One of the world’s leading manufacturers of rotary foilers has now extended its product range to offer the ultimate in foiling performance

With more and more label converters looking to find ways of adding value to their products or develop specialised niche markets, it is perhaps not surprising that techniques such as rotary foiling have been growing rapidly in recent years.

With more and more label converters looking to find ways of adding value to their products or develop specialised niche markets, it is perhaps not surprising that techniques such as rotary foiling have been growing rapidly in recent years.

But it’s not only label converters using these techniques. The lightweight carton sector has also begun to see the benefits of rotary foiling on narrow- or even midsize presses, both for added value and for image and effect.

More recently, label producers and users have been looking at methods and techniques for using specially designed rotary foilers as a means of creating security effects and images on labels. Coupled with security foiling is also the whole growth of hologram technology on labels.

Little wonder then that manufacturers of high quality, high performance engraved brass foilers have been experiencing rapid growth in their business. Add to that the capability of supplying foil printing heads, foil savers and hologram equipment, and it sets the scene for why companies such as Fine Cut International are receiving lots of interest in the foil blocking market.

Supplying rotary foilers worldwide – Europe, Americas, Australia, China – Fine Cut have developed an international reputation for foilers which are individually crafted to the highest standards of precision and service. But then that is perhaps not surprising given the company’s early background in the manufacture and supply of high quality engraved brass bookbinding tools.

Today the company still has a division producing bookbinding tool and also has screenprinting, engraving, label press suppliers and hot-foiling divisions. However, it is rotary foilers which now make up the company’s core business. They have also recently launched a Special Machine Division to supply additional periphery products and further options for foiling customers.

With foil blocking on labels and packaging estimated to be growing at 22 per cent per annum the demand for both rotary foilers and all the necessary peripherals is growing rapidly. So much so that Fine Cut look to offer the ultimate in foiling products and service.

With today’s print technology and designs it is vital to minimise the variables that occur. Brass dies are engraved to the very highest standards and the heating of the die is critical to the end results in terms of fit. When heated the die will expand a given amount at a given temperature.

To hold – the best register the temperature of the die must remain constant. Many original foiling stations use electrical elements to heat the dies – a method which is less reliable in terms of temperature control for larger cylinders than the preferred method now offered by Fine Cut, the Activ-Oil system of oil heating, which is designed to retro-fit to most label presses.

Capable of keeping the oil within 2°C of target, from temperature right up to 250°C, the unit can be used at the end of a run to reduce the temperature of the cylinder quickly, allowing for more rapid changeover times.

Within the Impression Control Unit is an oil temperature display and air pressure on/off control, plus other more finite controls. Impression is made by two air cylinders acting on the die mounting blocks, so forcing the brass cylinder against the anvil. When the air supply is cut or the machine is stopped for any reason, the cylinder will automatically lift off impression. This eliminates problems of foil burning onto the stationery foiling cylinder.

Within the Activ-Oil system there is also the option to either cover an existing anvil cylinder or supply as new. The coating is a specially developed compound to allow for the pressures and movements endured whilst foiling to ensure a good quality image.

An optional foil unwind/rewind unit ensures foil tension remains constant, irrespective of speed.

With the rapidly growing interest worldwide in rotary foil blocking the need to have maximum control of foil wastage has also become a priority. Indeed, it’s estimated that some 62 per cent of foil may end up in the bin – a considerable annual cost just thrown away.

Today Fine Cut also supply a range of foil-savers which are built under license from Total Register Inc at their Lancing-based factory, which can reduce foil wastage down to almost zero per cent – and have an average payback period of just 8–10 months.

The foilsavers control the motion independent of press drive, synchronising the foil exactly to the web speed during foil blocking whilst repositioning the foil ready for the next image, therefore, significantly reducing foil wastage.

‘We had been selling Total Register foil-savers for some time’ explained Fine Cut managing director Peter Tyler ‘but the increased demand caused unacceptable lead times in both Europe and the states. It was therefore decided that Fine Cut, with its engineering base, should make the units under license. This has reduced delivery times to around 4/5 weeks – and we have a demo unit available for viewing at the factory.’

In addition to conventional hot foil, the Fine Cut foilsaver is capable of stamping registered holograms and continuous pattern holograms.

‘Few companies can offer the expertise and experience on rotary foil blocking that we can’ says Steve Horne, business development manager for Fine Cut. ‘We can offer all the components needed for foil blocking, from the heating unit and foiler right through to the new foil-saver range.’ Obviously this single source of supply means that the company can offer total professionalism and commitment to the needs of customers looking for the ultimate in foiling performance.

But its not just foiling technology at which Fine Cut excels. The company is also a supplier of high quality flexible dies suited to the conversion of all paper products from business forms, envelopes to self-adhesive labels.

For the cutting of synthetics such as acetate or polyethylene items then the company uses the Super Die which benefits from additional CNC machining, which gives an edge profile ready to tackle the most resilient synthetics. Complementing the supply of flexible dies are the necessary magnetic cylinders.

Additionally the company has embarked upon a Total Quality Management strategy to continually improve its quality and service to customers. Substantial investment in the latest plant and equipment has also aided the company’s pioneering attitude.

The company’s expertise embraces every aspect of machine engraving from the traditional pantograph to investment in sophisticated 4-axis 3-dimensional CNC machines linked to full CAD/CAM workstations and the latest in communications and software.

Placing an order has also been optimised, with details accepted by phone, fax, post, e-mail or ISDN. Advice and assistance on all areas of product selection are offered.

Most recently Fine Cut have instituted an ‘Excellence in 2000’ programme in association with the local Business Link.

The aim throughout has always been to balance the very latest in computer-controlled machinery with a subtle blend of craftsmanship – something, which makes them unique in their attitude to quality.

Certainly this approach has served Fine Cut well to date and looks set to keep them at the forefront of the foiling market for many years to come.