Both processes transfer a metallised layer to a substrate; everything else about them differs. The decision is usually made by run length, substrate heat tolerance, and whether the metallic needs to be overprinted.
Side by side
| Criterion | Hot foil | Cold foil |
|---|---|---|
| Tooling | Heated die per design | Printing plate, no die |
| Heat applied | 100–160 °C | None (UV cure) |
| Brilliance | Highest | Slightly lower |
| Edge definition | Sharpest, holds fine serif | Good, softer at small sizes |
| Speed | Press-cycle limited | Full press speed, inline |
| Setup cost | Die cost per design | Plate cost, no die |
| Heat-sensitive films | Restricted | No restriction |
| Overprint to create colours | No | Yes |
| Best run length | Short to medium | Long |
| Emboss in the same pass | Yes (combination) | No |
Where the crossover sits
Cold foil's advantage is that it runs inline at press speed and needs no die, so its cost per unit falls with volume while hot foil's cycle time does not. In practice the crossover for packaging and commercial print falls somewhere in the tens of thousands of impressions, depending on image area and how many designs share a press setup.
Below that, the die cost is small relative to the extra press time cold foil setup consumes. Above it, cold foil is normally cheaper — and if the design puts metallic under a large printed area, cold foil is the only route that can produce metallic colours by overprinting.
Recommendation by scenario
- Premium spirits or cosmetics carton, short run, fine crest: hot foil.
- Long-run pressure-sensitive labels with large metallic panels: cold foil.
- Heat-sensitive BOPP or shrink film: cold foil.
- Raised metallic logo with emboss in one pass: hot foil (combination die).
- Metallic base overprinted in several colours: cold foil.
- Short-run digital covers with no tooling budget: neither — use digital toner-reactive foil.
MOQ and lead time by product
Minimum order quantity and production lead time for the products used in this industry. Each row links straight to the product page with full specifications.
| Product | MOQ | Lead time |
|---|---|---|
| Cold Stamping Foil | 500 sqm | 7–15 days |
| Premium Metallic Gold Hot Stamping Foil | 50 kg | 15–20 days |
| XG1080G Hot Stamping Machine | 1 set | 45–60 days |
Frequently asked questions
Is cold foil cheaper than hot foil?
- On long runs, yes — it needs no die and runs inline at press speed, so unit cost falls with volume. On short runs hot foil is usually cheaper, because the die cost is small compared with the press time cold foil setup consumes.
Does cold foil look as good as hot foil?
- Close, but not identical. Hot foil is brighter and holds sharper edges on fine type, because the heated die presses the foil directly into the substrate. Cold foil is slightly softer at very small sizes but is visually indistinguishable in large solid areas to most viewers.
Can cold foil be overprinted?
- Yes, and that is one of its main advantages. Printing process colours over a cold foil base creates metallic golds, coppers and greens without stocking separate foil colours, which hot foil cannot do inline.
Which process suits heat-sensitive film?
- Cold foil. It cures with UV rather than heat, so films such as BOPP and shrink sleeves that would distort at hot stamping temperatures can be decorated without dimensional change.
Can I use both on the same job?
- Yes, and premium packaging often does: cold foil inline for large metallic areas, hot foil for a registered logo or seal where maximum brilliance and edge definition matter.