Put Foil In Your Plans

Hot stamping will distinguish your organization's printed materials. Here are the answers to all your "foilish" questions.

If you want your in-plant shop to be viewed as an indispensable company asset, then you've got to offer customers a great product. Hot stamping is an excellent, value-added service for the business-savvy in-plant printer.

Simple applications like a tasteful metallic border on an important report or a spiffy, eye-catching holographic icon on a brochure will distinguish your organization's collateral and enhance its image—two results that can ultimately build business for you and your company. Whether you choose to do the work in-house or outsource the project, it's good to be familiar with the basics of hot stamping foil materials and processes.

Stewart Glazer, vice president for sales and marketing at Crown Roll Leaf, in Paterson, N.J., a manufacturer of hot stamping foils and holographic diffraction gratings, introduces readers to the potential of this media by answering commonly asked questions.

What is hot stamping foil?

Technically, hot stamping foil is a carrier film with a release coat, and a thin layer of vaporized aluminum sandwiched between the color coat (top coat) and the sizing (adhesive coat).

More simply stated, it is a treated film that is used to transfer decorative coatings onto various substrates for exciting visual appeal. The range of finishes on film available to in-plant printers is vast: metallic; gloss pigment; matte pigment; tint and pearl; special effects like marble and holographic patterns; and unique, textured effects, such as snake skin, imitation leather and woodgrains.

What are the common applications of hot stamping foil for the in-plant printer?

In-plant printing operations can use hot stamping foil to enhance business cards, letterhead, envelopes, brochures, banners, binders, folders, manuals, reports, cartons, promotional items, tickets, tags, labels—any printed collateral that requires a subtle, sophisticated or dazzling, high impact surface decoration that will command attention and set the item apart from an ordinary printed item.

What is hot stamping?

Hot stamping is a dry form of decorating, printing and marking a substrate. A die is created and mounted on a platen. The foil is placed between the die and the substrate to be decorated. The die is heated, pressed against the foil and the color coat is released from the film and adheres to the substrate. The clear film is then discarded.

Are there different types of stamping processes?

There are several types but the most common are flat stamping, embossing, debossing and combination stamping. Flat stamping uses a flat die in the shape of the desired image. The result can be seen but not felt. Embossing and debossing use male and female sculptured dies. Embossing raises an image in the paper fiber while debossing lowers it to create a chiseled look. Combination stamping incorporates flat stamping and embossing or debossing.

Magnesium and copper dies are used for routine flat stamping and some debossing. Brass dies are preferred when foiling and embossing are to be done in one pass. Brass can also be more precisely sculpted or tooled to exacting specifications.

What paper grades can be used?

Smooth, coated and uncoated paper and board stock will accept hot stamping foils. The choice depends on the look desired. Smooth stocks are recommended for higher metallic foils, especially if lettering is less than 8 point or fine line detail is involved. When using tints or pearls, uncoated stock is recommended. Tints should be stamped on natural colored stocks. When ordering foil, let the supplier know what kind of stock you'll be working with so a foil made especially for that grade can be shipped.

Can foil be printed on? Are there special considerations?

Yes, hot stamping foils can be printed on, though the substrate may be resistant. Be sure to inform your supplier about the application, as there are foils made just for this purpose.

Will foil accept laser inks?

Yes, but there are factors to be aware of. Laser printers generate extreme heat, so know your equipment's operating temperature. Also, some delicate or textured paper stocks may also falter under the extreme heat from the laser printer and corrupt the integrity of the foil, causing it to crack, peel or dull. Consult with your foil supplier for a foil that will tolerate extremely high heat, and be sure to do a test run of your paper stock.

What are the limitations to foil stamping?

Most substrates are easily hot stamped. However, resistance to the foil material can occur on substrates that have cured, UV or thermostat coatings. To overcome these obstacles, inform the supplier about the project and request a hot stamping foil made specifically for these kinds of coatings. In addition, seek testing support.

What machines are used for hot stamping? Is there smaller-format equipment that would be useful to an in-plant printer?

The size of the area to be stamped dictates the kind of machine that will be used. Large scale, high-volume projects are generally outsourced to shops equipped with Bobst, Kluge, Geitz or C&P presses. But for in-house work, small and mid-range presses are available from such equipment manufacturers as Franklin, Wagner and Kluge, to name a few. A small hand press or vertical press will easily handle sheets 8x12˝ or less using small metal dies. Today there are also flexographic presses that have rotary in-line stamping attachments that are ideal for in-plant work.

To gain the best results with minimum waste on your hot stamping foil project, consult the graphic artist, the equipment manufacturer and the foil supplier. The foil supplier in particular should offer full creative support, answer any technical questions, patiently support testing of foils, inks, adhesives and substrates, and provide hot stamping foil within 48 hours of ordering.