.

        PUR adhesive has many advantages and is becoming more common among customers as a requirement to be used on their books. PUR can bind varnished, UV-coated, carton, mylar and other difficult stocks, where EVA adhesive may struggle with certain coatings or substrates. PUR also is a great choice for digital printing because this type of adhesive isn’t affected by ink migration. It is also a great option for tough papers, cross-grained stocks and higher basis weight recycled papers.

        Difficult substrates aren’t the only reason to use PUR: It makes for a higher quality book with excellent flexibility and lay-flat qualities, especially for larger books. Page pulls are usually 40 to 60% higher than when using EVA. And, for most applications, less PUR adhesive is needed, which helps decrease the possibility for adhesive to creep out during the nipping process.

        Be cautious when opting for the PUR route, because equipment is going to be more costly and require more maintenance. Since PUR cures when it comes into contact with air, the system needs to be sealed every night. That can be done by applying grease to the nozzle and pot. Failure to complete this step could lead to curing throughout the system.

        Another concern with PUR is the MDI (diphenylmethane diisocyanate) emitted during the curing process. This can be emitted as vapor or aerosol and can cause allergic reactions to the skin or respiratory issues. MDI levels drop drastically once substrates are joined, so this is mainly a concern during preventive maintenance. There are tools to test the MDI levels in a facility. These levels can be lowered with venting and other techniques. Finally, the curing time for PUR is much longer than for EVA; it is common for binderies to wait a full 24 hours before shipping finished books.

        EVA is a great option for more standard operations. The handling of this adhesive, along with maintaining the system, is much easier than with PUR. Binderies can move much faster when using this product due to the fast curing time. EVA has very quick set points that allow for a short cure time, meaning faster turnaround for trimming and the finished piece.

        EVA also is a much more cost-effective option for both the equipment and the adhesive itself. Milling is still extremely important when using EVA, but it’s not as much of a factor as when using PUR. Binders using EVA can notch bind their books. This means that small notches are cut into the spine and filled with glue before the cover is applied. This is not recommended for PUR applications. PUR needs the peaks and valleys of the fibers across the entire spine to succeed. Overall, EVA hotmelt glues still have their place in book-binding – especially when binding thread-sewn books – as the thicker glue allows for greater penetration into the spine area of the folded sections.

        In summary, both processes are still widely used within print finishing and bindery operations. The question of “which is best?” needs to be replaced with the question “which is most suitable?” The decision to use one over the other is job-specific and involves numerous considerations – from substrate used and thickness of the book, to the intended use of the product and financial constraints to produce.

        PostPress would like to thank Duplo USA Corporation (www.duplousa.com) and BC Adhesives (www.bcadhesives.com) for their assistance with this article.


        Which One is Most Suitable

        Advantages of PUR adhesives

        • Aggressive adhesive for coatings, digitally printed stocks, other tough surfaces
        • Isn’t affected by ink migration
        • Excellent flexibility and better lay-flat qualities
        • Use less adhesive – less likely for adhesive to “creep”

        Advantages of EVA adhesives

        • Runs on less costly machinery and less maintenance on machinery
        • No concerns with the MDI (diphenylmethane diisocyanate) emittance
        • Much shorter curing time for faster turnarounds
        • Less costly adhesive and best choice for many standard applications

        Standard Finishing Systems’ StitchLiner Mark III

        December 28, 2018

        by Lara Copeland, contributing editor
        PostPress

        Standard Finishing Systems, a North American distributor of print finishing and paper handling solutions based in Andover, Massachusetts, dates back more than 100 years. Partnering with equipment manufacturers to deliver solutions to many markets – including commercial, in-plant, trade bindery, quick print, data center, financial print, direct mail, forms, education and government – Standard offers a range of pre/post paper handling solutions from Hunkeler of Switzerland and a comprehensive line of automated finishing equipment from Horizon International of Japan. In addition to Horizon folders, perfect binders, trimmers, collators, bookletmakers, slitters/creasers and diecutters, Standard also offers Horizon saddlestitchers. The latest introduction in Horizon’s line of saddlestitchers is the Standard Horizon StitchLiner Mark III.

        Standard’s Director of Marketing Don Dubuque stated that the Mark III “has been equipped with the latest in automation technology, including true end-to-end support for variable thickness production, a key innovation for personalized and short-run work.” The market requirements continue to evolve, and this system was designed to meet those ever-changing demands. “It improves on previous technology in virtually every way,” Dubuque offered. Featuring increased productivity up to 6,000 booklets per hour and expanded booklet size, the Mark III allows for the production of a wider range of applications, including landscape-size booklets, 12×12″ calendars and pocket booklets as small as 4.5×3.5″.

        “As the market’s requirements for highly individualized short-run work continue to develop, the StitchLiner Mark III provides the tools to minimize changeover time and maximize efficiency,” Dubuque explained. From flat sheet collating, scoring, folding, and saddlestitching through three-knife trimming, all the system’s processes are managed through the fully automated set-up, which includes settings for stitch adjustment, so that stitch length and leg balance can be changed job-to-job or on the fly. At the trimmer, manual adjustments are not required for book thickness, and a unique 4-side jogging design achieves accurate trimming quality with 1-up or 2-up production.

        Dubuque said that in order to keep pace with faster printers and the demand for quicker and quicker turnaround times, finishing equipment must have a blend of speed and versatility. “The StitchLiner Mark III’s automation technology allows for fast and easy set-up and changeover, as well as the application flexibility to take advantage of it. As the variety of customized, short-run work increases, the Mark III is uniquely outfitted to allow printers to eliminate bindery bottlenecks and meet those turnaround requirements,” he concluded.

        Customers have welcomed this new saddlestitcher with praise. Dubuque mentioned that the reception has been “universally positive” from new customers and owners of previous Horizon saddlestitchers alike. “Our clients praise both the quality of the output as well as the speed and efficiency of the machine,” he said. “One Mark III customer reported that the system was running so fast that they had to put a second person on it to help unload, and that work that used to take six or seven hours was now being finished in less than two.” More positive feedback provides testimony to the fact that the machine is built to be durable. “The engineering of the machine ensures high uptime and a long life; we even had one customer tell us that after purchasing the Mark III, he considers himself set in saddlestitching for the next 15 years.”

        Technical details:
        The StitchLiner Mark III features speeds up to 6,000 booklets per hour, and it can produce and trim booklets up to 0.39″ thick with a maximum stitch thickness of 0.195″. It can process sheets between a weight range of 52.3 and 350 gsm.

        Next Page »



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