2021 Feb/March

Association News: February/March 2021

March 12, 2021

Gold Leaf Awards Move on Through Pandemic

The FSEA 28^th Annual Gold Leaf Awards Competition will close in early March, and FSEA will be conducting the judging of the entries shortly thereafter. The competition recognizes spectacular print decorating and binding work on greeting cards, presentation folders, labels, invitations, folding cartons and much more. Technologies such as cold foils, digital foils and coatings, laser cutting and specialty UV coatings have helped fuel the growth in the annual competition. “We are always amazed at the different types of work and the creativity of the pieces entered in the awards,” said Assistant FSEA Director Dianna Brodine. “We see entries come from all over the world.”

This year’s winners will be announced during a virtual awards ceremony later this spring tied to FSEA’s Online Learning Experience. Check the FSEA website (www.fsea.com) for details on the upcoming event. In addition, FSEA is planning to display the winners in each category at its scheduled FSEA Summit this fall, October 5, 2021, in Orlando, Florida, prior to PRINTING United 2021.

The annual FSEA Gold Leaf Awards would not be possible without its sponsors. FSEA would like to recognize and thank the sponsors for this year’s competition.

Platinum Sponsors:

BOBST
Crown Roll Leaf
Eagle Systems
H+M USA, L.P.
ITW Foils & Thermal Films
Infinity Foils, Inc. – a UEI Group Company
Kurz Transfer Products
Metal Magic
Mueller Prost
OWOSSO Graphic Arts, Inc.
Sakurai USA, Inc.
UNIVACCO Foils Corporation
Universal Engraving, Inc. – a UEI Group Company

Gold Sponsors:

Breit Technologies LLC
LasX
THERM-O-TYPE

FSEA to Hold Spring Summit: Add Value to Print

FSEA has announced it will hold a new event in its FSEA Conference series – the FSEA Spring Summit: Add Value to Print. The online event, occurring weekly from April 28 through May 19, will be held one day each week, with two hours of programming each day. Each weekly event will have a distinct program theme, covering current issues in print decorating, finishing and binding. Week One of the Spring Summit will feature topics on Print Decorating and Sustainability; Week Two will focus on Metallic Decorating Design and Troubleshooting; Week Three will discuss UV Coatings Design and Troubleshooting; and Week Four will be dedicated to Binding & Finishing Design and Troubleshooting.

Attendees can register for the full four-week series or choose to register for individual sessions. This provides flexibility in event cost. In addition to the weekly programming, content will include interviews featuring new finishing/decorating/binding technologies and equipment.

For more details, visit www.fseaconference.com. Complete programming and registration will be available by April 1, 2021.

FSEA Launches New Website

The FSEA has launched its newly revamped website at www.fsea.com. The updated site reflects the specialty print finishing and binding work done by the association’s members, with vivid images and detailed explanations of the processes used to create the stunning greeting cards, labels, cartons, folders, hardcover books and other printed media. In addition to expanded “Members Only” areas, the website provides all visitors access to critical information on the sustainability of decorated print products in response to the increased interest in the recyclability/repulpability of foil-decorated print. Visit the new site at www.fsea.com.

When You See a Fork in the Road, Take It

March 12, 2021

By Chris Kuehl, managing director, Armada Corporate Intelligence

Yogi Berra’s wise words resonate more these days than ever. We are in a topsy-turvy world: The pandemic has devastated part of the economy, but not other parts. The service sector has been slammed with the worst recession seen since the 1930s, while much of the rest of the economy has carried on as before. Housing is strong, manufacturing is mostly back to normal, exports and imports are at their usual levels, and so on. To add to the litany of business challenges, there has been the most contentious election in decades and the most chaotic transition in over a century. The result is a somewhat flummoxed business community unsure of what to expect now. To the rescue comes the economist – famed for our ability to predict the past! There are three scenarios in play right now as far as the melding of economics and politics.

Scenario 1: For the optimist

The first scenario has the support of 25% of analysts. This asserts there will be three important developments between now and the middle of the year. The first and most likely is that vaccine distribution will reach acceptable levels by the start of the summer. There still is debate over what herd immunity will require, but it is thought to be defined by at least 240 million immunized people in the US.

Once that level is reached, the load on hospitals will decline and lockdowns will start to lift, allowing a service sector recovery. This is the second assumption – a grand reopening of the sector where consumers once spent the majority of their disposable income. This has been referred to as the “great divergence,” as consumers will switch from buying stuff to buying services again. The third development will be a resumption of some normal working patterns. People still will be working at home to a degree, but many will be back to their offices and workplaces. That has significant implications for the oil sector. Oil demand will be up, and it is likely to exceed supply for a while – and that spells inflation to a degree. Prices that had been between $40 and $50 a barrel will creep up to between $60 and perhaps $80, at least for a while. That also will mean higher prices for the raw materials.

Scenario 2: For the realist

The second scenario essentially twins with the first. It also assumes there will be progress as far as vaccine distribution and the subsequent economic recovery, but there are additional issues that will have an impact on the economy. The most important will be the influence of politics. The Biden administration has a typically long list of changes and actions it wants to work on (as always takes place when there is a change in leadership). Which of these policy directions actually will emerge this year? One result of the dead tie in the Senate is the emergence of the centrists as power brokers. Nothing of real consequence will pass without their support, and that means paying close attention to four centrist Republicans (Mitt Romney, Susan Collins, Lisa Murkowski and Ben Sasse) and three centrist Democrats (Joe Manchin, Jon Tester and Kyrsten Sinema). This group likely will temper big tax hikes and big projects such as the Green New Deal or Medicare for All. Look for tweaks and alterations as opposed to big shifts.

There has been a sense thus far that Biden favors incentives over restrictions and penalties. This means encouraging the development of alternative energy as opposed to attacking fossil fuel use head-on. It means focusing trade relations on export promotion as compared to restricting imports. This scenario is attracting about 50% support from economists and underpins the assumption that growth will be between 4.0% and 5.0% by the end of the year.

Scenario 3: For the pessimist

There always has to be a negative scenario as well. Roughly 25% of analysts still assert that everything will not develop as expected and the 2020 recession will drag on through 2021. The major issue remains the pandemic, but just as important is the reaction of the consumer and of government. Just because the vaccine is widely distributed by April and May, there is no guarantee that cautious governments will reopen. It could be the end of the year before many states and cities allow restrictions to lift. Then there is the willingness of consumers to pick up where they left off. Will people go back to the restaurants and bars, attend events, be willing to go back to the office and travel for business? Many will, but is that enough? There are three hurdles for the economy to clear: 1) acceptance of the vaccine, 2) acceptance by government sufficient to reduce the restrictions and 3) acceptance by consumers sufficient to resume old patterns.

What’s next?

The data thus far supports the notion that enough people ultimately will accept the vaccine for herd immunity to occur. In December of last year, the polls suggested that around 30% were unwilling to take the vaccine, but that number now is less than 15%, as there have been few reports of bad reactions to the drug. The reduction of pandemic protocols is another story altogether. Thus far there has not been much reduction of restrictions as the pandemic numbers have not changed. It is assumed that more controlled situations will reopen first – restaurants and retail. Events and anything that draws crowds of strangers will be the last. The optimists think there will be openings by late spring, and the pessimists assert it is more likely to be late summer.

The final wild card is the consumer. Have the new ways of doing things taken hold? Will people want to go back to the office? Will they want to shop in the brick-and-mortar shop again or has the online option taken over? These are questions that can’t be answered adequately at this point.

On top of all the scenarios that are rooted in the pandemic response, there will be discussions regarding what the US political situation will mean for the economy. Trump now has departed, and attention is focused on the man who replaced him. Interestingly enough, there is not a great deal known about the plans and strategy that will emerge now. The most significant clue thus far is that Biden has surrounded himself with political veterans and people who worked with him in the Obama years.

For many industries, there will be pressure to be part of the solution on issues such as climate change, solid waste and other green initiatives. Some industries already have been a target on these green concerns. The push will be toward finding compromises in terms of design and usage for certain types of products. There will be threats and opportunities as the agenda on these issues develop. Thus far, the Biden approach has been oriented toward incentives as opposed to outright regulatory bans, but the latter tactic likely will be employed as well.

Chris Kuehl is managing director of Armada Corporate Intelligence. 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.

Digital Decorating – Where Does It Fit and Where is It Going

March 12, 2021

By Liz Stevens, writer, PostPress

As print embellishment technology continues to evolve, it is important to understand the advantages and limitations of certain processes. FSEA Executive Director Jeff Peterson sat down with a trio of executives to get the latest insights on digital technologies for coating, foiling and decoration.

Applications for digital decorating

When it comes to digital decorating, some applications are a better fit for using digital spot and digital raised coatings and digital foil. Christine Yardley, president of Print Panther, voiced her view that while these digital embellishment technologies can be adapted to just about anything, she finds that small-run packaging, a somewhat niche market, is an ideal application. “I think the best fit is small-run packaging, cards or brochures and, really, any marketing material or direct mail,” she said. According to Yardley, embellishment and protective coatings currently are very popular. “Nowadays, I don’t see too much small-run packaging that doesn’t have some kind of raised coating or foil,” she said.

Rick Salinas, vice president of marketing, Duplo USA, pointed to great interest for digital embellishment in the book industry and among consumer products producers as they target first-time customers. “When you go into a bookstore,” he said, “if you notice, they use embossing, debossing, soft-touch and foils now. Some of the book covers are like works of art. It addresses the challenge of getting somebody to pick up your book – trying to get that little edge when you don’t have brand recognition.”

The same goes for branding of other consumer products. “It has become hugely popular for first-time customer engagements,” he explained. “What I mean is, when producers don’t have brand recognition and they are trying to engage people.” Salinas raised the example of the marijuana industry, where there is no main brand; there is no Marlboro in the marijuana industry. “When people walk into dispensaries,” he said, “they just see a wall full of items. Sellers have to have something that engages people; that is why they use foil and soft-touch and raised coatings.”

From his vantage point, Myron Werner, director of sales, packaging and printing, KURZ USA, has seen eager adoption of digital decorating by online print providers of photo cards, invitations and small business marketing collateral. “These are areas where a lot of people have excelled with these technologies,” Werner said. “The benefits of digital foiling and spot coatings – quick speed to market, no changeover time, variable data – are perfect for continuously changing jobs or for a brand that requires small-run packaging.”

Digital vs. traditional

DigitalFoil_PrintPanther_Gold — Christine Yardley, Print Panther, utilizes her digital embellishment technology for clients that range from real estate to pharmaceutical.

At Print Panther, Yardley has a short list of criteria for choosing digital or traditional embellishment. “Right off the bat, it is the length of the run. If it is a super long run, I don’t think digital is the right choice. And, also, size restrictions.”

She noted that the intricacy of the image to be printed is another decision factor. “If it is super intricate, I can sometimes get a better result with traditional foil.” Also on her checklist are substrate and stock thickness. “If I am using a really laid or textured stock, it could be better suited for a traditional embellishment. And thickness of the stock matters because sometimes there is a limitation on my equipment as to the acceptable thickness.”

Salinas did not offer a hard and fast checklist but stated that he has seen a real experimental push in the industry, with elaborate, multi-step digital techniques producing some spectacular results. He did point out three criteria for making the digital vs. traditional decision for a job: quantity, whether there is variable data to be printed and whether there is a tight job budget. Peterson concurred, stating that while commodity items like toothpaste demand a low price point for packaging, when a product’s selling price is high enough, elaborate packaging may not only be a reasonable expense but also may be a must for creating a stand-out product.

For Werner, the substrate and the print process are critical components to review when deciding whether to go the digital embellishment route. “There are a lot of different digital technologies and equipment out there,” he said. “Knowing what the substrate is going to be and what the process is going to be – the print process – makes a big difference in whether digital is right or not for a job. At KURZ, for example, we have a toner-based system that would work on dry stocks very effectively, but you would have difficulties with our inkjet systems when working on some of those dry stocks. How the equipment and the substrate work together is critical to selecting digital or more traditional processing methods.”

Advantages of digital coatings and foils

When it comes to the big advantages of digital coatings and foils as embellishment techniques, Salinas pointed to fast turnaround and limited operator intervention. “In being able to create an embellishment through a digital file,” he said, “many times you can be producing the piece within minutes of it arriving at the shop, especially if you have an automated workflow.”

He described, for example, how his company’s spot UV coater works with EFI’s job flow. “We can take the fifth color file – for the polymer – right out of the job file when they send it to the press; that color file goes straight to our machine. So, as soon as the material comes off the digital press, it goes into our machine which reads the bar code with the instructions for the digital spot layer. No user intervention at all. That is what the digital advantage gives you.”

Werner agreed with Salinas that digital files offer an advantage, and he pointed out that the ability to make changes to a digital file provides flexibility not offered with traditional techniques. “With those digital files, you don’t have the tooling,” he said, “so you don’t have to order the tooling, you don’t have to produce the tooling and you don’t have to pay for it. This also increases speed-to-market and allows you to do very high-end work and very small volumes.”

Salinas noted that it is feasible to produce just one piece and that a lot of innovation can be accomplished with a digital format that cannot be done with traditional methods. In addition, in some instances, it is possible to apply foil as a first step and then begin the 4-color digital process on top of the foil, opening up new creative design avenues.

Limitation with digital

As with any technology, there are limitations of the digital process that potential buyers should be aware of before wading in. Werner said that it is important to be clear on what new techniques are desired and then to fully understand the range of equipment, including the capabilities and limitations of each set-up.

“In our portfolio,” he explained, “we have digital foil technologies that can be incorporated not only as a finishing technique but also as a pre-print process where customers can then create their own metallic colors and unique designs by overprinting.” Also in the marketplace are digital decorating technologies that use a polymer-based adhesive with hot foil release technology, and some that transfer using more of a cold foil methodology. Understanding the various techniques and the substrates to which they are best suited, finishers either can choose a prepress, pre-print type decoration or a postpress, post-print decoration.

Werner stressed that all processes and equipment have some limitations but that the limitations vary from equipment to equipment and from technique to technique. “It is important to understand what you can do with what type of decoration,” he said, “and then understand what type of consumables will be needed for that process and equipment.”

Yardley reiterated her thoughts on the limitations of digital processes. “The length of the run is not as much of an issue anymore because they are making up for speed on these new machines,” she explained. Yardley pointed out that if it is a very intricate foil design, a more traditional foil stamping method usually works best. She also stated that the final cutting and finishing step is a very important aspect to consider because, as she said, “You can’t just cut your business cards on a guillotine. Finishing is a huge part of it, and with digital you can’t do your finishing in a traditional way anymore.”

Digital-Ink-jet-Coating — Texas Bindery used Duplo’s Raised UV Coater and Laminator/Foiler to create this short-run Kratom label.

Salinas also emphasized this aspect of going digital. “You have just created this stack of beautiful, raised UV covers or maybe embossed,” he said. “What now? You just can’t pick up that stack with raised spot UV on the right side of the sheet but not on the left and walk over to a guillotine cutter, because now you’ve got a waterfall of paper with polymer that is going to get crushed when you put it into your guillotine cutter.” Salinas has seen an increase in the popularity of his company’s slitter cutter creasers, which can finish that type of work without damage.

What to keep in mind

Yardley noted that potential buyers should know that digital equipment requires operators with a certain level of skill, especially prepress and file prep skills. She also said that digital machinery has environmental requirements. “I think it is very difficult for a large shop to put a smaller digital profile within their shop,” she explained, “because the environment has to be so clean and so perfectly controlled for digital foil and varnish to really work well. You can’t stick a digital inkjet decorating machine in the middle of a litho shop; it has to be a very clean and orderly environment for this to work.”

Salinas advised potential investors to consider the entire workflow of a digital choice, as opposed to focusing only on the embellishment process. “Getting an understanding of workflow is first,” he said. “Then the question is: What are you trying to achieve by adding this embellishment? Is spot UV where you should start? Is foil where you should start? Is it hot foil; is it cold foil? Do you want to do it inline with raised spot UV?” And, echoing Yardley, Salinas stressed operator skills. “It all looks easy at the show, but there is a big learning curve on that type of equipment.”

Werner’s advice mirrored that of Yardley and Salinas: Understand the entire process; learn about equipment capabilities and which equipment marries well with which embellishment techniques; and know that operator skills and good workflows will be very important with new machinery. “It is critical to understand what you can accomplish in one pass or how many passes your processes are going to require,” he said. “If you think you are just going to get these units and do some of these really exotic, beautiful pieces all in one pass, and it is all going to be automatic, you really need to understand what the capabilities are and what the consumables are so you can make sure that the whole process works effectively.”

Market for digital decorating

DM-Kalender — KURZ DIGITAL METAL® technologies are easily
overprinted and can be applied to any digital printing
process or operation, inline and offline.

Yardley felt that the market was ripe for digital decorating. “Today, very few people want print without some kind of added value, without some kind of embellishment,” she said. “Most of my clients, which range from real estate to pharmaceutical, want that extra punch to their marketing materials, especially coming out of this COVID-19 situation.”

Yardley sees her expertise as a real value-added element. “I don’t have to sell the embellishment, but I have to sell the limitations,” she said. “It really is educating your client with good advice. They might think they want their logo in foil, but they haven’t thought it through completely.” Yardley sees giving good advice as another way to lock in a client. “Once you get their marketing material the way they want it – you’ve got their color perfected, you’ve got the foil they want, you’ve got the look they want – then they come back to you because you have locked them in. They can’t just go down the street or order from an online printer to get what they want. They have to come to you because you give them that extra value.”

Salinas offered two recommendations: Encouraging effective design and showing clients their options. “Sometimes it takes people a little bit of time to understand that less is more,” he said. “People get carried away with embellishment, and you almost lose the effect because they have gone so overboard with it. Learning that balance is important.”

On the flip side, showing clients their options, even after they have passed on embellishment, can be very useful and Salinas has seen this in practice. “When some of our clients talk to customers about embellishment and the customers decide, no, that wasn’t really what they wanted to do, digital embellishment can really show itself off. Because the stuff is done digitally and is so easy, when they deliver the job, they will send along samples with embellishments just to show how it could look. Fifty to 60% of the time, the next time that job comes in, the customer goes with the embellishment because it just wowed them so much,” he said.

Werner agreed wholeheartedly. “It is difficult to put a piece of print advertising out there and convey to your target audience what you are really doing,” he said. “They need to see the piece in their hands, to touch and feel it.” Werner recognizes the challenge of operating in a virtual environment, as social distancing keeps people apart. “People are going to have to look into how we can show off these pieces electronically more effectively in the future. But the simplest answer to this question is to show the samples and have people touch and feel them. They sell themselves.”

PostPress would like to thank Christine Yardley of Print Panther (www.printpanther.ca), Myron Werner of Kurz Transfer Products (www.kurzusa.com) and Rick Salinas of Duplo USA (www.duplousa.com) for their assistance with this article which was summarized from their participation in the FSEA Online Learning Experience virtual workshop “Digital Decorating – Where Does it Fit and Where is It Going.” For more information on this topic – as well as other video presentations – visit the FSEA Online Learning Experience’s YouTube playlist by visiting www.FSEAConference.com.

Looking Forward to virtual.drupa

March 12, 2021

Interview with Sabine Geldermann, project director drupa, Messe Düsseldorf

Though the original plan for drupa 2021 was to have a live event from April 20-28, at the fairgrounds in Düsseldorf, Germany, plans changed due to the continuing impact of the COVID-19 pandemic. Now a virtual event is taking place at virtual.drupa.com, April 20-23.

How will moving to a virtual format alter the experience for attendees?

No virtual format will be able to replace the experience of a face-to-face event, where attendees explore with all their senses products, innovations, technology trends and, above all, engage in personal meetings. However, we consider it our responsibility to offer our global print and packaging community a virtual industry platform that provides new impetus for reactivating business and offers digital sales opportunities. Our goal is to enable customer contact points and to expand our expertise in the interests of our community via digital formats as well. The three preview days in 2020 already have successfully demonstrated our goal to combine the best of both worlds.

What can attendees expect from the event?

Attendees will meet a representative number of international key players along the entire value chain of the print and packaging industry in three sections: Conference Area, Exhibition Space and Networking Plaza. Personal contact also is possible in the form of meetings in virtual chat rooms with exhibitors. We are only just starting to admit exhibitors, who now are gradually completing their online profiles and also uploading videos, web sessions and product information. The process is in full swing and is intensifying as we get closer to the event.

In addition, we will offer a high-quality conference program that is aligned with relevant technology trends and global megatrends and will highlight important impulses for future business models. Keynotes, industry experts and brand owners are on the agenda, and we will publish a preview of the program soon.

What opportunities should attendees be sure not to miss?

The daily keynotes at the kick-off of the virtual drupa will certainly be a highlight and will of course – if attendance is difficult due to time differences – be available on demand 24/7. The program offers fascinating brand stories, case studies and future technology topics – which is why participants should register for the event free of charge starting in March at virtual.drupa.com.

Participants should use all three segments of virtual.drupa to continuously contact exhibitors of their network, and they also should search for product innovations in addition to new contacts via the matchmaking tool and an intelligent keyword search to achieve the best contact results.

What are you looking forward to with virtual.drupa?

We are looking forward to seeing customers from all over the world – at least digitally – after a long time and providing a platform that enables business activity and networking in times of the pandemic. Already, in preparation for the event, we are hosting regular video conferences with exhibitors, partners, associations and our worldwide representatives, which underline the importance of customer connectivity that we globally enable. We need to remain optimistic and serve the needs of customers until we can hopefully schedule face-to-face meetings around the world again, starting in the summer.

All customers are talking about digital fatigue and can hardly wait for the return to live events. This is what we are looking forward to the most, because the industry needs a new perspective, trust and confidence for the near future.

Adapting Business Practices Amid the Pandemic

March 12, 2021

By Brittany Willes, editor, PostPress

As COVID-19 continues to have an impact worldwide, companies have faced major challenges when it comes to keeping employees safe, staying in touch with customers and adapting to new regulations. Many previous business habits and best practices have had to transform or change completely in the face of a shifting market. Despite some of the more egregious setbacks, many businesses also have been able to take advantage of new opportunities that might not have otherwise been realized.

For many industries, when the first wave hit, it was a shock to the system – and to the status quo of business operating practices. “I like to think that we continuously challenge our critical thinking as an organization, but there is nothing like a pandemic to make this an urgent priority,” said R. J. Windler, president of Diecrafters, Inc., Cicero, Illinois. Luckily for Windler and Diecrafters, the company already had decent systems in place, allowing it to adjust more easily to shifting conditions. However, that didn’t mean there still weren’t significant adjustments to be made.

“Unfortunately, we had to make changes to facilitate social distancing that negatively impacted production line efficiencies,” Windler noted. “We were quite thankful for the Paycheck Protection Program, which helped us support these inefficiencies so we could keep our team working and better cope with losses caused by slower net production.”

Despite some of the negative changes forced by the pandemic, there have been some unexpected positive impacts as well. While many sectors, such as those reliant on retail, certainly have taken a hit, others, such as packaging and direct mail, have thrived. “Packaging was expected, but direct mail was more of a surprise; although, perhaps it shouldn’t have been,” said Windler. “Highly decorated mail has a much higher response rate. We anticipated that lower-costs mailings, which do not come through our shop, would replace high-end, heavily decorated mailings. To the credit of the marketing folks driving mailing, the opposite has been true. They obviously recognize that it is better to spend more on the vehicle that realizes a considerably higher response as opposed to getting cheap.”

“Business has to go on; companies have to market,” stated Glenn Schuster, president of DATAGRAPHIC, Commack, New York. “As a specialty printer, we service the advertising and marketing industry, and when people want to grow their business, they need to advertise. Online advertising is only good for certain businesses. It’s not as effective. In my mind, there still is great value in getting something physical in the hands of consumers that they can touch and feel and pass around. We deliver a tangible product in the end.”

While DATAGRAPHIC’s printing solutions pipeline still is not where it was pre-COVID-19, other areas of the business have picked up to help offset the difference. “Like a lot of finishers, we started producing some PPE,” he said. “We’ve been diecutting face shields for some local suppliers and that has been helpful. We’ve done more than 300,000 so far. That’s something that has not only been good for business, but it feels good to us, to our employees and to our customers, to know that we are doing our little bit to contribute.”

Diecrafters and DATAGRAPHIC are not the only companies finding new opportunities and new ways of operating – by serendipity or by force – as a result of the pandemic. “It’s been a bit of two-edged sword, something of a wakeup call. We’ve had to have an attitude adjustment,” said Steven Behrmann, co-owner of Behrmann Printing Company, Inc., Southfield, Michigan. “We have used this forced opportunity to fine-tune our labor force. Out of necessity, we were forced to match our labor hours exactly to the workshop.” According to Behrmann, this resulted in the company’s survival but also much stress as many longstanding and loyal employees had to be laid off.

Despite this setback, the business has been able to continue finding ways to succeed. “Fortunately, as our business has evolved, we have a fairly vibrant brokerage component to our sales mix, which has remained strong from a sales perspective,” said Behrmann. “This also has enabled our company the financial security to weather the difficult finishing market.”

Schuster echoed Behrmann in terms of labor challenges and shifting workforce priorities. “One of the major changes for us since the pandemic started is that our people have had to take on more responsibility,” he remarked. “We have people who are doing what was previously the work of 1.5 or two people. It’s definitely been an adjustment as we learn to do more with fewer resources.”

While many business practices have been forced to evolve or outright discontinue, some things will remain the same. “Our industry has been in transition for a number of years,” said Behrmann. “We have concentrated on having the best quality and customer service, and this has not changed.”

For all three companies, one of the things that has changed significantly – and is predicted to continue going forward – is the trend toward remote workforces. “The change in the office paradigm is here to stay,” said Behrmann. “Offices will be smaller; employees will be working from home to a greater extent with much less person-to-person contact. Fewer products that we produce will be required. This will require adaptability to matching your resources to the available sales opportunities. Companies may look to expand products and services offered, such as packaging, digital and specialty short-run packaging or digital foil and diecutting.”

Schuster agreed the change in office paradigm is likely to remain, along with a shift in employee responsibilities. “A lot of bosses are going to realize they made it through the crisis with only one person performing in a role where maybe three were previously. Maybe those three people were only working at 75% capacity and really they only need one or two people in that particular role. I think that’s going to be a big difference as we go forward,” he said.

Virtual meetings also are likely here to stay – perhaps not in the same volume as during the pandemic, but they’ve proven to be a useful tool. “I’m an old timer who values looking people in the face while shaking hands,” remarked Windler, “but make no mistake, there are ways to develop and utilize e-tools to foster relationships that are just around the corner.” Windler also predicted that robotics and automation will continue to push forward, not just as a result of the pandemic but as a general push toward enhanced production efficiencies.

In the end, there can be little doubt the pandemic has altered the ways companies do business. Some of those alterations will prove to be permanent while others simply will be temporary measures. If there is a silver lining to everything that has, and will continue to, happen, it is that many companies and industries have faced their toughest challenges and emerged on the other side.

As Schuster noted, “This was a good lesson for how to manage your business and to realize that anything can happen.”

Duplo USA’s DDC-810 Raised Spot UV Coater

March 12, 2021

By Lara Copeland, writer, PostPress

With intentions to fill a void in the market, Duplo USA Corporation, a Santa Ana, California, provider of innovative print finishing solutions to the graphic arts industry, introduced its DDC-810 Raised Spot UV Coater back in 2017.

“The available technologies at the time were expensive,” said Duplo Product Manager Anthony Gandara, “and many printers and brand owners liked what these technologies could do but could not afford to invest in them.” He said they also did not know how to justify purchasing the technology since they did not have any immediate need or demand for this type of embellishment work. “But they could see the benefit and value that this type of technology could provide,” he added.

Printers searching for quick, easy and affordable technology to enhance the value of their printed products will find value in the DDC-810. Using Duplo’s technology allows printers to turn their, “plain CMYK prints into an experience that their customers can actually touch and feel,” said Gandara. Printers have used this added value to differentiate themselves from competition, and he said they have been able to sell their printed products for much higher premiums, which in turn, has helped them to generate profit on jobs that they normally would not.

Offering superior accuracy and producing high-quality raised spot UV embellishments, the DDC-810 is easy to use – only requiring the printed sheets with registration marks, a PDF of the spot layer and an operator. “The DDC-810 is the ideal solution for customers who want to increase the value and profit of their printed products,” Gandara said.

Together, the DDC-810 and the EFI Jobflow simplify and streamline the file preparation and submission to the printer and DDC-810. “With just one click of the mouse,” Gandara explained, “Jobflow will impose the job, apply the registration marks for the DDC-810 and add barcode or QR codes for the DDC-810 and Duplo slitter/cutter/creaser to enable automatic job set-up of variable image and job processing.”

Gandara said that the response to the technology has been great. In the last two years, Duplo USA has hosted the Shima Awards, a contest that recognizes a Duplo customer for its creativity and uses of embellishment. “We have seen so many great examples of applications and jobs that our customers have produced; their creativity is simply amazing,” he added.

According to Gandara, “The DDC-810 is compact and extremely easy to use; plus, it can be installed and begin running jobs in one day.”

Technical details

The DDC-810 is a completely digital process, only requiring the printed sheets and a PDF or TIF of the spot layer. The printed sheets are loaded into the feeder. The maximum loading capacity is 5.9″ and the maximum sheet size is 14.33 x 29.13″. It supports a wide range of coated papers, substrates, laminates, toner and offset printed output.

As the sheets are fed, they are side registered and pass through the dust roller to remove any dust from the surface of the paper or substrate. Two CCD cameras read the registration marks that are printed on the sheets. The 600 x 600 dpi inkjet heads precisely and accurately apply the spot UV layer onto the printed sheets. Up to seven different thicknesses can be applied in a single pass. The polymer is instantly cured as the sheets pass under the UV lamp.

Understanding the How and Why for Quality Creasing Outcomes

March 12, 2021

By Joe McDowell, vice president, Channel Creasing Matrix/CCM Die Supply

fibrous-material — Fibrous material generally is used in the folding carton and printing industry. These materials generally are diecut using flat steel-rule dies on either a platen-style press or cylinder-style type.

It is important in most everything to understand both the how and why to solve issues and teach people the best solutions. As it relates to creating a quality crease during diecutting, a better understanding of how and why a crease forms in various substrates can lead to better outcomes. Although the results will vary based on specific conditions and situations, most people can achieve the same result if they simply follow the proven formulas and communicate.

With the many changes in substrates on the market today, there still are three basic ways to crease materials during the diecutting process – matrix, phenolic counter or steel counter plate. Which of these is the best way to crease the product? The answer could be all of them, depending on the substrate qualities and characteristics. To be clear, this article only is addressing flat diecutting. Rotary diecutting is something completely different. To simplify, it may be helpful to categorize the substrates into three categories.

Fibrous material – This would encompass any material made up of paper fibers that are compressed together to form a sheeted material. These generally are known by some of the following names: SBS, CCNB, chip, Kraft back, recycled board, etc. These are the materials seen every day in cartons, folders, mailings, etc.
Fluted materials – Generally known as corrugated or cardboard. This material usually is a Kraft material either found in brown box form or, more and more, in shelf-ready display or POP display. Many times, these fluted materials can be found either printed directly on or laminated with a label or fiber board material. This can cause many problems depending on the material laminated.
Plastic cartons – People are looking at this style of carton for a variety of reasons, one of them being the visualization of the contents, readily seen with the simplicity of the print. Another positive about this type of product is the virtual lack of moisture degradation that occurs if it gets wet. Creasing of this type of material normally is not done with a counter material. It can be, but normally it is done with a form of slitting or by perforating the plastic.

There are many determining factors when trying to crease fiber board. The following are a few considerations:

The design of the finished product. Finding the proximity of the creases to each other and the cutting rule can lead to variations in the die manufacture and counter used.
The substrate to be used. Various substrates have different characteristics, and they all will have unique attributes that need to be handled accordingly.
The type of press to be used. Is it a platen style or a cylinder press? Many people ask if it really makes a difference. The answer is: Absolutely. There are many ways to get around the differences, but they all entail a little work, and, if not done correctly, can cause more problems on press that may not seem to be, but can be, related to creasing.
The length of the run of the product. Some counter materials are made for short runs of 15,000 or less, while others can run hundreds of thousands of impressions.

If these items are not discussed in more than a passing conversation, it is guaranteed there will be a problem during the diecutting process. Sometimes that problem is taken as status quo. For example, a long makeready may seem like standard practice; however, it doesn’t have to be.

In many cases, the problem lies in the communication, or lack thereof, between the diemaker and the diecutter. If a diecutter would tell the diemaker about the problems that are occurring, the diemaker may make some suggestions or changes. On the other side of that coin, the diemaker needs to ask some of these questions to make sure the best tooling possible is being made.

Understanding folds

To understand why fiberous material folds the way it does, it is important to look at the makeup of the material.

With a common SBS board, the fibers are bonded together and run in the same direction. Thus, the material can be creased with grain (creasing in the same direction as the grain) or cross grain (where the crease runs perpendicular to the grain direction). The proper way to get a good crease is to break or delaminate these fibers while stretching the upper and lower liners of the material. How fibrous paper reacts under pressure and what causes the material to delaminate has been studied – not only the vertical pressure of the crease rule but the lateral pressure as well. This lateral pressure comes from the material being forced into a narrow channel. In the old days, the formula used to be 2 x the paper thickness + the crease rule width. This formula would put a line in a piece of paper, allowing it to fold. The problem came as the quality of print increased, different types of printing became available and the drying of the materials evolved. Many of the drying techniques have changed for inks today, and the quality of the material has changed with much of it being recycled. The newer methods of drying have added challenges in the diecutting/creasing processes.

Originally, the creasing rule was 2 x the paper thickness. However, using this formula and trying to fold or bend the paper over without changing the dynamics of the paper (displacing materials) will stretch the face or front liner over a greater surface area, which is created by the mass of material meeting at the crease area. When this happens, there will be cracking all through the crease. The formula used today is 1.75 x material thickness + crease rule width. This formula is based on the principle that proper creasing is created by delaminating the fibers.

This is achieved when the channel that the paper is forced into is narrower than the original formula. This causes the material to pinch at the top of the channel, stretching the upper and lower liners slightly and breaking the bond between the fibers. Now when the item is folded, the lower liner and the fibers that were delaminated move out of the way, and the top liner stretches around a smaller surface area.

As the fibers move out of the way, the face or top liner can wrap around the material without cracking. This is how a crease in fiber material should work, and most times it does. However, there are times when the coating was dried at a greater temperature so it would dry faster, and this causes a dry stock or dry print. This, in turn, may look as if the board is cracking when in fact it is the ink.

Grain direction

fiber-holes-clusters — When creasing with the grain, fibers have a tendency to cluster.

Which way is best to run the crease? Across grain will give a more stable crease than with grain. The reason for this can be found when looking at the way in which the delamination occurs. The material will delaminate in long lines when creasing across grain. However, when creasing in grain direction, a different type of delamination occurs. Imagine the fibers as a bunch of straws in a glass. Now put something in that glass, and the straws will separate but remain in clusters. This is what happens when creasing in grain direction. The fibers have a tendency to cluster.

The delamination is a series of holes or pockets. If these pockets or clusters move too close in the same direction, there may be some cracking, even if the channel width is the same in both directions (with and cross grain). To eliminate this, narrow the channel to the matrix that is the next size down. This will break the clusters down even more. This allows the material to move evenly when folded and not to cluster in the same place.

Another common issue is how to make the crease wider. This can be done by plugging the thickness of the crease rule into the formula. However, this should be done with caution. Although it will provide a quality crease (as far as delaminating), it also will deliver a ropey, wide crease that will not fold squarely. One side or the other of the crease will become dominant, and this dominance will switch from side to side, not remaining constant. A good rule to follow is that the channel width used should be no greater than between three to four times the thickness of the material being diecut. There have been times where 4 ½ is acceptable, but the general rule is three to four times.

Crease rule height

Channel width is very imperative for correct delamination; however, it is not the only factor in obtaining the proper crease. The height of the crease rule also must be considered. The height is calculated by using the following formula: (cutting rule – material being diecut) – (membrane thickness).

The membrane is the material used to hold the matrix together and is present in between the channels. If the material is metal, it is approximately .010″ thick. If it is Mylar or plastic, it usually is .005″ thick. Some believe there is no need to reduce the height of the membrane, but this is not true.

The industry has acceptable tolerances for the materials that go into the diecutting process. Cutting rule and crease rule is +/- .001″. This is potentially a .002″ difference. The cutting plate is +/- .002″, which is potentially another .004″ difference from end to end. In essence, there could be a .003″ difference between the rule and the plate when adding the tolerances together in any given area. Over the length of the plate there can be a difference of .006″. Now the argument will be made to makeready the low areas. This is true but only for the cutting rules.

Back to the formula for the height of the crease rule: Take into consideration the tolerances mentioned in the previous paragraph. If the membrane is not taken out when figuring the crease rule height, it can bottom out on the crease leaving what is called standoff in the cut areas near a crease. The membrane still is in the channel, so the crease rule would push the paper in the thickness of the material, and the membrane, still being intact, would then act as a barrier from the cutting rule making a full cycle. In this case, the diecutter might believe the die is not right, the cutting rule is bad or that it is necessary to stop the press and do makeready. Worse yet, the diecutter adds pressure and forces the cut while the crease cracks. All of these could be avoided if the formula had been followed.

When using a phenolic counter, it is important to know how much material is left in the membrane of the channel. The difference can create challenges with the crease and the cut, as well as cause the problem of standoff.

Many diemakers today have settled at .006″. If the membrane is not taken into consideration, a few different problems can occur. First, the cut doesn’t go all the way through and the product doesn’t strip at all. Second, the product cuts but only in certain areas and ends up with a checking problem (where the bottom ink seems to strip off in pieces). Nicks can become stronger, making blanking or stripping a tougher task and a major makeready delay. And, of course, the crease will be cracked either on the surface or under the ink and can surface on the folder-gluer, if not on delivery.

Common types of cracks

There are several types of cracks normally seen when trying to crease certain papers. Some of the results and causes are discussed in the following:

Cracking on the sides of the crease (usually noticed on delivery before folding). This usually is caused because the channel is too narrow.
Cracking on the bottom of the crease (usually noticed on delivery before folding). This is the result of the crease rule being too high.
Cracking on the folder-gluer, where the crease looks nice on delivery but cracks when folded. Proper delamination has not occurred and too much material is in the way of the top liner. This generally is caused by a crease rule that is too low.

These problems can be avoided by following the formulas and with proper communication between the diemaker and diecutter. There are many other problems that occur because people do not follow formulas nor take into account the collateral damage that can happen when focused on only the problem at hand. When it comes to creasing, some subtle changes can make major impacts on profitability in the diecutting job.

Joe McDowell is vice president of Channel Creasing Matrix/CCM Die Supply. He has been in the converting industry for 30 years and has been studying the effects of creasing on paper and corrugated for the last 25 years. CCM is part of the C&T group of matrix companies. For more information, visit www.ccmdie.com.

Holograms Shine in the Battle to Protect Against ID Fraud

March 12, 2021

Dr Paul Dunn, chairman, International Hologram Manufacturers Association (IHMA)

Fraudulent passports, driver’s licenses and fake documents cost governments, issuing agencies and other global organizations billions of dollars a year in lost revenue. Corporate reputations also may suffer, and investments stifled, as funds are diverted to cover losses, while the cost of paying for anti-counterfeiting measures to bring criminals to justice can run into hundreds of millions of dollars.

But in the fight against counterfeiting and fraud, holography – propelled by advances in materials and applications – is valued, particularly in securing data and thwarting criminal interference, tampering, alteration, forgery or imitation. New technology, innovation and advanced processes ensure protection against the forgery of variable information, most notably photographs and personal data.

Overt technology such as holograms offer a means of protection and authentication and a warning about the dangers of counterfeiting. Indeed, in the wake of the COVID-19 pandemic, the threat has increased significantly and countries around the world are looking at ways to tackle the problem and better secure documents. In South Africa, for instance, the government currently is considering adopting biometric technology to stem the rising tide of identity fraud, which recently caused losses in excess of one billion rand – more than $61 million US (www.biometricupdate.com).

A new generation of high security now is being seen with highly innovative holograms becoming available, raising levels of ID document security and protection and providing the latest tools to help law enforcement keep up with criminals. The new Photonics HoloSystem is an example of how the technology is being developed to make forged documents easier to spot. The developers behind the project believe it will allow for the numbering and personalization of individual holograms, even where they are rapidly created, stopping criminals from being able to overcome them for years to come.

Growth

The continued growth in the use of holography as a security device points to the technology’s deep underlying versatility, cost effectiveness and graphical flexibility. Indeed, holography will continue to flourish in those markets where a premium overt security feature is required. For example, with a passport, the top target for counterfeiters is the biodata. Sector manufacturers such as De Le Rue are working with state and commercial security printers and providers to protect this information using secure ID components, which include the addition of holographic laminates to help protect against the risk of alterations to the genuine holder’s details.

Governments and other issuers of ID cards, passports and driver’s licenses must protect an increasing array of documents from wide-ranging attacks by implementing more security technologies. Increasingly, governments are turning to polycarbonate as their material of choice to deliver the most secure, durable and climate-resistant identity cards.

Holography is meeting these needs as demonstrated by OpSec Security’s recent launch of Fuse, a high-performance hologram applied in register, and by IQ Structures, another manufacturer of holograms, bringing forward a polycarbonate film solution with edge-to-edge holographic patterns.

These innovations can help to robustly combat the most frequent counterfeiting attacks. They also protect documents from so called ‘chain attacks’ – criminals who counterfeit a weaker document, such as a driver´s license, before going on to attempt to forge a passport later.

An advanced, holographic, thin-film laminate from Demax Holograms offers bespoke construction for enhanced security and design to protect paper passport data pages against alteration, replication and simulation, including laminate removal and reuse. Custom-shaped characters can be produced anywhere within the laminate, allowing the opportunity for their integration with printed features.

Fully tested for chemical and mechanical resistance, the laminate provides superior adhesion to the substrate and will disintegrate under any form of attack, making its reuse impossible. With the added benefit of custom-shaped edges, the fraudulent use of a second laminate on top will become immediately obvious. The technology, which offers an array of naked-eye features that go beyond conventional diffractive optical variable devices, also provides high counterfeit resilience as the effects cannot be reproduced or imitated using alternative techniques.

Holograms also are playing their part in the fight against fake academic documents as fraud of education certificates and diplomas becomes ever more sophisticated – and on the rise – affecting students, employers and universities. According to a UK National Qualification Agency survey, only one in four university admission staff feel confident spotting fake documents.

So most academic institutions will produce certificates and diplomas that combine security print techniques with physical devices, most often a hologram. Physical anti-counterfeiting features can reduce the risk of tampering and interference while digital solutions help in intelligence and identifying conspirators working within the system. They also can facilitate fast and convenient authentication. While nothing is immune from the threat of counterfeiting, colleges and universities are fast becoming aware that holograms and other anti-counterfeiting technologies can make illegal copying or reproduction difficult and provide a means to verify legitimate credentials.

Important part

While holography faces challenges as ID technology and associated criminal behavior continue to evolve, the evidence shows that its ability to find new applications ensures that it remains a potent anti-counterfeiting measure. Holograms will continue to play an important part in moving overt protection to the next stage of development, ensuring quality and checking the trade in ID counterfeiting while those documents not displaying security holograms are seized and destroyed.

Moreover, the use of well-designed and properly deployed authentication solutions, as advocated by the ISO 12931 standard, enables those with ID protection responsibilities to verify the authenticity of a legitimate product, differentiating it from counterfeits. Even those that carry a fake authentication feature can be distinguished from the genuine item if that item carries a carefully thought out authentication solution. The advantages holography offers will continue even as digital and mobile ID technologies gain traction.

The International Hologram Manufacturers Association (IHMA) is made up of almost 100 of the world’s leading hologram companies. Members include the leading producers and converters of holograms for banknote security, anti-counterfeiting, brand protection, packaging, graphics and other commercial applications around the world and actively cooperate to maintain the highest professional, security and quality standards. For more information, visit www.ihma.org.

Art and Paperboard – Metsä Board Showcases Specialty Techniques

March 12, 2021

By Brittany Willes, editor, PostPress

“There is an increased need for printed educational materials,” remarked Marko Leiviskä, graphic packaging designer for Metsä Board, Espoo, Finland. “The younger generation of designers is focusing more on electronic media formats. Printing and converting is a world of its own where designers can have a greater role in creating something with a ‘wow’ factor vs. just ‘Okay.’ But an understanding of how the process and equipment work to create outstanding visuals is needed. The printer and converter should be seen not simply as the place to print everything but rather as an important part of the creation chain.”

With that in mind, Metsä Board set out to create a promotional brochure that would showcase various specialty techniques, specifically hot foil stamping and embossing, demonstrating how printed pieces can be made to stand out. “The brochure serves as a tool for storytelling,” said Leiviskä. “Stories and pictures are easier to recall than technical specifications or details and can be used as a guideline for creating. That’s why we wrapped everything into one brochure.”

A particular story told by the brochure is how metallic effects can be utilized and enhanced to create a stunning piece. “Our perspective pays homage to the surface characteristics of metal,” Leiviskä continued. “There are techniques that can be used to enhance the metallic appearance – from cheaper to more expensive. We wanted to highlight and compare these.”

To do so, Leiviskä opted to have the brochure printed on Metsä Board Prime FBB Bright 355 g/m² I 23.6 PT. “Because we used hot foil stamping on both sides, heavy grammage was chosen,” he explained. Thickness also played an important role. If the material was too thin, tooling marks easily would be seen from the other side of the sheet when the hot foil was applied with great pressure and temperature.

According to Leiviskä, the sense of touch also was an important consideration when selecting the paperboard. The reverse side forms the outside of the brochure; the side that the consumer touches. That’s why Leiviskä wanted to highlight the printing results and capabilities on that side. The front cover actually is the reverse side of the board and the opened spread is the coated side.

Because touch would be such an important element of the final piece, Leiviskä specifically chose not to use silver PE/PET laminated board to reduce the use of plastics and to reveal as much paperboard as possible. “Laminated surfaces would impact the touch and feel given that the consumer would be handling the plastic surface instead of paperboard,” he said.

The 3-fold design illustrates a variety of foil stamping and embossing choices, including the cover that was first foil stamped with a silver metallic and then overprinted CMYK. Demonstrations of overprinting foil, foil on top of printing, embossing, foil embossing and micro embossing were all present in the piece. “We even foiled on the reverse side, which is not usually done, to show that it is possible,” said Leiviskä. “We added microembossing of the foil to highlight what can be achieved with foils above and beyond applying them on top of the printing.”

For replicating the metallic output, “We showcased several options benefitting from the fact that offset colors are transparent, which allowed for the possibility of using overprinting with each process color,” he continued.

When it came to printing on the foil, common litho-offset was used instead of UV offset. “This works when special overprintable foil is used,” said Leiviskä. Using the hot foil stamping instead of PE or PET lamination when creating the metallic effect left paperboard surfaces visible on areas where the metallic did not appear and without the plastic lamination. Furthermore, water-based varnishes were used to keep everything as environmental friendly as possible.

Overall, the final product went through machinery approximately 26 times, with the final brochure boasting matte and glossy water-based varnishing with five different types of foil and embossing techniques. While the graphics and layout were done by Leiviskä, all specialty treatments, such as the foiling and embossing, were done by specialty finisher Starcke Oy in Eura, Finland. The brochure then was printed using 6-color printing (CMYK plus two Pantones) by Grano, Helsinki, Finland. The brochure was finalized in English before being translated into six additional languages. Luckily, all the special treatments were designed so that only the printing plates needed to be replaced, streamlining the production process and making it more efficient.

With so many elements at play, it is no surprise the brochure presented some challenges during the production process. “When you push everything to its limit and beyond trying to achieve perfection, you also face challenges,” Leiviskä confirmed. “For this project, we experimented with several foils before we started the printing process to find the right combination – printable foil that also adhered the best on the paperboard’s less-coated side.” While doing test runs, Leiviskä found that it helped to use water-based varnish on the reverse side, then apply the hot foil on top of the varnish and then print on top of the foil to get the best results.

“The foil sticks on the reverse side without the varnish,” he said, “but when you print on top of it, it may cause some challenges.” According to Leiviskä, this is a good example of the importance of knowledge of printing and converting with regard to the designer. “Understanding, pre-working and study of machinery and techniques in general help to overcome the challenges and master the cost effects,” he stated. “We are glad to have professionals like Grano and Starcke to help create such a demanding project.”

It is impossible to successfully complete a project like this alone. “This type of project, with this much sophisticated printing and embellishments, must have trusted partners and continued communication,” stated Markus Jensen-Eriksen, production director of Grano. Minna Tervo of Starcke commented that four different over-printable silver foils were tested and KURZ foils were selected for the project. Tervo, who was in charge of the project at Starcke, said that the machinery used for foiling and embossing were both Bobst and Kluge EHG and EHD foil stamping presses.

The brochure has been a great success for Metsä Board. “Response has been extremely positive,” said Leiviskä. “It has been warmly welcomed as a tool to communicate further on printing and converting-related subjects. The ‘wow’ effect has clearly been achieved.”

Sustainability and Shine: Tendero Collaborates with Gasperini for Luxury Box

March 12, 2021

By Lara Copeland, writer, PostPress

Currently in a period of expansion, Envases Tendero, a specialty packaging company based in Alicante, Spain, recently opened its new logistics center. To commemorate the 2019 event for this family-owned business, the company held a gala and introduced customers to a new machine for manufacturing luxury boxes. Tendero needed special packaging to demonstrate its capabilities, one that would standout and shine; therefore, the Tendero luxury box was created and manufactured as a gift for its guests.

“The Tendero Box fully achieves that goal,” exclaimed Technical and Sales Manager Giulia Gasperini at Gasperini, hot foil and emboss specialists in Prato, Italy. Gasperini collaborated with Tendero on this special project by providing the engravings to create the unique glitter effect to decorate the inside and outside of the box. “Tendero has chosen to rely on Gasperini for the creation of an innovative glitter effect achieved with a hot stamping technique, which makes the finished product entirely recyclable and, therefore, sustainable,” Gasperini commented.

The design and concept of the box were created by Tendero in partnership with Gasperini. First used and made famous by Apple, the rigid box was manufactured with sharp edges. This technical solution is in high demand in the rigid box market. It also meets a popular need increasingly desired by customers – it is made of a single material.

A truly recyclable product – since only paper and paperboard were used in manufacturing it – the box is unique due to the aforementioned glitter effect that was hot stamped with Gasperini’s copper dies. Typically, screen printing is the technique used to achieve a glitter effect. “The Gasperini dies provided the excellent result on the finest details, with incomparable precision and sharpness,” Gasperini stated. Made with 99.7% pure copper, the dies also are eco-sustainable and totally recyclable, a theme seen throughout production at Tendero.

Pulp-dyed papers were used in creating the box. Gruppo Cordenons supplied Black Plike paper for the lining of the box, a “very beautiful, fine paper with soft-touch finish that is perfectly suited for hot stamping,” Gasperini said. The inner box is lined with Metalli Lucidi paper from Icma. Gasperini said this echoes the golden finish of the hot stamping on the lid. A Saroglia FUB/D 56×74 cm machine was used for the hot stamping, and the rigid box manufacturing was done on an Emmeci MC2018. No other printing process was involved. A cooper metallic foil was used to create the glitter effect and wording on the top cover of the box.

Tendero takes corporate social responsibility seriously by focusing on sustainable development goals, objectives created by the UN in 2015 to help protect the planet, among other things. Working in collaboration with Gasperini and its hot stamping technology aided Tendero in honoring its sustainability policy. “As we know, there is always great attention toward eco-sustainability, and this contributes even more to the complete recyclability of the product,” Gasperini noted. The project was reportedly smooth sailing with no particular problems related to creation or manufacturing. “Tendero and Gasperini worked side-by-side and everything went smoothly,” she explained.

With Gasperini’s glitter effect designed by its technical department and the manufacturing at Tendero facilities, the box was deemed a success. This inventive collaboration was recently recognized, winning Gold in the Foil or Embossed Rigid Box category as part of the 2020 FSEA Gold Leaf Awards. Gasperini reported that customers loved the box. “It needed to get attention, and that goal was fully achieved,” she said. With this success, Tendero now is working on projects for 2021.