Standing strong
In many industries it could be said a worker is only as good as the tools they carry. But when it comes to signage, perhaps just as important is the materials and surfaces they are working with.
Innovations in technology and different types of substrates mean sign-makers now have more options than ever with opportunities to innovate with new sustainable alternatives.
Though soft signage is a popular option, providing a lot of customisation and flexibility, in many circumstances only a rigid substrate will give the user what they need.
Cost, accessibility, and even durability are all factors to consider in this area, with recent changes in laws, weather, and pricing making big impacts on the area of substrates.
Going green
When it comes to the signage industry, printMAX has been supplying the wide-format and signage industries with a comprehensive and trusted range of hardware and consumables for almost 20 years. Managing director of the company, Michael Bolton, says: “We’ve carefully selected a great range of products to offer our customers and have great partnerships with both Roland and Mimaki to offer users choice and expertise with both leading product ranges.”
PrintMAX is a Roland, Mimaki, and Summa authorised dealer that specialises in a range of hardware and consumables
It’s printMAX’s experience with a wide array of products that has allowed it to see the changes in rigid substrates throughout the years. “We supply a full range of rigid substrates, from Perspex, PVC foam, aluminium composite, and much more. Our customer base is diverse as are their requirements, but by partnering the great capabilities of LED-UV flatbed printers with the unlimited rigid substrate options, you can create something unique, long lasting, and of high quality.”
Looking at the changes printMAX has seen in customer requirements over the past year, Bolton says: “We’ve noticed an increased demand for environmentally conscious products. The sector has long been calling out for greener solutions, and with the end-customers requiring this from their print suppliers, it’s great to be able to supply products to help in this regard.
The sector has long been calling out for greener solutions, and with the end-customers requiring this from their print suppliers, it’s great to be able to supply products to help in this regard”
“Earlier this year saw the introduction of Palight Re-NU, the UK’s first 100% recycled PVC foam, along with a 100% recycled acrylic and a 50% recycled PETg. I believe with a growing need for environmentally friendly solutions, these are going to be in high demand.”
Luke Martyn, marketing manager at Perspex Distribution, agrees that recycled and ‘green’ products are far more popular, adding: “In response to the needs of our customers, we have greatly increased the scope of recycled and sustainable materials within our range. The majority of our material ranges now offer at least one option with a higher recycled content, including some exciting new products offering a 100% recycled option.”
Perspex Distribution offers a range of sheet materials and LED lighting
With governments now putting more pressures on businesses to decrease the use of plastics and non-recyclable materials, many companies have looked to develop new products to meet customer demand.
“PERSPEXre is our first range of 100% recycled PERSPEX® cast acrylic sheets. Available from across all five of our branches, PERSPEXre meets the growing demand from sign-makers, printers, and end-users for recycled substrates with a long lifespan,” says Martyn.
In order to ensure recycled waste is being used effectively, Martyn states: “We have increased our growing range of recycled substrates with the recent launch of the Palight Re-NU, a 100% recycled PVC Foam in a first for the UK print market. Palight Re-NU is manufactured by Palram in its County Durham manufacturing plant and has been developed to utilise recycled waste from its end-users and production line.
“Palight Re-NU is produced as a co-extruded PVC providing a constantly reliable white surface allowing print professionals to get the best image quality and colour accuracy from their printers. The 100% recycled content contains a mixture of post-consumer waste recycled from end- users, as well as pre-consumer waste processed via Palram’s own in-house recycling centre.”
Knowing your product
New products and ways of working have meant that businesses have been collaborating more than ever in order to stay relevant and work in the most streamlined and effective way.
Trade only manufacturer for the signage industry SignFab has been in the industry for over 20 years, giving it a wealth of experience with different materials and partners.
SignFab’s waste contracts ensure a large proportion of its manufacturing waste is recycled
Steve Muton, production director explains: “As trade suppliers, we do not work directly with end-users; however, through our connections with Make it Happen Signage Consultancy, we are aware that there is a move toward many retailers, universities, and local authorities asking for the eco-credentials of the materials used.
“As metal fabricators, SignFab already works daily with materials that have high recycled content and are readily recycled. In fact, International Aluminium, the global body representing the aluminium industry, states that 75% of the 1.5bn tonnes of aluminium produced is still in circulation today.”
Discussing commonly used materials, SignFab still sees consistent demand for the likes of mild steel, stainless steel, aluminium, aluminium composite, and acrylic. However, Muton says trends in the marketplace have seen demand for copper and brass signage increase leading to new laser investments.
As described by Muton, SignFab has demonstrated the collaborative side of the industry as it has worked with Make it Happen Signage Consultancy as a facilitation partner for its signage workshops.
SignFab has demonstrated the collaborative side of the industry as it has worked with Make it Happen Signage Consultancy as a facilitation partner for its signage workshops”
Through this partnership the two companies have been able to network together and understand the needs of the industry as a whole. Make it Happen’s workshops mean that hundreds of employees in the signage industry are able to get hands on experience with materials and processes that further the knowledge on rigid substrates, and sustainable credentials.
Aimee Davies, Make it Happen’s brand consultant and creator of the Sustainability Bootcamp, says: “Organisations and brands are increasingly communicating their sustainability intentions, while some actively communicate this through their choice of materials.
Thanks to her knowledge of the industry and sustainability, Davies has had a first-hand look at the transition into greener materials. “A natural aesthetic is increasing in popularity, which, taken to the extreme, has seen a rise in feature walls and signage incorporating plants and greenery. The use of wood is also on the rise, but buyers and suppliers must ensure materials are FSC-certified, or else they could be supporting illegal activities and deforestation.
“Demand for greener supply chains is increasing globally as organisations look beyond their immediate sustainability commitments and ask more discerning questions from their suppliers. I have had conversations with people who have lost projects because they couldn’t meet the new green criteria being asked of them. I can see buyer demand shaping the rigid substrate market increasingly towards more sustainable materials, but there is a huge knowledge gap in the industry.
“People will need to catch up on sustainability matters and materials or else get left on the shelf, while savvier companies get on board. What was once niche is increasingly becoming mainstream.”
Traditional materials in signage continue to evolve, especially as previously well-used materials become more difficult to recycle or reuse. Speaking about the use of PVC, Davies says: “There is an increasing awareness that these products are either incinerated or else release greenhouse gasses when they break down.
“Many retailers and brands are now putting their foot down and demand PVC-free alternatives, this has driven a wave of innovation that has seen a host of new rigid materials emerge.”
The move to more sustainable materials has meant an increased popularity in alternatives such as wood and paper board which has brought new businesses to the signage industry.
Sole UK manufacturer of recycled paper honeycomb, Dufaylite Group has helped bring innovation to the print and signage industries.
Managing director at Dufaylite, Ashley Moscrop says: “Traditionally popular is our Ultra Board Graphic and 3D products. Ultra Board has a honeycomb core and is created from recovered fibres, so it’s already had at least one life before even reaching the printers. 66% of the paper used to create the board is already recycled making it an easily recyclable product.
Dufaylite launched its Design Lab earlier in the year to help collaborate with clients
“Ultra Board 3D is available in 10mm and 16mm thickness. Better for the environment, the product uses significantly less paper, due to the hexagonal honeycomb core, and the 16mm is almost 28% lighter than its corrugated centred competitors, whilst boasting the similar strength and capabilities. 3D Board is a real game changer and provides a great alternative to the market, making life even easier for printers.”
Supporting the already established collaboration in the industry, Dufaylite has worked with suppliers such as Premier Paper, and also supports clients in finding the right solution for them.
Moscrop adds: “We have also launched a new dedicated design website to meet the needs of printers, which provides technical help in the form of cutting files of different designs to help users understand how to work with our materials better and create more creative solutions.
“We pride ourselves on innovation and as such are continually developing and launching new products to meet the needs of the market. Our different thicknesses provide varying options and use significantly less paper, keeping it light whilst remaining strong.”
The future of rigid substrates
Though the future looks brighter for sustainable and eco-friendly materials, increasing costs and restrictions on the likes of energy and shipping has currently put a squeeze on many industries in the UK and across the world.
One industry reliant on the materials that are seeing increases is the signage industry, especially when it comes to rigid substrates.
Bolton says: “The stock challenges faced at the end of the pandemic impacted the entire industry, and the increase in costs undeniably affected this sector. However, the overall cost of producing printed rigid substrates remains a cost-effective method of application. UV flatbed printers are low-energy producers, plus by removing the need for lamination, vinyl application, and added processes, you’re ultimately removing costs from the production of a standard sign.
“The direct-to-substrate market will, in my opinion, continue to grow as users look for quicker, cost-effective, and diverse processes, without compromising on quality.”
Martyn adds: “Like all businesses in the UK, we have been impacted by the various increases in fixed costs caused by rises such as energy costs.
“One benefit within our product range is our large focus on UK-manufactured products. Over 80% of our products are manufactured in the UK. This was particularly beneficial when shipping costs and delays from the Far East were causing issues for some manufacturers.
“The efficiencies of distributing a product manufactured close to our end market has driven Perspex Distribution to focus on its UK supply chain. Sign-makers are also increasingly looking at where their materials are sourced from and how long their journey from factory to installation really is. Over 80% of our range is manufactured in the UK, including Aluminium Composite, PVC Foam, Polycarbonate and PETg, reducing the lifecycle mileage and CO2 footprint within our product range.”
The increasing of costs, and even the newfound popularity of certain products can all have knock on effects to businesses. While paperboard has been embraced for its green credentials, this newfound popularity, along with ramifications from the pandemic, has put a greater demand on paper.
Moscrop says: “Unfortunately, we have come under a lot of pressure from increasing paper prices. The paper manufacturing process uses a lot more energy than others, plus the increased demand for paper solutions has driven up overall costs.
“It really is crucial for buyers to look at the true lifetime costs and not just one-off purchase costs, especially during this tough economic climate. Whilst pretty much everything is increasing in price, there are still the benefits of recyclable solutions, especially with honeycomb boards which really does make it worth the investment. Displays can be made to be longer lasting, and the material is lighter than corrugated centred competitors due to the true honeycomb strength.
“At the end of use there are also financial returns for recycling the product, which offsets against the cost of the material in the first place and the costs to send alternative non-sustainable materials to landfill.”
Speaking of the challenges faced by sign-makers, Davies adds: “The rigid substrate market is a global one that often relies upon worldwide trade and shipping. The pandemic, the closing of ports, and a shortage in shipping containers significantly increased shipping costs and affected sheet aluminium availability and prices. At its peak, the industry saw sheet aluminium materials rise by 75% in just under a year. To maintain competitiveness, some manufacturers could stockpile materials while others used it as a sales tool to hold prices in exchange for early project commitments. At the same time, many struggled to win projects due to inflated material costs or else fell short on making healthy margins.
O Factoid: According to global body International Aluminium, 75% of the 1.5bn tonnes of aluminium produced is still in circulation today O
“The energy crisis now gives the industry a new challenge. With its lower energy consumption, UV print technology will undoubtedly shape our industry moving forwards. I predict a rise in UV printer sales which could see a move towards more direct-to-media printing on a host of different substrates, including ACM and sheet timber. This would also provide potential opportunity for reuse and repeat preprint. I am already seeing hoarding companies and exhibition builders advertising this re-print service for its potential sustainability merits.
“When it comes to fabricated signage, metal substrates will always continue to rule. With their superior strength and durability, they simply hold their own when it comes to any signage product needed to withstand the elements and the test of time. Few, however, appreciate the sustainability merits of metal. Scrap metal and recycling had existed since as early as 440BC when records first began, and the infrastructure to recycle metal is deeply embedded within our culture.”
Certain materials and substrates can become popular at different times of the year
As evident in recent changes to everything from monarchs, prime ministers, and prices, the future is filled with change. Sign-makers continue to use materials that have stood the test of time and have become well used for good reason.
But new products and approaches to circular economies have meant many are keen to change processes and mindsets. While the current trajectory might be rocky for the likes of costs and materials, the innovations and partnership within the industry give good reason for sign-makers to remain optimistic that things will get better.
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