Modern Cold Stamping Foils
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Modern Cold Stamping Foils
Introduction
Modern cold stamping foils began as a simple, dieless technique for applying a metallic finish to self-adhesive labels on reel-to-reel printing presses. While there are some drawbacks, the process has advanced significantly, offering numerous advantages.
Advantages of Cold Foiling
One of the main benefits of cold foiling in reel-to-reel printing is its efficiency. Hot foiling can slow down the printing process because the press speed is limited by the foiling speed. Additionally, conducting hot foiling as a separate pass can incur extra costs. The expenses associated with hot foil dies are also higher compared to printing plates or sleeves, and the process requires energy to heat the dies.
Cold foiling on the reel-to-reel method involves printing a UV-curable adhesive in the desired foil design, laminating the foil to the adhesive through a nip, curing the adhesive with UV lamps, and then removing the foil from the printed web. The UV-cured adhesive helps the foil adhere to the design.
Efficiency and Speed
Cold foiling's speed depends on the UV lamp strength and the optical density of the foil. The aluminum layer in cold foils needs to be thinner than in hot foils to allow UV light to pass through. Though this isn’t a concern with transparent films, it often involves foiling over an opaque white ink layer. In such cases, the UV beam passes through both the lacquer and aluminum layers to cure the adhesive.
By fixing the lamps in a set position, printers ensure consistent curing. Cold foiling ultimately increases speed and eliminates the need for dies, cutting costs and saving energy?"a significant benefit today.
Quality and Limitations
Despite its advantages, cold foiling isn’t universally adopted due to quality issues. It generally lacks the brilliance of hot foiling, and manufacturers provide a limited color range. The surface energy of cold foils is also low, affecting the overprint's adherence. Large printed areas may experience poor scratch resistance and tape adhesion, though many accept this trade-off for cost savings. Current developments are addressing these challenges, but truly over-printable cold foils remain difficult to achieve.
Recent Innovations
Recent innovations in cold foiling include sheet-fed offset litho applications, where adhesive is applied using traditional oxidation drying offset. Silver foils can be overprinted with transparent inks to create attractive colored metallic effects?"a patented process. Developments are also underway with offset UV adhesives and inks, although adhesion is still a concern.
Growing Popularity
The global use of cold foils is rapidly increasing, particularly in the offset field. Major European printing machine suppliers are offering specialized equipment and retrofit options for existing printers. With continuous improvements, the quality of modern cold stamping foils is quickly nearing that of hot foiling.
Conclusion
Modern cold stamping foils have transformed from a simple technique into a sophisticated process, offering speed, cost-effectiveness, and energy savings. While challenges remain, ongoing innovations are closing the gap in quality between cold and hot foiling, making cold foiling an increasingly attractive option.
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