White, yellow and pink carbonless form sheets with a pen on a printer’s workbench.

Carbonless Paper for Commercial Printers:
Making the Magic Happen

When people ask us how carbonless paper works, we sometimes joke that it’s magic. I mean, it sure feels magic when your writing copies through 4 sheets before your pen leaves the page.

The truth is, carbonless isn’t magic: anyone who’s ever printed on carbonless paper knows it’s not as simple as waving a wand. You have to know your stuff and pay attention to detail as you print.

But once you understand carbonless paper and how to print on it, you’ll be able to consistently and reliably make customers “ooh” and “aah” at your high-quality carbonless forms.

What is carbonless paper, and how does it work?

If you’re wondering how carbonless paper works, don’t worry. Most of us at the Randolph office have wondered the same (I’m personally still going with ‘magic’ as a working explanation). We won’t go into the scientific explanation of the reactions in the paper here, because the most important thing to understand is that carbonless paper makes copies using pressure. As soon as your pen pushes down on the page, the process begins.

However, you can’t just put two sheets of carbonless together in any which way. The sheets have special coatings which let the magic happen, and they have to be stacked in the right order.

Let’s look at a simple two-part form. You want to write on the top sheet and have it copy onto the bottom sheet. The top sheet has a coating on its back, so it’s called CB, for “coated back.” The bottom sheet has the coating on its front, so it’s called CF, for “coated front.” When you press on the top sheet, the coated back reacts with the bottom sheet’s coated front, and your writing gets transferred.

If you want more copies, you can add sheets in the middle called CFB, for “coated front and back.” Each one has a coating on the front to receive a copy and a coating on the back to make another copy on the sheet below. You still use CB on top and CF below.

Two-part and three-part carbonless forms showing CB, CFB, and CF sheets and their coating positions.

We hope that made sense. If not, feel free to just call it magic.

Why do customers want carbonless?

So, you kind of get how carbonless works, but who cares? Why do people use this stuff?

 

Think about times when you need to make copies on the go, without having a copy machine on hand. Repair orders, service receipts, purchase orders, and packing slips are all common uses for carbonless.

Hands reviewing printed paperwork with a pen and pencil.

The world is racing towards digitalization. But just because fancy tech exists, that doesn’t always mean it’s the most practical option. Your carbonless forms help customers get copies without high-speed internet, new software, time-sink tech training, or expensive gadgets that get even more expensive when they break.

If you have customers working in heating and cooling, auto repair, healthcare, delivery, or food service, then you probably have customers that use carbonless. For even more uses of carbonless, read our blog on ten industries that use custom carbonless forms.

Which carbonless paper should you use?

The paper needs to suit your press as well as your customer’s job. Here are two main Nekoosa grades to know:

Universal Carbonless: for offset and dry toner/laser

As the name might suggest, Nekoosa’s Universal Carbonless gives you an option for either offset or digital dry toner/laser printing. This can be an especially useful option to have if your customer requests you to add numbers, barcodes, or other details that change from form to form.

Digital Carbonless: for dry toner/laser

If you’re printing on digital dry toner/laser equipment, Digital Carbonless is another grade to consider. It’s designed for that equipment, including forms with changing information.

Before you order, check that the grade is right for your machine. If you’re unsure, give us a call. We’re happy to answer your questions and make sure you receive the product that’s right for you.

How many parts, colors, and sheets do you need?

This part isn’t as complicated. The main thing to figure out is how many copies your customer needs. If they need one copy of an original, pick two-part. If they need two copies of an original, pick three-part. If they needed a billion copies? A-billion-and-one-part (wouldn’t that be a fun job?)

Color makes it easier to tell the copies apart, so there are plenty of options there.

Figuring out how many sheets you need for the job is only slightly more involved. All you need to do is multiply the number of finished form sets they need by the number of parts. So 1,000 3-part forms need 3,000 sheets. Don’t forget extras for setup, test runs, or misprints.

Not a math person? Here’s a calculator tool to help:

How many sheets for the job?

2,000individual sheets

One form per sheet, before cutting. Add extra for setup and waste.

Understanding carbonless collation

As we mentioned, it’s really important to get the order of the sheets right when you’re printing on carbonless. That’s why we offer pre-collated carbonless, or stacks of carbonless that already have the right sheets in the right order.

Different printers work in different ways. Some print on the top of a sheet, some print on the bottom. Those differences impact the direction and order of the sheets, so Nekoosa offers its Universal and Digital ranges in straight and reverse. Choosing the right collation is essential to making sure your carbonless works as expected.

Here’s a simplified diagram showing straight vs. reverse collation for three-part:

Three-part carbonless paper collation: straight order is CB, CFB, CF; reverse order is CF, CFB, CB.

You can work out which sequence you need by following a sheet of paper through your machine and seeing how it prints. Try sending a few plain sheets through. Mark the top-facing side and number the sheets so you can tell which one feeds first. Print two test pages, then look at which side was printed and how the pages stacked. Use that information with Nekoosa’s loading charts or your machine’s instructions to choose straight or reverse.

Check Nekoosa’s Universal Carbonless loading chart (PDF, opens in a new tab) or Digital Carbonless loading chart (PDF, opens in a new tab) for guidance. If you have any questions about the collation your machine requires, give us a call. We’re happy to look into it for you.

Tips for getting your carbonless paper ready to use

Universal Carbonless is a bit of an introvert. Nekoosa recommends keeping it wrapped until you’re ready to use it and resealing your leftover sheets. For best quality, give it some time to adjust to the room’s conditions before you print. Be gentle with it, too, because if you put accidental pressure on the sheets, you could end up leaving an unwanted mark.

As you review the design of the form, put yourself in the user’s shoes. Is there enough room to write? Are the labels clear? Maybe they’ll be leaning on a clipboard as they walk around, so perhaps that signature box needs a little more room under it.

A gloved hand marking a volunteer schedule on a clipboard outdoors.

Some other tips from Nekoosa to keep in mind: On U20, Nekoosa recommends light ink coverage for printing on the back and warns that heavy coverage can hide the transferred image. For U20 on an offset press, Nekoosa recommends low-tack inks and only as much printing pressure as needed. Check other places where the machine puts pressure on the sheet, too. And if you use UV inks, follow the curing guidance, because too much UV exposure can impact the coating reactions.

Checking for quality

Before you finish the job, take a completed set and write on it to make sure everything is copying through the way you want it to. Look at every copy: Nekoosa recommends checking the transferred image on each part.

While you’re checking, look at the rest of the form and ask yourself a few key questions:

  • Is the handwriting readable on every copy?
  • Do the printed fields line up?
  • Is the form number right on every part?
  • Are the colors in the right order?
  • Is the form easy to write on and separate?

If you’re numbering digitally, check a few sets in a row. Every part in one set should carry the same number, and the next set should have the next number.

You might want to ask someone else to check the proof. As we’re sure most printers will agree, it’s easy to get fatigued and start missing things when you’ve been working on a design all morning!

Using fan-apart glue to keep sets together

Fan-apart glue is a nifty invention. It keeps your sheets together as a set, but keeps that set separate from other sets. I’m assuming this also works via magic.

Fanned stacks of white, yellow, and pink carbonless paper.

After you apply the glue (here’s a handy guide), each set will stay together and remain separate from the others. It’s not hard to use, but do test it on a few sheets before putting it on the whole order.

Making your job easier for next time

When your job is done, keep a finished set for yourself and take notes on the specifics that went into the job. We occasionally make our own carbonless forms here in the office, and each time, I ask myself why I didn’t write down which side our machine prints on. Maybe you can learn my lesson for me!

If you take good notes, you won’t have to work everything out again when your customer comes back for another carbonless form to “ooh” and “ahh” over.

Browse our carbonless paper, or give Randolph Next Day Paper a call at 1-800-752-2339 so we can help you choose the right product for your job. We’re happy to help you make the magic happen.

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