BOOK THREE / Ink & Stock
Inks There is a limited number of ink systems that can be applied to materials beyond conventional colours. In most cases these systems work best when applied via silk-screen, although some can be printed lithographically. Scented ink Scented inks can be supplied in a wide selection of smells and can also eb synthesised to use a specific fragrance. They tend to be suspended at a molecular level, within a semi clear base. This is then screen printed on to the substrate. As scented inks are water based they can only be printed on unsealed paper (paper not plastics). On other surfaces water-based ink does not adhere to it and will scratch off. The scent has will usually lose potency over time. If you plan on using a specific existing fragrance it requires close liason with the ink maker. Heat-sensitive ink These inks are supplied in a limited range of colours. Black is the preferred colour as it creates dramatic results. Heat sensitive inks are suspended in a semi-clear base and works best when screen printed. The reactive temperature can be varied according to climactic conditions. As with scented inks, the system is water based and is supplied for printing on paper based substrates. It can be used on plastics but a number of layers of varnished will need to be applied for it to key in. This is time consuming and not very cost-effective. Heat-sensitive ink also has a tendency to scuff if not properly sealed. It can look best laminated in black, as this intensifies the colour. Rub-removable ink Normally used on scratch cards or other promotional items, rub-removable ink is latex based. It is supplied as a metallic, as it’s function it to obliterate what it overprints. The ink is quite fragile and difficult to work with, but it can be effective when printed in solid areas. It gives a rubberised feel and communicates that the area should be handled with care. Pearlescent and Iridescent inks These inks can be printed on all substrates and create a different shade of metallic colour depending on how close the viewer is to the print. They tend to be used on gift cards but also work well as solid areas with text reversed out. Other Ink Systems Other ink systems include light-sensitive ink (which only reacts in natural sunlight) glow-in-the-dark ink and glitter ink. Vegetable-based ink Inks that are made with vegetable based oils (as opposed to mineral-based sucha pertoleum) and that, as a result, are more environmentally friendly. Soy-based inks Inks derived from soy bean oil as opposed to petroleum, and mixed with pigments, resins, and waxes. One of many different vegetable based inks.
Materials Acrylic Can be supplied in a large range of colours and thicknesses, Acrylic tends to have a high gloss finish and is prone to scratching. For this reason it is supplied with a protective film on both sides of the material. It is available in cast and extruded acrylic sheets. Cast acrylic sheet is produced between 2 sheets of glass, it is more rigid that extruded acrylic, easier to cut and glue and is available in a wider variety of colours and finishes. Extruded is made from granules of plastic and is the preferred material for thermoforming. Acryic can be cut with a saw, once it has been sawn the edges can be flame polished which will leave a gloss finish. Flame polishing a sheet of acrylic that has been already printed on can cause the ink to crack. Acrylic can be glued although only highly water-based adhesives can be used. The material can also be softened on a wire and heat bent in to angles. Heat bending can also cause acrylic to flare out at the bend , this is especially hard to rectify when the item is being mass produced. Foil blocking can be applied to acrylic, acrylic can also be engraved but is costly and time-consuming. Screen printing a translucent white has the same effect as engraving and can be a cheaper alternative. Glow-edge acrylic is one of the more unusual materials available. There are chemical inside the sheet that emit a bright glow when light hits the material. The thicknesses and colours available are restricted but there is a sheet available in a 0.3mm thickness, this can be guillotined and would be suitable for business cards etc. Bible Paper An extremely thin printing paper, and has been made from a variety of materials, from rags to wood pulp. It is exceptionally strong and retains a reasonable degree of opacity. Today bible paper is usually made from wood pulp and is employed for other text-heavy tomes, such as dictionaries. Printing with bible paper can cause problems, the paper tends to stretch and curl due to the thinness. Bible paper foil blocks very well but care needs to be taken because of it’s lightness. The strength of the paper allows it to be creased and folded many times without the print cracking. Book Cloth Woven cotton that is coated in a starch and pigment mixture that has been subjected to live steam before being spread across the cloth. The granules of starch burst open and thicken , causing the material to thicken, giving the starched effect. Drying is usually done by a steam heated drum, cloth is wrapped around it during its journey through the spreading machine. The heat dries the starch the starch on to the cloth. When the material is glued, the process is reversed as water in the glue softens the starch granules, making the material pliable and easy to wrok with. The starch prevents the glue from penetrating through the cloth. Books had originally been bound in animal hides and papyrus, but both materials were costly and difficult to work with. An animal hide was an irregular shape with a number of perfections. With the onset of mass printing and increased literacy by the middle of the 19th century, the demand for books intensified, and these materials could not cater for what had been the preserve of the rich. Cloth was cheaper and could be supplied on a reel, so it was more efficient to use. It is more common to find paper-backed or tissue-lined book cloths on the market. These differ from cotton book cloths on the market. These differ from cotton book cloth as their material is predominantly from a synthetic source, such as rayon. Cotton book cloth has the disadvantage that adhesive will penetrate the cloth when glued. Rayon has a flexible backing or lining that prevents this, and is cheaper than cotton. A further disadvantage is the availability of much brighter colours and more variances of weave. Cotton book cloth tends to be associated with dry legal or medical tomes, whereas as rayon with art or design based projects. Cotton cloth is more durable than rayon. Coloured Paper The majority of coloured papers are supplied uncoated. The choice of colours and weights are fairly broad. Coloured paper can be supplied with a range of embossed textures on one side of the material. These finishes are used a lot for packaging, report cover and stationary. Weights of colour paper range from 100gsm to 350gsm. For a thicker material sheets have to be bonded together or duplexed, this is effective but can make the material very expensive. Colour paper is suited to all printing processes, screen printing and foil blocking are particularly effective. Black paper that have a high carbon content can have an adverse reaction to foil blocking. This can affect the appearance of the foil. Coloured paper die cuts and creases well and is therefore a good choice for packaging. Cork Cork is the bark of the cork tree. Cork is extremely bouyant as more than 50% of the structure is air, yet it remains solid. Because of this it is very compressible without breaking, making it flexible and resilient. As the surface is naturally uneven finish can be problematic,particularly when attempting to print fine text or complex logos. Cork can be die-cut and guillotines with relative ease. The application fo cork could be seen as limited. It’s uneven surface and cellular structure, coupled with the various tints available as a tile could make the material useful. It is worth including ithin a palette of surface textures and materials for presentation to a client.
Corrugated Cardboard Corrugated cardboard consists of flat outer sheets sandwiching a central core or filling of corrugated fluted paper (called a medium) that resists crushing under compression. When used in a box this gives cushioning to the boxes contents. The liner and medium are glued together along the outsides of the peaks and valleys of each flute, boxes are usually designed with the flutes running vertically for stacking strength. Common flute sizes are A, B, C, E and F, at the smallest there is a micro flute size. This letter designation relates to the order in which flutes were invented,not their sizes. Flute sizes refer to the number of flutes per lineal foot, with A being the least and biggest. Corrugated card is usually supplied in white or brown both sides. In addition, doube and triple wall corrugated boards are manufactured for specialised industrial applications. Micro-flute is manufactured for fine-printed packaging, when a printed sheet is laminated to the material. It is important to exercise caution when die cuttig or creasing this laminated material, as it has a tendency to crack the print. It can be creen printed and flexo printed. It can be foil blocked although this is not suited to the material. Felt Felt is made from wool matted together into fabric by beating, rolling, suction and pressure. The most common wool used in felt manufacture is sheep wool. Some felts can be dyed in a veriety of colours. Felt is available direct from the manufacturer, brighter colours tend to be available at handicraft markets. The largest palette tends to be supplied to a thickness of 1mm. It is rare to find thicker felt in colours other than black. This is partly because you cannot dye the felt consistently. A more limited palette of colours, but one with a far more interesting texture is provided by ‘industrial’ felts. Usually supplied in off-white, grey and brown, this industrail felt is used to polish and finish jewellery and metalwork and can be found encasing the strikers of church bells. Industrial felt could be seen as having a texture and finish aligned to materials such as grey board and corrugated cardboard. Printing methods tend to be restricted to screen printing, and it is difficult to achieve a fine print as the material is quite fibrous. Felt makes an interesting covering material and can be converted into book jackets as an alternative to book cloth. It cannot be used as a covering material in box making as it cannot be glued. Flexible PVC Flexible PVC (Polyvinyl chloride) is a variant of rigid PVC. The inroduction of plasticesers to the substrate, first attempted in the 1920s makes the material more pliable. Flexible PVC is now commonly used in the manufacture of stationary such as binders and holders for car-parking permits. Unlike rigid PVC, flexible PVC is available in an extremely large selection of colours and finishes. The colour and weight selection is very broad, encompassing day-glo tints right through to black, like coloured paper it is available in a number of embossed finishes. Flexible PVC should be used with care as each version has a specific use or application and it can react to any print that it comes in to contact with. It has a tendency to lift print off surfaces - the print often attaches itself, like a transfer, to this substrate. This occurs because of the high proportion of plasticiser in flexible PVC. Flexible PVC can be screen printed, and some grades can be printed lithographically It debosses very well when high-frequency welded, a process which is ideally suited to this substrate. Flexible PVC is supplied on reels and is notoriously difficult to convert into flat sheets. Specific inks are required for printing on flexible PVC. In addition it is not possible to print then deboss in register, as the high-frequency welding process will lift the ink. There are unusually uses of flexible PVC. For instance, a thin, black, embossed flexible PVC is appropriate for coffin linings, where as it’s white counter part is used to line babies prams. There is a semi-translucent version that is used for blood bags, while thicknesses of up to 5mm are used for factory-door curtains. Flexible PVC is an invaluable material and worth experimenting with. Grey Board Made from recycled waste paper using a production process that is very energy intensive. Bales of waste paper are placed into a pulper - a steel cauldron filled with water, fitted with a rotor arm. The soaked waste paper then begins to break up, and the turbulence produced by the rotor arm nixes the fibres with the water, producing slurry. This slurry is pumped into a head box, from which it is distributed on to an endless screen called a wire. In the first few metres of the wire the board takes shape. The water disperses and the paper fibres remain behind and bind with each other. The wet board is squeezed between 2 presses where supporting felt soaks up and removes more water. The board is becoming more rigid. The board is then passed over steam-heated cylinders, causing most of the remaining water to evaporate. The resulting grey board is now ready to be used in it’s raw state or can be laminated. Grey board has a wide variety of traditional uses. Because of its low cost and rigidity it is principally sold to make covers for hardback books, and forms the core material in high frequency welded binders, files, diaries and even jogsaws. It is a material that serves a purpose and tends not to be seen. Despite being very rigid, grey board is still soft enough to be foil blocked, giving a debossed effect. Interesting results can be achieved by foil blocking with a clear foil. It can also be screen printed, though the
board may need to be sealed as it is very porous. Another alternative is to screen print the image twice to ensure a good coverage of ink, this causes problems with registration. When the matt surface is laminated , grey board has an unusual apperance, as the lamination takes on all the imperfections in the surface of the board. Grey board tends to crack when being creased. Grey board can warp when left in daylight due to it’s high water content. The board should be left shrink wrapped until it is required. Grey board is a rough looking material and can be imbued with all manner of meanings. It feels recycled and looks industrial, with a look and feel of being distinctly unprocessed compared to paper. This lends itself to projects requiring a grittier, industrial feel. In some cases, attempting to make it look beatiful can create an uneasy relationship between material and process. This unease serves to maximise the end result. High-Density Foam High density foam has a 3-stage production process, commencing with polymer being blended in line and extruded into solid sheet or slab form. This sheet is then cross-linked to create a lattice-like structure at a molecular level within the material. This allows the material to be thermal moulded, as cross-linked foams can be stretched and compressed, and retain their shape when cooled. High density foam has a range of applications but can principally be employed by the designer as a packaging material to house a series of items securely and attractively without having to resort to over-engineered cardboard executions. Typically the foam is supplied in buns or sheets with a manufacturing skin that makes the foam appear hard and shiny. Most fabrication operations require that the skin is removed from one or both faces and that the sheet is split to a specific thickness. This is the first stage of the sheet being ready for production. It is possible for high-density foam trays to be form cut, but the material in the well of each aperture will have been cut all the way through, if this happens it will continuously fall out. A better process is to rout the shapes, a process in which the coordinates of the design are computer programmed; a routig drill will then grind out all of the surplus material fromt eh tray and form the required apeture. High density foam is commonly supplied in white and black, with coloured having to be made to order. There are many grades of this material, all of which have specific applications, medical packaging for example. It can be printed on, but very rudimentary results can be achieved. It should be noted that high density foam can expand by as much as 2% depending on the ambient temperature of a room it is in. For this reason it should not be used if the required fit is very exact. Despite the problems with the material high density foam has great potential. It provides the designer with the ultimate alternative to conventional packaging materials. Leather There is an almost infinite choice of leather to use. It is an expensive material to use, and decisions based on expectation of how leather should feel and smell will lead you to higher-priced skins. Leather is mainly available at specialist merchants who normally supply skins to make handbags and belts and therefore are structured towards this market. The use of leather in a project generally denotes wealth, tradition and luxury. Leather can be screen printed, embossed and foil blocked. It should be noted that, as leather is animal skin the surface and texture of leather is a variable which could hamper the application of a design. Care should be taken when glueing as leather has a tendency to contract when mounted or bonded. More rigid leather will die-cut and trim far better than softer pig-skin or goat-skin leather. The range of colours readily available tends to be very basic, with the palette rarely deviating from brown, black or blue. Brighter colours tend to be dyed especially for clients requirements. If cost is an issue there are a number of synthetic materials that mimic the grain of leather, and some have even been developed to smell like it too. Metal Metal could be regarded as a material that has very limited applications with the design process. It has a look, feel and density that will rarely be appropriate. Cost is an important factor when considering using metal for a project. A reason for this is the extra processes that metal has to go through prior to being ready to work with. The materials most commonly used by designers are aluminium and stainless steel, both of which are easily cut, creased and screen printed. Stainless steel is much harder than aluminium and can be supplied in very thin gauges. The thinner the gauge the sharper the edges become. Stainless steel is good for having designs etched in to or through it’s surface. Aluminium is a lightweigh popular substrate for binders. Its edges do need to be sealed or anodized by immersing the material in an anodizing solution and running an electric current through it, otherwise it is prone to oxidisation and marking from fingers. There are not many suppliers and manufacturers who can produce high quality finished goods from metal.
Mirri-board Mirri-board is manufactured by laminating thin films of metalised polyester to different base papers and boards. Its metallic and reflective surface lends itself principally to specialty packaging such as perfume cartons. The wide variety of colours and finishes should allow you to specify it’s use for other applications. There is also a range of holographic boards utilizing metalised polyester film that carriers a micro-embossed holographic pattern. There is no choice beyond those patterns already available. Therefore any project that uses these materials has to be very specific in its requirements. The patterns also have ‘shim lines’. These barely detectable lines occur where the pattern is butted up against itself and repeated. They are unavoidable and can create a grid over the finished work, which may be regarded as unsightly. Despite their highly reflective and smooth surfaces, these materials can still be printed conventionally. With lithographic printing, inks must be selected that dry on non-absorbent substrates. UV curable inks are also preferred. Caution needs to be exercised when handling more reflective boards as they have a tendency to scratch and mark. This laminated surface is soft, with any minor blemish being obvious because of the reflective quality of the material. Inks must be selected that will dry on non-absorbent surfaces. Certain inks needs to cure for up to 48 hours, or they will scratch. Foil blocking and blind embossing both produce amazing results , and it is worth exploring different foil combinations on this stock. Overprinting in translucent tints can produce interesting results on more iridescent versions of the material. Newsprint Newsprint has to be strong and have a high opacity in its principal use for newspapers and comics. Traditionally it is used in web printing, where the paper is supplied via a roll as apposed to separate sheets. Because of the materials lightness and tendency to absorb ink, newsprint can be hard to print on conventionally. The surface of newsprint is highly irregular becasue of its content which is predominantly from recycled sources. Newsprint is available in a veriety of weights, particularly lighter weights. This is because the newspaper market want thinner and lighter substrates whoch are more cost-effective. This also makes heavier stocks harder to find. Polypropylene An extremely common and widely used substrate across all areas of indsutry, products and design. This is because of it’s strength, versatility and resistance. There are many variants of the material. Production utilises a slurry, which is catalysed through heat and pressure. These conditions are varied depending on the intended use of the product. The material does not present any cracking problems and can withstand very high temperatures. It’s environmental impact is low due to limited use of natural resources, low emissions, durability and optimal recycling capabilities. The only water used in its production is in the cooling process which is a closed operation. So there is no pollution of rivers and streams. Sheet polypropylene comes in a broad variety of colours and thicknesses. The most commonly available sheets have a calendered, leather like, embossed surface, likely because this variety of the material marks easily. The texture is also very waxy, which can be offputting. However, it screen prints well and can be printed conventionality. It foil blocks and embosses without warping the finished sheet. Unlike rigid PVC, polypropylene can be scored without snapping in 2. It scores to leave a live hinge but care should be taken to avoid cutting all the way through the material, as the density of the material can vary across the sheet. Sheets of polypropylene can be welded together, which can be a better alternative to a locking tab when used for a box. It can also be riveted and stitched. The popularity of polypropylene has been to the detriment of other materials. In the form of extruded film it is replacing cellophane, metal and even paper as it is very resistent to being punctured. It is bright, durable, easily available and seen everywhere. Although polypropylene is widely marketed, the choice of solid opaque colours available from stock can be limited. The white and clear sheets offer a greater range of weights and finishes. Recycled polypropylene made from plastic bottles is also available. Polystyrene ommonly referred to as expanded polystyrene (EPS), has many uses from ceiling tiles through to transportations packaging and use as a building material. It remains largely unexplored for design based applications. The mould of polystyrene is a 3 part process. In the first part tiny spherical EPS beads are expanded up to 40 times their original size. In the second stage the boards are stored in huge canvas silos and are left to absorb air for 24 to 48 hours. In stage 3 the freshly expanded beads are poured into manufactured moulds where steam and pressure are applied, softening the beads and compressing them so that they bond together into the required shape and density. A black variant of EPS exists that is used in thermoinsulation. The colour comes from introducing carbon flakes into the beads to enhance its thermal performance. This is an more aesthetically pleasing variant of the standardised white EPS. Sheet polystyrene is moulded in large locks that are cut using hot wiring cutting machines. The cell structure of this material means that in appearance the material seems quite smooth but printing will achieve mixed results.
Rigid PVC PVC (polyvinyl Choride) is one of the most commonly used and widely available substrates. It is one of the most valuable products in the petro-chemical industry. The majority of PVC is used in construction and heavy industry. It’s ease of manufacture and huge number of varieties make PVC a quick fix choice for numerous applications beyond these industries. PVC is in common used virtually everywhere. It is used for credit cards in its original form. In a softened form it is used for document wallets, they have a harder, dryer feel that polypropylene, a material commonly used for this application. For use in printing the material is normally supplied in white or clear sheets across a finite number of weights. There is a clear, mark-resistant version available; this has a calendered appearance, giving it the look of tracing paper. PVC is not supplied in a range fo colours. Virtually any printing process can be applied to rigid PVC. It offers a synthetic alternative to paper. Rigid PVC is expensive to print with, the client and designer need to be aware of it’s limitations. As PVC is not regarded as environmentally it can be off-putting to the designer and client. Care needs to be taken when die-cutting rigid PVC as the edges can become very sharp. Foil blocking and embossing can create particularly interesting results. However the material can become uneven during these processes. Rubber Rubber is used throughout a wide variety of industries, however it is not as avaiable as you might expect. Rubber is not somethings you would use for a printed project as you paper. Rubber is highly flexible so is very difficult to print on as the ink needs to be as flexible as the substrate itself. Supply of flexibe inks is very limited and the choice of colours remains highly restrictive. It is not possible to deboss the material as it is too dense. There are flexible PVCs avaiable as alternatives. A good source for coloured rubber is domestic floor tiles. These tend to be more rigid that black flooring rubber, but the reverse of the tile can be uneven to allow flooring glue to be applied. Latex is a very thin alternative to rubber. Commonly used in fetish clothing, latex can be glued or bonded together to form pches or covers. Latex is very fragile and has a tendency to dry out and fall apart. Rubber bands are a good alternative for binding if you do not want to use staples. Self-adhesive Self adhesive materials are made with a water-based adhesive, this is roller coated on a silicone-coated backing or release paper. The adhesive is allowed to dry off and the nominated top sheet applied. The adhesive then transfers itself to the top sheet. Self adhesive materials are supplied with either a solid or split/crack release paper. So-lid-back means you have to peel the release paper back from the edge of the sticker. Crack-back allows you to split the backing paper and get to the adhesive side more quickly. Crack back is easier to use but it does have a tendency to show through on the printed side. Also, it prohibits prinitng on the reverse of the release paper. The range of adhesives available is very wide, from industrial to domestic, it is advisable to state the application you will need the material for. This helps avoid overpaying for the material. Self adhesive materials are available in a number of finishes and colours. All self adhesive products can be printed and finished by any process, and do not pose any problems. Synthetic Paper Characterised by their strength and printability, some are waterproof, chemical resistant and tear resistant. They are stronger than paper and often easier and more versatile to use. Looked at closely some synthetic papers will have a faint iridescent sheen, and most have an interesting texture. Synthetic paper all suffer from a myriad of litho printing problems, particularly ink not dryng and the material curling. Printers tend to overcome the issue of ink not drying by applying layer upon layer of varnish after printing, this causes an uneven effect on the print. Material responds well to screen printing and to foil blocking, embossing results are mixed as the emboss does not stay in the material. They can be perfect bound, though static build-up between the sheets can cause problems. Synthetic papers can be creased and folder without ever snapping. Tyvek A synthetic material made of high-density polyethylene fibres, these make tyvek lightweight yet strong, resistant to moisture and tear resistant. Tyvek resembles paper as it can be written and printed upon, it was used for New Zealand driver’s licences between 1986 and 1999, some countries have printed their currency on it. Tyvek cannot be recycled in noral recycling facilities. Very few printers have a set-up that allows for tyvek to be printed on lithographically. It has a tendency to curl if the wrong inks are used when screen printed. Whilst it can be foil blocked, the heat of the process can cause the material to cockle. Rigid versions are available, but these are often used for clothing. Tyveks application is limited to jobs that require a futuristic or industrial feel currently.
Velcro Discovered in 1948 by Swiss engineer George de Mestral. Velcro has many applications across a spread of industries. In design it can be used as an alternative closure device, it being readily available in strip and dot form. It is available in a wide variety of colours from pastels to brights. Further development from velco companies is velcro that can be printed on digitally, lithographically or by silk screen. Wood In the majority of cases where wood is used it needs to be thin, have a grain and be capable of being printed on. A type of wood that is suitable for print work is TULIPWOOD, WHICH CAN BE STAINED AND VARNISHED TO LOOK LIKE ANY WOOD AND HAS A GOOD GRAIN TO IT. Silk-screen printing is a tried and tested method of applying ink to wood, if the wood is hard enough it should be possible to foil block it. Shop-fitting companies will be able to give you valuable information and help you understand issues surrounding getting the right sizes and finish you require. Paper Paper qualities GSM, grain and paper direction are key physical characteristics to consider when selecting and using a stock for publication. GSM (Grams per Square Metre) A weight measurement that is part of the paper specification based on the weight of paper per square metre of the stock. The higher the gsm value, the more weighty a stock feels. An A0 page is equal to one metre square, meaning that grams per square metre equates to the weight of a single A0 sheet. Paper Grain Paper produced on a paper machine has a grain because the the fibres from which it is made line up during the manufacturing process in the direction that it passes through the paper making machine. The grain is in the direction in which most of the fibres lay. This characteristic means that paper is easier to fold, bend or tear along it’s grain direction. Direction The direction of the fibres in paper for laser printers such as those found in offices, typically has a grain that runs parallel to the long side of the paper. This allows the paper to pass more easily through the printer. Paper types & print quality Paper characteristics that affect printability include; smoothness, absorbency, opacity and ink holdout. Smoothness The smooth surface of these stocks is obtained through the use of filler elements that may be polished with calendering rollers. These are typically glossy as well. Absorbency Stocks have different absorbency levels, which is the degree to which the ink penetrates it. Printing inks tend to dry quicker on absorbent stocks, but absorbency may cause problems such as dot gain. Opacity Opacity is used to describe the extent to which whatever is printed on one side of a sheet shows through and is visible on the other. High-opacity papers have no show through. Ink holdout This is the degree to which a stock resists ink penetration die to its relative lack of absorbency. Coated stocks may be particularly prone to ink holdout as the ink sits on the surface, which in turn increases drying time.
Type of paper Antique Notes A high quality paper with a clay coating on both sides to give a good printing surface, especially for halftones, where definition and detail are important. Primary uses To add texture to publications such as annual reports. Secondary uses Stationary and flyers. Effect a textured stock with a rough or matt surface. type of paper art notes a high-quality paper with a clay coating on both sides to give a good printing surface. primary uses colour printing and magazines secondary uses glyers, calendars and brochures effect a glossy, high brightness surface that is smooth to the touch type of paper artboard notes uncoated board primary uses cover stock secondary uses flyers and packaging effect a stiff stock type of paper cartridge notes a thick white paper. Ink and pencil drawings are particularly well produced on this. primary uses stationary and annual reports secondary uses mail shots effect a stiff feel, available in several colours.
Type of paper cast coated notes wet-coated paper is pressed (cast) against a hot, polished metal drum to obtain a high gloss primary uses magazines and brochures secondary uses promotional material effect a smooth glossy surface type of paper chromo notes a waterproof coating is applied to one side of the paper to allow for embossing and varnishing processes. primary uses labels, wrappings and covers secondary uses applications where only one side has to be printed effect clay coated on one side; can be glossy or matt type of paper flock notes paper coated with flock; very fine wollen surface. Used for decorative covers. Other coatings might be refuse r vegetable fibre dust to give a velvety or cloth-like appearance. primary uses decorative covers secondary uses packaging effect a textured decorative surface. type of paper greyboard notes line or unlined board made from waste paper. Packaging material. primary uses packaging material secondary uses covers effect rough texture, good bulk and grey colour
type of paper mechanical notes produced using wood pulp and acidic chemicals, this paper is suitable for short-term uses as it yellows and fades quickly. primary uses newspapers and directories secondary uses magazines, inserts, flyers, coupons and books. effect higher brightness and smoothness than newsprint, but uncoated and matt type of paper NCR (No Carbon Required) notes a carbonless coating to make duplicate copies. Available in 2 to 6 part. primary uses forms and purchase orders secondary uses receipts effect the application of pressure produces an impression on subsequent parts. type of paper newsprint notes made primarily of mechanically-ground wood pulp, this is the cheapest paper that can withstand standard printing processes. It has a short life-span and reproduces colour poorly. primary uses newspapers and comics secondary uses low quality printing effect absorbent, comparatively rough surface. type of paper plike notes a rubberised substrate primary uses cover stock secondary uses flyers effect rubbery texture
type of paper uncoated woodfree notes this paper is the most commonly used in non-commercial printing. Most stationary and printer/photocopier paper falls into this category. primary uses office paper secondary uses forms and envelopes effect a white paper with a slightly rough, non-glossy surface. Paper stocks and how they react to colour Stock Uncoated or offset Characteristics Highly absorbent, which means sharp colour images are difficult to reproduce. Colour reproduction Good, but limited if sharp images are required Use magazines Stock Matt Charcteristics Coated stocks have a dull surface Colour reproduction excellent, flat colour with low glare. Ideal for photorealistic images. Use magazines, books, flyers, brochures, catalogues Stock Silk/satin/ semi-gloss Characteristics More coating than matt but less than gloss stocks Colour reproduction excellent, low glare, ideal for photorealistic images Use magazines, books, flyers, brochures Stock Gloss Characteristics Coated paper with a smooth and high-white gloss surface. Colour reproduction excellent, ideal for reproducing bright colour use Staple of magazine production, brochures
stock Cast-coated characteristics heavy, clay-coated stock. Pressed (or cast) while still wet against a polished, hot, metal drum to produce a high gloss finish, usually on one side of the sheet. Colour reproduction excellent colour reproduction use magazines, flyers, brochures stock tracing paper characteristics transulecent stock with little space between paper fibres. Low ink absorption, difficult to print on. colour reproduction possible but very limited use special projects stock tissue paper characteristics thin, highly-absorbent stock colour reproduction unsuitable use not applicable
Stock/materials for packaging. Plastics In total plastic packaging only uses 2% of all crude oil produced. Despite being carbon-based, plastics break down extremely slowly, over hundreds of years. Especially in oxygen starved landfills. Most of the plastic ever produced still exist in some kind of form. Plastics offer a great deal in terms of shape, lightness and performance. Their environmental qualities depend on largely on the recycling facilities available. In terms of shape plastic bottles are far less restrictive than glass, and make a positive contribution to the environment through their lightness and recycling potential. Clear plastic bottles have the most potential for reusability; as reprocessing plants focus on clear PET and HDPE they are more likely than coloured ones to be effectively recycled. PET (Polyethylene Terephthalate) Positives Clear, recyclable, light, durable, low gas permeability, weldable Negatives High cost (compared to PVC), average moulding detail when blow-moulded, brittle Typical uses Clear bottles thermoformed or injection-moulded trays vacuum formed dessert and yogurt pots blister and clam packs films cartons puches jars resealable tubs clear presentation tubs flow wrap bags HDPE (High-Density Polyethylene) Positives Low cost, recyclable, durable, wide variety of surface effects, good moulding detail, lightweight compared to glass. Negatives Clear HDPE is slightly cloudy, coloured HDPE is unlikely to be recycled back into packaging, transporting empty bottles to the filling site is effectively shipping air, so on-site moulding is preferable, converns over the unchecked proliferation of HDPE carrier bags. typical uses opaque or translucent bottles tottles flip top/screw top closures flow wrap bags carrier bags films flexible tubes jars PVC (Polyvinyl chloride) Positives Low cost, high clarity, durable, wide variety of surface effects, good moulding detail, weldable Negatives environmental doubts over processing emissions, evidence of links to cancer and infertility, can compromise PET recycling, transporting empty bottles to the filling site is effectively shipping air, so on-site moulding is preferable
typical uses clear and high gloss coloured bottles blister and clam packs films flexible wallets cartons flexible tubes blow-moulded jars clear presentation tubes LDPE (Low-Density Polyethylene) Positives Low cost, lightweight, flexible, moisture resistant, weldable Negatives environmental concerns over harm to marine life, concerns over unchecked proliferation of carrier bags. typical uses flow-wrap bags carrier bags bottles lids six-pack holder films flexible tubes transit packaging jars trays/punnets pouches beverage cartons dessert pots PP (Polypropylene) Positives robust, rigid, resistant to high temperatures, detailed moulding, excellent surface detail Negatives often not recyclable (although this varies by country). typical uses resealable tubs flip-tops/screw-top closures pull-tops injection-moulded trays/punnets films bottles cartons flexible tubes flow-wrap bags carrier bags jars pumps trigger tops puches (doy bags)/sachets transit packaging PS (Polystyrene) Positives insulating, impact absorbant (as foam) flexibe Negatives Brittle, can be inefficient to recycle (particularly in foam form)
typical uses pots trays burger boxes transit packaging injection moulded jars Glass Positive infinitely recyclable, durable, reusable, better barrier material than plastic, can have recycled content, inert Negative high cost compared to other container materials, high use of energy in production and recycling, high weight compared to plastics, transportation uses more energy, glass containers have to be empty when they are transported to the bottling plant. Typical uses bottles jars Metal Aluminium and steel are important packaging materials that are used particularly for their barrier properties and strength. Aluminium Positives lightweight, cheap, easily and efficiently recycled, shapes can be customised, can have recycled content Negatives aluminium production uses a great deal of energy, cans are usually shipped empty to the manufacturer. typical uses beverage cans bottles aerosols trays doy bags foils screw-top closures beverage cartons flow-wrap bags lids spiral wound tubes pie cases/containers Steel Positives cheap, easily recyclable Negatives steel production uses a great deal of energy, cans are usually shipped empty to the food or beverage manufacturer typically used tins for storage/presentation aerosols beverage and food cans crown caps, twist lids
Paper and card Paper has exceptional qualities, with many potential structural uses including bags, envelopes, labels and wraps. Introduction Card is sustainable (from the right source), compostable, recyclable, versatile and inexpensive. The trouble with cardboard boxes is that they often look boring, despite cards sculptural potential whoch tends to be underexploited. This is because complex card folding is more time consuming than using a preglued carton. Paper typical uses labels wraps for pots bags inserts dessert pots resealable tubs beverage cartons Card/cardboard positives biodegradable, compostable, recyclable, sustainable, low cost Negatives high use of energy in production, production can be polluting, managed forsests can be a threat to biodiveristy, card can be heavy particularly recycled. typical uses cartons sleeves/envelopes trays swing tags transit packaging spiral-bound tubes backboards Moulded pulps Moulded pulp packaging is more expensive to produce than card because of it’s moulding costs, poor print finish and the relative inefficiecy of stacking ad transporting the moulded shapes. Introduction It is underexploited and tends to be used as transit packaging, or a greener alternative to expanded polystyrene. Most commonly used for egg boxes. Pulp made from softwood is the most familiar type, there are other source though such as; bagasse (sugar-cane fibre), palm fibre and bamboo; cotton, hemp, flax, kenaf, wheat straw, reeds and rice straw are routinely pulped. Like most plant-based materials pulps emit methane if lanfilled, but it can be recycled with paper based products. Recycled paper pulp Positives recycled content, cheapy, readily available, diverse uses. Negatives the moulding process uses a large amount of energy and water; the reprocessing and recycling of paper into pulp uses a lot of energy, water and chemicals. typical uses transit packaging egg boxes trays burger boxes
Moulded bagasse pulp Positives good-qualoty mouldings, can be used in conventional and microwave ovens, use of sugar-cane waste, recyclable. Negatives Sugar-cane production is linked to desturction of rainforests and pressure on food crops, high use of water and energy, GM crops may be used in it’s production. typical uses pots trays burger boxes disposable plates and cups Moulded palm fibre Positives good-quality mouldings, makes use of palm oil residue, recyclable Negatives Palm-oil production is linked to the destruction of rainforests typical uses trays burger boxes pots disposable plates and cups Moulded bamboo fibre/pulp Positives abundant and fast growing, takes surface detail, recyclable Negatives threat to rainforests, bamboo is not a waste material from another process Biodegradable Plastics Biodegradable plastics are generally designed to break down quickly in outdoor conditions and are specifically targeted at products normally associated with littering or which may harm wildlife. Biodegradable plastics positives biodegradable, no residue negatives require specific conditions to break down not as strong as additive based conventional plastics, can potentially contaminate recycling stream. typical uses food tray lidding, overwrapping carrier bags beverage bottles food trays Hydrolytically biodegradable plastics postives biodegradable, no residue negatives susceptible to water damge, require specific conditions to break down, not as strong as additive-based conventional plastics, can potentially contaminate the recycling strea.
Degradable plastics Degradable plastics are designed to degrade quickly as a result of being exposed to specific environmental factors, such as oxygen, water or light, which make the ‘disappear, rather than remain in landfill or at sea for many years. Incorporating an additive, such as starch in the plastic masterbatch makes them break up into small pieces. Hydrolytically degradable plastics Positives degradable, no visible residue Negatives fossil-based plastics are used in their production, require specific conditions to break down, can potentially contaminate the recycling stream. typical uses carrier bags wraps for newspapers transit packaging OBPS (Oxo-[bio]degradable plastics) positives degradable, may be recyclable, no perceptible residue. Negatives fossil-based plastics are used in their production, require specific conditions to break down, may leave toxins in the soil, can potentially contaminate the recycling stream. typical uses carrier bags wraps for newspapers PBPS Postives degradable, no visible residue negatives fossil-based plastics are used in their production, require specific conditions to break down, may leave toxins in the soil, can potentially contaminate the recycling stream. typical uses takeaway food packaging carrier bags Bioplastic Bioplastics are derived from crops, typically maize but also palm oil, sugar cane and softwood. Not all of them are biodegradable, some are identical to conventional plastics. As a sustainable alternative to fossil plastics they are often hyped as being the answer to environmentalist’ prayers. The majority of bioplastics lack many of the qualities that make conventional plastics so indispensable. They also raise uncomfortable questions about farming methods and the use of land for nonfood crops. Starch Postives Mouldable, compostable, usually hydrolytically biodegradable Negatives breaks down quickly so uses can be limited. typical uses transit packaging burger boxes base material binding medium
Paperfoam Positives biodegradble, robust, good surface detailing, recyclable with paper, lightweight Negatives hydrolytically biodegradable to some extent typical uses trays for CDs transit packaging High Amylose Corn Starch Positives Durable, readily compostable, mouldable, water soluble (hydrolytically biodegradable) Negatives biodegrades on contact with water, high land use, can potentially contaminate the recycling stream Typical uses foam trays biodegradable carrier bags bagging films PLA (Polylactic Acid) Positives Extremely durable, mouldable, behaves like fossil-based plastics Negatives Not readily compostable, can easily contaminate conventional recycling streams, high land use, often uses GM crops. Typical uses films clear bottles dessert pots resealable tubs transit packaging punnets flow-wrap/carrier bags PHA (Polyhydroxyalkanoate) and PHB (Polyhydroxybutyrate) Positives durable, readily compostable, mouldable, water soluble Negatives high cost, hydrolytic biodegradability can limit where PHA and PHB are used typical uses carrier bags films bottles yoghurt pots Green Polyethylene Postives durable, easily recycled, same properties as conventional polypropylene Negatives high cost, high land use Typical uses bottles caps films carrier bags
BIO-PET (polyethylene terephthalate) Positives clear, from renewable sources, recyclabe, light, durabke, low gas permeability, weldable Negatives High cost, high land use, brittle when bow moulded. typical uses clear bottles Cellulose-Based Films/Cellophane Positives Low cost, recyclable, compostable Negatives Mainly limited to low performance films typical uses clear film wraps carton windows clear labels flow-wrap/carrier bags Wood Positives strong, durable, projects quality, water resistant, natural, sustainable (depending on the source) Negatives high cost compared to alternatives, lack of flexibility, limited printing options, weight, not usually recyclable Typical uses crates cheese packaging presentation packaging traditional packaging paper and card cellulose-based films