Presented by Don Burdge - 07/21/2011

Both are tactile print processes which improve both reader retention and response. Beyond that, one is hard pressed to think of greater opposites.

“Wanting to achieve the feeling of a handcrafted, tactile,

enduring and authentic printing – a depth of ink that sits above

the surface of the paper is very appealing to designers and print

buyers today” says Sabine Lenz, founder of PaperSpecs.com. “But

they are savvy buyers who have lots of questions about the cost

of the materials and processes and their environmental

implications.”

History of Processes

Reputations of each

How they’re made

Environmental Impact

Advantages & Drawbacks

Ideal Products for each

Ideal Paper SpecsPrice comparisons

Preparing Artwork

Questions & Answers

Agenda

Engraving: The oldest printing process

Engraving pre-dates the 1440 Gutenberg Press

Early engraving was made with hand-etched dies

Metal plates were introduced in the 1440’s

Engraved recesses are still filled with ink

Paper is still pressed against the die with as much force possible

Hand etched engraving plate

Etching detail

Modern Engraving Plates

Reputation of Engraving

Engraving has been revered as the highest form of printing craftsmanship

Its exclusivity boosts its appeal for premium printed communications and other applications where authenticity is essential

Engraving connotes prestige

Most royal proclamations included engraving to ensure authenticity (seals, crests, and/or titles)

Engraved Invitation

Engraved Invitation

The Engraving Process

More labor intensive

requires separate dies for each color

image area must be within 4 ½” x 9” per die

image must NOT be further than 7 ½” from the edge of the sheet

presses apply 4000 psi of pressure to the paper which causes bruise on back of sheet

Cannot run as fast as other print processes using cylinders

Hand-fed Engraving Press

Hand-feeding

Inking unit

Environmental impactof Engraving

has come to be recognized as the “greenest” print process

Zinc and Copper plates recycled

engraving inks are entirely water-based making them ideal to recycle

engraving inks emit zero volatile organic compounds (VOC)

engraving inks are cleaned of presses using water as opposed to solvents used

for offset printing

Recycling used plates

Advantagesof Engraving

Sharpest detail work possible

Will not “melt” in desktop or laser printers or high speed copiers

Metallic colors reflect light and shine when burnished (embossed with a

second pass without ink)

Engraving ink is opaque and sits on top of paper, as opposed to staining

the fiber of paper. Good for light colors on dark stocks.

Engraved Print

Engraving Detail

Engraving detail

Engraved 1.5 inch Logo

Drawbacksof Engraving

Limited to 4 1/2 “ x 9” image area

Limited to running one color per press run

Cannot reproduce process color, screens or gradients

Back of paper will have a bruise, not great for 2 sided printing

Engraved solid colors can either have a modeled or screened look

Image can run or “spit” on some paper finishes; like linen paper

Can be expensive - depending on run length, image area and number of colors

Engraved Solid

Engraved solid Detail

Where authenticity is necessary (US currency is still engraved to deter counterfeiting)

Invitations, Announcements and Corporate Brand Collateral - To connote prestige and quality

Stationery - Will not melt like thermography when run through laser printers

For Products when environmental impact is a priority

For designs with extremely fine line or intricate detail work

To enhance reader retention by adding texture to printed products

For specifications of light printing on dark stock

Ideal Usesof Engraving

Engraved US CurrencyEngraved US CurrencyEngraved Logo

Engraved Invitation Suite

Thermography

“Thermo-grave”

“Engrave-o-print”

“Fried-printing”

Thermography has only been around since the mid-1900’s.

Became possible when thermo-plastic resin arrived as a by-product of petroleum refining

Arrived without any historical cache

Sold as raised printing for half the price

Thermography struggled to find an audience in graphic communications

Only captured engraving’s audience when various printers gave it trade names like “Thermo-grave” or “engrave-o-print”

Thermography: Engravings wanna-be

The Thermography Process

Begins with offset printing (Lithography)

The paper is dusted with resin powder while the ink is still moist

Resin is vacuumed off the sheet, only leaving it on the ink

Paper passes through a heat tunnel which causes resin to swell

Multi-color thermography requires only a single application of resin for full color work

ThermographyMachine

Text

Offset (Litho) Press

Environmental Impactof Thermography

Petroleum-based resin has a negative environmental impact

Thermoplastic resin is considered a toxic waste by-product in the recycling

process

UV-cured thermography cannot be recycled at all and will never decay naturally

Collected Chemical Waste

Advantagesof Thermography

Faster Presses than engraving

Lowest cost for raised printing

Shiny finish with pockmarked solids, which can be an asset in some designs

Can be run on any size litho (offset) press with print area limited only by the heating tunnel; most common tunnel size is 11” wide

Ideally suited to very large, solid coverage

Business Card with Thermography

Business Card with Thermography

Intermission

• Stand up

• Stretch

• Scratch

• Yawn

• Don’t check your e-mail yet

Drawbacksof Thermography

Not suited for fine serifs, punctuation, or other precise detail

No matter the shape of the image, the final results tend to look rounded

Colors may be distorted from PMS “uncoated” to the “coated” spectrum

Can only thermograph spot colors, not process CMYK

Ink can melt when run through laser printers and high speed copiers

Solid areas of ink appear pockmarked.

Business Card with Thermography

Letterhead with Thermography

Ideal Usesof Thermography

When run lengths or artwork makes engraving impractical

When tactile printing is desired and images are produced in quantities of tens of thousands

When raised transparent spot varnish or raised spot color is desired

Designs can use the specific nature of thermography to achieve some interesting and unique effects

Business Card with Thermography

Clear Thermography Detail

Head to Head

Thermography

50’s TechnologyPoor DetailLarger Print SheetsTransparent InksGlossy FinishCosts Less

Engraving

Old World PrestigeSharp DetailSize Limited

Opaque InksShiny Metallics

Costs More

Engraving and Thermography used for Added Security

Paper SpecsEngraving:

Smooth finish better than Liner or textured to minimize “spitty” type

Hard finish better than soft to minimie bruising

Uncoated better than coasted due to bruise around image area

Heavier stock better that time paper: pressure can “warp” time paper

Neenah Paper better that anyone else ;)

Thermography:

If you can lithography it, you can thermograph it

Generic Pricing

Engraved Business Cards:

250 engraved business cards black ink on white 80# stock.

Gang run price at BurdgeCooper

$52.00

Thermo Business Cards:

250 thermographed business cards black ink on white 80# stock.

Gang run price at BCT

$12.00

Engraved Pricing Factors

Static Tasks - regardless of quantity

1. RIP and Proof file

2. Make file, Etch plate (die)

3. Make-ready die on press

4. Match ink color on press

5. (repeat for 2-4 each color)

6. Minimum time: 1.5 hour

Variable Tasks - quantity dependant

1. Buy Paper

2. Cut Paper to press sheets

3. Run press sheets on press

4. Trim press sheets to final size

5. Inspect and package

6. Minimum time: 1.5 hours

Minimum time: 3 hours + Material

Engraving Plateon Press

Engraving Counter

Thermographed Pricing Factors

Static Tasks - regardless of quantity

1. RIP and Proof file

2. Make plate(s)

3. Make-ready plates on press

4. Match ink color(s) on press

5. 1 or 2 colors run together

6. Minimum time: .75 hours

Variable Tasks - quantity dependant

1. Buy Paper

2. Cut Paper to press sheets

3. Run press sheets on press

4. Trim press sheets to final size

5. Inspect and package

6. Minimum time: .75 hours

Minimum time: 1.5 hours + Material

Therm-o-type machine

First: Identify process call outs on spec sheet

Thermography

If project is only thermographed prepare art like any other spot color print project, identify color swatch as “PMS(xxx) Thermo”

If it is to be used as a finishing technique identify it as a color swatch and label it as “PMS(xxx) Thermo”

Engraving

Color separated line art (each color will require a Color Swatch)

Preparing your artwork

Thank You

Special Thanks for Neenah Paper for Underwriting this Presentation

Special Thanks to Paper Specs.com for Presenting it

Special Thanks to you for attending

Los Angeles

800-421-8703

hughg@burdgecooper.com

Atlanta

800-325-7513

rogerd@burdgecooper.com

To watch videos of Engraving and Thermography and to download this

presentation visit

www.BurdgeCooper.com/paperspecs