Technical Guide · 2026 Edition
Security Foil — Registered Holographic & Anti-Counterfeit Hot Stamping Foil
Security foil is a hot stamping foil engineered with an embedded optical anti-counterfeit feature — holographic diffraction, dot-matrix, kinegram-style animation, custom-logo registered hologram, or tamper-evident VOID release — that cannot be photocopied, scanned or replicated with consumer printing equipment. The flagship sub-grade — registered holographic foil — uses machine-vision register marks to land the security image at the exact same coordinate on every carton, label or document at register tolerance ±0.15 mm. This guide covers the 6 standard security grades, register-control mechanics, press settings, and MOQ-from-1-roll sourcing.
What is security foil — and what makes registered holographic foil different?
Security foil is a hot stamping (or cold stamping) foil engineered with an embedded optical anti-counterfeit feature — holographic diffraction pattern, dot-matrix micro-pixels, kinegram-style 2D/3D animation, custom-logo hologram, micro-text, nano-text, or tamper-evident VOID release — designed so the feature cannot be scanned, photocopied or replicated with consumer printing equipment. The flagship sub-grade — registered holographic foil (also: register-controlled holographic foil, register hologram, position-controlled hologram) — adds machine-vision register marks at the foil edge so a register-equipped stamping press lands the security image at the exact same coordinate on every impression at ±0.15 mm tolerance. That locked-position behaviour is the gating requirement for serialised security applications: banknotes, passports, tax stamps, pharmaceutical authentication, brand-protection labels and certificates where the hologram must align to a serial number, guilloché frame or logo. Browse the matching Holographic Hot Stamping Foil range or read the Holographic Foil guide for the full pattern catalogue. Compare against transparent holographic foil for overlay-style security on top of CMYK artwork.
How registered holographic foil is made & stamped — 5-step closed loop
Holographic master engraving
Your custom logo (or selected stock pattern) is engraved into a holographic master plate at sub-micron resolution. Master controls the diffraction angles, viewing-tilt animation and any embedded micro/nano-text overlays.
Pitch embossing on PET web
The master roller hot-presses the holographic image into a ~10 nm aluminium + clear-lacquer stack on 12–25 µm PET carrier, repeated at fixed pitch along the web — typically 12, 16, 20, 24, 28 or 32 mm depending on stamped-image size.
Register-mark printing
A black optical register mark (or magnetic Hall-readable mark on the metallised layer) is printed at the foil edge once per pitch — this is the synchronisation signal the stamping press reads to lock the foil to the substrate.
Register-controlled stamping
On press, an optical / magnetic sensor reads each register mark; the PLC compares against substrate-feed position and adjusts the foil-pull servo every cycle. Result: hologram lands at ±0.15 mm tolerance on every stamped impression at 4,000–6,000 sheets/h.
Inline AOI verification
Downstream automated optical inspection camera verifies hologram presence, position and pattern integrity on every sheet; failed impressions are diverted automatically — critical for banknote and pharma applications.
6 standard security foil grades — pick by threat model
Grades 1–3 ship from stock at 1-roll MOQ. Grades 4–6 require tooling and KYC + NDA.
| Grade | Security Level | Stock or Custom | Best For |
|---|---|---|---|
| 2D/3D Holographic (rainbow) | Entry-level | Stock — 6 patterns | Cosmetics authentication, retail anti-tamper, promotional |
| Dot-Matrix | Mid | Stock — 8 patterns | Brand protection, electronics, certificates |
| Pillar-of-Light | Mid (+ premium aesthetic) | Stock — 4 patterns | Luxury cosmetics, spirits, fragrance with anti-counterfeit |
| Kinegram-style / 2D-3D Animation | Mid–High | Custom (engraving fee) | Diplomas, certificates, mid-tier government documents |
| Registered Custom-Logo Hologram | High (banknote-adjacent) | Custom (engraving + register fee) | Tax stamps, excise labels, pharma serialisation, brand protection |
| Tamper-Evident VOID | High (irreversible) | Custom (release-layer tooling) | Pharma cartons, electronics warranty, controlled substances |
Registered vs non-registered holographic foil — decision matrix
| Parameter | Registered Holographic | Non-Registered Holographic |
|---|---|---|
| Image position on substrate | Fixed, ±0.15 mm tolerance | Random / scattered |
| Press requirement | Register-control unit mandatory | Standard stamping press |
| Foil consumption | Optimised — 1 image per pitch | 3–5× higher (pattern wasted) |
| Custom logo capable | Yes — your engraved master | Stock patterns only |
| Suitable for serialisation | Yes — image aligns to serial / barcode | No |
| MOQ | 500 m² (stock pattern) / 1,000 m² (custom logo) | 1 roll (stock) |
| Lead time | 12–45 days | 5–7 days |
| Typical end-use | Banknotes, tax stamps, pharma, brand protection | Decoration, cosmetics, novelty, retail |
| Tooling cost | USD 1,200–4,500 one-time | None |
Security foil — technical specifications
| Parameter | Stock Holographic | Registered Hologram | Banknote-Grade OVD |
|---|---|---|---|
| PET carrier thickness | 12 µm | 16–19 µm | 19–25 µm |
| Aluminium layer | ~10 nm | ~10 nm | ~10 nm + barrier coat |
| Holographic pattern | Stock (rainbow / dot-matrix / pillar) | Custom logo + stock combo | Custom + nano-text + magnetic |
| Register marks | None | Optical or magnetic, per pitch | Optical + magnetic + IR |
| Pitch options | n/a | 12 / 16 / 20 / 24 / 28 / 32 mm | Per project |
| Register tolerance @ 4,000 sph | n/a | ±0.15 mm | ±0.10 mm |
| Roll width | 200–1,600 mm | 200–1,300 mm | 200–1,000 mm |
| Roll length | 120 / 300 / 600 m | 120 / 300 m | 120 / 300 m |
| Stamping temp. | 115–130 °C | 115–125 °C | 115–125 °C |
| Nip pressure | 8–12 bar | 8–10 bar | 8–10 bar |
| Lightfastness (Blue Wool) | 6–7 | 6–7 | 7 |
| MOQ | 1 roll | 500 m² (stock) / 1,000 m² (custom) | Project-based + KYC |
| Lead time | 5–7 days | 12–45 days | 60–90 days |
Where security foil and registered holographic foil are used
Banknote-grade OVD security foil with registered custom-logo hologram, nano-text and magnetic strip — the gold standard for currency, passports, visas and driving licences. Project-based, KYC + NDA required.
Registered custom-logo hologram with optional UV-fluorescent ink and serialised numbering — standard finish for tobacco tax stamps, spirits excise labels and pharmaceutical track-and-trace.
Registered hologram + tamper-evident VOID on Rx cartons, vaccine packs and controlled-substance labels — defeats both counterfeiting and label-swap attacks. EU FMD and US DSCSA compliance.
Kinegram-style or registered hologram with university or government logo — anti-counterfeit overlay on degrees, professional licences, training certificates and academic transcripts.
Custom-logo registered hologram on cosmetics, fragrance, fashion accessories, premium electronics and replacement automotive parts — defeats grey-market and counterfeit supply.
Registered hologram + dot-matrix on neck labels, bottle seals and cigarette pack stamps — combined with serialised track-and-trace codes for excise compliance and supply-chain integrity.
Technical Specifications FAQ
Q01What is security foil?+
Security foil is a hot stamping (or cold stamping) foil engineered with an embedded optical security feature — holographic diffraction pattern, kinegram-style 2D/3D animation, micro-text, nano-text, guilloché, custom-logo hologram, or tamper-evident VOID release — designed so the feature is impossible to scan, photocopy or replicate with consumer printing equipment. Construction is the standard 5-layer foil stack (PET 12–25 µm + release wax + clear or pigmented lacquer + embossed + metallised layer (~10–50 nm Al) + heat-activated adhesive) but with security tooling: a precision-engraved holographic master, optional micro/nano-text overlays, optional VOID release layer, and (for the registered grade) machine-vision register marks that lock the security image to a defined position on every stamped impression.
Q02Security foil vs registered holographic foil — what's the difference?+
Security foil is the umbrella term covering all foils with an optical anti-counterfeit feature. Registered holographic foil (also: register-controlled holographic foil) is the highest-spec sub-variant: the holographic image is repeated at a precise pitch along the web (typically 12, 16, 20, 24, 28 or 32 mm) and a stamping press equipped with a register-control unit reads optical or magnetic register marks at the foil edge to synchronise foil advance with substrate position. Result: the security hologram lands at the exact same coordinate on every carton, label or document, register tolerance ±0.15–0.30 mm. Non-registered holographic foil scatters the pattern randomly across the stamped area — fine for decoration, but a non-starter for serialised security applications where the hologram must align to a logo, serial number or guilloché frame.
Q03What are the 6 standard security foil grades?+
(1) 2D/3D Holographic — full-spectrum rainbow diffraction, entry-level security. (2) Dot-Matrix — millions of micro-dots with computer-controlled angles, kinetic effect on tilt. (3) Pillar-of-Light — vertical light columns, premium luxury + security crossover. (4) Kinegram-style / 2D-3D Animation — image animates / changes / morphs as the substrate tilts, mid-grade security. (5) Registered Hologram (Custom-Logo) — your logo embossed at a precise pitch with register marks, locked-position stamping, banknote-grade. (6) Tamper-Evident VOID — when peeled, releases a 'VOID' or custom pattern on the substrate, irreversible. Grades 1–3 ship from stock at 1-roll MOQ; grades 4–6 require tooling (USD 800–4,500 one-time) and 25–45 days lead time.
Q04How does register-controlled holographic foil stamping actually work?+
Four-step closed-loop. (1) Foil web carries a holographic image repeated at fixed pitch (e.g. 24 mm) plus a black register mark printed or laser-etched at the foil edge every pitch. (2) An optical sensor (or magnetic Hall-effect sensor on metallised marks) on the stamping press reads each mark as the foil unwinds. (3) The press PLC compares the mark position against the substrate-feed position (read from a second sensor on the carton/label feeder) and adjusts the foil-pull servo every cycle. (4) The hologram lands at the same coordinate on every stamped sheet, register tolerance ±0.15–0.30 mm at 4,000–6,000 sheets/h. Our XG1080G fully-automatic hot stamping machine ships with this register-control unit factory-fitted.
Q05How do security foils resist counterfeiting?+
Five layered defences. (1) Holographic diffraction pattern — physically embossed into ~10 nm aluminium at sub-micron resolution; cannot be photocopied or scanned (a copier captures only one viewing angle, loses the rainbow and kinetic effects). (2) Micro-text — readable only under 10× loupe, defeats consumer-grade scanning. (3) Nano-text — readable only under 200× microscope, defeats high-end scanners. (4) Custom-logo registered hologram — requires your engraved master plate (held by manufacturer under NDA), defeats grey-market foil supply. (5) Tamper-evident VOID — releases a pattern on peel, defeats label-swap attacks on pharmaceuticals, electronics, certificates. Premium banknote-grade OVD security foil combines all five plus colour-shift inks and machine-readable magnetic codes.
Q06How to stamp security foil — register tolerances and press settings?+
Three rules. (1) Register-control unit is mandatory for registered hologram and tamper-evident grades — a standard stamping press without register control will scatter the image randomly and burn through 3–5× more foil. (2) Press temperature 115–130 °C, nip pressure 8–12 bar; security foil aluminium is ultra-thin (~10 nm for holographic, ~50 nm for VOID) and the embossed pattern is heat-sensitive — overheating above 140 °C blurs the hologram. (3) Polished brass die only (never chemically etched zinc) — sharp edges keep the hologram pattern crisp at the stamped boundary. Register tolerance ±0.15 mm at 4,000 sheets/h, ±0.30 mm at 6,000 sheets/h on the XG1080G class.
Q07What substrates and end-uses require security foil?+
Banknotes, passports, ID cards, visas, driving licences, tax stamps and excise labels (registered hologram + nano-text). Pharmaceutical secondary packaging — Rx cartons, vaccine packs, controlled-substance labels (registered hologram + tamper-evident VOID). Premium electronics — smartphones, cosmetics-grade authentication labels (dot-matrix + custom-logo hologram). Certificates, diplomas, university degrees (kinegram-style + micro-text). Spirits and wine excise stamps, tobacco tax stamps (registered hologram + colour-shift). High-value automotive parts authentication (tamper-evident VOID). Luxury fashion brand-protection labels (custom-logo registered hologram). Election ballots and government documents (banknote-grade OVD).
Q08What is the MOQ and lead time for security foil?+
Stock holographic patterns (2D/3D rainbow, dot-matrix, pillar-of-light, 4 stock kinegram-style designs): 1 roll (~640 mm × 120 m ≈ 77 m²), 5–7 days FOB Shanghai. Registered hologram with stock pattern (no custom logo): 500 m², 12–15 days. Custom-logo registered hologram: 1,000 m² MOQ, 35–45 days, plus one-time engraving tool fee (USD 1,200–4,500 depending on logo complexity, pitch and security level). Tamper-evident VOID foil with custom release pattern: 1,000 m² MOQ, 30–35 days. Banknote-grade OVD with nano-text + magnetic strip: project-based, quote on application, NDA + KYC required. Free A4 swatch packs of all stock security patterns ship in 5 business days to qualified buyers.
Free security foil swatch pack
Tell us your threat model, substrate and end-use — we'll ship an A4 swatch pack of all stock security patterns (2D/3D rainbow, dot-matrix, pillar-of-light, kinegram-style samples) within 5 business days. Custom-logo registered hologram quotes within 24 hours under NDA.