Digital Foiled Labels

Foil labelling, a special type of printing process, has long been associated with luxury, elegance, and prominence. The shimmering, metallic finish that it brings to labels offers a unique aesthetic appeal and serves a significant marketing purpose by boosting brand image and ensuring that products stand out on the shelves.

At its most basic, foil labelling involves the application of metallic or pigmented foil onto a surface, typically a label, under the action of heat and pressure. The foil, which can come in a variety of colours from gold and silver to blues, reds, and greens, adheres to the surface, producing a decorative, metallic sheen. The resultant foil labels are often used for packaging, brand promotion, and security purposes across various industries, including cosmetics, wines and spirits, gourmet foods, and high-end retail products.

Foil labelling is not a new concept. The technique of applying metallic leaf to surfaces can be traced back to ancient Egypt, where gold leaf was used to adorn the sarcophagi of the Pharaohs. However, the modern process of foil stamping has its roots in the 19th century, with the advent of hot foil stamping technology.

Throughout the years, the technology and processes for foil labelling have evolved significantly. From traditional hot foil stamping to modern techniques like cold foil stamping and digital foiling, the industry has continued to innovate, enhancing the quality and diversity of foil labels available to businesses

Hot foil stamping, also referred to as foil blocking or dry stamping, is a versatile printing technique that involves the application of metallic or pigmented foil onto a material by the use of heat and pressure. This method leaves behind a glossy, radiant finish that adds a touch of luxury and exclusivity to any product it embellishes.

Hot foil stamping is a process that uses heat and pressure to transfer metallic foil onto a surface. It is one of the oldest and most common methods of creating foil labels, and it is known for its ability to provide finely detailed and durable results. Hot foil stamping is an effective way to add a shiny, metallic finish to a wide variety of materials, including paper, plastic, leather, and more.

The process of hot foil stamping begins with the creation of a die or stamp. The design of the label is etched or engraved onto a metal die, which is then heated. A roll of thin foil goes between the die and the material to be stamped.

When the heated die presses the foil onto the material, the heat activates an adhesive layer on the foil causing it to stick to the material in the shape of the design. The high temperature also facilitates the embossing of the design, giving the label a slightly raised, tactile finish. The excess foil is then removed, leaving behind the foiled design on the material.

Hot foil stamping can be used on a wide variety of materials. Paper and cardboard are the most commonly foiled materials, but hot foil stamping can also be applied to leather, vinyl, textiles, and some types of plastic.

The foils used in the stamping process are usually metallic, available in colours such as gold, silver, copper, and other metallic hues. Holographic and pigmented foils are also used to create a variety of visual effects.

Yes, hot foil stamping is generally waterproof. Once the foil has been applied to the material through heat and pressure, it forms a strong bond resistant to water, mild chemicals, and normal handling.

For hot foil stamping, you typically need specific hot foil dies. These dies are usually made of metal—brass, copper, or magnesium—and are designed to withstand the high temperatures used in the process. Regular dies used in processes such as die cutting may not be suitable for hot foil stamping due to their inability to handle the heat required for the process.

Cold foil refers to the application of metallic foil onto labels using an adhesive rather than heat to affix the foil. Like hot foil, it gives labels a shiny, metallic finish that is sure to attract attention. However, cold foil offers greater speed and adaptability, especially when applied on delicate materials that might be sensitive to heat.

The primary difference between hot and cold foil stamping lies in the application process. Hot foil stamping uses heat and pressure to apply the foil, whereas cold foil stamping uses a UV-curable adhesive and pressure.

In hot foil stamping, a heated die is pressed onto the foil, transferring it to the material beneath. In contrast, cold foiling applies an adhesive to the material in the shape of the desired design, then presses the foil onto the adhesive. The adhesive is then cured (hardened) using UV light, and the excess foil is removed, leaving the design behind.

The other notable difference lies in their applications. Hot foil stamping is generally better for intricate, detailed designs and tactile (embossed or debossed) labels, while cold foil stamping is ideal for jobs requiring quick turnaround times, full-colour process printing, and compatibility with delicate materials that may not withstand high temperatures.

Cold foiling involves several steps:

1. The label material is fed into the printing press.
2. The design is applied to the label using a UV-curable adhesive instead of a heated die.
3. The metallic foil is then pressed onto the adhesive-coated label material.
4. As the material moves through the press, it’s exposed to UV light, which cures (hardens) the adhesive.
5. The foil adheres to the adhesive areas, and the excess foil is removed, leaving the metallic design on the label.

Cold foil stamping offers several advantages. It’s faster and more adaptable to various materials compared to hot foil stamping. This process is especially beneficial for heat-sensitive materials, and it allows for high-speed application, making it suitable for high-volume projects.

Also, since it doesn’t require heat, cold foiling can achieve a broader range of colours by printing over the foil. This expands the palette of metallic shades available beyond the traditional golds and silvers to virtually any hue imaginable.

However, it’s important to note that while cold foiling is efficient and versatile, it does not provide the same tactile effect as hot foiling, and it may not be as suitable for designs with intricate detail or requiring a textured finish.

Digital foiling, or digital foil printing, is a relatively modern technique that offers several advantages over traditional hot and cold foil stamping methods, particularly when dealing with smaller print runs or designs requiring high levels of customization. Here are some of the key benefits of digital foiled labels:

1. No Need for Custom Dies: Unlike hot foil stamping, digital foiling does not require the use of custom dies. This eliminates the time and cost associated with die creation, making digital foiling a more cost-effective option for small to medium-sized print runs.
2. Faster Turnaround Time: Since there are no physical dies to create or set up, digital foiling can significantly reduce the production time. This makes it a great option when you need labels quickly.
3. High Levels of Personalization: Digital foiling is capable of variable data printing, which allows for the customization of each individual label without slowing down the printing process. This feature is ideal for labels requiring personalized information, like names, addresses, unique codes, or variable graphics.
4. Versatility of Design: With digital foiling, you can easily adjust your design without incurring additional costs related to the creation of new dies. This flexibility is particularly beneficial when dealing with prototypes or when you anticipate needing to make changes to the design.
5. High-Quality Finish: Digital foiling offers a high-quality, professional finish that closely rivals that of traditional foiling methods. The resulting labels are vibrant and eye-catching, ensuring your products stand out on the shelves.