Six pillars to produce extraordinary labels most efficiently
Labels are for many products an important factor to attract the attention of potential buyers and to give the product value and emotionalize. Embellishment offers a broad portfolio of possibilities to support these goals. Various embossings, colours, special foils and their combinations offer unique design possibilities.
Manufacturers of such highly embellished labels are excellently positioned in the market and focus on three points: Efficient embellishment equipment, smooth processes and efficient access to all relevant information regarding tools and consumables.
The result: efficient, profitable processing for exquisite, inspiring labels. And a strong, unique competitive position.
1. The design brief - the foundation for exceptional labels
From the point of view of a printing company, the production of extraordinary labels is basically no magic art. Many of the skills required are already available and a lack of knowledge or experience can be easily acquired through external partners.
Of the utmost importance - and decisive for efficient project management - is a professional design briefing in which the key players jointly define the framework conditions for the project. Also on board: the customer as client, designer and - decisive for the feasibility - the printing company.
In many projects today only designer and customer sit at the table. The result: often outstanding designs that are either impossible or extremely time-consuming to produce. The early involvement of the production manager brings a great deal of know-how into the project and the feasibility is in the focus right from the start.
In the briefing discussion, wishes, goals and approaches are defined together. A meaningful structuring of the individual steps and dependencies is essential for the success of the project. In addition, realistic assessments of timelines and the planning of time buffers are important components of a good design briefing.
Description of the design requirements using "Gin Kyburg" as an example
2. The team - the closer the cooperation, the better the result
The efficient production of highly embellished labels often means exhausting what is technically possible in all the disciplines involved. The quality of the collaboration between designer and printer is a decisive factor for the efficiency of the process and the quality and price structure of the result. In addition, a close partnership with an appropriate tool manufacturer and a competent network for questions in the areas of substrate, foils and process technology are recommended.
Team variant 1: Designer & Label Engineer as service provider
At the Pantec design partner #eskju a designer and an experienced printer and label engineer form a team. Idea and feasibility form a unit. Unnecessary setbacks, redesign etc. are a thing of the past. Data is created and structured accordingly for the further production process. Suppliers can deliver faster, results become more precise.
Team variant 2: Close partnership between designer & printer
viergestalten design, the Pantec partner for the Laola label, is a close cooperation partner of Etiketten Carini and knows both the machinery and its possibilities and works closely with the Carini production team.
Team variant 3: Own design department in the print shop
Many of our customers have set up their own design department. The model is similar to variant 1 and offers all its advantages. Thanks to the very short communication channels, demanding projects can also be implemented very quickly.
In addition to an efficient core team, the network with local partners for tools, foils and substrates is also very important. Contact us for information on suppliers in your region.
The concept phase for sophisticated labels is highly exciting, because in this phase creativity meets technical and economic feasibility. And this tension has to be redefined for each job, because each project brings in new requirements.
With regard to embellishment, the challenge is to select the refining techniques that best meet the requirements from the multitude of available techniques. And to optimize the design in such a way that it can be produced efficiently.
Often, marginal changes or adjustments in the design result in enormous cost savings or increased productivity.
The optimal combination of requirements and feasibility
The embellishment part in the design defines the major part of the costs in the manufacturing process. The embossing machine has a massive impact on the resulting machine speed - and thus on productivity. Foil consumption can often be significantly reduced with slight adjustments to the design. And even in terms of tooling costs, a smart design can reduce manufacturing costs and, as a result, set-up costs.
Know how about material and tooling is very helpful in optimizing the embellishment process. The company's own experience, the wide range of sample books and the competent contact persons at the suppliers help here on a daily basis.
4. Choosing the right embellishment technology to keep the costs low and the productivity high
Rotary stamping with SWIFT™
Single images are normally applied with rotary technology. The usage of hot foil technology offers great advantages, especially in logistics. SWIFT™ moves and places each foil image individually in register.
Pantec SWIFT™: Placement of images in register and foil saving
Flatbed embossing with RHINO™
Flat embossing can be used in many different ways and can have many advantages over the rotary process. Especially when embossing on open materials, there are great advantages in terms of process technology.
RHINO™: Flat bed hotfoil, embossing & foiling in register
Due to the rotating foil head, several foils can be applied in one machine cycle crosswise to the web direction. In addition, flat tools are cheaper and easier to set up. In terms of design, 3D flat embossing, micro and nanostructures and multifoiling offer perfect register that "shine" in the truest sense of the word.
5. Cooperation between Tooling manufacturer and Label Printer
The cooperation between tooling manufacturer and Label Printer or Designer plays a central role, especially in complex flat embossing refinements. If micro- and nanostructures are to enhance the label, the tool plays a decisive role. And it is the toolmaker's know-how that gives the label the high-end touch that is required.
Of course, it is an advantage if the designer takes into account what the machine can do right from the design stage.
The tool manufacturer's briefing includes background information and knowledge of the embossing machine, specific descriptions of the desired embossing effects, foil application and embossing temperature. Topics such as 3D proofs and embossing should also be determined in advance.
6. The selection of the right materials
Substrates and foil types play a central role in the selection of the right materials. As a rule, the substrate is selected in the first step of a project. Factors such as optical impression and haptics play a central role.
However, it is also important to ensure that the selected paper can reproduce the printings, embellishments and finishings desired in the design. Sample books offered by substrate manufacturers are a valuable aid in this respect.
Sample books help with the selection of the substrate.
On the basis of the substrate, the technically suitable foils are then selected on the basis of the following parameters:
Embossing process: flat / rotary
Further requirements such as overprinting, ...