Lead Time Each Added Pass Buys between Approval and Pallet
Each added pass adds 24 to 48 hours of lead time through mandatory inter-pass drying, thermal stabilization, tooling lead times, and offline queue staging.
Micro-Embossing Brass Tooling
Tooling Precision
Precision metal dies featuring microscopically engraved patterns are used to apply detailed textures and foil designs to luxury paperboard packaging. Micro-embossing brass tooling utilizes computer-numerical-control engraving and chemical etching to create complex, multi-level relief patterns on a solid brass block. This tooling allows for the high-speed transfer of fine visual effects onto coated boards and foils, creating a tactile surface that resists wear.
The durability of brass makes it suitable for long production runs where steel dies would be too expensive and magnesium dies would wear out too quickly.
Thermal Conductivity
Fast heat transfer is necessary to activate the adhesive backing of hot-stamping foils during the embossing process. Micro-embossing brass tooling has high thermal conductivity, which allows the die to maintain a uniform temperature across its entire surface during high-speed runs. This consistent heating prevents incomplete foil transfer and cold spots that could ruin the micro-embossed pattern.
Thermostatically controlled heaters on the press hold the dies within close tolerances.
Substrate Reaction
Substrate deformation must be carefully controlled to prevent the brass rules from cutting through the paper fibres. The moisture content of the paperboard must remain stable to prevent cracking. Correct pressure settings ensure sharp definition without tearing the board.