Cold Foil : innovation and sustainability in packaging

Zoom on…. the Cold Foil

In a market where sustainability and creativity make the difference, Cold Foil (also known as ‘cold foil stamping’) has established itself as an innovative alternative for packaging metallisation. At EGISA, we have experienced exponential growth in the use of this technology over the last 4 years, simultaneously reducing our dependence on metallised PET. Below, we explore the main advantages of Cold Foil and how this trend is transforming the luxury packaging sector.

What is Cold Foil?

Cold Foil is a stamping technique used to apply metallic effects on a material or substrate, without the need for heat. Unlike hot stamping, which uses heat to transfer the foil in a post-printing process, Cold Foil is applied at room temperature and in-line during offset printing. This allows all stages of printing a case to be carried out on a single press in a single pass, eliminating additional processes, improving efficiency and reducing energy consumption. In addition, the precision of application and perfect offset registration minimise material waste, thus optimising the use of resources.

Striking metallic colours and versatile designs

One of the main advantages of Cold Foil is its ability to create a wide range of colours and metallic effects in a single pass.

The Cold Foil process is carried out on the first bodies of the offset press: it involves printing a layer of adhesive offset ink on the board, followed by the application of a metallic film (silver, gold or holographic). This aluminium film adheres only to the areas where the adhesive has been applied, allowing the metallised areas to be overprinted with different colours, creating unique metallic shades. This versatility is key for perfumery, cosmetics and premium beverage brands looking for striking and sophisticated designs.

A major advantage of Cold Foil is that it offers a ‘’smart and intelligent metallisation‘’ of the cardboard: it is applied only in the areas where the metallic colour or effect is desired, optimising the use of the material and maintaining the original whiteness of the substrate. This is essential in luxury packaging, as there is no need to print layers of opaque white as in other processes using metallised PET, which significantly reduces ink consumption.

Environmental sustainability

Cold Foil contributes significantly to reducing the use of plastics in packaging. Unlike other metallisation methods that incorporate plastic films, such as metallised PET, this technology allows metallic effects to be applied directly onto the carton without adding layers of plastic. This facilitates its recovery and further treatment within conventional recycling processes, without the complications associated with metallised PET.

The aluminium layer deposited on the cardboard is extremely thin (approximately 0.02 μm, i.e. about 6000 times thinner than a human hair, according to Kurz, our main supplier of foil films), so it does not alter the material properties and does not interfere with the recyclability of the packaging.

In EGISA, over the last 4 years, we have reduced the consumption of metallised PET by more than 45%, replacing it with Cold Foil in numerous high-end packaging projects.

Production efficiency and cost reduction

The cold stamping process does not require specific tooling (unlike hot stamping), which reduces set-up times, energy consumption, waste generation and production costs. Furthermore, as mentioned above, it does not require heat to transfer the metal layer, which reduces energy consumption and CO₂ emissions associated with the process, optimising production efficiency. By running in-line during offset printing, the Cold Foil process eliminates the need for additional steps, optimising production time and reducing costs.

Application on a wider range of materials

Until recently, Cold Foil could only be applied on coated materials, those with a light layer of stucco that closes the pore of the cardboard, facilitating the application of the adhesive ink and subsequent adhesion of the aluminium layer. However, thanks to the evolution of adhesive inks, Cold Foil films and our improved application expertise, we can now also offer Cold Foil application on some uncoated materials, expanding the design possibilities in packaging.

A growing trend

The market is increasingly embracing Cold Foil as the preferred option for metallising packaging. At EGISA, Cold Foil consumption has grown by more than 150% in the last three years, reflecting the industry’s transition towards more sustainable and efficient solutions.

Cold Foil not only allows brands to create stunning and sophisticated designs, but also offers clear advantages in terms of sustainability and efficiency. At EGISA, we remain committed to this technology, demonstrating that luxury and sustainability can go hand in hand in the packaging of the future.

Contact us and find out how Cold Foil can transform your luxury packaging projects!