Paper or plastic? No, we are not talking about grocery bags, but rather about the different materials, also known as substrates, that we print on here at Huston Patterson.
When explaining to anyone what HP does, it’s easy to say that we simply “put ink on paper”. We use several multimillion-dollar printing presses, in a wide range of sizes, to lay down inks and coating on paper.
Well…usually it’s paper…
The substrate we print on most is paper, but it’s not always the same type, weight, thickness, or even color. We use several different versions, depending on how the paper is being used to create the final product or package. Our machines are extremely sophisticated and can print nearly anything that an artist can dream up.
Fun fact: The machines that we use in the packaging industry are the same presses used to print United States paper currency at the US Mints.
If we are printing our most used product, a litho label, we put ink and coating onto a thin sheet of white offset paper. Usually a litho label is laminated (glued) to a corrugated sheet, and it completely transforms the packaging. Taking it from a plain brown sheet of corrugate, to a multicolor creatively designed package that will draw the attention of any potential consumer.
Our next most used substrate is board stock. This type of paper is used to make folding cartons (think of lightweight cereal or food boxes), or it can be laminated to single face corrugate. In this process, one less layer of paper is being used to create a corrugated sheet, therefore saving money in the long run. This method creates the same elaborate box as a litho label but is generally used for higher quantity orders due to the savings realized by eliminating one layer of paper.
If we get into the thicker board stocks, they are more widely used for folding carton applications, where the board is thick enough to become its own package without the need for corrugated board. Also, at these thicknesses we are frequently asked to source kraft or brown board stock to print on the natural paper background rather than white. Recyclable and environmentally friendly comes to mind when you see a kraft box with decorative print showing off the product.
Offset paper and board stocks are used in our facilities most of the time, but every so often we get an order or request to print on a different substrate.
Recently, floor decals and signage for practicing social distancing can be seen in most public spaces. Many of these signs are printed on materials that have a thin layer of plastic film on top of the print and an adhesive on the unprinted side. We refer to this as having a “sticky back”. This material can be printed exactly like normal paper, but can be peeled off and stuck in place, like a sticker.
Generally, this type of application would use paper with a thin plastic film on top to protect it from foot traffic, or it would be made completely from a plastic like polymer to make it very durable. If this application used paper without any type of plastic protector, it would not last very long and would need to be replaced much more often to remain effective in its messaging.
We also print on many other types of plastic substrates that are used in various ways. On our digital press, we can print onto Plasticorr (aka plastic corrugate). It is used for reusable boxes for the likes of USPS or Frito Lay, as they are transporting product back and forth from distribution centers to homes and businesses. A reusable plastic box is better for them than using new paper boxes each time. Plasticorr is also commonly seen around your hometown during election time. Nearly all political yard signs are printed on this material. The material is much more resistant to the weather than paper is and has found its home where the elements and frequent handling can take a toll.
Clear plastic is another substrate that we will put ink down on. Often a white ink is involved in this process to help make the background look like paper. This substrate is often seen in a retail setting. Think of a hanging advertisement or pricing card, or a sign that could be exposed to high levels of temperature, moisture or light. This type of substrate is seen as a longer lasting solution to paper signage.
There are many other substrates that we have seen a client request which are marketed as paper but have special qualities to make them unique. One of my favorites is foil paper, which will give a metallic look. Or maybe holographic paper is needed, and we create a hologram using the paper. Or Stone Paper, which has crushed stone and glue mixed in with paper to form a heavy and thick sheet of playable paper.
Being able to print on several different types of materials is a great advantage for us and our clients. Providing options and solutions to package printing is what we do best. We take pride in being able to offer creative solutions, so that our clients can deliver the best product possible to their clients.
If you are interested in learning more about what we do, please feel free to reach out to a Huston Patterson Client Service Manager, including myself – Kyle Milley.
For more tips from the Real People of HP, explore our additional blogs and videos, or contact us directly at Huston Patterson.