What is packaging finishing?

The appearance of packaging has many facets. The basis for this is the material, the shape and the colors. The simplest way to design packaging for a product is to print it with one or more colors.

The essential information about the content and the manufacturer is applied. With an appealing design you can achieve a lot here without much effort.

However, there are numerous products where printing alone is not enough to differentiate or stand out from the competition, to catch the eye of potential buyers. This applies, for example, to packaging solutions for high-value goods and luxury items of all kinds, such as jewelry, cosmetics, confectionery, or expensive beverage bottles.

Packaging finishing takes place after printing in the finishing department. Some processes, such as embossing or blind embossing, have been around since late antiquity.

Other finishing methods such as hot foil stamping or UV varnishing have only become possible thanks to modern technical developments.

Embossing ensures that a package not only stands out visually and looks particularly classy, but also has a unique haptic design. Cellophaning also conveys a special feeling, but at the same time also serves to protect against moisture or dirt.

In the context of sustainability, however, you need to consider which packaging finishing processes are environmentally friendly and which are not. For example, papers and cardboard packaging that have been UV coated cannot be recycled without great effort, but are a case for residual waste.

From a sustainability perspective, precisely configured packaging is always better. Small start-ups benefit from this just as much as large companies.

What are the variants and possibilities of packaging finishing?

Not only are the packaging solutionsdiverse,
so are the finishing options.

There are various classic and modern packaging finishing processes. These can be used individually or in combination with each other to give paper and cardboard an additional appearance in addition to the ink application. The main categories are:

• Blind embossing
• Hot foil stamping
• Punching and laser punching
• Dispersion coating
• Cellophaning/film lamination
• Partial UV coating
• Scented varnish
• Flocking

In the next sections, we would like to go into more detail about these processes to give you a first impression of the wide range of possibilities for packaging finishing and thereby perhaps provide you with ideas and inspiration for your next project.

 

Blind embossing

In blind embossing, the respective graphic motif or lettering is raised or deepened with the aid of a separately made embossing die or in an embossing machine. This is referred to as raised or deep embossing.

Several surface levels and a variety of shapes can be created, producing impressive effects in the interplay of light incidence and shadow.

This classic method of finishing can be seen as well as felt. You have to keep in mind that the embossing also appears as a negative shape on the reverse side of the printed product.

The blind embossing itself is merely a three-dimensional reshaping that does not cause any environmental pollution. Paper and cardboard with such a finish can be recycled without any problems.

However, additional materials, usually brass or steel, and energy are required to make the stamp tool. However, this is long-lasting, so that high runs can be produced without having to make a new tool.

Hot foil stamping

For this packaging finishing process, very thin colored or aluminum foils are applied to the base material under strong pressure and high temperatures, with the foil itself serving only as a carrier material and being removed again after the work step has been completed.

With the use of iridescent metallic inks, lettering, logos and other, arbitrary motifs can be pressed onto paper and cardboard in a high gloss. This creates unique, noble-looking effects that give any packaging a high-quality appearance.

The process is also used for holograms when products are to be provided with copy protection.

Cardboard and paper with hot foil stamping can be recycled without hesitation after use, as ink removal during the processing of waste paper, known as deinking, is not a problem.

In our blog you will find everything about packaging finishing, deinking and many other exciting topics.

Punching and laser punching

Mechanical die-cutting, like blind embossing, does not require any additional materials, apart from the production of the die-cutting tool. There is therefore nothing to stop punched paper and cardboard being disposed of in waste paper and recycled.

With a creative design, die cutting can achieve very unusual effects>. Similar to a viewing window, die cutting also allows a view of the contents of the package.

Another example of an individual effect is the punching out of lettering with a colored background. This creates a three-dimensional impression. The punched out sections do not necessarily have to be rectangular. Curves, jagged shapes and other patterns can be created just as easily.

Laser die-cutting is ideal when the motif calls for very fine and filigree cutouts, because then conventional die-cutting dies reach their limits and cannot offer the same precision.

With lasering, different degrees of heat can be set to produce different depths. One disadvantage in terms of sustainability with laser die cutting is the energy consumption.

Dispersion coating

The dispersion coating is therefore applied immediately after printing and dried immediately with a further device. The matte, silk matte or glossy varnish protects the surface against dirt and abrasion and is also water-repellent.

A variant of the dispersion coating is the so-called Irodin varnish. He can Pigments from Sand or Metal contain, which create a special visual effect.

In terms of sustainability, dispersion coating is the most environmentally friendly of the various coatings. For the most part, it consists only of water, binders, waxes and resins. Recycling, however, requires a little more effort, as the varnish penetrates the cardboard. This is because print finishes such as varnishes can only be removed from the waste paper with difficulty, and in some cases not at all, by the deinking process. This also applies to dispersion varnish.

Cellophaning/film lamination

Cellophaning or lamination involves applying a film from the roll to the surface of the printed product using heat or adhesive. The films usually have a thickness of 12 µm to 30 µm and are usually made of polypropylene, sometimes also of polyester or acetate. Polyamide is used for digital printing.

Cellophane-coated products not only aim for a higher advertising effect, but also protect the printed motif against moisture, abrasion and dirt.

The market offers matte and glossy films, each of which provides a different character. A glossy film enhances the intensity and brilliance of the printing inks, while a matte one provides a velvety-soft impression.

Recycling of laminated packaging is only possible if the film has been applied on one side. Cardboard packaging cellophane-coated on both sides must be disposed of in the residual waste, so it must be rated negatively in terms of sustainability.

The variety of packaging finishes allows numerous design options for successful marketing and differentiation from competitors. However, it is important to weigh up to what extent the sustainability concept is best served by which process, without having to fear disadvantages on the market.

Partial UV coating

Partial UV coating creates special effects and contrasts through the visual and tactile difference between coated and uncoated surfaces on the printed product. The relief printing variant further enhances this difference due to its three-dimensionality.

The coatings used consist of 100 percent solids. In addition to acrylates and other auxiliaries, photoinitiators are particularly important. They decompose under the influence of UV radiation and thus activate the crosslinking process of the acrylates.

This chemical reaction cures the coating film in a fraction of a second, eliminating the need for a separate drying time. The work step takes place either inline in the press or offline in special coating machines.

Scented varnish

In addition to the look and feel, you can add an olfactory sensory impression to the packaging finishing. Special scented varnish is available for this purpose.

The screen printing process is best suited for this, as it allows thicker layers than offset printing, for example. The varnish is applied like a fifth printing ink. It consists of synthetic resin in which microcapsules containing the fragrance are embedded.

On the finished product, the buyer must rub or lightly press the appropriate areas so that the capsules burst open and release the fragrance. This packaging refinement adds another dimension to your design. However, it should be chosen carefully, because people's perception of smells varies greatly.

A scent can arouse pleasant emotions in one person, evoke old memories or generate curiosity, but have negative effects on another person, especially if the scent is too strong and is therefore perceived as unpleasant.

In terms of environmental compatibility and sustainability, scented varnish cannot be clearly classified. Such refined cardboard packaging can indeed be recycled, as the layer of the coating is very thin. However, there is as yet no process for producing the microcapsules from a biodegradable material.

Flocking

During flocking, fibers made of different materials are electrostatically applied to the cardboard provided with adhesive. The feel of a flocked surface is determined primarily by the ratio of fiber thickness to fiber length and by the type of flocking material. The longer and thinner the fibers, the softer the corresponding areas feel.

The materials used for flocking are usually viscose and polyamide, but also cotton and polyester. The adhesives are either acrylic dispersion or PUR two-component adhesives.

Flocked packaging is one of the most expensive finishing products and has a truly unique look and feel. However, they cannot be recycled, so there are major trade-offs in terms of sustainability.

In which industries are refinements particularly useful?

In principle, packaging finishing is suitable for any industry in order to achieve a special effect and thus differentiate from competitors. However, the cost-benefit ratio must also be calculated.

As already mentioned at the beginning, high-quality finishing techniques are mainly found in packaging for high-value and high-priced goods. Or, to put it casually: finishing a bread roll bag with more than simple printing would be too much of a good thing.

Do finishes fundamentally contribute to sustainability?

Every packaging finishing means additional consumption of material and energy. Therefore, the answer to the question must be no. However, there are processes that do not use environmentally harmful and climate-damaging substances and high energy consumption during production and allow easy recycling after use. If you value sustainability, you should turn your attention to these.

Conclusion: Not all packaging finishing is sustainable

The possibilities for packaging finishing are many, especially when different processes are combined. Some are unproblematic in the context of sustainability, others are not.

The use of varnish in particular should be viewed skeptically, as it penetrates deep into the paper or cardboard structure and makes recycling much more difficult or completely impossible. So you should consider carefully so that sustainability and unique advertising effects complement each other well.

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