Decorative Choice by Way of New Processes
By Jeff Peterson, Executive Director, Foil & Specialty Effects Association
Over the last several years, a great deal has changed in how the printed sheet can be enhanced and protected through specialty decorating processes. Technological advancements in the cold foil process, new specialty UV processes, and laser cutting technology are just part of what is now available to create spectacular designs that can stand on their own or enhance printed material such as cartons, greeting cards, invitations, folders, and much more.
Sheetfed Cold Fold Technology
Although cold foil is not brand new to the marketplace, the technology to apply it has become more reliable and has become very popular in the narrow-web flexographic market for label applications. Where it has seen more recent growth has been with the application of cold foil in-line with large-format sheetfed presses. This technology utilizes a tacky adhesive that is applied in the first printing head of a sheetfed printer. The foil is nipped to the adhesive and the foil carrier is stripped away, thereby applying the foil only where the clear adhesive is laid down. Press manufacturers are offering this technology on new presses and there are retrofit units on the market for existing presses.
The print finisher/foil stamper may look at this process as a competitive one to conventional foil stamping, but in reality it has much more of an effect on metalized board or paper. The cost of applying the cold foil to a standard carton stock and then overprinting the foil can be much more cost effective than using a metalized board for many applications. For applications where foil is utilized in just certain areas of the sheet or carton, even if overprinting is involved, traditional methods of hot stamping the foil and then overprinting is more cost effective. Applying cold foil in-line on a sheetfed press is best suited for coated stocks and does not perform as well on dry, porous stocks.
It must be pointed out that cold foil technology does not provide the overall brilliance that can be achieved with applying foil through traditional hot stamping methods. So there are limitations that will continue to keep traditional foil stamping a viable option for many applications.
Specialty Coating and Films
UV coatings, both spot and flood, have been a popular choice for adding a protective shine to all types of printed materials. Recently, extensions to standard UV have surfaced, providing even more choices to enhance the printed sheet. One of these newer technologies is a process called Cast and Cure or film casting. This technology creates diffractive surfaces to produce high-gloss, matte, and holographic finishes with the use of UV coatings and specialty film and can be utilized on both sheetfed and web-fed applications.
The film casting process utilizes a specialty film that has micro-embossed holographic pattern. Once the UV coating is applied, the film lays over the top of the sheet before the coating is cured. Then the sheet with the film still applied runs through the UV dryer and is cured. The film is stripped away, leaving the holographic effect on the sheet. Because there is no actual transfer of a foil or material on to the substrate, the film can be reused several times before new film is needed.
In addition, there is now an array of specialty UV coatings available that can be applied with standard off-line UV coating equipment. These coatings included raised (embossed) UV that applies a heavy pattern (up to 5 mils) to the printed image. It provides both a visual and “special feel” to a printed piece. There are also glitter UV coatings where small metallic flakes can be added to the coating, providing a unique look and an alternative to the conventional glitter process. Thermochromic UV coatings that change colors with temperature change, as well as texture, pearlescent, and even glow-in-the-dark coatings are available.
A new digital process for applying UV has splashed onto the scene that applies the coating through a digital inkjet process versus traditional coating techniques. This technology can apply a flat UV or “raised embossed” spot UV effect to all types of printed materials, including stationary, brochures, greeting cards, folding cartons, and more. The process provides an economical UV solution for short to medium-sized runs and works well for digitally printed materials.
Laminating films have seen many changes over the past few years as well. Films are no longer relegated solely to clear films used for protecting printed materials. Laminating films are now available in many metallic and holographic patterns that can be overprinted or foil stamped. Clear iridescent films are also available, providing a unique appearance when tilted from side to side. They are completely translucent, allowing graphics and text to show through and still provide a unique pattern with the film. Laminating films are an excellent choice when wanting to combine protection with a colorful enhancement. Depending on the application, the ability to provide rigidity to a printing piece in different thicknesses is one of the big advantages that laminating films offer over other decorating processes.
Laser Cutting
Laser cutting continues to grow as a decorative alternative and can provide extremely intricate cutout shapes and graphics. The technology has grown and costs have decreased, making laser cutting a more feasible option for greeting cards, stationary, packaging applications, and promotional mailings. Although laser cutting is making inroads into functional diecutting applications, especially in the digital arena, it is not a preferred process or competing process to standard diecutting. If a shape or printed sheet can be diecut conventionally, that is still the best option, especially in larger quantities. Laser cutting is an excellent choice to provide extremely detailed cuts for decorative purposes and is most cost effective for small-to medium-sized runs. The running speed for a laser cutting job can run from 200 to 2,000 sheets per hour, depending on the job requirements.
Currently, most laser cutting is done by specific companies specializing in the process that work closely with print finishers or packaging houses. However, as the cost of the machinery and technology decreases, adding laser cutting services through print finishers will begin to become a more viable option in the future.
Conclusion
Today, a multitude of effects and processes are available as enhancements to printing or as a standalone decorative processes. There are now a variety of high-visibility effects and finishing techniques to explore and to offer to customers-whether providing it themselves or working together with partners to provide the finished product. The key in today’s market and particularly in the current economic items is to offer a variety of services, including new innovative solutions for the customer.