The Rise and Rise of Print Finishing
By Dr. Horst-Dieter Branser
In the years since drupa 2004, demand for paper and finishing techniques has expanded worldwide, and nowhere more than in commercial and packaging printing. This expansion has gone hand-in-hand with mostly small run sizes and rising demand for increasingly diverse finishing work and combination solutions. Along with this, the trends towards greater use of color and a general demand for higher quality products have gained momentum.
Equipment suppliers to the print and media industry are responding to these new demands by offering not just machines for multi-color production, but also the option of inline finishing with additional printing units.
In parallel with these trends, demands for reduced make-ready and set-up times, greater energy savings and the option of processing innovative, resource-conserving consumables, such as films, adhesives, varnishes and inks, have also risen significantly.
Novel product finishing solutions introduced in Düsseldorf back in 2004 have since become integral elements in the printing process. Print-finishing techniques such as coatings, gold and silver inks, die-cutting and embossing, and hot and cold foil application, are now routinely used to add value to high-quality print products and packaging materials. These finishing techniques give print products an exclusive appearance, and both machine and material manufacturers at drupa 2008 will be introducing products and services in line with this market trend.
Raising the bar at the point of sale
At the point of sale, packaging materials must make a product stand out from its competitors and reflect its market value and branding. Higher value products invest more in sophisticated packaging to achieve this — with the cosmetic industry and its high demands for packaging, a good example of this.
Using the latest production techniques, greater added value can be attained for high value print point of sale and advertising displays, without incurring prohibitive production costs. Because advertising of this kind has an increasingly short life cycle, manufacturers at drupa 2008 will be presenting high-tech electronic systems that support the rapid production of advertising and display materials. In this context, digital printing with flatbed processes will be integrated more tightly into the production process.
Coating
Coating is the most popular method of print product finishing, with the capability of adjusting gloss values from matt to high gloss. Coatings offer print products the necessary protection against wear and tear from mechanical forces and other factors. Attractive design effects can be achieved with coatings by combining gloss value and color in an infinite number of ways.
Coating manufacturers are currently developing a single solution for both matt and gloss effects using just one water-based dispersion coating system. The solution is expected to be unveiled in time for drupa 2008, with production trials already underway. In this process, the coating is applied by a coating unit to an entire surface area, achieving both matt and gloss effects using a single coating plate. The result is very good registration between matt and gloss areas.
Technological advances have already made it possible to apply matt and gloss coatings in a single pass on presses equipped with the right printing and coating units. Brochures, envelopes and presentation folders can be given a sophisticated finish using one coating unit with chamber-type doctor blade and an upstream inking unit capable of processing print varnishes. Further advances expected in this area include glossy coatings with still higher gloss values and faster processing times, enabling finishers to further process press sheets without delay.
Hybrid Finishing
One future alternative finishing technique is the hybrid method. Exhibitor KBA AG has been a pioneer of hybrid finishing from the outset and has entered into partnerships with other machine manufacturers such as Heidelberger Druckmaschinen AG, in order to advance and publicize the process. Thanks to the continual development of the hybrid method, it is safe to assume that solutions compatible with both expensive UV inks and standard inks will become available in the near future. All machine manufacturers in the segment are expected to market solutions based on this combination technology in time for drupa 2008, and ink manufacturers will also be presenting their new products.
Because of the need to take into account the rapid hardening of hybrid inks and UV coatings, hybrid technology is set to expand the options for using inline die-cutting, which, unlike conventional systems, prevents ink and/or varnish from building up on the cutting die.
Since hybrid machines offer various modes of operation, they are equipped with IR, hot-air and UV drying units that make the process cost-intensive. Dryer system manufacturers are therefore working on modular and energy-efficient solutions. Development work on UV coating processes aims to minimize the energy consumed by the UV dryer in the press without making the UV coatings significantly more expensive.
Should these improvements become a reality, hybrid finishing has the potential to become a very economical, versatile and high-quality inline finishing method, which additionally offers the opportunity to enter the UV segment. Printing inks with increased pigmentation for the purpose of achieving higher gloss values, as well as advances in the coatings sector, particularly with regard to thermo-sensitive varnishes, have been announced.
Following drupa 2008, the hybrid process will be available for most sheetfed offset market segments, offering a window of opportunity for customer acquisition. Put simply, hybrid technology gives printers access to outstanding and versatile inline effects, without the disadvantages of double coating or simple UV printing. A good result depends, above all, on selecting the right materials—ones that have been tested and matched.
UV Prints
UV prints are an economical solution, and not only for large printing businesses. Small print shops can also impress customers by offering complementary value-added products and services. A prime example is the use of a Heidelberg Speedmaster SM 52 with UV equipment. Other machine manufacturers can be expected to shortly enter this market segment with new products in the same class.
Printing press manufacturers selling machines designed for UV printing use special dryer configurations such as IR and UV drying systems and cold-air units. These mean that sheets do not come off the press as hot as they did in the past and can now be processed immediately. Because machines of this kind are equipped with two coating circuits, the complex process of changing coatings can be eliminated. Another selling point is the ability of these machines to expand the range of coating material options to include metallic effects and even plastics.
These exciting innovations can help printers to present a more confident face to the market and counter the need to negotiate the price of every job. But print customers need more than just general information on the new technical possibilities—simply communicating their existence is not enough. Customers must be encouraged to take advantage of these technical innovations and convinced of their value with the use of new ideas and practical examples. The drupa trade fair provides a chance to provide these and a platform for discussing technical issues.
Cold foil finishing
Coating, film lamination, embossing, metallic effects and cold foil transfer applications can give advertising products, calendars and packaging materials a special touch. Variety, individuality and luxurious effects can be achieved by mastering service, development and technology challenges. These products will be on display in Print City or the other exhibition areas at drupa, to persuade industry professionals of the advantages of these new finishing technologies and equipment.
OFT GmbH, based in Neuss, Germany, markets a cold foil finishing technology to its customers. Drawing upon years of experience, the company developed a processing machine built by KBA and in use since January 2007. Various materials, combined with exclusive finishing, create visual and haptic effects for premium brands. A range of special processes are available for meeting brand protection or finishing requirements. Expect to see machine solutions of this kind exhibited by printing press manufacturers in 2008.
MAN Roland AG will be exhibiting the Prindor InlineFoiler it recently introduced to the market. Cold foil transfer opens up opportunities in application and design that were previously either unachievable with hot foil stamping, or only at great expense and effort. MAN Roland will have innovations on offer for the economical and technically practical combination of both processes in a single press run. Cold foil transfer requires two printing units. Most noticeable at first glance are the two additional top-mounted modules on the press. They can be arranged on any two, adjacent printing towers and ensure steady, low-torsion transport of the foil. By using two top-mounted modules for winding and unwinding the foil between two printing towers, the load is distributed evenly so as to avoid putting excessive stress on an individual tower. Two printing units are required for the actual foil transfer: the first transfers a special adhesive via the inking unit to the substrate with the resolution and detail of an offset plate; the second transfers the foil to the substrate, which is partially coated with adhesive. Any unused foil is rewound onto the backing material.
Heidelberger Druckmaschinen AG markets the FoilStar system for finishing print products with metallic effects of dazzling brilliance and will be demonstrating the technology at drupa 2008. It enables a wide variety of unusual finishing effects for labels, folding cartons and high-end commercial print jobs. A Speedmaster CD 74, Speedmaster CD 102 or Speedmaster XL 105 equipped with the FoilStar can apply high-quality finishes to a wide range of substrates. The FoilStar achieves metallic effects that add value to your customers’ print products.
Users are often unaware of one of the key advantages of cold foil transfer over offline hot foil stamping: after transfer, the foil lies flat on the substrate and can be printed over immediately.
Inline processes
When it comes to inline processes, such as perforation, cutting, creasing, scoring and die-cutting, printing presses in general are capable of offering economical solutions. Prerequisites today include, above all, magnetic blankets with the related tools, or cutting dies in the form of plates, which can be used in a printing unit after ink application or, for a more elegant solution, in a coating unit.
Stand-alone die-cutting solutions are in demand for both short and long production runs. The Dymatrix die-cutting and embossing systems from Heidelberger Postpress GmbH make for high productivity and flexible application. High-quality, sophisticated products, such as packaging for cosmetics and food, must be processed with maximum precision and fulfill very strict quality requirements. The company markets five die-cutting machine solutions: the Varimatrix 105 and Dymatrix 105 are designed for newcomers to the segment with the Dymatrix 105 able to combine die-cutting and embossing in one system; the Dymatrix 106, 113 and 142 are for larger formats and designed for higher output levels. Future developments are expected to lead to greater automation, meaning shorter make-ready times and greater efficiencies.
The ProCut 74 and ProCut 105 die-cutting machines from Kama GmbH are constantly being improved. The larger model can also be equipped with a hot foil stamping system, the 74 model with a hot foil stamping system and/or hologram unit. The machines operate with two separate foil feeders and a precision control system.
The versatile machines marketed by the Bobst Group for die-cutting and embossing are designed for the industrial sector. The Bobst SP Autoplaten product line ranges in working width from 76 cm to 162 cm. Faster cycles times and greater automation can be expected in the future. The Bobst+Steuer business unit will be launching new machines, such as the Foilmaster and Foiljet, for hot foil stamping.
With equipment of this kind, print shops, die-cutting and finishing business can differentiate themselves with targeted products and services, offering customers greater added value. All die-cutting equipment suppliers are working on solutions for transferring safety features to high-quality luxury, pharmaceutical and cosmetic products and a good selection of these solutions will be on display in Düsseldorf in 2008.
Special Coatings
Special gold, silver, pearlescent, rub-off and scented coatings can be utilized for luxury products. Gold and silver coatings are usually applied as spot finishes, as they would otherwise obscure the actual printed image on a folding carton due to their high metal pigment content. The same applies for pearlescent coatings, although when used with less pigmentation, they can achieve a very subtle effect and in this case be used on an entire carton. Rub-off coatings are applied over a previous coating layer. They do not bond entirely with the underlying layer and can be rubbed off. Scented coatings containing microencapsulated fragrances are added during manufacturing. When the coating has hardened on the final product, the microcapsules are permanently incorporated in the dispersion coating layer until later rubbing of the surface causes them to break open and emit their scent. New fragrances and improved processability can be expected in this segment.
Outlook
At drupa 2008, both printing press manufacturers and companies marketing post-press equipment will be offering extensive finishing solutions with inline technologies given priority. However, run lengths and delivery deadlines will always need to be taken into account, because it can pay in some cases to combine different printing processes or use specialized machines. Shorter make-ready times in all machine classes will attract a great deal of attention, because run lengths will continue to shorten, while demands for color and finishing techniques will continue to rise.
The combination of offset preprints with gravure, screen or flexo printing is a finishing option which is not yet being used to the maximum. Combination finishing techniques covering the entire spectrum, including for example iriodine inks and matt, glossy, spot or UV coatings, can be supplemented with hot or cold foil stamping, holograms or die-cuts, because different methods used together can add value to the finishing process. Large-format offset presses will play a key role in the finishing sector in the future. Sheetfeed gravure, in combination with other printing processes, will continue to grow.
The German Association of Print Finishers will be showing not only technical equipment solutions at drupa 2008, but more importantly, an expanded range of materials, such as substrates with increasingly high whiteness. Overall, developments in coatings and foils will lead to a greater selection for users in response to the dramatic rise in demand for variety and specialty products. Laminating systems using water-based adhesives and significantly more energy-efficient carbon-type drying equipment, high-output inline embossing systems and new hot-melt laminating machines will all be popular objects at the trade show. For many exhibitors, Competence in Finishing will not just be a buzzword at drupa 2008, but an accurate description of the machine technology and materials on display.
Dr. Horst-Dieter Branser is a trained letterpress, offset, and gravure printer. After graduating from the College of Printing Technology in Leipzig, Germany, he acquired experience as a vocational technical school teacher and as a contributor to developmental aid projects in Africa. As an instructor at the Technical College, he also conducted scientific work, earning his undergraduate and doctoral degrees in the field of print finishing. He held management positions both as a student and in printing businesses. He has been working as a journalist since 1991. As technical editor and later editor-in-chief of the German publication “Druckwelt,” for Schlütersche Verlagsgesellschaft mbH (Hanover) and Druck Medien Verlag (Waiblingen) publishers, his work focused on describing the economic aspects of technological developments in the print and finishing sectors. Branser transferred in 2000 to Deutscher Drucker (Ostfildern), where he served as editor for the areas of print finishing, label and packaging printing, as well as digital printing. Since retiring in 2006, he has been working as a freelance journalist from his office in Leipzig.
