Steve Katz, Associate Editor10.14.21
The embellishment process in the label converting industry is not one-size-fits-all. There are a multitude of options that label converters can turn to in order to meet their customers’ demands for labels that shimmer, shine and “pop.” In addition to metallic and shiny substrates like foil and metalized paper, or metalized ink, there are also embellishment-specific machines utilized to bring the bling. And there’s more to embellishment than looks – tactile effects are another way brand owners can differentiate their labels and packaging.
It’s a wide spectrum of options available to converters. Here is a look (in alphabetical order) at what suppliers are offering in the embellishment space.
A B Graphic
A B Graphic International (ABG) has expanded its range of modules for its Digicon Series 3 with the launch of DigiJet.
DigiJet is an online or off-line fully digital embellishment unit, allowing for multiple processes in one pass, including spot varnishing, digital foiling and tactile screen on any size of print run. Its main features include two inkjet heads with UV pinning and UV curing, automated cold foil throw-off, a shuttle system for zero waste and stop-start at job changeover, chill rollers for sensitive materials, prepress software and food-compliant fluids.
Available in single bar or dual bar configurations, DigiJet technology allows the quantity of varnish to be easily adjusted to a height of 225 microns, thereby varying the required finish. Jobs can be automatically changed on the fly, and the DigiJet module can be integrated with workflow and MIS options as preferred.
“DigiJet is a revolutionary module for the digital market,” states Matt Burton, AB Graphic International’s global sales director. “With technology improving all the time, digital embellishment is where the future is – perfect for short runs, no tooling costs, the ability to change jobs quickly, variable data, personalization and dramatically reduced lead times.”
Actega Metal Print
Earlier this year, ACTEGA Metal Print reported that German label manufacturer Kolbe-Coloco Spezialdruck successfully completed the beta program for EcoLeaf, ACTEGA’s sustainable and cost-effective metalization technology unit.
Announced as the world’s first EcoLeaf customer in March 2020, Kolbe-Coloco concluded the ACTEGA beta program in less than 11 months. Installed on the company’s Gallus RCS 430 modular inline labels press, the business is now using the EcoLeaf technology for paid commercial jobs. Representing 20% of all label jobs it produces, and as part of a phased transition, the business is now gradually moving all its foil-based work to EcoLeaf.
Stefan Klinksiek, Kolbe-Coloco’s CEO, comments, “EcoLeaf is already enabling us to enjoy resource savings and significantly less waste. What’s more, the ACTEGA technology has also become a real catalyst for new business, too. Brands truly engage with its benefits and see it as a premium service. There’s no doubt that EcoLeaf has provided us with a competitive edge.
“Despite the pandemic, the installation of EcoLeaf went very well. After initial alignment of software and hardware, we started the first tests in June and were delighted with the results,” concludes Stefan Klinksiek. “Now that we’ve moved into commercial sales, we predict ROI from Ecoleaf by 2022, with the anticipated need of a second unit in the not-too-distant future.”
In addition to processing all the learnings from its beta program, the team at ACTEGA Metal Print has also redesigned and launched a new outer skin for the EcoLeaf unit featuring a cover that offers user friendly functionality, durability and a sleek style.
Cartes
Expanding the range of modules in its GT360 and Gemini360 series, Cartes has developed an exclusive embellishing technology – Jet D-Screen– that allows converters to deposit a thicker layer of ink. According to Cartes, this was previously impossible to achieve with inkjet technologies.
The modular Jet D-Screen (JDS) digital unit allows users to create multi-layer effects, such as spot coating, complex tactile raised effects and Braille printing, as well as very detailed foil and metallic
doming transferring.
In just one step, it is possible to personalize and enhance labels, with no tooling costs, instantaneous startup and no material waste. With the JDS, the work of the operator has been simplified, allowing the selection of options from already predefined settings, as well as the choice of the material to be used, to achieve immediate production in the JDS unit without waste.
Materials that are printed with the JDS system do not need to be varnished or treated before, as these processes may distort the “texture” of the material.
At the recently concluded Label Congress, Cartes highlighted the Jet D-Screen to the US market. Enrica Lodi, sales and marketing manager at Cartes, commented, “The Jet D-Screen unit for digital embellishment allows you to personalize and beautify labels in just one step, with no tooling costs, with immediate startup and without any waste of materials.”
K Laser
K Laser wrote the book on cold foil – literally. Authored by J. Michael Rivera, general manager, Cold Foil Business Unit, Cold Foil for Dummies details not only the steps in the cold foil converting process, but also how to enter the market with a minimal investment, provide faster turnaround, eliminate downtime and increase profits.
K Laser Technology (USA) specializes in cold foil application and is the exclusive manufacturer of KOLDfoil ONE, a cold foil formulation where the same roll of cold foil can be used for flexographic, digital or offset cold foiling processes. With manufacturing and warehousing capacity in Santa Ana, CA and Sarasota, FL, K Laser can provide its customers with local inventory and fast production turnaround time. The company also prides itself on offering what it says is the largest selection of cold foil colors and holographic patterns in the industry.
According to Rivera, “Cold foil printing comes from a simple idea: “Using a standard printing plate, an image is printed onto a substrate with the use of a UV-curable cold foil adhesive. A UV dryer then activates and cures the adhesive. The extracted foil is affixed to the printed adhesive and an image is created. It was indeed a simple idea, yet the cold foil process was elusive to many printers. We spent more than 15 years of research and development, testing, trials and tribulations of the cold foil printing process. We partnered and worked closely with leaders in the flexographic printing industry to better understand the intricate combinations of ink, anilox, printing plates and substrates. The result of all this research is in the pages of Cold Foil for Dummies.”
In addition to its cold foil consumables and printing expertise, K Laser also offers the JetFX Digital Cold Foil Module. The JetFX Digital Cold Foil Module is now available as a retrofit to all makes of flexographic presses. This digital module enables metallic foils and holograms to be digitally applied to various label and packaging substrates, efficiently and economically. With KOLDfoil ONE, coupled with the advantages of the JetFX Digital Cold Foil Module, converters have an economic solution to position themselves as a premium printer, without the high price tag of new capital equipment, K Laser says.
KURZ
KURZ features a comprehensive offering of machines, application software, and coatings in the digital finishing and embellishment space. Since the first DM-Liner was introduced in 2014, KURZ has continuously developed its digital finishing solutions. The third generation of the KURZ DM-Jetliner and DM-Uniliner 2D delivers embellishment technology with improved design and custom-tailored features.
The machines, while optimizing digital finishing unit functions, also increase the number of potential substrates, both plastic and paper, and are suitable to several applications, from shrink sleeve labels to coated and uncoated papers.
Both the DM-Jetliner and DM Uniliner have “inkjet on transfer layer” technology. Here, the surface to be printed remains unchanged, despite the large number of possible substrates. This allows for precision control of processes, in reduced time and labor.
The DM-Jetliner is ideal for companies that already produce digitally printed labels and would like to expand their design options. This digital finishing module is easily integrated into the production chain of an HP Indigo 6900, thus allowing metalization without changes to existing processes. The DM-Jetliner applies finishes inline during the preprint process, subsequently overprinting them in the same
process step.
The DM-Uniliner 2D also applies finishes with glossy metalization and bright color effects. This standalone production unit can be used independent of printing systems and processes. It is a solution that provides preprint or postprint finishing, making the DM-Uniliner 2D system suited to companies that value flexibility with a high degree of finishing automation.
Both the DM-Jetliner and the DM-Uniliner 2D combine the advantages of digital finishing over traditional embossing processes. They are foil-saving units with minimal setup time and high printing speed, and are thus a sustainable finishing solution that significantly reduces energy consumption.
Nilpeter
Nuceria Group, part of All4Labels, recently installed Nilpeter’s new High-Build Inkjet Varnish Unit on its MO-4 combination offset press, and offers extensive embellishment capabilities. Featuring an industrial design, the High-Build Varnish Inkjet Unit is touchscreen based, with an easy-to-use graphic user interface. The unit supports a wide range of substrates, such as PP, PE, PET and foil, and can be positioned at any point in the press configuration.
“The new high-build inkjet print bar allows us to achieve faster delivery times with high embellishment jobs, and the increased agility offers economic benefits without compromising quality,” says Guido Iannone, president, Southern Europe & Global Spirits, All4Labels.
Nilpeter’s High-Build Varnish Inkjet Unit can be used to create rich textures – emulating expensive substrates, enhancing beautiful designs or providing grip – which interact with light in ways that are often underutilized in packaging design. HL technology can be combined with flood coat matte varnish for emulating micro embossing techniques used in paper manufacturing or digitally applied embossing effects to text or image details. When combined with a lamination/foil bar, the unit enables extreme foil effects to be produced for added impact. The High-Build Varnish Inkjet Unit provides a low overall cost of production, less material waste, faster make-ready, and increased production rates.
Omet
With a mission to increase profitability for printers, Omet has targeted the challenges of waste reduction, time and energy savings. These efforts have led to the new Cold Foil Saver, which allows printers to use the same foil twice for the same print, enabling increased cold foil savings by up to 50%.
Initally launched at Labelexpo Brussels in 2019, the new product has been made available for all Omet flexo printing machines starting from iFLEX up to X6. It can also be available as a new attachment that can be installed by all existing Omet customers.
“The reduction of waste and the resulting cost savings guarantee greater productivity and increased profitability for customers. Omet customers will now be able to achieve the same quality by limiting raw material consumption by up to 50%, and hence also produce less waste when compared to existing solutions,” says Marco Calcagni, sales director, Omet.
SPGPrints
SPGPrints recently launched its RSI III rotary screen integration unit, which enables a fast, cost-effective way of applying value-adding functional and visual effects in a single pass. The unit is ideal for adding high opacity white ink for no-label look applications, creative spot and flood varnishes, metallic effects, and rich, opaque colors for striking designs. Tactile effects, including raised lettering and Braille, can be quickly applied in one, uninterrupted process.
The RSI III features ergonomic improvements for safety, time-savings and increased productivity. A new long-life web-cleaning scraper automatically removes ink splashes from the web after stoppages or when operating in slow-rotation mode. This enables thorough drying of the substrate while minimizing contamination of the rollers and usable print.
A new display screen offers enhanced viewing angles, reducing the amount of movement necessary for the operator to obtain clear, accurate readings. The RSI III comes in widths from 10" to 26", and integrates into almost all inline flexo, offset, letterpress or gravure label presses.
Xeikon
Fusion is a recent addition to Xeikon’s broad portfolio of digital equipment for labels and offers converters maximum flexibility to meet demand for eye-catching labels. With complete digital finishing and embellishment capabilities, Xeikon’s FEU (Fusion Embellishment Unit) is based on MGI technology and provides UV spot varnish, tactile varnish, foiling, 3D textures and holograms across a wide range of substrates, including clear on clear, common BOPP and paper facestock up to natural structured papers.
Offering reduced setup time and no need for tooling, FEU uses inkjet technology where any area of a label can automatically receive spot UV varnish, with or without raised 3D textured effects. Similarly, for foiling applications, the digital label area can receive digitally controlled foil with or without raised 3D effects, with limited complexity compared to analog. Xeikon’s FEU is a standalone solution. This enables it to embellish printed materials originating from different technologies. It is also able to pre-print foil onto substrates. Optionally, Xeikon’s FEU can be equipped with a semi-rotational diecutting unit so that it will deliver fully embellished and finished labels.
It’s a wide spectrum of options available to converters. Here is a look (in alphabetical order) at what suppliers are offering in the embellishment space.
A B Graphic
A B Graphic International (ABG) has expanded its range of modules for its Digicon Series 3 with the launch of DigiJet.
DigiJet is an online or off-line fully digital embellishment unit, allowing for multiple processes in one pass, including spot varnishing, digital foiling and tactile screen on any size of print run. Its main features include two inkjet heads with UV pinning and UV curing, automated cold foil throw-off, a shuttle system for zero waste and stop-start at job changeover, chill rollers for sensitive materials, prepress software and food-compliant fluids.
Available in single bar or dual bar configurations, DigiJet technology allows the quantity of varnish to be easily adjusted to a height of 225 microns, thereby varying the required finish. Jobs can be automatically changed on the fly, and the DigiJet module can be integrated with workflow and MIS options as preferred.
“DigiJet is a revolutionary module for the digital market,” states Matt Burton, AB Graphic International’s global sales director. “With technology improving all the time, digital embellishment is where the future is – perfect for short runs, no tooling costs, the ability to change jobs quickly, variable data, personalization and dramatically reduced lead times.”
Actega Metal Print
Earlier this year, ACTEGA Metal Print reported that German label manufacturer Kolbe-Coloco Spezialdruck successfully completed the beta program for EcoLeaf, ACTEGA’s sustainable and cost-effective metalization technology unit.
Announced as the world’s first EcoLeaf customer in March 2020, Kolbe-Coloco concluded the ACTEGA beta program in less than 11 months. Installed on the company’s Gallus RCS 430 modular inline labels press, the business is now using the EcoLeaf technology for paid commercial jobs. Representing 20% of all label jobs it produces, and as part of a phased transition, the business is now gradually moving all its foil-based work to EcoLeaf.
Stefan Klinksiek, Kolbe-Coloco’s CEO, comments, “EcoLeaf is already enabling us to enjoy resource savings and significantly less waste. What’s more, the ACTEGA technology has also become a real catalyst for new business, too. Brands truly engage with its benefits and see it as a premium service. There’s no doubt that EcoLeaf has provided us with a competitive edge.
“Despite the pandemic, the installation of EcoLeaf went very well. After initial alignment of software and hardware, we started the first tests in June and were delighted with the results,” concludes Stefan Klinksiek. “Now that we’ve moved into commercial sales, we predict ROI from Ecoleaf by 2022, with the anticipated need of a second unit in the not-too-distant future.”
In addition to processing all the learnings from its beta program, the team at ACTEGA Metal Print has also redesigned and launched a new outer skin for the EcoLeaf unit featuring a cover that offers user friendly functionality, durability and a sleek style.
Cartes
Expanding the range of modules in its GT360 and Gemini360 series, Cartes has developed an exclusive embellishing technology – Jet D-Screen– that allows converters to deposit a thicker layer of ink. According to Cartes, this was previously impossible to achieve with inkjet technologies.
The modular Jet D-Screen (JDS) digital unit allows users to create multi-layer effects, such as spot coating, complex tactile raised effects and Braille printing, as well as very detailed foil and metallic
doming transferring.
In just one step, it is possible to personalize and enhance labels, with no tooling costs, instantaneous startup and no material waste. With the JDS, the work of the operator has been simplified, allowing the selection of options from already predefined settings, as well as the choice of the material to be used, to achieve immediate production in the JDS unit without waste.
Materials that are printed with the JDS system do not need to be varnished or treated before, as these processes may distort the “texture” of the material.
At the recently concluded Label Congress, Cartes highlighted the Jet D-Screen to the US market. Enrica Lodi, sales and marketing manager at Cartes, commented, “The Jet D-Screen unit for digital embellishment allows you to personalize and beautify labels in just one step, with no tooling costs, with immediate startup and without any waste of materials.”
K Laser
K Laser wrote the book on cold foil – literally. Authored by J. Michael Rivera, general manager, Cold Foil Business Unit, Cold Foil for Dummies details not only the steps in the cold foil converting process, but also how to enter the market with a minimal investment, provide faster turnaround, eliminate downtime and increase profits.
K Laser Technology (USA) specializes in cold foil application and is the exclusive manufacturer of KOLDfoil ONE, a cold foil formulation where the same roll of cold foil can be used for flexographic, digital or offset cold foiling processes. With manufacturing and warehousing capacity in Santa Ana, CA and Sarasota, FL, K Laser can provide its customers with local inventory and fast production turnaround time. The company also prides itself on offering what it says is the largest selection of cold foil colors and holographic patterns in the industry.
According to Rivera, “Cold foil printing comes from a simple idea: “Using a standard printing plate, an image is printed onto a substrate with the use of a UV-curable cold foil adhesive. A UV dryer then activates and cures the adhesive. The extracted foil is affixed to the printed adhesive and an image is created. It was indeed a simple idea, yet the cold foil process was elusive to many printers. We spent more than 15 years of research and development, testing, trials and tribulations of the cold foil printing process. We partnered and worked closely with leaders in the flexographic printing industry to better understand the intricate combinations of ink, anilox, printing plates and substrates. The result of all this research is in the pages of Cold Foil for Dummies.”
In addition to its cold foil consumables and printing expertise, K Laser also offers the JetFX Digital Cold Foil Module. The JetFX Digital Cold Foil Module is now available as a retrofit to all makes of flexographic presses. This digital module enables metallic foils and holograms to be digitally applied to various label and packaging substrates, efficiently and economically. With KOLDfoil ONE, coupled with the advantages of the JetFX Digital Cold Foil Module, converters have an economic solution to position themselves as a premium printer, without the high price tag of new capital equipment, K Laser says.
KURZ
KURZ features a comprehensive offering of machines, application software, and coatings in the digital finishing and embellishment space. Since the first DM-Liner was introduced in 2014, KURZ has continuously developed its digital finishing solutions. The third generation of the KURZ DM-Jetliner and DM-Uniliner 2D delivers embellishment technology with improved design and custom-tailored features.
The machines, while optimizing digital finishing unit functions, also increase the number of potential substrates, both plastic and paper, and are suitable to several applications, from shrink sleeve labels to coated and uncoated papers.
Both the DM-Jetliner and DM Uniliner have “inkjet on transfer layer” technology. Here, the surface to be printed remains unchanged, despite the large number of possible substrates. This allows for precision control of processes, in reduced time and labor.
The DM-Jetliner is ideal for companies that already produce digitally printed labels and would like to expand their design options. This digital finishing module is easily integrated into the production chain of an HP Indigo 6900, thus allowing metalization without changes to existing processes. The DM-Jetliner applies finishes inline during the preprint process, subsequently overprinting them in the same
process step.
The DM-Uniliner 2D also applies finishes with glossy metalization and bright color effects. This standalone production unit can be used independent of printing systems and processes. It is a solution that provides preprint or postprint finishing, making the DM-Uniliner 2D system suited to companies that value flexibility with a high degree of finishing automation.
Both the DM-Jetliner and the DM-Uniliner 2D combine the advantages of digital finishing over traditional embossing processes. They are foil-saving units with minimal setup time and high printing speed, and are thus a sustainable finishing solution that significantly reduces energy consumption.
Nilpeter
Nuceria Group, part of All4Labels, recently installed Nilpeter’s new High-Build Inkjet Varnish Unit on its MO-4 combination offset press, and offers extensive embellishment capabilities. Featuring an industrial design, the High-Build Varnish Inkjet Unit is touchscreen based, with an easy-to-use graphic user interface. The unit supports a wide range of substrates, such as PP, PE, PET and foil, and can be positioned at any point in the press configuration.
“The new high-build inkjet print bar allows us to achieve faster delivery times with high embellishment jobs, and the increased agility offers economic benefits without compromising quality,” says Guido Iannone, president, Southern Europe & Global Spirits, All4Labels.
Nilpeter’s High-Build Varnish Inkjet Unit can be used to create rich textures – emulating expensive substrates, enhancing beautiful designs or providing grip – which interact with light in ways that are often underutilized in packaging design. HL technology can be combined with flood coat matte varnish for emulating micro embossing techniques used in paper manufacturing or digitally applied embossing effects to text or image details. When combined with a lamination/foil bar, the unit enables extreme foil effects to be produced for added impact. The High-Build Varnish Inkjet Unit provides a low overall cost of production, less material waste, faster make-ready, and increased production rates.
Omet
With a mission to increase profitability for printers, Omet has targeted the challenges of waste reduction, time and energy savings. These efforts have led to the new Cold Foil Saver, which allows printers to use the same foil twice for the same print, enabling increased cold foil savings by up to 50%.
Initally launched at Labelexpo Brussels in 2019, the new product has been made available for all Omet flexo printing machines starting from iFLEX up to X6. It can also be available as a new attachment that can be installed by all existing Omet customers.
“The reduction of waste and the resulting cost savings guarantee greater productivity and increased profitability for customers. Omet customers will now be able to achieve the same quality by limiting raw material consumption by up to 50%, and hence also produce less waste when compared to existing solutions,” says Marco Calcagni, sales director, Omet.
SPGPrints
SPGPrints recently launched its RSI III rotary screen integration unit, which enables a fast, cost-effective way of applying value-adding functional and visual effects in a single pass. The unit is ideal for adding high opacity white ink for no-label look applications, creative spot and flood varnishes, metallic effects, and rich, opaque colors for striking designs. Tactile effects, including raised lettering and Braille, can be quickly applied in one, uninterrupted process.
The RSI III features ergonomic improvements for safety, time-savings and increased productivity. A new long-life web-cleaning scraper automatically removes ink splashes from the web after stoppages or when operating in slow-rotation mode. This enables thorough drying of the substrate while minimizing contamination of the rollers and usable print.
A new display screen offers enhanced viewing angles, reducing the amount of movement necessary for the operator to obtain clear, accurate readings. The RSI III comes in widths from 10" to 26", and integrates into almost all inline flexo, offset, letterpress or gravure label presses.
Xeikon
Fusion is a recent addition to Xeikon’s broad portfolio of digital equipment for labels and offers converters maximum flexibility to meet demand for eye-catching labels. With complete digital finishing and embellishment capabilities, Xeikon’s FEU (Fusion Embellishment Unit) is based on MGI technology and provides UV spot varnish, tactile varnish, foiling, 3D textures and holograms across a wide range of substrates, including clear on clear, common BOPP and paper facestock up to natural structured papers.
Offering reduced setup time and no need for tooling, FEU uses inkjet technology where any area of a label can automatically receive spot UV varnish, with or without raised 3D textured effects. Similarly, for foiling applications, the digital label area can receive digitally controlled foil with or without raised 3D effects, with limited complexity compared to analog. Xeikon’s FEU is a standalone solution. This enables it to embellish printed materials originating from different technologies. It is also able to pre-print foil onto substrates. Optionally, Xeikon’s FEU can be equipped with a semi-rotational diecutting unit so that it will deliver fully embellished and finished labels.