Testimonial from a Flesh Co customer

Several months ago we had the opportunity to help Matt Mock, Safeguard,  with an integrated project that had been a pain point in the past.  Below is a recount of our follow up conversation.

Flesh Co> What event initiated your first call to Flesh Co?

Matt M.> I met with Flesh Co representatives at the Safeguard Exchange in Vegas.  I believe the year was 2013.  I had sample of the project with me and sought out Flesh, I knew you had the capabilities I was looking for.

Flesh Co> How did the Flesh Co team handle your inquiry?

Matt M.> Wonderfully and very quickly.  They put me in touch with Sandra Baker and I have been working with her ever since.

Flesh Co> How would you describe the success of the project from quote to product delivery?

Matt M.> Awesome.  Easy to communicate with, quick to answer and very detail oriented…..I was not used to this from the vendor who used to handle the order for me.

Flesh Co.> What was your client’s level of satisfaction with the Flesh Co product?

Matt M.> No issues with the final product.  When you don’t hear from the client after delivery, that is usually a good thing.  I did follow up and for the first time in 3 years the order was correct.

Flesh Co.> What would you say to other peers regarding doing business with Flesh Co?

Matt M.> Make them your first call for integrated products.   Flesh’s quality control is far superior.

Flesh Co.> What else would you like to share with your peers regarding your experience with Flesh Co?

Matt M.> I have fired the previous supplier for any product that Flesh can do.  Quality, speed, communication are all wonderful.

We sincerely appreciate Matt’s comments and trust; and we look forward to serving his future integrated product needs.

For more information on Integrated Solutions offered by Flesh Co, visit us at FleshCo.com.

Print to deter counterfeiting

Holographic foil securityA good design to deter counterfeiting requires layers of security.   Covert and overt features in the paper can be combined with printed security features and possibly even post print options.   In the sample shown, the distributor included a holographic security foil as well as thermochromic ink.  These two features guard against document forgery by digital attackers using scanners or color copiers.  The security foil cannot be copied due to the reflectance of the 3D image.

The thermochromic ink (lower right corner) reacts to the heat from the scanner light source and dissipates before the scan occurs rendering the area colorless.  Both of these features not only deter scanning and other digital attacks, they can both be used in the field for on-site document authentication.   The first line authenticator merely needs to rub the thermochromic icon to determine if the document is real or counterfeit.   Utilizing covert and overt print-based features will add two additional layers to the paper-based features producing a very secure document.

Money OrderNo document can be guaranteed against counterfeiting as often times the point of presentment is where the lack of security exists.  However, layering security features in the paper, print and post production formats provide the best protection from attacks.   Post production normally involves the digital printing device used to print the variable data on the final document prior to issuance.  Some digital presses are equipped to print UV inks as well as microprint fonts.  Smaller desktop models, such as the TROY SecureUV printer, can add variable data in a covert manner.

About us

Flesh Co is a leader in document security design and production.  For more information on our security offering contact our sales team at Fleshco@Fleshco.com or request one of our Document Security sample kits.

Download our security whitepapers HERE.

Other information on security printing:

Healthcare two-write system

Two-write systems are documents that are created in a manner that allows information to be added to one side, then flipped so additional information can be added to the back.   Many years ago, this design would have included something as simple as a three part form using bond and carbon construction.  Part one would be a 20 lb bond, part two a heavy ledger or tag substrate and, part three, another 20 lb bond sheet.  Standard carbon would be used between parts one and two.  The carbon between parts two and three would be run with the carbon side facing up.   In effect, creating two unit set forms that allowed information to be transferred from part one to part two.

unit set two write systemRecently we produced a carbonless design for a client of a two-write system.  This process involved creating a four part form.   Part one is a standard weight CB sheet and part two is a ledger basis weight with CF coating.   Part three, as you may have figured out, is a CF coated ledger run upside down with part four being standard weight CB sheet run two write systemupside down.   By gluing the top and bottom stubs of the unit set construction, the client receives a two-write, carbonless unit set form.

In this case, unique binder punching was included for inserting into a medical ring binder.  (We often see medical punching that requires punch holes at the top and sides of the same document.)   The two-write system is an effective document design allowing business forms with two separate functions or purposes to be combined into a single document keeping critical medical data together for immediate access.

two write unit set designFlesh Co produces a wide variety of applications for the healthcare marketplace.  Many of these are form and label designs using affixed or integrated labels with 1D and 2D variable barcoding.   You can request one of our Healthcare Vertical Market Kits and other samples by visiting our sample request page at Fleshco.com.


2017 PSDA Emerging Distributor Summit

The PSDA has announced the dates for the next Emerging Distributor Summit meeting.  The summit will take place on March 4-5, 2017 in St. Louis Missouri.    The meeting is open to members and non-members.  The EDS meeting is a great opportunity to network with other leading print distributors from across the country.

Embassy Suites by Hilton St. Louis Airport
11237 Lone Eagle Drive
Bridgeton, MO. 63044     Map

View the agenda

Hotel Information:
Room Rate: $149
Call 1-800-EMBASSY – mention the PSDA group room block.
Click here to reserve your room online.
Book by Friday, February 10, 2017, to receive the PSDA discounted rate.

Registration Rates: Register Here
Register by 2/3/2017: $299
Register after 2/3/2017: $399

Rates above are for PSDA members.

Non-members may attend for an additional $100.00


PSDA 2017 CEO Summit Jan. 30-Feb. 1

Join us at the 2017 PSDA CEO Summit taking place Jan. 30 – Feb. 1 at the spectacular Biltmore Hotel in Coral Gables, FL. The PSDA planning committee is creating an event experience that will feature new education formats, fresh networking opportunities and a few surprises. Most importantly, you will have ample time to engage with and learn from more than 100 of your peers.   This is one event you do not want to miss.  If you are not a PSDA member, there is still time to join to take advantage of this conference.

View the agenda



Label/Form combinations drive efficiency

Label/Form combinations are an effective means of combining a business workflow document with various labeling applications.   There are three primary methods of creating a label/form application.   Affixing the label to the document face, adding a full ply of label material or creating a label from the document substrate by using a liner and die cutting process.

Affixed design

In this format, the base document is normally produced by offset press, typically rotary offset.  The label portion is manufactured by flexography.   During the final stages of production the labels are affixed to the face of the business document.  There are several advantages to form and label designs.  As the document is imaged with variable information the label is imaged as well.   This can reduce the print time since the label is no longer imaged as a separate function.    Because the label is affixed to the form, time may also be saved during the labeling function as the worker does not need to track down or print a label matching the documentation.  This can also reduce the potential for mislabeling errors.

affixed label

Affixed labels allow for a variety of substrates to be used outside of the traditional EDP smudge-proof face stock.   Films, vinyl and even synthetics can be affixed to create removable and more durable labels.  Using more traditional label stock also gives the user access to a wider scope of adhesives ranging from static cling to aggressive tire label adhesive.    Multiple labels can be applied or, in some designs, a single label will be die cut to create smaller labels.

Affixed label applications are normally found in manufacturing where products or package shipments can be labeled during the manufacturing process.  Other markets that may be potential users of label/form applications would include transportation, warehousing and distribution.  Affixed labels are also used in direct mail campaigns to engage the mail recipient to affix the label to a response card.

A drawback to the affixed design is the fact that the label rests on top of the document.   If the document is imaged using an impact or inkjet printer, there is the potential for the print head to snag on the label.  In addition, imaging using a laser printer may be challenging if the variable data is close to the edge of the affixed label surface.   However, for many label/form applications, affixed labels are an efficient solution.

Form with label design

Label and form combination

 Some applications may require more labels or larger labels.  In these cases, an entire page of label material can be incorporated into the business document.  Typically these are unit set constructions though continuous designs are available.  One advantage to this design is the opportunity to use various sized labels on a single page.  This could include a shipping label, product marking label, return goods label and more.  In areas where multiple components need to be marked or project tracking can be improved using barcoded labels, this format can be very effective.   As with an affixed label, the label is printed by flexography while the form is printed using offset imaging.   Both the form and label can utilize barcodes or human readable numbering.

Integrated design

An integrated label design utilizes a special liner material which is applied to the back of the document in the area of the label.   The liner transfers adhesive to the back of the specified label area, then the face of the document is die cut to the correct label size.  In this format, the stock used for the document is also used for the label.   This can reduce the overall cost when compared to an affixed label design.   Integrated label designs allow for imaging on most printers such as impact, laser, inkjet and even high-speed digital presses.   Like the other label/form designs, efficiency can be improved and a reduction in time, as the document and label are printed in one process.  Also, multiple labels can be created by using various die cutting patterns.

integrated address labels

Integrated label designs are frequently found in the healthcare industry where multiple labels, each with a matched barcode, are necessary.   Integrated labels are also heavily used in the warehouse and distribution markets where a package label can be incorporated into a pick/pack list which may expedite the fulfillment process.

Regardless of the selected design, a cost justification can be created to compare current process cost using separate form and label products to projected processing cost using an affixed, label/form or integrated design.  Regardless of the selected format, form and label combinations are an excellent solution to improve workflow while potentially reducing product marking and shipping errors.  Print resellers can learn more by contacting our sales team or visiting our website at Fleshco.com.

Units Sets

If you have been in the business forms industry for any amount of time, you’re aware of the overall decline in some areas.  Many laser cut sheet products are now being imaged on blank paper or have migrated to a pure digital format.  Continuous forms became laser cut sheets and, in some cases, continued that path to blank stock or digital format.   Unit set format production, sometimes referred to as “snap outs”, has actually stabilized.   Many of these applications cannot be supported effectively by digital or cut sheet designs.  As with any business forms design, the format and construction should help the customer move information efficiently.

Why unit set design

Many of these applications require the input of information in the field.  This means handwriting data to the document.  For example, the heating and air conditioning company that services your home.  They arrive, perform the service and complete a work authorization form documenting their service, time and costs.  Or the local officer who pulls you over for speeding and issues you a traffic citation.   These and other forms are more difficult to replace with digital technology and, therefore, can be a great source of consistent reorders.

A business document performs three basic functions.  It can store information, transfer information and allow someone to retrieve information.  A business form should be designed for maximum efficiency in each of those tasks.   Screening and color coding can be used to lead the eye to the correct areas for input or reading.  Copies should be tagged so dispersing to the correct departments or persons is easily accomplished.  All designs should be focused on improving productivity, increasing information flow and reducing errors created by poor, inaccurate or lack of data.

Potential customers

  • Plumbing
  • Electrical
  • Law enforcement
  • Fuel delivery
  • Courier services
  • Lawn care
  • Cleaning services
  • Repair



  • Pocket form – Designs used to hold copies of information such as service records or payment.
  • Transfer tape – Used to seal a pocket form or affix a document to a product for tracking purposes.
  • Variable imaging – Provides a means to track production, orders or other information tied to an account, client or service performed.
  • Form and Label – Applications incorporating integrated, affixed or sheets of labels into the document for shipping, product marking, chain of custody or other tracking processes.


Unit set designs can be valuable sources of print sales as they are less likely to be replaced by a digital technology.   Innovative designs can incorporate labels, cards, variable imaging, tags, tape and other value add features to make the form more effective and efficient to the client’s business operations.  For more information on unit set applications visit our website at Fleshco.com and request a Unit Set sample packet.  For a quote on a current business document application, call our sales team at 800.835.0098.

5s is the name of the game

As part of Flesh Co’s on going continual improvement process, a 5s Blitz was recently performed on their IT and CTP (computer to plate) areas. 5S is a system designed to reduce waste and optimize productivity by maintaining an orderly workplace and using visual guides to produce more consistent operational results.   The five components of the process are sort, set in order, shine, standardize and sustain.

Randy Lewis“During our Kaizen events where we rebuild a piece of equipment, we use the 5S process to organize tools and the press work area”, says Randy Lewis, VP of Manufacturing. “By applying the same 5S process to work areas such as IT and CTP, we will lay new groundwork to stabilize, simplify and standardize those departments where what is supposed to happen does happen, on time, every time, day and night. It’s about organization, discipline and team building.  Flesh Co is committed to utilizing Lean Manufacturing and Six Sigma tools throughout each department; it’s our DNA for a continuous improvement culture”.  (Hear from Randy on Six Sigma)

After the 5S program is completed, parts and tools most often needed are arranged for quicker access. Work areas are cleaned and the organizational process documented so the new standards will be maintained.   Once implemented, the new standards set in place become the norm for that work area and we can link 5S activities with other continuous improvement initiatives in our organization.

To see  before and after photos of the 5S Blitz and past Kaizen events click HERE>

The Flesh Co CTP 5S team

5 S team

Back row left to right:

Oral Smith, Lori VanDyne, Dakota Bingham, Shelley Perez

Front row left to right:

Charles Swesey, Derrick Carson, Rick Holsinger, Cathy Shiflett


The Flesh Co IT 5S team


Back row left to right:

Ben Daugherty, Marvin James, Rene Cares, Seth Little, Casey Westhoff

Front row left to right: Jillian Flesh, Jennifer Meeks, Derrick Carson

Guest ID card used at The Inn on Biltmore Estate

If you have stayed at The Inn on Biltmore Estate, you may have noted that the check in folio has two clean release cards.  These cards are imaged during the check in process with your name, arrival date and an ID number.   The cards act as your identification as you access the various services during your stay.

clean release ID cardIdentification cards are frequently used at resorts and other destination venues to allow patrons to access services without having to carry cash or formal identification such as drivers license or a credit card.  This is more convenient for the customer and adds to the overall customer experience.  With the average hotel stay only 3-4 days, clean release or integrated cards are perfect for short term identification.  So which format works best?

The decision could depend on the type of resort and how often the card would be presented.  Venues where moisture would come in contact with the card, would lean toward a clean release card which is a synthetic material and water resistant.  The card is affixed to the face of the document, and therefore, more conducive to laser printers than inkjet where the print head might catch on the edge of the card.

Integrated cards are created by applying face and back lamination to a 28# ledger substrate, creating durable cards that stand up to multiple presentations.   As they are made with an internal paper ply, moisture could penetrate the card.  Integrated cards have no raised surface for moving print heads to catch, so they are very good for both laser or inkjet imaging.