UV “Cast & Cure” plus matt/gloss varnishing effects

USP: Strong visual contrasts, holographic effects
Effects: Matt/gloss lacquer effects, resource-friendly holographic effects
Suitability: Cosmetics industry | food industry | tobacco industry
Machine requirements:  4-colour offset press with double coating unit and UV installation plus Cast & Cure stamping unit.
Design requirements: As the desired effect acts like a holographic film application and can also be placed over entire areas, initially nothing needs to be taken into account with regard to graphic design. However, as a matt/gloss effect was also used in this example, clear motif edges need to be enhanced graphically for it.
Description of the effects: In the Cast & Cure technology, the rlc | packaging group presents a resource-friendly solution for the production of specially finished packaging. A multifunctional special film is used to emboss a microscopically fine relief in the still wet UV lacquer. Refraction then creates an eye-catching holographic effect on the surface of the packaging. And resources are saved, because no additional production step is required for this additional finish using a double lacquer system with connected applicator.

Furthermore, it uses reusable films instead of applying films to the print job. The process offers manufacturers an environmentally-friendly method for upgrading and designing individual packaging.
Description of the print sample: In this print sample, a folding box with an inner compartment is to be given a high quality, low-migration finish that is resource-friendly and inexpensive. The elements that are to be finished are all based on the WEILBURGER Graphics GmbH
Comments: Like all complex print finishes, this one also requires clear project planning and the coordination of all parameters between all of the companies involved in the production chain. Both materials and process steps must have been defined and matched to each other in the preliminary phase.

As our print sample is to be applied to a food packaging, attention must be paid to the migration properties of the chosen materials. The inks and lacquers used for this job are certified and approved for use in direct or indirect contact with food. Highly refined food packaging can also be produced through careful use of certified substrates and low-migration materials, specifically inks and varnishes.
Implementation: First of all, the print job is prepared conventionally and the drawn packaging elements placed on the blank. Then we start to work out the effects.

The main element in these effects is to be the WEILBURGER Graphics GmbH logo, and in particular the striking
“G” in GREBE Group. It is cascaded evenly over the whole printed sheet. We take into account the fact that all the drawn elements will later have the holograph effect, and all non-drawn elements will be matt at the end. The yellow surfaces are now completely covered in order to maximise the effect, with only the company logo omitted in the tuck-in flaps on the top and bottom of the packaging.

As the UV lacquer is to be applied by flexo plate, no half-tones should be used as they would have to be roughly screened later and thus would destroy the printed image. To help save costs, the matt lacquer is simply applied by rubber blanket. It should be omitted around the adhesive flap, which is why we put the adhesive flap down as a special colour for stripping the blanket with a cutting plotter

The result is exported as a PDFX-1a:2001 file and passed on to the print shop.

As the stamping film for this process has to be provided in various patterns, the desired effect has to be chosen from the printer‘s or finisher‘s pattern book. We chose a diffractive effect that is reminiscent of organised diamond chips.

In the final print production, an 18 cm3/m2 anilox roller is used for the glossy UV lacquer and a 9 cm3/m2 anilox roller for the matt UV lacquer.

In order to ensure that the effect is successful, the UV gloss lacquer must not be completely cured before the microstructure of the film is embossed on the surface.


1. Offset machine:

rlc | packaging
Cast & Cure
foil embossing

Low migration printing ink
Low migration printing ink
Low migration printing ink
Low migration printing ink

WG_Cast_n_Cure_EN.pdf 3.66 MB