What is a durable graphic?
Decals, labels, overlays, in mold, and dimensional products fall into a category referred to as durable graphics. While the category lacks a hard and fast definition, durable graphics need to perform in one way or another, usually for several years. Many durable graphics are outdoor and must resist Ultraviolet rays (UV), chemicals and abrasion for a minimum of five years. Other decals may never leave the indoor environment, but still need to perform in harsh environments like repeated exposure to hot wash cycles or repeated scratches.
At Romo Durable Graphics we focus only on durable graphics. When we find an opportunity intended for single use (a water bottle label for instance), we refer it to industry partners more qualified to meet the client’s needs than we are.
In other words…
We live in a world full of durable graphics, yet most don’t give them a second thought. We refer to them as signs, billboards, decoration, logos, nameplates, banners, decals…even cave drawings! We use the term to collectively describe a visual message put upon a surface that conveys a visual message.
We can’t claim to be the first to use the term Durable Graphics, though it wasn’t often used 20 years ago. The most common method of creating replications is printing, thus, most in the printing industry refer to the process of creating it (lithography, flexography, screen printing, digital printing, etc.) instead of the end product.
Throughout history creating durable graphics was never referred to as such. It’s doubtful a prone Michelangelo stared at the ceiling in the Sistine Chapel thinking, “I’m going to turn it into a durable graphic”, but he certainly did!
One can debate the merits of lumping Michelangelo’s masterpiece with decoration that goes on products (which is primarily what we do at Romo). But that’s our inspiration–creating beautiful, enduring images that capture the essence of what it represents.
There’s no hard and fast rule about what’s considered durable. If an item is intended to be used once and thrown away, we kindly pass on that opportunity to printers better suited to that market.
Our niche is producing graphics for durable items used for several years like lawnmowers, boats, vehicles and appliances. Take a look in your garage – they all have durable graphics on them. Most product decoration takes the form of a decal (sticker, if you will), but there are many ways to decorate a surface.
Isn’t it a sticker?
Ah yes, the sticker question. When we describe what we do as durable graphics (or decals, overlay, appliques, etc.) many retort, “So, it’s a sticker?”
The term ‘sticker’ represents artwork of one kind or another that can be ‘stuck’ to a variety of surfaces.
With all due respect to the term, it’s like saying a SmartCar and a Cadillac Escalade are both cars. Yes, they’re both cars in terms of engineering, performance, and durability, but…you get the picture.
The fact is, most artwork that goes on durable products requires a high level of knowledge and in-depth engineering than a sticker.
what’s the difference between a “decal” and a “sticker”?
Cheap stickers are produced on paper or inexpensive plastic that isn’t intended for long-term use. Decals, appliques, face plates, and other forms of product decoration start with high-quality materials, specifically engineered for intended use and material adhesion. Inks, pigments, and colorants mark another difference. Stickers use dyes which make them susceptible to fading. There’s a huge difference between a cheap sticker and a well-engineered decal or graphic that’s intended to represent a brand for many years of service for the consumer.
Why aren’t you called Romo Screen and Digital Printers anymore?
We prefer to focus on the end product rather than the way it’s made. When we called ourselves, Romo Screen and Digital Printers, we chased any opportunity that could be screen or digitally printed. This “inside out” approach typifies our industry.
When we freed ourselves from the constraints of existing processes, we started finding endless ways to have fun with graphic. These creative enhancements may be visually or functionally (i.e., adding electronics inside the decal to automatically direct consumers to online manual website). We start by asking, “Have you ever thought about….?”, add creativity, and then figure out how to make it happen.
We refer to this “outside in” approach as Discovery. It’s amazing what you can do with a durable graphic when you think about it differently!
Why are my labels falling off?
This occurs when the adhesive on the label mismatches the surface to which it’s applied. In some cases, the label was simply engineered without fully taking the surface into account. All labels aren’t created equal. The adhesive on the back of the label comes in a variety of stickiness. They are created to adhere to different materials: metal, plastic, glass, etc. The details matter! Different colors within the same powder-coat paint line can even accept adhesion differently.
Another cause might be that the surface has changed. Paint and powder-coat manufacturers can change ingredients. Plastic pellet manufacturers may change formulation for cost or performance for their largest applications. Any such change could impact the way the finished surface behaves with adhesive.
We do extensive surface and adhesion testing prior to engineering any new project. We help navigate through unforeseen changes. Whether you are working with us or not, please don’t be afraid to pick up the phone and call us. Decals falling off at a photo shoot or just as the product is ready to ship out the door are not fun situations! We’ll help any way we can.
What can I do to make sure my labels stick?
Prepare! Work with a vendor that understands the ins and outs of decals. During the engineering process (yes, durable graphics are an engineered part), a good supplier will want to understand the intended use. Each situation is unique and requires upfront project information. We like to obtain a sample of the surface to find a best fit for cost and performance. If the supplier isn’t asking you questions about adhesion properties, find one who does.
What is the shelf life of printed decals? When will labels go bad?
Most decal manufacturers will honor a 2-year guarantee if labels are properly stored. Adhesives can degrade over time IF not applied to a substrate. How? A slow chemical reaction occurs causing adhesive to become brittle – weakening its performance.
WHAT IMPACTS LONGEVITY OF ADHESIVE-BACKED DECALS?
Storage and Temperature Variation Suggestions:
Away from natural and artificial light
Flat surface or shelf
In a plastic bag or bin (or both!)
Not stacked too high
Consistently between 60 – 75 degrees Fahrenheit
An average humidity of 50%
Extreme changes will affect adhesive
HOW DO I KNOW IF MY LABELS ARE INEFFECTIVE?
The best way to address a suspect pack of labels is testing. Randomly choose 3 decals from a package. Clean the surface with isopropyl alcohol first and then apply. After 24 hours, bad labels will exhibit these traits:
Edge curling
Adhesive oozing
Fading or discoloration of surface image
HOW DO I AVOID DECAL EXPIRATION?
Utilize a FIFO (first in, first out) inventory system. Use oldest products first.
Don’t place large orders just to get the best pricing.
Consider a vendor-managed inventory system. It starts with placing a blanket purchase order, create minimum and maximum bin levels and the vendor is responsible for filling inventory.
Do your labels stick to metal, plastic, fiberglass, gel coats, powder coats and other industrial surfaces?
Yes, our graphics go on every imaginable industrial surface. Each application requires planning and engineering. No matter who you are working with, if you want art that properly represents your amazing brand for years to come, please do not skip this step!
what should a decal cost?
Let’s hit the topic no supplier wants to talk about! Cost, cost, cost.
Of course, the short answer is, “it depends”. But we want to give you some guidelines and understanding as to the factors that drive it:
Intended use
It makes sense that something that lasts longer, looks prettier and offers more functionality costs more. That’s general true. The more demanding the environment, the higher quality of raw materials required. The raw materials often encompass three areas:
- Base material
- Adhesive
- Ink
Each category merits its own post, and we’ll cover each of them. And more durability doesn’t always mean more cost. The intended use makes all the difference. or example, a boat engine may have different requirements on the same unit. Several pieces of art may go above water, one may be subject to submersion. What visually looks very similar may require different performance attributes. That’s why it’s so important to pick the right partner.
Base Material
In general, however, if your application is for a fairly non-performance sensitive graphic intended to be legible for a few years, we might find a mid-tier, versatile vinyl that fits that application quite well for reasonable cost. The same goes for other types of plastic (and btw, the majority of durable graphics use plastic as a base material) such as polyolefin, polyester and polycarbonate. Each offer a variety of classes (and thus costs) for intended use.
Adhesives
Adhesives depend on the surface in which the graphic is applied. And no, they aren’t remotely created equal. Decals go on glass, painted metal and all forms of plastic. The surface energy determines how well something will adhere to it (there are several other factors, we’ll stick to that for now). Traditional painted metal usually has a friendly adhesion surface (high surface energy), while powder coats impart a more difficult surface in which to apply a decal (lower surface energy). Even different paint lines from the same manufacturer make a difference. Not always, but it’s definitely worth testing before the products roll off the line with a different color.
Ink
Much of what we do can be summed up in one word- pigmentation. The proper pigmentation, and therefore ink, makes all the difference. But it doesn’t usually make a huge difference from a cost standpoint. If you need a durable graphic, you’re going to need a durable pigment. While there is a big difference between well pigmented inks and dyes, if you’re in the durable pigment area, unless it needs to be conductive, the specific variety of ink won’t impact the cost that much.
Average Price
To give you an idea of the average price, here’s pricing for vinyl decals, 3 colors and a protective coating:
4” x 5” 500 pieces $1.35 each
6” x 8” 500 pieces $1.95 each
Obviously, all of our decals are custom-made for each customer so price will vary. We pride ourselves on being an extension of our customer and believe the art on the outside says everything about the art on the inside.
Do I need a durable graphic for my product?
We refer to a graphic as durable when it goes on a product intended for more than one use, usually far more. A durable graphic often must withstand harsh outdoor conditions, including water, sunlight, abrasion and exposure to chemicals. Not all durable graphics go outside, however. The faceplate on your oven, for example, likely won’t see much outdoor activity. It will still be exposed to cleaning chemicals, finger pushes and swipes, cleaning chemicals, high temperatures and even some UV light.
So if you’re manufacturing a product that will be subject to challenging conditions over a life of several years, you need a durable graphic. It should be engineered and tested in conditions that replicate or mimic field conditions.
What is the minimum order quantity for labels?
The short answer is, we don’t require minimums.
We try to separate the volume and price as much as possible for our OEM clients. During the planning process, we work out a single price that we use over the course of the whole year. This allows us to run Kanban quantities so the client never has to change the price. This delivers cost certainty, which they love, in addition to eliminating the need to buy a high quantity to get a low price. In many cases, we also eliminate purchase orders, freeing up buyer time to work on more constructive activities than cutting PO’s. Clean up, smaller quantity orders are covered at that single price as well.
That isn’t to say volume doesn’t impact price. We simply use quantity and price to arrive at a fair model for both parties. Then we don’t have to worry about it again. Truth be told, we prefer to run low quantities (and do) to keep inventory turns high and obsolescence low. Basing run quantities on forecasts leads to all kinds of unintended problems when the forecasts (understandably) don’t go as planned.
I need labels fast! Do you have a quick print turnaround?
Because we run low quantities relative to industry standards, we waste very little production time on graphics the customer doesn’t immediately need or want. This turns conventional wisdom on its head, because we set up presses much more often. We prefer to spend resources on set up reduction rather than producing large amounts of inventory. Lower quantities means our presses aren’t tied up running jobs where most of the quantity is going to sit on a shelf. That’s a waste of time and money for everyone.
Jobs naturally flow through our process quickly. We’ve produced parts in hours in emergency situations for our customers. You’ll never find a vendor who understands the urgency of a line down situation like Romo. Normally, a job flows through our plant in a couple weeks, often less. Big jobs might take more time, and new jobs require planning and engineering.
What is a Vendor Managed Inventory (VMI) Stocking Program?
VMI was developed to ease our client’s daily inventory process for frequently used labels.
What is VMI?
V endor (Romo)
M anaged (is responsible for)
I nventory (counting and restocking all items in the program)
While some customers stock hundreds of durable graphics on their floor, other only stock 50. Each customer we service has a custom VMI program. Branding logos, warning decals, and custom decorations can all be included in the program. Romo checks current inventory weekly or bi-weekly and stocks bins based on inventory scans from the last visit.
A VMI or Kanban program reduces stock outs, which means less stress for purchasers. Work is stressful enough! Durable graphics shouldn’t add to it.
Romo manages decals stocking program for customers that qualify based on number of SKUs, EAUs, and facility set up. Each program is set up individually. Contact us if you want to learn more.
Why are my decals fading in the sun?
Simply, sunlight breaks down color. We’ve all seen that Coke can on the side of the road where the red is almost faded away. You may think it’s been there for some time, but maybe not as long as you think. Red color breaks down very quickly when exposed to the sun’s natural rays.
Color, in general, comes from two sources – dyes and pigments. Dyes add color to all types of materials, including printed products like Coke cans. Dyes do not perform well in the world of durable graphics. They degrade far too quickly in sunlight, no matter how you try to protect it.
Durable graphics use pigments for color. Pigments resist color degradation far better than dyes. The size and depth of the pigmentation matter a great deal. The outside of your car, for example, has a very dense layer of pigmentation, with specially engineered clear coats on top of it. The clear contains UV absorbers (similar to a permanent sunscreen) which block harmful UV rays before they get to the pigment. That’s why paint jobs on cars last so long.
In the world of durable graphics, inks matter a great deal to how the graphic fares outdoors. Digital printing uses small dots of four colors (cyan, magenta, yellow and black) that blend to fool your eye into seeing shades of color. While a useful tool (and far more durable than it used to be) the nature of color formation is at a disadvantage against over screen. The process of screen printing allows for laying pigment down in thick, vibrant, solid color. That’s why screen printing is still the best way to achieve the color density needed to resist the natural elements.
That’s not to say all digital fades more quickly than screen printing. Your supplier needs to apply advanced weathering tests to all forms of pigment used no matter how it’s delivered or protected with clear coats and laminates. Pigments are still volatile to sunlight. We test every pigment system we put into the field to ensure you are getting what you paid for.
Who makes fade resistant labels?
Blame the sun. Ultra Violet (UV) light can break down color very quickly.
Absorption and reflection determine what colors we see. When light hits molecular structures, the particles absorb wavelengths of light. The portion not absorbed reflects out. That’s the color we see. This reaction “excites” molecules, which release the energy in the form of heat. The reaction over time causes the molecules to change structure and impacts the wavelength of light absorbed by the molecule, thus changing the light reflected outward. We see a different color.
Red color naturally absorbs higher energy wavelengths of light, making them more prone to break down. That’s why a Coke can at the side of a road will lose color so rapidly.
Let’s look at the two primary substances used for color – dyes and pigments.
Dyes
Dyes consist of organic compounds, soluble in a variety of liquids. Dyes impart color by absorbing into materials. They are very small in particle size. Commercial uses of dyes include clothing, leather, paper, wood, concrete and even food. Dyes, while versatile and safe, break down rapidly in the environment. UV light breaks down the chemistry that holds dye particles together. As they break apart, the color disappears.
Printing inks use dye because they are plentiful, safe and cheap. Many forms of printing don’t require longevity. If you’ve seen a full-color paper that’s been outside for a few days, it’s likely exposed area has lost much of its color. Colored furniture exposed to UV light will fade, even behind glass that blocks part of the harmful light spectrum. Some dyes last longer than others, with those absorbing higher energy levels more susceptible to color change.
Dyes are wonderful ways to add color to a wide variety of objects. Graphics intended to last, however, are not one of them. The particle sizes are too small and volatile to UV light. There is simply no way to protect them long term.
Pigments
Pigments are inorganic compounds insoluble in most liquids. Instead of naturally bonding to a material, as dyes do, pigments require a carrier. Pigments mixed with a carrier cure to form a thin film on the application surface. Like dyes, they absorb the portion of light we don’t see, and reflect that which we do.
Pigments particles measure 1-2 Microns…many, many times larger than dyes. This makes them more able to reflect the color we want to see over long periods of time. Pigmented inks also hold up better when subject to other conditions, such as water and chemicals.
Think of a good durable graphic as similar to the paint on your car. We have similar pigments and protectants available. They come in different forms and are applied differently, though the principle applies.
Protectants
No matter the base ink system, a good way to extend color is to put a protective layer of the top of it. This can come in the form of a laminate or clear coating of ink. Not all laminates and clears have protectants in them. Like the ink systems below, they must be engineered for conditions.
Laminates and coatings that offer extended protection contain UV absorbers. These act just like sunscreen. They absorb harmful wavelengths of light and emit them as heat. This “blocks” the damaging wavelengths before it reaches the colorant. Top layers also protect against abrasion, water and chemicals.
Life expectancy
As you can see, we want to avoid any dye-based system for your durable graphic. Dyes, even protected, don’t stand much of a chance beyond a few months.
A pigmented system with ample protection can last at least five years, well longer in many cases. One thing we can’t predict is weather, which is why it’s so difficult to warrant a graphic for any length of time. There are so many factors that can affect what happens in real life.
Good graphic suppliers have testing equipment that mimic outdoor conditions. Romo subjects graphics to hundreds of testing procedures. Even with the best equipment, it’s very difficult to predict life expectancy from a lab. We rely on years of experience to engineer graphics to its suited use.
Summary
If you’ve had a graphic fade on you, be sure to specify the following next time around:
Number of years you want it to last.
Describe the conditions it will be used.
Think of unusual conditions it might incur during use
As always, be sure to work with a partner who knows their stuff. The more familiar they are with your situation, the more they can engineer something that looks good for years to come.
Why are my decals scratched up?
Consumers use products in creative ways! That means the decals and labels are going to experience abrasion. It could be running a mower under overhanging bushes, or bumping a boat up against a pier. Scratches happen.
Surface-printed decals are more susceptible to abrasion. Coatings and laminates help protect them, but the ink is still on top of the substrate. There’s only so much you can do.
Another option is to print on the backside of a clear, durable plastic such as polycarbonate. The outside may get scuffed, but the decoration underneath stays until the part itself gets destroyed. This option is usually far more expensive and limited in terms of practical use.
We conduct extensive abrasion testing in applications where the graphic will likely be exposed to scratching and scuffing. There are tradeoffs. If you’re having this problem, contact Romo or your current supplier to investigate engineering options.
Who is GB Frank? How is it related to Romo Durable Graphics?
Since 1956, GB Frank has been a trusted supplier of overlays, graphics, and point-of-service (POS) decals in the bankcard industry. Ten years ago, GB Frank was acquired by Romo Durable Graphics. Since then, the offering have changed from credit card imprinters to window decals and terminal POS decals.
Does Romo make credit card window stickers?
Yes, through our GB Frank product line, we can custom print one-sided and two-sided window stickers for merchants. We also sell standard products on our GBFrank.com website.
Where can I find 2 sided window stickers?
GBFrank.com or call us directly at (920) 712-4083. We’ll be happy to create you vision.
What is the best way to apply a decal?
There are so many answers to that question. For a simple explanation, see our step-by-step process to applying pressure-sensitive decals.
Application should be a factor your supplier takes into account when designing the decal with you. Changing a shape slightly can make a big difference for your production people. Certain materials are easier to apply than others. Masks and laminates can help as well.
It is not an easy process. We try to make it as simple as we can. If you’re having a tough time with decal application, connect with us and we’ll try our best help!
How do I apply a graphic without getting air bubbles?
I hate air bubbles! Don’t you? Incorporating backslits is one way to place the decal before applying the entire label. Also using squeegees aids in the smoothing. A mild soap water solution works to allow the graphic to ‘float’ reducing the chance for air bubbles.
Air bubbles may appear on a graphic perfectly applied after it’s been on the product for a while. This typically results from out-gassing in the underlying material. Outgassing is the release of gas that was dissolved, trapped, frozen or absorbed in some material.
The surface material should be fully cured and at room temperature. With some plastics, the molding process may leave a residue on the surface. Try removing the residue with isopropyl alcohol. In severe cases, the plastic may require flame treating to raise the surface energy enough to allow adhesion.
If all this doesn’t work, contact your existing supplier or Romo. We’re happy to help!
Do i need a durable graphic for my product?
We refer to a graphic as durable when it goes on a product intended for more than one use, usually years. A durable graphic often must withstand harsh outdoor conditions including; water, sunlight, abrasion and exposure to chemicals. But not all durable graphics go outside!
The faceplate on your oven likely won’t see much outdoor activity but will be exposed to cleaning chemicals, finger pushes and swipes, high temperatures and even some UV light.
So if you’re manufacturing a product that will be subject to challenging conditions over its life (several years) you need a durable graphic.
Are your stickers UL approved?
UL approval means the decal construction must go through a test protocol at Underwriter’s Laboratory (UL). This is your supplier’s responsibility, along with their base-material supplier.
UL approval costs money to maintain, which may increase the price of your graphic. Such approval usually comes about because your product demands it. UL approval does not necessarily mean the graphic is well suited to your application; it means the material has passed a series of UL tests. In other words, you can purchase a UL approved label that doesn’t work for your application. You can also purchase a non-approved UL construction that works perfectly fine. In fact, most of what we produce does not require UL approval.
There’s nothing wrong with UL approval. If your product requires it, and it means something to your consumer, by all means, do it. Just make sure your supplier goes through the proper application testing.
We manufacture UL approved decals. All we need are the specifications from you. UL visits Romo quarterly to check our quality and ensure we meet UL Standards on constructions that require it.
what should i look for when deciding to buy a durable graphic?
Look for a company that knows what you need!
The graphics world used to be regional by default. Artwork was done by hand making it difficult to do business long distance. The digital world opened up your options, which in turn drove specialization on the supply side of the graphics industry.
Take Romo. We started in 1953 by two Green Bay guys named Les Rose and Bill Motre (RoMo…get it?). They specialized in screen printing, and their market consisted of anything local that could be most economically produced. This included banners, locker room signs for the Packers, grocery store specials and the like. Because this area was centered on the paper industry, most of the printers in the area specialized in printing on paper–making Romo a bit of a black sheep. Screen printing lent itself to more durable images than those on paper.
As technology grew in the 1990’s, geographic boundaries began to dissolve. People making durable products demanded quality programs and consistency not necessarily required in the banner making business. Since then, the market has become much more specialized. Suppliers good at doing graphics for the interior of stores set up capabilities to perform for that market. Companies like Romo gravitated to the Original Equipment Market (OEM).
We all belong to one big community called SGIA (Specialty Graphic Imaging Association). This community generally splits into two parts: Graphics and Apparel. We won’t delve into apparel side here, although if you are looking for an apparel supplier, SGIA is a good place to start.
Most of us on the graphics side of the market produce images that are referred to as Durable Graphics. But your intended use makes a big difference. While technically we can make banners, there are companies in our industry far better suited to that market. And while the local sign company down the road can produce decals, they aren’t well suited to produce engineered parts for a sophisticated OEM.
Technology creates choice. You have many. Do research. Look for a company that knows your market well, whether it’s banners or product decoration. We focus on the latter, commonly referred to as Industrial Graphics. There are other fantastic Industrial Graphic suppliers in our market. If we find you’re better served by one of our competitors, we’ll gladly refer you. We want your experience to be a good one, whether it’s with us or someone else.
Do I need an ISO certified printer?
If you are an OEM making durable products for consumers, the answer is probably – Yes.
Consumer quality standards demand products that work. Consumers like simple, elegant designs that are easy to use. Of course, simple and elegant doesn’t mean easy – quite the opposite. It requires innovation, sophistication and strategic foresight from those making it.
ISO certification doesn’t guarantee any of these things, but it’s a strong indication you’re dealing with a company serious about them. At a minimum, it says your supplier has business processes in place to deliver what you need from a durable graphic standpoint.
The graphic represents your brand, in front of consumers worldwide, for many years to come. Consumers draw conclusions about quality and your product and reputation based on the way a product looks. Make sure you have a supplier that cares as much (or more) about it as you do.
We believe the art on the outside of a product says everything about the art on the inside. That’s one reason we’re ISO 9001:2015 Certified.
Do you make tamper resistant labels? Absolutely! Tamper-resistant labels require certain materials and manufacturers that know how to work with them.
Are your labels made of destructible vinyl? We print on destructible vinyl all the time.
Can you print on Lexan?
Yes – Lexan is a brand name in the polycarbonate material classification. Decals/overlays made of polycarbonate resist abrasion (see Why are my decals scratched up?) and add an upscale look to products such as cars, appliances and control panels. These products often incorporate touch or push button functionality for the user. The ink is printed and then adhesive is applied to the back of polycarbonate. The ink is in a sandwich between plastic and adhesive. Safe and sound.
Polycarbonate may not be the best option for certain applications. Polyesters, acrylics and scuff-resistant vinyl offer some similar looks with different advantages. They also have disadvantages. Polycarbonate constructed decals are typically expensive. Material options change. Your supplier shouldn’t be merely quoting to a print all the time. Polycarbonate constructions offer some great cost savings opportunities. Make sure you’re working with proactive suppliers that gives you options!