Frequently Asked Questions | FAQ |
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Film Lamination The major requirement is to print using wax free inks. The three different specifications for lamination are sealed edge, guide & gripper clean, and flush cut. They are outlined as follows: 1) Sealed Edge: You need to provide sheets trimmed down to the net size. Star will encapsulate the sheet on both sides, allowing the film to extend beyond the sheet, thereby sealing the sheet within the lamination. 2) Guide & Gripper clean: You need to provide sheets in the original press sheet format. Star will laminate either one side or two. The film will completely cover the image area, but will be inset from the edge of the sheet on one side. The other side is trimmed flush to the edge with our automatic slitters. These sheets can then be trimmed, or die cut without affecting the integrity of the registration. Please note that one side lamination is only possible to this specification. 3) Flush cut: You will provide sheets trimmed down to the net size. We will encapsulate the sheet, and then trim the sheets on all four sides down to the edge of the paper. Please note that this is very costly, and the quality of the finished product is substandard. How do I know what type of lamination I need? The best way is to send us a sample with a description of the application. If this is not possible, call or E-mail Norm. Can lamination be glued? Any lamination can be glued, depending on the adhesive used. Automatic gluing machines using white glue require special glueable film. We stock this film. It is best to test the substrates before production. --------------------------------------------------------------------------------
UV Coating For best results, inks must be free of paraffin waxes, silicones, or other slip additives. UV coatings do not adhere properly to such. Also, avoid inks with alkaline pigments. Alkaline pigments are found in Reflex blue, Rhodamine red, PMS purple and any dark blue to violet color ink regardless of pigment. Although these inks may normally be coated, they have a tendency to bleed and can cause the overall color to change significantly. Contact your ink supplier for availability of inks without alkaline pigments. If you are concerned about a "marginal" ink, send us a printed sample in advance of the actual job, and we will test it for you. Inks should be completely cured/"dry" before UV coating. Normally, 24 to 48 hours should elapse before coating. Running a job with an aqueous primer can reduce this time, but moisture contained in the substrate can cause "blooming" or pinholes in the coating. If emulsified at all, additional time may be required to insure their cure/"dryness". Additionally, if the job is to be coated on two sides, an extra day should be scheduled between the coating runs. UV coating should be applied to a smooth stock with a clay or enamel coated surface. No Uncoated stocks. Cast coated stocks as Kromekote should also be avoided. How much spray powder can I use? Spray powder on a printed sheet will only be intensified by the coating process and will give the sheet an undesirable "sandpaper" effect. If spray powder must be used, use only a minimum amount of an uncoated, small particle powder (30-50 micron). To further minimize the problem, a "dusting" or "dead-heading" pass on an offset press is highly recommended. Star has sheet cleaning units to minimize the problem associated with spray powder on the sheet. As always, spray powder applied during the printing process should be absolutely minimized, however the addition of the sheet cleaning units will relieve some of the undesirable "sandpaper" effects. What are the requirements for a sheet to be converted? Any scoring required on a job should be done after sheets have been coated, not before. Most foil-stamping (including foil-embossing) can be coated over. Be sure to notify your foil supplier that you will be UV coating and have them supply a foil that is compatible with UV. UV coated sheets normally cannot be foil-stamped. Optimum stock thickness for UV coating .007 and up, especially if it requires folding. Lightweight stocks tend to curl up and may crack when folded. Normally leave jobs in press sheet size. Do not trim before coating. This is particularly true if pattern or "spot" coating is to register to printing. Also, be sure to clearly mark the gripper and guide on a sample sheet. Additional suggestions... Supply a clearly defined rule-out or film positive of area to be coated. When supplying a positive, the areas of the sheet to be coated should be black on the film, leaving clear the non-coated areas of the sheet. Due to the "deep gloss mirror finish" that UV coating gives, it also has a tendency to reflect fingerprints on the finished piece when dark, solid colors have been used. Try to avoid these colors whenever possible. --------------------------------------------------------------------------------
Blister/Skin The temperature (indirect) should be 350O F The Dwell time should be 3 seconds+ (studies have shown that using our coating can reduce your dwell time during the fulfillment process). Pressure should be 60 psi. What are the fulfillment parameters for Skin packaging? The re-melting temperature is about 200O F. Note: exact heat sealing conditions will vary according to the type and gauge of plastic film or base stock used; whether the heat is directly or indirectly applied; and the calibration of the processing equipment. Some films may require precise control of temperature and cycles. We suggest that you test our coated board prior to production. How should I store my coated stock prior to production? Immediately remove banding or plastic stretch wrap from pallets and store in a cool dry location. This allows the sheets to breathe and allows any residual moisture to evaporate. Never store coated sheets in the open, exposed to the sun as this may cause the sheets to brick and stick. Keep boxes of coated cards stored in a cool, dry location, preferably under 80O F. Stack individual cards on their sides within boxes. This prevents the cards from bricking, sticking and picking caused by the pressure from the weight of the stack. Additional notes... The coating applied to your blister/skin board is processed using equipment of the latest Swiss drying technology. The coating material used is the finest in the industry, featuring aggressive fiber-tearing bond, UV discoloration resistance, good gloss, and clean air quality compliance. Prior to each run, several vigorous tests are conducted by Star's Process Control staff. Your coating production will only begin when all quality control requirements are met: bond strength consistency, coating appearance, and coating cure/board "dryness". Thereafter, hourly quality checks are conducted to detect any variations in the process that may affect your product quality. All testing and checks are recorded, logged and available for review upon request. -------------------------------------------------------------------------------- Bindery
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