Digital Output Nov 23

NOVEMBER 2023

pg. 17

Flatbed Printing Spotlight | pg. 8 PVC-Free Window Media | pg. 10 DIGITALOUTPUT.NET VOL XXIX, NO. 11 • $6.95 USA

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ON THE COVER: The Wrap Institute installed this vehicle wrap using media from General Formulations . See page 17.

features 10 } Clear Alternatives

Editor’s Input ................................................................ { 4

PVC-Free Window Media Innovating products to meet demand.

Marketplace ................................................................. { 6

17 } Take the Easy Road

Departments

Application Spotlight ................................................. { 8 Target Chart .................................................................{ 15

Plus Marketplace Spotlight ................................................ { 6 Advertiser’s Index/Companies Mentioned ........... { 16

by Melissa Donovan

Wrap Films Offer Ease of Application The magic combination of adhesive, liner, and �ilm.

by Melissa Donovan

22 } Reconsidering Rigid Paper-, Wood-, and Fiber-Based Rigid Materials Opportunities for these substrates continue to grow.

by Cassandra Balentine

Showcase Advertisers............................................... { 16

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C A P T U R E

C R E AT I O N

O U TPUT

FINIS HING

VOLUME XXIX, NO. 11 DIGITALOUTPUT.NET ISSN: 1083-5121

EDITOR IN CHIEF

Thomas Tetreault ttetreault@rockportpubs.com

Preservation in Print For the eco-conscious there are many ways to consider the environment while printing. One method is being aware of materials used, what they are made up of, as well as whether can be recycled after use.

PVC-free media is a continuing conversation and seen in applications ranging from wallcoverings to floor graphics. This issue we explore PVCfree media for window graphic substrates. Clear Alternatives discusses the push in recent years towards PVC-free alternatives and where that demand derives from.

For the eco-conscious there are many ways to consider the environment while printing.

Reconsidering Rigid looks at paper-, wood-, and fiber-based rigid media options for direct printing. Compared to foamboard, poly-based materials, and aluminum composite materials, these options allow for a true circular process required to meet sustainability objectives. They offer recyclability, as well as a host of other benefits and we are seeing them used in all sorts of applications from traditional display to furniture.

Beyond preserving the environment, we look at saving in another way this issue—time. Print providers look to various tools, hardware, and media solutions to maximize their time. In the vehicle wrap space, media that offers ease-of-installation features does just that. Take the Easy Road explores advancements in vehicle wrap media, specifically with slideability, repositionabilty, and bubble-free application.

Whether the environment, time, or money—how are you preserving for the future?

Best regards,

EDITOR Melissa Donovan mdonovan@rockportpubs.com ASSOCIATE EDITOR Cassandra Balentine cbalentine@rockportpubs.com WEB EDITOR Melissa Mueller ART DIRECTOR Sarah M. White swhite@rockportpubs.com CONTRIBUTORS Olivia Cahoon, Tim Greene, Mark Hanley, Melinda Tetreault, Amber Watson ADVERTISING SALES PUBLISHER Thomas Tetreault NATIONAL ACCOUNT EXECUTIVE Amanda Doyon adoyon@rockportpubs.com 978-921-7850, Ext. 170 Subscribe online at digitaloutput.net

CORPORATE & PUBLISHING OFFICE 100 Cummings Center, STE 321E Beverly, Massachusetts 01915 ROCKPORT CUSTOM PUBLISHING, LLC CHAIRMAN Jeffrey Jensen PRESIDENT & CEO Thomas Tetreault Digital Output is published monthly by Rockport Custom Publishing LLC. ©Rockport Custom Publishing, LLC 2023. Reproduction by any means of the whole or part of Digital Output without written permission from the publisher is prohibited. Views expressed in the editorial pages do not imply our endorsement.

Vendors: We welcome your product news. Include prices, slides, photos, and digital files with your press release. Please forward product samples and media kits to Reviews Editor, Digital Output, 100 Cummings Center, STE 321E Beverly, MA 01915. We cannot be responsible for unsolicited product samples.

SUBSCRIPTION RATES

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POSTMASTER

Please send address changes and form No. 3579 to: Digital Output, 100 Cummings Center, STE 321E, Beverly, MA 01915.

Periodical Class postage rates paid at Beverly, Massachusetts and additional mailing offices.

Melissa Donovan, editor mdonovan@rockportpubs.com

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CHANGE OF ADDRESS NOTICE

Six to eight weeks prior to moving, please clip the mailing label from the most recent issue and send it along with your new address (including zip code) to: Digital Output magazine, change of address notice, 100 Cummings Center, STE 321E, Beverly, MA 01915. Attention: Circulation Department.

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Canon Enhances Colorado M-Series Canon U.S.A., Inc. announces enhancements for the Colorado M-series designed to provide customers with increased versatility, improved performance, and greater productivity.

A Magnetic Media Kit for the Colorado M-series printers allows users to handle approved magnetic

MUTOH AMERICA, INC.

roll media up to 0.03 inches thick.

SUPPLY55, INC.

Colorado M3 users can now access a temporary 30-day speed license. This feature empowers M3 printer users to optimize their printing speed, allowing them to operate at M5 speeds during peak seasons or high-demand projects.

Colorado UVgel White Ink is introduced in larger oneliter bottles, fully compatible with M5W Pro series printers, in an effort towards efficiency and convenience. This upgrade offers a more cost-effective price per milliliter compared to the 700ml bottles.

Finally, the Jumbo Roll Interface feature enables seamless integration with jumbo roll production systems, including the UVgel Print Factory and UVgel Wallpaper Factory. With the Jumbo Roll Inter-

Print Braille Legally

Finishing Simplified

Printing ADA compliant Braille signage with a Mutoh UV LED printer is a great way to increase profits. Mutoh is the only printer manufacturer legally authorized to offer UV LED printed ADA compliant Braille signage using DCS’ patented intellectual property. Don’t be caught violating those patents by using an unauthorized printer.

Engineered and manufactured in Europe, the KalaXY Cutter/Trimmer reduces labor and increases profits by eliminating the time consuming task of manually cutting printed digital images. The line of automatic XY cutters are the ideal solution for processing a wide range of media including wallpaper, paper, direct to film, canvas, laminated/encapsulated films, banner material, polycarbonate, and other non-woven roll goods. Increase your output while reducing operation costs with KalaXY Cutters. For more information visit supply55.com, call 734-668-0755, or email sales@supply55.com. INFO# 208

Don’t let other printer manufacturers blindside you into thousands of dollars in legal fees by violating those patents. Request a print sample from the XpertJet 461UF and XpertJet 661UF printers today. INFO# 207

face, the Colorado M-series empowers print shops to tackle larger production runs while minimizing

FLEXcon Debuts WALLdeco 6780 with Microsphere Adhesive

Mutoh Unveils the ValueJet 628MP Printer

FLEXcon Company, Inc. launches FLEXcon WALL-

multi-purpose inkjet printer, the ValueJet 628MP.

Introducing Lintec E-3000 ZC

deco 6780, a 6-mil white vinyl with a microsphere

This new printer has been improved with enhanced

Lintec of America unveils E-3000 ZC, an innovative

repositionable, removable adhesive for short-term,

capabilities including the use of MP31 ink, which

film with an optically clear polyester composition

indoor wall graphic applications.

delivers exceptional prints on a variety of substrates.

the need for frequent roll changes.

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complemented by a specially formulated top coating

Mutoh America announces its new 24-inch wide

MP31 ink is equivalent to eco-solvent ink in weather

tailored for optimal performance with latex printing

Microsphere adhesive technology differs from

resistance, abrasion resistance, and color develop-

technology. When expertly printed and skillfully ap-

standard pressure-sensitive adhesive technology in

ment while providing a smooth, natural finish that

plied, the E-3000 ZC film achieves a remarkable level

that micron-sized spheres are introduced to a binder

brings out the natural appearance of the substrates.

of clarity, imparting the visual impression of direct

adhesive system that holds the various, randomly

The ValueJet 628MP with MP31 ink combination

printing onto glass surfaces.

located spheres together as well as to the adhesive.

caters to a spectrum of needs, including high-mix low-volume production, making it ideal for crafting

Before applying Lintec E-3000 ZC, if durability is

WALLdeco 6780 is ideal for home décor, retail

gifts and novelties, as well as package prototypes,

required a Lintec overlaminating film would also be

displays, interior wall decorations, advertising, and

shrink wrap proofing, and labels. Its compact design

required. The use of an overlaminating film acts as

murals. Both the film and adhesive have been tested

and unique printing capabilities open doors to fresh,

a protective layer, guarding against environmental

on smooth flat painted wallboard to ensure applica-

creative possibilities, delivering reliable and consis-

factors.

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tion success.

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tent prints.

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advertorial

Doubled Production Output Customized Workflow Automation System

by Tony Curcio

T

KM Print Solutions, based in Akron, OH, is a leading wide format printer founded in 2008. It specializes in graphics production, kit packaging, ful�illment, and advanced fabrication services. Its primary market is the retail sector. Luke Messner, president, TKM, invested in customized automation technology to speed up the company’s work�low while reducing errors and turnaround times. “The goal was to double production without increasing prepress headcount,” says Messner.

The man charged with this responsibility was Chris Copeland, I.T./production solutions manager, TKM. “We needed to develop an ef�icient, seamless system to reduce prepress bottlenecks that would allow us to feed more �inished �iles to our current printers,” shares Copeland.

The customized work�low uses Enfocus Switch with Pitstop pre�lighting and Esko’s Phoenix for imposition.

Using the meta-data from TKM’s MIS system eliminates errors by reducing human touchpoints, allowing prepress operators to concentrate on more value-added work as opposed to tedious, error-prone data entry.

According to Messner, “printing has become more about people and processes. It’s better to discover issues with submitted �iles early in the process rather than later.”

Unprecedented Improvements and Efficiency

Under Copeland’s direction, TKM achieved signi�icant, measurable improvements in many areas of its business by partnering with Signi�icans Automation. Today, its

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customized, automated imposition technology provides accurate estimates of all production requirements. Plus, its automated prepress department has signi�icantly increased production without adding more employees.

“We are now able to better handle complex jobs such as those with multiple �iles and large volumes,” adds Copeland. “In fact, with the addition of Esko Phoenix, imposition tasks that used to take us most of the day are now accomplished in under one hour.”

Real Printers, Real Results

TKM joins a growing list of Signi�icans clients across North America experiencing cost and time savings that are boosting their pro�it margins. “The bottom line is why pay for extra staff or new equipment, when a custom work�low automation setup will enable you to handle all the extra work with the employees and equipment you already have?” asks Marc Raad, president, Signi�icans.

The Human Element

“Working with Signi�icans’ specialists is like working with kindred spirits. Their knowledge and experience with software and print production provides a valuable resource to develop new ideas and concepts,” says Copeland.

“Signi�icans is revolutionizing the way things are done at TKM,” adds Messner.

For an assessment of your work�low automation needs, call 877-463-4465 or visit signi�icans.com. D

2

1 & 2) With the help of Significans, TKM integrated a streamlined prepress workflow that is now interfaced with its order entry system. TKM’s prepress technicians are now better equipped to fix problem files well ahead of the print process, reducing print errors, increasing production efficiencies, and boosting profits.

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Upgrade with Results Meet Client Demands for Quick Turnarounds

by Melissa Donovan

N

arrow and wide format printing make for a powerful combination when operating under one roof. Many print service providers (PSPs) are in a position to offer business cards to car wraps. Use a wide format hybrid device—flatbed and roll capabilities—and you have a one-stop shop.

GAM Graphics and Marketing, based out of Sterling, VA, is one of those companies. It is a full-service design, print, sign, and mailing shop offering high-quality, cutting-edge design, print, and fulfillment services.

Quick Facts

a variety of products. A 14,000 square foot location, which houses offices, a production facility, and a warehouse, allows GAM to provide these services to its client base, of which is concentrated in VA, MD, and Washington DC— but shipping is conducted across the U.S. The production facility holds an array of technology. It has been an all-digital shop since 2013 and added wide format in house about 20 years ago. Today wide format is about eight percent of its total sales.

Owning a First

GAM is the first company to install an AccurioWide 250 hybrid UV LED wide format inkjet printer from Serving clients since 1976 in verticals like property manKonica Minolta Busiagement, homeowner ness Solutions U.S.A., associations, banking, Inc. The family-run and credit unions to With two days of training, we had business is no strangconstruction, restauemployees who had never worked in that er to Konica Minolta, rants, and non-profit a client of the comorganizations, the department running the machines. pany’s for over three PSP employs 11 staff — Nathaniel Grant, president, GAM years. GAM also owns members that help a Konica Minolta the company produce

1 & 2) GAM recently installed a Konica Minolta AccurioWide 250 printer to meet faster turnarounds in house.

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1

2

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AccurioPress C14000, bizhub Press C6000, and AccurioPress 6136 digital press.

Once installed, the printer was quickly up and running. “We found this to be one of the easiest machines to learn to operate.

With two days of training, we had employees who had never worked in that department running the machines,” admits Nathaniel Grant, president, GAM.

Solid Proof

Proof the Konica Minolta AccurioWide 250 is a fit is seen in multiple ways. Grant says production turnaround times increased by 100 percent. GAM prints 4x8foot panels at full bleed in less than five minutes. A 4x8-foot sheet of coroplast is printed in less than three minutes.

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The Konica Minolta AccurioWide 250 is a hybrid device, so GAM easily switches between substrates like coroplast, aluminum, Dibond, and PVC for flatbed printing to perforated window films and vinyl using the roll capability. Grant notes that the hybrid nature of the printer is advantageous and the roll-to-roll option even more so because it allows for printing on wider material than the dedicated roll-toroll printer it currently owns.

Combine for Success

Combining wide format hybrid devices with automation software and automated finishing equipment makes hitting those quick turnaround times even easier. D See page 16 for more info.

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by Melissa Donovan

PVC-free media may reduce environmental impact, and many brand owners are committed to doing just that. When designing and printing window graphics, an eco-friendly alternative is beneficial for any print service provider (PSP) serving this segment.

“The demand for PVC-free media, especially for windows, has increased in recent years { 10 } November 2023 | Digital Output

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due to heightened environmental awareness and sustainability concerns. Many businesses and consumers seek more eco-friendly alternatives to traditional materials like PVC. This demand is also influenced by regulatory changes and industry initiatives promoting the use of environmentally responsible products,” shares Rene Bourgeois, VP sales North America, ASLAN Selbstklebefolien GmbH.

Demand for Windows

PVC-free media optimized for digital printing is advancing rapidly, with many manufacturers enhancing and innovating their material selections to meet high demand. This includes substrates specifically designed for window graphics.

Above) An example of Continental Grafix’s iTac Clear. Production and installation courtesy of LIGANOVA Production, Inc.

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“There has been a push for alternatives to traditional PVC window graphic materials, driven in large part by some of the chemical components that were used in PVC in the past and a desire for what are viewed as more sustainable options. Certain plasticizers or phthalates found in PVC that were linked to negative environmental or health impacts drove both the push to replace, as well as the need to reformulate the existing solutions,” shares Jay Kroll, product manager, cut, transit, and wall solutions, General Formulations.

Consumer demand plays a huge part, which ultimately drives print

providers to request PVC-free materials and subsequently manufacturers to supply them. “The sustainable movement in many aspects of our society has been growing for years. More recently, we’re seeing the confluence of more severe, frequent, impactful weather events; the coming-ofage of millennial consumers; and better technology to produce and print PVC-free media,” explains Michelle Kempf, VP, sales and marketing, Continental Grafix USA, Inc. “End use clients are demanding more ‘green’ alternatives. While we always offered PVC-free media, we now offer recycled content

polyester-based media. This helps architects and clients get LEED points for projects. This has been driving some of the demand,” admits James Halloran, VP, sales and marketing, Lintec of America, Inc. Jodi Sawyer, strategic business unit manager, FLEXcon, says consumers are holding brands accountable for sustainable actions across their supply chains and the subsequent impact. As such, “brands collaborate with suppliers on ways to lower their carbon footprint.Brands explore ways to eliminate the use of printed vinyl and are requesting products that offer higher post-consumer waste

content. PVC is viewed as harmful to the environment when landfilled or burned for waste energy.”

Marketing and design agencies that work for these big brands follow suit by requesting print jobs that utilize PVC-free materials. “This gateway to big brands is a requirement all PSPs now must consider when purchasing materials if they wish to stay in the competition,” says Kieran Blacknall, Drytac academy manager, Drytac.

Encouragement

PSPs should consider PVC-free window media for certain jobs.

There are many positives to

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waste content; supports circularity; thinner gauged films reduce waste; polyethylane terephthalate (PET) films offer superior clarity; and when coated with water-based adhesive, less solvents are used in the manufacturing process.

1 PVC-free window media, with the obvious being sustainability, but there are others as well.

“Offering PVC-free options will distinguish you from the competition and raise your profile with searching print buyers. The investment for you is small but the results could be huge. You will also find that a lot of your existing work can be completed with PVC-free media, helping you to reach your sustainability goals faster,” explains Blacknall.

offering PVC-free media provides clients with a wider range of choices and appeals to those who prioritize eco-friendly solutions,” says Bourgeois.

“PVC is typically not recyclable and will not degrade in any landfills. The switch to a PVC-free option provides the possibility to offer a product that can be recycled,” adds Brian Ebenger, VP of business development, XCEL.

PSPs who work with PVC-free media, whether for windows or another surface, are presented in a different light. “PVC-free options can enhance a provider’s reputation as an environmentally conscious partner. Additionally,

Finally, “using PVC-free media may help the PSP comply with any regulations or incentives that encourage the use of eco-friendly materials. Overall, working with PVC-free window media options can benefit both the PSP and their clientele,” suggests Amanda Smith, marketing and communication

INFO# COMPANY 122 ASLAN Selbstklebefolien GmbH

WEBSITE aslanvinyls.com

companies mentioned

See page 16 for more info.

123

Continental Grafix USA, Inc.

124

Drytac

cgxusa.com drytac.com

125

FLEXcon

flexcon.com

126

General Formulations

generalformulations.com

127

Lintec of America, Inc.

digitalwindowgraphics.com

128

Mactac

mactac.com

129

Nekoosa

nekoosa.com

130

XCEL

xcelproducts.com

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manager, graphic and signage solutions, Mactac.

It’s important to partner with the right manufacturer. “Working with manufacturers who understand material science is helpful.

They can recommend alternative products that are a directional improvement over current materials in terms of impact on the environment,” explains Sawyer.

She continues by listing beneficial properties of PVC-free window media compared to PVC like they are plasticizer-, lead-, and phthalate-free; CONEG and CPSIA compliant; tear resistance aids in installation and removal; rigidity of the film makes it easier for novice installers and/or store employees to install large format window graphics; excellent dimensional stability; graphic won’t shrink or distort with temperature changes; available with post-consumer

1) Drytac ViziPrint Impress Clear film was used to produce a window installation that explored gender identity, religious iconography, and Latin American Pop Art. The wide format division of printer manufacturer Mimaki recently collaborated with creative professional Anabella Bergero to produce the window installation, printed on Drytac ViziPrint Impress Clear film.

“PVC-free window media options can offer performance enhancements over their PVC counterparts. Optical clarity, extended longevity, ease of installation/removal, and quality printing finish are a few of those advantages,” shares Kempf.

Kroll points out that not every job necessitates a PVC-free media.

“Pragmatically, I would encourage a PSP to use PVC-free media only when it is specifically requested for specific jobs. While there are some PET or polypropylene (PP) options that are highly functional, they still lack the consistency and variety of traditional PVC.”

“It’s always important to consider the specific needs and requirements of your project when choosing window media. While PVC-free options can be a great choice for many applications, there may be certain environments where it’s not the best fit.

For example, if you’re installing windows in an area that experiences extreme temperatures or high levels of moisture, you may want to consider options that are better equipped to handle these conditions,” suggests Smith.

No PVC

If the media in question is free of PVC, what is in it? Alternative materials are PET or PP. digitaloutput.net

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A quick chemistry lesson, PVC or polyvinyl chloride, refers to specific oils and salts used in the manufacture of the film, shares Kroll. “PET and PP are still oilbased products, but they lack the chorine component. PVC also requires plasticizers to give it flexibility—think of the difference between PVC pipes in your house versus vinyl vehicle wrap films.

These are the same base composition with obviously very different additives and manufacturing methods. Whereas PP and PET are typically blown or extruded.”

“PVC-free window media does not contain polyvinyl chloride. It is halogen free. Nothing replaces polyvinyl chloride in PVC-free materials. PVC-free films are more homogenous than PVC. They contain mostly polymer resin with very little additives, if any. This makes it possible for trim waste, post-industrial processing waste to be reused/ recycled back into the base polymer. PVC formulations, which may contain 50 percent additives and stabilizers, cannot be repurposed in the manufacturing process,” adds Sawyer.

Bryan Baab, product development manager, wide format graphics, Nekoosa, cites a recent European plastics study. In it, “the Life Cycle Assessment benefits measured a 50 percent reduction in carbon footprint and a 20 percent reduction in fossil resources when using PP films versus calendered PVC films in the same application. This environmental benefit results in a reduction of more than 50 percent of global warming potential when compared to PVC.” digitaloutput.net

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PET is often made up of post-consumer content, like plastic bottles for example. “This makes those films highly sustainable as they are not only eliminating PVC with it but also reducing the use of new PET made from fossil resources.

And still, quality, performance, and affordability are maintained while minimizing the carbon footprint,” explains Bourgeois.

While PET or PP are the most common components, Smith points out that other alternative materials are bio-based like cornstarch or sugarcane. All four examples “offer similar performance and quality to PVC-based products but are much more sustainable and environmentally friendly. Sometimes these nonPVC products can be recycled depending on the municipality.”

Reduce without Sacrifice

Can alternatives like PET and PP still offer the same quality, performance, and affordability as their PVC counterparts? Or are these features something sacrificed while gaining in sustainability?

that are PVC-free are usually higher in quality, clarity, and performance. Material pricing varies but PVC-free options are typically easier to install, lowering the overall cost of doing business,” explains Ebenger.

“PVC-free window products can be recycled so the environmental aspect is always positive. Options

Installation of PP graphics is easy, as is removal. “Due to the PVC-free polymer, there is no film shrinkage. These films are plasticizer free. Installation of PP

As aforementioned, there are many advantages to using PVCfree window media. If anything is sacrificed, other advantages are gained. Sawyer argues that “for promotional window graphics that will change out every few months, the outdoor durability of a PVC-free film of one year or less, for example, meets the requirements for short-term graphics without sacrificing performance.”

Halloran believes PVC is inferior to PET when decorating glass.

“The reasons for this are PET is more dimensionally stable in the heat and doesn’t crack in the cold when on glass. It is also a reasonably priced film. PVC-free PET films have better optical properties and uninstall better at the end of their lifecycle.”

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“PVC-free options range from roughly 20 to 50 percent higher than traditional PVC economical material,” states Ebenger.

However, the cost difference has decreased compared to the previous decade, notes Bourgeois. This in turn makes PVC-free options more accessible to a broader range of customers.

2 graphics is easy, and removal is efficient as there is no film stretch when compared to calendared vinyl,” says Baab.

“PET, for example, is a great alternative to PVC for window graphics because it offers excellent optical clarity and is extremely dimensionally stable where PVC may expand or contract, which can result in undesirable results such as edge curl,” shares Kempf.

Blacknall seconds PET being a great alternative. “PET film is a particularly good example of a PVC-free alternative for window graphics. It has dimensional stability that exceeds PVC and works great with permanently removable adhesives, making it an ideal product for easy-to-install window applications.”

2) LoopPET Metal ASLAN CRA 31 is a PVC-free, print and cut film, double-sided metalized gold and silver, containing 70 percent post-consumer recycled PET.

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Kroll believes that while the amount of polyolefin going into these products may be reduced—or the fact that they may be missing certain chemical components found in PVC, “the overall supply chain impacts and special top coatings or treatment processes likely negate or at best, balance, any environmental benefit. And they are typically more expensive with a shorter lifespan in the end application.”

“Using PET or PP films can produce great results, equivalent to that of PVC films, providing we recognize the fundamental differences in materials and explain the differences to our customers,” stresses Blacknall.

Cost Differences

PVC and PVC-free window media are not manufactured the same, nor have the same components.

Suffice to say the pricing per square foot can differ per material type.

Sawyer believes PVC-free lowtack window media and PVC low-tack window media are comparable in price. “As demand shifts over time towards PVCfree films, supply volume/quantity increases can result in lower raw material prices. Essentially, the more the market shifts toward PVC-free, the more readily used and accepted it becomes, and the higher volume impacts price positively.”

Price comparisons differ based on the manufacturer. For example, Nekoosa’s PVC-free line of products are offered at the same price as their vinyl equivalent, according to Baab.

And while we can compare product to product, it is also worth keeping the project it is being considered for in mind. At the base level PVC and PVC-free media might cost the same, but adding in certain variables may change this.

Kroll gives the example of a PP film with a low-tack removable adhesive, this would have a similar cost to a 3.4-mil matte white vinyl with a low-tack removable adhesive. However, the PP comes with limitation of only being

compatible with UV ink. “Special top coatings to make that same film compatible with eco-solvent or latex inks drives the cost up significantly, if such coating options are even available.”

“PVC is one of the most widely used materials in the graphic arts and is relatively cheap in comparison to PVC-free. Alternative films are growing in popularity but we may have to wait a while longer to see real price benefits in PVC-free print media,” adds Blacknall.

One to Watch

PVC-free media in general is a category to keep an eye on. “The demand for PVC-free media is likely to continue to grow as more people become aware of the environmental impact of PVC and seek out alternatives,” predicts Smith.

With the number of products available combined with the demand, it could become a little confusing when determining which truly is sustainable. “Don’t fall for greenwashing—certain films might be PVC-free but use plenty of fossil resources, energy etc.—especially if they are made without recycled content,” cautions Bourgeois.

For more information on PVCfree window graphic media check out digitaloutput.net for a product roundup.

Also, we explore PVC-free media specific to wallcovering applications in our November webinar and the December issue of the magazine. D

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Made Up of Recycled Content Option

PVC-Free Option

3m.com/windowwraps arlon.com aslanvinyls.com graphics.averydennison.com cgxusa.com contravision.com dkgroup.com dafgraphicmedia.com magicinkjet.com drytac.com fdcfilms.com flexcon.com gbc.com generalformulations.com gpa-innovates.com grafityp.com thegriffnetwork.com grimco.com gogsg.com hascographics.com hexis-graphics.com/us hplfmedia.com glassapeel.net kapco.com kernowna.com kodakwfmedia.com lexjet.com digitalwindowgraphics.com macpapers.com/wide-format mactac.com/graphics sourceone.nazdar.com nekoosa.com orafol.com piedmontplastics.com plastiprint.com qmls.com que-media.com rolanddga.com sihlinc.com coloredfilms.com tekra.com transcendia.com ultraflexx.com u-p.com xcelproducts.com yupousa.com

3M Commercial Solutions Arlon Graphics, LLC ASLAN Selbstklebefolien GmbH Avery Dennison Graphics Solutions Continental Grafix USA, Inc. Contra Vision North America, Inc. D&K Group, Inc. DAF Products Dietzgen, a Sihl Group Company Drytac FDC Graphic Films, Inc. FLEXcon Company, Inc. GBC SEAL General Formulations GPA Grafityp Selfadhesive Products NV Griff Paper and Film Grimco, Inc. GSG Hasco Graphics, Inc. Hexis HP Inc. Infinity Media Company Kapco Graphic Products Kernow North America KODAK LexJet Lintec of America, Inc. Mac Papers & Packaging Mactac North America Nazdar SourceOne Nekoosa ORAFOL Americas, Inc. Piedmont Plastics Plastiprint Quality Media & Laminating Solutions Que Media Inc. Roland DGA Corporation Sihl Inc. Solar Graphics Tekra Transcendia Ultraflex Systems, Inc. Universal Products, Inc. Xcel Products, Inc. Yupo

Non-Adhesive Back*

Website

145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190

Clear Perforated Adhesive Back

INFO# Company Name

Perforated Adhesive Back Unperforated Adhesive Back 50/50 60/40 75/25 70/30 65/35 80/20

Image Courtesy of Tekra

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*Cling, static, suction cup, microsuction, or alternative technology. Contact manufacturer or vendor for more information. #12

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PAGE

INFO# #15

WEBSITE

16 fastchangeframes.com

14 Alpina Manufacturing, LLC

16 bannergrip.com

14 Delivery Signs

16 yardsignsresellers.com

1 FDC Graphic Films, Inc.

11 fdcfilms.com

2 FELLERS

5 fellers.com

3 Flatbed Tools

9 flatbedtools.com

4 ImagineThis

2 imaginetr.com

5 Lintec of America

13 digitalwindowgraphics.com

6 Mutoh America, Inc.

27 mutoh.com

16 Neenah

16 neenahpaper.com

12 Newlife Magnetics LLC

15 newlifemagnetics.com

7 Newlife Magnetics LLC

19 newlifemagnetics.com

11 Significans Automation

7 significans.com

8 Signs365

28 signs365.com

9 Summa

9 summa.com

10 VTX Tools

19 vtxtools.com

COMPANY

PAGE

#14 INFO#

#13

ADVERTISER

13 Alpina Manufacturing, LLC

110 3M

17

111 Arlon Graphics

17

122 ASLAN Selbstklebefolien GmbH

10

112 Avery Dennison Graphics Solutions

17

100 Competitive EDGE

22

123 Continental Grafix USA, Inc.

10

101 DGS USA

22

124 Drytac

10

113 EVOLV

17

114 FDC Graphic Films, Inc.

17

125 FLEXcon

10

115 FLEXcon

17

126 General Formulations

10

116 General Formulations

17

201 Konica Minolta Business Solutions

8

102 Lamitech, Inc.

22

127 Lintec of America, Inc.

10

128 Mactac

10

117 Mactac

17

103 Metsä Board Americas

22

104 Monadnock Paper Mills

22

129 Nekoosa

10

105 UltraPartners, LLC

22

106 Xanita

22

130 XCEL

10

#16

digitaloutput.net

10/18/23 9:45 PM

by Melissa Donovan

ith continued vehicle wrap product advancements, installation is easier than ever—sometimes only one installer is needed to apply an entire vehicle wrap.

Part of the success involves enhancements in adhesion technology. Each digitaloutput.net

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manufacturer has their own secret sauce, but most offer pressure-activated adhesives that slide and reposition with air egress technology that reduces bubbles, wrinkles, and air entrapment.

“Ease of installation is a critical factor for print service providers (PSPs) and wrap

installers. The industry recognizes that quick and efficient installations are more profitable. Customers expect

Above) The Avery Dennison Supreme Wrapping Film Celestial Satins, with color Solar Dawn pictured here, are three new iridescent shades added to the Supreme Wrapping Film ColorFlow color portfolio. Using Easy Apply RS adhesive technology makes application faster and easier, no matter the skill level of the applicator.

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1 faster turnaround times. PSPs need products that are consistent, produce vivid colors, are easy to handle, and offer specific products that can be less expensive.

Installers need materials that are easy to work with to meet those expectations,” explains Ryan Allen, regional technical specialist, North America, Avery Dennison Graphics Solutions.

Adhesion, in addition to a number of other components—the film, liner, and overlaminate—play critical roles in creating media that offers ease of installation.

In Need

Ease of installation is continually in demand from PSPs as well as vehicle wrap installers.

“Adhesive technology of film has come a long way. Ease of installation is a must in a business setting where you need to get the finished product out the door

1) Installers should carefully work with the film to conform with the curves and recesses of the vehicle. Use the proper tools for smoothing and trimming around edges of doors and OEM installed trim work as shown here from Avery Dennison’s 2023 Trainer Day. 2) Two graphics printed with HP latex technology and installed by Superior Auto Design in Pompano Beach, FL using EVOLV media.

{ 18 } November 2023 | Digital Output

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2 as quickly as possible, but still offer a high-quality application,” asserts Michael Aldrich, product support specialist, FDC Graphic Films, Inc.

According to Louie Calma, technical solutions specialist, Arlon Graphics, ease of installation or application widens the range of application expertise. This translates to effortless scheduling and on-time delivery.

“Yes, products with easy application features widen the range of application skills needed to complete the job,” agrees Ritchie Daize, senior technical solutions manager, Arlon Graphics. “This is especially true when print shops send wrap kits out to contractors to apply. Contractors will often charge a premium to apply graphics without easy application features.”

A simpler installation allows print providers to take on more jobs.

“The faster and easier you can correctly install a wrap the more wraps you can produce in a given time frame. That higher throughput ultimately means more profit for the business,” suggests Marc

Bagley, transportation segment marketing manager, 3M.

Demand for ease of installation is partly driven by the lack of skilled laborers. “Complex installation processes require skilled labor, which can be expensive and hard to find. Simplifying the installation process helps shift the installation preparation and basic installation service to more novice installers. This allows highly specialized or certified installers more time to focus on revenue-generating activities for the shops, including intricate and detailed wrap designs requiring more advanced installation skills and expanding their range of services,” admits Allen.

According to Mattia Casarotto, area manager, EVOLV, there are always new installers with little experience approaching this industry, which makes it important to have products with ease-ofinstall features available.

Trends in wrapping also dictate whether ease of installation remains popular. “Of late, more commercial vehicles are partial wraps or vehicle signage where

the surface is flat or has simple curves, and the advertisements are changed out more frequently compared to full wraps. In transit messaging, more partial wraps are sold now than full bus and train wraps. The conformability to compound curves and long-term durability that cast vinyl offers in these cases may be over-engineered, and calendared vinyl with an air egress liner is a suitable and more economical alternative that still provides ease of installation,” explains Jodi Sawyer, strategic business unit manager, FLEXcon.

“Installers will always be in favor of products that improve their processes, or offer greater reliability without any extreme effort. Anything that we as manufacturers can do to ease their load is going to be appreciated, and we are constantly looking for ways to improve the product and process for a better overall product and experience,” says Matt Edwards, product manager of digital print media, General Formulations.

All Levels

Vehicle wrap installers range from experienced professionals to newcomers, says Allen. And this digitaloutput.net

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in 2023, where vehicle wrapping has been around for decades.

The stability of the application is astounding and a testament to how successful vehicle graphics messaging for a business can be.

With this in mind, more interested parties are becoming involved in wrapping, which is why ease of installation is for all experience levels—novice to professional.

“Providing ease of installation for all levels ensures consistent, vibrant results customers expect.

It ensures satisfaction and reflects positively on the converter and installer,” stresses Allen.

Both ends of the spectrum benefit, notes Daize. “Low-contact adhesive systems that are often associated with easy application make wrapping easier and more manageable for novices and faster and more profitable for experienced installers.”

There is nothing wrong with “frustration-free application” as it “keeps a high morale and motivation for all levels,” says Calma.

Also, many wrap jobs aren’t straightforward—there are multiple factors that can effect the final application, this includes the printer used, the ink type, vehicle accepting the wrap, and even the climate. Any of these reasons could be why media featuring ease-of-install characteristics would be preferred.

“Depending on the curvaceousness and complexity of the vehicle being wrapped in addition to the customer’s expectations one film may be more advantageous digitaloutput.net

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over another. Take a cargo van with a deep recess and a customer that does not like the look of a commercial cut or cut-and-drop for example. In that instance, an installer is going to want a more conformable film that can be set into a deep recess with less heat,” shares Bagley.

He explains that in warmer areas, wrap films across the board tend to tack up a little more so those installing further South tend to prefer lower tack films, especially in non-climate controlled conditions. The opposite is true in colder climates. In the North, installers tend to favor films with a slightly higher tack level.

“The complexity of the installation, the size, scope, and risk involved are factors that impact the material selection and the importance that ease of installation plays,” agrees Sawyer.

#7

According to Nate Goodman, technical product manager, graphic and signage solutions, Mactac, “researching the product beforehand is important and determining whether it suits your skill level to avoid potential frustration or damage. Ultimately, whether a product is easy to install depends on the user’s experience and familiarity with the technology.”

None the less, “most veteran installers will tell you that they can install anything, as their experience with various materials and surfaces has put them in a position where they learned how to listen to the film and feel the adhesive, regardless of the application,” admits Edwards.

#10

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Main points to note in relation to adhesion technology for an ease-to-install product include air egress, tack, respositonability, and ultimate bond.

3

Working Together

Today’s vehicle wrap media products are much easier to work with during install for multiple reasons. Narrowing it down, there’s the adhesion technology—which plays a large role, in addition to the release liner, facestock, and overlaminate.

“From a broad standpoint, the industry has advanced in terms of installation training and education and increased collaboration between the media manufacturers, printers, and installers to better understand how the materials, the printing and converting, and the methods used for install can impact the ease and ultimate success of the installation,” shares Sawyer.

instrument that is an excellent mix of flexibility with consistency, conformability with control, and with increasing quality of look and durability.”

Adhesive Technology

Specifically, “adhesive technology has advanced in many ways to make wrap films easier to apply,” explains Daize.

According to Edwards, the adhesive, film, and liner “all working in concert have created an ideal

“Adhesive is key for a quick and easy install. There are permanent, removable, and slideable adhesive systems. All three need repositionability to tack down, remove, and reapply in case of bubbles or other challenges during installation. The slideable technology allows quick and easy positioning because it will not stick to the application surface when it is being put in place, explains Goodman.

INFO# COMPANY 110 3M

WEBSITE 3m.com/graphics

companies mentioned

See page 16 for more info.

111

Arlon Graphics

arlon.com

112

Avery Dennison Graphics Solutions

graphics.averydennison.com

113

EVOLV

theevolv.com

114

FDC Graphic Films, Inc.

fdcfilms.com

115

FLEXcon

flexcon.com

116

General Formulations

generalformulations.com

117

Mactac

mactac.com

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Air egress is essential. “There is nothing worse than laying down a difficult panel only to discover a bubble right in the middle that requires you to either puncture the graphic film or snap part of it back up,” admits Bagley.

“In today’s market, it is a necessity for vehicle wrap films to have air egress to allow for a bubblefree and dry application. Next is the adhesive’s pre-tack. Once the liner is removed, the less pre-tack there is, less effort is needed to snap up the graphic and reposition,” says Calma.

Adhesive with a medium to low tack allows for easier repositionability of the graphic to the surface, states Sawyer. “The tack of an adhesive is the force required to break an instantaneously formed bond. When an adhesive has a high initial tack, it can make repositionability of large panel graphics more challenging because the adhesive grabs onto the surface and is not easily repositioned.”

Then there is the repositionability after squeegee pressure. “The adhesive must remain workable for the next few minutes—prior to post-heating—to allow for correction such as wrinkles or

3) A vehicle wrapped by The Wrap Sanctuary with GF 830 AutoMark Cast and 831 AutoMark Cast Gloss Laminate. 4) Products with air egress release liners such as FLEXcon BUSmark AE aid installation by allowing trapped air to escape easily, making for smooth, bubble-free installation for vehicle and truck signage.

bubbles. And finally, the ultimate bond. The adhesive must be able to stay down on complex curves and grooves even without the use of primer or adhesion promoters,” shares Calma.

“A preferred adhesive type for vehicle wraps is a long-term removable acrylic adhesive. This specific type of adhesive offers a low initial tack, and gains adhesion over a period of time. Removability is key and finding an adhesive that lifts when it is needed and that will not separate, is very important. It means the adhesive leaves no residue behind once the film is removed from the surface of the vehicle,” says Allen.

To achieve optimal installation, Edwards suggests a grey adhesive, providing opacity to prevent the paint color from impacting the look of the graphic. This adhesive has just the right amount of tack to hold when needed, but release when necessary to slide.

“For vehicle wraps with compound curves, products with repositionable, slideable adhesives are often preferred because they allow the product to hover over the surface and be repositioned multiple times with ease without distorting and stretching the graphic. Once the graphic is in place, pressure activates the adhesive and allows it to wet out and bond to the surface,” explains Sawyer.

Additional Considerations

Besides the adhesive, another important component to easeof-install media options is the release liner. “An easy liner release digitaloutput.net

10/18/23 9:48 PM

prevents the film from prestretching and zipper lines. It also eliminates the need for a second person to pull the liner from the opposite side,” explains Calma.

“The liner, or backing quality, is a crucial component. High-quality liners ensure that the material can be unrolled and applied smoothly, minimizing tension and reducing the risk of errors. While adhesive quality is vital, the role of the liner in facilitating smooth handling and application is equally important,” agrees Allen.

The liner acts as backbone to the whole configuration. “It provides stability, lay flat characteristics, and prevents stretching during printing and handling. It also will impart air release channels in the adhesive so the film can be applied without bubbles being trapped behind it. While the adhesive is crucial, the film and liner help to make the installation process as smooth and easy as possible.

The film conformability, stability, and elongation properties affect whether an application tape needs to be used and how to handle it when installing,” shares Goodman.

The facestock or film and overlaminate should not be overlooked. “These components affect the dimensional stability of the overall construction. Some rigidity in the film is beneficial to minimize pre-tack and prestretching,” says Calma.

Aldrich agrees that film technology is important. “Cast vinyl being the go-to for most wraps there are calendered films also with lots of plasticizers allowing digitaloutput.net

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this film to be more flexible to help go around rivets and most complex curves. This allows for a more cost-effective, shorter term option for customers that want a good looking wrap but want to save some money.”

Softer films, which are easier to stretch, also aid in ease of installation, according to Casarotto.

Laminate choice has an impact.

“The thinner the laminate typically the more conformable. Also consider the surface energy because that correlates with the amount of friction your squeegee or wrap glove has as it slides over the face of the film,” adds Bagley.

Edwards agrees that film and liner play critical roles in the mix, and other components “come down to experience and equipment, spending time building your craft and identifying the best methods and aides to get the job done consistently and with the highest quality.”

Slide and Reposition

Considering two of the more common terms in adhesion technology for easy install include repositionability and slideability, can one exist without the other?

According to Allen, repositionability and slideability go hand in hand. “They work together using the same technology to accomplish each of the tasks. Together they reduce a large amount of issues that become present at time of installation. While slideability enables the material to glide across the surface much more easily, repositionability

4 offers the opportunity to make larger adjustments after the film has touched the surface. Both features contribute to a successful, easy installation and save time.”

A material that is repositionable, but not slideable is possible.

“Slideability is created both with the formulation of the adhesive as well as the pattern of the air-egress liner. It is feasible that you could formulate a slideable product that becomes instantly permanent when pressure is applied, but that lack of repositionability would make it much less helpful for actual applications,” admits Edwards.

“You can have one without the other. This would most likely depend on the installer’s experience with vehicle wraps and decal applications and how comfortable they are with installations and understanding and applying the techniques needed without one of these features,” suggests Aldrich.

For Calma, it depends on how you define repositionabilty. “When I evaluate wrap films or train applicators, I refer to repositionability as the ease and ability of

the film to be repositioned after squeegee pressure is applied.”

Another factor—the application.

“Though they are often paired together you can technically have a film that has one technology but not the other. In cases like box trucks, a surface that is relatively flat but needs a cast film for the conformability over rivets, you may not need repositionability but want air release channels due to the size of the panels,” says Bagley.

Easy Street

Media designed for ease of installation is in demand for multiple reasons. A wrapper or PSP may employ novice installers, or perhaps they want to speed up production to wrap more vehicles in less time.

Advancements primarily in adhesive technology are furthering the potential for films boasting ease of installation, but other components like the media itself, liner, and overlaminate also play a role.

To learn more about vehicle wraps and this category of media, visit digitaloutput.net and register for our latest webinar on the topic. D November 2023 | Digital Output { 21 }

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by Cassandra Balentine

any types of printable materials fall under the rigid umbrella. These include plastics and metals, as well as paper-, wood-, and fiber-based options.

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depending on the requirements and specifications of the job at hand.

This type of media is often used for display purposes, from point of purchase (POP) to trade show booths. “The applications are truly endless but in general, you’ll find them used for promotional

signage, exhibits, wayward signage, window displays, floor displays, and more,” comments Tim Bolton, president, UltraPartners, LLC.

Room to Grow

Beyond retail and event displays, paper-, wood-, and fiber-based rigid digitaloutput.net

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media options are moving into new spaces. As awareness of availability and product quality increase, Bolton is confident that opportunities for this type of rigid substrate will also grow.

Bob O’Neill, national sales manager, Competitive EDGE, U.S./ Canada Falconboard Manufacturer Reps, sees many trade shows, stores, and other consumer-visited areas starting to embrace rigid paperboard products to displace their legacy “this is what we have always used” projects.

For example, Roberto Rodriguez, managing director, DGS USA, sees new applications including tri-dimensional structures such as backdrops, trade show booths, POP displays, and furniture.

For wood-fiber rigid products in particular, Vince Queau, senior sales representative, Monadnock Paper Mills, says typical applications include retail, both indoor and outdoor signage and displays; replacements for vinyl, styrene, and PVC; as well as shelf talkers and trade show displays.

Specific to paperboard, Adam Reiser, GM, Lamitech, Inc., suggests that it is a prominent material in most retail environments due to its versatility. Its applications include packaging and retail displays. Paperboard is also utilized for gift and specialty

Opposite page) Monadnock’s ENVIsual Board is part of the Envi line of products. It is FSC certified, available in 100 percent post-consumer, wood fiber that is recyclable. 1) Distributed by DGS, Falconboard is available in thicknesses from 0.25 to two inches and different finishes such as white/kraft/white, white/black/white, all white, all black and all Kraft.

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boxes including elegant jewelry displays and decorative gift boxes, greeting cards, tags, journals, and books. “Because of growing trends in sustainability, ecofriendly brands increasingly turn to recycled or sustainably sourced paperboards.”

Paperboard and fiber-based materials are versatile and offer numerous design and functional possi1 bilities. “They can be easily printed upon, molded, and folded, allowing for creative packaging solutions without sacrificing sustainability. This adaptability makes them an attractive option for businesses looking to enhance their brand image while prioritizing eco-friendliness,” notes Mark Beamesderfer, packaging services director, Metsä Board Americas.

Sustainability is a big driver for new uses of paper-, wood-, and fiber-based rigid media. While the discussion surrounding ecofriendly options is complex, it is safe to say that many print buyers seek plastic alternatives wherever and whenever it makes sense.

“The ‘green’ movement is gaining genuine traction now, with opportunities expanding daily,” comments Reiser. “It seems that every day a brand manager is asking for something more

sustainable. Increasingly, companies inquire about the materials, asking questions like, ‘what is this made from?’ and ‘how do we recycle it?’ This reflects a broader shift towards environmental responsibility and consciousness in the printing community.”

Queau sees a strong desire for reduction in single-use plastics and global interest in recyclability, compostability, and biodegradability. “We are committed to constant innovation and development of new ways to provide sustainable products that demonstrate advancements in durability without compromising the ultimate goal of being able to recycle and reuse with the most minimal environmental impact.”

O’Neill agrees, adding that it’s imperative for rigid board distributors to embrace paper-based substrates and have it readily

available for their print customers. “Distributors who have filled in their warehouses with custom printable rigid paperboard products alongside their rigid plastic materials are now being rewarded by their print customers and have gained a significant advantage against their competitors.”

The mass adoption of sustainable products is in its infancy, as the market becomes more accustomed to use. Rowan Maher, CMO, Xanita, expects more innovation and opportunities to follow.

“Tons of current applications are temporary and don’t need to be made of traditional substrates, like applications such as graphics for social and corporate events decoration, brand activations, temporary pop-ups, and trade show booths that need to be easy to handle and in some cases disposable/recyclable,” notes Rodriguez.

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before, during, and after production and easier and cleaner to cut and transform. “This is especially important if the printing machines are close to the ‘cutting’ equipment; more cost effective in terms of freight; and easier and faster installation and turnaround.”

Back to sustainability, Queau feels that responsibly sourced, wood fiber-based substrates often lend for ease in recyclability. “After the use of fiber-based products, the ability for it to be repurposed into a new product is an attractive advantage and is what customers and businesses are requesting.”

Limitations 2

Advantages

When considering rigid media options, paper-, wood-, and fiber-based solutions present many advantages.

Bolton says the top ones are recyclability, low CO2 emissions, high-quality print and fabrication characteristics, as well as price.

“All are very important but in the grand scheme of things, using a fiber-based option allows end users to confidently dispose of their campaign materials with the existing channels they have at store level. This allows for a true circular process we all need to meet sustainability objectives.”

Aside from sustainability considerations, Maher points out that the strength-to-weight ratio of 2) Monadnock offers a portfolio of environmentally-friendly substrates including rigid board.

{ 24 } November 2023 | Digital Output

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rigid solutions like Xanita board is “astonishing.” “The versatility of Xanita board is also something that many other materials can’t compete with. The product is regularly used for retail POP displays, trade shows, shopfitting, visual merchandising and store design, caskets, and signage.”

Versatility is another advantage to paper-, wood-, and fiberbased rigid substrates. “Paperboard’s properties and versatility make it a preferred choice for many retail applications, from packaging to displays. Paperboard’s versatility and excellent print surface, ability to be easily converted, and various finishes make it adaptable for eye-catching creations,” shares Reiser.

Rodriguez says many of these options are easier to manipulate

While paper-, wood-, and fiberbased rigid media offer many benefits, challenges may also arise based on the specific job.

Reiser points out that for one, paperboard can absorb moisture, which may cause it to warp or lose its rigidity.

Maher sees the biggest limitation as long-term outdoor applications, without treating or adding “protection” to the materials.

“Generally speaking, the construction of fiber-based substrates have a more limited use for outdoor applications when fully exposed to the elements.

When there is additional protection, they can have longer durability outdoors, an example being bus shelter applications,” comments Queau, adding that it is important to consider the specific needs of an application when reviewing the pros and cons of a particular media.

Essential Characteristics

Specific factors like cost, durability, print quality, and weight are considered when looking at different types of rigid media for a particular job. Let’s review what the experts have to say about each.

Cost

The cost of paper-, wood-, and fiber-based rigid media options compared against other products depends on the application and substrates considered.

“It goes both ways, it depends on the substrate,” admits Maher.

Queau stresses that it’s difficult to make such a generalized statement in either direction as it pertains to wood fiber or polymerbased substrates. “The main reason for this is that rigid substrates come in many different, unique options with various fiber and chemical compositions that are custom designed to meet a specific application—especially as it relates to customer-specific needs for durability and longevity.”

With the exception of some commonly used lightweight PVC foamboards, O’Neill says most rigid paperboard substrates are generally lower priced than other PVC-based options.

Rodriguez agrees, noting that paper-based rigid substrates are less expensive than other plastic materials when comparing the same material thickness. For example, half-inch PVC versus half-inch honeycomb board.

Reiser points out that paperboard is generally considered

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to be a more economical option compared to rigid substrates like foamboard and other plastic materials. “This is because it is less expensive to produce, manufactured domestically, and derived from renewable resources.”

“Depending on the application, fiber-based options shouldn’t be much more than traditional resin or metal substrates,” notes Bolton.

Durability

Again it’s hard to generalize specifics, but paper-, wood-, and fiber-based rigid substrates don’t typically perform as well outdoors for a long length of time when compared with plastic- or metal-based alternatives.

“In most cases rigid plastic, steel, and aluminum are better suited for outdoor signage applications.

For indoor applications rigid paper boards tend to last well within the timelines needed for the promotion, which makes it a more eco-friendly choice when evaluating campaigns,” shares O’Neill.

Rodriguez says for applications that require a long-lasting product, which will be constantly exposed to contact and manipulation or used outdoors—POP floor displays, for example, medium density fiberboard (MDF), acrylic, PVC, or aluminum composite material (ACM), are probably the best option. “For any other applications, paper-based substrates work well,” he states.

Bolton points out that fiberbased substrates have come a long way and some are now confidently used for indoor and digitaloutput.net

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outdoor applications. “Products can be used nicely in outdoor applications replacing styrene and fluted polypropylene materials and allowing for transparent disposal into paper recycling bins.”

The suitability of paperboard in terms of durability largely depends on its intended use. “For short-term packaging or signage, it might be ideal. For long term, heavy duty, or outdoor use, other materials might be more appropriate. Paperboard’s durability is versatile and can be adapted to various needs, but it might not be suitable for all applications, especially those requiring extreme strength or resistance to harsh environmental conditions.

Coatings can be applied to make it more resistant to moisture, but it might still not be suitable for applications requiring prolonged exposure to wet conditions,” explains Reiser.

Queau says Monadnock focuses on developing wood fiber substrates that contain durable characteristics similar to plastics—water resistance, strength, and longevity, while providing curbside recyclability.

Maher feels that a discussion of durability is more dependent on the application and the design rather than the substrate itself.

“For example, if someone were to use a paper material designed for indoor use for an outdoor application, and the material fails due to torrential rain. The argument shouldn’t be that the substrate is less durable than something fit for outdoor use like an ACM, it should be that the November 2023 | Digital Output { 25 }

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FIT FOR PURPOSE Certain rigid substrates, like paper-, wood-, and fiber-based options may be considered eco-friendly compared to alternatives like foamboard, aluminum composite materials (ACM), and polybased materials. However, it is important to look at sustainability objectively.

“In an era where environmental consciousness is at its peak, the packaging industry is under immense pressure to adopt eco-friendly practices. The detrimental impact of packaging substrates, such as styrofoam and foam-based boards, ACM, and plastic-based materials on our planet

incorrect substrate was used for the application.”

Print Quality

A durable, cost-effective, versatile material doesn’t mean much to a print provider if it’s not easy to print to.

Luckily, Reiser says paperboard is widely regarded as an ideal material for printing. It is compatible with various printing techniques, such as offset, digital, flexography, and screen. “This versatility allows for a range of design possibilities. It is also suitable for various post-printing processes such as die cutting, embossing, laminating, and folding, allowing for endless creative designs.”

Adhesion of the ink to the substrate is another consideration.

companies mentioned INFO# COMPANY 100 Competitive EDGE

is driving the search for sustainable alternatives. Paperboard and fiber-based packaging have emerged as frontrunners in this quest, offering a range of benefits that make them inherently more environmentally friendly,” says Mark Beamesderfer, packaging services director, Metsä Board Americas.

to materials like ACMs and plastics, utilization of renewable resources, contribution to circular economy, reduced energy consumption, minimizing toxicity, versatility for design and functional purposes, consumer preference for sustainability, and minimizing the instance of less sustainable products.

Beamesderfer outlines eight points of consideration that support and promote paperboard and fiber-based materials as more eco-responsible choices—including natural biodegradability and decomposability, lower carbon footprint compared

He stresses that in all cases, it is important to understand that print and packaging must be fit-for-purpose, and there will always be exceptions or differences in perspective when determining what’s best for the planet.

“I think it’s better in the case of paper-based rigid substrates since it has a porous printing surface,” offers Rodriguez.

O’Neill points out that most rigid paperboards’ top and bottom liners are print treated. “Printing on paper compared to plastics is typically an easier process with digital and screen equipment in the channel.”

Maher stresses that any substrate designed for the printing industry should print well. “Most printers are running jobs at production speed and quality, which means print quality is generally not paramount over speed and efficiency—unless printing fine art or photography—for the most part as long as you can color match with the substrate and it’s

See page 16 for more info.

WEBSITE competitiveedgereps.com

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DGS USA

dgs-usa.com

102

Lamitech, Inc.

lamitech.com

103

Metsä Board Americas

metsagroup.com/metsaboard

104

Monadnock Paper Mills

mpm.com

105

UltraPartners, LLC

ultrapartnersllc.com

106

Xanita

xanita.com

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able to provide a good finished representation of the brief, that’s all that really matters.”

Queau shares that many substrates are purposely designed with smooth surfaces and specialty coatings that enable the product to be printed with high definition and vibrant color as well as are built to support heavy ink coverage. “Many are designed with universal coatings that allow the same rigid product to be printed across a variety of print platforms.”

Weight

In the realm of rigid media, weight is an important consideration.

Reiser says paperboard is generally available in thinner dimensions in thicknesses ranging from 0.008 to 0.180 inches.

“Paper-based rigid substrates such as honeycomb board are substantially lighter than rigid substrate options like ACM, and poly-based materials, especially if we compare, again, same thickness products. The main reason

for this difference is that the internal structure—in this case the honeycomb—is 90 percent air,” says Rodriguez.

According to O’Neill, the beauty of rigid paperboards is that most of them have a fluted and/or honeycomb structure to create strength, which is lightweight.

For Xanita board, Maher says on average it is 75 percent lighter than MDF and is considerably lighter than comparable ACMs and plastics.

Alongside providing durable performance, Queau admits that Monadnock’s products are intentionally designed with high levels of clean, recycled wood fiber rather than filler. This unique mix of fiber rather than fluff or filler provides a high level of rigidity and weight.

These characteristics allow for the product to lay flat and remain intact for long periods of time on display. Compared to some of the synthetic products in the marketplace, fiber-based products are either the same or lighter depending on how they are manufactured.

Rigid Options

Paper-, wood-, and fiber-based rigid substrates continue to improve in terms of versatility, cost, and durability. As consumers worldwide trend towards replacing plastics with more sustainable solutions, these materials are ready to shine. However, it is important to consider the job at hand, what these materials are replacing in terms of longevity, and what needs to be added in terms of pre- and post-treatments to ensure success. D digitaloutput.net

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