TABLE OF CONTENTS IC COLDOIL AUTHOR. Introduction 1. Why Use Cold Foil Printing? 1. To Whom Do I Sell? 3. The information contained in

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2 IC COLDOIL TABLE OF CONTENTS Introduction 1 AUTHOR Why Use Cold Foil Printing? 1 To Whom Do I Sell? 3 Cold Foil Printing Offers Many Opportunities 4 How Does Cold Foil Printing Work? 6 Types of Cold Foil Printing 7 Equipment Required 8 What Process Should I Use? 8 Dry Lamination (Conventional) Press Set-Up 10 Suggested Web Paths 11 Process Guidelines 15 Foils 21 Troubleshooting Guide 22 Wet Lamination (Cure Thru) Press Set-Up 24 The information contained in this handbook is a compilation of data collected in more than six years of research and development. To ensure success with cold foil printing, we strongly suggest that you follow the recommended guidelines and avoid any shortcuts. We currently have a 10" wide, four-color UV flexographic press at our training facility that is available for job proofing, training, and seminars. We urge you to use our facility to familiarize yourself with the cold foil printing process. We at A m a g i c a n d B e a c o n Adhesives want to help you succeed! Suggested Web Paths 26 Process Guidelines 31 Foils 35 Troubleshooting Guide 36 Afterword 37 Any part of this handbook cannot be reproduced without the written consent of Beacon Adhesives J. Michael Rivera Vice President of Sales Amagic Holographics,INC. A member of K Laser Group

3 Page Page 11 INTRODUCTION FOIL INTENSIFIES THE PRINTED IMAGE. FOIL SIGNIFIES PROSPERITY AND SPLENDOR. FOIL PRINTING HAS A HIGH PERCEIVED VALUE. COLD FOIL Throughout history, foil has been used to decorate many important aspects of our lives. It was used on temples, palaces and, most importantly, in manuscripts. Pure gold was the primary source of foil. It signified prosperity and splendor. After the painstaking task of pounding gold into thin layers, the foil was then formed onto armors, caskets, statues and shields. It was also used on important documents as a seal or certification. Today, gold foil is still being used extensively as it was long ago. Foil is a valuable tool used to enhance illustrations, packaging, and labels. Look through today s aisles and you will see that the most noticeable products are imprinted with foil. WHY USE COLD FOIL PRINTING? ALTHOUGH THE BASIC CONSTRUCTION IS THE SAME, EACH FOIL MANUFACTURER HAS THEIR OWN PROPRIETARY MANUFACTURING TECHNIQUES AND COMPONENTS. THEREFORE, EACH BRAND OF FOIL HAS ITS OWN STRENGTHS AND WEAKNESSES. TYPICAL FOIL CONSTRUCTION The majority of foil used today is not pure gold, but is a construction of thin film, release coating, lacquer, aluminum, and adhesive as illustrated below. Although the basic construction is the same, each foil manufacturer has their own proprietary manufacturing techniques and components. Therefore, each brand of foil has its own strengths and weaknesses.

4 Page Page 2 WHY USE COLD FOIL PRINTING? ROTARY HOT STAMP Foil is widely used today on a rotary hot stamp system. It provides fine edging and a smooth foiled image. This system is used in-line on a web press that utilizes an engraved cylinder in which the image is heated either electrically or through heated oil. Narrow web presses typically incorporate an electric system while wide web presses employ an oilheated unit. The heat causes the foil to transfer onto the substrate. The width of the job and the amount of coverage affects the maximum running speed. Rotary hot stamping involves a high cost of initial investment and, since it uses an engraved cylinder, is inflexible to design changes and impractical for job testing. Also, the high cost of the engraved cylinder makes it inefficient for short runs. PLATEN HOT STAMP The second most common use of metallized foil is with a platen hot stamp system. This system is mostly used off-line where foil is required on a preprinted substrate. It is widely used in the offset printing industry and in the manufacture of special occasion ribbons. This process utilizes interchangeable flat plates which are heated electrically. The heated plate then descends and applies pressure onto the substrate. The substrate is either hand fed or webbed through the machine. A platen hot stamp system is quite economical, but runs at a very slow speed. Due to its slow speed, installation for an in-line process can be complicated. The types of graphics are usually limited to text and bold images. Since this process is time consuming, it s suitable only for very short runs. ALTHOUGH THE BASIC CONSTRUCTION IS THE SAME, EACH FOIL BRAND HAS ITS OWN STRENGHTS AND WEAKNESSES. THE HIGH COST OF AN ENGRAVED CYLINDER MAKES ROTARY HOT STAMPING INEFFICEINT FOR SHORT RUNS. A PLATEN HOT STAMP SYSTEM IS QUITE ECONOMICAL, BUT RUNS AT VERY SLOW SPEEDS. METALLIZED SUBSTRATES CAN SUBSTANTIALLY INCREASE THE COST PER LABEL. METALLIZED SUBSTRATES For years, metallized substrates have been widely used in the gravure printing of gift wrapping papers. This application is now gaining acceptance in the packaging industry. Typically, the printer will print on top of the metallized substrate to cover the areas that do not require a foiled image. Although metallized substrates accept water-based, solvent-based, and UV-curable inks, there are still some issues regarding adhesion and foil integrity in the blister packing industry. Since overprinting is required, this application is quite limited. Metallized substrates can be purchased in sheet or web form but the additional expense substantially increases the final cost of the job.

5 Page 3 TO WHOM DO I SELL? COLD FOIL PRINTING CAN PREVAIL OVER THE MEDIUM RUN MARKET. TYPICALLY, ANY PRODUCT REQUIRING A HIGH SHELF APPEAL IS A GOOD CANDIDATE FOR COLD FOIL PRINTING. COLD FOIL PRINTING IS A PERFECT FIT FOR LOW COST JOBS. COMPETITION Cold foil printing was never designed to entirely replace the hot stamp system, although cold foil printing allows for greater flexibility and lower operating cost. Rather than competing against hot stamping, cold foil printing allows the printer to expand his foil market. CANDIDATES Typically, any product requiring a high level of shelf appeal is a good candidate for cold foil printing. Household consumables, cigarette cartons, wine labels, and cosmetic packaging are usually the heavy hitters. With the advent of holographic, diffractive and refractive foils, foil has broadened its use to include packaging and board applications. While rotary hot stamp dominates the long run market and platen hot stamp has the very short run market, cold foil printing can prevail over the medium run market. A medium run can be defined as a foil application in which the size of the job cannot justify the cost of an engraved cylinder and would be too time consuming to run on a platen hot stamp system. Cold foil printing is a perfect fit for low cost jobs such as children s stickers and gift tags. Jobs that were printed with gold or metallized ink also fall into this category. These jobs have a tendency to appear as a matte color and do not have the brilliance of foil. Process Comparison Process Maximum Speed Initial Cost Job Cost Graphics Design Changes Ideal Run Cold Foil Printing 700 fpm None Low (photo polymer plates) Half tone to full flood Flexible Long and Short Runs Rotary Hot Stamp 150 fpm High High (engraved die) Limited to Text and Bold Images Inflexible Long Runs Platen Hot Stamp 120 cycles/min Medium Low (plates) Limited to Text and Bold Images Flexible Short Runs Metallized Substrates 700 fpm None High (substrate) Limited to Trapping Flexible Long Runs

6 Page 4 TO WHOM DO I SELL? Cold foil printing is suitable for the packaging industry. Large printed areas with a small foil image, printed logos over a square, oval, or a special shape foiled image, and security strips for DVD and CD covers are but a few applications for this industry. Although these are long run jobs, a printer can expect substantial savings with cold foil printing. Industry Cosmetic Food & Drug Wine Pharmaceutical Beverage Cold Foil Market Type of Job Labels for lipstick, make-up, nail polish, sample products, Shampoo labels, toothpaste boxes Labels for local wineries Label for nutritional supplements Labels for local beverage companies COLD FOIL IS SUITABLE FOR THE PACKAGING INDUSTRY...ALTHOUGH THESE ARE LONG RUNS, A PRINTER CAN EXPECT SUBSTANTIAL SAVINGS WITH COLD FOIL PRINTING. Consumer Packaging Miscellaneous New products geared for market testing Security strips, holograms on blister packs Children s stickers, gift tags An exciting new application is also available with cold foil printing. In the past, halftone metallic effects were impossible with the use of foils. Now such effects can easily be achieved with cold foil printing and open many different options in the design of labels and packaging. The end-users must be made aware of this new application which can give a printer the competitive edge. COLD FOIL PRINTING OFFERS MANY OPPORTUNITIES! Below is a list of other opportunities possible with cold foil printing: Traditional hot stamp jobs, particularly the type that has multiple sizes and are short run. Security strips, such as CD or DVD, concert and sport tickets. Product identification system (random image). Pattern flood with overprint images using opaque or transparent inks. In-house converting of holographic substrate. Opaque pigmented foils or preprinted image (without metal). Cold Foil Printing can also be accomplished with a rotary letterpress or web offset press. Combination embossing and foil transfer without the use of heat. Can be used with a foil saver system. Ideal for wide web applications. AN EXCITING NEW APPLICATION IS ALSO AVAILABLE WITH COLD FOIL PRINTING... HALFTONE METALLIC EFFECTS. COLD FOIL PRINTING CAN ALSO BE ACCOMPLISHED WITH A ROTARY LETTER- PRESS OR WEB OFFSET PRESS.

7 Page Page 15 COLD FOIL PRINTING OFFERS MANY OPPORTUNITIES Below are some examples of cold foil opportunities: Small Price Tags Dietary Supplements, ideal for multiple label size Return labels for special occasions and non-profit organizations Traditional Wine Labels, ideal due to short run requirements Toothbrush Packaging Holographic random image for product identification In-house converting of holographic substrates for bumper sticker, license plates, and high-end packaging Labels for the health and beauty aids, cosmetics and shampoo products. Holographic image for anticounterfeit applications Transfer opaque white for single bump printing.

8 Page 1 HOW DOES COLD FOIL PRINTING WORK? NOT JUST FOR FLEXO PRINTING! The idea behind cold foil printing is quite simple: using a standard printing plate, an image is printed onto a substrate with the use of a UVcurable cold foil adhesive. A UV dryer then activates the adhesive. The extracted foil is affixed to the printed adhesive and an image is created. There are two types of processes of cold foil printing available - wet or dry lamination. Each process uses a specially formulated adhesive that is not interchangeable with the other. It is important that each application is carefully reviewed to determine which one is best suited for the printer s needs. Although the following process was originally designed for use on a flexographic press. Further tests have proven suitability on other printing processes such as rotary letterpress, web offset printing and screen printing. It is important to remember that positive control of the substrate is required to ensure success. Page 6 EACH PROCESS USES A SPECIALLY FORMULATED ADHESIVE THAT IS NOT INTERCHANGEABLE WITH THE OTHER. IT IS IMPOR- TANT THAT EACH APPLICATION IS CAREFULLY REVIEWED TO DETERMINE WHICH ONE IS BEST SUITED FOR THE PRINTER S NEEDS. K LASER TECHNOLOGY INC. is curently working with various machine manufacturers for possible applicationof off-line cold foil printing, sheet-fed offset and the wide web flexo printing industries. Future Applications of Cold Foil Printing Type of Printing Process Web Offset Sheet-Fed Off-Line Cold Foil Printing Machine Web-Fed Off-Line Cold Foil Printing Machines Cold Foil Printing with Foil Saver Option K LASER TECHNOLOGY INC. IS CURRENTLY WORKING WITH VARIOUS MACHINE MANUFACTURERS FOR POSSIBLE APPLICATION OF OFF-LINE COLD FOIL PRINTING, SHEET-FED OFFSET AND THE WIDE WEB FLEXO PRINTING INDUSTRIES. Converting Machines For Converting of Holographic Substrates Specialty Machine for the Transfer of Pre-Printed Images Magnetic Strip Applications Lamination of Opaque Substrates

9 Page 7 TYPES OF COLD FOIL PRINTING FOR DRY LAMINATION, BEACON S CATIONIC ADHESIVES, MAGNA- CRYL 4505, 4503 OR 4512 CAN BE USED. DRY LAMINATION (CONVENTIONAL) For dry lamination, Beacon s cationic adhesive, Magna-Cryl 4503, 4505 and 4520 can be used. Using a standard printing plate, an image is printed onto a substrate from a standard print station. The UV dryer activates the adhesive which makes the adhesive tacky. The foil is then nipped onto the substrate with a nip roll or a spare anvil in a die station, and then is immediately pulled away to the waste wind-up. The extracted foil is affixed to the printed adhesive and an image is created. Printed image UV light foil FOR WET LAMINATION, BEACON S FREE RADICAL ADHESIVE, MAGNA-CRYL 4520 CAN BE USED. Wet Tacky Hard A STANDARD PRINTING PLATE CAN BE USED FOR PRINTING THE COLD FOIL ADHESIVE. WET LAMINATION (CURE TRU) For wet lamination, Beacon s free radical adhesive, Magna-Cry 4520 can be used. Using a standard printing plate, an image is printed onto a substrate from a standard print station. The foil is then laminated onto the substrate, which is then passed under a UV lamp station. The printed adhesive is cured thru the foil, bonding the foil onto the substrate. The foil is then stripped and wound to a waste wind-up. UV dryer BEACON S COLD FOIL ADHESIVES HAVE BEEN SPECIALLY FORMULATED TO CURE WITH A STANDARD 400 WATT UV DRYER. Printed image Wet foil Hard

10 Page 8 EQUIPMENT REQUIRED Cold foil printing has allowed many printers to enter a new market with minimal investment. The following industry standard equipment is required: standard print station die station or a high pressure nip station for dry lamination/ laminating station for wet lamination UV dryer with variable output control laminating arm and waste wind-up Standard printing plate mounted on a print cylinder 80 durometer (or higher) nip roll or a spare anvil WHAT PROCESS SHOULD I USE? THE BIG QUESTION! As with any process, the industry is always looking for that ONE cold foil process that can accomplish everything. In the past, while printers have been successful with cold foil printing, many have had difficulties in recreating their success on their second job. Remember, each process has it s own advantages, it also has it s own individual limitation. Using just ONE process has resulted in many Hit or Miss results. We highly recommend that you familiarize yourself with both the wet and dry lamination process and their advantages and limitations. This will enable you to decide which process is more suitable based on the type of your printed job. Type of Job Wet Lamination Dry Lamination Cold Foil on Top of Water- Based Inks Cold Foil on Top of UV- Curable Inks Compatible Compatible Not Compatible Compatible Cold Foil in any Print Station Easy Complicated Medium to Large Images Excellent Poor Small Amount of Images Poor Excellent Small Open Circles Poor Excellent COLD FOIL PRINTING HAS ALLOWED MANY PRINTERS TO ENTER A NEW MARKET WITH MINIMAL INVESTMENT. AS WITH ANY PROCESS, THE INDUSTRY IS ALWAYS LOOKING FOR THAT ONE COLD FOIL PROCESS THAT CAN ACCOMPLISH EVERYTHING. WE HIGHLY RECOMMEND THAT YOU FAMILIARIZE YOURSELF WITH BOTH THE WET AND DRY LAMINATION PROCESS Fine Line Reverse Poor Excellent Paper Substrates Medium Excellent Film Substrate Excellent Excellent Easy to Operate Yes Medium Post Cure None 24 Hours

11 Page 9 DRY LAMINATION (CONVENTIONAL) PRESS SET-UP [1] It is important that a die station is located immediately after the print station that will be printing the adhesive. The nip process requires high pressure. Cam and air actuated nips usually cannot provide the sufficient amount of pressure needed, resulting in pinholes and rough edges. Since all flexographic presses have multiple die stations, it is best to use the first die station immediately after the print station. RELOCATION OF THE UV DRYER TO A HORIZONTAL POSITION IS MANDATORY TO ENSURE SUCCESS. THE UV DRYER MUST BE INSTALLED AS CLOSE AS POSSIBLE TO THE DIE OR NIP STATION. CAM AND AIR ACTUATED NIPS USUALLY CANNOT PROVIDE THE SUFFICIENT AMOUNT OF PRESSURE NEEDED FOR GOOD FOIL TRANSFER. THE PRINTED SIDE OF THE SUBSTRATE CANNOT MAKE CONTACT WITH ANY IDLER ROLLS. APPLYING MORE ADHESIVE WILL ONLY INCREASE DOT GAIN AND CREATE A BUMPY IMAGE [2] Re-web the press so that the substrate enters the first die station immediately after the print station. The printed side of the substrate cannot make contact with any idler rolls between the impression cylinder and the first die station. This will smear the printed image. [3] Relocate the UV dryer between the print station and the first die station. UV dryers are typically installed in a vertical position right after the hot air dryers. Relocation to a horizontal position is mandatory to ensure success. Once the UV dryer has been relocated, it can be used in that same position for UV printing and coating. [4] For ease of operation, the laminating arm and waste wind-up must be located within the immediate vicinity of the first die station. Nip Location: Printed image UV light foil Wet Tacky Hard Printed image UV light Ideal set-up, with the right amount of adhesive for the job When less adhesive is required for the job, the adhesive will cure faster resulting in a bad foiled image. Applying more adhesive will only increase dot gain and create a bumpy image. foil Wet Tacky Hard

12 Page 10 DRY LAMINATION (CONVENTIONAL) Printed image UV light foil Move nip point close to the UV Wet Tacky Hard The ideal solution is to locate the nip point immediately after the UV dryer. This will enable the printer to perform a wide variety of print jobs. Most Hit and Miss results are caused by this problem. CHOOSING THE RIGHT NIP: Choosing the correct type of nip station is very critical. It must the incorporate the following features: Aluminum or hardened steel Base Roll. Hardened steel is preferred for easy clean up. It is recommended that the Base Roll is driven with the press especially with presses that runs at low web tension. Since a high degree of pressure is required for full foil transfer, this can cause a drag on the web resulting in poor registration. A driven Base Roll will help maintain web tension. An 80 durometer (or higher) nip roll or a spare anvil can be used to laminate the foil onto the substrate. A low durometer nip roll will cause pinholes. When using a nip roll, try to get the highest durometer possible. A gear driven nip or a spare anvil is preferred to ensure that the foil will travel the same speed as the substrate. It is important that the foil comes in contact with the substrate at the nip point to prevent air entrapment. This can result in a faded foil image. Make sure that the nip roll or spare anvil and the bottom anvil are completely clean. Any contamination will transfer to the foil image. THE IDEAL SOLUTION IS TO LOCATE THE NIP POINT IMMEDIATELY AFTER THE UV DRYER. THIS WILL ENABLE THE PRINTER TO PERFORM A WIDE VARIETY OF PRINT JOBS. MOST HIT AND MISS RESULTS ARE CAUSED BY THIS PROBLEM. MAKE SURE THAT THE NIP ROLL OR SPARE ANVIL AND THE BOTTOM ANVIL ARE COMPLETELY CLEAN. ANY CONTAMINATION WILL TRANSFER TO THE FOIL IMAGE. INCORRECT C ORRECT Foil Substrate Foil Substrate A non-heated engraved cylinder can be used to transfer the foil and to emboss the image at the same time. The engraved cylinder MUST not have a recess at the inside part of the image. Foil Substrate IT IS IMPORTANT THAT THE FOIL COMES IN CONTACT WITH THE SUBSTRATE AT THE NIP POINT TO PREVENT AIR ENTRAPMENT.

13 Page 11 DRY LAMINATION (CONVENTIONAL) SUGGESTED WEB PATH All of the flexographic and rotary letterpress manufacturers now offer a cold foil option for new press purchases. For existing flexo presses, please refer to the recommended web paths below. ALLIED GEAR Foil Unwind Print Station UV Dryer Foil Rewind For Allied Gear Flexomaster 3, Flexomaster 4, 300 and 500 Series, the UV dryer must be relocated into a horizontal position. Position the UV dryer as close as possible to the first die station. For 500 Series presses, bypass the middle nip assembly prior to the first die station. Die Station Press Set-Up on an Allied 300 Series Press AQUAFLEX/CHROMAS Print Station UV Dryer Foil Unwind Foil Rewind Pressure Bar available through Aquaflex For Aquaflex LC, DBX, BX, LX, Instraprep and Instaflex, the UV dryer must be relocated in a horizontal position. The middle nip station can be used as a cold foil nip station providing that the rubber nip is replaced with a high durometer (85 durometer or higher) nip and a pressure bar is installed on top of the nip assembly. Note that the air cylinders in a standard nip assembly will not be able to apply enough pressure to attain a good quality of foil transfer. Press Set-Up on an Aquaflex DBX

14 Page 12 DRY LAMINATION (CONVENTIONAL) SUGGESTED WEB PATH ARPECO ENGINEERING Foil For Arpeco presses, a nip station must be installed after the UV dryer. This nip station is available as an option from Arpeco Engineering. Print Station UV Dryer Press Set-Up on an Arpeco press GIDUE MARK ANDY 2200 Foil Print Station UV Dryer Die Module Press Set-Up on a Gidue press For Gidue presses, a cold foil module can be purchased from Gidue. This cold foil module is a complete system with a UV dryer, unwind, rewind and a nip station. An accessory module or a similar extension must be installed For Mark Andy 2200, an accessory or a similar extension must be installed between the last print station and the first die station. The UV dryer must be relocated in a horizontal position and must be installed as close as possible to the first die station.

15 Page 13 DRY LAMINATION (CONVENTIONAL) SUGGESTED WEB PATH MARK ANDY 4150 & 4200 Print Station UV Dryer Foil Die Module For Mark Andy 4150 & 4200, relocate the UV dryer on a horizontal position and install the dryer as close as possible to the first die station. Due to the die station frame, the UV dryer will be positioned 16 away from the first die station. This will limit the printers capability to using aniloxes with 500 line count or lower. Remember, for dry lamination, a high capacity UV dryer is NOT required. Tests have shown that a small portable UV dryer can provide sufficient amount of curing and is easier to install between the die frames. NILPETER Infinite variable UV output dryer system Press Set-Up on a Nilpeter press For Nilpeter flexo and letterpresses, a cold foil module is available through Nilpeter. This module includes an infinite variable output UV dryer, a nip assembly, a rewind and an unwind. Due to the compact design of the Nilpeter presses, this module is required to accomplish cold foil printing. Notice that this module has been designed with a longer dwell to allow the printer to use foils with tighter release properties.

16 Page 14 DRY LAMINATION (CONVENTIONAL) SUGGESTED WEB PATH THE UV DRYER MUST BE INSTALLED AS CLOSE AS POSSIBLE TO THE DIE OR NIP STATION. THIS WILL ENSURE THAT THE COLD FOIL ADHESIVE IS AT ITS HIGHEST TACK LEVEL AT THE NIP POINT. ROTOPRESS 3500 & 4000 Print Station UV Dryer Foil FOR FLEXO AND LETTERPRESSES THAT ARE NOT LISTED, PLEASE PROVIDE A WEB PATH AND WE WILL NOTIFIY YOU OF OUR RECOMMENDATIONS. Die Module WEBTRON 1000, 1600 & 1800 UV Dryer Foil Print Station Die Module

17 Page 15 DRY LAMINATION (CONVENTIONAL) ALL OF OUR COLD FOIL ADHESIVES HAVE BEEN DESIGNED TO BECOME HARD WHEN FULLY CURED. THIS PROVIDES THE PROPER ADHESION TO PASS THE STANDARD TAPE AND SCRATCH TESTS. SINCE IT IS POSSIBLE TO UNDER-CURE OR OVER-CURE THE COLD FOIL ADHESIVE, THE FOLLOWING FACTORS ARE OF GREAT IMPORTANCE: NIP LOCATION RELATIVE TO THE UV DRYER AND LINE SPEED. TO ATTAIN A GOOD COLD FOIL IMAGE, IT IS IMPORTANT THAT THE ADHESIVE IS CURED TO A POINT WHERE IT CAN PROVIDE THE HIGHEST LEVEL OF TEMPORARY TACK PROCESS GUIDELINES: CURING DRY LAMINATION COLD FOIL ADHESIVE In the past, most printers performing cold foil printing utilized a pressure sensitive adhesive. These adhesives remained tacky and provided a foiled image which can be scratched. This required an overcoat or lamination to protect the foiled image. All of our cold foil adhesives have been designed to become hard when fully cured which provides the proper adhesion to pass the standard tape and scratch tests. An overcoat or lamination is NOT required to protect the foiled image. Since it is possible to under-cure or over-cure the cold foil adhesive, the following factors are of great importance: Line Speed Nip Location relative to the UV dryer Line Speed: To attain a good cold foil image, it is important that the adhesive is cured to a point where it can provide the highest level of temporary tack. This can be achieved by varying the press speed. A low press speed can over-cure the adhesive and a high press speed can under-cure the adhesive. The cure rate can also vary depending on the color of the substrate. If the cold foil image is being overprinted on top a preprinted ink, the color of the ink can also change the cure rate. Printed Adhesive UV Light Light Colored Substrate When performing cold foil printing on top of a white (or light colored) substrate, the UV light bounces off the substrate and cures the adhesive twice resulting in high press speeds. Printed Adhesive UV Light When performing cold foil printing on top of a clear (or dark colored) substrate, The UV light goes through the substrate, or is absorbed by the dark color, and cures the adhesive once resulting in low press speeds. Clear or Dark Colored Substrate

18 Page 16 DRY LAMINATION (CONVENTIONAL) UV Light Printed Adhesive When performing cold foil printing on top of a white (or light colored) pre-printed ink, the UV light bounces off the ink and cures the adhesive twice resulting in high press speeds. UV Light Light Colored Ink Substrate TO ATTAIN A GOOD COLD FOIL IMAGE, IT IS IMPORTANT THAT THE ADHESIVE IS CURED TO A POINT WHERE IT CAN PROVIDE THE HIGHEST LEVEL OF TEMPORARY TACK. Printed Adhesive When performing cold foil printing on top of a black (or dark colored) pre-printed ink, The UV light is absorbed by the dark color and cures the adhesive once resulting in low press speeds. Dark Colored Ink Substrate JUST LIKE STANDARD PRINTING, COLD FOIL PRINTING WILL REQUIRE A SKILLED OPERATOR TO CONSISTENTLY P RODUCE HIGH-QUALITY PRODUCTS AND PROFITABILITY. CHOOSING THE RIGHT JOB: Cold foil printing can be achieved with any type of job that is normally printed on a printing press. As with any new process, you must carefully review the job and consider the current capabilities of your press. Remember that cold foil printing will take up a print station and a die station. Just like standard printing, cold foil printing will require a skilled operator to consistently produce high-quality products and profitability. PRINTED DESIGN: One of the exciting development in cold foil printing is the capability of printing screen work and halftone. But as with flexographic printing, dry lamination cold foil printing has limitations regarding the types of printed design. Since the cold foil adhesive has a tendency to cure faster on halftone and fine type compared to line work and solids, both cannot be run on the same photopolymer plate. SINCE THE COLD FOIL ADHESIVE HAS A TENDENCY TO CURE FASTER ON HALFTONE AND FINE TYPE COMPARED TO LINE WORK AND SOLIDS, BOTH CANNOT BE RUN ON THE SAME PHOTOPOLYMER PLATE.

19 Page 17 DRY LAMINATION (CONVENTIONAL) EACH MAGNA-CRYL ADHESIVE HAS BEEN DESIGNED FOR A PARTICULAR SUBSTRATE FOR ADHESION AND SCRATCH RESISTANCE AND ARE NOT INTERCHANGEABLE. BEACON ADHESIVES MANUFACTURES THREE VERSIONS OF MAGNA-CRYL 4505 TO GIVE THE FLEXO-GRAPHIC PRINTER EASE OF CONTROL OVER THE PRESS SPEEDS. CHOOSING THE ADHESIVE: Select the type of cold foil adhesive depending on the type of substrate that will be printed. Note that each Magna-Cryl adhesive has been designed for a particular substrate for adhesion and scratch resistance and are NOT interchangeable. There are three types of Magna-Cryl adhesives that are currently available; Magna-Cryl use for paper substrates: Beacon Adhesives manufactures three versions of Magna-Cryl 4505 to give the flexographic printer ease of control over the press speed. The Magna- Cryl 4505 has a window in which the foil will transfer with the highest quality and adhesion. Each grade can also be mixed to attain running speeds between the original grades. The Magna-Cryl 4505 can be printed over free radical UV inks and coatings, but not over water or solvent based inks. Magna-Cryl 4505 can be printed next to an image printed with water or solvent based ink as long as trapping does not occur. Magna-Cryl 4505S Color: Red Magna-Cryl 4505M Color: Blue Magna-Cryl 4505F Color: Green Slow Medium Fast Press Speed: fpm Viscosity: 1200 cps Press Speed: fpm Viscosity: 900 cps Press Speed: fpm Viscosity 500 cps THE MAGNA-CRYL 4500 SERIES HAS BEEN DESIGNED TO WITHSTAND THE STANDARD TAPE AND SCRATCH RESISTANCE TESTS. WE RECOMMEND THE USE OF A DOCTOR BLADE TO MAINTAIN CONSISTENCY AND THE EVEN DISTRIBUTION OF ADHESIVE. Magna-Cryl use for paper or film substrates: There is only one version of Magna-Cryl 4503, which has been specially formulated for use with paper, polypropylene, OPP and BOPP. Magna-Cryl 4503 can be printed over free radical UV inks and coatings, but not over water or solvent based inks. It can be printed next to an image printed with water or solvent based inks as long as trapping does not occur. Magna-Cryl 4503 Color: Blue Press Speed: fpm Viscosity: 900 cps Magna-Cryl use for letterpress on paper or film substrates: There is only one version of Magna-Cryl It has been formulated for use on letterpress machines. It is a free radical adhesive and can be printed on top of water-based and UV-curable inks. Note that the Magna- Cryl 4580 may not be able to provide full adhesion to the substrate and an overcoat or lamination might be required to protect the foil image. Magna-Cryl 4580 Color: Blue Press Speed: fpm Viscosity: 1200 cps

20 Page 18 DRY LAMINATION (CONVENTIONAL) Other types of film substrates: We are constantly testing new adhesives for other film applications. Please contact us to get an update on new developments. For specialty and custom film applications, we can perform a test run to investigate the compatibility of the adhesive to the substrate. SPECIAL NOTATION: When using cationic UV products, formation of benzene as a by-product during photo initiation and polymerization process is possible. Small amounts have been detected during the curing process. Due to many variations related to formulation and pressroom options, and exact quantification of the benzene level is difficult to confirm. OVERCOAT AND LAMINATION: The Magna-Cryl 4500 Series has been designed to withstand the standard test for scratch resistance and the standard tape test. Over-coating or lamination are not required to protect the printed image. CHOOSING THE RIGHT ANILOX: Start with a ceramic anilox with 300 line, 6.5 bcm. The logic line count is the same as when printing UV inks. Fine detail will require higher line count while large block areas need lower line counts. We recommend the use of a doctor blade to maintain consistency and the even distribution of adhesive. For uncoated paper stock, use a lower line count to compensate for absorption. For film substrate, use a higher line count. PREPARING THE PRINT STATION: The Magna-Cryl 4505 and 4503 are cationic adhesives. They are incompatible with water and solvent based inks. If the print station was used with water or solvent based ink, it must be washed with vinegar before cold foil printing. If there is any dried ink in the anilox cells, clean with Xylene and then dry with acetone. Make sure that the solvents have sufficiently evaporated prior to pouring the adhesive. LAMINATING ARM AND WASTE WIND-UP: Set the tensions on both the laminating arm and waste wind-up to low. Maintain a low tension setting to avoid any slack on the foil. High tension will cause the foil to travel faster or slower than the substrate and will result in rough edging or cracks in the image. PRINTING PLATES: Cold foil printing does not require a special printing plate. A standard printing plate can be used. Standard sticky-back tapes, magnetic print cylinders or trail edge mount systems can be used. START WITH A CERAMIC ANILOX WITH 300 LINE, 6.5 BCM. THE LOGIC LINE COUNT IS THE SAME AS WHEN PRINTING UV INKS... FINE DETAILS WILL REQUIRE HIGHER LINE COUNT WHILE LARGE BLOCK AREAS NEED LOWER LINE COUNTS. FOR UNCOATED PAPER STOCK, USE A LOWER LINE COUNT TO COMPENSATE FOR ABSORPTION. THE MAGNA-CRYL 4505 AND 4503 ARE CATIONIC ADHESIVES. THEY ARE INCOMPATIBLE WITH WATER AND SOLVENT BASED INKS. COLD FOIL PRINTING DOES NOT REQUIRE A SPECIAL PRINTING PLATE. A STANDARD PRINTING PLATE CAN BE USED.

21 Page 19 DRY LAMINATION (CONVENTIONAL) THE UV LIGHT THAT CURES THE MAGNA-CRYL 4500 MUST NOT VARY IN ENERGY OUTPUT AS THE PRESS CHANGES SPEED. IT IS IMPORTANT THAT THE PRINTED SIDE OF THE SUBSTRATE DOES NOT MAKE ANY CON- TACT WITH AN IDLER ROLL BETWEEN THE PRINT STATION AND THE DIE STATION. WE RECOMMEND THAT THE IDLER ROLLS, IMMEDIATELY AFTER THE FIRST DIE STATION, ARE COATED WITH TEFLON TO PREVENT PICKING THE FOIL IMAGE. DRYER SETTINGS: Although the Magna-Cryl 4500 Series adhesives were tested with a 600 watt UV lamp in the 32nm range, most UV dryers installed on flexo presses will easily cure Magna-Cryl The UV light that cures Magna-Cryl 4500 MUST NOT vary in energy output as the press changes speed. Variations will make it difficult to find the window of foil transfer. If your UV dryer has an auto ramp, turn this option OFF. In addition to varying the running speed by mixing different grades of our Magna-Cryl 4505, you can also vary the running speed by changing your dryer setting to low, medium or high. For example: using the Magna-Cryl 4505M (medium) with a 400 watt UV dryer at High setting, your average running speed will be about 165 fpm. By changing your dryer setting to Medium, you can reduce your speed to about 125 fpm, and a dryer setting of Low will reduce your speed to about 80 fpm. Note that these figures are estimates and can change depending on the UV lamp output, lamp life and overall condition of your UV dryer. IDLER ROLLS: It is important that the printed side of the substrate does not make any contact with an idler roll between the print station and the die station. When webbing the press, make sure that all idler rolls are bypassed in this area. We recommend that the idler rolls, immediately after the first die station, are coated with Teflon to prevent picking the image after the foil transfer. At this point, the adhesive is still tacky and will require up to 12 hours to fully cure. UNLIKE CONVENTIONAL INK PRINTING, COLD FOIL PRINTING IS NOT FORGIVING WHEN THE PHOTOPOLYMER PLATE AND THE SUBSTRATE HAVE BEEN CONTAMINATED WITH DIRT. DIRT CONTAMINATION: Dirt contamination from the substrate is an important issue with cold foil printing. Unlike conventional ink printing, cold foil printing is not forgiving when the photopolymer plate and the substrate have been contaminated with dirt. The contamination usually stays in the plate until it is manually removed. Dirt contamination causes large holes in the foil image which are visible to the naked eye. It is highly recommended that a web cleaner, or other means of contamination removal, is used to prevent this problem.

22 Page 20 DRY LAMINATION (CONVENTIONAL) READY, GET SET GO COLD!: 1) Mount the photopolymer plate onto the print cylinder and position the print cylinder into the print station. 2) Prepare the print station using the same procedure when printing inks. Adjust the plate cylinder with a check gauge or you can do it manually. 3) Set the fountain roll and doctor blade and pour the adhesive into the ink tray. Make sure that the adhesive is metered correctly. 4) Load the foil onto the laminating arm and web as described in the Recommended Web Path. 5) Position the nip roll or the spare anvil into the first die station and apply a slight pressure. 6) Make sure that the UV dryer is on, the auto ramp option is off and the heat setting is on LOW. 7) Run the press at around 50 fpm and activate the impression. Set the print cylinder fine adjustment as you would using standard procedures. The cold foil adhesive has been tinted to enable the operator to see the image. 8) Increase the nip pressure at the die station until an image appears. Make sure that even pressure is applied to prevent the substrate from tracking. It is typical to apply a high degree of nip pressure to attain a fine edge on the image. 9) Increase the speed until the image becomes clearer and full foil transfer is achieved. 10) If the resulting speed is too low, increase the UV dryer output to Medium or High until the desired speed is attained. 11)Do not perform a tape or scratch test until post cure is complete (within 12 to 24 hours). A STANDARD PHOTOPOLYMER PLATE CAN BE USED FOR PRINTING THE COLD FOIL ADHESIVE. SET THE PRINT CYLINDER FINE ADJUSTMENT AS YOU WOULD USING STANDARD PROCEDURES. INCORRECT PLATE CYLINDER ADJUSTMENT CAN RESULT IN CROWNING AROUND THE FOIL IMAGE. MAKE SURE THAT THE AUTO RAMP OPTION IN THE UV DRYER IS OFF. MAKE SURE THAT THE NIP ROLL OR SPARE ANVIL AND THE BOTTOM ANVIL ARE COMPLETELY CLEAN. ANY CONTAMINATION WILL TRANSFER TO THE FOIL IMAGE. IF RESULTING SPEED IS TOO LOW, INCREASE THE UV DRYER OUTPUT UNTIL THE DESIRED SPEED IS ATTAINED.

23 Page 21 DRY LAMINATION (CONVENTIONAL) IT IS MANDATORY TO USE SPECIFIC FOILS FOR THE COLD FOIL PRINTING PROCESS. A STANDARD HOT FOIL WILL NOT TRANSFER WIHEN USING COLD FOIL ADHESIVE. ALTHOUGH THE BASIC CONSTRUCTION IS THE SAME, EACH FOIL BRAND HAS ITS OWN STRENGTHS AND WEAKNESSES. FOIL To ensure success. we now provide our own This foil has been specially formulated to perform with all of our Magna-Crtyl cold foil adhesives. Our will work on both dry and wet lamination process and are interchangeable.they are avaiable in: Conventional Colors (Color matching is available) Holographic Security Images. Pigmented It is mandatory to use specific foils for the cold foil printing process. A standard hot foil will not transfer when using a cold foil adhesive. When choosing the right foil, remember that although the basic construction is the same, each foil manufacturer has their own proprietary manufacturing techniques and components. Therefore, each foil has its own strengths and weaknesses. We have tested samples from all of the major manufacturers of foil and found that each one behaved differently depending on the printing job. Each foil has its own properties regarding release, porosity, adhesion, and printability. These factors must be taken into consideration when choosing the right foil for a specific job. There is no one foil construction that can be used for all types of cold foil printing. We recommended that you test the foil for each specific print job. BASIC COLD FOIL CONSTRUCTION TO ENSURE SUCCESS, WE NOW PROVIDE OUR OWN THIS FOIL HAS BEEN SPECIALLY FORMULATED TO WORK IN CONJUNC- TION WITH ALL OF Magna-Cryl COLD FOIL ADHESIVES. ADHESION: Foil adhesion is generally tested with a tape, scratching, or by rubbing the foil image. When a foil image has poor adhesion, it's generally due to the construction of the foil. Our have been formulated to provide permanent adhesion. Remember to perform a tape and scratch resistance test after the assigned 24 hour post-cure. PRINTABILITY: Issues regarding printability occur when a job requires ink to be printed on top of a foil image. Our have shown sufficient adhesion to both water-based and UV-curable inks. On certain applications,such as blister packaging, adhesion requirements are more stringent and will require a good combination of foil, priners, and inks. Consult with suppliers before committing to the job.

24 Page 22 DRY LAMINATION (CONVENTIONAL) TROUBLESHOOTING GUIDE: Problem Possible Cause Solution Foil does not transfer at all Foil transfers for about 30 minutes and then stops to transfer Foil transferring at very low speeds Foil transfer not even across the web Lines showing across the web Cracks across the image Wrong web path Adhesive is over cured Adhesive is contaminated Incorrect foil (hot stamp foil) Contamination from the anilox cells Contamination from the anilox cells Nip pressure uneven Nip roll worn or grooved Stripping angle not correct Web is touching the dryer frame Foil tension is too high Foil is too loose Foil is slipping through the nip roll Foil is sticking to the nip roll. Follow recommended web paths from previous pages Move dryer setting to low and/or increase press speed Wash down the print station with Xylene, acetone and vinegar. Let dry before using. Do not re-use the adhesive in the ink pan Make sure that foil being used has been configured for cold foil Wash down the print station with Xylene, acetone and vinegar. Let dry before using. Adhesive in ink pan can be re-used Wash down the print station with Xylene, acetone and vinegar. Let dry before using. Adhesive in ink pan can be re-used Adjust nip pressure until foil transfers evenly Replace nip roll Change stripping angle Check web path and make sure that the web does not touch the dryer frame. Decrease tension in the laminating arm and waste wind-up Replace with a tighter foil Replace nip with a spare anvil or a driven nip roll Clean or replace nip roll Smeared image Incorrect web path Check web path and make sure that the printed image is not touching any idler roll Rough edges Adhesive is over cured Low nip pressure Foil is too tight Set UV lamp power to medium or low. Increase press speed Increase nip pressure Replace with loose foil. change foil path and let the substrate and foil laminate for a longer period of time

25 Page 23 DRY LAMINATION (CONVENTIONAL) Problem Possible Cause Solution Wrinkles Faded image Large holes in image Pinholes in image Crowning around edges Ghosting Incorrect foil tension Incorrect foil path Low nip pressure Nip roll too soft Contamination in the plate Contamination in the substrate Contamination in the anvil or nip roll Low nip pressure Foil is too loose Incorrect plate cylinder adjustment Incorrect plate cylinder adjustment Incorrect web path Adjust tension in the laminating arm and waste wind-up until wrinkles disappear Check web path and re-web the foil Increase nip pressure Replace nip roll with higher durometer nip Clean plate cylinder Install a web cleaner, a tacky roller or a tacky cloth Clean anvil and nip roller Increase nip pressure Replace with a tighter foil Re-adjust plate cylinder Re-adjust plate cylinder Check web path and make sure that the printed image is not touching any idler roll Foil filling in reverse Too much nip pressure Reduce nip dwell Decrease nip pressure Increase rewind tension Replace nip with a harder durometer nip Poor scratch resistance and foil adhesion Adhesive is not fully cured UV lamp power is too low Bad foil Untested substrate Decrease running speed Increase lamp power to high Replace foil Contact Beacon Adhesive for substrates not listed under section Choosing The Right Adhesive

26 Page 24 WET LAMINATION (CURE-THRU) PRESS SET-UP: [1] It is important that a nip station is located immediately after the print station that will be printing the adhesive. Manual and air actuated nips are acceptable. Wet lamination nip station does not require a high degree of pressure. A die station will not be required for this application, but a secondary nip station must be located after the UV dryer. [2] Re-web the press so that the substrate enters the nip station immediately after the impression cylinder. The printed side of the substrate cannot make contact with any idler rolls between the impression cylinder and the nip station. This will smear the printed image. [3] Relocation of the UV dryer is not required, but it is best to locate it as close as possible to the laminating arm. An idler roll located directly under the UV lamp is highly recommended. This will ensure that the substrate and the foil are perfectly laminated at the point of cure. [4] For ease of operation, the laminating arm and the waste wind-up must be located within the immediate vicinity of the print station. Since the wet lamination process does not require a high degree of pressure, manual, cam and air actuated nips are acceptable. ENTRY NIP: An 85 durometer (or higher) nip roll can be used to laminate the foil onto the substrate. Install this nip roll between the print station and the UV dryer. The foil must be laminated onto the substrate before the UV dryer. A bare idler roll can be used as an anvil under the nip roll. A secondary nip roll must be installed after the UV dryer to strip the foil away from the substrate. When using a nip roll, try to get the highest durometer possible. A low durometer nip roll will cause pinholes. It is important that the foil comes in contact with the substrate at the nip point to prevent air entrapment. This can result in a faded foil image. Make sure that the nip roll and the bottom roller are completely clean. Any contamination will transfer to the foiled image. IT IS IMPORTANT THAT A NIP STATION IS LOCATED BEFORE AND AFTER THE UV DRYER, THIS WILL HELP MAINTAIN SUBSTRATE AND FOIL TENSION DURING PRODUCTION RUNS. SINCE THE WET LAMINATION PROCESS DOES NOT REQUIRE A HIGH DEGREE OF PRESSURE, MANUAL, CAM AND AIR ACTUATED NIPS ARE ACCEPTABLE.

27 Page 25 WET LAMINATION (CURE-THRU) Entry Nip: It is important that the foil enters the entry nip in a 45 degree (or higher) to prevent creasing. It is critical that the foil and substrate is perfectly laminated between the nip and the point of cure. Any crease, air pockets or foil lift will result in poor foil transfer quality. Do not feed the foil directly from the roll, this will crease the foil. Make sure that the idler roll under the UV dryer is level. Any small amount of crease on the web will cause the foil to lift at the point of cure. Substrate Entry Nip Idler roll Foil Foil must enter in 45 degree an- Exit Nip: A secondary nip assembly must be installed after the UV dryer. This will help isolate the substrate and foil in the UV dryer and provide a consistent results job after job. Do not rewind the foil directly to the rewind roll, this will crease the foil. Make sure that there is an idler roll between the exit nip and the rewind roll. Correct Way Exit Nip UV Dryer Foil Stripping with the use of and idler roller after the UV dryer will work but the press operator will need to constantly adjust the waste wind up tension to keep the foil laminated onto the substrate. Stripping with the use of the bottom roller will result in the foil bunching up right before the idler roll. The amount of foil bunching up will increase and will eventually ride up to the UV dryer. Remember, unlike standard lamination process, wet lamination cold foil printing uses a small of adhesive. You cannot rely on the adhesive to keep the foil laminated onto the substrate! Wrong Way Substrate Wrong Way Bottom Idler roller Foil Idler roller Foil bunching up Foil Substrate

28 Page 26 WET LAMINATION (CURE-THRU) IDLER ROLLS: It is important that the printed substrate does not make any contact with an idler roll between the print station and the entry nip station. When webbing the press, make sure that all idler rolls are bypassed in this area. Since foil transfer is achieved at the point of cure, it is highly recommended that an idler roll is installed under the UV dryer lamp. Make sure that there is a good amount of wrap in this idler roll. This will assure that the foil and the substrate are completely laminated at the point of cure. Foil UV Lamp IT IS IMPORTANT THAT THE PRINTED SUBSTRATE DOES NOT MAKE ANY CONTACT WITH AN IDLER ROLL BETWEEN THE PRINT STATION AND THE ENTRY NIP STATION. Substrate Idler Roll SUGGESTED WEB PATH All of the flexographic and rotary letterpress manufacturers now offer a cold foil option for new press purchases. For existing flexo presses, please refer to the recommended web paths below. SINCE FOIL TRANSFER IS ACHIEVED AT THE POINT OF CURE, IT IS HIGHLY RECOMMENDED THAT AN IDLER ROLL IS INSTALLED UNDER THE UV DRYER LAMP. ALLIED GEAR Print Station Entry Nip IT IS IMPORTANT THAT THE FOIL ENTERS THE ENTRY NIP IN A 45 DEGREE (OR HIGHER) TO PREVENT CREASING. UV Dryer Exit Nip A SECONDARY NIP ASSEMBLY MUST BE INSTALLED AFTER THE UV DRYER. For Allied Gear Flexomaster 3, Flexomaster 4, 300 and 500 Series, the UV dryer might need to be relocated in a higher position to allow room for the entry and exit nip station.

29 Page 27 WET LAMINATION (CURE-THRU) SUGGESTED WEB PATH: AQUAFLEX/CHROMAS Foil Unwind Foil Rewind Print Station Entry Nip UV Dryer Exit Nip For Aquaflex LC, DBX, BX, LX, Instraprep and Instaflex, the UV dryer might need to be raised up to allow room for the exit nip station. Install and entry nip station and use the impression roll as the base roll. Install a exit nip station after the UV dryer. Entry and Exit nip stations are available through Aquaflex/Chromas. Install additional idler rollers so that the foil can be webbed correctly. Wet lamination can be accomplished in any print station providing that there is an unwind and rewind within the immediate vicinity. GALLUS STACK PRESS Foil Unwind For Gallus stack presses, the only location to perform cold foil is the top print station as shown below. Install an entry and exit nip station on top of the idler rollers before and after the UV dryer. Make sure that the idler rollers are clean and free of marks. If your press has a hot stamping option, use the existing unwind and rewind. If not, you will need to install an unwind and rewind for the foil. UV Dryer Exit Nip Entry Nip Foil Rewind Print Station

30 Page 28 WET LAMINATION (CURE-THRU) SUGGESTED WEB PATH: COMCO COMMANDER & MSP From Foil Unwind For Comco Commander and MSP, Comco s laminating nip station is required which will be used as the entry nip station. Replace the nip roll with a hard durometer nip (85 durometer or higher). Install a exit nip station after the UV dryer. Install additional idler rollers so that the foil can be webbed correctly. Entry Nip UV Dryer Entry Nip To Foil Rewind Additional Idlers From Foil Unwind Exit Nip Exit Nip COMCO WITH OVERHEAD CHILL DRUM COMCO CADET Entry Nip Chill Drum From Foil Unwind UV Dryer To Foil Rewind Foil Unwind Foil Rewind Exit Nip Print Station Entry Nip Additional Idlers UV Dryer Exit Nip

31 Page 29 WET LAMINATION (CURE THRU) SUGGESTED WEB PATH: ILMA 340 For Ilma 340, a laminating nip station must be purchased for use as the entry nip. Specify a hard durometer nip roll of 85 durometer or higher. Install an exit nip station between the UV dryers. There is no space available for installation of the exit nip station after the second UV dryer. Install additional idler rollers so that the foil can be webbed correctly. Print Station Entry Nip From Foil Unwind Chill Drum To Foil Rewind Substrate Exit Nip UV Dryers Additional Idlers MARK ANDY For Mark Andy Scout 2200, 4150 & 4200 install a nip station on top of the idler roller just before the UV dryer. Install an exit nip station after the UV dryer. Install additional idler rollers so that the foil can be webbed correctly. Foil Unwind Foil Rewind Entry Nip Mark Andy 4150 or 4200 Mark Andy Scout or 2200 UV Dryer Exit Nip Exit Nip Additional Idlers

32 Page 30 WET LAMINATION (CURE THRU) SUGGESTED WEB PATH: NILPETER FA-2500 & FA-3300 For Nilpeter FA-2500 & FA-3300, an entry and exit nip station are available though Nilpeter. Make sure that a high durometer nip roll is specified when ordering the nip assembly. Install additional idler rollers so that the foil can be webbed correctly. Entry Nip From Foil Unwind To Foil Rewind INSTALL ADDITIONAL IDLER ROLLERS SO THAT THE FOIL CAN BE WEBBED CORRECTLY. Press Set-Up on a Nilpeter FA-2500 & FA-3300 UV Dryer Exit Nip Additional Idlers MAKE SURE THAT THE NIP ROLL AND THE BOTTOM ROLLER ARE COMPLETELY CLEAN. ANY CONTAMINATION WILL TRANSFER TO THE FOILED IMAGE. ROTOPRESS 3510 & 3513 For Rotopress 3510 and 3513 an entry and exit nip station are available though Rotopress. Make sure that a high durometer nip roll is specified when ordering the nip assembly. Install additional idler rollers so that the foil can be webbed correctly. Entry Nip Foil Unwind Foil Rewind UV Dryer Additional Idlers Exit Nip

33 Page 31 WET LAMINATION (CURE THRU) SUGGESTED WEB PATH: WEBTRON 1000, 1013, 1618 & 1620 For Webtron 1000, 1013, 1618, &1620, a laminating station can be purchased through Webtron which can be used as an entry nip station. Make sure that the nip roll is replaced with a hard durometer roll. Install an exit nip station after the UV dryer. Install additional idler rollers so that the foil can be webbed correctly. Entry Nip Foil Unwind Foil Rewind UV Dryer Exit Nip Additional Idlers PROCESS GUIDELINES JUST LIKE FLEXOGRAPHIC PRINTING, COLD FOIL PRINTING WILL REQUIRE A SKILLED OPERATOR TO CONSISTENTLY PRODUCE HIGH- QUALITY PRODUCTS AND P ROFITABILITY. HALFTONE AND SCREEN WORK HAS A TENDENCY TO FILL IN IN THE WET LAMINATION PROCESS. CHOOSING THE RIGHT JOB: Cold foil printing is possible for any type of job that is normally printed in a flexographic or letterpress. As with any new process, you must carefully review the job and consider the current capabilities of your press. Remember that wet lamination cold foil printing will take up a print station, laminating arm and waste wind-up. Just like flexographic printing, cold foil printing will require a skilled operator to consistently produce high-quality products and profitability. PRINTED DESIGN: Since the concept of wet lamination cold foil printing requires the adhesive to cure while it is laminated to the foil, it has its limitations. Halftone and screen work has a tendency to fill in in the wet lamination process. For absorbent substrates, more adhesive lay down is required to compensate for the soak-in. CHOOSING THE ADHESIVE: There is only one type of adhesive that is currently available for wet lamination. Note that the adhesives for wet and dry lamination are NOT interchangeable.

34 Page 32 WET LAMINATION (CURE THRU) Magna-Cryl use for paper substrates: There is only one version of Magna-Cryl This has been tested for use on paper, PP, OPP and BOPP. Magna-Cryl 4520 is a free radical adhesive and can be printed over free radical UV-curable inks, coatings, and water or solvent based inks. Other types of substrates: We are constantly testing new adhesives for film applications. Please contact Beacon to get an update on new developments. For specialty and custom film applications, we can perform a test run to study the compatibility of the adhesive to the substrate. Magna-Cryl 4520 Color: Green OVERCOAT AND LAMINATION: The Magna-Cryl 4520 Series has been designed to withstand the standard tape and scratch resistance tests. Over-coating and lamination are not required to protect the printed image. Press Speed: fpm Viscosity: 900 cps CHOOSING THE RIGHT ANILOX: Starting point is a ceramic anilox with 300 line, 6.5 bcm. The logic in-line count is the same as for UV inks. Fine detail will require higher line count while large block areas need lower line counts. We recommend the use of a doctor blade to maintain consistency and even distribution of the adhesive. For uncoated paper stock, use a lower line count to compensate for absorption. PREPARING THE PRINT STATION: The Magna-Cryl 4520 is a free radical adhesive. Although these adhesives are compatible with water and solvent based inks, the print station must be cleaned thoroughly to avoid any adhesive contamination. If the print station was used with water or solvent based ink, it must be washed with vinegar prior to use for cold foil printing. If there is any dried ink in the anilox cells, clean with Xylene and then dry with acetone. Make sure that the solvents have sufficiently evaporated prior to pouring the adhesive. LAMINATING ARM AND WASTE WIND-UP: Set the tensions on both the laminating arm and waste wind-up to low. Tension setting should be maintained just enough to remove the slack. High tension will cause the foil to travel faster or slower than the substrate and will result in rough edging and a smeared foil image. REMEMBER THAT WET LAMINATION COLD FOIL PRINTING WILL TAKE UP A PRINT STATION, LAMINATING ARM AND WASTE WIND-UP. SINCE THE CONCEPT OF WET LAMINATION COLD FOIL PRINTING REQUIRES THE ADHESIVE TO CURE WHILE IT IS LAMINATED TO THE FOIL, IT DOES HAVE ITS LIMITATIONS. THE ADHESIVES FOR WET AND DRY LAMINATION ARE NOT INTERCHANGEABLE. THERE IS ONLY ONE VERSION OF MAGNA-CRYL IT IS A FREE RADICAL ADHESIVE WHICH CAN BE PRINTED OVER FREE RADICAL UV- CURABLE INKS, COATING, AND WATER OR SOLVENT BASED INKS.

35 Page 33 WET LAMINATION (CURE THRU) COLD FOIL PRINTING DOES NOT REQUIRE A SPECIAL PHOTOPOLYMER PLATE. THE UV LIGHT THAT CURES MAGNA-CRYL 4520 MUST NOT VARY IN ENERGY OUTPUT AS THE PRESS CHANGES SPEED. SINCE FOIL TRANSFER IS ACHIEVED AT THE POINT OF CURE, IT IS HIGHLY RECOMMENDED THAT AN IDLER ROLL IS INSTALLED UNDER THE UV DRYER LAMP. COLD FOIL PRINTING IS NOT FORGIVING WHEN THE PHOTO- POLYMER PLATE AND THE SUBSTRATE HAVE BEEN CONTAMINATED WITH DIRT. PHOTOPOLYMER PLATES: Cold foil printing does not require a special photopolymer plate. A standard.067 or.045 plate can be used. Standard sticky-back tapes and print cylinders are also required. DRYER SETTINGS: Although the Magna-Cryl 4520 was tested on a 600 watt UV lamp in the 32nm range, most UV dryers installed on flexo presses will easily cure Magna-Cryl The UV light that cures Magna-Cryl 4520 MUST NOT vary in energy output as the press changes speed. Variations will make it difficult to find the window of foil transfer. If your UV dryer has an auto ramp, turn this option OFF. You can vary running speed by changing your dryer setting to low, medium or high. DIRT CONTAMINATION: Dirt contamination from the substrate is an important issue with cold foil printing. Unlike conventional ink printing, cold foil printing is not forgiving when the photopolymer plate and the substrate have been contaminated with dirt. The contamination usually stays in the plate until it is manually removed. Dirt contamination causes large holes in the foil image which are visible to the naked eye. We highly recommend that a web cleaner, or other means of contamination removal, is used to prevent this problem. GASSING: Gassing is a common problem with the wet lamination process and only occurs when printing water-based inks. Since water-based inks have alcohol and amines, these emissions can lift the foil and prevent it from laminating with the adhesive at the point of cure. The result is a foil image with small to large holes. Since all waterbased inks have different formulations, it is difficult to determine which inks system works best with cold foil printing. Example of air pockets AIR POCKETS: Air pockets are the result of bad nip angle. This can be resolved by changing the angle of nip, please refer to page 25 for correct the nip angle.

36 Page 34 WET LAMINATION (CURE THRU) READY, GET SET GO COLD!: 1) Mount the photopolymer plate onto the print cylinder and position the print cylinder into the print station. 2) Prepare the print station using the same procedure when printing inks. Adjust the plate cylinder with a check gauge or you can do it manually. 3) Set the fountain roll and doctor blade and pour the adhesive into the ink tray. Make sure that the adhesive is metered correctly. 4) Load the foil onto the laminating arm and web as described in the Recommended Web Path. 5) Apply a slight pressure on the nip roll. 6) Make sure that the UV dryer is on, the auto ramp option is off and the heat setting is on high. 7) Run the press at around 50 fpm and activate the impression. Set the print cylinder fine adjustment as you would using standard procedures. The cold foil adhesive has been tinted to enable the operator to see the image. 8) Increase the nip pressure until an image appears. Make sure that even pressure is applied to prevent the substrate from tracking. 9) Adjust the tension on the laminating arm and the waste wind-up and make sure that the foil is traveling the same speed as the substrate. 10) Increase the speed until the image becomes clearer and full foil transfer is achieved. 11) When increasing speed during a production run, make sure that a sample is tested to ensure that the adhesive has been fully cured. 12) Since the adhesive will be fully cured, a tape or scratch test can be performed at this time. A STANDARD PHOTOPOLYMER PLATE CAN BE USED FOR PRINTING THE COLD FOIL ADHESIVE. SET THE PRINT CYLINDER FINE ADJUSTMENT AS YOU WOULD USING STANDARD PROCEDURES. INCORRECT PLATE CYLINDER ADJUSTMENT CAN RESULT IN CROWNING AROUND THE FOIL IMAGE. MAKE SURE THAT THE AUTO RAMP OPTION IN THE UV DRYER IS OFF. MAKE SURE THAT THE NIP AND IDLER ROLLS ARE COMPLETELY CLEAN. ANY CONTAMINATION WILL TRANSFER TO THE FOIL IMAGE. SINCE THE ADHESIVE WILL BE FULLY CURED, A TAPE OR SCRATCH TEST CAN BE PERFORMED AT THIS TIME.

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