When it comes to eye-catching packaging, Gillette leads the market. They continued the trend by working closely with Diamond to achieve a metallized effect on the packaging for the launch of their premium Gillette Fusion® ProGlide™ shaving system.

Procter & Gamble understands the role that packaging plays in their “First Moment of Truth” (FMOT) initiative, which considers in-store brand perception. The packaging for Gillette’s Fusion® ProGlide™ shaving system still needed to deliver the “wow” factor but do so sustainably and without the use of metalized lamination, added costs, or increased lead times.

As a natural evolution of Diamond’s greenbox initiative, the company applied its tradition of innovation to green packaging design. Diamond’s new Green Chic™ packaging delivers “Beauty without Compromise” by capturing the essence of high profile brands while communicating an environmentally-friendly image and awareness. Diamond demonstrated its Green Chic™ model in the Fusion® ProGlide™ packaging through the use of more sustainable converting methods, including the inline application of MiraFoil® metallic coating and Cast and Cure holographic effects.

MiraFoil® specialty coating delivers “Foil on Demand at Print Speed”. It is an economical alternative to foil stamping which can be applied in-line. The environmentally-friendly coating is recyclable, uses no heavy metals, and results in less material and energy usage compared to an off-line foil stamping process. The conversion to MiraFoil® from foil-laminated board (used in previous versions of Gillette packaging) resulted in reduced costs and shorter lead times.

“The old technology could be recycled but had a different recovery value,” said Michael Marcinkowski, Senior Engineer R&D, Global Package Development. “Plus, it’s harder on the carbon footprint because you have to send the board out to be laminated and then ship it back to the converter. With MiraFoil®, you eliminate that entire process because you can print all in one pass, all on one station, on one machine. The product lifecycle with associated carbon dioxide release is much better. When you do an analysis, such as with the Wal-Mart Scorecard, the MiraFoil® process gives you some wins.”

Diamond applied MiraFoil® in an initial flexo dispersion coater on its new state-of-the-art Heidelberg Speedmaster XL 105 offset printing press prior to printing additional colors and coatings — all in a single pass.

To create the holographic effect, Diamond utilized a cost effective, inline process that produces high-gloss, holographic finishes through the use of UV coatings and specialty film. Because there is no actual transfer of film onto the substrate, the film can be reused several times before new film is needed. This resulted in less material and energy usage compared to an off-line foil stamping process.

“The package is out there and looks great!,” said Marcinkowski. “It has a definite ‘wow’ factor.”

As the Consumer Product Safety Improvement Act (CPSIA) continues to make its way through various legislative hurdles, questions continue to arise regarding lead and phthalate testing and its applicability to finishing operations. Not all finishers are clear as to the testing requirements and the manner in which the requirements will affect their business.

Lead and phthalate testing and certification requirements were to be enforced as of February 10, 2010. However, after feedback from the printing community as well as other regulated industries, stays have been granted by the Consumer Product Safety Commission (CPSC), extending the deadline for testing and certification requirements to December 31, 2011. Manufacturers, however, have been required to meet the lead and phthalates limits since the Act took effect on February 14, 2009.

What is CPSIA?

In August 2008, the U.S. Congress established safety standards for children’s products – including books and items that may be considered toys – under the Consumer Product Safety Improvement Act. The Act set acceptable levels for lead and for certain phthalates, which are chemicals that make plastic soft, and requires third-party testing for lead in certain products intended for children ages 12 or under. As can be imagined, the print and publishing industries reacted strongly to the CPSIA and questions are still arising as to its implications for printers, binders and finishers. The full text of the CPSIA can be found at http://www.cpsc.gov/cpsia.pdf.

What Is A Children’s Product, Children’s Toy and Child Care Article?

According to the FAQ section of the Printing Industry of America’s website:

• The term “children’s product” is broadly defined by the CPSC, as a “consumer product designed or intended primarily for children 12 years of age or younger” and includes such items as children’s books, magazines, flashcards, etc.
• The term “children’s toy” is defined by the CPSC as a “consumer product designed or intended by the manufacturer for a child 12 years of age or younger for use by the child when the child plays” and would include printed materials that have “play value” such as bath books, sticker books, coloring books, etc.
• The CPSC defines “child care articles” as a “consumer product designed or intended by the manufacturer to facilitate sleep or the feeding of children age three and younger or to help such children with sucking or teething” and includes such products as sleepwear and pacifiers.

What Testing Must be Done for CPSIA Compliance?

As noted, the testing requirements were granted a stay and are now taking effect on December 31, 2011. The CPSC is working on a comprehensive testing rule which will detail the testing requirements, such as sampling, frequency and quality control measures. Testing will be allowed to be conducted on either the finished product or each component. Due to work done by the printing community, several key component materials were exempted from the testing and certification requirements by the CPSC on August 26, 2009. These materials are paper, CMYK inks, coatings, animal-based glues, untreated leather, thread for bookbinding and inaccessible parts. Several other components have not been exempted, and they include foils, laminates, spot inks, non-animal-based adhesives, saddlestitching wire and plastic and metal coils for coil-bound products.

Finishers need to be aware of their responsibility in regards to compliance regarding the individual components that are used to make a children’s printed product (e.g., paper, inks, foils, binding components). Component manufacturers should be able to provide proof and results of lab testing and accreditation upon request.

What are Coil Manufacturers Doing to Meet CPSIA Requirements?

Anna Massey, sales and marketing manager for Gateway Bookbinding Systems, Ltd., explained the process the company went through to confirm that its PLASTIKOIL binding is lead- and phthalate- free. “When the legislation was originally initiated, we immediately went to work with our base resin and colorant suppliers. We already knew that our PVC base compound was lead-free and phthalate-free because it is actually a food grade compound. However, we still had our compound supplier confirm through accredited lab testing that the material was well within the <100 ppm lead content and < 0.1 percent phthalate content that was stipulated.” Massey said that because the PLASTIKOIL product is manufactured in 45 different colors, Gateway also had to confirm that all 45 colors met the specifications.

To assist its binder partners, Gateway keeps all lab testing and accreditation on file and available upon request. All of its PLASTIKOIL coil and filament customers are provided Certificates of Conformity, offering assurance that Gateway’s products meet the CPSIA standards.

Matt Roth, vice president for Spiral Binding Co./James Burn, explained that the certification process was relatively simple, albeit expensive. The company knew compliance would be critical to its customers since it was a wire-bound book that started the original lead scare in the United States. “Not only do we support the Nation’s cause to make sure our children’s books are bound safely, we viewed this as an opportunity to distinguish ourselves and our bindery partners from those using low-priced imported wire that might not be CPSIA-compliant and lead- and phthalate-free. With certification on file, our bindery partners can feel confident using our products in their operation and can prove to their customers that the binding elements they use in their books are safe.”

In part two we will examine how CPSIA affects printed products and the use of hot stamping foils.