When it comes to substrate choices, these days you have more options than just coated or uncoated. The range of synthetic media has grown in the past few years — but are these papers right for your in-plant’s specific applications? There are pros and cons to synthetic materials and applications where they make sense.
Kellogg Community College Print and Document Services printed this Emergency Management Guide on synthetic media. | Credit: Kellogg Community College Print and Document Services
In-plants using synthetic media tend to have specific use-cases. For example, notes June Lewis, senior process specialist at Kellogg Community College Print and Document Services, in Battle Creek, Michigan, synthetic media really shines in applications where durability is crucial.
“We used this for most of our COVID signage, and we just started using a 12mil Synaps for our ID badges,” she says. “We also use it for our emergency management guide.”
In short, applications where moisture or tearing might be an issue will turn out better if synthetic media is used rather than paper and lamination.
Related story: Synthetic Media vs. Lamination
Justin Mikita, manager of Print Services at Giant Eagle, stands with the Xerox Iridesse his in-plant uses to print on synthetic paper. | Credit: IPI
Another in-plant using synthetic media finds it to be a great choice for tags and labels. “We do a ton of tags, of all different sizes, that are used in the perishable departments of our grocery stores,” notes Justin Mikita, manager of Print Services at Giant Eagle, in Pittsburgh. “We also do a lot of POS signage, especially if it’s going to be displayed for a longer period.”
The Benefits of Synthetic Media
What makes synthetic media a popular choice for applications like those? For one thing, these substrates are far more durable. They are tear resistant, waterproof, and can easily be cleaned if they get dirty.
“Synthetic paper is a broad term for plastic alternatives to traditional, fiber-based paper and can be comprised of several different polymers, each with varying degrees of durability,” explains Jeremy Underhill, vice president of sales at MGX. “In general, synthetic papers provide superior durability versus traditional paper in the form of tear, water, and chemical resistance. This can extend the life of the end application, requiring less reprints and reducing costs over the life cycle of the piece. They can also provide economy versus lamination.”
Tags printed on synthetic media by Giant Eagle Print Services. | Credit: IPI
And that economy is a big point in synthetic media’s favor: while the substrates themselves generally cost more than a traditional media in the same category, when you add in the costs of laminating — not only for the materials, but the labor and time needed to perform the extra steps — you’ll either break even, or synthetic materials will come out less expensive.
“Synthetic paper won’t wrinkle, delaminate, or fray along the edges, ensuring a clean, professional look over the lifetime of the printed application,” points out Laura Slovensky, senior manager of product marketing at Nekoosa. “It also improves operational efficiency by eliminating the time-consuming lamination step, allowing printers to streamline production. Additionally, printing on synthetic paper requires few consumables while delivering superior results.”
That is something Mikita has found out firsthand. He points out that for his in-plant, “printing directly on synthetic paper saves an incredible amount of time and hassle of laminating. Also, the cost of rolls of lamination film and upkeep of the equipment.”
That said, Lewis points out that one thing to keep in mind is that a synthetic media will often have more of a matte finish versus the glossy finish of many laminates — so remember that if the finish is important to the final product.
The Flip Side — Cons to Synthetic Media
Both Mikita and Lewis note that battling static is one of the biggest drawbacks of synthetic materials.
“We only have digital presses; it does hold a lot more static in the sheets as they exit the printer versus paper media,” notes Lewis, whose shop uses a Canon imagePRESS V1000 to print synthetic materials. “Heavy ink coverage on the thicker media can be more challenging in getting even coverage. But you can either let it sit overnight or pull the sheets apart to dissipate the static.”
Mikita agrees, noting that his operation runs both Xerox Iridesse and iGen presses, and while the static is worse on the Iridesse, the quality is also better, so that becomes a consideration when choosing which press to use.
“We normally let the jobs sit for a day before we try to do any finishing on them,” he says. “We’ve tried everything under the sun to eliminate static and have yet to find a good solution.”
There are steps an in-plant can take to minimize static, however, MGX’s Underhill notes.
A conference badge printed on synthetic material by Kellogg Community College Print and Document Services. | Credit: Kellogg Community College Print and Document Services
“Maintaining the relative humidity in the pressroom at 50-55% can significantly reduce static,” he says. “The incorporation of tinsel, static string, and ionized air or blowers throughout processes can also be helpful. Some coatings — like our DT [dry toner] coating for production dry toner presses — are designed to aid static dissipation and can make an incredible difference.”
Nekoosa’s Slovensky further suggests that placing printed sheets on a grounded metal table before finishing can also help to dissipate the static. While there is no magic solution for ensuring static doesn’t build up, a combination of these tactics can absolutely help minimize the issues and make synthetic media options much more attractive. That said, in general letting the sheets rest for a bit directly after printing rather than sending them straight into finishing will mean far less complications with static.
Another issue with synthetic media — especially the thicker options — is that it can have sharp corners when cut. To avoid that, Mikita notes, “We round-corner some jobs that are customer facing, so our customers don’t get cut. We try to grab the sheets away from the edges when handling.”
Rounding corners is also a tactic Lewis uses on jobs on thicker media, although she notes that for thinner media, the edge isn’t much different from traditional paper.
Finally, while some synthetic media can be recycled, that is not true of all options. Especially for in-plants where sustainability is a major issue, make sure you’re talking to your media suppliers about what materials went into their synthetic offerings, and whether or not they can be recycled — and if there is a special process needed to recycle them.
When it comes to prepping your presses for running synthetic media, just like with any new substrate option, you’ll want to make a few adjustments to get the best results.
“Preparation for running synthetic paper can vary significantly by technology and model,” Underhill notes. “Winding sheets can help with feeding. If printing via conventional offset, identifying a specialty, higher-oxidizing ink intended for synthetic use is crucial. Additionally, changing to a larger particulate spray powder, running smaller lifts, and having space to rack sheets is critical to success. Some synthetic papers, like our UniSyn Synthetic Paper line, have topcoats that minimize the special setup required when printing conventionally. When printing UV offset, ensure the synthetic paper has a dyne level in the low-to-mid 40s or is top-coated to optimize ink wet out and adhesion.
“For digital presses like HP Indigo and production dry toner equipment, establishing the proper paper profile is imperative,” Underhill continues. “Working with materials that have been prequalified with OEMs as well as mills with technical support and expertise can simplify this process.”
In the end, deciding whether or not synthetic media is right for your specific operation and applications is subjective. The best advice is to have a long conversation with your media suppliers to learn more about the options, find out if they have done testing on your specific equipment — and what those results were — and ask for samples of potential synthetic substrates you’re considering. Pay close attention not only to quality and end-results, but how the media handles and what, if any, changes you would need to make to get optimum performance.
If you regularly produce applications that need durability and longevity, then synthetic media might be a great choice. But if you’re producing mostly applications that aren’t meant to last long, or won’t be in high-traffic or weather-exposed areas, laminated paper might be the right choice. In the end, it comes down to options — and you have more than you might realize.
The Pros and Cons of Synthetic Media
When it comes to substrate choices, these days you have more options than just coated or uncoated. The range of synthetic media has grown in the past few years — but are these papers right for your in-plant’s specific applications? There are pros and cons to synthetic materials and applications where they make sense.
Kellogg Community College Print and Document Services printed this Emergency Management Guide on synthetic media. | Credit: Kellogg Community College Print and Document Services
In-plants using synthetic media tend to have specific use-cases. For example, notes June Lewis, senior process specialist at Kellogg Community College Print and Document Services, in Battle Creek, Michigan, synthetic media really shines in applications where durability is crucial.
“We used this for most of our COVID signage, and we just started using a 12mil Synaps for our ID badges,” she says. “We also use it for our emergency management guide.”
In short, applications where moisture or tearing might be an issue will turn out better if synthetic media is used rather than paper and lamination.
Related story: Synthetic Media vs. Lamination
Justin Mikita, manager of Print Services at Giant Eagle, stands with the Xerox Iridesse his in-plant uses to print on synthetic paper. | Credit: IPI
Another in-plant using synthetic media finds it to be a great choice for tags and labels. “We do a ton of tags, of all different sizes, that are used in the perishable departments of our grocery stores,” notes Justin Mikita, manager of Print Services at Giant Eagle, in Pittsburgh. “We also do a lot of POS signage, especially if it’s going to be displayed for a longer period.”
The Benefits of Synthetic Media
What makes synthetic media a popular choice for applications like those? For one thing, these substrates are far more durable. They are tear resistant, waterproof, and can easily be cleaned if they get dirty.
“Synthetic paper is a broad term for plastic alternatives to traditional, fiber-based paper and can be comprised of several different polymers, each with varying degrees of durability,” explains Jeremy Underhill, vice president of sales at MGX. “In general, synthetic papers provide superior durability versus traditional paper in the form of tear, water, and chemical resistance. This can extend the life of the end application, requiring less reprints and reducing costs over the life cycle of the piece. They can also provide economy versus lamination.”
Tags printed on synthetic media by Giant Eagle Print Services. | Credit: IPI
And that economy is a big point in synthetic media’s favor: while the substrates themselves generally cost more than a traditional media in the same category, when you add in the costs of laminating — not only for the materials, but the labor and time needed to perform the extra steps — you’ll either break even, or synthetic materials will come out less expensive.
“Synthetic paper won’t wrinkle, delaminate, or fray along the edges, ensuring a clean, professional look over the lifetime of the printed application,” points out Laura Slovensky, senior manager of product marketing at Nekoosa. “It also improves operational efficiency by eliminating the time-consuming lamination step, allowing printers to streamline production. Additionally, printing on synthetic paper requires few consumables while delivering superior results.”
That is something Mikita has found out firsthand. He points out that for his in-plant, “printing directly on synthetic paper saves an incredible amount of time and hassle of laminating. Also, the cost of rolls of lamination film and upkeep of the equipment.”
That said, Lewis points out that one thing to keep in mind is that a synthetic media will often have more of a matte finish versus the glossy finish of many laminates — so remember that if the finish is important to the final product.
The Flip Side — Cons to Synthetic Media
Both Mikita and Lewis note that battling static is one of the biggest drawbacks of synthetic materials.
“We only have digital presses; it does hold a lot more static in the sheets as they exit the printer versus paper media,” notes Lewis, whose shop uses a Canon imagePRESS V1000 to print synthetic materials. “Heavy ink coverage on the thicker media can be more challenging in getting even coverage. But you can either let it sit overnight or pull the sheets apart to dissipate the static.”
Mikita agrees, noting that his operation runs both Xerox Iridesse and iGen presses, and while the static is worse on the Iridesse, the quality is also better, so that becomes a consideration when choosing which press to use.
“We normally let the jobs sit for a day before we try to do any finishing on them,” he says. “We’ve tried everything under the sun to eliminate static and have yet to find a good solution.”
There are steps an in-plant can take to minimize static, however, MGX’s Underhill notes.
A conference badge printed on synthetic material by Kellogg Community College Print and Document Services. | Credit: Kellogg Community College Print and Document Services
“Maintaining the relative humidity in the pressroom at 50-55% can significantly reduce static,” he says. “The incorporation of tinsel, static string, and ionized air or blowers throughout processes can also be helpful. Some coatings — like our DT [dry toner] coating for production dry toner presses — are designed to aid static dissipation and can make an incredible difference.”
Nekoosa’s Slovensky further suggests that placing printed sheets on a grounded metal table before finishing can also help to dissipate the static. While there is no magic solution for ensuring static doesn’t build up, a combination of these tactics can absolutely help minimize the issues and make synthetic media options much more attractive. That said, in general letting the sheets rest for a bit directly after printing rather than sending them straight into finishing will mean far less complications with static.
Another issue with synthetic media — especially the thicker options — is that it can have sharp corners when cut. To avoid that, Mikita notes, “We round-corner some jobs that are customer facing, so our customers don’t get cut. We try to grab the sheets away from the edges when handling.”
Rounding corners is also a tactic Lewis uses on jobs on thicker media, although she notes that for thinner media, the edge isn’t much different from traditional paper.
Finally, while some synthetic media can be recycled, that is not true of all options. Especially for in-plants where sustainability is a major issue, make sure you’re talking to your media suppliers about what materials went into their synthetic offerings, and whether or not they can be recycled — and if there is a special process needed to recycle them.
When it comes to prepping your presses for running synthetic media, just like with any new substrate option, you’ll want to make a few adjustments to get the best results.
“Preparation for running synthetic paper can vary significantly by technology and model,” Underhill notes. “Winding sheets can help with feeding. If printing via conventional offset, identifying a specialty, higher-oxidizing ink intended for synthetic use is crucial. Additionally, changing to a larger particulate spray powder, running smaller lifts, and having space to rack sheets is critical to success. Some synthetic papers, like our UniSyn Synthetic Paper line, have topcoats that minimize the special setup required when printing conventionally. When printing UV offset, ensure the synthetic paper has a dyne level in the low-to-mid 40s or is top-coated to optimize ink wet out and adhesion.
“For digital presses like HP Indigo and production dry toner equipment, establishing the proper paper profile is imperative,” Underhill continues. “Working with materials that have been prequalified with OEMs as well as mills with technical support and expertise can simplify this process.”
In the end, deciding whether or not synthetic media is right for your specific operation and applications is subjective. The best advice is to have a long conversation with your media suppliers to learn more about the options, find out if they have done testing on your specific equipment — and what those results were — and ask for samples of potential synthetic substrates you’re considering. Pay close attention not only to quality and end-results, but how the media handles and what, if any, changes you would need to make to get optimum performance.
If you regularly produce applications that need durability and longevity, then synthetic media might be a great choice. But if you’re producing mostly applications that aren’t meant to last long, or won’t be in high-traffic or weather-exposed areas, laminated paper might be the right choice. In the end, it comes down to options — and you have more than you might realize.
Toni McQuilken is the senior editor for the printing and packaging group.