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Cast-Coated
vs. Conventionally Coated Paper
Kromekote and Kromekote Glass both have an ultra-smooth surface and mirror-like
gloss that stands out from ordinary coated sheets. Our “wet” cast-coating
process imparts a surface that is flatter, smoother, glossier, and more
resilient than conventionally coated or other cast coated sheets. Additionally,
this process provides all Kromekote grades with a surface that is absorbent
and therefore especially receptive to ink. To get that unique surface,
SMART uses a patented method of applying coating to the sheet. Instead
of using the standard calendering process – with high speed, high
pressure and high temperature – we use slow, steady pressure from
our 22 mirror-like chromium drums to cast the finish onto the sheet. The
result is a paper that sets up more quickly on press to ensure faster turnaround
and delivers exceptional print quality.
Kromekote Grades vs. the Competition
Today, there are a number of cast-coated papers to choose from, as well
as papers made by other methods that try to imitate the look and feel of
a cast-coated sheet. But none of them can match Kromekote and Kromekote
Glass for quality and consistency. That’s because SMART controls
every step of the papermaking process, starting with carefully selected
pulps. Then we manufacture our own basestock and fully pre-coat the stock
on our paper machine. This allows you to do four-color process printing
on both sides of the sheet, whether cast or uncast. We’ve had over
sixty years to perfect the product, and we keep improving it all the time.
Our new Kromekote and Kromekote Glass are brighter and have a blue-white
shade that will enhance your printed piece but to really appreciate these
grades, you have to see them perform on press.
Kromekote and Kromekote Glass Means Exceptional Press Performance
Any cast-coated sheet can look dazzling when you first un-wrap it. But
the true test of a paper is how well it performs on press. That’s
where our Kromekote grades really shine. Here’s what you can expect
from Kromekote and Kromekote Glass:
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Sharper, crisper dot formation - Because
its surface is so receptive to ink, Kromekote and Kromekote
Glass ensure minimal dot gain. In fact, tests show that
Kromekote and Kromekote Glass control dot gain better than
the leading foreign or domestic cast coated sheets. |
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Quicker turnaround - Inks set
so quickly on Kromekote and Kromekote Glass saving you
several hours over competing brands. |
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In short, Kromekote and Kromekote Glass
deliver consistent runability and printability, while saving
you a considerable amount of time. |
More Products, Better Service
Kromekote is available in over 100 stock items. This is the widest selection
in the industry, including a comprehensive range of recycled cast-coated
papers. Kromekote Recycled (C1S only) contains 50 percent recycled fiber;
including ten percent post-consumer waste based on sheet weight. Kromekote
Recycled provides the same brilliant surface as regular Kromekote. Custom
Kromekote C1S Cover recycled products are available on a manufacturing
basis with up to 30% PCW.
Whether you prefer recycled or virgin stock, you’ll find it readily
available from merchants throughout the country. Kromekote products are
available in everything from label stock to 18 point folding board in cut-size
to standard folio sheets. It’s also qualified for web printing in
one-side cover in both 6 and 8 point. Equally important, when you choose
any SMART Papers brand, you’re assured of the industry’s most
comprehensive technical service and sales support. That includes our dedicated
sales management team, product managers, outside sales, customer service
representatives and field technical service representatives. It also includes
a special toll-free number (800-443-9773) that puts you in direct contact
with our Customer Satisfaction Coordinators in Hamilton, Ohio anywhere
in the country.
Production Tips: How to Make the Most of Kromekote
An exceptionally versatile paper, Kromekote always brings added value to
your end use. The ultra-smooth surface and extra rich gloss provides greater
impact to a host of printed material ranging from annual reports, folders,
packaging and book covers to greeting cards, menus, posters, and calendars.
And its versatility extends to all kinds of printing processes such as
Offset Lithography, Flexography, Silkscreen, Gravure, and Letterpress.
You can emboss, foil stamp and die-cut Kromekote being assured of excellent
results time after time. But whatever you have in mind, you’ll find
that Kromekote performs best if you adhere to a few simple guidelines.
The following tips will help you make the most of Kromekote from prepress
and make-ready to finishing and binding. And remember, if you have any
questions about a particular process or end-use, help is just a phone call
away through our sales offices or our toll-free Customer Satisfaction Coordinators
number (800-443-9773) in Hamilton, Ohio.
Kromekote Textures
When printing Kromekote Textures (i.e. – canvas, premium linen, silk,
vertical) by lithographic presses, extra pressure is required to get the
ink down into the valleys of the embossed pattern as would be needed printing
any embossed sheet. Because of the uneven surface of embossed sheets, smaller
pile heights may be necessary to prevent marking. When foil stamping, it
is essential to use the proper pressure to get down into the pattern. Be
aware this will cause de-bossing of the sheet in the foil areas.
Kromekote Glass
When printing Kromekote Glass due to its even smooth and slightly less
absorbent surface, inks will not set up quite as fast as Kromekote. Therefore,
slightly smaller pile heights may be necessary to prevent marking.
Prepress
Like all papers, Kromekote grades should be fully acclimated to pressroom
temperatures before it is unwrapped. We recommend storing Kromekote at
75° Fahrenheit and 50 percent humidity. With all papers of this type,
there is a chance of two-sidedness. While we make every effort to minimize
this, make sure to lay out your jobs carefully, and keep in mind that the
smoothest side is packed facing up.
Make-ready
The absorbent surface of Kromekote grades simplifies the make ready process.
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Color balance is achieved quickly. |
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Because Kromekote grades are
smooth and level minimal printing pressures are required. |
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For a clearer, sharper print, run the black
first and let the finish come through by overprinting the
other transparent colors. |
Running
Kromekote grades are extremely uniform sheet to sheet, therefore color
densities are easier to maintain than with conventional machine coated
sheets. Kromekote’s absorbent surface allows ink to set up quickly
resulting in the ability to run higher piles in the delivery thereby increasing
production. Quicker ink set up times facilitates faster turn around time.
Offset Spray
When offset spray is needed, use it sparingly to avoid getting a rough
finish. Spray tends to cling to freshly printed surfaces, thus diminishing
the smoothness for which Kromekote is noted.
Inks
While the cast-coated surfaces of Kromekote grades appear hard, they actually
absorb ink extremely well, and are especially compatible with today’s
fast-setting inks. To achieve optimum printed gloss and scuff resistance,
consult your ink supplier.
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For best results, use inks that are compatible
with Kromekote grades. |
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Use gloss transparent inks,
which let the high gloss surface shine through. |
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Avoid heavily pigmented inks, like chrome
yellows and greens, deep maroons, and reds or blues with
bronzy overtones. |
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When combining black with other colors,
use a good grade of high-density halftone black. |
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Matte inks yield a bold contrast against
Kromekote glossy surface. You might also want to apply
a varnish or aqueous coating o avoid finger marking. |
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With matte, as with fluorescent or metallic
inks, consult your ink supplier to determine the formulation
that’s most appropriate for Kromekote grades. |
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Soy-based inks can yield excellent printing
results on Kromekote grades, but make sure to consult with
your ink supplier when using them for the best results. |
Varnish
On areas of heavy ink coverage, or pieces that will be handled often, varnish
is recommended. Spot or overall varnish coverage will deepen tones, sharpen
contrast, and protect the page from scuffing and finger marking. Kromekote
grades can accept both matte and gloss varnishes, either separately or
together.
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Always match ink formulation
and varnish. Check with your ink supplier to make sure
the compounds you plan to use are compatible. Avoid spirit
varnish, which tends to yellow the bright-white surface
of Kromekote grades. |
UV and Aqueous Coatings
UV and aqueous coatings are applied to a sheet after printing, primarily
for protection. While aqueous coating – a water-based solution – is
generally less expensive, UV coating provides greater rub resistance and
exceptional gloss.
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Because UV coatings tend to yellow-coated
papers when applied directly, precoat the sheet with a
press size, press varnish, or aqueous coating. This will
also reduce the amount of UV coating needed to achieve
optimum gloss. |
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When foil stamping in conjunction
with UV coating, aqueous coating, or varnish, check with
your coating supplier to ensure that the effect won’t
be compromised by any chemical reaction. |
Offset Lithography
Because Kromekote grades are so receptive to ink and water, the following
precautions will yield the most satisfactory printing results:
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Check blanket and cylinder pressures to
avoid using too much pressure. |
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Run Kromekote grades at one
or two thousandths less pressure than you’d normally
run for ordinary coated stock of the same basis weight. |
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Keep water applications to a minimum: a
little goes a long way. |
Gravure Printing
To take full advantage of Kromekote's ultra-smooth surface, use inks that
tint, stain, or dye, such as Flexographic inks. Avoid heavily pigmented
Gravure inks, which will result in a rough, grainy surface. Consult your
ink supplier for advice.
Letterpress
Follow the same general procedures for letterpress as for lithography.
(See above.) Packing is critical to firm will result in embossing the sheet.
When printing by UV letterpress, check with your ink supplier, and keep
your ink fluid to ensure uniform coverage.
Flexography
When using Kromekote grades on Flexography, avoid pigmented aniline inks.
Compound a variety of inks for the cover value required. When using UV
Flexograghic inks consult your ink supplier. They may need to increasing
ink viscosity so that the ink doesn’t absorb unevenly. It may be
advisable to use press sizing, place UV lamps closer to the printing station,
or use more UV lamps.
Silkscreen
Silk-screening on Kromekote grades can be accomplished the same as with
any coated sheet and requires no special procedures.
Thermography
To prevent blistering, minimal heat is recommended when using Kromekote
grades for thermography. Two-side cover is not recommended for this process.
A special manufacturing grade, Kromekote C1S Cover Thermographic, is available
and guaranteed for this process. Contact our customer service department
for your special needs in thermographic printing.
Liquid and Film Laminating
There are many liquid and film laminates to choose from. To find the best
for your particular job, you should test new coatings or methods of application
before running a job.
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Use minimal heat. Too much heat will dry
Kromekote grades and make it brittle. |
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Avoid liquid or film laminating
both sides of Kromekote grades as moisture entrapment may
cause bubbling and blistering. However, if lamination is
required on both sides, use minimal heat for drying. |
Foil Stamping
Both fine-line and large area foil stamping are easily achieved on Kromekote
grades. As long as it is done only after the ink is dried, no special precautions
will be necessary.
Embossing and Debossing
You will get an exceptionally clean embossed image on Kromekote grades
using either hot or cold embossing systems. Most printers prefer hot embossing.
No special precautions are needed.
Die-Cutting
Always die-cut Kromekote grades with the cast-coated side facing the die.
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Keep die-cutting blades as sharp and smooth
as possible. |
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Wipe blocks and blades occasionally
with a tack cloth to remove dust, coating particles, and
fiber. We recommend scheduling Kromekote grades first on
your die-cutting equipment. |
Scoring and Folding
To achieve the best results when scoring or folding Kromekote grades, follow
these simple rules:
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To avoid cutting through the coating, use
a roundnose or bullnose rule that is one-and-a-half to
two times wider than the thickness of the stock being folded. |
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Kromekote grades should be fully
acclimated to pressroom temperatures before it is unwrapped
to insure scoring and folding performance. We recommend
storing Kromekote at 75° Fahrenheit and 50% relative
humidity. |
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Make sure to follow the grain direction
for working folds. Stationary folds should run across the
grain. |
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Avoid scores that are too narrow or too
shallow (depth again should be one-and-a-half to two times
the sheet thickness) and channels that are too narrow or
too wide. A score is deep enough when a pronounced ridge
shows on the reverse side. Fold with the ridge on the inside
and the score on the outside. |
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Although our new Kromekoteplus has
been formulated to prevent “crack on fold”,
breaking and cracking of the ink along the fold line can
occur if improper techniques are used. Be sure to follow
all of these recommendations to insure the best results. |
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Scoring on press is not recommended. |
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Use a bulking dummy to ensure proper placement
of scores for spines and hinges. |
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Make sure the spine is the appropriate size
for the contents. |
Trimming
Although SMART cannot be responsible for trimmer related defects, following
these procedures will help you achieve the best results:
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Make sure the trimmer blades are sharp and
smooth. |
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Trim Kromekote grades with the
cast-coated side up. |
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Back trim split sheets to keep dust off
the front cut. (Back-trimming is a procedure to remove
1/16” of paper from the front side of the knife.) |
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Lubricate the knife blades frequently with
a silicone spray while trimming. |
Binding
Kromekote grades are compatible with all binding methods. Use it as you
would any coated paper.
Web Offset Printing and Finishing
Kromekote one-side cover in both 6 and 8 point is qualified for web printing.
Follow these tips:
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Use low temperature inks and the lowest
possible oven temperatures. |
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As with all heavier-weight paper,
adequate chill-roll capacity is necessary to cool the web
properly. |
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For the best scoring results, run the job
through the sheeter and score off press. The scoring mechanisms
on most web presses do not provide an adequate score. |
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Other finishing operations on Kromekote
grades should also be done off press. |
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Keep slitters and knives properly adjusted
to avoid dusting and flaking when additional processing
is needed. |
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Kromekote two-side cover grades are not
recommended for heat-set web printing. |
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