Stickers are a preferred way to represent your business in an effective, attractive and cost-efficient way. Vinyl stickers offer colorful graphic display with great quality.  They can be put outside since they are more resistant to the influence of weather than the ordinary paper stickers. They can be made with gloss finish, die cut and have a richer variety of shapes, designs and applications. That’s why they allow us more creative options. Stickers are a versatile way to meet our advertisement goals and grab the attention of potential customers. This is because of their vibrant color palette, abundance of designs, endurance to sunlight, moisture and other weather conditions.

When choosing a suitable type of sticker for the purposes of our advertising campaign, we should consider several factors. They include – what environment we plan to put the advertisement, whether it will be outdoor or indoor, for how long and the size type we want.

Most importantly, we should determine what is more important for us durability or price. By learning how vinyl is made, we can be able to make a more informed and wise choice of a suitable vinyl material for our signage.

What are vinyl stickers?

In short, vinyl films are made from polyvinylchloride (PVC) polymer. This gives rigidity, to the material and other ingredients like pigments and plasticizers, to achieve additional flexibility. Also fillers, heat stabilizers and UV absorbers increase the film’s resistance to UV radiation.

Types of adhesive stickers

Stickers can be two types: cast and calendered. These two terms simply describe the processes in which vinyl stickers are made. At first sight they may look the same but the technology behind their manufacturing process is different. Therefore comes the question which type of vinyl sticker to choose for our business.

Let’s take a look at the advantages and disadvantages of both adhesive vinyl types.

Calendered vinyl

In simple words the manufacturing process of calendered vinyl can be described as something similar to kneading a dough. The film for this type of vinyl is made from similar ingredients to these used in the cast vinyl’s film.

PVC powder, liquid softener, stabilizers, colors, resins are mixed into a fine powder mixture called “melt“, which goes through an extruder where it’s blend into a uniform mass. Adhesive is also add to the liquid mixture which can increase the film’s thickness with 1 to 2 mm. Next, the series of large calendering rolls in the extruder, which are heated up to 350 °F, rotate and flatten out this paste into a 2.0 to 4.00 mm thick strip whose length can reach 90 feet depending on the customers’ specifications.

The calendering process

The calendering process includes heat and constant pressure and stress put on the vinyl strip, that is stretched and then pressed into its final form. After that, the film goes to an embossing station, where different patterns and gloss effects are added. To get a high gloss, vinyl film different embossing tools and calendar line settings are used, for each surface. After this process, the calendered vinyl film is cooled down and transported to a winder.

Because the end result is a stiff and thick flim, which is not pliant enough to be applied on a variety of complex surfaces, calendered vinyl is suitable for short-term advertising campaigns. Its advantage, over the cast vinyl, is that it costs less and is usually printed in large batches. It’s resistant to scratches and more easy to handle due to its heavy weight. This makes the vinyl stickers more easy for replacement.

Calendered Vinyl Durability

Calendered vinyl can last from 1 to 7 years depending on whether it’s made from monomeric or polymeric plasticizer. The quality of the plasticizer has a key role to the performance of the vinyl material. It’s suitable for short-term or medium-term display, such as window and floor graphics, partial wraps and especially point of purchase.  So, it may not be a good option for vehicle wrapping. This is because we need a durable material with high resistance to UV rays and the elements. This vinyl type also has a limited color palette to choose from.

Contrary to the belief that the thickness of the calendered vinyl adds more resistance, its life is shorter than this of the cast vinyl stickers. It’s not protected against heat and cold exposure, because tends to shrink to its original size.

Fortunately, there are improvements in the production of calendaring vinyl stickers. They include more glossy finish, addition of adhesive and new colors, better formulations and the reduction of the internal pressure and stretching. This decreases the stickers’ level of shrinkage, improves the appearance and brings their quality closer to this of the cast vinyl stickers.

When the correct adhesive is added, calendered vinyl can be printed with a variety of colors and gloss levels to meet the needs of almost any outdoor application. Around 15 years ago, when the printing industry started,using vinyl for the first time, the vinyl casting technology was considered the best method for printing prime quality stickers.

Cast vinyl

We can describe the process of vinyl casting as something similar to baking a cake. The vinyl used for cast vinyl stickers is made by preparing a mixture of different liquid ingredients (PVC resin, pigment, plasticizer, UV-absorber, fillers, heat stabilizers). They are added to a bowl in a specific order and then mixed together for a specific amount of time and with a particular speed to result in a stable mixture.

A thin film of this mixture, which is called “organosol”, is poured on a casting sheet, which sets the texture of the film. Then it goes through ovens which bake it in order to evaporate the solvents. A hard film should form which is then wound in large rollers for further adhesive coating.

This printing process offers a stable and flexible film with surface gloss. This holds well the colors and adheres smoothly to a variety of surfaces, because there is no pressure and stress. Since cast vinyl stickers are thin, they can last really long time (5 to 12 years). You can also apply them on all types of uneven surfaces like curves and corrugations. Vinyl stickers are perfect for outdoor display use. A good example is a fleet vehicle wrapping, but depending on the raw materials used in the printing process.

When compared to calendered vinyl sticker, this type of sticker has more durability, conformability. It doesn’t crack, shrink or fade, it’s glossier and offers more color options. That’s because the casting machines are smaller than the calendaring  machines and their sheets are short. The materials in cast vinyl stickers has higher quality than these calendered vinyl contains. The UV absorbers and pigments help them preserve their color better. It’s considered best long-term advertisement sticker option, but it’s only disadvantage is that its price is high.

In Conclusion

Calendered and cast are simply terms describing the technology by which vinyl is produced. They shouldn’t be solely related to the performance characteristics of the vinyl film such as weather resistance, glossiness, thinness, shrinkage level.

If your goal is indoor signage or short-term outdoor display, then calendered vinyl stickers are the type for you. But if you want outdoor vinyl sticker that will last long and has high performance on different surface applications, then the top choice is cast vinyl.

Before choosing a type of vinyl sticker, it’s essential to decide what are the goals of our advertising campaign in order to avoid redos and waste of money.

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What is banner printing?

What better way than advertising banners to spread the message about your business? It also gives you the opportunity to represent it in an attractive and eye-grabbing way. Vinyl banners offer every business owner a great opportunity to advertise their business in an original and varied way.

Because of their versatility and wide scope of applications, vinyl banners are really practical advertisement method. They can have a huge impact on the audience, when the right location and fine artwork elements are available.

As wide format applications, they can be put literally everywhere. Therefore, because of their wide range of applications, the factors for future damage to the banners can vary significantly.

The sphere of large-format printing services is constantly changing and facing the challenge to meet the industry’s increasing demands for quality and faster turnaround. Innovative solutions are needed to meet the new requirements of both the business and the customers.

What are vinyl banners?

Vinyl is a popular banner choice and it’s preferred for its durability, cost-effectiveness and is suitable for one-sided and double-sided signage. Also, they can be customized according to the user’s needs.

Vinyl banners are made from two products: polyester mesh (scrim) and vinyl.  Their strength is due to the polyester mesh. The density of the mesh fibers is measured in units called deniers. A polyester mesh with high fiber density leads to a smooth scrim vinyl.

While we may think that the higher the deniers the better, this is not always true. A 1,000 denier mesh is not always stronger than a 500 denier for instance.

Liquid vinyl banners contain chemicals, which are mostly polyvinyl chloride or some plasticizer, which is used as a softening agent. They can be monomeric or polymeric, from which polymeric plasticizers add more flexibility and increased durability. Vinyl banners, containing monomeric plasticizers, when put outside usually don’t last longer than 1 year.

How banner material is made?

There are two ways to make banner material: it can be coated / dipped or laminated. The coating dipping process is feeding the polyester mesh into a coater, which covers the scrim with a hot vinyl mixture usually containing polymeric plasticizer. The lamination process includes two vinyl layers that are flattened together around the scrim mesh.

The lamination process is mostly preferred because of its low price and is suitable for short-term advertising campaigns. On the other hand, the process of coating is considered to create the best quality banner material for long-term advertising goals and is worth its price.

In order to achieve a great design with a desirable quality, we should have a good understanding of how vinyl banners are printed.  We should consider capabilities of the specific printer, the ink and also the specific display and finishing techniques such as lamination.

One of the key aspects, that play a key role in the quality of the end product, is the level of durability of the prints. The other deciding factor is what type of ink will be used in the printing of the vinyl banner. There is the question how long the banners will last?  Will they require lamination to have good resistance to the elements or won’ t need any lamination?

Before making a choice of a vinyl banner and specific large-format printing technology, we should first ask ourselves for what period of time we need the particular banner? What type of location we picked to put it on? We should decide what type of vinyl banner printing technology will be most suitable for our needs.

Generally printing techniques are divided into latex, eco-solvent  and UV-cure systems.

Latex vs. eco-solvent ink

Let’s take a look at the types of inks used in the vinyl banners printing process. Latex inks are the first water-based inks, which can be used for printing on a big variety of coated and uncoated surfaces. This type of ink contains water-soluble co-solvents, but it is not just pigments dissolved in water. Latex inks contain many compounds and surfactants, which let the ink to adhere properly to uncoated surfaces and the anti-scratch agent that protects the ink.

Because water carries the ink, the ink is non-toxic, odorless, non-flammable and produces zero amount of volatile organic compounds. Therefore the ink doesn’t require special workplace ventilation or handling and meets the health, environmental and safety regulations .

During the printing process, heaters evaporate some of the water enhancing the adhesion of the colorant layer. This process lets the concentrated latex polymer particles and wetting agents to meld and form a continuous layer, that chemically bonds to the print media. This helps to close in the pigment to form an even, durable colorant film. This process of film coherence is called “curing”.

If we consider durability, latex and eco-solvent inks contain pigments, which makes them resistant to scratches, smudges and light exposure. HP latex inks provide most durable results, that exceeds these of eco-solvent inks and their results are equal to those of low-solvent inks.

When compared to eco-solvent inks, latex inks offer better scratch resistance. They are also a better choice for vehicle wrapping, since latex ink prints are evenly stretchable on printed and unprinted areas. They are also an eco choice, because their water-based compounds and recyclable substrates lessen the impact of printing on the environment.

HP Latex Technology

HP Latex Technology is a single-step process and includes ink, that can be used for printing of signage on soft fabric, designed for indoor use. This ink can be used with coated and uncoated fabrics and offers high-speed printing. It provides odorless result and flexibility, which creates the feel of an uncoated material.

This printing technique is called soft signage and it’s increasing its popularity. It can be printed on cotton, polyester or other type of fabric. It offers better appearance than the traditional PVC or self-adhesive vinyl banners. The option to choose from recyclable fabrics makes it more eco-friendly.

PSP printers for example offer many options for textile printing such as HP Latex Technology, UV-curable ink technology and dye-sublimation technology.

Latex vs. UV-cure inks

Latex Vinyl Printing

Latex printing technology makes it possible to print flexible indoor graphics. The first advantage of latex ink is that it dries fast and thus allows the manufacturer to offer same-day delivery. The banners printed with eco-solvent ink require lamination in comparison to the latex ink prints, which offer vivid and durable ready-to-use prints. This can be finished directly after printing and have no smell.

The second advantage of this ink technology is, that it has wide scope of applications. Latex inks can be applied on different coated, uncoated and flexible materials. They can be used for printing not only vinyl banners, but also outdoor and indoor applications, wall paper, canvas, textiles, films, transit signage and others.

When it comes to image quality, we can say both latex and eco-solvent inks are a good choice. They offer rich color palette and photo-like image. But in the case of latex ink, it is easier to achieve best quality of the image and maintain it even through a wide range of applications.

UV-cure print technology

We can achieve excellent quality with HP Latex printers, which have automatic nozzle detection ensuring best quality and color consistency. But if we plan to print on rigid surfaces, UV-cure print technology is better than latex printing. It is suitable for printing on flexible substrates. Latex printing may not be a good option to print on textiles such as fashion or household garments. This is because the printed material won’t be durable enough. If we want to get the desirable durability, the textile should be pre-coated or post-printed.

If we want to print on polyester, we should use dye sub printer and if we want to print on textiles like silk, linen, cotton, we need pigmented inks, reactive and acid dyes. Solvent inks go well with ink banners and offer good durability, when put outside, even without lamination.

We should remember that, if we want to print with UV-cure ink, we should use vinyl banner material designed for this type of ink, but then the price can go up. The polyester-based vinyl banner printing material is suitable for UV-cure inks.

Vinyl banners printed with UV-cure ink usually last 6 months, because they contain monomeric plasticizer and with time disappear from the banner making it more rigid and likely to crack in cold weather.

Vinyl bannner types

Scrim

Scrim banners are suitable for outdoor use and is one of the most durable as it consists of 1 layer of PVC polyester fabric laminated with 2 layers of clear vinyl. Its weight doesn’t determine the banner’resistance. They keep the graphics readable even when the wind is blowing.

Coated/dipped

It’s worth its high price since is highly durable. It’s suitable for vehicle side graphics and billboards.

Smooth

It’s mostly used for indoor application, because it has no scrim mesh and can fall apart easily. It’s preferred for its clear and vibrant image display.

Backlit

It can be used for long-term advertisements. It can be used both indoor and outdoor as it contains polymeric plasticizer.

Mesh

Mainly used for outdoor banners such as wall-mounted and road banners, building wraps and fencing and is preferred for windy spots because the mesh holes let the wind move through them. Mesh banners are lightweight and have a long life, since they contain polymeric plasticizer. Another advantage of them is that they offer vivid water proof color that last long thanks to the semi-solvent ink used in the printing. Also they are flame retardant and air pollutants resistant.

Speaker mesh:

It can be used for covering a concert scaffolding and wrapping buildings.

Matte:

It has indoor and outdoor use and is preferred because it’s a strong and long-lasting material with light weight which makes it easy for transportation.

Block-Out:

When compared to the other banner types, it’s the heaviest. Because there is a black line in the center of the material it has an ability to block out light and that’s why it is preferred for outdoor use. Its material is strong and is durable in all kinds of weather.

Sintra/Coroplast:

Good option for store advertisement, lawn signs and pole banners.

Types of banner finishes: Hems, grommets, seams, pockets

In the case of grommets, if we have to make many numbers of banners, then we should better use automated grommeting machines. If we want pockets, hems or seams, we may need a heavy sewing or hot air welding machine to achieve best appearance. If our goal is long-term advertisement, then we should choose reinforced hem. There is the option of using a banner tape.

Lamination

Lamination is a finishing method, which consists of the application of a transparent film or liquid (clear coat) on the surface of the printed vinyl banners. The advantages of this finishing technique are that it increases the durability of the banner. It adds gloss or matte look and also makes the banner more rigid and fit for applying on large surfaces.

Film lamination is the most commonly used technique and is preferred for its low price and high level of protection. In the long term it can offer good protection from water and chemicals as well as scratches and abrasion. The addition of UV filter in the film makes the banner resistant to light exposure.

Liquid lamination, also called clear coat, is suitable for PVC banners and canvas made from flexible substrates. They are also suitable for vehicle fleet wrapping when an economical solution is needed. One of its disadvantages is that its application is more difficult, because a steady layer of liquid should be applied.

Banner priting & durability

Our choice of vinyl banner should depend on how much durable we want our vinyl banner to be? The different environments call for different durability level of the banner material.

There are generally three types of banner resistance: light-fade resistance, scratch and abrasion, water and chemical resistance. For instance light-fade resistance means how much a vinyl banner is resistant to light. Depending on the intensity of UV light exposure, every vinyl banner have different life expectancy.

For example, tests show vinyl banners printed with inks containing pigments, such as HP latex inks, usually last longer than the vinyl banners, printed with inks that contain dyes. Eventually banners printed with HP latex inks also fade over time, depending on the level of UV exposure. There are three generations of HP latex inks.

Water and chemical resistance

Water and chemical resistance shows the ability of a banner to endure water, different chemicals and cleaning products, which can come into contact with. Indoor banners can be regularly cleaned with water and detergents, while vehicle banners are likely to have contact with fuels.

Scratches and Abrasion

In the case of scratch and abrasion resistance, tests show that when anti-scratch agent is added to the HP latex ink, this gives the vinyl banner high level of scratch resistance. This type of resistance limits the risk of potential damage during the finishing, installation and display of unlaminated vinyl banners.

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If you are searching for an effective way to give more information about your business and send a message to your customers, wide format printed vinyl is a really great way to do this. Vinyl Printing and Vinyl banners are a form of advertising where you can send them for printing with your individual artwork for business or personal purpose.

Now most modern banners are printed with large format inkjet printers which are capable of photo quality printing in a variety of types and sizes, from miniature decorative banners to large outdoor banners –  billboards. They help you spread your message to a large public in a short period of time by using your personal vision. That way your campaign will achieve a stunning result. Vinyl banners exceed the traditional methods of advertisement such as brochures, postcards and flyers and also offer a great return on our investment.

What are the advantages and disadvantages of vinyl banners printing?

Advantages

1. Promote your business with vinyl banners

They are a great way to promote your business in a quick, inexpensive and eye-cathcing manner. They can not only help you find new customers, but also to show the world that you are here in a stylish way. 

Vinyl banners help your potential clients learn more about your business. Generally, they are an advertisement that has high impact on the audience. They are a great way to capture the attention of your clients at areas of high traffic. They are also very good if you are offering discounts, new products, grand openings, or when you want to spread news about your upcoming company events. There are also a variety of color solutions: black, white, clear, reflective.

2. Indoors and outdoors advertisements

Vinyl banners can be in the form of indoor and outdoor advertisements and they are easily portable and flexible.  Moreover vinyl printing and banners are extremely durable. You can put them outside and they can survive the elements. Vinyl banners are considered short-term signage. They usually last 1 year, but there are cases when they last even longer, for 2-3 years. The most popular ways for finishing vinyl banners are hems and grommets.

3. Complete customization

Another advantage of vinyl banners is that they are completely customizable. You can print tnem in a variety of sizes and finishes according to the customers’ wishes. Vinyl printing can be also matte or gloss.  When it comes to vinyl banners printing, matte vinyl banners usually look better with their vibrant colors and allow the text to be very well visible even from a far distance. Gloss print vinyl banners on the other hand are not always a good option because they reflect the sunlight and you can’t see the artwork on them easily.

4. Practical to use

Vinyl banners are also a perfect way to utilize vertical space. And as they can contain a lot of informational text, it’s no wonder that vinyl banners are a favorite type of advertisement among small or big businesses. You can reposition this type of banners whenever you like. You can take them down and hung back again when you want. And they are also really not weighty and easy to use.

5. Special Stands for Vinyl Banners

If you don’t want to hang your vinyl banners, you can put  them on special stands such as aluminium or snap plastic hangers, if your purpose is indoor show display. 

Disadvantages

Be careful with the price

Vinyl printing is cost-effective advertisement method. To get even better price for vinyl banners, you have to order them in bulk. This is very useful for companies or institutions that need to show hundreds of the same banners in their territory. If it’s too good to be true, most likely it is. Quality comes with a price. We from ShockWave Print do our best to keep the prices as affordable as possible which doesn’t include using low quality materials.

How Vinyl Printing Works For Your Business?

If you requested proof we will send it to you right before printing. So, in such situations, you should beforehand check your design for any mistakes and flaws. They can be text mistakes, low resolution images, white borders, wrong color or imagery visualization. Make sure you or your designers team will fix them before your approval.

Also, a part of your important information on the image can be cut off and this will be a real problem. Don’t forget to check it in advance. Once we receive your approval the job is submitted for print and we cannot cancel or change anything. In such cases, don’t forget to tell us exactly what you want.

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