Solid Solutions
While equipment choice is critically important to the finished product, sign-makers must also consider the materials they are working with in order to achieve the highest quality possible.
Rigid substrates are used across all manner of signage applications and demand for new and improved solutions is always high. The onus is very much on manufacturers and developers to come up with innovative products that will allow sign companies to continue to stretch the boundaries.
Here, we cast an eye over some of the latest products available to the market and the type of work sign-makers should be looking at in order to grow.
High Quality
First up is Perspex Distribution (PDL), which counts a range of rigid substrates among its portfolio of products. Marketing manager Luke Martyn says there are many important qualities that sign-makers need to be looking for in their rigid sheets based on their end applications.
Perspex says there are a number of important qualities sign-makers should look for in rigid sheets based on their end applications
“A good rigid substrate should be durable and able to withstand the elements outside as well as offering the necessary resistance to scratches, dents, and other physical damage,” he says.
“We offer a range of materials for each application from a ten-year external warranty with Perspex acrylic, to incredibly strong galvanised steel Multishield.
“A smooth surface is paramount for a high-quality direct print and easy application of vinyl or other materials. Even when not printing, a smooth surface ensures a better finish for mounted displays. All our PVC foam and aluminium composite sheets are extruded to the tightest tolerances with a number of ranges being specifically developed for digital print.
“Sign-makers should consider the environmental impact of the substrate they choose, opting for materials that reduce wastage through longevity of display, are recyclable, or made from sustainable sources.”
Delving into the PDL range of products, 80% are made in the UK, Martyn says the company has greatly increased the scope of recycled and sustainable materials within its range in direct response to customers’ needs. Most of its material ranges now offer at least one option with a higher recycled content including some new products with a 100% recycled option.
Stand-out solutions include PERSPEXre, its first range of 100% recycled Perspex cast acrylic sheets. Available from stock across all five PDL branches, Martyn says PERSPEXre meets the growing demand from sign-makers, printers, and end-users for recycled substrates with a long lifespan.
“PERSPEXre is manufactured using 100% recycled methyl methacrylate (rMMA), obtained from Perspex acrylic sheet and production waste,” Martyn says, adding: “This waste is depolymerised using various techniques including a distillation process which recovers methyl methacrylate (MMA), turning this waste back into its original monomer regardless of original colour or aesthetic effect.
“Importantly for sign-makers, the material is produced to the same standards as virgin Perspex acrylic, including a ten-year external warranty, meaning the material is not only 100% recycled but also offers a longevity that greatly decreases the impact of needing to regularly replace the material.”
Looking at current demand, Martyn was keen to highlight the range of bright and vibrant colours available in the Perspex acrylic portfolio. For example, the Perspex Sweet Pastels collection of eight vibrant pastel colours is available now from PDL.
“We also offer a bespoke colour matching service where new Perspex acrylic colours can be produced based on a pantone reference or colour sample,” Martyn says, adding: “Our Colour Matching lab can also produce colours depending on various factors including light transmissions, illumination source, and surface finish such as gloss or matt.”
Sustainability is Key
Elsewhere, Antalis provides a wide range of materials for use across a whole host of projects in both the print and signage sectors. Paul Neale, visual communication product manager at Antalis, says sign-makers should be looking for innovation to help differentiate their offer from suppliers that lead the way with new product introductions.
“Rigid substrates need to perform for a range of applications, indoor and outdoor, and be as sustainable as they can be,” Neale says, adding: “A recent Antalis development was the new Exten Opaque Polypropylene range, including HMPP. We see Exten Opaque PP as the ideal replacement for other materials such as PVC and HIPS.
Antalis’s Exten Opaque was showcased at Sign & Digital UK by swissQprint
“The newest range of opaque grades is an improved shade of white and retains between 98-100% opacity for two-sided printing by way of UV litho, screen, and digital inkjet.
"Large-format sheet sizes, in a range of thicknesses from thin gauge 220µ up to 850µ, make it a great choice for many types of application.”
A unique feature of the Exten range, Neale says, is the Prime-Ex coating applied during extrusion. Prime-Ex not only extends the shelf-life of PP to 12 months, but also improves ink adhesion.
Having been developed initially for horticultural labelling application, it is highly effective in challenging outdoor and wet conditions.
The latest extension to the Exten range is the Visual UV HMPP grades. Neale says that these materials are suitable replacements for a host of other rigid plastics for indoor and outdoor applications.
O Factoid: The latest opaque grades in the Antalis Exten Opaque PP range retains between 98-100% opacity for two-sided printing by way of UV litho, screen, and digital inkjet O
“HMPP is a modified blend containing mineral filler to add rigidity,” he says, adding: “The rigidity likens the material to the stiffness of Rigid PVC and HIPS, whilst retaining all the sustainable benefits associated with polypropylene, which has a lower carbon footprint as well as being 100% recyclable.
“The HMPP grades are a good substitute for PVC, and even foam products for indoor and outdoor signs. Most health and safety signage applications are an obvious area where HMPP could be utilised.
Our strategy is to continue to add polypropylene-based materials to our range in order to drive wider use of this polymer type”
“Our strategy is to continue to add polypropylene-based materials to our range in order that we drive wider use of this polymer type. The existing Antalis brands of Priplak, Exten, Triaprint, Correx, Biprint, and Yupo can all be recycled together. More customers and more applications taking up the use of Polypropylene materials, will help drive the industry toward widespread recycling.”
Desirable Results
Switching to another angle, printer manufacturer swissQprint says its machines can handle a whole host of rigid substrates, making them a solid choice for sign-makers taking on certain types of work.
Stephen Pridham, sales manager of swissQprint, says there are two equally important sides to the equation, and that choosing a quality direct-to-substrate printer from the outset is just as important as the choice of the correct, quality rigid substrate.
swissQprint says printer choice is equally as important as selecting the right rigid substrate
“An informed combination of these two considerations will give the best chance of regularly achieving the desired result,” Pridham says.
“At swissQprint, our range of printers have been specifically designed and engineered to work with an ever-broadening array of substrates to meet the growing needs of PSPs.
“However, even with the correct equipment, failures during printing can still occur, and are often down to incorrect media choice, or handling.
"To reduce these occurrences, the key characteristics that a quality rigid substrate should demonstrate include good lay flatness, an even thickness, a consistent blemish-free finish, and - crucially - good ink adhesion.
“Where applicable, an easily removable, residue-free, liner is also highly desirable. If cut-to-size substrates are to be sourced they need to be ‘square’ cut with no raised, blurred, or frayed edges.”
Going further, Pridham says inconsistent, poor-quality rigid media can adversely affect print quality and printer reliability, sometimes causing significant damage, material wastage, and excessive downtime, with increased costs in operation and damage to a company’s reputation. He adds that the selection of rigid substrates purely on the basis of cost, while initially attractive, can often lead to lower productivity and inconsistent results.
These, he says, are two consequences of buying the cheapest option that may not become apparent until it is too late. “While using quality products might initially seem unnecessarily costly, the decision to 'buy right, buy once' will almost invariably pay dividends in the longer term; a single removal of the need for a reprint could be the difference between profit and loss on a project.
“In an ideal world, the use of the best quality substrates available for every application is of course preferable. There will still be instances where 'standard' substrates might seem sufficient, for high-volume, low-margin applications. But the reduction in wasted materials and production time by using quality substrates may still contribute to enhanced profitability in the long run, even on these projects.”
However, Pridham warned that there are many sectors in the sign-making industry where the use of quality, certified, and tested substrates will also provide print service provider clients with the peace of mind they seek. He offers the example of any application where public liability is a concern or extended durability is required.
“While perhaps initially unseen by the client, this decision, if factored into the value of the work will often contribute to repeat business or new work, from clients looking to source consistent ‘dependable’ media,” he explains.
Finally, Pridham says the benefits of choosing high-quality rigid substrates reach beyond their enhanced performance in printing; with another factor that should not be overlooked being the supply and delivery process.
However well produced, he says 'value' substrates can be easily damaged by poor storage or handling during the delivery phase. Easily crushed substrates such as fluted card being bound too tightly can lead to a significant percentage of the supplied material being unusable.
“Additionally, sourcing media that has not been stored for too long in a delivery hub is also advisable, especially for substrates that have been treated during the manufacturing process to make them more suitable for UV printing,” he says, adding: “Thus, the advantages of buying lower cost rigid substrates can be reduced through wastage, even before printing has begun.”
There is more than enough food for thought here for sign-makers. While the temptation may be there to go down the route of cheaper materials to save on costs for both yourself and the customer, the reality is that you are simply not going to get the high-quality results that you and your clients are after.
Have conversations with suppliers and manufacturers in order to identify the most effective solutions for each project you are working on. This could include highlighting some of the key requirements for the job, such as sustainable targets or the environment where the piece will be installed. Selecting the right material for each job will cut down on errors and allow you to reap the benefits in the long run.
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