JohnsByrne installs cold foil system to add flexibility and innovation

Founded in 1959, the organization remains a family-owned operation, with founder John B. Gustafson’s four sons, Corey, Jack, Mike and Pate, running the business as president, chief operating officer and executive vice presidents, respectively.

‘We are a very client-centric, customer-focused operation,’ said Corey Gustafson. ‘We look at the marketplace and look for ways to provide solutions to problems our customers are having, and new ways to enhance their current product lines. We try to be very proactive about getting in front of our clients’ needs and the available technology, and the Eagle Systems Cold Foil system proved to be a great compliment to our offering; it was the right fit, at the right time.’

The Eagle Systems Cold Foil system is a module that can be installed on most lithographic offset presses. The foil is applied in-line as the job is being run and can be done by changing a single plate on the press before the run starts, allowing shops the flexibility of printing as normal or printing with in-line foil as needed. Foil is applied using a two-step process, both done in-line on the press. The first is to apply the adhesive to the substrate, using one of the printing units on the press, in register. Second, the foil carrier and substrate are pressed together, and where there is adhesive, the foil will release onto the substrate.

He noted that while the company has, and continues to offer, hot stamping technologies, there were some applications where that process wasn’t a perfect fit. And while there were ways to get it done, Corey Gustafson noted that cold foil, ‘gives us a great deal of flexibility, now, and nuance to our offerings.

‘We can provide different solutions to the same problem, to find the one that best suits the project, product and customer. It’s a different tool in our belt.’

One of the differences they have found is that the Eagle Systems Cold Foil system lays down gradation that is not able to be produced with hot foil stamping.

‘We’re now able to produce halftone gradation similar to that in a printing process,’ continued Corey Gustafson. ‘Talk about solving problems. Also, when we don’t have to take that extra step of off-press stamping, we’re able to save a pass or process — we can run it once, and we’re done at press speeds of 15,000 impressions per hour. It’s innovative, and it saves time and money on those jobs.’

Eagle Systems president Mike King said: ‘I’ve seen a rise in cold foil in recent years. The applications are limited only to the printers’ imagination, and for JohnsByrne in particular, I am excited to see where the company takes it. It offers a new, innovative option it can bring to high-end customers, and gives it the ability to say “yes” to more projects, with less time and money required to make it happen. We are excited to work with them, and we are looking forward to watching where they take this technology well into the future.’