COLD FOILING is hotter news than ever at Shave & Gibson Packaging, with the installation of a fully automatic Eco-Eagle system that, according to managing director Richard Downes, looks set to become the gift that keeps on delivering.

‘The module opens the door for a wide variety of high-quality gifting work, which we’re very thrilled about,’ he confirms. ‘We’ve always been in the hands of external suppliers for all our foiling needs and this investment will put the control over quality and service delivery firmly in our hands, where it belongs.’

Brett Leppington of Printequip, the local market representative since 2019, explains that lithographic cold foiling is an inline printing process performed on a six-colour sheet-fed offset press that positions metallic foil anywhere on a printed sheet with litho precision at full press speeds.

The Eco-Eagle system, billed as disruptive technology at its finest, can be retrofitted to almost any offset press, which may be used for regular printing when it’s not foiling, he adds.

Brett elaborates on the process: ‘An adhesive ink is placed in the ink tray and printed onto the sheet with a standard printing plate and blanket from tower one. The Eco-Eagle cold foil module is placed on top of tower two. Silver foil unwinds and moves through the blanket and impression cylinder nip before being transferred to the adhesive print. The carrier film is then rewound without telescoping or creating foil dust. In towers three to six, silver foil is overprinted with regular offset, conventional or UV inks to give a colourful and brilliant finish.

‘It’s possible to achieve halftones, fine lines, fine reverse outs, anything from a single dot to full coverage, at 18 000 sheets/hour.’

Impressive images as Eagle takes flight

Since it was commissioned in June, Richard and the production team have had tremendous fun putting their new high-tech toy through its shimmering paces. ‘We are still in trial mode, but have printed some really interesting and impressive images on different substrates,’ he explains. ‘The consistent quality we’re achieving is really something else.’

The unit will be a boon for Shave & Gibson’s gifting, liquor and high-value items, Richard continues. ‘This is work previously unattainable to us or, at best, difficult to manage. Carton designs are becoming more complex and elaborate, and the unlimited options that our in-house foiling capacity provides allows for greater product enhancement. We can also offer exciting, value-added features to existing products. Several customers are already voicing their interest.’

The ease of use is as appealing as the aesthetics capabilities, Brett and Richard agree. No additional operator inputs are needed besides loading and webbing the foil. The unit is also connected to a 24/7 service centre by internet connection and any adjustments, service, support or upgrades to software can be done from anywhere in the world at any time.

‘The “live” side of the foil never comes into contact with any surface, there are no dancer rollers, no operator console and foil break and dust are eliminated,’ Brett asserts. A single web of foil or multiple combinations from 5cm to the full width of the press can be accommodated.’

Advanced foil detection systems prevent press damage and the Eco-Eagle is fully enclosed to protect operators from injury.

Delivers on less power than a hairdryer

The cherry on top for sustainability-minded users such as Shave & Gibson is the unit’s ultra-small environmental footprint. Lithographic cold foil is fully recyclable and the carrier polyester may be reused, but also has value to recyclers. This distinguishes it from competing products such as foil-lined board, which is destined for landfill.

What’s more, the Eco-Power feature developed by Eagle Systems offers an energy consumption promise that not even a hairdryer can match.

Shave & Gibson’s national sales manager Bill Furniss is thrilled at the prospect of banishing delays caused by having to wait for a slot with a foiling house. ‘Now we can offer a one-stop print and foil service at significantly-reduced lead times,’ he proclaims.

Over the years, the company has received repeated endorsements from customers and from the industry, reflected in numerous awards for innovation and packaging excellence, and in several top supplier commendations. With the plunge into cold foiling, Richard may need to source a larger awards cabinet in the near future.

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