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    PostPress

    Print Decorating, Binding and Finishing

    Foil Stamping

    Elevating Magazine Covers with Embellishments

    by Katy Ibsen, managing editor
    PostPress

    First impressions mean a lot, especially for print magazines and catalogs. A cover image carries significant responsibility, capturing enough of a reader’s attention to be picked up. Iconic artwork isn’t going away, but many publications now are incorporating texture and specialty effects on covers for added impact.

    “Neurological studies show that humans gather their information through all senses, and people remember things longer and more clearly if they address more than just the eyes,” said novum Editor-in-Chief Christine Moosmann. “Consumers quite happily spend more money on packaging that is well designed and uses a paper with interesting haptics or elaborate printing.”

    novum is known for eye-catching covers that feature a variety of applications, but the magazine isn’t alone. Overwhelmingly, consumer, business to business (B2B) and catalog publishers are seeing embellishments as a critical value-add to differentiate themselves from competitors or to elevate their brand.

    PostPress explores this trend by visiting with a few magazine publishers that have found print embellishments beneficial to their brand awareness.

    Worth magazine

    WorthWorth is a global media brand connecting to an audience that embraces worth beyond wealth. “Worth informs and inspires a community of affluent, influential and aspirational individuals to be their best selves,” said Amy Petriello, art director.

    The quarterly print magazine regularly uses spot gloss for its masthead/logo and dull UV on the balance of the cover to create a matte effect.

    “We almost always feature an original illustration on the cover and have [art] submitted to us as vectors, so that the illustration can have spot UV applied on portions we’d like to highlight,” she added.

    Worth’s “Power 100” edition, recently released, features a 4-color silver metallic ink with gloss UV coating.

    “This is our 10th Annual Power 100 issue, about the most powerful people in the world of global finance, so it is a special issue that we wanted to celebrate,” she said.

    According to Petriello, postpress applications have helped to emphasize Worth’s covers, which showcase beautiful lasting artwork, intended to be kept, displayed on coffee tables and collected.

    novum – world of graphic design

    novum Magazinenovum, a cult design magazine, was founded in 1924 under the name of Gebrauchsgraphik. Published in German, English, French and Spanish, novum is read by designers all over the world.

    “Now in its 95th year, novum has certainly written design history and still has a very high standing in the design community,” said Christine Moosmann, editor-in-chief.

    As one would expect, a design magazine strives to set itself apart and novum doesn’t disappoint readers with its captivating covers, featuring many variations of specialty applications. In 2000, the brand began experimenting with fine papers and various print finishing techniques on the cover.

    “In the beginning, we just did it for fun, but we got a strong response from our readers. They loved the papers, the finishings and the inspiration they got this way,” said Moosmann “Eventually, paper manufacturers and printers realized that our covers were a great marketing tool for their products and services. So, whenever a new paper or a new printing technique came up, we got the chance to try it out on our cover – designer’s heaven!”

    While Moosmann believes specialty effects are an important element of communication today, they can be overused.

    “It is important to use papers and finishings intelligently,” she said. “A lot of ‘bling bling’ foils do not necessarily make a successful product. Sometimes, a rough paper combined with an unusual printing technique will do the trick. It is important to design with care; readers and consumers can sense that.”   

    A sampling of novum covers include foil on the entire cover, diecut stacking dolls and even a cover which featured a playground for stickers found inside the magazine. The cover of the August 2019 edition showcased a highly pigmented silver on deep black cardboard for a visual and textured effect.

    mg

    mg MagazineServing the cannabis industry is mg magazine, a B2B publication covering retail, business and branding. According to its publisher, Darren B. Roberts, the magazine’s mission was to create a reflection of who is really behind the industry, not just on a manufacturing level, but on a legal level.

    “We strive to put out an image that represents the level of professionalism, skill and education [in cannabis],” he said. That mission allowed the magazine to be more creative.

    “Most B2B publications are not spending money and exploring what can be done in print – some industries don’t require it,” he said. “I think that for B2B, service companies or products, whether they be printed products, panels or whatever it is they are putting out there, it’s important that they reflect the personality and the people of the industry. And in this particular industry, you have a mix of professionalism and creativity.”

    mg has achieved respect within the cannabis marketplace, elevating itself as a creative, yet trustworthy resource for industry leaders. In part, it has reached that designation as a result of its attractive covers.

    An edition that covered the vape sector featured a multi-layer emboss with both high and dull varnishes. The “50 Best Companies to Work for in Cannabis” featured a matte varnish, gold foil and trapped emboss. Roberts explained that mg wanted to represent all the various sectors of the industry on the cover, which was designed by The Hybrid Creative.

    “Applications really do have an impact. And it does matter,” said Roberts. “Just the coating that you use on the cover will keep somebody reading the publication longer … and it’s all on a subconscious level. It’s very fascinating.”

    Sustainability with Ecofoil®

    Crystal Ecofoil
    Crystal’s Ecofoil process allows foil to be added to the inside pages of magazines or brochures at a feasible cost.

    Mark Kempster, Managing Director of Crystal Press Ltd, has seen brands and publishers wanting more and more foil embellishments, with multiple colors and more complex foil designs. To achieve this, many have used a metallized polyester (MetPol) material and printed over the top. However, sustainability has become an serious issue for MetPol users due to it being a PET laminated stock which cannot be recycled. As a solution to this issue Crystal recently launched its range of Ecofoil boards that apply the foil without the need for the lamination process. The Ecofoil board range contains no PET or any other plastic product so it is 100% recyclable and can be branded as such.

    “In my opinion the use of MetPol is one of the single biggest issues facing the packaging industry and it seems likely that it is only a matter of time before there is a huge backlash against packaging materials that contain MetPol. However with the introduction of Ecofoil there will still be a cost-effective and practical way to produce foil-based packaging in all run lengths,” stated Kempster.

    The Ecofoil process also provides an economical way to add a metallic foil to other pages within a catalog or magazine beyond just the cover. Crystal has one customer who has used hot foil stamping on its covers for several years; however, switching to its Ecofoil process has allowed them to add foil within the inside pages of their high-end brochure at a feasible cost.

    “Ecofoil has created a massive change in our business,” concluded Kempster. “I believe it will become the biggest part of our business within the next 12 – 18 months.”

    From the Printer With Love

    Direct SupplyPrinters are equally in tune with the emerging trend of distinguishing covers. Chris Haag, director of sales at Royle Printing, spoke to the printer’s role in helping deploy embellishments to create unique catalog covers – which must stand out among other printed matter.

    “We have actually seen an uptick in interest in applying creative covers in particular to printed materials, whether that’d be in catalog form or magazine form,” he said. “Both of those segments are exploring it, and there has been a recognition that print provides a much more tactile delivery of information than electronic means.”

    Royle’s capabilities include gloss and matte UV in line on the web press; gloss, dull or satin varnish on sheet-fed press; soft touch, UV or aqueous coatings in line; strike through (such as spot gloss UV) with a dull varnish; and reticulated strike through UV.

    According to Haag, cost of applications is a factor for many publishers, suggesting that embellishments often are used for annual, anniversary or special issues.

    Diesel Forward“You’re going to see those [applications] in a higher value catalog that is displaying products that are higher dollar volume, and in particular those catalogs are meant to have a one-year shelf life. So, we see them a lot in those applications,” he said.

    Examples of catalogs printed by Royle include Direct Supply and Diesel Forward.

    In general, Haag has seen an increase in applications over what was used 10 years ago. As for the next 10? Hopefully, more of the same.

    “People are recognizing that print is really mission critical to a multichannel approach. And so, even brands that might live and start online are coming into print. And then, once they get into print, they’re looking for ways to stand out in the mailbox and raise response rates, too.”

    Brausse Group’s 1050SFi Foil Stamper and Diecutter

    by Lara Copeland, contributing editor
    PostPress

    Brausse Group, a member of the Bobst Group since 2012 and headquartered in Vancouver, Canada, provides machinery that now incorporates proven group technology, delivering an excellent product at an affordable price. With over 30 years of experience in design and manufacturing of its diecutting and folder-gluer machines, the company’s Brausse 1050SFi foil stamper and diecutter comes with a number of high-end features.

    “With Brausse being a member of Bobst Group, proven group technology and existing technology in electronics engineering and functionality can be seen throughout the press,” said Matthew Sharp director of sales and marketing at Brausse Group North America. The foil stamping and diecutting controls are easy to use on the computer’s touchscreen, and “with our Advanced Foil Control System (AFCS), which provides reliable and precise foil-advancing controls, the operators can make any adjustments during operation,” he added. The press includes a pneumatic, push-button die chase locking mechanism to ensure safe and operator-friendly die changing, which eliminates the use of a wrench to remove the chase. A slanted feed table allows for stable and accurate registration, especially for lightweight paper at high speeds. The sheet stretching air blower included in the delivery section lets the operator add air as needed to help the sheets to lay flat. “This helps during fast speeds,” Sharp commented.

    The 1050SFi assists operators in reducing downtime during runs. “This piece of equipment allows the operator to make a number of important changes to the machine while it still is running, which helps reduce downtime,” Sharp said. Additionally, with both an automatic feeder and delivery section, the press does not have to stop when adding more material or removing finished product.

    More updated components of the machine make the 1050SFi something operators can use with ease, resulting in efficiency. A redesigned platen offers a more leveled impression to reduce makeready time, while a precision ground 15 mm-thickness insulation plate located behind the heating base optimizes heating efficiency and maintains constant temperature. A sandwich plate with micro-adjustment in both running and cross direction allows for quick set-up and facilitates effortless makeready. The push and pull side lays (OS and OOS0 with photo sensor sheet arrival control) are easy to use as well. A self-diagnostic touchscreen detects the location of an alert and provides information on how to repair or clear an error. The pneumatic one-push, button-activated safety doors are operator-friendly. Finally, the machine comes equipped with a tape inserter that has a counter which allows the operator to pre-set and insert a piece of paper tape to mark the load.

    “We are extremely happy with the 1050SFi,” Sharp exclaimed. “By utilizing proven group technology, we have brought a very advanced press to the market at a very reasonable price point.” In fact, customers already are responding positively to the new technology. Sharp said that due to the price point of the press and all the improved features, “the response has been fantastic.” Operators also are pleased.

    Technical Details

    The Brausse 1050SFi foil stamper and diecutter features a max speed of 7,500 sheets per hour. The machine also offers 300 tons maximum cutting pressure. Folding carton stock range is 90g/m2 to 600g/m2. Corrugated stock range is maximum 4 mm
    (B Flute).

    Foiling the Forgers – Hot Stamping Foil Adds Security to Documents

    by Mark Filby
    Security Foiling Limited

    Hot stamping foils have long been used to create stunning visual effects for all types of printed materials, including folding cartons, labels, greeting cards, stationery and much more. And, although foils have been used for many years for security applications, the concerns in the marketplace with counterfeiting of all types of documents have helped spark continued growth in this area.

    Let us look at some of the specific applications for hot stamping foils as it relates to security.

    Practical applications of hot stamping foil to add security to documents

    • Transparent foils – used as a lamination to encapsulate data and photographs to provide evidence of tampering; sometimes incorporating UV reflective properties. (identity documents, university certificates, etc.) See Figure 1.
    • Metallic foils – used to protect the substrate against duplication. The high reflectivity and bright shiny finish are much harder to recreate digitally (tax receipts, licenses, work permits, etc.).
    • Holographic foils can create dramatic light diffractive features that change color and appearance, which makes accurate copying or simulation very difficult (tax stamps, checks, bank drafts, etc.). See Figure 2.

    The stamping process “embeds” the feature into the substrate and can create a tactile effect to the image. Foil can be combined with complex embossing dies to personalize the stamped image (as seen above in Figure 2). Foil also can be used as an additional layer of security – integrated and combined with the document to provide a defense against fraudulent alteration or duplication.

    In many instances, the HSF is used as a dramatic visual representation of the customer’s own branding.

    Foiled security image – the authentication challenge

    Adding any type of security feature to a document should always provoke a discussion about authentication: How do you know the feature is genuine? How can you check? What type of checking is practical for this document?

    As with all document security features, hot stamping foils authentication features can have up to three means of authentication.

    • Level One – Visual feature, such as color change, that requires no “tools” to check.
    • Level Two – Features that require the use of tools, such as microtext magnification, screen reveal slides, hidden features revealed by laser pens, etc. See Figure 3.
    • Level Three – Forensic features that require extensive laboratory testing and possible destruction of the document.

    The design of the hot stamping foil security feature must recognize the customer’s needs and how they may use the feature in practical terms. Level One features remain the primary method of validating documents, often due to time constraints in checking documents (concert and sporting event ticketing, requiring quick movement of crowds into the venue). Level One features are almost always combined with Level Two and Three features.

    Higher level authentication methods may only be used when documents are questioned. This allows more time for that document to be checked more thoroughly (typical in border control applications or government investigation bureaus) in a controlled environment. The hot stamping foil feature will be one part of a more thorough document examination and may act as an early detection device of a document being viewed as suspicious.

    Personalizing – adding unique features to hot stamping foil and holograms

    Personalization is a feature that can be added to the hot stamping foil before the stamping process. There is technology available today that can add sequential numbers to the holographic image on the foil roll to add traceability of both the hologram before stamping and the documents after they are stamped. Foil is a perfect material for adding additional personalization and can be authenticated at Levels One and Two.

    • Sequential numbering – can be recorded during document creation and authenticated later by electronic methods. See Figure 4.
    • Halftone images & photographs – strong brand identity. See Figure 5.
    • Text threads – a continuous line of text running through the feature. See Figure 6.
    • Covert information – revealed by back lighting or UV light. See Figure 7.

    These features are more sophisticated and require higher skill levels and equipment to replicate or imitate. They create additional barriers for a counterfeiter.

    On-demand document security

    Hot stamping foil features can be applied in the centralized format common to most print production facilities or in an on-demand environment with unique, easy-to-use desktop solutions. See Figure 8.

    On-demand security is effective in situations that require localized issuing of documents such as tax collection offices, customs authorities, banking, etc. Careful consideration must be given to local support of the document-issuing system to ensure local service levels are maintained.

    The on-demand desktop solutions were first developed almost 30 years ago to address an increasing need for government departments to issue their own documents and validate the issuing process with the security feature – an evolution of the rubber stamp or wax seal. On-demand application of holograms and other hot-stamped security features are there to enhance preprinted document security features and provide higher levels of control over the document creation and issuing processes.

    The desktop hot stamping unit impresses the hologram or hot foil into the surface of the document and makes removal or change of the feature without detection very difficult – particularly useful for forensic document examination where such fraud attempts would be much easier to detect.

    The desktop solution has security access control, and audit trails can be manually or digitally created to record who issues which documents and when. This creates a deterrent for internal fraud and allows document issuing responsibilities to be clearly defined.

    There are strong arguments to adopt this approach where security is paramount:

    • Fully validated documents are not stored in bulk and open to theft or misuse.
    • The security printer does not have to distribute fully validated stock or develop enhanced security in the distribution chain.
    • The customer can control the number of valid documents and when they are issued.
    • Documents without the security feature are invalid.
    • The document creation process can be easily audited (with appropriate controls).

    In many applications customers prefer to add some local content to the security document – ensuring that labor is used locally and supports the local economy. On-demand security gives control over the document issuing process and supports local content demands.

    In summary, hot stamping foils provide a visually attractive, tactile enhancement and very effective authentication feature when thoughtfully integrated into the document. They can be combined with emerging electronic document technologies: near field communications- (NFC) enabled documents can instruct the user in the correct method of validating the document and hot stamped feature using smartphones and bespoke readers. Holographic foils continue to develop dramatic high-resolution features and color change authentication. The future of hot stamping foil in the security market looks very bright indeed.

    Since 1987, Security Foiling Limited (www.securityfoiling.co.uk), based in the United Kingdom, has manufactured the MicroPOISE™ range of hot stamping machines dedicated to the document and plastic card security sector. It has more than 2,500 installations across 105 countries. Its resellers and technical partners offer hot stamping and embossing document security solutions with full design and technical support services. Together it champions the use of hot stamping foil and holograms to defeat the counterfeiter and fraudster and put the document issuer in control.

    Well-Executed Makeready Can Be a Game Changer

    by Greg Faddis, direct sales professional, UEI® Group Companies

    Improving the makeready component of a job can make a big impact to the bottom line. It is often an overlooked cost center that when materials, processes and tools are improved, profit is generated. From the obvious benefit of an excellent foil-stamped or embossed job to the efficiencies and cost savings generated, well-executed makeready can be a game changer.

    There are so many variables in today’s foil stamping and embossing jobs that it’s important to have good makeready practices in place. It goes beyond understanding your equipment well, it now includes more options with paper, inks, coatings and complex design choices. Having the correct makeready products and knowledge are critical to having an effective makeready technique appropriate to the job.

    The basic principles for a hot stamping job are heat, dwell and pressure. In most cases, a hot stamping job makeready set-up is with hard phenolic board or epoxy glass board and a spot sheet underneath utilizing makeready tapes.

    For some jobs a traditional hot stamping makeready is the answer, but with more complex designs that include both fine-line detail and solid areas/panels together with reverse-out areas, additional techniques need to be added. To have foil cut cleanly around the images, a harder makeready surface is needed, but when you also need to foil stamp a solid area, consider adding a cushion makeready. If you find challenges with cleanly stamping the fine lines while keeping the reverse-out areas open, you may try combining both hard and cushion makeready techniques. This makeready technique starts with the traditional phenolic board or epoxy glass board but with Tough Film underneath. The Tough Film acts as a shock absorber to even out the overall pressure while providing an extra “cushion” in areas where it is needed.

    Other aspects of foil stamping that may get overlooked include adjusting the heat and speed of the press. If open areas start to fill in with foil, start by turning down the press temperature, then try increasing the press speed. If you are not getting the foil coverage needed, then turn up the temperature of the press and if the foil still isn’t transferring as desired, slow down the press.

    Embossing makeready

    When embossing or debossing, the makeready technique choices increase depending on the application. First, the embossing or debossing job adds another element – the pre-cast counter. One of the best emboss/deboss makeready techniques is the floating counter makeready technique because it provides the most flexibility for the operator.

    The floating counter makeready technique starts with a float sheet that is taped onto the platen press, which provides the floating aspect. Start with a thin sheet of paper underneath the makeready float sheet, as it will be used as the spot sheet. It is essential to have a spot sheet so you can apply the makeready tape to build up the weaker spots of the image. By taping the spot sheet to the platen (top only) it provides the press operator the ability to remove it for applying makeready tape while replacing it accurately underneath the float sheet.

    After you have your makeready float sheet and spot sheet set, begin mounting the pre-cast counter. Apply a double-sided tape (e.g. DuploFLEX FOL) across the entire back of the pre-cast counter (don’t remove the tape backing until later). On a hard surface, and utilizing a tool called the counter pin extractor, place the white counter pins onto the Counter Pin Extractor’s positioning end and inset the pin into the holes in the pre-cast counter.

    It is important to execute the preparation of the pre-cast counter on a hard, flat surface to keep the counter pins at a 90-degree angle, which is required to correctly position the pre-cast counter onto the engraved emboss/deboss die. Now, it is appropriate to carefully remove the double-sided tape backing.

    After everything is in place, make an impression with your press to transfer the pre-cast counter onto the makeready float sheet. After the transfer, remove the counter pins, using the pointed end of the counter pin extractor.

    With the counter and engraved die mounted to the press, it is recommended to “cap” your counters. There are a few choices for capping a counter, depending on the substrate and type of image you are embossing/debossing. The most common would be yellowboard or silver cover film.

    Yellowboard is a good choice for both multi-level and single-level embossing/debossing jobs, as it works with a variety of substrates from heavy to light weight. You can also easily cut yellowboard to match the size of your pre-cast counter and apply masking tape to the edges (avoiding image area) to hold it onto the pre-cast counter. It is recommended to slightly moisten the yellowboard by using a spray bottle (apply two mist sprays) or a wet rag to rub over the top of the yellowboard.

    With the yellowboard moistened, turn your press on impression and run for a few minutes without pulling any paper. As the press continues to hit on impression, the yellowboard will begin to take form and shape of the image from the pre-cast counter. This process also will help dry out the yellowboard, at which point you can proceed to pulling press sheets. Depending upon your first impressions, you can then apply makeready tape to your “spot” sheet.

    In addition to embossing or debossing projects, the floating counter makeready technique also is used for combination foil stamping and embossing jobs. The makeready set-up is generally the same; however, one key difference is how to “cap” your pre-cast counter.

    Combination engraved dies are embossing dies that have a foil cutting edge on the outside edges of the image. This edge allows the foil to “cut” away from the substrate while keeping the non-image area free of foil stamping. Foil stamping with a combination engraved die requires a thinner makeready product to “cap” the pre-cast counter.

    A makeready product called DuraCover is a great place to start when capping your pre-cast counter for a combination job. DuraCover is applied, just as you would yellowboard, by cutting a piece equal to the size of your pre-cast counter and taping its edges to the pre-cast counter. After that, follow the necessary spot makeready steps as you normally would for a foil stamping and embossing job.

    A second option, with combination engraved dies, is to use Silver Cover Film (instead of the DuraCover). Silver Cover Film has an adhesive backing, so the masking tape is not needed to apply it to the pre-cast counter. Both DuraCover and Silver Cover Film are great for helping to eliminate diecutting on the edges of the foil and embossed image, and they also assist in achieving embossing/debossing depth for better definition of the combination die image.

    While there are certainly more techniques, the above seem to help solve many makeready needs. As our industry grows, technology changes and integrates with new and existing equipment. We must continue to educate ourselves with proper makeready techniques and craftsmanship that meet today’s needs.

    UEI® Group – with a world headquarters in Overland Park, Kansas (US), has several companies and sales offices throughout the world specializing in foil stamping and embossing, including the US, Great Britain, Germany, and Denmark. UEI® Group also offers its products through market developers worldwide. UEI® Group’s leadership in providing quality products, innovative solutions and technologies has made it a market leader. Visit www.ueigroup.com for more information.

    Digital Foil Technology Opens New Doors

    by Melissa Larson, contributing writer, PostPress
    The new MGI JETvarnish 3D Evolution has expandable sheet options up to 29×47″/75x120cm at 3,300 B2s per hour.

    Eye-catching metallic effects are among the latest beneficiaries of the digital post-print revolution. Digital inkjet technologies with raised varnishes and foils, as well as laminating processes (foil sleeking), are being used for a variety of specialty print applications. The usual digital benefits – easy artwork, no makeready, no waiting, economic short runs, one-offs or variable data from copy to copy – are joined with the ability to add metallic foil and dimensional varnishes through digital processes.

    “The last 20 years have marked the steady adoption of digital design, workflow and press equipment in the marketplace – with both toner and inkjet-based systems,” explained Jack Noonan, marketing manager at MGI-USA in Melbourne, Florida. “The next phase of this evolutionary process will be to extend the flexible benefits of digital technology to the last frontier of job completion: the realm of postpress finishing. Examples of digital enhancement include 2D flat spot varnish coats, 3D raised dimensional textures and embossed variable data foiling (VDF).

    “A beneficial result of these new developments will be a growing market awareness about new types of ‘sensory-based’ print applications designed to create a memorable impact in a world of omni-channel communications. The tactile and optical special effects represent a powerful new way to use print as an information medium,” Noonan added.

    PostPress spoke with foil print production suppliers and business owners using the latest techniques to see how they are used and what the advantages are for various types of printed pieces. They also gave insight into how offering digital foil has helped them forge stronger connections with their customers.

    The technology

    According to Noonan, MGI JETvarnish 3D presses produce 100% digital print enhancements with dramatic and dynamic 2D/3D foil highlights for applications on hundreds of substrate surfaces, including paper, plastic and synthetic stocks. MGI demonstrated the first digital 2D UV process at Drupa 2008 and the world’s first 3D UV and digital foil embossing system at Drupa 2012. At Drupa 2016, MGI expanded the JETvarnish 3D product series with capabilities from 12×18″ to B1+/full sheet (29×47″) and 16.5″ rolls.

    “The JETvarnish 3D system can utilize variable data processing to create individually unique embossed foil impressions for images and alpha-numeric text,” Noonan said. “This print enrichment process translates into customer relationship-building benefits with the advantage of highlighting the impact and power of print in the marketplace. MGI digital special effects help printers energize the communication campaigns of brands and result in highly profitable new application revenue streams.”

    The Scodix Ultra2 Pro with Foil – Multi Material Digital Enhancement Press – provides brilliant foil effects for a wide variety of substrates.

    The Scodix Foil Station, available from Scodix Inc., Saddlebrook, New Jersey, is an optional module that runs inline with the company’s Scodix Ultra Pro digital enhancement press. It delivers foil capabilities such as high gloss, embossing and a variety of densities for short to medium runs, using a highly advanced, efficient digital process. Scodix Foil is ideal for coping with short to medium runs where long makeready and set-up times can be drastically decreased and tooling completely eliminated. It’s also highly suitable for converters and existing finishers offering foil for high-end short to medium runs.

    “Scodix Foil is designed for short to medium runs, particularly those where foil applications would previously be outsourced or require lengthy and costly makereadies,” said Lynn Kolevsohn, director of marketing. “Being a digital enhancement technology, Scodix Foil delivers what customers demand: brilliant foil effects, with no waste or mess. The application deploys a range of foils compatible with a wide variety of substrates including offset, digital, plastics, laminated or non-laminated and coated or uncoated. This enables us to deliver high-quality applications such as business and greeting cards, folders, book covers, brochures, labels, packaging, invitations and more.

    “Scodix effects also can be combined, so foil-on-foil is possible, as well as Scodix Sense (high gloss embossed varnish) on foil. Stunning effects can be produced that simply would not be possible with traditional methods,” she continued. “Another major selling point for Scodix Foil is that it works with variable data and can be personalized. Applications that would be cost-prohibitive through traditional methods – whether producing runs of one, or thousands – the process is cost effective. Prototyping – for applications such as folding carton packaging – is also possible.”

    Ticket to new business

    David Rula, partner and business development director of Digital Marketing Services, Inc. (DMS), Pelham, Alabama, has had an MGI system since January 2018. “We’ve been able to access a higher-level clientele, for instance advertising firms, and the capability of our MGI system is a differentiator.”

    These higher-level projects include mailers for luxury cars, fine art commemorative posters, ticketing, high-end book and brochure covers, and premium small packaging, such as that used for cannabis. Variable data also lets DMS do ticketing, and the company is in beta testing to work with the National Football League on ticketing, where the variable data capability will make quick work of row and seat numbers.

    The dazzling effects are sometimes difficult to get across in pictures or descriptions. “It’s hard to express to prospects,” said Rula. “A picture doesn’t do justice to what the finished product will look like. Sometimes clients need a sample before they can appreciate the visual and tactile effect.” The MGI system allows DMS to print and embellish a complete sample proof at a reasonable cost.

    Opening channels

    C&T Print Finishing, Inc., a family business in South Windsor, Connecticut, recently purchased an MGI JETvarnish 3DS with iFOIL press. According to principal Tracy Cole, this machine was obtained with the intention not to compete with the printers, but to embellish a printing company’s printed materials.

    “This new technology has opened doors to new customers and business, across all of New England, in addition to our existing commercial printing customers,” she said. “This also has opened up communication channels with designers who can design specifically with the MGI in mind – schools and colleges looking for posters and logos, and the average person looking for ‘Save the Date’ cards or invitations.”

    Cole said the MGI system allows C&T to provide a less expensive way to achieve the desired foil effect, because the customer does not have to pay for a traditional hot stamping die. The press “prints” UV at 2D or 3D levels, and the foil adheres to the UV. In addition to the metallic foil effect, the customer also can achieve an embossed effect with raised 3D inkjet varnish capability. The spot 2D UV alone, applied to a printed piece, improves the appearance of the printed product immensely. In addition, this technology allows C&T to offer variable foil at a low cost.

    When the customer needs to see what the finished piece will look like, it’s easily accomplished.

    “C&T frequently produces a variety of proofs, at little to no cost to the customer, because we don’t need to order a die, wait for the die to arrive and then spend hours on a difficult set-up,” said Cole. “Once we receive a properly set up file, MGI’s AIS (artificial intelligence scanner) allows for a quick makeready process. This capability makes it very efficient to produce samples within minutes, modify the sample based on the customer’s needs and quickly rerun a new proof.”

    Having this type of proofing process on the MGI also allows C&T to provide a true foiled proof to the customer. The finished metallic foil may be accomplished through the JETvarnish or through a more traditional foil stamping method, depending on the type and length of the job. This ability actually can help bring in further work on traditional foil stamping equipment as well.

    Shelf shout

    According to Kolevsohn, localization is another incentive for brands to make smaller runs, as products are tailored from region to region. The process comes with a high level of complexity, which is managed easily through digital technology.

    “For example, well-known beverage brands can create 10 different packaging variations for one whisky brand, increasing shelf appeal in different local markets,” she said. “A bright version – incorporating lucky reds, yellows and greens – might suit the Chinese market, while a subtler version could work better in the British market.”

    While it’s important to ensure there is an element of “shelf/shout,” something that makes packaging and the product itself unique is also key. These factors also make it difficult for the brand to be copied, reducing the risk of counterfeit goods, according to Kolevsohn.

    SunDance Marketing Solutions, Orlando, Florida, utilizes its MGI process to lay down the polymer coating, then laminate the foil over the clear polymer.

    “SunDance has all the latest foiling equipment and technology in house to achieve optimal efficiency, while delivering a stunning final product at a price point our customers love,” explained Kandi Johansmeyer, senior VP of sales and marketing.

    SunDance now offers digital variable foil for one-to-one marketing projects or corporate identity collateral. “We combine the latest digital printing methods with in-house finishing techniques to enhance the overall look and feel of a digital printed piece,” said Johansmeyer. “If customers need to execute a variable data job, but want to add some extra flair, we have several options available. We can utilize traditional hot foil stamping finishing services or foil sleeking techniques to create the desired end result. These processes allow us to execute highly personalized, custom small-run jobs with the additional visual and tactile enhancement of metallic foil.”

    SunDance offers an extensive color selection of foils, including holographic foils, custom foil colors, metallic foils, gloss or matte pigment foils and even refractive patterns that can be added to the stamp to produce an eye-catching 3D image range of options.

    According to Noonan, “These market trends translate into a very significant opportunity for printers to increase work volumes, new client acquisition strategies and profitability ratios. The advantages of digital print enhancement also can contribute to achieving new business development goals from a marketing and sales perspective. Digital print enhancement can be a key driver for future growth and a method of competitive differentiation for all print service providers.”

    “The growing success of service providers utilizing digital enhancement technology to embellish and decorate color ink output means that they can strengthen both their bottom line revenues and their customer relationships,” Noonan concluded.

    Alternative Available for Hot and Cold Foil Waste

    by Carson Weisbord, Channeled Resources Group
    Photo courtesy of Channeled Resources Group.

    For many manufacturers, waste is an out of sight, out of mind problem after it leaves the facility. The garbage truck comes, waste is loaded up and it’s hauled away. That’s it. Many believe there is no choice when it comes to the destination. This certainly applies to hot and cold foil roll waste. A large majority of it is currently disposed of through the landfill.

    Recently, the Foil & Specialty Effects Association (FSEA) has partnered with Channeled Resources Group to work toward changing this mindset and creating an alternative for foil waste disposal. The Chicago-based organization has long been an advocate for responsible environmental practices in manufacturing. Utilizing a global network, Channeled Resources finds sustainable alternatives for nonrecyclable waste and other obsolete materials. “We are delighted with the new relationship with FSEA. This partnership is a win-win for both: it allows for the development of needed feedstocks for Convergen’s engineered fuel, while providing a sustainable solution for FSEA members,” said Calvin Frost, Channeled Resources Group chairman.

    A sustainable alternative for foil waste

    Convergen Energy uses a variety of obsolete waste materials, including spent hot and cold foil rolls, to manufacture EPA-approved combustible fuel pellets shown here. Photo courtesy of Channeled Resources Group.

    For many years, Channeled Resources focused exclusively on materials resold in secondary markets. In 2008 that changed. As the manufacturing world continued to increase focus on sustainability, Channeled Resources Group partnered with Convergen Energy, out of Green Bay, Wisconsin, to pursue a new venture: Waste-to-Energy. The new program provides a sustainable alternative for materials that have no value in secondary markets and would otherwise be sent to landfills. Convergen uses a variety of obsolete waste materials, including spent hot and cold foil rolls, to manufacture an EPA-approved combustible fuel pellet. These pellets remove and reduce coal usage in industrial power plants, burning far cleaner.

    For eight years, Convergen sold these pellets to coal-burning power plants across the Midwest. At first, the volatile energy market led to struggles with revenue and inconsistent outlets for pellets. That all changed in 2016 when Convergen purchased a commercial power plant in L’Anse, Michigan. Pellets now are trucked from Green Bay to L’Anse daily to be used as fuel for energy generated by the plant and sold to the grid. Vertical integration has allowed the firm to focus on increasing material volume, growing revenue and closing the geographic loop for waste. Convergen’s processing volume has increased threefold since July 2017.

    Cost effective and environmentally friendly

    The Waste-to-Energy program is also easy for companies to join. Manufacturers send full truckloads of gaylord boxes filled with obsolete foil rolls to Convergen’s Green Bay facility. Upon arrival, rolls are guillotined, shredded and mixed with other nonrecyclable materials to produce fuel pellets. This solution offers an environmentally-friendly means of removing used or obsolete rolls from the waste stream with minimal changes to waste disposal practices. A gaylord box of foil material accounts for around 1,000 to 1,500 pounds. Once about 15 to 20 of these boxes are filled and stored, the manufacturer simply schedules a pick-up. The process minimizes freight costs and carbon emissions by shipping truckload quantities of material to Convergen.

    While foil stamping produces a beautiful end product, more than 50% of the material used in the manufacturing process often is sent to a landfill. Disposal costs are on the rise, as landfill tipping fees in the Midwest increased nearly 27% in 2017. Increased tipping fees and efficient shipping methods allow manufacturers to make a transition to sustainable waste disposal at equal or lesser cost compared with landfill disposal.

    Sustainable alternatives are becoming critically important as landfills begin to reach capacity. If waste flow continues at current volumes, it is expected that landfills could be full within 14 years. Additionally, when waste sits in a landfill, it releases large quantities of methane, a pollutant 30 times more potent than carbon dioxide. Residential waste also continues to rise, increasing tipping fees. Waste-to-Energy curbs methane emissions and helps avoid the construction of more landfills by decreasing demand.

    Accessibility and future expansion

    Convergen’s facility receives material from all over the Midwest on a daily basis, working with Green Bay-based freight carriers to coordinate backhaul pickups of Waste-to-Energy material. This minimizes carbon footprint as the trucks picking up this material would otherwise come back to Green Bay empty. Channeled Resources utilizes a trusted network of freight carriers to offer rapid, seamless pickup services.

    The current service area includes Wisconsin, Illinois, Minnesota, Iowa, Michigan, Indiana, Ohio, Kentucky, Pennsylvania, Georgia, Missouri and North Carolina. As capacity grows, the program plans to add collection sites and increase the service area in Chicago, St. Louis and Kansas City by early next year.

    Photo courtesy of Channeled Resources Group.

    Almost all pre-consumer paper and plastic products can be utilized in this process, including printed products. However, no PVC, metal or food grade material can be used in the fuel in order to maintain a high level of quality and minimize greenhouse gas emissions. Convergen also provides certificates of destruction for all materials, ensuring confidentiality for its customers. The certification also allows manufacturers to promote their conservation efforts to customers.

    Waste-to-Energy is a valuable first step toward building a circular manufacturing economy. Through this process, waste generators can provide a renewable energy input at a comparable cost to landfilling.

    Users of hot and cold foil now have an early opportunity to pursue sustainable waste management and work toward mitigating the long-term impacts of climate change.

    For more information on the new partnership between FSEA and Channeled Resources Group, please visit www.fsea.com or email Jeff Peterson at jeff@fsea.com.

    Started in 1978, Channeled Resources has grown into a global supplier of coated, treated, and laminated papers and films. In addition to manufacturing, Channeled Resources is a leader in developing alternatives to landfill use for pressure-sensitive adhesives, silicone-coated release liner and specialty films. Our goal is to provide cost-effective and environmentally responsible solutions to our global customers and suppliers. For more information: www.channeledresources.com

    Studying the Response: Foil Attracts Consumer Attention

    by Dianna Brodine, managing editor, PostPress

    Capturing consumer attention can result in big business, and those involved in print and packaging know that “shiny on the shelf” is an advantage for those looking to stand out in the retail aisles. Thousands of successful product launches can be associated with the use of a high-visibility enhancement, but rarely is solid data available to prove that the use of a specialty print effect increased the likelihood of purchase.

    The Foil & Specialty Effects Association (FSEA) recognized that validation of physical and emotional responses to high-visibility enhancements would offer the print finishing industry a tool to support the decision to incorporate high-visibility enhancement within a brand development plan. As technology allows the capture of increasing levels of human response to stimulation, the accumulation of scientific data to validate high-visibility enhancements becomes possible.

    The study detailed in this article proves that in a highly competitive category, where consumer personal preference is a significant factor in the purchase decision-making process, the addition of a high-value enhancement to packaging greatly increased the likelihood of purchase. In fact, the unknown brand – created solely for this study – was able to outperform national brands with decades of name recognition.

    Study procedures

    The Sonoco Institute of Packaging Design and Graphics at Clemson University, in partnership with R. Andrew Hurley’s research program, conducted an eye-tracking study in the CUshop Consumer Behavior Lab. The Sonoco Institute was created to exploit the synergies that exist between the graphic communications and packaging science departments at Clemson University. The study was developed in conjunction with the FSEA to observe the effects of foil stamping on consumer interaction and test the hypothesis that a package embellished with foil would increase attention to the product when compared to the same product without foil.

    The approximately 180 participants (30 for each control and 30 for each stimuli) were offered no incentives and participated in the study over three days. Demographic information was collected after the participant completed the study. Participants were asked to wear Tobii Glasses, which track pupil movements at 50hz/s (one-fiftieth of a cycle per second) and record the viewed scene with a forward-facing camera. Each participant was first calibrated with the glasses, then escorted into the CUshop to shop as normal. Next, the participant was handed a shopping list with a randomized listing of products. The participant was instructed to shop as they normally would and, when ready to make a selection, to write down the product code (between two and three digits) onto the space provided on the shopping list. When complete, the participant exited the shop and filled out a survey on a computer.

    Coffee study results

    Disposable single-serve coffee packaging was the focus of the study. A fake brand of coffee – Zapotec – was placed on a grocery store shelf alongside a competitive array of brand names, including Maxwell House, Gevalia, Donut Shop, Green Mountain and Keurig’s proprietary brand, Eight O’Clock. Three total packages were assessed – one package per day of the study – including a plain printed package (control), a package with red foil added and a package with gold foil added.

    Purchase data was monitored. The Zapotec coffee package with no foil enhancement (the control package) rated lowest among all brands for those making a purchase decision. Adding gold foil stamping to the Zapotec packaging, however, attracted consumer attention that led shoppers to purchase the fake coffee brand just as often as Maxwell House and Green Mountain and more frequently than Eight O’Clock. Adding red foil stamping to the Zapotec package led the consumers in the study to choose unknown brand Zapotec over Maxwell House and Eight O’Clock.

    In addition to purchase decision, the Tobii glasses utilized in the study allowed the CUshop researchers to collect data on what caught the consumer’s eye during the shopping experience. The red foil stamped area on the Zapotec packaging attracted the study participant’s attention 1.5 times faster than the same packaging without the high-visibility enhancement. The gold foil increased the rate of attraction, with the foil stamped area looked at 2.5 times faster than the control package.

    While factors such as cost, brand loyalty and shelf location have significant influence on those making a purchase decision, the ability to attract and keep attention on crowded retail shelves is critical for brands looking for greater market share. The study data included additional information, including the following:

    • The samples containing high-visibility enhancements achieved a Total Fixation Duration (TFD) that was longer than 50 percent of the name brand placeholders on the shelf. TFD is the time, in seconds, spent on average by participants fixating on the item. This confirms that the initial attraction due to the package enhancement had transitioned to attention.
    • More than 46 percent of the study participants said they perceived packages with specialty printing to be of higher quality.

    Conclusions

    Once thought to be applicable for only luxury items, stamping foil applications now can be identified in many different markets. Publications, grocery items, pharmaceutical products, clothing, social stationery, gaming cards and promotional displays are now commonplace applications for stamping foil applications. Holographic foils have come into favor as a method of adding a level of product security to product packaging.

    In addition to adding to the perception of quality and providing security, foil also attracts attention. This is particularly critical when attempting to differentiate a product on a crowded supermarket shelf. Today, stamping foils are available in over 100 shades of metallic finishes, dozens of decorative printed finishes and – in the last three decades – optically variable finishes. The possibilities for attracting consumer attention seem endless.

    FSEA will be releasing a full white paper containing greater detail on the study results. To request the white paper, email FSEA Executive Director Jeff Peterson.

    Managing Foil Inventory

    by Jeff Peterson, editor-in-chief, PostPress
    A foil inventory system can reduce waste, avoid downtime and save time.

    In the print finishing world, having a sophisticated inventory system never has been of upmost importance. Finishers, as a general rule, do not have a great deal of inventory of paper or other products because many jobs are brought in by the printer/customer and then sent back before being shipped to the end user.

    One area where inventory management can be important, however, is with hot stamping foil. This has become even more critical in recent years with the growth and use of new paper stocks and coatings, which has created more foil formulations for different substrates. Creating a system that will help estimators, salespeople and operators keep track of the foil on hand can save money and production time in many cases – but, this is more easily said than done. “Managing foil inventory is a difficult task,” said Brian Bowland, Great Western Foils, Simi Valley, California. “There is no easy way to keep track of it without physically checking it on some type of consistent basis.”

    Inventory software

    One way to keep better track of foil inventory is to use a software system. This can be effective in managing foil, but it takes a concerted effort to track not only the number of rolls in inventory, but also the feet left on each roll. “A quality foil inventory system will know how much material is on each roll,” said Mark Porter, president of Dienamic MIS Software, St. Catharines, Ontario, Canada. “If the next job comes in and requires 1,500 feet, the operator will want to choose to finish off the 500-foot roll in inventory and then start another 1,000-foot roll for the balance.” Knowing that a 500-foot-long roll of the specific foil for the job is on hand potentially saves the finisher the cost of purchasing an entire master roll. The savings can be passed to the customer or help drive a higher profit margin on the job.

    A foil inventory system also can force structure with the management of the foil rolls, because it can specify the exact location from which foil is taken and returned. This structure results in less time looking for foil and less waste from possibly having to repurchase it.

    Utilizing a software system to help manage foil inventory can provide many benefits, including:

    • reduce waste during production;
    • help ensure sufficient quantities are available for production to avoid downtime;
    • manage batches of foil received by specific foil suppliers so if there are quality issues, they can be traced; and
    • reduce time looking for foil rolls and costs associated with purchasing foil that may be in the plant but cannot be found.

    Reducing and controlling foil inventory

    Another way to keep foil inventory manageable is to have policies that help the foil stamper use it in creative ways, such as producing a foil color chart for customers, using it for a finisher’s self-promotional piece or donating a foil stamping project for a nonprofit event.

    Another way to keep foil inventory manageable is to have policies that help the foil stamper use it in creative ways. For example, an inventive idea would be to produce a foil color chart for customers. “Producing a foil color chart has been an excellent tool for promoting our business and minimizing the number of foil colors that we keep in stock – especially in the gold and copper range, where there seems to be an unlimited number of shades available,” said Paul Adametz, president of The Letterpress Shoppe, Pittsburgh, Pennsylvania. “We produced a large quantity of color charts several years ago and distributed them to all the printers, designers and ad agencies in the Pittsburgh region. Because of the mass distribution, my competitors regularly have to deal with their customers specifying Letterpress Shoppe foil color numbers.”

    Adametz said his company controls foil inventory by specifying that quotations are based on using Letterpress Shoppe standard foil shades. “With this policy in place, we rarely have to buy a custom shade without being able to charge the customer accordingly,” Adametz explained. The Letterpress Shoppe also tries to quote “off-the-shelf” foils when customers indicate they want something a little different than what is shown on the color chart. “Our customers have access to hundreds of end rolls that we have sorted by color without paying for a custom foil purchase,” Adametz added.

    Yet another idea to use leftover foil in inventory is to use it for a finisher’s self-promotional piece or for a nonprofit event where the finisher would donate the foil stamping of the project. In addition to using leftover foil, donating the foil stamping for a special invitation can provide great free publicity for the foil stamper.

    Bowland said foil stampers do not need to stock very many foils in inventory, especially if they have easy access to a selection of foil through a distributor or foil manufacturer. “Every roll a foil stamper keeps in inventory hurts the company’s bottom line,” he explained. Bowland suggested keeping on hand general gold and silver foils that can work on a broad range of substrates. He also recommended that foil stamping companies stock clear foil. “With the increased popularity of spot coatings and other specialty coatings, clear hot stamping foil has gained in popularity as well,” he said. “Many of our foil stamping customers now inventory it along with gold and silver and sometimes a black and white foil, too.”

    Bowland added that calculating the correct foil for the particular job also is important in controlling foil inventory (see Figure 1 on Foil Calculation Formula). This can help control the rolls left over from a particular job.

    Conclusion

    Whether a foil stamper uses a software system and/or creates specific policies to help control foil inventory, the key is that it is important to do something. Utilizing a software system of some type, as well as doing things like having a color chart with limited foil colors and controlling the foils that need to be inventoried, can go a long way toward keeping money in the bank instead of on the shelf.

    PostPress would like to thank Mark Porter, Dienamic MIS Software, Inc.; Brian Bowland, Great Western Foils, Inc.; and Paul Adametz, The Letterpress Shoppe L.P., for their assistance with this article.

    Foil Calculation Formula

    To figure the correct foil for a particular job, three specifics are needed:

    1. Total # of impressions/sheets. Remember to count total sheets, not finished pieces. Also, be sure to not calculate from the total sheets received. Provide the needed quantity asked for by the printer or customer and do not stamp an unnecessary amount.
    2. Length of pull. Determine which direction the foil will run on the press and then measure the length of the image being foil stamped. Take the image size and, to be safe, add ½” to all sides. If the foil stamper can be involved early in the project, many times a small adjustment can help decrease the total foil usage and save the customer foil costs.
    3. Number of cut rolls needed out of a master roll (24″ or 25″ wide). Once the size of each roll has been determined, calculate how many rolls can be cut from a master.

    Formula:
    # of impressions times the length of the pull (in inches) divided by 12 (divide by 12 to convert from inches to feet). Take this number and divide by the number of cut rolls out of a master.
    This will provide the foil stamper with the footage needed in master rolls. As an example:

    # of impressions: 10,000
    Length of pull: 6″
    Cut size: 3″ (8 rolls out of a master)
    10,000 times 6 divided by 12 divided by 8 = 625

    This calculates to 24″ x 625′ needed to complete the job. Since foil is commonly sold in 200′ increments, and sometimes 1,000′ masters are the minimum, one master 24″ x 800′ or 1,000′ will be needed to complete the job.

    Q&A: A Look Inside the Narrow Web Decorating/Finishing Marketplace

    Foil products and the adhesives used with the cold foil process have improved significantly over the past few years.

    PostPress asked two industry veterans in the narrow web decorating/finishing arena (Tom Kirtz, president, Telstar Engineering, and Michael Rivera, vice president, K Laser Technology) to provide some insights on the current landscape and what we can expect to see changing in the foreseeable future.

    What were the turning points in hot foiling inline that helped it grow into a feasible option for flexographic printers? Is there still room for growth in the hot foil side of the business?

    Although inline foil with narrow web flexo had been around for quite some time, flexographic printers were not willing to slow their presses down to the speeds they would have to run at to effectively apply foil inline. Improvements in the release of the foils by foil manufacturers began changing this, along with more flexible and cost-effective solutions for hot stamping tooling.

    “We saw the potential in the hot stamping market for narrow web several years ago and acquired a hot stamp equipment manufacturer to add to our converting equipment line,” stated Kirtz. “We made several engineering upgrades and believe we encouraged this growth with the availability of retrofit hot stamping equipment for all types of label presses.”

    “Another major turning point in the growth of hot stamping inline was the development of flexible rotary dies that could be utilized with magnetic cylinders,” added Rivera. “This provided a more cost-effective solution for shorter runs and faster turnaround times for the customer.”

    Rivera believes the rotary hot stamp market most likely has peaked as far as growth opportunities, but there are many customers who still are interested in the look of a hot stamped image and the opportunities will continue to be available for the flexo printers offering it.

    Cold foiling inline has continued to grow in popularity. What percentage of the market for foil decorating would you estimate is cold foil vs. hot foil?

    Cold foil inline also has been available in the marketplace for many years; however, consistency and reliability simply were not obtainable to spark significant growth. Foil products and the adhesives used with the cold foil process have improved significantly over the past few years. This has helped develop a huge increase in its acceptance and growth for label decorating. Rivera estimates that the cold foil market now holds about 80 percent of the foil decorating market for narrow web flexo printing.

    “Cold foil is an acceptable foil decorating process and now is considered an industry standard,” stated Rivera. “However, because cold foil is limited to non-porous substrates, its market share is not expected to change significantly.”

    “We have seen significant grow with cold foil and Cast & Cure™ for narrow web applications,” added Kirtz. He stated that his company currently is manufacturing more than twice as many cold foil units to hot stamp units for narrow web flexo presses.

    What label applications are more suited for hot foil, and which applications are more suited for cold foil? What factors go into an end user decision between the two processes?

    “To go hot or cold with foil isn’t always a clear choice,” stated Kirtz. He pointed out that some designs and substrates demand one or the other, and there can be issues with the quality level demanded by the job and even the press speeds required to remain profitable. “If you have been doing hot stamping and are faced with a customer demanding cold foil, you may find you can add this process to your existing press at a cost that still allows you to make a profit,” continued Kirtz. “You may even end up expanding your product lines for your sales staff.”

    “One of the major factors in the decision between utilizing cold or hot foil is the substrate being used,” added Rivera. Cold foil must have a non-porous stock to perform effectively, so labels designed to use an uncoated stock are going to be more suited for hot stamping. Cold foil works best for plastic label substrates because there is no heat involved when applying the foil, which can distort the plastic film.

    What do you see changing and growing in the label decorating/finishing marketplace?

    “There are units now available that can provide hot and cold foil, along with Cast & Cure™ decorating,” said Kirtz. “Imagine foil combined with rotary screen, metallic, glitter varnish, heat embossing or embossed-look effects… there is so much more to come!” Kirtz went on to say that there is a lot of talk about digital and digital labels. He does not look at digital as a separate technology, but rather a complimentary opportunity for label printing and decorating.

    Rivera noted that more printers are applying foil decorations to digitally printed labels. “The digital print market for labels has shifted its finishing strategy from an “inline” to an “offline” process,” he said. This shift mainly was dictated by the maximum running speed of the digital press. While digital presses run substantially lower in speed than the finishing equipment, more printers are opting to perform their decorating/finishing process offline, where one decorating/finishing press can serve two or more digital printing presses.

    Kirtz added that hot foil holographic security applications area is where he is seeing a growing demand due to increased concerns about counterfeiting. “These techniques provide an extremely difficult-to-duplicate graphic identity,” added Kirtz. “It’s like creating a virtual fingerprint, only better.”

    “I don’t believe we have tapped the potential, especially when it comes to combining various decorating effects,” concluded Kirtz. “There is such a huge demand for new and more exciting graphics, and we don’t yet know how this will all tie into digital applications, for example. Label designers are becoming more tech savvy and bring new ideas to the table. It’s our job to figure out how to achieve their visions.”

    2015 Narrow Web Supplement

    Sheet-Fed Foil – Hot and Cold!

    by Mike King, Eagle Systems
    In instances where the majority of the sheet or the entire sheet includes foil, cold foil can be a cost-effective choice. Large coverage of foil on the sheet will allow maximum use of the foil ribbon.

    With the variety of manufacturing options available to add multi-sensory packaging effects, brands across all industries are beginning to branch out and use foils. One of the most talked about points of confusion is the difference between hot foil and cold foil, along with the pros and cons are of each method. This article will explore the pros and cons of these two separate methods for sheet-fed foil processes. Choosing the right method is tied to many factors, but having a baseline understanding will help with price, speed to market, branding and, ultimately, consumer impact.

    Foil coverage

    For most applications, the cold foil process is done inline on the printing press. If the image area (the area on the sheet that will be foiled) is small and does not make use of the majority of the foil roll over the sheet, there can be an excessive amount of waste in foil that is not applied. Comparatively, the hot foil process (most commonly performed offline on a hot stamping machine) allows for the foil roll to precisely index in small increments and thus maximizes the use of the entire foil ribbon. So, for smaller areas of foil coverage, hot stamping usually is the best choice to maximize the use of the foil.

    In instances where the majority of the sheet or the entire sheet includes foil, cold foil can be a cost-effective choice. Large coverage of foil on the sheet will allow maximum use of the foil ribbon. In addition, if the job requires multiple colors of foil, then cold foil will be more economical, as it is all done in one pass and then overprinted to create the separate colors.

    It is important to remember that saving foil necessarily does not calculate to job cost savings, as the whole picture needs to be considered. What most people don’t realize is that job cost savings also encompass the process, logistics and other materials, as well. Sometimes, the breakeven point could be at 1,000, 10,000, 100,000 or even 1,000,000 sheets before one process becomes more cost effective over the other. It is imperative to look beyond the actual foil material cost.

    Where cold foil really becomes a game changer is when comparing it to using a laminated foil metallic board. Cold foil inline can create huge savings over laminated board and provide more flexibility with inventory. The other advantage over a foil laminated stock is that the portion of the package or product that is white can be reversed out of the foil, which eliminates the need to print white opaque ink in these areas. The white ink can create problems on press and sometimes needs two passes to properly cover. Other areas, like glue flaps or just plain printing on foil laminated board, can create challenges because the printing is being applied to a plastic material. The major savings is the actual dollar-for-dollar cost against the cold foil with board vs. foil board. A 10-cent savings is $100,000 dollars on 1,000,000 sheets at the end of the year. Imagine the savings if the cost was 53 cents apart! In the cold foil process, multiple webs of foil can be run, which realistically would be a small percentage of actual foil use. With foil board, the whole sheet is paid for and used, regardless.

    Substrate considerations

    Certain substrates can pose a challenge for the cold foil process, such as uncoated stocks. During the cold foil process, a layer of adhesive is applied to the sheet. Uncoated stocks tend to absorb the glue, resulting in less adhesive for the foil to adhere to when applied. This can lead to uneven surfaces, rough edges and flaking of the foil. Comparatively, hot foil stamping provides more latitude with substrate types since the foil is applied by a heated application onto the sheet vs. the use of an adhesive. So, the type of stock or substrate can have a huge impact on selecting cold foil vs. hot foil.

    Inline vs. second operation

    There only are two colors available in cold foil, with the most popular being 98-percent silver and 2-percent gold. Hot foil has a wider range of metallic foil colors readily available, such as gold, silver, blue and red.

    The cold foil process is done inline on press and, therefore, eliminates the need for a second offline operation of hot foil stamping. Being inline also means that inks, varnishes and coatings can be applied over the cold foil on press, whereas this would require an additional press pass following the hot stamping process. There are inline efficiencies of cold foil with proper equipment and the knowledge of the process. However, if there are challenges with the setup and coordination of the cold foil process working with the printing process, the potential cost savings of performing the foil inline can diminish.

    Sheet-fed cold foil process is approximately 30 years old, but only has truly developed into a viable and economical solution in the last six to seven years. With only around 160 cold foil systems in operation worldwide, those interested in pursuing cold foil must do their homework and speak with others involved already in the process. Of course, this scenario also is true with the hot foil process. Utilizing the proper equipment for hot is essential in today’s world.

    Careful planning and utilization of reliable equipment are essential to ensuring the job runs consistently and that the printing press does not have to be stopped multiple times through the run.

    When a customer is looking for a foil and embossed image, many times the foil and embossing can be applied at the same time on an offline foil press utilizing a combination (foil and embossing) die. When this is the case, running offline vs. inline is the better option because a separate pass will be necessary either way to accomplish the embossed image.

    Foil tension also can be an issue if the proper cold foil equipment is not being used. Some cold foil units require special foil tension programming which, if not properly set, can cause tension issues and breaking. This can cause foil damage, foil dust and inferior product. Without proper tension throughout the run, there is the risk of the foil not being applied securely to the sheet and allowing proper bond with the ink. There are retrofit machines that do not require special programming for foil tension and help eliminate this issue.

    Foil color

    There only are two colors available in cold foil, with the most popular being 98-percent silver and 2-percent gold. Also, a limited number of holographic patterns now are available for cold foil. For larger orders, foil manufacturers may be able to provide specific colors and patterns with a cold foil formulation. To achieve a specific color other than the silver or gold, it is necessary to lay down ink over the foil being applied on press. Utilizing four-color process (CMYK), there virtually are an unlimited number of colors that can be created through overprinting cold foil. PMS colors can be used to create a particular color as well.

    Comparatively, hot foil has a wider range of metallic foil colors readily available, such as gold, silver, blue and red, etc. In addition, hot foil stamping offers other types of foils, such as holographic, specialty patterned, pigmented and clear foil options that are not available with the cold foil process.

    Brilliance of foil versus flexibility

    Hot foil traditionally results in a more brilliant look vs. cold foil – although the final outcome of a cold foil transfer has come a long way in recent years. The customer needs to make the final determination on what will work best for the specific application. Hot foil may provide more overall brilliance, though cold foil has more reflective angles than hot foil because of the sheer process and the way it is applied.

    The idea behind the cold foil process is that various colors of foil need not be stocked and any color under the rainbow can be created with CMYK or PMS colors. The beauty of this is even more apparent when the customer comes in for a press check on cold foil and says the color is off a bit. With the cold foil process, the color easily can be changed with prepress adjustments on the printing press because the color comes from the overprint on the foil.

    In the same scenario with hot foil, there may be a delay in the job if the foil stamper does not have the customer’s exact color pick of foil in stock. Unfortunately, many foil stamping shops have a lot of unused hot foil and a great deal of it never gets used again. With the overprinting of silver foil for most cold foil applications, there is little to no leftover inventory that cannot be used in the future.

    Conclusion

    When choosing between hot and cold foiling, it’s important to keep the end game in mind. It’s best to start with the product’s particular needs and then find a match based on how well the capabilities of each technology align with the product. The following questions are examples of what needs to be addressed:

    • What is best for the application? It is key to understand what the product does and who it’s targeting. The application itself should be able to point to one process over the other.
    • What is the budget? While budget shouldn’t be the first consideration, it often can dictate a particular solution.
    • With what substrate is the foil being used? Again, the substrate may determine the preferred method of foiling. Certain substrates only work with hot foil, while others are best with cold foil.
    • What type of look is being sought? One of the easiest ways to decide whether to use hot or cold foil stamping relies on the type of look the customer wants. The customer is the ultimate decisionmaker to determine the best approach.

    Mike King is owner and inventor of Eagle Systems’ hot and cold products. For years, Eagle Systems has focused solely on foil machinery and foil process developments, including the introduction of high-tech servo technology to the world of hot foil indexing. For more information on hot and cold foil products, visit www.thefoilexperts.com.