Instant Attention Grabber

This month and next month, packagePRINTING will cover two types of packaging enhancements closely linked together: stamping and embossing, and next month, foil decorating.

According to Steve Lee, vice president and director of technical support with RotoMetrics, “Stamping and embossing have quickly become recognized as value enhancements.” It’s well known that consumers experience a tremendous amount of visual noise as they peruse store shelves. “In the competitive retail world,” says Christopher Raney, vice president, folding carton, Bobst, “you need a package to stand out on the shelf. Whether it is foil or embossing, they will both make a difference.”

Jim Kingsby, technical service manger, ITW Foilmark adds, “Foil stamping and embossing give a package eye-popping appeal a the point of purchase. The content in the package is only as good or unique as the label it bares.”

Steady progress

There have been several notable enhancements to stamping and embossing equipment during the last 10 years. The most recognizable improvements have been in speed and efficiency.

Lee states that equipment speeds have increased and foil stamping and embossing have kept pace by introducing high-speed foils, quick changeover foil stamping and embossing dies/tools, and improvements in product performance.

Frank La Croix, vice president, Matik North America, says, “In the last 10 years, we have seen the ability to run sheetfed foil stamping presses faster. This is brought about by new foil formulations that transfer at these higher speeds, and foil tension controls that allow for quick transfer of the foil onto the sheet without creating any slack in the foil web that results in web breaks.”

Raney adds that key improvements have been the speed of foil stamping, which is possible because of accurate foil advances. “Register systems are either conventional (foil effectively registered to the sheet edge) or dynamic (allowing the foil image to be positioned to the print for much higher register accuracy),” he says.

Some advances in stamping and embossing machinery have taken the process out of the finishing room and back to the press room. In the case of cold-foil application, “This gives converters and printers enhanced capabilities including the ability to produce a product in a single-pass process,” says Mark Rasmussen, product manager, postpress packaging, Heidelberg USA.

Rasmussen also lists technology improvements that greatly reduce waste and increase productivity as improvements during the last 10 years. He cites better web tension control systems that allow optimal control of foiling materials as the impetus for waste reduction and increased productivity. “With computer-assisted manufacturing, more intricate designs can be created less expensively. Specialty embossing and foil stamping is more widely accessible now—not just the exclusive domain of the trade finishers,” he says.

There have also been advances in the oil heating systems used for hot-foil stamping. Contained oil heating systems—where the oil does not come in direct contact with the hot stamping cylinder itself—operate by feeding the oil into a hollow mandrel on which the cylinder (solid or magnetic) is ­affixed. “Heating in this manner is very ­efficient and avoids the possible mess of oil systems where the oil is pumped directly into the hot stamp cylinder,” says Lee. “These systems are generally built using larger diameter mandrels to keep the wall thickness of the hot stamping cylinder as thin as possible, optimizing heat transfer.” Other systems use electrically heated, oil-encapsulated mandrels, eliminating oil hoses and pumps next to the press.

Hansjorg Gietz, of Gietz AG, says stamping and embossing are no longer something just for trade foil finishers but, “more and more big packaging companies are starting to in-source stamping capacities.” He cites two reasons: first, the efficiency of today’s ­machines; and second, labeling and packaging printers views that foil stamping as a value-added step where they can earn money.

Staying in shape

As more printers integrate stamping and embossing into their workflows, their investments do not end with machinery. If employing stamping or embossing automatically adds value to the package, ensuring that the equipment used is a necessity.

There are many ways to keep stamping/embossing machines operating at peak efficiency. Lee states that all components should be inspected in a hot stamp station at least once a month. He also adds that ensuring rotation accuracy is the most important aspect of every station in a printing machine—and is no exception for hot stamping and embossing stations. “For hot stamping, as part of monthly maintenance/calibration, indicate the impression roll to ensure it is within the manufacturer’s recommended TIR (total indicator reading) that is of the proper durometer and not worn, which will affect successful stamping,” he says.

La Croix says that many presses have jam-ups that can cause damage to the heat plate and heaters of the press. “The honeycomb base must make ­total contact with the heat plate to have accurate heat transfer to the dies. The foils today do not allow for variances in temperature as in the past,” he says.

Kingsby says in most cases there are not any parts that require periodic replacement, but “having available drive belts, relays, and photo sensor as replacement parts is a huge advantage.”

Raney adds, “Of course, ensuring that the machine is working correctly and that any defects are fixed is a must. In particular, the heating elements and heating zones that exist must all be operational. This will help guarantee that the right temperatures are used to apply the foil.” He also says that all shafts and reels for the foil should be maintained to ensure that the foil is accurately unwound and there are no unnecessary holdups to restrict the foil unwinding.

Implementing lean manufacturing techniques including—preventive maintenance programs for equipment as well as rigorous cleaning programs to assure high-quality—results are important, according to Rasmussen. “It’s also important to have the supplier come in and perform measurements to maintain original equipment specifications,” he adds. “And of course, building strong relationships between your operators and suppliers of both machinery and materials is crucial for optimizing your production process.”

Replacement time

There will come a point when it is just not economically feasible to hold onto a machine, no matter how well it has been maintained.

For Raney, the time to replace stamping/embossing machines is as often as possible. “There was a long period of limited advancement in foil stamping equipment,” he says. “However, in the last few years, there have been a number of improvements that have really improved the register accuracy and the possibility to run faster.”

Rasmussen has a “green” take on when to replace equipment. “Stamping equipment can easily last a decade or longer, but in today’s eco-friendly environment, the amount of energy your machine uses—especially if it’s older—may become an issue,” he says. Newer equipment, outfitted with servos and solid state electronics, will be more energy-efficient, run faster, and provide higher quality, he adds.

Is it that easy?

Stamping and embossing may be two of the most cost-effective methods to enhance a package, but they aren’t necessarily easy to accomplish. First, there is a variety of foils that, ­according to Raney, “allow a customer endless possibilities to enhance a package design. The foiling will be an additional pass, but for the highest quality packages to deliver a high-quality impression to the customer, this is the best way.”

Second, it requires trained operators. Rasmussen says, “Skilled operators are a rarity. Although science is employed in the control systems on the machinery side, foil stamping itself is an art, not a science”. According to Rasmussen, expert pressmen can coax top performance out of even the newest, most technologically advanced presses. “Even though foil stamping is becoming more automated,” he says, “a highly qualified operator can really make it shine.” pP