FTA (изд-во). Flexography: Principles And Practices. Vol.1-6
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4 FLEXOGRAPHY: PRINCIPLES & PRACTICES
MECHANICS OF DESIGN PREPARATION 22
Thumbnail Sketches..............................................................22
Comprehensive Roughs ........................................................22
Rendering (Finished Comp).................................................22
Presentation............................................................................23
Electronic Imaging and Computer Graphics......................23
The Work Flow Process..................................................23
Experimentation..............................................................23
Presentation and Approval.............................................24
PRODUCTION ART 26
Design Elements ....................................................................26
Typography.......................................................................26
Overprints.........................................................................30
Trapping............................................................................31
Die Lines...........................................................................32
Illustrations ......................................................................32
Object-oriented Artwork ................................................33
Bitmapped Graphics........................................................35
Line Drawings and Clip Art............................................35
Photography.....................................................................36
Halftone Images...............................................................37
Duotones...........................................................................39
Alternative Screens.........................................................40
High-fidelity Color Printing............................................41
Scanning ...........................................................................41
Bar Codes.........................................................................42
Color Reproduction and Line Count.............................43
Color..................................................................................47
FINAL APPROVAL 49
Color Proofing........................................................................49
PROGRAMS AND APPLICATIONS 50
Layers ......................................................................................50
Drawing Programs.................................................................52
Page Layout Programs ..........................................................52
Raster Image Programs.........................................................53
Special Effects........................................................................55
Integrating Programs.............................................................55
Color Management Programs...............................................56
FILE FORMATS OF IMPORTED OR PLACED GRAPHICS 57
COMPLETED DESIGN GUIDELINES 61
PREPRESS
INTRODUCTION 65
IMAGE CAPTURE 67
Scanners..................................................................................67
Scanning Images ....................................................................68
Producing a Color Separation for Flexo.............................69
Highligh/Shadow Treatments.........................................70
Separation Techniques: GCR/UCR/TAC .......................70
Cutback Curves/ICC Profiles.........................................70
Digital Photography...............................................................71
Minimum/Maximum Dot Requirements.......................72
Use of 100% GCR.............................................................72
CMYK vs. RGB Proofing.................................................72
Scanning Department Setup.................................................72
PREFLIGHT QUALITY CONTROL 74
Size/Dimensions.....................................................................74
Scanning Techniques.............................................................74
Inks Requested vs. Inks Required........................................74
Special Colors: Spot or Process Match...............................75
Ink Rotation and Trapping....................................................76
Tint Builds – Three-color Type or Tints..............................77
Screening Requirements.......................................................77
Vignettes/Gradations/Blends................................................77
UPC Positioning.....................................................................78
DESKTOP/PREFLIGHT 79
“Reading” Files.......................................................................79
Preflight Responsibilities......................................................80
Software Versions............................................................80
Low-resolution Placed Images.......................................80
Live Images.......................................................................81
Imported EPS Files.........................................................82
Fonts..................................................................................82
Line Weights/Font Sizes..................................................82
Tints and Screen Builds..................................................82
Vignettes and Gradations...............................................82
Equipment and Software................................................83
JOB ASSEMBLY/LAYOUT 84
Hardware and Software........................................................84
Technical Responsibilities....................................................85
Using Layers.....................................................................85
Placing High-resolution Images.....................................85
Silhouetting of Images....................................................85
Assignment of Screen/Tint Values
and Color Information..................................................85
Trapping (Spreads and Chokes)....................................86
Bar Code Creation/Placement.......................................86
Application of Distortions..............................................86
Dot-gain Compensation..................................................87
FILM OUTPUT/IMAGESETTING 89
Film Properties.......................................................................90
Emulsion...........................................................................90
Orientation........................................................................90
Film Thickness.................................................................90
Finish.................................................................................90
VOLUME 2
6 FLEXOGRAPHY: PRINCIPLES & PRACTICES
Image Properties....................................................................90
Screen Ruling and Screen Angles..................................90
Dot Shape.........................................................................91
Combination Screening ..................................................91
Registration and Mounting Marks.................................91
PROOFING 93
Types of Proofs.......................................................................93
Concept Proof..................................................................93
Color Target Proof...........................................................93
Contract Proof.................................................................94
Proofing Systems ...................................................................96
Analog Proofs...................................................................96
Press Proofs.....................................................................96
Digital Proofs...................................................................97
BACK-END QUALITY CONTROL 100
Checking Proofs...................................................................100
Dot Gain..........................................................................100
Solid-ink Density............................................................100
Ink Hue/Spectral Data...................................................101
Substrate.........................................................................101
Checking Films.....................................................................101
D-min/D-max..................................................................101
Dot Shape and Accuracy..............................................101
Screen Rulings and Angles...........................................102
Trap .................................................................................102
Distortion and Compensation......................................102
Color Breaks.........................................................................103
The Last Look.......................................................................104
CUSTOMER SERVICE 105
Job Engineering/Preflight...................................................105
Estimating/Quoting..............................................................105
Order Entry...........................................................................105
Liaison Between Customer and Plant...............................106
“Last Line of Defense”.........................................................106
APPENDIX 107
A: FIRST Specifications in Preflight................................107
B: Preflight Checklist.........................................................108
PROCESS COLOR
INTRODUCTION 111
COLOR THEORY 113
Perfect Spectra.....................................................................113
Additive Color................................................................114
Subtractive Color...........................................................114
Real-world Spectra ..............................................................115
Quantitive Color – CIELab Color space............................118
Light Sources..................................................................118
Eye Response.................................................................119
CIE Color Space.............................................................119
L*a*b*..............................................................................119
L*C*h°.............................................................................120
Color Difference............................................................120
Metarism.........................................................................121
Gamut..............................................................................121
COLOR MEASUREMENT 123
Densitometer........................................................................123
Density............................................................................124
Dot Percent ....................................................................124
Trap .................................................................................124
Print Contrast.................................................................125
Hue Error/Grayness ......................................................125
Spectrophotometer..............................................................125
COLOR MANAGEMENT WORKFLOW 127
ACHIEVING OPTIMUM PRESS PERFORMANCE 130
Press Optimization...............................................................130
Press Characterization........................................................131
Target ..............................................................................131
Types of Characterization...................................................131
Visual Characterization.................................................131
Line Characterization....................................................133
Screen Characterization...............................................133
Process-color Characterization...................................133
Cutback Curve......................................................................133
CIELab Correction (ICC Profiles) .....................................137
Gray Balance ........................................................................140
Process Control....................................................................141
APPENDIX 143
A: Reference Resources ....................................................143
B: Density-based Measurements......................................144
C: Colorimetric Calculations ............................................145
INDEX 147
VOLUME 2
CHAPTER 1
Design
2 FLEXOGRAPHY: PRINCIPLES & PRACTICES
ACKNOWLEDGEMENTS
Author/Editor: Kelley Callery, Flexographic Technical Association
Contributors: Lucinda Cole, Flexographic Technical Association
Eugene L. Green, Sr., Wilson Engraving Co., Inc.
Dana Lamb, California State University, Fullerton
Veronica Michalowski, Gaylord Container
Frank N. Siconolft (retired), Matthews
International Corporation
Pantone and PMS is a registered trademarks of Pantone, Inc. Apple, Macintosh are registered trademarks, and
TrueType is a trademark of Apple Computer, Inc. Adobe, Adobe Acrobat, Adobe Dimensions, Adobe Distiller, Adobe
Illustrator, Adobe Pagemaker, Adobe Photoshop and PostScript are trademarks of Adobe Systems Incorporated or its
subsidiaries and may be registered in certain jurisdictions. QuarkXpress is a registered trademark of Quark, Inc.
FreeHand is a trademark of Macromedia, Inc. DOS and Windows are trademarks of Microsoft Corporation. All other
trademarks are the property of their respective owners.
All trademarks have been used in an editorial fashion with no intention of infringement.
G
raphic design for packaging is
the process of translating the
image that the customer has in
mind into a finished package.
In order to accomplish this
task successfully, a designer
requires a great deal of information before
and during the entire design process.
To accomplish its many objectives, flexo-
graphic design has to play a number of roles.
This chapter talks about how fabrics, paper
products, packaging, shipping cases, labels
and any other flexo-printed product can be
designed most effectively.
Over the past 20 years, the graphics arts
industry has seen fundamental changes in
the way color is reproduced. Every aspect of
color reproduction has undergone a com-
plete transformation as the industry has
moved from traditional mechanical prepress
to digitally-based methods of production.
The work involved in preparing color art-
work for printing has transitioned from dedi-
cated high-end equipment at specialized
trade shops to standard desktop computers
used by the designer. The roles once filled by
typesetters, camera personnel, strippers and
color separators have dramatically changed,
and in some cases even disappeared with the
advent of electronic prepress (Figure
b
).
When a designer develops packaging
graphics, many considerations relating to the
type of package printing must be reviewed
and applied in order to achieve success and
meet the customer’s marketing needs. A suc-
cessful design is eye catching and stands out.
It is achieved within the proposed budget,
and the final printed piece must look as good
as the approved contract proof.
DEFINITION OF DESIGN
Design is an orderly combination of formal
elements that produces a composition. In
flexography and other printing processes,
design is the visual plan of line, mass and
color, selected and assembled to accomplish
a designated goal. That goal may be to con-
vey beauty, or simply to provide information
by the arrangement of copy on a label. Often,
the goal is to sell a product. In that case, the
design has to have impact and it must pro-
vide identification and information about the
item. Sometimes the design goal involves the
printed product itself, as with giftwraps, tex-
tiles, cups and containers.
A designer’s job is to translate the client’s
ideas into a finished product that will satisfy
consumer preferences. In the case of label-
ing, packaging and shipping containers,
design is often the only means that identifies
the product, the brand and the manufacturer
or packer. In addition, many products
depend heavily on package design to estab-
lish their image for merchandising, advertis-
ing and promotion (Figure
c
).
DESIGN 3
Introduction
b
(Following pages)
The package printing
process from start to
finish.
c
Most products depend
on package designs to
identify the product and
to establish their image
for merchandising,
advertising and
promotion.
c
4 FLEXOGRAPHY: PRINCIPLES & PRACTICES
B
O
B
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’S
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The Packaging Process
Design
Scanning
Imagesetting
Off-Press
Proofing
Stripping and Imposition
b
DESIGN 5
B
O
B
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B
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Platemaking
Printing
Folding, Binding,
and Finishing
Shipping
6 FLEXOGRAPHY: PRINCIPLES & PRACTICES
T
he printer or separator must
supply the designer with specif-
ic information about print para-
meters. This is usually part of
the press characterization infor-
mation, and is best furnished
very early in the design process. The design-
er’s understanding of the flexo criteria
should be used creatively to maximize the
many benefits of the flexographic print
process (Figure
d
). Advantages of flexo
include: the use of many colors, including
metallic and fluorescent inks, a wide variety
of substrates with unique characteristics
(Figure
e
), and many special finishing
effects like embossing, foil stamping, holo-
grams, varnishing and UV coating.
In addition to meeting with the printer, the
designer must also work closely with the con-
sumer product company to meet its market-
ing objectives, requirements and goals. For
the consumer product company and the
Design Considerations
d
Successful design
creatively utilizes the
many unique features
of the flexographic print
process.
B
O
B
’S
d