Sample & Quotation Request Guide for Functional & Security Printing

What Your Brief Needs to Specify Before We Can Quote Security Printing #

Most packaging categories can be quoted from a dimension sheet and a print-ready PDF. Functional and security printing cannot. The reason is straightforward: a holographic hot-stamp foil, a UV fluorescent ink layer, a conductive trace, and a thermochromic indicator all have different substrates, different press configurations, different material lead times, and in some cases different regulatory requirements. We cannot quote them interchangeably from a generic brief.

Before anything else, your brief needs to answer four questions:

1. What is the primary authentication or functional purpose?
Overt features (visible hologram, color-shift ink) use different material sourcing than covert features (invisible UV fluorescent, microtext, chemical taggants). If your product uses both — common in pharmaceutical secondary packaging — state that explicitly. We stage these as separate print passes, and that affects both tooling cost and lead time.

2. What substrate will carry the security print?
Our standard functional printing runs on substrates between 80 gsm and 400 gsm. Coated boards (C1S and C2S), PET film, and white BOPP are the most common. Uncoated stocks are feasible for some conductive inks but create adhesion variance that must be pre-tested. If your brand packaging is already specced on a particular board, send us the grade name and caliper — we’ll confirm compatibility before sampling begins.

3. What serialization or variable data volume are you expecting?
Static security print (same feature across the whole run) and serialized print (unique QR, data matrix, or alphanumeric per unit) require different production setups. Serialized jobs require inkjet or laser integration on our line, with a minimum viable run of 5,000 units before per-unit cost becomes reasonable. Below that threshold, the digital setup cost dominates.

4. Is end-market regulatory compliance required?
Pharmaceutical packaging for EU markets must align with EU Falsified Medicines Directive 2011/62/EU serialization requirements. Food-contact applications require ink systems cleared under FDA 21 CFR or EU Regulation 10/2011 depending on destination. We need to know the target market before we can confirm ink formulation compliance.

If your brief does not address all four of these, our standard practice is to send back a Pre-Production Clarification Form (internally we call it the PPC-F) before we begin quoting. This is not a delay tactic — it prevents a misquoted sample that doesn’t match your actual specification.

For structural packaging information, include finished dimensions (L × W × D in mm), desired board grade or at minimum the weight range the product carries, and any die-cut or window cut requirements. Window areas interact directly with holographic and fluorescent features — placement matters for authentication scanner access and visual inspection angle. If you already have a dieline, attach it as a locked PDF or DXF. Do not send editable AI files as the structural brief — coordinates shift across software versions.

Artwork File Requirements for Functional and Security Print Jobs #

Standard offset artwork requirements apply as a baseline: print-ready PDF/X-4, minimum 300 dpi at final output size, 3 mm bleed on all cut edges, all fonts embedded. For security printing specifically, there are three additional requirements that differ from standard packaging work.

Microtext and fine-line elements must be supplied at minimum 0.2 pt stroke weight for positive microtext and 0.3 pt for reversed (knockout) microtext. Below these thresholds, the elements fill or drop out on press. We cannot recover fine security detail from artwork that has been rasterized or saved from a low-resolution source — this is a pre-press dead end.

Security feature placement zones must be marked as separate layers in the artwork file. Our press operators need to register holographic foil stamps, UV overprint layers, and conductive traces as distinct passes. If your security features are merged into the base artwork layer, the file requires rework before we can proceed to pre-press, adding 2–3 working days before sampling starts.

Color specifications for functional inks require a Pantone or spectral target separate from aesthetic brand colors. UV fluorescent inks, for instance, have no visible color under standard D50 illuminant — their “color” only exists under 365 nm UV excitation. You cannot specify them with a CMYK or Pantone visual reference. We specify these internally by excitation peak and emission peak, confirmed against our UV lamp calibration records per CIE Publication 15:2004 colorimetry standards. When you brief us, confirm the excitation wavelength you expect authentication devices in your supply chain to use — 254 nm, 365 nm, and 395 nm sources produce different visibility results from the same ink formulation.

Sample Types, What Each Costs You, and When to Request Each #

White samples cost the least and iterate fastest, but they confirm nothing about security feature performance. We see brands approve a white sample, skip the printed proof, and go straight to a production sample — then discover that the holographic foil registration is 1.2 mm off the artwork intent. That requires a new production sample and resets the timeline. The printed proof stage exists precisely to catch registration and feature-placement issues before production tooling is committed.

For security printing specifically, we strongly recommend evaluating received samples under at minimum three conditions: standard D65 illuminant, 365 nm UV lamp, and a handheld authentication scanner if your brand uses one. We can supply a UV verification protocol checklist based on our QC-14 inspection procedure if you need one for your internal approval workflow.

Cost-Performance Trade-offs When Comparing Supplier Quotes #

Quote comparison across suppliers is harder in security printing than in standard packaging because the scope is frequently not equivalent. A quote for “holographic foil stamp” from one supplier may include a registered hot-stamp with ±0.3 mm tolerance. From another supplier, it may be a non-registered cold-foil with ±1.5 mm tolerance. Both are technically “holographic foil stamp.” The authentication effectiveness is not the same.

Three parameters to verify before comparing line items:

Registration tolerance on security features. For overt authentication features like holographic stamps or color-shift patches, we hold ±0.3 mm on sheet-fed offset. For covert UV features printed as a separate pass, we hold ±0.5 mm relative to the base print. Ask every supplier for their stated tolerance and request a sample batch that demonstrates it — not just a spec sheet claim.

Ink system certification. For regulated end markets (pharmaceutical, food-contact), ask specifically which ink formulation is used and confirm it carries the appropriate clearance. An ink supplier data sheet showing compliance with REACH Regulation EC 1907/2006 restriction requirements is a minimum — it does not automatically confirm food-contact clearance under 10/2011. These are different documents. A supplier who cannot produce both for the appropriate market is a sourcing risk.

Security feature origin and traceability. Holographic foils and optical variable devices (OVDs) should come from an identifiable manufacturer with a chain-of-custody record. We source holographic master origination from accredited OVD manufacturers and maintain a supplier audit record per our AVL Gate B review procedure. If a quote does not specify foil origin, ask. Counterfeit holographic foil exists and is not a theoretical risk — it circulates in the spot-foil supply chain and defeats the authentication purpose entirely.

The counterargument to premium security features: if your primary use case is internal track-and-trace rather than consumer authentication, serialized inkjet printing with a data matrix code per ISO/IEC 16022 Data Matrix standard is frequently a lower-cost and operationally simpler solution than overt holographic features. We’d rather quote you the right specification than the most expensive one.

Specification Notes for Brand Partners #

When you brief us on functional or security printing, the single most useful document you can provide is a completed authentication threat model — meaning a clear statement of what counterfeiting or diversion scenario you are designing against. That document determines everything: feature selection, substrate, serialization volume, and compliance scope.

The most common brief gap we encounter is undefined quantity tiers. Security printing unit costs shift significantly between 10,000 units, 50,000 units, and 200,000 units — not because of print run economics alone, but because tooling amortization (foil dies, embossing plates) spreads differently. Provide minimum three quantity tiers in your RFQ. This lets us show you the actual cost curve rather than a single number that may not reflect your production reality.

Our standard timeline from completed brief to white sample is 5–8 working days. Printed proof follows structural approval at 10–15 working days. Production samples require 18–25 working days from final artwork sign-off. The primary variable that extends these timelines is specialty material lead time — certain optically variable foils and taggant inks carry 15–20 working day procurement lead times from our approved suppliers. If your launch date is fixed, tell us upfront and we will check material availability before confirming sampling milestones.

Frequently Asked Questions

What file format is required for security print artwork, and does microtext need special treatment?
Submit print-ready PDF/X-4 with 3 mm bleed and all fonts embedded. Microtext must be supplied as vector paths, minimum 0.2 pt stroke for positive elements and 0.3 pt for reversed — any rasterization of fine security detail before submission cannot be recovered at pre-press, regardless of resolution.

How many quantity tiers should I include in a quotation request?
Include at least 3 tiers. In our experience, the cost-per-unit difference between 10,000 and 50,000 units on a job with holographic tooling is significant enough that a single-quantity quote misrepresents the actual economics. We use the tier spread to show you where the tooling amortization curve flattens out.

Do I need separate compliance documentation for UV fluorescent inks used on food-contact packaging?
Yes. REACH compliance under EC 1907/2006 and food-contact clearance under EU Regulation 10/2011 or FDA 21 CFR are separate requirements. A REACH-compliant ink is not automatically cleared for food contact. Confirm the target market and packaging layer (primary, secondary, tertiary) when you brief us so we can specify the correct ink system from the start.

What is the difference between a printed proof and a production sample, and can I skip the proof stage?
A printed proof is a flat sheet confirming color accuracy, security feature placement, and ink adhesion — produced before production tooling is committed. A production sample is a complete, assembled unit produced on the actual production line. Skipping the proof stage is possible but carries a real risk: if holographic registration or UV feature placement is off, the next correction requires a full production sample reset at 18–25 working days, versus a proof correction at 10–15 working days.

How do I evaluate a holographic foil sample to know if it meets authentication quality?
Check three things: visual registration of the holographic patch against its intended position (should be within ±0.5 mm for most applications, ±0.3 mm for premium), foil adhesion by running a 3M 610 tape peel test per ASTM D3359 Method B, and optical variable effect under 45-degree light angle shift. A foil that shows no color shift or pattern change under angle variation has either failed during application or is not a genuine OVD — both outcomes need to be flagged before approving production.

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Planning a packaging project? Contact our team to request a complimentary specification review and sample quote.