Prepress
Grafobal offers comprehensive prepress preparation of orders from the design of the package structure and the new design, the actual processing of the graphics and other documentation with the output to the CTP and the production of printing forms.
The prepared documents are approved of by the customer after each step to ensure the compliance of the real output with their requirements.
Cold foil stamping
Cold foil stamping takes place immediately before printing, directly in the printing machine in one pass. The metallized layer is transferred from the carrier film to the cardboard by means of a special adhesive and pressure without the use of embossing dies. The motif embossed with foil can be printed with conventional colors, which thus acquire a luxurious metallic effect.
In addition, when using one shade of foil, we achieve an almost unlimited color spectrum of metallic shades by suppressing it. Another advantage of cold stamping is the exceptional accuracy with subsequent offset printing.
Cold stamping technology is a separate production technology that does not replace the hot foil stamping method.
The teamwork of a graphic designer and a technologist is a prerequisite for the right decision which of these "stamping" technologies to use for maximum benefit and achieving the desired effect.
Offset printing
It is optimal for multi-colored (postcards) graphic motifs. The maximum printing sheet format of 140 x 100 cm enables the optimization of the lay-out of folding boxes and reduces material consumption, especially for large orders.
As a rule we treat the surface of sheets with offset printing with some of the following technologies: dispersion varnishing, UV varnishing, special varnishing, lamination, hot foil embossing, relief embossing and window patching.
We use machines from renowned German manufacturers like Manroland, Heidelberg and KBA with 2 to 9 printing units and up to two varnishing aggregates.
Components are integrated in each machine to control the print quality throughout the entire process.
We have our own "in house" mixing room for offset colors where apart from standard colors and special colors we also prepare special low migration colors for foodstuffs and colors for the printing of films.
Printed material:
- Paper 50-180 g/m2
- Cardboard 180-600 g/m2
Flexography printing
It is suitable for 1-3 color simple motifs (lettering, logos, symbols) for group and transport packaging with a simple shape cut. The maximum cross-sectional dimension which we can print multicolored flexoprinting of is 1405 x 2810 mm.
Printed material:
- Three-layer laminated corrugated cardboard type G, F, E and B.
- Cartonnage for group and transport packaging from 3 and 5 layer corrugated cardboard
Color mixing room
We have the most advanced dosing and mixing devices for mixing offset colors. They enable mixing three comprehensive ranges of colors in two separate systems directly in the production plant in Skalica, which ranks us among the absolute top European manufacturers of packaging.
For food packaging we use the latest "Full Safe Basic" system for mixing low migration colors that comply with the ISO 22000 standard for food service. We significantly upgraded the original system of mixing standard colors and expanded it with the possibility of preparing special colors on film and non-absorbent surfaces.
We sample the selected shade of color on the specific material which will be printed on.
Water absorption or the shade of material slightly changes the coloring and therefore we then adapt to the desired final shade. In this way we ensure that, for example, group and consumer packaging, which are made of different materials have the same coloring.
We sample the desired shade of color and apply the desired type of varnish to the sample (matte, glossy, UV varnish) so the customer assesses the final coloring after surface processing.
The biggest advantage of an "in house" mixing room of colors is flexibility. If necessary, we can also correct the coloring or add the missing quantity of color, directly during the production of orders without unnecessary downtime. Therefore, we can prepare the calculated amount of color without reserve and thus also save considerable costs.
Varnishing
Varnishing is used to make the design on all or part of the packaging or other printed products more attractive. It also protects the surface of the packaging from damage or provides it with special features such as the desired lubricity, resistance to moisture, grease, high or low temperatures and so on.
We use standard matte and glossy varnishes, special varnishes (high gloss, high matte - "gentle touch", "drip-off" varnish) and functional varnishes (blister, barrier, non-skid, heat-resistant, pearl, low migration for foodstuffs). We obtain very interesting visual effects particularly through an appropriate combination of the varnishes used.
UV varnishing can be performed on line or off line up to the sheet size 890 x 1260 mm.
Lamination
Lamination with transparent film is mainly used to protect products for long-term or multiple use such as exclusive packaging. Mainly polypropylene film in transparent, opaque, soft touch, colored and holographic finishes are used. We use metallic polyester film for exclusive packaging that we subsequently print and varnish.
The advantage of laminating is the high resistance to mechanical damage and the striking visual and tactile impression.
Hot Foil Stamping
Goods in packaging processed by this technology are spontaneously seen by the consumer as exceptional and luxurious with high added value.
This is achieved by a realistic metallic effect on the packaging, or other polygraphic production.
We use gold, silver and colored films, while special films (diffractive, holographic, ..) are used less often. This technology is mainly used in packaging for brand name alcohol, chocolate, desserts, cosmetics and gifts.
Die-Cutting and Embossing
Die cutting machines from the Swiss firm BOBST are capable of cutting out shaped cuts and at the same time also carry out relief embossing in one operation from a printed sheet of paper, smooth or corrugated cardboard.
Machines with so-called two step peeling (breaking) are capable of cutting out the packaging, removing all the waste and dividing the sheet into individual cuts, so that without any additional operation it can be fold processed in the machine.
Window patching
Window patching is an attractive form of presenting goods through the cut out opening in the folding box, which is sealed over with transparent film. We use PET, PE and PVC film for sealing over the cut-out windows, which can also be applied over the corner of the packaging.
A special category of window patching is the production of folding boxes for sanitary towels, for which we replaced PE foil with paper. The sealing over of windows with paper ensures the sanitary protection of towels during gradual consumption and enables the full recycling of the packaging along with the window.
Gluing
We can stack and glue both standard and non-standard packaging designs in 1, 2, 3, 4 and 6 points, including conical packages.
Elimination of the risk of mixing packaging is ensured by the code reader, which automatically sorts each container with a different or illegible code. Bonding with code readers are used mainly for sensitive commodities such as packaging for pharmaceuticals and cosmetics.
The option to apply Braille to the packaging is especially designated for pharmaceutical products.
We produce paper bags with euro cut-outs or without on special machines. They are mainly used for seed packaging, banking purposes or as gift wrap for small items.
