Choosing a Host of Applications with Large-Format Board

When it comes to the world of signage, large-format board plays a pivotal role in the production of certain products. For years many substrates have been tried and tested, while recently new products have come to the market to answer environmental concerns.

One of the big positives of the 2020 pandemic was the huge increase in sustainable initiatives that were embraced around the world. With much of the world hitting pause, many companies had a chance to readjust operations, while consumers re-evaluated their preferences for the way they receive and experience products. People’s renewed appreciation for nature, and the increase of ecommerce meant that fibre-based products become increasingly popular.

This was especially evident in the wide-format print and signage industries, where many new innovations in materials meant that sign-makers could provide new sustainable solutions to brands, retailers, and events (once they were back up and running).

When it comes to rigid boards used for advertising, products can have several different names or references, be it display board, fibreboard, foam board, PVC, corrugated, honeycomb, cardboard panels, wide-format board, or as we have titled this article – large-format board.

So, what are the options currently available in this sector and what can printers and sign-makers consider when using these materials?

Important Substrates

When it comes to using display boards, the applications can be vast, with uses including hoardings, point-of-sale (POS), pop-up systems, exhibition graphics, wayfinding, and window displays.

When it comes to the many products produced by the industry, Venture Banners, a trade-only supplier of large-format print, supplies a large array of options. “We produce a range of graphics on PVC foam board in 3mm and 5mm, lightweight fluted board, and aluminium composite material (ACM) boards,” says Scott Conway, director and co-founder of Venture Banners.

“These are all printed direct-to-substrate with UV inks, can be printed as single-sided or double-sided, and are extremely durable,” Conway adds.

When it comes to the popularity of board materials, Conway points to the durability of these products and their adaptability for long-term installations and regular reuse. While the packaging sector has turned to paper-based products in order to avoid unrecyclable plastics, the signage industry has worked with numerous recyclable materials for a significant amount of time.

Conway explains: “ACM Board is fully recyclable in the UK. The aluminium composite panels are separated from the core material and can then be shredded and smelted for use in new aluminium products, while the polyethylene core material can be granulated and reused in other polyethylene products.”

Conway also points to PVC foamboard as a solid and strong yet lightweight option, which continues to be popular due to its M1/B1 fire-ratings, which makes it compliant with UK and European fire safety standards.

Another option used by Venture Banners is fluted board, with Conway adding: “Fluted board is a flexible and durable, lightweight yet rigid twin-walled polypropylene with a corrugated centre and is commonly used for estate agency boards along with numerous other indoor and outdoor uses.”

With any foam-based products some expansion can occur in heated conditions and direct sunlight, causing the product to warp if there is no room for expansion such as when in a frame

When it comes to working with these substrates, Conway stresses that it's important to choose the right material for each individual use case. “With any foam-based products some expansion can occur in heated conditions and direct sunlight, causing the product to warp if there is no room for expansion such as when in a frame,” says Conway.

“Of course, for many of our customers one of the advantages of working with Venture Banners is that they have access to a wider range of substrates than they might if trying to stock the materials in-house. As a result, they can combine their customer knowledge and our expertise to ensure that every printed board is the right one for the job.”

From Packaging to POS

One of the big drivers of the embracing of fibre-based materials has been packaging, due to the increased use of materials that can be recycled by consumers at home.

A company that would have seen the use of these solutions in both packaging and display products, would be PACFORT, a specialist manufacturer of engineered paper products which it says are great alternatives to wood, plastics, and foams.

Marie Lunt, who works in business development and growth at PACFORT, says her recent appointment at the company has meant helping introduce the brand to the UK market. “Our offering provides the signage industry with a fully recyclable, durable, and printable cardboard panel that meets both sustainability and performance needs,” says Lunt.

When it comes to the products PACFORT offers in this space, Lunt says the business offers two products specifically for the large-format and display industries. “The first product is Hexblanc, a versatile honeycomb core product available in various sizes to meet the unique needs of our clients.

“The second option is our patented Ahblanc product, which features a durable NDC core that provides exceptional strength and longevity, making it ideal for more permanent structures. Each product boasts its own distinct advantages.” Lunt also says that PACFORT is in the process of developing a premium product for sign-makers and display specialists, so has encouraged potential users to watch this space.

When it comes to the environmental benefits of large-format board products, many of the positives may seem obvious.However, with many other materials still favoured for certain applications, and many end-users still not fully embracing recycling, paper product suppliers are continuing to remind customers of the many benefits of their solutions.

Many of our materials, including Xanita and our recycled display boards like Eska, are FSC-certified and designed to reduce environmental impact

Lunt explains: “In short, our products are engineered to minimise waste, extend their usefulness, and reduce overall environmental impact, aligning with a more sustainable approach to manufacturing and usage.”

To demonstrate the key benefits of PACFORT products, Lunt points to areas like material efficiency, cost-effectiveness, recyclability, environmental impact, and eco-friendly development, as positives for paper-based options.

“Both Hexblanc and Ahblanc are designed with advanced core structures (honeycomb and NDC), which maximise strength while minimising the amount of material used,” explains Lunt, who adds: “This reduction in material waste contributes to a more efficient use of resources, reducing overall environmental impact.”

When it comes to cost effectiveness, Lunt says that paper-based materials can be more affordable than alternatives like PVC and can have reduced transport costs, allowing business to balance sustainability with budget considerations.

“As part of our commitment to sustainability, both products are designed with recyclability in mind,” says Lunt, adding: “This means that once the boards reach the end of their lifecycle, they can be recycled or repurposed, reducing landfill waste.

“The materials used in the production of these boards are sourced with sustainability in mind, ensuring a lower environmental footprint during manufacturing. The reduced material usage and efficient production processes also contribute to less energy consumption in manufacturing.”

When it comes to printing on large-format board, PACFORT also suggests testing the materials on machines, gathering samples, and evaluating what works best for your company in order to achieve the quality finish that you want. “Experimentation, collaboration, and ongoing discussions with others are key to finding the most effective solutions,” says Lunt.

An Extensive Range

The popularity of paper and alternative substrates over the past few years has led to a number of new products, including smaller-format media types like traditional paper.

A supplier of a variety of these papers and materials is Antalis, which describes itself as a distributor of visual communication media. The company’s products can be used for a range of applications, including vehicle wrapping, interior decoration, and large-format display solutions.

When it comes to large-format and display boards, Antalis provides products like Katz Board, Katz Outdoor Board, Libra Weatherboard, Libra Display Board, Dispa, and Xanita. Many of the company’s products have been used for numerous award-winning projects in the retail and exhibition spaces.
Speaking of the company’s latest display board release, Paul Neale, visual communication product manager at Antalis, says: “The latest addition in February this year is Eska Brown, the only solid Kraft coloured board available in the market.

“Eska Brown is rigid and flat, made from 100% recycled fibres, offering a natural and sustainable look and feel. With excellent printability using UV inkjet, screen, and latex printing technologies, it is an ideal PVC-free alternative for environmentally conscious businesses and can be easily die-cut and finished to shape making it ideal for POS and display applications.”

When it comes to Antalis’ environmental focus, Neale says that sustainability is at the core of the company’s product offerings. “Many of our materials, including Xanita and our recycled display boards like Eska, are FSC-certified and designed to reduce environmental impact.”

Neale adds: “These products are great at their job and are easily recyclable by the end user after use. They support circular economy principles, utilising recycled fibres and PVC-free alternatives to help businesses reduce their carbon footprint.

“Antalis is committed to driving sustainability and innovation in the signage industry. Through continuous investment in eco-friendly materials and partnerships with leading manufacturers, we ensure our customers have access to the latest products.”

In order to support their environmental claims, many businesses have paired up with accreditation systems or created their own ratings. In order to help customers understand product types and the impact they have, Antalis has created the Antalis Green Star System for visual communication products, which rates media types on a scale of one to five stars.

Neale explains: “The scoring system compares the environmental performance of Antalis products. This classification is grounded in a strict set of criteria based on two key parameters: raw material and end-of-life. The more stars a material has, the more sustainable it is.”

With a variety of products, materials, and build options, it’s clear that large-format board has a whole host of applications with many elements to consider, especially now that sustainability plays such a big part of the process.

Whether using more traditional materials for their reliability and endurance, or new fibre-based products, in order to fit environmental criteria, sign-makers need to continue expanding their substrates.

The more products and solutions at your disposal, the better. With a host of trade-suppliers out there, and quick delivery and sample boxes available, wide-format printers and sign-makers can often be spoilt for choice when choosing the right solution.