We wanted to do a before and after blog posting on the cold foil business card process to give our readers some tips on how to set up there files. This is a new printing process, which a lot of you graphic designers haven't work with before…it works like this. Design your full color business card like you normally would in Photoshop. Next, create a new channel to indicate where you want the silver foil to go down on the card by highlighting those areas in Red (100% magenta and 100% yellow). You can have the entire card covered in foil or just certain areas for extreme highlight effects This is pretty much the same set up as Spot UV business card except the silver foil gets printed first.
When the cold foil business card file gets to the printing press department the printers lay down the silver foil first and then print the CMYK over the card stock and the silver foil. The ink is transparent enough to allow the silver to show through creating a full color foil effect. We also have a Metallics Unlimited business card process which isn't as shiny as the foil but shares the same file set up.
Some tips on designing a full color, cold foil process business card: Don't use thin fonts in your layout if you are going to have foil in that area. Registration is not as exact with this process and the thin fonts might have a small haze when printed. Screens or watermarks don't exactly work the same on the silver foil as they do on traditional coated paper stock. Most traditional screens or watermarks are around 20%. To achieve that effect on the cold foil process business card you would have to bump that screen up to 50%. Always add an extra 30% to all of your screen effect and you should be in good shape.

Front of Cold Foil Process Business Card Proof
The client wanted this card to have a matte black finish with shinny foil highlights in the tribal design and logo. The Photoshop file is set up with an additional channel named "Foil" and has those areas in sold RED.

Back of Cold Foil Process Business Card Proof
The back of this card is to have the green tribal bands and all the text and logo in foil with the black being in a matte finish. We will not UV coat this card in order to maintain the uncoated finish. Once we get these business cards photographed we will add them to this blog so our clients (Professional Creatives and Graphic Designers) can see the difference between the electronic proof and the actual printed piece.