Hot-foil printing transfers a foil finish onto suitable packaging using a heated metal printing block and pressure. It is how a logo moves from an artwork file to a distinctive mark on a jewellery box or gift bag.
But what is the printing block, why is its artwork reversed, and what happens when the foil meets the box? Here is a closer look at the process, using our own Box for Britain branding.
The images are illustrative process visuals, rather than photographs of our workshop or machinery.
1. Start with clear logo artwork
A good result starts before the press is switched on. The artwork needs to work at the size it will appear on the packaging. A logo that looks clear on a large screen may need adjustment when reduced to fit a small ring-box lid.
We look at the design, its intended position and the available printing area. Fine lines, small lettering and closely spaced details need particular attention. The aim is a recognisable logo with a clean impression, rather than simply making every element as small as possible.
A vector PDF or Adobe Illustrator file is preferred. If you only have a different file type, send it to us so we can discuss whether preparation is needed. An artwork proof lets you check the size, wording and position before printing.
2. Turn the artwork into a metal printing block
A printing block, also called a die, is the physical tool that carries the design. It is different from the artwork file: the press needs a raised surface that can make controlled contact with the foil.
Depending on the block material and manufacturing method, metal is engraved or etched away around the artwork. This leaves the printable elements raised above the surrounding surface. Engraved brass and etched magnesium are examples of methods used in hot-foil die manufacture; the illustration shows the principle rather than specifying the block used for every order.
Why is the logo backwards on the block?
The printing face carries a mirror image of the artwork. When it presses onto the packaging, that reversed design produces a correctly readable impression. The raised elements are the parts that transfer the foil; recessed background areas do not print.
3. Transfer the foil with heat and pressure
The block is mounted in the hot-foil press. A thin foil carrier film is positioned between the heated block and the supported packaging surface.
When the press closes, heat and pressure transfer the foil finish where the raised artwork makes contact. The carrier film moves away, leaving the design on the packaging. This is a foil transfer process, rather than ink being sprayed onto the box.
The foil, packaging surface and press settings need to work together. A textured surface can behave differently from a smooth one, which is why printing suitability must be checked for the selected product. Gold, silver and black are among the foil options described in our current branding service.
4. Check the finished impression
The finished branding should be considered as part of the whole presentation: its position on the lid, its scale beside the box, and how clearly the lettering and details appear.
Our example shows gold foil on the outside lid of a black cardboard box. Printing positions depend on the packaging. For our in-house service, top-of-box printing is available on suitable cardboard boxes; Leatherette, Everest and Velvet collections can be printed inside the lid. Send the product reference so we can confirm the options.
Can the printing block be used again?
Yes. Your block can be reused for suitable future printing orders. If you have ordered from us before, mention the previous order so we can check the existing block. A different logo size may require another block, so it is helpful to consider the sizes you want to brand when planning your range.
Questions before ordering branded packaging
What is the minimum order for printing?
Our printing service has a minimum order quantity of 300 pieces. Fully bespoke packaging can have different requirements; we will confirm these for your project.
How long does a printing order take?
Our current guidance is around two weeks for a first printing order while the logo block is set up, and a maximum of one week for repeat printing orders. Include your required date with your enquiry so we can confirm the timing for your order.
Where can I check charges and artwork requirements?
Our Branding & Custom Packaging FAQs explain printing blocks, charges and artwork requirements. For bags or a different packaging project, contact us for the applicable printing quote.
Ready to put your logo on your packaging?
Start by exploring our jewellery boxes and gift bags, or read about our bespoke and logo-printing service.
For a quote, email info@boxforbritain.co.uk with your chosen product, quantity, artwork, preferred foil colour and required delivery date. If you are planning a fully bespoke bag, you can also explore our Custom Gift Bag Builder.
We will help you identify suitable packaging and printing options for your brand.