Traditionally, metallic foil is added to a piece after it has been run through the press in a separate process known as foil-stamping also known as hot foil stamping. Now, there are several new methods for adding metallic foil to a printed piece. In one instance, the foil can be added inline on the press rather than requiring a separate operation.
Cold Foil Transfer
Cold transfer works on either flexo (web-fed) or offset (sheet-fed) presses with six or more roller/color units. On multicolor presses, the first roller/color unit applies adhesive in the shape of the design; the second roller/color unit applies the foil. The foil, then, sticks to only areas where the adhesive resides. The remaining roller/color units of the press allow for printing CMYK inks on top of the foil in-line during the same press pass. Thus, a wider array of colors can be created in addition to the traditional foil colors of gold and silver. In addition, it’s possible to use foils incorporating holographic effects with this method.
Digital Foiling
As it’s name suggest, digital foiling is foiling that can be applied using digital presses. Digital foiling has two application methods: 1) using a toner-based adhesive; or 2) using a polymer (varnish) adhesive to affix the foil to the paper.
- Toner Based Digital Foiling – This method is a 2- or 3-step process: 1) the area of the design to receive foil is first printed in black using a digital printer or a digital press; 2) the printed sheet is then run through a separate device (called a “sleeker”) that utilizes heat to activate the adhesive in the toner and affixes the foil to the design; 3) the foiled sheet can then be passed through a digital color press again to imprint CMYK colors alongside of or on top of the foil to create a broad array of metallic effects.
- Polymer (Varnish) Digital Foiling – A piece is first printed using an offset or digital press where a polymer adhesive is applied where the design calls for a foil application. Then, in a another operation, the piece is run through a digital enhancement press to add the foil. Applying a thicker layer of adhesive during the initial press run makes it possible for the foil to be raised above the surface of the paper creating an embossed effect. Or, the printed sheet with foil can be passed through the digital enhancement press again where a spot coating can be applied on top of the foil rendering texture and a raised appearance.
Foil Substrate
Like clear plastic laminate films, a foil substrate (or “metallized laminate”) is applied to cover an entire sheet of paper or card stock. This foil substrate can then be printed (e.g., labels, packaging, etc.) as can the back side of the sheet. While foil colors are limited to the standard silver and gold, imprinting CMYK inks on top of the foil can create expansive color effects. And, as with cold foil, holographic foils and “brushed” effect foils are available to extend the visual possibilities.
If you have any questions about New Foil Application Methods, give us a call at 330-597-8560. We’re happy to help you get the most out of your printing project.
Photo by Beth Macdonald
