2021 Feb/March

Perfect Binding Machines – What to Know Before Purchasing

March 12, 2021

PostPress

When it comes to investing in new equipment, it is always crucial to do a lot of research and ask the right questions before purchasing. No matter the industry, no matter the equipment, it is better to be overly diligent rather than risk possible setbacks and loss of product or profit. To that end, PostPress recently sat down with Bob Flinn, director of business development for Standard Finishing Systems, to discuss what operators should know and look for when it comes to purchasing new perfect binding equipment.

What questions should binders ask when selecting a new perfect binder?

Some binders are designed for high-volume production environments while others are better suited to small- and medium-sized shops. Whether the binder has a continuous print engine or a cut-sheet print engine, the type of perfect binder needed will be dependent on several factors, including: the type of work being produced, the number of print engines, the production environment, the speed of the print engine, the turn time for each job, job volume, overall workflow and run lengths.

With this information, operators will have a better idea of whether a single-clamp or a multi-clamp (high-speed) binder is the best fit. For example, in the case of high-volume applications with limited variability, a multi-clamp binder may be the best fit. However, for high-volume short runs or book-of-one production, it may be more efficient to have two single-clamp binders rather than one multi-clamp binder. When evaluating perfect binding solutions, buyers should make sure to discuss their print environment and needs with their sales consultant.

Are there specific features to look for when working with digitally printed materials?

Those working with digitally printed materials should look for perfect binders that have been designed for this new era of digital print and book-of-one production. Older generations of perfect binders do not come equipped with the level of automation needed to keep up in digital print environments.

The rise of digital print production has coincided with the continued increase in demand for personalization and customization in courseware, photobooks, on-demand novels and more. This has shortened run lengths and increased the level of variability from job to job. Without automation, shops can run into massive bottlenecks in the finishing process because of the increased number of changeovers required to produce this type of work.

If already in a digital print production environment or if there are plans to move in that direction, companies should look for perfect binders with automated, on-the-fly set-up via barcodes and/or calipers to meet the increase in book-of-one and short-run book production.

Which paper stocks work best for perfect binding? What stocks are best to avoid?

Choosing the right substrate for perfect binding depends on a number of factors, such as the type of perfect binder purchased, usage and stylistic concerns, as well as simple best practices. For example, there are several perfect binding methods, such as EVA (hot melt) binding, PUR (polyurethane-reactive) binding, notch binding and sewn softcover binding.

If the binder is using EVA binding, it will perform quite well with non-coated stocks, such as bond, vellums, text and book stocks. Coated stocks and printed pages that have printing or coatings running into the gutter will result in a good-looking product, but the binding strength of EVA with these stocks will not meet industry standards.

If the binder is looking to do PUR binding, the range of stocks that will yield good results includes coated papers, heavier weight substrates, photo paper and even some synthetic materials that can be seen in field manuals and medical applications. PUR lends itself to a strong, flexible and lasting bind even with stocks which are “closed” or yield less paper fiber to which the glue can adhere.

Sewn softcover binding is the combination of machine-sewn signatures and hot melt binding. This method will produce a long-lasting binding with coated or non-coated papers. However, it typically does cost more and takes more time to produce than other methods. Additionally, the need for folded signatures means that this method is not well suited for many digitally printed products.

Finally, much like sewn softcover, notch binding uses a special notching process during the signature folding, in combination with EVA binding, to improve the binding strength of a softcover book. This is not a common method in today’s market, but it does produce a stronger bind for EVA adhesive even when using coated stocks.

How can operators cut down on rejects and waste in the binding process?

Today, automation is the key to reducing waste and rejects. The latest generation of perfect binders come equipped with barcode readers and inline integrity solutions that can perform sheet, signature and book-block-level tracking, as well as cover-to-book-block matching.

Depending upon the configuration, these systems can reject incomplete book blocks or book blocks with the pages out of order, catching and removing errors before they become a problem. To go even further, the rejected book then can be identified via barcode and used to generate a reprint file – all without operator intervention.

Or, if there is a situation involving a mismatched cover and book block, automated binders can alert the operator for correction or ejection. Automated inspection systems like this are integral to reducing waste in the perfect binding process.

Some in the industry still are wary of automation. The first generation of automated machines had steep learning curves and raised questions about quality and integrity. Luckily, those days are long gone. Automation today is much more user friendly, more accurate and extremely reliable.

Furthermore, it already is an essential component of every other production process, from order entry to pre-press to printing. At this point, it is essential to have automation in finishing to keep pace. In the case of continuous print, this is of even greater importance. Higher production speeds mean that recovery from an error and/or downtime can be more costly compared to cut-sheet.

PostPress would like to thank Standard Finishing Systems for its assistance with this article. For more details on the company’s perfect binding and other finishing equipment, visit www.standardfinishing.com.

Metallic Decorating and Sustainability

March 12, 2021

By Jeff Peterson, executive director, Foil & Specialty Effects Association

When I have presented at tradeshows and conferences on behalf of the Foil & Specialty Effects Association (FSEA), I’ve told audiences that it wasn’t too many years ago that when a brand owner or printer wanted to include a metallic decoration on printed material, the only real choice was hot foil stamping.

Today, there are many other choices in the marketplace, including cold foil transfer, toner-based digital foiling and polymer-based digital foiling, as well as pre-metallized paper and/or board.

Although many of our FSEA members have had concerns about the emergence of other metallic decorating processes – especially those who have relied on more traditional hot foil stamping – what actually has happened is that the addition of these new processes has helped market and showcase the use of metallic decorating, creating more activity for all the different techniques. In addition, as I will explain in more detail throughout this article, each type of metallic decorating process has advantages and disadvantages, and, in most cases, fits specific applications.

Metallic decorating and sustainability

Before we discuss metallic finishes in detail, I want to address the sustainability issue with metallic decorating processes. There continues to be confusion with brand managers and consumers who want to include all metallic finishes into one category. As our industry is aware, there is a huge difference between transfer metallic foil processes and foil laminated board/paper in terms of recyclability. We must educate brand managers that hot, cold and digital foils are applied through a transfer process and the plastic film carrier is not applied to paper/board. With foil laminated board, the metallic finish is applied to the board along with the plastic film, creating a more difficult product to recycle or repulp.

FSEA recently commissioned a new study entitled “Repulping of Foil Decorated Paper.” The study demonstrated that transfer foil decorated paper or board does not create problems in the recyclability/repulpability of paper or board in a common repulping process. Again, it is important that we educate those who ask about the difference in these processes and promote transfer metallic processes as a sustainable choice when selecting a metallic finish for printed materials. If readers are interested in the new study, contact me for a copy of the report.

It has been suggested – and I am in favor of developing a plan as an industry – to begin using the word “transfer” when selling and discussing the use of transfer foil processes such as hot, cold and digital foil decorating. In other words, FSEA members and others would begin to refer to it as hot transfer foiling or hot transfer metallic, rather than hot foil stamping. Cold foil would be referred to as cold foil transfer, and digital foiling would be digital foil transfer. A strategic plan to begin identifying transfer processes so they are not grouped with foil laminated paper/board can help in the education process to distinguish between the two. FSEA will be providing more details on this and other sustainable solutions in the coming months.

Hot foil stamping (hot transfer metallic)

As discussed earlier, hot foil stamping has been the conventional way to apply foil for decades, and it still is the most popular choice of metallic decorating worldwide. By far it is the most versatile process when applying foil – meaning it has a much broader range of paper stocks it can work on; it encompasses the broadest range of foil colors and adhesives; and it provides the ability to create finished decorated looks that other foil processes cannot, including foil and embossing in one pass and refractive (micro-etched) patterns onto the surface of the foil. It also provides the greatest array of equipment choices in the marketplace to foil stamp different sizes of sheets and substrate choices.

The disadvantage of hot foil is the cost of the tooling – the foil stamping dies (engravings) needed to apply the foil. With both cold and digital foil processes, there are virtually no tooling costs to apply. However, the tooling cost is only relative to the size of the foil job; although, if the run length of a job is small, it can be a significant cost. Hot foil stamping also is a secondary process that happens once a sheet is printed. This can add time to the job and, of course, costs.

Cold foil transfer (cold transfer metallic)

Cold foil transfer for sheet-fed applications is not new by any means, but it has become more popular for many applications due to the advent of better foil products that run faster and keep a metallic sheen when they are applied. Improved adhesives and technology in cold foil transfer machinery also have been a part of growth in recent years.

The main advantage of cold foil transfer is in its elimination of a secondary process. Cold foil can be applied in the first two stations of an offset press, and then the additional stations on the press can apply CMYK over the top of the foil, creating virtually any color under the rainbow. Cold foil also does not have to utilize tooling (dies). It is an excellent choice for projects where significant foil coverage is required. In those instances, cold foil transfer is a great alternative to foil laminated board, where the entire sheet has a metallic finish. In most cases, white opaque ink is needed for certain areas on the sheet (especially with folding carton work), adding an additional station and printing plate needed on the press. In addition, white ink is notorious for being difficult to work with. Cold foil transfer allows the areas that need to be white to be “knocked out” of the foil design, eliminating the need to use white ink.

From a disadvantage standpoint, cold foil transfer does not provide the full versatility of hot foil stamping as it relates to the paper stocks. Although there has been some success recently with cold foil on uncoated stocks, it is most effective on coated papers. Cold foil also is not usually the best choice when foil is required only in specific areas of a design. Because the foil is running through the press at high
speeds, there is less control of the foil. If the design doesn’t call for a large usage of foil, hot foil stamping may be a better choice.

Both hot foil and cold foil transfer processes are better choices for medium- to larger-sized runs, mainly due to the set-up time required with cold foil and the higher tooling costs of hot foil projects. Smaller runs often are better suited for digitally applied foil.

Digital foiling (digital transfer metallic)

Digital foiling processes have caused some confusion in the industry because there are two processes identified as digital foiling – one which uses printed toner as the adhesive for the foil and one that uses an inkjet-applied polymer as the adhesive. FSEA and its Foil Cheat Sheet (which was produced in cooperation with PaperSpecs) has identified the two processes as toner-based digital foiling and polymer-based digital foiling. Let’s take a look at each type.

Toner-based digital foiling

This is a simple two- or three-step process utilizing a rich black toner from a digital printing press (not inkjet) as the adhesive and then using a heated lamination process to adhere the foil to the toner images. This process can be referred to as “sleeking.”

A key advantage of this process is the lack of any tooling or dies needed to create the foil image, making it a great choice for shorter runs or prototypes. Because a digital printer can be used to print out the images that will include foil, every sheet can be personalized or include different information in foil without adding costs. Personalized invitations or gift cards are a great application for toner-based digital foiling. In addition, using a silver metallic foil, the foiled sheet can be sent back through a digital printing press where all types of metallic hues can be created by printing over the top of the foil layer.

The primary disadvantage of toner-based digital foiling is that it is not a feasible option for larger runs of foil. Because it takes multiple steps to create an image, it is best suited for shorter runs and would not be recommended for any type of large-run application. It also is limited to mostly coated stocks or stocks specifically created for digital applications.

Polymer-based digital foiling

There now are specific machines on the market today that can apply a polymer through an inkjet process to a printed piece; then the foil adheres to the areas where the polymer has been applied. Adding a thicker layer of adhesive also allows for the foil to be raised above the paper level, providing an embossed look to the foiled image. Sensors on the digital decorating inkjet press can ensure registration of the print and polymer adhesives. Some systems in the marketplace apply the polymer and foil in one pass and others apply the polymer prior to the foil being laminated in a process similar to toner-based digital foiling.

One advantage of this process – as with toner-based digital foiling – is that dies or plates are not needed to apply the foil; instead, it is done through an inkjet process. As with the toner-based process, personalization is possible using foil where this is not a feasible option for hot or cold foil processes. Another advantage of polymer-based digital foiling is that a clear polymer (coating) can be applied in a separate pass over the foil or in other areas on the printed piece, offering specialty spot coatings and foil in one design to create spectacular looks for all types of printed materials.

The process produces spectacular work, but it is suited for targeted application types. One of the disadvantages of polymer-based digital foiling is that it is best suited for small- to medium-sized runs – it is not set up for a 50,000- to 100,000-sheet run. This type of foil decorating also is not recommended when applying large areas of foil due to how the adhesive is applied (digital inkjet). Because of this limitation, it is not commonly overprinted with 4-color process. And, as with toner-based digital foiling, there are limitations on paper stock – coated stocks or stocks designated for digital printing are best suited.

Foil substrates

There still are many applications, especially in the folding carton arena, where foil laminated or foil transfer paper/board is popular. Foil laminated board often is used for very large runs where the carton or sheet has heavy coverage of a metallic finish.

The obvious advantage of using a foil laminated substrate is the ability to create the needed metallic finish in one pass on an offset press without the use of a retrofitted cold foil unit or foil stamping the sheet in a separate process. This can provide cost savings for very large runs where the metallic finish is used throughout the design of a carton or label.

However, there are several drawbacks to using a foil laminated substrate. First, the cost of the material can become quite expensive. It can be more cost efficient to add cold foil inline on standard SBS stock for heavy coverage or to foil stamp in a second pass when the metallic finish is to be added in specific areas only, especially in medium to large runs.

In addition, when using a foil substrate, there usually are areas that need to have a white background, especially on cartons and labels. In those cases, white opaque ink must be applied, which means a separate station on the printing press must be used to apply it. As mentioned previously, white opaque ink is not easy to work with and can cause many challenges on press.

FoilCheatSheet_cover — The FSEA Foil Cheat Sheet identifies the two digital foiling processes – toner-based and polymer-based.

Last, but certainly not least, is the sustainability issue with foil laminated substrates that was raised earlier. The Foil & Specialty Effects Association has invested in two separate studies and will be conducting more in the future to demonstrate and reinforce that transfer foil decorated paper and board do not create problems in the recycling/repulping of paper and/or board in a common repulping process. This includes transfer hot foil, cold foil and digital foil processes. This does not include foil laminated products, since plastic film is included with the metallic finish. This is a key difference between the processes and must be considered when determining which metallic decorating process should be used in the production of a metallic finish.

Selecting a metallic finish for printed materials is an entirely different adventure than it was several years ago, with many factors to consider. It is important to look at all factors involved to choose the right process for the right application. FSEA is available for consultation when there are questions. It’s a jungle out there!

Jeff Peterson, FSEA executive director, has been involved in the foil industry for more than 30 years. He has written numerous articles for FSEA’s official magazine, PostPress, and other industry-related publications. He also has conducted seminars at print industry events, including GRAPH EXPO, PRINTING United and Odyssey Expo.

Much of the information found in this article is summarized and illustrated with foil decorated examples in FSEA’s Foil Cheat Sheet. This half-sized guide is available through FSEA by visiting www.fsea.com.

Industry Influencer: Sue Lund

March 12, 2021

PostPress

Custom print finisher The Occasions Group specializes in greeting cards, napkins and envelopes. Vice President of Business Development Sue Lund has been with the company for more than 30 years. After graduating college, she began working with Taylor Corporation, the parent company of The Occasions Group. She has held a variety of positions since then, including sales manager, account executive and director of product development.

Lund recently got together with PostPress to discuss her time in the industry, challenges The Occasions Group has encountered as a result of the pandemic and what opportunities she sees for the industry in the next few years.

How did you get your start in the greeting card/invitation industry?

I managed a high-end retail store. One of my customers was a leader at Taylor Corporation and encouraged me to interview for a sales manager position. Three interviews later and I was hooked.

I have spent my 33-year career with Taylor working in sales, product development, marketing and now business development. It is a wonderful industry, and I have met lifelong friends in our partners, our suppliers and our competitors. We focus on life’s celebrations. I can’t imagine doing anything else.

What changes have you seen in the industry over the last several years?

From our perspective, the following are several key changes that have impacted the industry:

E-commerce – Consumers are doing their shopping online. We are the print partner for brands in the holiday card and wedding markets, and all their orders are placed on their own e-commerce sites and with large online retailers like Amazon.
Personalization – Consumers want unique cards and invitations. We are seeing incredible growth in this space.
More designs and shorter runs – Consumers want choices. Our partners are looking for solutions that enable them to have smaller print runs. This allows them to test designs, offer more designs and eliminate obsolescence.
FOIL! – Consumers love foil. Foil cards and invitations are growing double digits each year for the last seven years.

What challenges has The Occasions Group encountered because of the pandemic? How have you shifted to meet those challenges?

The Occasions Group offers print fulfillment to industry leaders in the life event and social stationery space. This includes weddings, graduations, baby, holiday and other life celebrations. The pandemic put a stop to traditional in-person gatherings, so our invitation and announcement business took a sharp turn almost immediately.

We quickly pivoted to focus on expanding our greeting cards sold online, and we’ve seen incredible growth in that segment. We also developed giftable products that took off, and we expanded our yard sign and banner programs. Parents and schools honored their kids with graduation yard signs. They were everywhere. We expect the same this year.

Our consumer holiday card segment also was incredible this year. It was more important than ever to connect with friends and family that folks hadn’t seen all year.

How do you believe the pandemic will continue to challenge the industry?

We are hopeful. We are expecting a strong year with growth beginning in March. We have refocused our attention to products consumers are seeking.

Of course, until we feel safe and are comfortable in larger gatherings, it will impact our invitation business, but I believe we will be back on our feet by year end. In many ways, the pandemic has helped our business by getting us outside of what we usually do and expanding into other product categories inspired by consumer trends that are likely to be around for a while.

How has the growing emphasis on sustainability affected areas like greeting cards, invitations and envelopes?

We partner with a few companies whose brand promises are to be environmentally conscious. Our manufacturing and custom print facilities are FSC-certified, which is how we are able to partner with these brands.

We have seen the most success with the sustainability message when it is marketed to consumers who seek that out. It’s more impactful when it is a brand-identity message or believable marketing content and not just a paper choice of PCW recycled paper.

I think the US is behind other parts of the world on sustainability, but it is a trend that will continue to grow, particularly in packaging. We do have partners that choose non-acetate options in single greeting cards and boxed cards, and we’re happy to give the option.

What are your predictions for the industry in the next five years?

We will continue to see growth in the greeting card market. Consumers want choices and convenience. Custom cards will see significant growth. Online shopping will continue to grow, but smaller boutiques will see growth as well.

We all need to be nimble enough to adjust as consumer behavior changes. We all had concerns when e-cards were launched. We found they really did not impact us as negatively as we thought. Customers like to touch and feel their cards and experience receiving a handwritten card or note in their mailbox. That will not go away.

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