Selecting and Processing Synthetic Papers

Synaps® synthetic papers provide 
printers with new sales opportunities
 to produce large format graphics, 
such as window posters, 
Point-Of-Purchase prints
 and tradeshow graphics.

The marketing experts tell us that products are made in factories, but brands are made in the mind. Through creative branding, that’s how "synthetic paper" was sold as a replacement for  traditional paper made of natural fibers. Make no mistake about it, synthetic papers are plastic films engineered to look like paper, feel like paper and print like paper. 

The big difference is that synthetics outperform paper. They resist water, grease and chemicals. Exposed to the sun, they exhibit minimal yellowing. Above all, unlike regular paper, they don’t tear. That makes them a great choice for demanding, long term applications.

The durability of synthetics opens up new opportunities for printers to produce maps, menus, cookbooks, children’s books, as well as for more demanding outdoor applications, such as banners, window posters, bus shelter graphics and on-premise signage.

Within the “catch all” synthetic paper classification is a wide range of product constructions specially formulated for all types printing technologies, including flexographic, gravure, offset, screen printing, as well as UV inkjet, latex, dry toner/laser and Indigo printing.

In producing temporary license plates, 
the state of Indiana uses a Ricoh 
dry toner printer to print variable data on
SYNAPS XM by Agfa.  Its optimized
 top coating withstands high fuser heat printing 
and ensures excellent toner adhesion.  

These product constructions include many different base materials, such as high density polyethylene, polypropylene, polystyrene and biaxially oriented polyester. Hybrid products combine synthetic and cellulose fibers. Some of these films are top coated; others are not. Synthetic papers are also available as pressure sensitive alternatives to vinyl films. Unlike some vinyl print media, synthetics contain no lead, no phthalates and no chlorine.

For outdoor graphics and other demanding applications, polyester based synthetic papers, such as Synaps® by Agfa, provide unmatched performance.  As a thermoset plastic, polyester resists heat better than thermoplastics, such as polypropylene, polyethylene and polystyrene, which tend to deform at higher temperatures. Polyesters also provide better chemical resistance, dimensional stability, rigidity and tear resistance.

While uncoated synthetic papers and nearly all top coated synthetics require special inks, a few synthetics feature top coatings that have ink absorbent properties and can be used as “drop in” replacement products for wood pulp papers. Top coated products, such as Synaps® OM, are compatible with standard offset inks, along with UV and latex inkjet inks. In addition to being receptive standard offset inks, top coatings also promote faster drying and crisper reproduction of the printed image.

For outdoor promotional banners,
synthetic papers provide a low cost
alternative to scrim vinyl banners.
Agfa’s Synaps® OM, pictured above,
was printed on an HP latex inkjet printer
and exposed to the elements for 6 months.

Some top coatings, such as the coating on Agfa’s Synaps® XM, are formulated to withstand the high heat of dry toner digital printing. In these products, the toner fuses with the coating, creating a durable finished product which does not require lamination for most indoor applications.  That eliminates one more production step as well as an expensive laminate.

For demanding applications, clear coating or lamination may be appropriate. Many synthetic papers will withstand outdoor applications. That doesn’t mean that the printed image is fade resistant. Printers may explore fade resistant inks.

As you are investigating the requirements of a job, make sure that you fully understand how the graphic will be used. Will the graphic be exposed to direct sunlight? How will the graphic be cleaned? Will the print be subjected to abrasion?

By conducting a thorough sales survey, you will better understand the customer’s needs, so that you can provide a product solution that satisfies his or her expectations. The survey process will also allow you to probe for dissatisfaction with their current supplier.

Production Requirements. If you are unfamiliar with synthetic papers, you will need to research the available products. The first step in qualifying new print media is to review the manufacturers’ technical data sheets and safety data sheets. These bulletins should explain how their products can be used and processed.

Because there are so many variables from one synthetic paper to another, and from one print environment to another, the next step is to evaluate the product on the production line. Conducting side by side tests will allow you to compare how these products run on the press.

Changing Behaviors. The big challenge in printing synthetics versus wood pulp papers may involve prejudices of press operators. Each synthetic product is unique, with distinct physical attributes.  Generally you will need to go through some learning curve in running a new print media. That’s a challenge in some shops, because press operators are often not willing to change their behaviors. The best products are the “drop ins” that don’t require special inks. But there are not many of those around. For that reason, a new print media requires some education on matters, such as conditioning, static, laminates and clear coating and notch sensitivity.

 Synaps® PS is a pressure sensitive 
synthetic paper alternative to vinyl films.

Conditioning.  Before you print a synthetic paper, condition the stock.  The day before running a job, bring the material into your shop, open up the package and allow the substrate to stabilize to the environment. This is especially important in the winter, when you are bringing in material from a cold warehouse into a warm shop. Colder media may take longer to dry.

Static.   Static builds up in plastic, when one sheet slides across another and dislodges electrons from the surfaces. This occurs more readily with uncoated films than with top coated sheets.  

Static causes a variety of problems. With the buildup of static, sheets may have difficulty separating, resulting in paper jams. Static also attracts dust, which detracts from the printed image. Static related problems are exacerbated when plant humidity is low. Ideally, to minimize static problems, maintain shop temperatures at 70° F with relative humidity at 50%.  Grounding of printing presses can also help dissipate any buildup of an electrical charge. Static eliminators on the press can also neutralize  static, which helps minimize problems, such as spider-webbing and dust attraction.

When printing specially-formulated synthetic papers on a dry toner/laser printer,  the following steps can minimize static:

I.        While some presses duplex synthetics with no problems, quite often it is best to print one side, let the sheets sit overnight to dissipate static and heat, and then print the second side the next day. 

II.       Before loading the printer, lightly fan all four edges of the ream. This usually discharges any residual static in the stack. 

Offset Powder. With most synthetic papers, you can prevent offsetting by spraying a coarser powder (ideally particles will be at least 40 microns) between the sheets. Excessive use of powders, however, can deaden the brilliance of the printed colors or result in a mottled image.

Added Protection. While overlaminates and clear coats are generally unnecessary, they can improve fade resistance, and chemical and water resistance, as well as improving the aesthetic appeal of the print. To protect against abrasion, multiple coating may be needed. Both water-based and oil-based varnishes have been used successfully. Sometimes thicker coatings are required compare to paper. To avoid any unpleasant surprises in production, always test the coating prior to running the job.

Notch Sensitivity. While synthetic papers are tear resistant, some plastic films are notch sensitive. To avoid tear out, take the following steps in finishing:

• When guillotining stacks of material, always use sharp, clean blades.
• When you are die cutting, use sharp hard steel blades with rounded inner corners. Avoid inside die-cuts less than or equal to 90 degrees.
• When drilling holes, use sharp drill bits, free of nicks. Tip: For best results, use Teflon coated bits.  Spraying the drill bit with ‘dry silicone spray’ facilitates drilling and significantly extends the life and sharpness of bit.                                                              

Conclusion. Whenever a job requires resistance against tearing, chemicals, grease and water, synthetic paper is the right choice. Today, you have a long list of products, each with its own unique physical properties and advantages. In addition to tags, pressure sensitive labels, synthetic papers provide you with new sales opportunities to produce large format graphics, such as  pressure sensitive window posters, roll up banner stands, Point-Of-Purchase prints and tradeshow graphics. 

Nekoosa Coated Products: Headquartered in Nekoosa, Wisconsin, Nekoosa Coated Products is known for 45 years of innovation in carbonless paper technology and more recently an expanding line of specialty products. The portfolio of specialty products includes: Synaps® OM and Synaps® Digital XM, premium synthetic papers from AGFA; MagneCote®, the world’s first magnetic paper; a full line of FSC®-certified (Forest Stewardship Council) digital coated papers and other specialty papers. Wingate Partners of Dallas, Texas acquired Nekoosa Coated Products in October of 2012. For more information on Nekoosa Coated Products, visit www.nekoosacoated.com or view our educational videos at Nekoosa Coated Products YouTube Channel

About Jim Hingst: After fourteen years as Business Development Manager at RTape, Jim Hingst retired. He was involved in many facets of the company’s business, including marketing, sales, product development and technical service.

Hingst began his career 42 years ago in the graphic arts field creating and producing advertising and promotional materials for a large test equipment manufacturer.  Working for offset printers, large format screen printers, vinyl film manufacturers, and application tape companies, his experience included estimating, production planning, purchasing and production art, as well as sales and marketing. In his capacity as a salesman, Hingst was recognized with numerous sales achievement awards.

Drawing on his experience in production and as graphics installation subcontractor, Hingst provided the industry with practical advice, publishing more than 150 articles for  publications, such as  Signs Canada, SignCraft,  Signs of the Times, Screen Printing, Sign and Digital Graphics and  Sign Builder Illustrated. He also posted more than 325 stories on his blog (hingstssignpost.blogspot.com). In 2007 Hingst’s book, Vinyl Sign Techniques, was published.

© 2015 Jim Hingst

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