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What is Foil Stamping?
Foil stamping is a value-added post-printing
process
Perceives eye-catching and higher quality
products
Uses pressure, foil film and sometimes heat and
metal dies to apply image
The Foil
Foil comes in a variety of colors, finishes, and
optical effects
Different types of foils are needed for fine lines
and solid print areas
Fine lines = tight release foil
Large solid areas = easy release foil
Silver and gold are most common foil colors
Lots of testing is done for these
Types of Foil Stamping
Hot foil stamping
Uses pressure and temperature to apply
Cold foil stamping
Only needs pressure to apply
Inline process
Foil fusing
Foil is bonded to a toner image area made
with a laser printer
What is Diecutting?
Diecutting is a value added service
Involves cutting the substrate into a specific
shape
Uses a steel cutting die
Generally diecutting equipment located inside
foil stamping equipment
Ring Toss!
True or false
Identify the Need
Business stationary
Promotional items
Menus
Business cards
Packaging materials
Labels
Old and new clients
Heidelberg Varimatrix 105 CSF
Heidelberg Varimatrix 105 CSF
Hot foil stamping, diecutting, embossing
capabilities
Maximum sheet size = 29.53in x 41.34in
7,500 sheets per hour
945 square feet of working space needed
12 heating zones
Paper as thin as .001 pounds/square inch
Corrugated as thick as .16 inches
Heidelberg Varimatrix 105 CSF
Variety of foils allowed
Chase-changing table for fast and easy set-up
Foil infeed aid
Foil rewinder and disposer
Heidelberg Varimatrix 105 CSF
Bobst Masterfoil 106 PR
Bobst Masterfoil 106 PR
Hot foil stamping, embossing capabilities
Maximum sheet size = 30in x 41.75 in
8,000 sheets per hour
1,400 square feet of working space needed
12 heating zones
Paper as thin as .004 inches
Corrugated as thick as .08 inches
Bobst Masterfoil 106 PR
Made to deliver highest quality and greatest
productivity in market
Lower beam cam movement
Foil unwind system
Power register II
Smart Feeder
Bobst Masterfoil 106 PR
Kluge EHG Series Half Sheet
Kluge EHG Series Half Sheet
Hot foil stamping, diecutting, embossing
capabilities
Maximum sheet size = 22in x 30in
1,700 impressions per hour
135 square feet of working space needed
2 heating zones
EZ Load Magazine
Toggle Base Hoist System
Kluge EHG Series Half Sheet
Thermo-type NSF Elite Foil
Press
Thermo-type NSF Elite Foil
Press
Foil fusing, diecutting, embossing capabilities
No die needed because of high speed foil
fusing
Maximum sheet size = 14.5in x 20.5in
5,000 impressions per hour
192 square feet of working space
1 heating zone
Automated by a computer touch screen
system
Thermo-type NSF Elite Foil
Press
Two foil support shaft
Two independently programmable foil draws
Two waste foil rewinds
Pre-loading and high pile capacity
Produces small to large orders
Thermo-type NSF Elite Foil
Press
Basket Toss
Pick the press
Outsourcing
Advantages
Cost effective
High quality
Disadvantages
Dont have control over the process
Turnaround time can be an issue
3-7 days average
Outsourcing Costs
Cost of foil stamping a 2x2 letterhead 8.5x11
that is already printed from our print facility.
Paper cost already incurred
$50 makeready
$40 per 1,000 sheets for run time
$2 per 1,000 sheets for foil
$48 for the die
Total cost for 5,000 sheets= $308
Total cost for 20,000 sheets=$938
Owning Equipment
Advantages
Receive all profits from foil stamping
Can control the process
In control of how fast you can foil stamp
Disadvantages
Costly equipment
Have to keep up with maintenance needs
Many extra needs and elements needed
Extra Needs Involved
Foil
Engraver
Etching machine
Imaging device
Diecutter
Dies
Worker with special skills for equipment
Cost In House
Cost of foil stamping a 2x2 letterhead 8.5x11 in
house that has already been printed
Heidelberg
Total cost for 5,000 sheets = $136.76
Total cost for 20,000 sheets = $537.05
Foil Fuser
Total cost for 5,000 sheets = $77.27
Total cost for 20,000 sheets = $309.10
New/Used
Buying new equipment
Warranty
Buying used equipment
Will need maintenance more often
Can get rebuilt for price of new
equipment
Installation
Two pieces of equipment require an addition
on
the building
The Bobst
Requires 1,400 square feet
The Heidelberg
Requires 945 square feet
Production area requires 100 additional
square feet
Additional concrete would need to be poured
to create reinforced slab
Installation
The remaining two fit into the current building
as is.
The Kluge
Requires 60 square feet
Would replace the small letterpress in
house now
The Thermo-type foil fuser
Requires 135 square feet
Installation
All 4 pieces of equipment require a 3-phase
power system
Needed for equipment using a lot of power
Needed for heating plates
3-phase circuit combines 3 alternating currents
of the same frequency. Each current is 120
degrees out of phase with each other.
Installation
Three separate
waves of power
produced
Power never drops
to zero
Power delivered is
always constant
Installation
Important to be prepared on installation day(s)
Reduces the interruption of work
Who should be present on installation day(s)?
Electrician to hook up press
Maintenance person to hook up press to
house air
Rigger if press is too large for forklift
Economic Analysis
This is the Budgeted Hourly Rate comparison
for each piece of equipment
Economic Analysis
This is the breakeven comparison for each
piece
of equipment
Economic Analysis
This is the payback comparison for each piece
of equipment
Which press is the
best after all?
Recommendation
Thermo-type
foil fuser
or
Outsource
until we reach
higher demand
Recommendation: Foil Fuser
Digital press allows for more VDP
Foil fusion allows foil to toner contact
VDP foil stamping
Business cards
Diplomas
Premium direct mail pieces
Stationary
Recommendation: Outsource
Continue using letterpress foil stamper
Outsource excess jobs
High quality
No purchase needed
As demand rises, reconsider equipment
investment
Support Material
http://www.bobst.com/usen/products/hot-foil-
stamping/hot-foil-
stampers/overview/machine/masterfoil-106-
pr/#.U1XtCxavOa4
http://www.heidelberg.com/www/html/en/conte
nt/products/postpress/die-
cutting/varimatrix_105_csf
http://www.thermotype.com/NSFElite.html
http://kluge.biz/index.php?page=ehg-series-
22-x-30
Support Material
http://ohsobeautifulpaper.com/?s=foil+stampin
g
http://www.thermotype.com/Foil-
Tech%20Q&A.html
http://www.tripplite.com/products/single-vs3-
phase