has built a strong reputation as the premier supplier of polyethylene sheet and components to numerous industries over the past 30 years. This reputation has endured numerous obstacles presented by changes in our global economies and markets through flexible service and quick response. Through the requests of our customers and reaction to the market changes, we have expanded our capabilities.FORM
flex
PROCESS CAPABILITIESFORM
flex
The information that follows is intended as guidance to assist in the development of products from concepts presented by our customers. Many of the limitations listed may be overcome through alternative design or construction. Please call FORMflex customer service to discuss your options.
EXTRUSION
POLYETHYLENE
| Surface | Gauge |
Min Width |
Max Width |
Min Length |
Max Length |
|
Matte |
.014 - .054 |
9" |
48" |
9" |
60" |
|
Matte |
.055 - .250 |
9" |
48" |
9" |
96" |
|
Crush |
.018 - .054 |
9" |
48" |
9" |
60" |
|
Crush |
.055 - .250 |
9" |
48" |
9" |
96" |
|
Co-ex |
.020 - .054 |
9" |
48" |
9" |
60" |
|
Co-ex |
.055 - .125 |
9" |
48" |
9" |
96" |
Smaller minimums may be obtained through guillotine or die cutting.
Roll stock is also available - call customer service for details.
Additional surfaces and/or combinations maybe possible with limitations
EXTRUSION
POLYPROPYLENE
| Surface | Gauge |
Min Width |
Max Width |
Min Length |
Max Length |
|
Matte/Matte |
.020 - .054 |
9" |
48" |
9" |
60" |
|
Matte/Matte |
.055 - .075 |
9" |
48" |
9" |
96" |
|
Matte/Polish |
.020 - .054 |
9" |
48" |
9" |
60" |
|
Matte/Polish |
.055 - .075 |
9" |
48" |
9" |
96" |
|
Diagonal/Lines |
.020 - .054 |
9" |
48" |
9" |
60" |
|
Diagonal/Lines |
.055 - .075 |
9" |
48" |
9" |
96" |
|
Co-extrusion |
.020 - .054 |
9" |
48" |
9" |
60" |
|
Co-extrusion |
.055 - .075 |
9" |
48" |
9" |
96" |
Smaller minimums may be obtained through guillotine or die cutting.
Roll stock is also available - call customer service for details.
Additional surfaces and/or combinations maybe possible with limitations
Polypropylene with polished surfaces on both sides is available in larger quantities at an additional cost
DIE CUTTING
Decoration Min Cut Size Max Cut Size
Gauge Range
Printed
½” x ½”
30” x 47”
.014 - .250
Plain
½” x ½”
44” x 33”
.014 - .070
Die cutting capability may be further limited by various combinations of size, gauge and tonnage resulting from the number of punches and the amount of cutting and scoring rule
The minimum sheet size restriction of 5” x 5” may result in higher material and/or die costs
Cold scoring in the die is recommended for products .035 gauge or less and may be adequate up to .055 gauge
Blind imprinting is available for the cost of the dies on most products and must consist of outlines and fine lines - no bold face type is permitted
SCREEN PRINTING
| Max Image Area | Min Sheet Size |
Max Sheet Size |
Gauge Range |
|
37" x 27" |
5" x 5" |
40" x 30" |
.014-.070 |
|
37" x 23" |
5" x 5" |
40" x 30" |
.071 - .250 |
° from horizontal with round dots and screen rulings of 65 or 85 line (when overlapping two tints use 22.5° for the darkest color and 52.5° for the lighter)Four-color, halftones & tints may require a larger minimum size sheet at an additional cost
Artwork should be set up to actual size of the product and may be submitted on a separated mechanical or disk
Minimum type size for good reproduction is 6 points and minimum line weight is .65 points
Bleeds should be restricted to .055 gauge material or less and must extend 1/8” beyond the cutting area, and mock bleeds can be no closer than 1/16” from cutting edges
Artwork should not be designed with reverses through more than one ink color and requires a minimum type size of 12 points and a minimum line size of 1.5 points
Halftones and tints should be provided at 22.5
Recommended gradient ranges are 15% to 85% at 65-85 line
Four-color process screen printing angles are 7.5
° for yellow, 22.5° for black, 52.5° for magenta and 82.5° for cyanFilms provided should be one piece, right reading, emulsion up positives including register marks
Ink colors should be limited to two colors on .014-.016 and three colors on .017-.023 with the maximum number of colors dependent on the thickness and number of overlapping colors
OFFSET PRINTING
| Max Image Area | Min Sheet Size |
Max Sheet Size |
Gauge Range |
|
39" x 27.750" |
20.5" x 14.5" |
40" x 28.375" |
.014 - .035 |
All products being offset printed require a clear varnish or UV clear coat to reduce scuffing
Conventional separation techniques & screen angles are recommended with up to 175 line ruling
Our offset printers prefer to work from art on disk accompanied by a black and white, color separated proof at 100% size
1/8” bleed allowances are required with register marks and color bars outside the bleed area
Traps should be established between .005” - .007”
Maximum dot density should fall between 300 & 400% with the Gray Component Replacement set at 70%
Various proofs and bluelines are available for approval
FINISHING
Various finishing capabilities are available to satisfy any stage of production up to providing a completed product for drop shipment to your customer. The chart that follows lists many of the more popular finishing capabilities. Please call your customer service representative if you require services not listed, or have questions regarding any limitations to these operations.
Hot Scoring - Foil Stamping - Debossing - Heat Bending
Beveling - Tab Cutting - Eyeletting - Riveting
Pocketing - Sonic Welding - GBC® Punching
Wire-O® Punching - Collating - Fulfillment Labeling-
Prototyping
Some of these processes may require special dies or tooling at an additional cost
Binding for two-piece covers may be available depending on the content and product specifications