May/June 2024

Industry Influencer: Gary Cohen

June 11, 2024

Gary Cohen is the executive director of RadTech International North America, a trade association devoted to promoting the use and development of ultraviolet (UV) and electron beam (EB) processing as an industrial technique offering energy savings, elimination of pollution, greater productivity, higher yields and the opportunity for improved, new or unique products. The association serves as an international forum and reliable source of education and information for individuals and organizations involved in the use of UV and EB processing or who supply equipment, chemicals or other materials to such users. With a background that includes work at the US International Trade Commission, Cohen is focused on supporting US manufacturing across a wide variety of industries, including print and packaging.

How did your career develop into your involvement with RadTech North America and the UV and EB curing industries?

I was born and raised in the Washington DC area – so, way too many lawyers and lobbyists concerned about politics. I started out at the US International Trade Commission looking at imports to the US that may be unfairly harming US industry. From that time on, my work always has focused on manufacturing, with subsequent positions at the Association for Manufacturing Technology and the Consumer Electronics Association / Consumer Electronics Show. That broad manufacturing perspective, focused on technology users, seemed to be a good fit for RadTech as UV/EB has so many applications across industries.

How do you see the industry embracing global trends, such as the circular economy and sustainability demands from manufacturers, brand owners and consumers?

The UV/EB industry is all in on circular economy and sustainability. In fact, it is members who encouraged us to tag our 2024 biennial event as UV/EB for Sustainable and Responsible Manufacturing. Over the years, our industry had grown a bit frustrated as we always have offered low to no VOC, CO2 and Hazardous Air Pollution solutions, but it was difficult for many companies to make the investment to change their processes. Moving to UV/EB means not just changing equipment, but also much of the process. Many of our members used to say that our real job was “changing mindsets” to get the word out about the various operational benefits of UV/EB that come with a more sustainable process.

What are the biggest challenges the UV, UV LED and EB curing industries are facing? How should the industry respond to successfully grow and thrive?

Understandably, it is hard for many manufacturers to make major changes to their processes. In some instances, companies have been running successfully for generations with their equipment, and change always comes with some perceived level of risk. The challenge of the UV/EB industry is to demonstrate not only the benefits of the technology, but that the technology may be implemented seamlessly
and easily.

As we are seeing federal and state regulations pop up around sustainability, UV/EB sometimes are excluded by regulators as they are not familiar with the technology and/or may have heard some misconceptions. Education is the key opportunity for our industry.

What trends are emerging in design and production that will influence the future of the UV, UV LED and EB curing industry? How do you believe this will affect the printing and packaging industries?

With increased computing power and artificial intelligence (AI) design programs, the ideas we have been talking about for years, such as mass customization, are becoming a reality. This technology is perfect to implement for inkjet, customization, direct to object and special effects. UV/EB offer nearly infinite tuning and precise curing.

Which markets/verticals are growing their use of UV, UV LED and EB curing technologies?

The graphic arts industries are by far the largest segment for UV/EB in North America. UV/EB seems to be accelerating its growth in food packaging and all types of printing, offering safe, sustainable solutions to printers for a range of substrates. That includes metal can decorating and coatings, and coatings and decorations for various flooring and wall covering applications.

While sustainability certainly is a driver to the growth of the technology, the main driver for UV/EB always has been the fact that it is an “enabling” technology, offering enhanced capabilities to print, coat and adhere on a wide range of substrates that may not be practically done in any other way. In addition to the environmental benefits, the hyper-speed (UV/EB cure nearly instantly, in most cases, with products ready for pack and ship immediately), increased capabilities to make new products and the efficiency of the UV/EB processes offer manufacturers real opportunities to benefit their bottom line.

What are your predictions for the UV/EB industry in the next five to 10 years?

I have been in the UV/EB industry for a long time, and part of the reason is because the technology and applications are rapidly evolving, making me very fortunate to be involved with this exciting technology. Big, amazing surprises about new applications and processes almost are a certainty, if the past is any indicator.

If the emphasis on energy savings, CO2 emissions and sustainability continues, the outlook for this technology is very exciting. In many cases, I am not sure there is any better way to meet such enviro-goals while enhancing product and process performance.

Sea Life Poster Journeys into the Future with AI

June 11, 2024

Edited by Erin La Row, writer, PostPress

An annual project became an award-winning piece of art for the team at Hinderer + Mühlich (H+M), based in Göppingen, Germany, with a US facility in Charlotte, North Carolina. “Sea Life” merged artificial intelligence (AI) with print embellishment to create an eye-catching undersea adventure on paper. The poster, anchored by an embellished sea horse, captivated the judges at the Foil & Specialty Effects Association’s 31st annual Gold Leaf Awards, where the project won Best of Show: Best Use of Foil & Embossing.

Heike Martetschläger, marketing and design manager, said the poster first began as a project to decorate the cover of Verpackungsrundschau, a German packaging magazine. H+M used the opportunity to bring together a team of specialists in each involved area of the project (paper, foil, stamping dies, machinery) to show outstanding embellishment and give inspiration to designers and brand owners. The final cover design then was turned into a large poster. The magazine is not on the market anymore, but H+M continues the tradition of the poster, large and small. Sea Life is the 17th edition of its posters, and the team already is working on number 18.

“In our posters, we incorporate current trends in fashion, design or social trends and transform them into embossed designs,” Martetschläger said. “In doing so, we continually push the limits to showcase the exceptional potential of H+M stamping dies. We also use this project to underline our capacity for innovation and expertise.”

What sets apart Sea Life from the other posters is that its artwork was created using AI. The team used ChatGPT to formulate prompts for MidJourney, a text-to-picture AI tool, to generate imagery. The team wanted to see and experience for itself if there is more than mere functionality to AI – exploring the creative potential of AI. While brainstorming, Wohlgemuth & Company, the design agency behind the poster, suggested taking the AI experience a level higher and starting a collaboration between ChatGPT and MidJourney.

“We used ChatGPT to formulate prompts for MidJourney, swiftly generating around 300 images. Precision in prompt wording proved crucial, guiding the AI to meet our creative vision. Our approach merged fashion, design and jewelry with an underwater theme, prioritizing visual impact over realism,” Martetschläger said.

While Midjourney produced astonishingly realistic results, occasionally it resulted in flaws. “Embracing AI presents an opportunity to learn and innovate, despite occasional quirks like six fingers or peculiar facial features,” Martetschläger added. But with the speed of improvements in AI tools, Martetschläger said she believes the flaws in their process now would be reduced.

With the design determined, the team set out to create the final product. David Bohne, general manager at H+M USA, said, “The poster was designed to combine various visual and tactile styles, such as nanoembossing, microembossing and textured embossing. The big posters were printed on Algro Design Advanced 315 gm while the small poster was made on Algro Design Duo 250 gr – both by Sappi. Details and respective art files for the various foil and embossed elements were meticulously created for H+M to produce the highest quality and precision brass dies for this project, and then stamped and embossed on a Gietz FSA 720 foil stamping press.”

To create the larger Sea Life poster, there was a total of six passes on the Gietz foil stamping press. This included several flat stamp passes of foils, nanoembossing and customized texture in the top Sea Life headline, and a final intricate sculptured embossing of the sea horse. The gems on the sea horse were created with a combination of a clear foil and round embossing.

Art is subjective. The effectiveness of the previous posters depended on the audience – some people related to the design while others didn’t, Martetschläger said, adding there is a lot of interest in the story behind the project and the use of AI to get the design. “Sea Life is one of the designs in recent years that created interest and positive feedback from almost everybody – especially when people get to hold it in their hands,” Martetschläger said. “We even received pictures of customers showing where they had hung it up at their workplaces and their homes.”

Cast and Cure Films from Breit Technologies

June 11, 2024

By Jeff Peterson, editor-in-chief, PostPress

How Does Cast and Cure Work?

The Cast and Cure process embosses a UV varnish so that it bends light, creating a holographic effect. While Cast and Cure film is temporarily ‘laminated’ to the varnish, UV light is cast through the film, curing the image into the UV varnish. The Cast and Cure film then is lifted off the substrate and rewound for reuse, leaving no film behind. The Cast and Cure material can be embossed with a variety of standard patterns and can support customized designs. It is compatible with clear label, wet label, coated paper, paperboard, film, heat-sensitive material and shrink film.

Cast and Cure creates affordable, sustainable and stunning visual and tactile effects. Since Cast and Cure leaves no material on the substrate, it does not obscure the underlying design. It’s easy to enhance existing designs without creating new artwork. Cast and Cure’s reusability reduces the cost of embellishment and dramatically reduces waste compared to the 1:1 application of other embellishments.

As stated earlier, Cast and Cure is reusable – reducing the cost and waste. With proper use, the films have been reused five or more times for certain applications. Breit Technologies offers dedicated Cast and Cure equipment for both sheet-fed and wide and narrow flexographic presses. There are several machinery options in the marketplace, including digital equipment that can apply Cast and Cure inline, as well as many popular cold foil systems. This flexibility in application methods allows for affordable embellishment regardless of print process or run size.

Applications

Cast and Cure commonly is used to embellish direct marketing pieces, prime labels, paper and flexible packaging, gift wrap, trading cards and other collectibles. Cast and Cure can be used either in spot or flood coat applications without obscuring designs. It typically is chosen in cases where dynamic brand differentiation is required, but cost efficiency and speed-to-shelf are key. It also can be advantageous for shorter-run projects. The subtle light diffraction of UV film casting looks particularly striking on dark or vivid colors; it does not reflect as well on lighter backgrounds. With custom designs, Cast and Cure can provide additional security features for brand protection as well.

Sustainability

Cast and Cure can be reused multiple times, reducing the amount of material waste and the carbon footprint of transportation of both raw materials and finished product. Cast and Cure film also is recyclable, reducing the embellishment waste stream. With UV and EB curing, Cast and Cure embellishment produces no VOCs and significantly reduces energy use in processing. Since no additional material is laminated to the substrate, Cast and Cure embellishment has no impact on the recyclability or compostibility of the product.

Breit Technologies inventories a variety of stock patterns and finishes. This includes 30 standard holographic patterns, scuff resistant matte, soft touch matte, Clear Super Gloss and non-holographic textures, such as brush stroke, canvas, linen and leather effects.

For more information on Breit Technologies’ Cast and Cure films and equipment, visit www.breit-tech.com or call 913.492.8081.

Trading Card Trends 2024

June 11, 2024

By Jeff Peterson, editor-in-chief, PostPress

The trading card industry continues on a positive trajectory. Just the sporting trading card industry alone expects to reach over $2881.7 million by 2028. The industry was strong before the pandemic, but COVID-19 sparked a resurgence that has continued today and is expected to continue well into the future. Other trends that have sparked growth include NFT (non-fungible tokens) integration that offers a novel digital experience, increases in special editions and autographs, and the overall online marketplace that has facilitated the ease of buying and selling trading cards.

At the core of the design of today’s trading cards is the use of specialty embellishments to help create differentiation and value. The creativity and application of metallics, specialty UV coatings, laminates and other embellishments continue to grow and prosper.

At the recent 2024 Print Embellishment Conference (sponsored by FSEA), one of the panels included a group of experts involved in the production of sporting and gaming trading cards. With the conference taking place in Dallas, Texas, the epicenter for trading card production in the US, the event provided a perfect landscape to bring sources together from different sections of the production process. The panel included Brandon Lesley, Fanatics; Jim Singer, Brodnax 21C Packaging; Stefan Congram, Cartamundi; and Doug Fontana, Xplor Group.

Trading cards (both sports and gaming cards) have seen a new spike in popularity in the last few years. Can you discuss why you believe this has happened, and do you foresee this growth continuing in the future?

Lesley: During the pandemic, people found new ways to spend their time and money, and people really got back into collecting. And, I predict the market will continue to increase and remain steady over the next 10 to 20 years for sure.

Singer: We have been printing and embellishing trading cards for many years. We have moved to cold foiling even base cards that are not the main collectibles. We also have been building up our digital workload and recently added 40″ digital printing and digital embellishment processes to our operation.

Fontana: I believe the pandemic certainly had a huge impact, with people staying at home and looking for hobbies. That clearly was the reason for the spike. We do a great deal of the finishing work on the trading cards, and the innovative ideas are amazing and are keeping the collectors interested.

Congram: We work on the gaming side of trading cards, and the pandemic certainly had a major impact. A lot of people who played board games in the 1990s as kids were bringing the board games back out again. And, coming out of the pandemic, there have been new licenses and new entrants in the gaming market that are sparking even more growth.

Both metallic and coating embellishment technologies continue to dominate the design and production of trading cards. Why do you believe this is the case? What drives the use of specialty effects and embellishments for cards?

Congram: It is the nature of the product itself for both gaming and sports cards. Collectors receive the cards in a sealed pack, and it is all about the chase. It is a treasure hunt. So, the nicer the piece of treasure is, the more valuable that chase card is that you’re looking for. The embellishments elevate the aesthetics of the card of that player and directly drive up the value of the card.

Fontana: Embellishments dominate the card world. It is the appeal and the hunt for the perfect card – a card that someone else doesn’t have. The trading card companies keep asking us to push the limits with specialty effects.

Singer: With new digital embellishment technology, set-up time is very quick and the tooling is zero, so we can provide all types of samples and prototypes and do a lot of innovative things with the cards. This provides the trading card companies additional choices for foils and specialty coatings.

Lesley: Collectors want to feel and touch things. We live in a digital world where everything is disposable. When people buy cards, they keep them. We discuss this with our designers all the time. You are designing something that someone can pass down to their grandchildren, as opposed to marketing materials or a digital asset. Embellishments make a difference because they create emotion for the collector as they go through packs – they are looking for something that really jumps out, as well as the texture and the shininess of it. People want something that makes them feel different as they break open a card pack.

What types of embellishments are you seeing being used on trading cards? Are you seeing growth in any specific type of embellishment technique or process?

Singer: We have invested a great deal in digital embellishment technology for trading cards, opening up new opportunities. We can create an etching effect using the raised polymer over the top of the foil with stunning effects. We also can get very fine line work with foil and spot coatings with our digital embellishment technology. We continue to try to innovate. Recently, we laid down a cold foil on a second surface so you can see through the adhesive to the foil. When you look at it from the front side, it looks like a piece of glass. The sky is the limit because our customers always are asking – what if we do this?

Fontana: We have been seeing a great deal of clear plastic, synthetic paper and other variable stocks. There continues to be R&D on different substrates and embellishments.

Congram: Certainly, different types of paper and substrates are being used. Some of our new games want a specific holographic pattern developed for them that has never been seen before. Three-dimensional holograms are making a comeback, too. I have seen new requests for registered holograms or patterns. The holograms also are important for authentication or anti-counterfeiting.

How has the increase in digital embellishment processes enhanced the growth of digital for larger runs that are done more conventionally with hot or cold foil processes?

Fontana: Digital embellishment technologies have allowed printers and finishers to be extremely creative for those special valuable cards in a pack. The lower-value cards go through embellishment processes as well – usually more traditional foil stamping, UV coating or cold foil. I believe that is where it is. The digital embellishment processes are being used for high-end, difficult-to-find cards in each pack.

Singer: Even more standard cards include cold foil and other processes, so the expectations are higher for every type of card. We, hypothetically, can run a mass volume with our traditional platform and through our digital processes, adding additional embellishments on certain cards. All the processes are working together – conventional processes with digital – creating even cooler, more interesting cards.

What types of changes do you predict for the trading card industry in the future? Do you believe embellishment processes will continue to be an important part of the industry moving forward?

Lesley: In the next three to five years, embellishments will continue to be a very important part of the trading card market – probably the most important part. You have to create value in different ways, and I think you do that through embellishments. Innovations and new processes will continue to happen. We have done more testing in the last year than we have in the previous six years on new processes and ideas and how to use them on cards.

Congram: I believe the complexity of processes will be a given. It’s not going to get simpler. We continue to have requests to make the creativity for our games and cards more exclusive. I predict more short runs and more frequent releases (drops) in the market. However, costs still will be a factor. We will have to find ways to keep costs in line. As the rarity model sort of shifts, and we want to give more people more rare cards, we are going to see the evaluation of production costs more heavily scrutinized.

Metallic Transfer Decorating, the Sustainable Choice for Print & Packaging

June 11, 2024

By Steven Schnoll, Schnoll Media Consulting

Sustainability is becoming increasingly important for the packaging world, including cartons, labels and more. Sustainability is not just a buzzword but a core part of the packaging industry value chain. Today, consumers, brands, packagers and governmental regulators are heavily focused on the environment and the demand for sustainable packaging solutions.

In the highly competitive retail marketplace, brand owners know that consumer attitudes are vital in purchasing decisions. Creatively designed packaging structures create a First Moment of Truth (FMOT) in purchasing decision-making. For brand organizations to thrive, creating dynamic packaging is paramount. Realizing this, Consumer Packaging Goods (CPGs) manufacturers turn to innovative technologies to help their packaging stand out. This includes metallics and other specialty effects for print that can transform and influence a consumer’s purchase decision.

Sustainability Education

Let’s define the words “repulpability” and “recyclability” regarding paper and packaging. Repulpability refers to the ability to convert paper back into pulp, whereas recyclability generally is about the capability of a substrate to be processed into new paper or paperboard. Repulpability is a critical characteristic of paper products that are intended to be recycled. When recycled, paper is mixed with water and turned into a slurry. The slurry then is screened to remove contaminants, and the resulting pulp is used to make new paper products.

It is a rapidly evolving area where CPGs and consumers are concerned but remain confused about sustainable packaging. Actual sustainability performance will depend on which element is prioritized. Sustainable packaging demands less use of natural resources, making repulpability very important (vs. managing natural resource depletion). Municipal Recycling Facilities (MRFs) also are critical in the packaging supply chain. How they process printed materials with metallic effects is essential to creating a more sustainable future. Packagers and brand companies want to learn from experts about significant research and the efficient and feasible recycling process for metallic transfer processes.

FSEA Studies Recyclability

In 2021, the Foil & Specialty Effects Association (FSEA) sponsored a sustainability study conducted by Georgia Tech’s Renewable Bioproducts Institute to demonstrate that paper and paper boards with foil-stamped metallic transfer foils can be repulped. Georgia Tech researchers tested a 12 pt coated, one-sided card stock with 50% up to 100% metallic transfer coverage. The conclusions:

75% of metallic transfers could be repulped with very low rejects.
The aluminum in the metallic transfer foil could be broken down into small particles and were removed from fibers during screening.
The sample sheet demonstrated similar physical strengths to recycled paper fibers.
It is feasible to repulp the paper that included the metallic transfer foil as it is done in standard recycling settings.

More recently, FSEA has taken a further step and has unveiled its newest study – Recycling of Fiber-Based Materials with Transfer Metallic Decoration. The study was commissioned by FSEA and was conducted by the Van Dyk Technology Center. The testing at Van Dyk, one of North America’s leading providers of comprehensive recycling and sorting systems, included 20 samples of eight different products. The following were the conclusions from the testing:

The eight folding carton and greeting card samples were tested at the Van Dyk Testing Center to mimic various functions found in MRF sorting plants in a laboratory setting.
All eight samples of folding cartons and greeting cards included an estimated 25% up to 75% coverage of transfer metallic decoration.
The summary of the test results for each of the eight fiber-based transfer metallic decorated samples demonstrated that 100% of all samples were sorted to be included in the recycling stream. None of the metallic decorated samples were sorted and destined for landfill.
Brand owners, Print Service Providers (PSPs) and designers have testing conclusions that transfer metallic decoration is most likely being recycled by MRFs.
The test results of the Van Dyk sorting study, with the conclusions from the FSEA Repulping of Foil Decorated Paper study, indicates that fiber-based transfer metallic decorated materials are recyclable and currently are most likely being sorted by MRFs to be included in the recycling stream.

(Both of the above studies/tests are available through FSEA.)

These findings will help packagers meet their sustainability goals without compromising their designs and branding initiatives. Customer expectations constantly are evolving. Consumers want to know that packagers are thinking about the environment as much as trying to make a lasting impression that generates a sale. Forward-thinking brands recognize the significance of ensuring sustainability, and now research clearly illustrates that the repulpability of metallic transfer foils achieves those evolving expectations.

Evolving Brand/Consumer Perspective

In January 2023, the non-profit member-based organization Two Sides commissioned a global survey study of 10,250 people from the independent research company Toluna. Two Sides findings stated that “55% of consumers surveyed prefer paper packaging over plastic.” This is a significant change in attitudes toward printed paper-based packaging. Respondents felt paper packaging is better for the environment than plastic and glass.

In an interview with Ben Markens and Brian Westerlind, who manage the Paperboard Packaging Council, Markens shared “that the ‘bling’ in folding cartons that employ metallic transfer materials creates a great value add for packaging companies selling to brand owners.” Markens pointed out “that while the vast amount of printed folding cartons have no metallic foil decorating, the majority of winners, like high-end beverages and cosmetic packaging (in their recent association competition) utilized foil decorating very effectively.” Markens continued with a significant potential issue for international packagers, “even though US packages are heavily invested in sustainability, the European Union is creating higher standards for sustainability than the United States.”

As brand leaders began to craft sustainability strategies and experiment with different metallic foil applications, they needed answers from suppliers. Diamond Packaging of Rochester, New York, is a leading packaging converter focused on green initiatives. Diamond Packaging realizes its sustainability actions can profoundly impact the industry and the environment. In a recent interview with Eric Longnecker and Dennis Bacchetta, the two made it clear through the Diamond Packaging Greenbox initiative that they are “empowering our brand customers with creative metallic design transfer capabilities that meet or exceed customer expectations for recycling folding cartons.” Diamond Packaging is committed “to focusing on sustainability throughout the entire operation.” They believe the company’s commitment to sustainability in their operation makes them more attractive to CPGs to seek them out as a supplier.

During an interview, Longnecker shared that “examining the scientific impact of foil transfer is an ongoing mission.” Bacchetta stated that 40% of all the folding cartons the company produced for customers utilize metallic foil transfer processes. Diamond Packaging has created a fact sheet called “Decorative Foil by the Numbers,” which takes a closer look at the consumer and environmental issues related to metallic foil in packaging. Its facts include:

The Value of Foils: Perception Research Services did a study in 2004 that showed that decorated foil packaging had an 80% higher appeal and brand awareness. This was supported by an FSEA study that found that foil had a 44% better chance of attracting consumer attention.
Recyclability of Foil: The Georgia Tech and Western Michigan research studies validate this premise.
Literally Splitting Hairs: The aluminum foil layer is less than .05 microns, a fraction of the width of a human hair.
Zone Coverage: Another way to analyze this fact is to take a jumbo roll of foil weighing 440 pounds and covering the length of 2.4 football fields. The amount of foil on that roll weighs 1.043 ounces and measures .66 cubic inches in volume, about the same as the tip of one’s thumb.
Carbon Neutrality of Paperboard: The American Forest and Paper Association and American Wood Council clearly state that paperboard is carbon neutral.

Attracting Consumers

As stated, consumers are focused on brand identification (FMOT). Metallic decorating is an excellent example of creating special effects on printed substrates that attract consumers to a specific brand. The power of using metallic effects, whether hot, cold or digital, is a significant brand identifier and attraction for consumers.

Chris Leary, a US distributor for Gietz and Vinfoil, shared an incredibly detailed presentation designed for packaging and metallic transfer processes. Leary illuminated the value chain for metallic cold foil decorating in this document. The presentation highlighted the value proposition and the “de-inkable and repulpable characteristics.” It also stated, “72% of consumers are influenced by product packaging, and 36% would consider avoiding a brand that isn’t actively trying to recycle packaging.”

Glorious Gaming is a dynamic, growing company producing computer accessories for gamers. Its products are colorful and exotic in their design. Therefore, according to Chris Wilson, the company’s packaging engineer, “We needed packaging that would be ‘eye-catching’ to our potential customers.”

The company did a great deal of research and determined that metallic transfer technologies met its packaging expectations. While its creative designs drive customers to purchase products, Glorious Gaming also wanted to make sure its packaging would be sustainable by being repulpable and recyclable. The FSEA Georgia Tech research built a strong confidence in using metallic foil decorating.

Working Toward the Future

Karen Kromat of Case Paper, a leading distributor of transfer metallic substrates, believes that “metallic substrates present a genuine growth opportunity for the printing industry.” While issues still have to be addressed concerning the plastic adhesive liners that are not recyclable, municipal recycling centers can successfully recycle vast quantities of metalized packaging products. Case Paper is committed to helping make its metalized transfer substrates as sustainable as possible while recognizing that many municipal recycling centers are rejecting plastic adhesives while accepting transfer metallic decorated recycling products.

A sub-committee of FSEA’s Sustainability Committee is working with MRFs to ensure that metallic transfer foil packaging is recycled correctly. The big question in front of the committee and for recycling facilities is ‘where does the decorated packaging material go?’ The goal is to have MRFs carefully test transfer metallic decorated packaging with many organizations to facilitate the best recycling processes. Frank Kelly, ITW ShineMark, sub-committee chair, said, “This is an ongoing process and FSEA is committed to finding workable solutions.” The goal is to increase MRF operations’ efficiency while simultaneously creating more recyclable and repulpable by-products.

Conclusion

FSEA is committed to assisting brand owners, converters, printers and consumers to develop the most dynamic, growth-oriented and exciting metallic transfer decorating methods for the packaging supply chain. Innovation and sustainability in packaging entrepreneurship are core values of everything it does. Helping the the industry design new environmentally friendly business models with dynamic metallic transfer embellishments while fostering entrepreneurial ecosystems around the globe will never be compromised.

PRINTING United Returns to Las Vegas

June 11, 2024

Make Plans To Be ‘Where the Industry Gathers’ in September 2024

Edited by Erin La Row, writer, PostPress

PRINTING United Expo 2024, a global printing event serving markets across all printing segments, will take place September 10-12 at the Las Vegas Convention Center in Las Vegas, Nevada. The three-day event, with the theme, ‘Where the Industry Gathers,’ will include over a million square feet of equipment, technology and trends on display covering all facets of the printing industry.

As this issue of PostPress magazine was going to press, more than 600 exhibitors from around the world already had booked booth space at this year’s Expo – with show organizers expecting 800 or more exhibitors to participate as had participated in 2023. The event will showcase the latest advancements in printing technology, featuring a wide range of interactive exhibits and demonstrations. Attendees will have the opportunity to explore the cutting-edge equipment, innovative solutions and groundbreaking techniques that are shaping the future of the printing industry.

For 2024, special Women in Print Alliance programming and events are being planned, as well as interactive show floor experiences and co-located segment-specific forums, such as the Apparelist Forum, PRINTING United AFTER DARK and more. The Foil & Specialty Effects Association (FSEA) will sponsor a presentation – Metallic Effects for Print. Jeff Peterson, FSEA executive director, will share information on the different metallic decorating methods available for print and the advantages and disadvantages
of each.

In a news release about the event, Mark J. Subers, president, PRINTING United Expo, said the Expo is more than an event; it’s a gateway to innovation, collaboration and boundless possibilities. Concepts in printing, such as sustainability, artificial intelligence (AI) and the latest in market trends – including net-new label and packaging opportunities – are areas of focus this year.

“In this dynamic space, connections are forged, ideas are sparked and the future of printing is shaped,” Subers said.

The following is a list of exhibitors involved in print finishing and embellishment processes to visit at Printing United:
Absolute Printing Equipment Booth #C1941
B&R Moll, Inc. Booth #C1991
Baumer hhs Booth #C1990
Book Automation / Meccanotecnica Booth #C701
Canon U.S.A., Inc. Booth #C1415
Capital Adhesives Booth #C2464
Challenge Machinery Booth #C2815
Colter & Peterson-Microcut Booth #C3169
CP Bourg, Inc. Booth #C2637
Cutworx USA Booth #C946
Die Cutting Advisors LLC Booth #C1445
Duplo USA Corporation Booth # C1961
Foil & Specialty Effects Association (FSEA) Booth #C4318
Gateway Bookbinding Systems Ltd. Booth #C130
Graphco Booth #C2351
Harris & Bruno Booth #C928
Heidelberg USA Booth #C2291
Hot Stamping Machines / O.R. Printer USA Booth #C1889
KDX AMERICA Booth #C1485
KURZ Booth #C2195
Leary Co., W. H. Booth #C2783
Match Machinery, Inc. Booth #C2341
MBM Corporation Booth #C3361
Muller Martini Corp. Booth #C2561
Neenah Booth #C104
Nobelus LLC Booth #C2545
Plastics Decorating Magazine Booth #C4318
PostPress Magazine Booth #C4318
UV+EB Technology Magazine Booth #C4318
Plockmatic Document Finishing, Inc. Booth #C1947
Punchmaster Tool & Die Ltd. Booth #C1008
Rhin-O-Tuff Booth #C2031
Rollem International. Booth #C1461
Sakurai USA, Inc. Booth #C1785
Skandacor Booth #C1225
Spiral Binding Booth #C912
Standard Finishing Systems Booth #C1561
Sun Chemical Booth #C3031
W+D North America Booth #C2769
Xerox Corporation Booth #C2614

For more information, visit www.printingunited.com.

Sakurai Demonstrates Specialty Coatings and Foils on 2024 Calendar

June 11, 2024

By Jeff Peterson, editor-in-chief, PostPress

The 2024 Sakurai Calendar, entitled “Beyond Your Imagination,” utilized screen printing and UV coating technology as well as its foil decorating technology to create a spectacular, seven pass calendar that was designed and printed by Kumazawa Screen Printing, Tokyo, Japan. The seven passes were printed, coated and foiled on a Sakurai Maestro Cylinder screen pPress, equipped with a Natgraph dryer and Sakurai LQM-105 screen foil hot foil stamper.

The design of the 2024 Sakurai Calendar was centered around the renewed Sakurai website and four symbolic designs utilized on the home page. The symbols represent the motif of “S” of Sakurai and express the technical skill, rationality and delicacy of the product. The other symbols represent innovation, society and co-creation. The direction of the design was to showcase the four symbols in dramatic metallic foil (red and silver) down the center of the B1 sheet size. The months and days of the year are decorated in gold, red and sliver foil colors down both sides of the design. The design was completed with specialty clear textures with clear UV coating applied throughout the background of the calendar.

The calendar utilized the LQM hot foiling technology to transfer a clear screen printed UV coating to the foil decorated areas. The coating works as an adhesive and reacts to the foil as it is applied. It allows large coverage of foil (demonstrated by the four symbolic designs) and finer lines (demonstrated by the days of the week for each month). In addition, the foil method provides the opportunity to lay down a raised screen coating and raised foil. It also is possible to include a textured clear as the base layer to give a foil a certain look. On the calendar, a sandy clear coating was applied as a base to a portion of the red metallic foil areas in the symbols, providing a unique contrast and different look. The foil for the calendar project was provided by Murata Kimpaku Co., Ltd.

The background was simply divided into two parts with a white background on the left side and a screen printed solid black background on the right side to highlight the foil. The final pass on the calendar laid down two separate clear UV coating patterns on both the white and black background. The two separate patterns demonstrated how two background patterns could be applied in one pass on the machine.

“We are honored that a Sakurai calendar was selected as a Gold Leaf Award winner for the fourth year,” said David Rose, vice president, Sakurai USA. “Our 2024 calendar truly showcases the overall capabilities of the Maestro press to apply both specialty coatings and inks, as well as decorative metallic foils.”

Protecting Print Businesses from Digital Disruption

June 11, 2024

By Tom Wojcinski, principal, and Michael J. Devereux II, CPA, CMP, partner, Wipfli

Is there anything a manufacturer can do to ensure its operations are not hacked? Unfortunately, there is no way that’s possible, especially in today’s connected manufacturing environment. Even if a printer or print finisher disconnected everything from the internet, it still could be the victim of a technology hack if physical access is available to any bad actors or those working on their behalf.

Cloud-based ERPs, digital transformation and Industry 4.0 solutions are creating efficiencies, customer engagement and business intelligence that are improving operations and profitability, which cannot be duplicated on analog systems. Consequently, however, this increased digitization creates greater risk to printers’ and print finishers’ data and operations; and the research has shown that no manufacturer is too small or too big to be safe from cyber-attacks. Leadership often assumes that no one will hack their company because the data isn’t valuable to others. The bad actors disagree, however. Data is valuable, and they would like to put the company in a position where it must pay a ransom to get its data back. And data isn’t just limited to financial information, it could include confidential customer information, bills of material, product designs, processing data, sampling results and more.

Wipfli recently conducted a survey of over 200 manufacturers. The survey found that almost half of the respondents experienced three or more network breaches in the past 12 months. That can be overwhelming to leadership, not to mention IT staff or the supporting organization.

Focusing on Manufacturing Resilience

A company’s data isn’t the only thing at risk. Cyberattacks can focus on physical assets, rather than digital assets. Cybercriminals can lock up or seize equipment operations. Not only can this result in a significant amount of unplanned downtime but can also pose a physical risk to employee safety.

For example, consider a printer or print finisher that stores and recalls processing data for each job within an ERP or MES system. What happens if those digital services are disrupted or the underlying operational data is held hostage? Or a worse scenario, what if the technical specifications are changed, and the print finisher continues to make end products that don’t meet internal or external specifications? Similarly, vision and quality systems within the plant could be vulnerable and the target of a potential attack. While some of this seems implausible or unlikely, cyber-attacks are becoming more sophisticated and aggressive, and exposure in these areas can cause very real risks to organizations.

Printers and print finishers can protect their operations by building and implementing resilience strategies to cyber-attacks. In this instance, resilience does not mean “bullet proof.” Rather, it means that a company can resist an attack, respond quickly and thoroughly when the attack occurs, and efficiently recover any data or business operations that are compromised. That starts by identifying weaknesses in the digital perimeter and then building a multilayered strategy to protect and respond to the cyberattack.

Common Blind Spots

There can be multiple physical and digital avenues into operations or data (including financial, operational, technical or front office information). Often, these paths are hidden or are seemingly insignificant. Outdated and unsupported hardware and software on the shop floor are two of the most overlooked sources of vulnerability. While this equipment may not be used like traditional PCs or laptops, it is still connected to the network. If it’s not maintained, it could be a security risk to the organization.

All too often, the IT department is not involved in all IT decisions. With the advancement of software-as-a-service model and cloud computing, it’s easier for employees to purchase new software, download applications or share files using the cloud, without the oversight of skilled IT or cyber professionals. Systems and software that are not vetted against company policies or maintained properly could pose additional, not-so-obvious risks. In addition, they extend the number of vectors a bad actor may use to gain access, often without a company’s knowledge, making it more difficult to protect data and operations.

A lack of real-time cyber monitoring is another common blind spot. Without real-time monitoring, a company has no visibility into attempts to infiltrate its network. Stopping and safeguarding against attacks is harder if a company does not know that they’re happening. For instance, real-time monitoring can protect against the violation of impossible travel rules. In this scenario, a legitimate user logs into the network from his or her home office in Milwaukee, Wisconsin. Let’s assume this is the corporate controller of a print finisher, just outside of Milwaukee. Then, just three hours later, the corporate controller logs in from Dublin, Ireland. This is an impossible travel scenario and clearly a sign that the corporate controller’s credentials have been breached. However, it could go unnoticed for some period of time without proper, real-time monitoring in place.

Creating a Multi-faceted Security Strategy

The most effective means to resist an attack is to establish a multilayer security strategy. At its most basic level, the strategy should include:

Password protocols: Require the use of strong passwords.
Email protections: Technologies that limit spam and spear-phishing attempts will reduce the risk of social engineering.
Multi-factor authentication (MFA): MFA requires users to take additional steps to verify their identity anytime when logging in or accessing a system or company app. MFA should be implemented on all removed access points, as well as internal administrative accounts. This includes email, VPN and all cloud-based applications.
End-point detection and response (EDR): EDR increases the ability to detect suspicious events by providing real-time visibility into potential attacks. EDR often is confused with antivirus software, which should also be used. Antivirus software looks for malicious programs running on the computer or network, while EDR searches for malicious activity in the memory of the computer.
Regular vulnerability scans and penetration testing: If a company is not monitoring its environment, printers and print finishers cannot identify their vulnerabilities or ways to fix them. Monthly or quarterly penetration testing of the external systems and vulnerability scans of the internal systems are critical to identifying weaknesses before they can provide access to bad actors.
Vulnerability management: Cyber criminals are regularly probing for security gaps. A company can make it more difficult for them by deploying security patches and software updates, removing unnecessary software and disabling unused system processes.
Air-gapped backups & segmented networks: If an employee can browse directly to the company’s backup files from its primary network, they are not safe from ransomware or other cyber-attacks. Separated backup files on a stand-along network that requires separate credentials often mitigates this risk.
Recovery testing: What happens if a company is attacked? Have steps been taken to restore the network, files or operations? Are the backups occurring as designed? A network failure or cyber-attack isn’t the best time to find out files haven’t been backed up or do not have the means of restoring them. Businesses need to regularly test the backup process to confirm the protocol is working, as designed, and intended.

The Importance of Employee Engagement in Cybersecurity

It’s critical that employees understand the importance of cyber security. Many hackers don’t hack systems, they hack people, as they’ve found it’s easier to trick someone into sharing their credentials than to break into a network. That is, if someone gives them the keys, why mess with the lock. It’s for that reason that employee engagement on cybersecurity is just as important as the focus on a company’s perimeter.

To start with, print-related businesses must put controls in place to govern how data and information are used, managed and stored. Sensitive data should be limited to those who absolutely require it to perform their job functions.

In addition to understanding where the data is stored and who has access to it, the best practice is to implement a comprehensive training program. Hackers will use a variety of social engineering techniques to steal information, including email (phishing), SMS text messages (smishing) and phone calls/voicemail (vishing). Training employees to be skeptical is key. When employees understand what they need to do and why, company operations will be better protected against cyber criminals.

Regular Cyber Assessments

Finally, manufacturing businesses operating in the print industry should engage in regular cyber assessments, whether that’s done internally by IT staff that keeps up with the cyber security trends or by an outside firm. These assessments provide visibility into potential avenues bad actors can access data. From there, businesses can develop or modify safeguards and policies that can better protect them from cyber fraud.

Tom Wojcinski is a principal in Wipfli’s cybersecurity and technology management practice. He leads a variety of engagements designed to help improve organizations’ cybersecurity posture, including cybersecurity risk assessment, control program development and implementation, incident response planning and simulation, vulnerability and penetration testing, security audit, control verification, and managed security services. Wojcinski is a frequent author and speaker on cybersecurity and information technology risk management topics.

Michael J. Devereux II, CPA, CMP, is a partner and director of Manufacturing, Distribution & Plastics Industry Services for Wipfli. Devereux’s primary focus is on tax incentives and succession planning for the manufacturing sector. He regularly speaks at manufacturing conferences around the country on tax issues facing the manufacturing sector.

For more information, visit www.wipfli.com.

Applications Portfolio Pushes Boundaries with Extreme Embellishment

June 7, 2024

Edited by Erin La Row, writer, PostPress

The team at Print Panther Direct, a commercial printer in Oakville, Canada, prides itself on creating beautiful, meaningful print. Printing print that matters is the philosophy that guides each project, including the Extreme Digital Guide 4 – the fourth of its Designer Guides – that was created to highlight the company’s print embellishment capabilities. The Extreme Digital Guide 4, christened the Applications Portfolio, weaves together the essence of its predecessors while further pushing the boundaries of embellishment with incredible detail. The Applications Portfolio’s aesthetic and tactile appeal captured the judges’ attention at the Foil & Specialty Effects Association’s 31st annual Gold Leaf Awards, where the project won Best of Show: Best Use of Digital Embellishment.

“Each spread was crafted to showcase our expertise but also to resonate with the evolving market demands, such as the cannabis packaging segment,” said Christine Yardley, president of Print Panther Direct. “The Applications Portfolio represents an evolving journey with Konica Minolta (KM), building upon the foundation laid by three previous Designer Guides.”

The creation of the portfolio began with research identifying emerging trends and market demands. From there, the Print Panther team conceptualized each spread, considering both aesthetic appeal and practical application. The design phase involved digital mock-ups and iterative refinements until each spread met the company’s exacting standards.

“We opted for a premium turned-edge binder/box to elevate the portfolio’s visual and tactile appeal. By using high-quality materials, we aimed to convey a sense of quality and craftsmanship that would resonate with our audience,” Yardley said.

The graphics for the portfolio were created using a combination of digital design software and traditional artistic techniques. Special consideration was given to the integration of imagery and typography to create visually compelling spreads that effectively communicated each concept. Additionally, the Print Panther team ensured that the design was adaptable to various printing techniques and embellishments, allowing it to achieve the desired visual impact.

The portfolio features a range of specialty effects and embellishments to enhance its visual appeal and tactile experience. This includes digital foil and varnish applications, as well as laminations, which add depth and dimension. Yardley said that these embellishments not only elevate the aesthetic quality of the portfolio but also highlight the versatility of KM’s printing technologies. The paper stock used was Supreme Silk Cover 12 point pages/box 80 lb text, laminated.

State-of-the-art printing technologies played a crucial role in achieving the desired quality and consistency across each spread. Stunning visual effects and unparalleled print quality were achieved with various KM Accurio presses, including Print Panther Direct’s Accuriowide 160 Press. Extreme embellishment was achieved with the KM JETvarnish 3D Evolution press.

Creating a product that has multiple embellishments and design processes can be challenging. Throughout the project, the team encountered various design and production challenges, including adhesion issues when applying CMYK on top of a chosen lamination.

“By leveraging our collective expertise, we were able to overcome these challenges and deliver a portfolio that exceeded expectations,” Yardley said.

Response to the Applications Portfolio has been overwhelmingly positive. Yardley said the portfolio has served as a valuable resource for designers and print professionals, inspiring creativity and showcasing the capabilities of KM’s printing technologies.

“Winning Best of Show in the Gold Leaf Awards was a moment of immense pride and validation for our team. It was a testament to our dedication, creativity and unwavering commitment to embellishments,” Yardley said. “We celebrated this achievement with gratitude knowing that it wouldn’t have been possible without the collective effort of every team member involved.”

Saddlestitcher Heads – 7 Deadly Sins to Avoid

June 6, 2024

By Team Technifold USA

As users increase the speed on a saddlestitcher (or any piece of bindery equipment,) they’re likely to see more and more defects as the speed increases. There are many components that make up an automatic inserting, stitching and trimming line, each designed with operating specifications and limits. If any single component is slightly worn or not set correctly, it will prevent the machine from running at its maximum designed speed. Lots of little defects and weaknesses can add up to big losses in productivity.

The stitching head is one especially critical area for proper operation of a saddlestitcher at any speed. Even the simplest of newer stitching heads is a complex piece of equipment which, if not properly handled, will cause slowdowns, poor-quality stitched books and machine downtime.

In a conversation with Dave Double of Double Equipment, which specializes in bindery equipment repairs, including servicing of stitcher heads, it was brought to light the seven common but costly mistakes that stitcher operators and bindery managers make with their stitcher heads.

1) Using the wrong lubricant. Several common heads use a one-way bearing in their wire-advance system. Operators often use the wrong grease which, at higher speeds, results in varying leg lengths in the stitch. This leads to a frustrating troubleshooting expedition where the operator is trying to ‘fix’ a head that simply requires the correct grease.

Also, stitcher manufacturers usually recommend light machine oil and not the automotive oil which often is used. Be sure to use precisely what is recommended.

2) Using the wrong amount of lubricant. Any stitcher operator who’s been around a while has made this mistake – put too much oil somewhere on the stitcher head and the next few thousand books are a nightmare! Excess oil makes its way through the head and through the rest of the machine. In extreme cases the only solution is to remove the head for disassembly, cleaning and proper oiling.

All that typically is required is ONE drop at the proper location and at the proper interval. If the recommendations say one drop per eight hours of running, make sure that it’s not two.

3) Using the wrong wire gauge for the job at hand. Two of the most commonly used wires are 24 and 25 gauge round stitching wire. They are good all-around wires for most commercial bookbinding and print finishing applications. But if the operator stitching a 3/16″-thick book, or slightly heavier, the 25 gauge is approaching its limit. Problems can arise when near the limit and running at high speed. If the operator goes beyond the thickness limit, he or she is almost certain to encounter new problems.

When stitching an extra-heavy or extra-thin job, be sure to use the best size of wire for the job at hand. It is not common to saddlestitch books beyond 1/4″ thick, but if an operator does and runs into problems, don’t forget to check wire gauge.

4) Using the wrong wire gauge for the stitcher head. Each stitcher head has its own suggested limits on wire gauge. Be sure to check the limitations of the wire gauge for each particular saddlestitcher.

5) Using inferior wire. Wire quality varies considerably among manufacturers. Some factors that affect stitching wire performance are tensile strength, consistency of wire size, cleanliness, resistance to flaking, type of coating and type of alloy.

For instance, an inexpensive galvanized wire may start to flake and/or leave excess wire shavings when cut inside the stitcher head. This, in turn, will clog the head and cause premature wear on numerous internal parts. It also can make it difficult to get a properly formed stitch at higher speeds. Generally speaking, a tinned wire or a premium galvanized wire will run better, with less flaking and a more consistent coating, cleanliness and strength. If a facility does enough stitching, consider the larger 70# spools equipped with a de-reeler. These are not wound as tight as the smaller spools, so there is less variation due to changes in the wire curl.

6) Lack of regular servicing. Stitcher heads need regular maintenance, lubrication and service. If a finisher or binder doesn’t have someone on staff who is qualified to rebuild and repair stitcher heads, send them out regularly to someone who can. It is money well spent that will keep the stitcher running smoothly.

7) Instruction manuals that never get opened. Each model has its own special requirements and peculiarities. It’s been said a person can learn either through wisdom or suffering. There is wisdom gleaned from reading the manual.

There have been instances when operators have transitioned to a different saddlestitcher, needed to install a new stitcher head and simply didn’t consider the differences in the saddlestitcher. This can cause enormous damage to the machine and head. Installing the wrong head can turn into hundreds or thousands of dollars in repairs.

No matter which stitcher head is being used, be sure it’s set correctly to give a good cut, consistent wire draw, equal leg lengths, proper clincher and clincher alignment, and correct compression.

Most bindery equipment operators like to have a performance edge available to them when they need it, especially if they want to go home early! Although running at maximum speed is not always the best way to get maximum yield, it sometimes is both possible and necessary. On those occasions when a bindery must run at maximum speed, it’s nice to be able to do it without gremlins like those mentioned above slowing operations down. The good news is that these stitcher head tips are simple to follow.

Thank you to Technifold USA for its assistance with this article. For more information, visit www.technifoldusa.com.