Bluebeard Coffee and Savor Brands Create First Cut Out Foil Bag

The knockout, or cut out to foil, technique is a coffee bag printing method where certain parts of the design are intentionally left unprinted so the metallic foil layer underneath becomes visible through the ink. In Bluebeard Coffee’s pioneering example, the navy blue background is printed over a metallic foil substrate. Areas that need a metallic shine, such as text or decorative accents, are left without ink. This allows the silver foil layer beneath to show through, creating a striking reflective effect. Because the look is created in the initial print run, there is no need for a separate foil stamping step. This saves time, lowers costs, and still delivers a high-end finish.

Why This Technique Stands Out

The cut out foil method quickly gained popularity for several reasons:

• More cost effective than hot foil stamping
• Maintains the bag’s barrier protection since foil is part of the main material
• Can be combined with matte or gloss finishes for striking contrast

An Industry First

Bluebeard Coffee’s bag is more than just an example of the knockout to foil technique. It was the very first coffee bag in the industry to use it, thanks to Savor Brands’ innovation. This milestone carried two major achievements:

• Aesthetic breakthrough – The design uses the metallic substrate as a core part of the artwork, rather than adding foil after printing.
• Industry first – Savor Brands proved that coffee packaging could combine visual impact with efficient production methods, inspiring roasters everywhere to explore new creative possibilities.

Feature	Cut Out Foil Technique	Hot Foil Stamping
Process	Leaves design areas unprinted to reveal foil	Applies foil with heat and pressure
Tooling	No custom die needed	Requires engraved metal die
Detail	Allows intricate details and fine lines	Best for bold shapes and simpler artwork
Production Speed	Done during the printing stage	Added as a separate finishing process
Cost	Lower setup and faster turnaround	Higher cost due to tooling and extra steps

About Bluebeard Coffee Roasters

Based in Tacoma, Washington, Bluebeard Coffee Roasters is known for small batch roasting that highlights the unique flavor of each origin. They focus on quality, community, and a passion for the craft of coffee.

Bluebeard Coffee Origins

Their coffee menu features a wide selection from celebrated growing regions, including:

• Honduras
• Colombia
• Mexico
• Ethiopia
• Nicaragua
• Rwanda

Each coffee is roasted to bring out its natural sweetness, body, and complexity.