The Foil Blocking Process

Here is our guide to the Foil Blocking Process (From artwork receipt to the finished product)
  1. The client’s artwork is sent to our in-house design studio – preferably a PDF, 100% black and actual size (unless specified) along with a guide for foiling position. See a full list of our artwork requirements here.
  2. We produce either a CNC engraved or an etched die in-house. Dies are metal plates produced in either magnesium, brass or copper to a standard 1.2mm (deeper finishes available on request). More information on our foil blocking dies can be found here.
  3. The die is positioned onto a heated honeycomb machine bed, heated to between 100-175°C and the substrate is prepared for foiling. Find a list of substrates we foil onto here.
  4. Using a combination of heat, dwell time and pressure the foil (supplied on rolls) is transferred onto the substrate. You can find out how the foil works here.
  5. The foil is transferred onto the substrate in the exact position required by the client and will remain on there permanently.
  6. All jobs are signed off by experienced managers and running sheets are checked during the run to ensure the best quality throughout.
  7. Foiled sheets are then sent back to the printer or 3rd party for further finishing (die cutting, gluing etc)
How Does Hot Foiling Work?

A printed copy of this document can be found in our brochure. Click here to request a full Blockfoil brochure.

The Foil Blocking Process
New to foiling? Here are a few more bits of information to help you along.

Does foil transfer to every material?
Generally speaking there is a foil ‘out there’ for every material. The grade of foil being used will depend on what material is being foiled onto. If you’re unsure what foil can be used on your material please get in touch. Also, the colour of the substrate being foiled onto can affect which foil should be used.

What is make-ready and how is it used?
The right make-ready can greatly assist in the quality of the finished job. Make-ready consists of a broad range of products; high-temperature tapes, presspahn, epoxy glass board, spray, blankets and foam to name but a few. For the full range of make-ready consumables see our associated partner Profoil Systems.

What machine will be used?
The machine being used for your foiling job will depend on several aspects. These include the paper size, the substrate material, sheet quantity, foil coverage and how fine the print is.

What is dwell time?
The longer the dwell time, the more foil will be transferred to the substrate. Solid areas generally require more dwell to finer items.