Visually attractive packaging is crucial for sales success, and although you may know a great deal of attention goes into making high-quality packaging designs, you may not realize how much of the overall look comes down to the details. Learn how you can use different finishes and press effects to take your packaging to the next level.
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This is one of the most popular coatings used in the industry. It provides a clear coating with a high gloss. An added benefit of UV coating printing is that it can also serve as a protectant.
UV coatings are a liquid-based, protectant coating that is applied and instantly cured with UV drying lamps. Compared to aqueous coatings, UV coatings provide an extreme-glossy finish and can deliver an abrasion- and rub-resistant performance. In order to get the best results, inks must be wax-free or UV compatible.
A great way to add a tactile or more dramatic effect is by using a raised UV coating printing. Adding more coating volume brings more added dimension that can accentuate the art or graphic, as well as invite the consumer to engage and touch the spot UV pattern or UV varnish printing.
A great example of this raised UV gloss coating can be seen on this Star Trek DVD o-sleeve cover.
A common use of spot UV is to draw attention to a certain area of the printed piece, such as placing spot UV pattern over a logo so that only the logo area is glossy.
If a luxurious shimmer appearance is what you’re looking for, then a pearlescent coating is the way to go. Pearlescent coatings can be either aqueous or UV-based. For UV-based coatings, a specific quantity of pearl additive is mixed with a gloss UV coating. Depending on the variation and size of the micron particle, the pearlescent coating can have a more dramatic or subtle effect. The AQ-based version of this coating is similar, but is mixed with a gloss AQ coating and pearl additive.
In the glitter coating family, pearlescent coatings are highly decorative and are used across multiple industries. The less-dramatic shimmer adds a unique appeal to any surface without having glitter overkill. The unique nature of a pearlescent coating may be applied over a number of different colors, which creates a pearl-like shade when viewed.
For a stark and bold look, glitter coatings are the way to go. Glitter coatings are made when large glitter particles (50-200 microns) are added into UV gloss coating. They also come in a wide assortment of colors.
Glitter coatings command and demand attention especially when they are applied and contrasted against a more subtle area of the packaging like the luminaire on the right. It is also easy to see how brilliantly the glitter effect is magnified when a light source is put behind it.
Varnishes serve many purposes included being used as a protectant to the sheet and, in the case of a dull varnish, can be used to create great contrast (step-off) against a higher gloss.
Like coatings, varnishes can be applied to very specific areas (spot varnish) or can be applied to a large print area or the entire press sheet (flood varnish).
If you have ever touched a package that seemed so smooth and so subtle that it felt velvet? This is due to a soft touch coating or soft touch varnish application that creates a soft, velvety texture. It also makes the piece look softer than one with a high gloss or textured coatings.
Silver and gold sheen coatings give any packaging a ritzy touch. These metallic sheens are shiny and bold without feeling too cold and metallic. Use under a base color to give it an extra gold glow or silver shimmer. Many industries continue to successfully use metallic sheens to reach their customers. Take advantage of the seemingly inherent desire of humans to gravitate towards metallic. If your budget doesn’t allow for foil stamping, metallic sheens are a great cost-effective alternative that delivers the same look and feel.
This UV coating contains very small particles, which results in a subtle, shimmer effect, creating a vibrant luster that is almost equal to a natural pearl’s sheen. Available in natural colors, this coating may appear silky smooth or as polished as a diamond. The incredible effects available with this coating make it a highly coveted way to make a package stand out. High standards of quality control make this trademarked coating a winner in almost every category.
This coating is known for their coarse and rugged tactile effect. Although it is softer than a sheet of sandpaper, the reputation of this coating is the grittiest when it comes to tactile coating effects. The grip of the coating is useful as a non-slip surface and works well in applications for multi-use packaging.
Sandpaper coatings are more subtle than grit coatings and provide only a slightly rough texture. The coating is similar to some unglazed clay work and gives plastics and paper products a slightly edgy feel.
In both coating applications, you can control the amount of texture that is applied on the sheet by the size of the billion cubic micron (BCM) rollers. The smaller the BCM rating of the coating roller, the lesser the amount of coating it can carry and be applied to the sheet and vise versa for higher BCM’s.
Both grit and sandpaper can be used on a variety of substrates that allow for a stimulating tactile experience.
Another way to achieve a signature visual and/or tactile effect is with an on-press process called reticulation. This effect is achieved when a spot varnish and an overall UV coating is applied. When these two are mixed, there is a chemical reaction that results in a tactile and visual effect.
Working with a printer who has the press technology to properly manipulate dwell/dry times of their dryers and who have the expertise to play with chemistries means you will get the most unique and incredible results.
Different pattern effects can also be achieved by using a varnish plate with a distinct pattern to it. By creating a reaction with the UV gloss coating and manipulating the dry times, the effects your packaging could feature are limitless.
Historically used to make a statement, embossing continues to be an assertion of elegance and luxury. Raising and depressing aspects of your packaging gives your customers a more interesting package handling due to the tactile coating.
Use a contrasting material in your design to differentiate the surface of your material or bring a character to life. Here are a few embossing and debossing techniques to consider.
This form involves raising or lowering features of a design in a sharp or rounded manner. Sculptured subjects are carefully rendered to depict definition and texture in a realistic manner. Sculptured embossing is often a hand-crafted process.
Similar to the sculptured process, the multi-level emboss or deboss features several different levels of texture. You will notice multiple angles and three-dimensional definition in this finish.
This style of embossing or debossing uses a single-level instead of multiple layers. It is a very trendy and modern style of finish.
This effect is accomplished with a foil stamping machine that uses a metal plate that has been engraved with an image of the desired design required for the particular application. As the plate strikes a roll of foil film, it causes the foil to adhere to the plate. The metal plate then strikes the substrate that is to be imprinted and transfers the foil onto the area of the document requiring the metallic effect. The result is a document that has a highly reflective image with a bright and dense metallic appearance.
This is a process that can be done in-line on a press. 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 the adhesive. The extracted foil is affixed to the printed adhesive and an image is created. Foil that does not adhere to the adhesive is removed.
Adding a metallic foil to your design provides variation in texture while starkly highlighting certain brand or graphical elements. Try combining foil with embossing or debossing to add depth to the product. The image on the right is an excellent example of a successful execution of an aggressive and impressive deboss with the use of metallic hot foil stamp. Observing closely, the real craftsmanship came with the ability to hold the adhesion of the hot foil stamp in the very fine areas of the snow flake, especially as a deboss was done as well.
Using a holographic foil or rainbow foils gives the package or piece the ability to change color combinations when viewed at different angles. This is a great way to add a pop of color to solid packages. Holographic foils provide a fun and sophisticated flair to product packaging.
Having clear foils provide high reflectivity, yet allow the printed image to be seen underneath. This is particularly useful for foods, beverages, consumable products and health and beauty offerings. It can also be used to give customers a preview of a new product.
Foils used for security purposes may include geometrical shapes, patterns and even brand logos that shift as the viewer changes focus. Take advantage of the mesmerizing effect by using it in a solid block rather than a border or small stamp.
For security measures, a foil with micro-etching can help prevent counterfeiting of items such as high-value coupons (shown above) that could easily be duplicated, causing retailers major losses as manufacturers will not recompense fraudulent coupons.
Perfect for small or large accents, foil is a beautiful finish to catch customers’ eyes.
Die cutting, a post-press finish, allows packaging and print pieces to have unique cutouts that can vary from simple to extremely complex. From shapes to letters, die cutting draws attention to the dimensional nature of the piece and the character of the substrate itself.
Partnering with an industry expert like JohnsByrne helps you create the desired effect for each project. Our team of experts have years of experience creating packaging that is protective, unique, appealing and consistent with your branding. To schedule a consultation and get started on your next project today, contact us at JohnsByrne today.
The main role of packaging is to protect the product from Point A (usually the manufacturing plant) to Point B (the ultimate user!).
But that’s not its only task. Packaging designs also serve as an advertising medium, letting manufacturers describe and promote their products with eye-catching words, colors, and fonts.
Contact us to discuss your requirements of wet strength. Our experienced sales team can help you identify the options that best suit your needs.
Packaging can even extend shelf life. It also allows oddly shaped items to stack neatly in a display and makes possible the use of machines to move pallets loaded with goods.
Additionally, packaging is a reflection of the manufacturer’s budget, advertising technique, and environmental awareness.
The type of packaging a manufacturer chooses depends on what they need. For something lightweight, paper and plastic fit the bill. Materials like metal or glass are heavier but more durable. Ultimately, choosing a packaging type comes down to stylistic choices, shipping conditions, shelf stability, and the product’s end user.
What are your choices? Here are five common packaging materials to choose from:
A nonporous, nontoxic material made from sand, glass is infinitely recyclable. One of its downsides is breakability — glass products may shatter in transit, costing the manufacturer money in the form of lost products and time spent cleaning up. It’s also heavier than plastic and requires substantial heat (energy) to produce.
But glass is an excellent barrier material, preserving the flavor of foods and drinks without leaching particles into them.
Manufacturers may design colored or textured glass containers with aesthetic appeal, encouraging people to buy the product inside. This is often the case with alcohol, soda, or candles.
Glass packaging is also reusable.
Polymers are the main ingredient of this synthetic material. When it comes to packaging, plastic may be flexible — as is the case with bags, wrappers, and stickers — or rigid — such as bottles, jars, and tubs, holding foods, drinks, detergents, pharmaceuticals, and more.
Plastic is also used inside other types of packaging in the form of packing peanuts or bubble wrap.
Plastic is lightweight, inexpensive, and strong enough to protect items during shipping. As a tape, it can bind packages together. Manufacturers can make it in a variety of colors and opacities.
However, it’s could be difficult to recycle plastic, so most of it ends up in landfills or the environment. It could break down into tiny pieces called microplastics that often contaminate waterways and food.
Researchers have discovered a way to turn some plastics into fuel, which could hopefully make it a more sustainable material in the future.
Pulp from wood or other sources, such as hemp or bamboo, makes up this type of packaging. Manufacturers often use it as a wrapper, paper box, shredded packing material, or in the form of paperboard. Corrugated boxes are made of two or more layers of paper stuck together by adhesive.
Paper is 100% recyclable, which can make it a sustainable choice of packaging material. Making it out of wood is less eco-friendly, but there are numerous up-and-coming alternatives that have a smaller carbon footprint. Bamboo, for example, grows quickly and comes back repeatedly after being cut down.
Paper can be less sturdy than other packaging materials, but it is durable in the form of board, and it’s lightweight.
Aluminum, steel, and other types of metal packaging are made by mining raw materials from the earth, then refining them. Metal can be more durable than glass or plastic, although thin metal is usually pliable and subject to bending out of shape.
Manufacturers use metal cans to package products as diverse as soda, green beans, paint, and shoe polish. Metal cans prevent food from spoiling, allowing it to be stored longer. Steel drums also transport large quantities of liquids, such as oil, for commercial use.
Metal can be dropped or subjected to high heat without breaking. Obtaining metal by mining is often an ecologically destructive process, but it’s easier to recycle than plastic. Metal packaging ranges from light to heavy depending on its thickness.
Also called multi-layer packaging, multi-material packaging is just what it sounds like — a combination of different material types. For example, juice boxes are made of layers of polyethylene, aluminum, and paper. Fertilizers and cement may be packaged in a structure made of paper and plastic, since paper by itself cannot withstand being wet.
Multi-material packaging can be engineered to guard products from moisture, like a metallized plastic bag that keeps potato chips crisp.
Unfortunately, this type of packaging is hard to recycle due to the mix of materials unless specifically designed to be easily separated.
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