FIRST the Scoop #Color2018 Joe Tuccitto jtuccitto@flexography.org (651) 319-5003 Mark R. Mazur mark.r.mazur@gmail.com (610) 574-6591
FlexographicImageReproduction Specifications & Tolerances
The Mission of FIRST FIRST seeks to understand customers graphic requirements for reproduction and translate those aesthetic requirements into specifications for each phase of the flexographic printing process including: customers, designers, prepress providers, raw material & equipment suppliers, and printers. The intention of FIRST is to provide all participants in the flexographic reproduction process with a common set of guidelines, tutorials, and data that can be used as communication and production tools.
Quality Prior to FIRST, many consumer product companies were creating individual package reproduction specifications. The generation of too many individualized specifications can become overwhelming to an industry resulting in manufacturing inefficiencies and confusion. In pursuit of a more universal approach, the FTA membership partnered with leading consumer product companies to create a universal set of flexographic specifications.
What is FIRST? FIRST is a set of guidelines to increase consistency in the flexographic industry.
What FIRST is Not! FIRST is not a the Flexo police. If you have a reason and your customer agrees, then you can do what ever you deem best.
What FIRST is Not!
FIRST Leadership Team Chair & Co-Chair Mark R. Mazur Robb Frimming SCHAWK! Board Liaison FTA Support Kim Madigan Smyth Shelley Rubin FTA Implementation & Communications Design Prepress Print Joe Tuccitto FTA Rose McKernon FTA Mike McGinnis RR Donnelley Eric Ferguson DataLase Chad Fulwiler En Point Marketing PJ Fronczkiewicz Flint Group John Gleich Group 360 Worldwide Sean Teufler Harper Corporation Mike Huey Siegwerk USA Jean Jackson
Celebrating 20 years of FIRST
Communication & Implementation Chapter 1 of FIRST Section Implementing FIRST: The Foundation External Communication Internal Communication
Communication & Implementation 1.0 Implementing FIRST: The Foundation 1.1 The Value of FIRST Specifications 1.2 Adopting & Implementing FIRST 1.3 FIRST Methodology 1.3.1 Press Optimization 1.3.2 Press Fingerprint 1.3.3 Process Control 1.3.4 Press Characterization 1.3.5 Process Improvement 1.4 Communication & Implementation 1.4.1 External Communication 1.4.2 Internal Communication
Implementing FIRST Communication is the foundation of FIRST. Using agreed upon terminology and a defined workflow, FIRST seeks to minimize miscommunication and promote the manufacturing of consistent, conforming flexographic materials.
Value of FIRST Specifications The mission of FIRST is to create a common set of specifications and communication protocols for the flexographic industry. FIRST seeks to identify the responsibility of each party in the package/product development process and facilitate communication between parties in order to quickly, efficiently and cost effectively produce attractive flexographic packaging.
Adopting & Implementing FIRST Specifications are created, or adopted, when a problem exists or improved results are desired. FIRST specifications cannot be fully implemented without understanding, cooperation and adherence by all involved parties.
FIRST Methodology FIRST supports the methodical approach to process control outlined in ANSI CGATS TR 012-2003 (R2011)
Optimization Determine preferred operating parameters Fingerprint Benchmark the process under conditions established during the optimization. Process Control Use statistical analysis to establish and maintain specific operating conditions. Characterization Capture color data for calibration within the prepress system. Continuous Improvement On-going run data should be used to improve quality, efficiency, and productivity.
Fingerprinting Optimization Process Control Continuous Improvement Characterization
Internal Communication Customer Service Press Room Graphics Management Plate Making
External Communication Prepress (If External) Customer Service Customer Press Room Graphics Suppliers Management Plate Making Designer
Chapters 2-9 of FIRST Design Section Design Introduction Getting Started Type and Design Elements Digital Photography Program Applications Document Structure File Formats and Usage Preflight of Final Design Prior to Release
Design Section Chapter 3.0 Getting Started 3.1 Recognizing Attributes of the Flexographic Print Process 3.2 Materials and Information Needed to Begin 3.3 File Naming Conventions 3.4 Understanding Color Management 3.5 Viewing Artwork, Proofs and Printed Material 3.6 Types of Proofs 3.7 Process Control Test Elements
Design Section Chapter 4.0 Type and Design Elements 4.1 Typography: Know the Print Process Capabilities 4.2 Custom and Special Colors 4.3 Bar Code Design Considerations 4.4 Screen Ruling 4.5 Tints 4.6 Ink Colors
5.1 Digital vs. Conventional 5.2 Digital Proofs for Digital Photography 5.3 Camera Setup Recommendations 5.4 Photographic File Format 5.5 Unsharp Masking 5.6 Resolution 5.7 File Transfer Recommendations Design Section Chapter 5.0 Digital Photography
Design Section Chapters 6.0 Program Applications & 7.0 Document Structure 7.1 Naming Conventions 7.2 Document Size 7.3 Working in Layers 7.4 Auto-Traced/Revectorized Art 7.5 Blends/Vignettes/Gradations 7.6 Imported Images 7.7 File Integrity 7.8 Image Capture Quality Scanning Considerations 7.9 Scaling & Resizing 7.10 Color Space
8.1 Specified Formats 8.2 Portable Document Format 8.3 Clip Art 8.4 FPO Continuous Tone Images 8.5 Special Effects 8.6 Image Substitution 9.1 Documenting the Design 9.2 Release to Prepress Design Section Chapters 8.0 File Formats and Usage & 9.0 Preflighting
Free Design Guide https://www.flexography.org/first/
Prepress Section Chapters 10-17 of FIRST Prepress Introduction Electronic/Digital Files Job Assembly Color Separations Process Color Final Films/Files/Digital Mask Specifications Color Proofs Printing Plates
Prepress Section Chapter 11.0 Electronic/Digital Files 11.1 File Formats. 11.1.1 TIFF/IT & 1-BIT Files 11.1.2 PDFX: FIRST Recommended File Transfer 11.1.2.1 Terminology & Guidelines 11.1.2.2 PDF/X Compliancy Requirements 11.2 File Exchange As the headers indicate this sections gives details on 1-bit tifs, the importance of lossless file compression, explains much of the terminology and give guidelines for its usage. There is also information on CxF spot color communication.
Prepress Section Chapter 12.0 Job Assembly 12.1 Image Trapping 12.2 Text & Graphic Elements 12.2.1 Line Color Type and Graphic Elements 12.2.2 Process Color Type and Graphics 12.2.3 Process Reverse/Knockout Text 12.2.4 Overprint Type 12.3 Vignettes/Gradations 12.3.1 Designing Vignettes 12.3.2 Vignette Fingerprint 12.3.3 Transparency/Effects 12.4 Bar Code Prepress Considerations 12.4.1 Bar Code Specifications 12.4.2 Prepress Provider Responsibilities 12.4.3 USPS Intelligent Mail Bar Code 12.5 Template Layout 12.5.1 Page Boxes 12.6 Eye Marks 12.7 Process Control Test Elements 12.8 Line Color: Print Characteristics Measured 12.8.1 Positive & Reverse Type Elements 12.8.2 Custom/Spot/Line Colors 12.8.3 Blends/Vignettes/Gradations 12.8.4 Bar Code: Minimum Size & Bar Width Reduction 12.8.5 Opacity of White Ink & Substrates 12.9 Process Color: Print Characteristics Measured 12.9.1 Gray Balance 12.9.2 Dot Area/Dot Gain/Tonal Value Increase 12.9.3 Solid Ink Density 12.9.4 Print Contrast. 12.9.5 Ink Trap 12.9.6 Registration & Total Image Trap Tolerance 12.9.7 Image Slur & Impression
Prepress Section Chapter 13.0 Color Separations 13.1 Gray Balance 13.2 Total Area Coverage (TAC) 13.3 Under Color Removal (UCR) 13.4 Gray Component Replacement (GCR) = C = 70% M = 30% Y = 60% K = 0% = C = 49% M = 0% Y = 43% K = 38%
Prepress Section Chapter 14.0 Process Color Calibration 14.1 Process Color Calibration Techniques 14.2 Traditional Dot Gain/TVI Curves 14.3 G7 Near Neutral Calibration (NNC) 14.4 CIELab Color Management System 14.4.1 Calibrating The Color Management System 14.4.2 The IT8.7/4 Characterization Target
Prepress Section Chapter 15.0 Final Films/Files/Digital Mask Specifications 15.1 Evaluating Physical Properties of Film Negatives 15.2 Dot Characteristics for Film/Digital Masks 15.3 Image Screening 15.4 Registration Marks and Microdots 15.5 Image Stagger 15.6 Calculating Distortion 15.7 Final File/Film or File/Mask Inspection Attributes M Y C 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0
Prepress Section Chapter 16.0 Color Proofs 16.1 The Purpose of a Proof 16.2 Types of Proofs 16.3 What are Proofing Standards, Specifications, Guidelines and Documents? 16.4 Standards, Specifications, Guidelines and Documents in Regards to Proofing 16.5 Spectrophotometer Guidelines 16.6 Viewing Artwork, Proofs & Printed Material 16.7 Proof Compliance Cover Sheet/Label 16.8 Proofing for Expanded Gamut Printing
Prepress Section Chapter 17.0 Printing Plates 17.1 General Plate Specifications 17.2 File Preparation for Digitally-Imaged & Laser-Engraved Plates 17.3 Digitally-Imaged Photopolymer Plates 17.3.1 Mask Specifications 17.3.2 Plate Evaluation 17.4 Laser-Engraved Rubber/Cured-Polymer Plates & Sleeves 17.5 Liquid Photopolymer Printing Plates 17.6 Conventional Sheet Photopolymer Printing Plates 17.7 Continuous Photopolymer-Covered Printing Sleeves 17.8 Molded Rubber Printing Plates 17.9 Printing Plate Measurement and Control
Print Section Chapters 18-23 of FIRST Print Introduction Print Evaluation Job Specific Print Variables Press Component Print Variables Bar Code Print Considerations Ink Room Testing Procedures
Print Section 18.0 Print Introduction 19.0 Print Evaluation 19.1 Measurement Tools 19.2 Using Process Control Test Elements 19.3 Line Colors: Print Characteristics Measured 19.4 Process Color: Print Characteristics Measured 20.0 Job-Specific Print Variables 20.1 Substrates 20.2 Ink 20.3 Specialty Inks & Coatings 20.4 Ink Metering System 20.5 Plate Package 20.6 Profiled Contract Proof 21.0 Press Component Print Variables 21.1 Press Dryers 21.2 Registration Control 21.3 Tension Control 21.4 Press Mechanics 22.0 Bar Code Print Considerations 22.1 Bar Code Specifications 22.2 Printer Responsibilities 22.3 USPS Intelligent Mail Bar Code 23.0 Ink Room Testing & Procedures 23.1 Color Matching 23.2 Ink Proofing 23.3 Ink Functionality Testing
20.0 Job-Specific Print Variables 20.1 Substrates 20.2 Ink 20.3 Specialty Inks & Coatings 20.4 Ink Metering System 20.5 Plate Package 20.6 Profiled Contract Proof Print Variables
20.0 Job-Specific Print Variables 20.1 Substrates 20.2 Ink 20.3 Specialty Inks & Coatings 20.4 Ink Metering System 20.5 Plate Package 20.6 Profiled Contract Proof Print Variables
20.0 Job-Specific Print Variables 20.1 Substrates 20.2 Ink 20.3 Specialty Inks & Coatings 20.4 Ink Metering System 20.5 Plate Package 20.6 Profiled Contract Proof Print Variables
20.0 Job-Specific Print Variables 20.1 Substrates 20.2 Ink 20.3 Specialty Inks & Coatings 20.4 Ink Metering System 20.5 Plate Package 20.6 Profiled Contract Proof Print Variables
20.0 Job-Specific Print Variables 20.1 Substrates 20.2 Ink 20.3 Specialty Inks & Coatings 20.4 Ink Metering System 20.5 Plate Package 20.6 Profiled Contract Proof Print Variables
20.0 Job-Specific Print Variables 20.1 Substrates 20.2 Ink 20.3 Specialty Inks & Coatings 20.4 Ink Metering System 20.5 Plate Package 20.6 Profiled Contract Proof Print Variables
21.0 Press Component Print Variables 21.1 Press Dryers 21.2 Registration Control 21.3 Tension Control 21.4 Press Mechanics Print Variables
21.0 Press Component Print Variables 21.1 Press Dryers 21.2 Registration Control 21.3 Tension Control 21.4 Press Mechanics Print Variables
21.0 Press Component Print Variables 21.1 Press Dryers 21.2 Registration Control 21.3 Tension Control 21.4 Press Mechanics Print Variables
21.0 Press Component Print Variables 21.1 Press Dryers 21.2 Registration Control 21.3 Tension Control 21.4 Press Mechanics Print Variables
Print Section - Key Elements Press Side Control Practices Production Control Targets Preventative Maintenance Practices Press Starting Points
Appendices A: Contact List B: Referenced Standards, Specifications and Publications C: Quick Reference Control and Test Targets D: How to Create the FIRST Printer Tone Scale with Integral Mask Flexo Plates E: 2D Codes (QR Codes, DataMaritx Codes and Snap Tags) F: Process Control of Spot Color
Contact List American Association of Textile Chemists & Colorists American National Standards Institute (ANSI) -- CGATS American Society for Testing & Materials (ASTM) Applied Image, Inc. Association of Independent Corrugated Converters (AICC) Automatic Identification and Mobility (AIM North America) Commission Internationale de l Eclairage (CIE) Composite Can & Tube Institute (CCTI) DFTA Envelope Manufacturers Association (EMA) Fibre Box Association (FBA) Flexible Packaging Association (FPA) Flexographic Pre-Press Platemakers Association (FPPA) Flexographic Technical Association (FTA) FTA Europe Ghent Workgroup (GWG) GS1 US IDEAlliance (International Digital Enterprise Alliance) International Corrugated Packaging Foundation (ICPF) International Organization for Standardization (ISO) National Association of Printing Ink Manufacturers (NAPIM) NPES Paper Shipping Sack Manufacturers Association (PSSMA) Paperboard Packaging Council (PPC) Plastics Industry Association Printing Industries of America (PIA) UK Society of Dyers & Colourists Tag & Label Manufacturers Institute (TLMI) Technical Association of the Pulp & Paper Industry (TAPPI) Technical Association of the Graphic Arts (TAGA) United Nations Standard Products and Services Code (UNSPSC) United States Postal Service (USPS)
Standards Over 200 Standards referenced Standard Title Abstract Important Highlights
Control and Test Targets Shows many of the common test elements used in Flexography. http://www.flexography.org/first_extras
FIRST Printer Tone Scale How to Create the FIRST Printer Tone Scale with Integral Mask Flexo Plates Goal: To provide the printer with a standard tone scale (with predictable plated dot values) to control the printing process independent of the prepress provider, platemaking system, bump curves, etc.
2D Codes (QR Codes, DataMatrix Codes and Snap Tags)
Process Control of Spot Color The Murray-Davies equation has been used to convert densitometric data into halftone values for almost 80 years. While this equation has been widely accepted for measuring and controlling press gain on process colors (CMYK) it has proven to be less than adequate for spot colors. With the ever increasing need to control brand colors tints and the growing popularity of expanded color gamut (ECG) ink sets (CMYKOGV) it became clear a new methodology was required. The new equation for measuring the tone value of a spot color is contained in ISO 20654:2017 Graphic technology - Measurement and calculation of spot colour tone value.
Process Control of Spot Color from CIELAB measurements t = (v xt v xp ) 2 + (v yt v yp ) 2 + (v zt v zp ) 2 (v xs v xp ) 2 + (v ys v yp ) 2 + (v zs v zp ) 2 Where: t = tone value of the patch measured s = solid p = paper (substrate) v x = L + (116*a/500) v y = L v z = L + (116*b/200)
Example
L a b 0% 92.03-0.32 1.11 10% 76.37 2.23-11.65 20% 69.00 3.71-17.37 30% 66.13 4.56-21.19 40% 62.10 5.64-25.51 50% 49.98 9.53-35.54 60% 42.87 12.69-42.14 70% 35.93 17.02-50.18 80% 30.24 21.74-56.93 90% 25.23 26.55-62.22 100% 18.25 35.55-70.27 Example v x v y v z 91.9554 92.0301 91.3844 76.8828 76.3653 83.1221 69.8587 68.9969 79.0709 67.1845 66.1271 78.4170 63.4125 62.1043 76.8975 52.1892 49.9790 70.5900 45.8142 42.8698 67.3118 39.8831 35.9347 65.0396 35.2870 30.2434 63.2619 31.3949 25.2345 61.3214 26.5006 18.2520 59.0106 BSCTV 0.0% 22.4% 33.0% 36.7% 42.2% 59.2% 69.0% 78.0% 85.2% 91.6% 100.0%
Example Note: The target is linear. 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Actual Cutback Smoothed Cutback
FIRST Methodology ANSI CGATS TR 012-2003 Outlines the 5 Steps of the FIRST Methodology 1. Optimization 2. Fingerprinting 3. Process Control 4. Characterization 5. Process Improvement
Optimizing the Process The goal of the optimization process is to identify the best combination of print variables to achieve the design requirements. The test conditions must represent normal production behavior and quality. The optimization process occurs prior to fingerprinting. It involves identifying the print variables that will produce the desired results with the substrate and ink colors specified by the customer.
Optimizing the Process Print variables can be grouped into two general categories: Job Specific Print Variables and Press Component Print Variables.
Optimization Objectives Anilox Rolls A banded anilox roll is used to determine optimum anilox volume, cell count and engraving angle for each type of graphics (process/line/combo/solid) on a given substrate with a specified ink formulation. The engravings on the banded anilox will vary based upon the type of graphics being printed (process/line/combo/solid) 1200 cpi 1.6 bcm 1000 cpi 1.8 bcm 60 XLT 1200 cpi 1.8 bcm 60 XLT 1200 cpi 1.6 bcm 60 XLT 1400 cpi 1.4 bcm 60 XLT 1200 cpi 1.7 bcm
Optimization Objectives Mounting Tapes Different mounting tapes are tested to determine optimum density and cell structure for each type of graphics (process/line/combo/solid) that will provide desired print quality and maximum longevity.
Optimization Objectives Inks and Coatings Determine ideal ink pigment load (strength) to achieve desired color and/or density and minimize dot gain/tvi while maintaining ink stability throughout the press run. Determine minimum coating weight to achieve desired Coefficient of Friction (CoF) and gloss values while minimizing dry rate and cost.
Optimization Objectives Plate Type Determine optimum plate material for each type of graphics (process/line/combo/solid) that will deliver desired print characteristics while maximizing plate life and therefore, minimizing cost.
Optimization Objectives Substrate Determine minimum surface tension level of film that will achieve acceptable ink adhesion.
Analyzing the Results
Analyzing the Results 1000CPI / 1.8BCM 1200CPI / 1.8BCM 1200CPI / 1.6BCM 1400CPI / 1.4BCM Setup Sample Density 2% 50% 90% Density 2% 50% 90% Density 2% 50% 90% Density 2% 50% 90% RP1 ( Xtra Soft SB) 1 1.41 4 73.6 97.8 1.21 4.1 71.6 98.2 1.17 4.1 69.8 96.7 1.12 5.6 68.9 98.6 2 1.35 4.5 73.9 98.4 1.23 4.3 72.3 97.5 1.19 4.2 71.7 97.3 1.14 7.9 69.1 97.6 3 1.39 4.4 72.9 97.7 1.24 4.1 70.7 96.7 1.19 4.2 69.8 97.2 1.17 5.2 68.6 97 4 1.33 4.4 74.2 98.7 1.25 4.2 71.8 97.3 1.21 4 70.5 96.7 1.18 8.5 69.4 96.9 AVG 1.37 4.325 73.65 98.15 1.2325 4.175 71.6 97.425 1.19 4.125 70.45 96.975 1.1525 6.8 69 97.525 RP2 (Soft SB) 1 1.55 5.7 72.1 97.2 1.47 4.8 71.4 96.5 1.46 4.6 70.5 96.7 1.25 3.6 67 96.3 2 1.61 9.6 74.3 98 1.44 4.7 73.4 97.7 1.42 4.5 71.7 97.5 1.3 4.7 69.1 97.5 3 1.6 5.3 74.9 98.1 1.48 4.6 72.9 98 1.43 4.3 70.4 96.8 1.33 7 70.3 97.3 4 1.56 7.5 73.7 98.2 1.49 4.5 73.5 97 1.45 4.6 72.1 96.3 1.26 6.1 71.5 96.4 AVG 1.58 7.025 73.75 97.875 1.47 4.65 72.8 97.3 1.44 4.5 71.175 96.825 1.285 5.35 69.475 96.875 RP3 (Medium SB) 1 1.74 3.8 74.6 97.6 1.55 5.1 71 96.7 1.51 4.3 70.1 95.7 1.43 2.3 68.5 95.9 2 1.78 4.1 72.5 97.8 1.54 4.8 71.4 96.8 1.5 4.5 69.8 95.9 1.39 3.6 68.7 96.2 3 1.76 4.8 74.8 97.7 1.53 5.7 71.7 97 1.49 5.4 70.2 95.8 1.4 4.6 68.8 95.6 4 1.78 4 73.4 97.4 1.54 4.7 70.9 96.6 1.48 5.2 69 96.1 1.41 4.7 68.2 95.8 AVG 1.765 4.175 73.825 97.625 1.54 5.075 71.25 96.775 1.495 4.85 69.775 95.875 1.4075 3.8 68.55 95.875 RP4 (Hard SB) 1 1.77 7.4 73.6 97.5 1.6 7.7 70.2 96.1 1.53 5.4 69.3 96.4 1.45 7.2 67.6 96.8 2 1.79 8.7 74.2 97.8 1.61 7.1 71.3 96.3 1.54 7.1 70 96.7 1.42 8.8 68.1 96.7 3 1.81 10.8 74.2 97.6 1.62 8.5 71.7 96.2 1.54 5.7 68.9 96 1.43 5.4 67.3 96.2 4 1.77 6.5 73.4 97.7 1.59 4.5 70.7 96.4 1.54 5.1 68.1 96.4 1.43 7 6735 97 AVG 1.785 8.35 73.85 97.65 1.605 6.95 70.975 96.25 1.5375 5.825 69.075 96.375 1.4325 7.1 1734.5 96.675 RP5 (Medium Plate & Soft Tape, Current Anilox 900/2.5) 1 1.41 9.3 83.7 98.9 2 1.39 10.2 85 100 3 1.43 12.8 86.2 100 4 1.37 9.5 84.1 98.9 AVG 1.4 10.45 84.75 99.45
Fingerprinting Fingerprinting is the act of benchmarking the performance of a press or a proofing system under known conditions at a given point in time.
What does fingerprinting mean? Fingerprinting = Calibration https://en.wikipedia.org/wiki/calibration The formal definition of calibration by the International Bureau of Weights and Measures is the following: "Operation that, under specified conditions, in a first step, establishes a relation between the quantity values with measurement uncertainties provided by measurement standards and corresponding indications with associated measurement uncertainties (of the calibrated instrument or secondary standard) and, in a second step, uses this information to establish a relation for obtaining a measurement result from an indication."
Calibration 1. Where are you? 2. Where should you be? 3. How do you get from where you are to where you should be?
Do We Really need to Calibrate Prior To Characterization? simple answer: yes You will get more uniform data sampling and as a result better profiles.
Dot Gain Analysis 100% 100% 90% 90% Dot % Printed 80% 70% 60% 50% 40% 30% 20% 7 points 2 points Dot % Printed 80% 70% 60% 50% 40% 30% 20% 5 points 4 points 10% 10% 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Dot % Electronic File 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Dot % Electronic File
Fitting a Curve 100% 100% 90% 90% 80% 80% 70% 70% Dot % Printed 60% 50% 40% 30% Dot % Printed 60% 50% 40% 30% 20% 20% 10% 10% 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Dot % Electronic File 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Dot % Electronic File
Do We Really need to Calibrate Prior To Characterization? simple answer: No If you are confident that you are close to your target, then you can combine fingerprinting and characterization into one press run.
Fingerprint Test Target Fingerprint Target Circa 1985 Fingerprint Target Circa 2015
Supplemental Elements of a Fingerprint Target slur targets lines (+/-) exposure guides vignettes microlines registration UPC codes solid bars
Should a Picture Be Included? Pictorials can be reassuring, but may mislead those conducting the test into producing a pretty picture rather than running to established aims.
2 Common Approaches to Calibration CMYK Curves Near Neutral Calibration 0% 5% 10% 20% 30% 40% 50% 60% 70% 80% 90% 95% 100% or C/M/Y 0/0/0% 5/3/3% 10/7/7% 20/15/15% 30/24/24% 40/33/33% 50/40/40% 60/50/50% 70/60/60% 80/72/72% 90/84/84% 95/92/92% 100/100/100% K 0% 5% 10% 20% 30% 40% 50% 60% 70% 80% 90% 95% 100%
Why Near Neutral Calibration? 1. Addresses how inks trap. 2. Takes into account non-ideal inks. 3. Better visual match between print processes 4. Today s standard. Profiling still required
Simple Dot Gain Compensation 100% 90% 80% 70% 60% 50% 40% 30% 20% 10% 0% 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% File 0% 5% 10% 20% 30% 40% 50% 60% 70% 80% 90% 95% 100% Dot Area Printed 0.0% 22.4% 30.5% 48.6% 61.1% 69.6% 75.9% 82.8% 89.3% 94.9% 98.5% 100.0% 100.0% Cutback 0% 2% 4% 9% 16% 24% 34% 49% 62% 72% 82% 89% 100%
Near Neutral Calibration G7 How-To Guide http://www.idealliance.org/products/g7-how-guide-download G7 How To 2009 pdf http://files.idealliance.org/g7/howto/g7%20how%20to%202009.pdf Buy http://www.chromix.com/curve3
Create Curves (near neutral) P2PSample 01H.txt P2PSample 01V.txt P2PSample 02H.txt P2PSample 02V.txt P2PSample 03H.txt P2PSample 03V.txt P2PSample 04H.txt P2PSample 04V.txt P2PSample 05H.txt P2PSample 05V.txt P2PSample 06H.txt P2PSample 06V.txt P2PSample 07H.txt P2PSample 07V.txt P2PSample 08H.txt P2PSample 08V.txt P2PSample 09H.txt P2PSample 09V.txt P2PSample 10H.txt P2PSample 10V.txt
Create Curves (near neutral) P2PSample 01H.txt P2PSample 01V.txt P2PSample 02H.txt P2PSample 02V.txt P2PSample 03H.txt P2PSample 03V.txt P2PSample 04H.txt P2PSample 04V.txt P2PSample 05H.txt P2PSample 05V.txt P2PSample 06H.txt P2PSample 06V.txt P2PSample 07H.txt P2PSample 07V.txt P2PSample 08H.txt P2PSample 08V.txt P2PSample 09H.txt P2PSample 09V.txt P2PSample 10H.txt P2PSample 10V.txt
Create Curves (near neutral)
Process Control The more process control elements included on production jobs, the better equipped the printer is to achieve the desired print result. Ideally, these five elements should be on all process color jobs: 1. Registration: color-to-color and print-to-cut 2. SID/Trap 3. Tone scales 4. Impression: anilox-to-plate and plate-to-substrate 5. Gray balance
Registration Proper image register is necessary to prevent unwanted colors and misalignments. The three main uses of registration marks are to identify: 1. Position/ location of the image on the substrate. 2. Color-to-color registration. 3. Square to the lead edge of the sheet (corrugated).
SID/Trap The objective of each press run is to match the densities and dot gains/ TVI established during the press fingerprint regardless of whether or not these densities conform to FIRST density specifications. The ability of one ink to lay smoothly over the next is referred to as ink trap.
The Printer Scale must be labeled with known finished values rather than input (mask or film) values. For example, on the Printer Scale a tint labeled 66% must measure ~ 66% (within accepted tolerances) on the plate after exposure, processing and finishing. Tone Scales
Optimum (kiss) impression is the minimum necessary pressure to transfer ink from the anilox to the printing plate and from the plate to the substrate. Slur is a blurred image, caused by over impression and sometimes mechanical press problems. Slur and impression targets quickly and easily indicate when the condition exists. Impression Targets
Gray Balance Patches When troubleshooting gray balance problems on press, some general guidelines to remember are: 1. If the ¼-tone CMY gray patch is not the same density, or neutrality, as the adjacent black tint, it is most likely due to an imbalance in dot gain/ TVI. This is further reinforced if the ¾-tone CMY gray patch is neutral gray. 2. If the ¾-tone CMY gray patch is not the same density and hue as the adjacent black tint, it is most likely due to either: off target ink densities, poor ink trapping, or shadow dot gain/ TVI out of balance.
Characterization The process of characterization is the determining the relationship between input data and the result (color) on the printed sheet. Characterization data is essential for color management tools. The most important point is that characterization data is of little or no value unless the printing condition being characterized is known and can be repeated. Characterization tests should never be conducted until fingerprinting has been completed, a printing specification has been established, and process control is in place to ensure that the process can be replicated.
CIELab Device Independent Color Space
Test Targets IT8.7/3 IT8.7/4
Test Targets IT8.7/4 Random (for press characterization) IT8.7/4 Visual/Ordered (for proof evaluation)
Why Use the Random or the Visual?
Idealliance TC1617x FIRST 5.0 The TC1617x is a new CMYK printer characterization target combining the patch values in the standard IT8.7/4 target with all the patch values in columns 4 and 5 of the P2P51 Target. The TC1617x maintains the same patch count as the IT8.7/4 by removing 29 duplicate patches from the IT8.7/4 and replacing them with the 29 patches in columns 4 and 5 of the P2P51 that were absent in the IT8.7/4. https://www.idealliance.org/gracol
How Will I Measure the Target? The first question you need to ask before running any characterization target is How will I measure the target?
Process Improvement Process improvement uses statistical analysis of printing process data to improve quality, efficiency and production yield. The database created as part of the process control step, is used to analyze the printing process to identify potential areas of improvement.
Process Improvement By continually monitoring and measuring the printing process, and capturing the data in a database, it is easy to determine if the corrective action implemented in process improvement actually results in the desired process improvement over time and across jobs.
Process Improvement The Process Control Database facilitates an understanding of the observed process trends, and causeand-effect relationships that can be used to build a process knowledge that allows future jobs to be more efficiently specified and/or higher quality products to be produced with existing equipment.
Chapter 16.0 Color Proofs FIRST 5.0 16.1 Types of Proofs 16.2 Proofing Methods 16.3 Proofing Sequence & Colorants (Pigments/Dyes) 16.4 Measurement of Contract Proofs 16.4.1 Densitometer Guidelines 16.4.1.1 Solid Ink Density of Contract Proofs 16.4.1.2 Dot Gain (Tonal Value Increase) 16.4.2 Spectrophotometer Guidelines 16.4.3 Viewing Artwork, Proofs & Printed Material 16.5 Proof Compliance Cover Sheet/Label 16.6 Proofing For Expanded Gamut Printing FIRST 6.0 16.1 The Purpose of a Proof 16.2 Types of Proofs 16.3 What are Proofing Standards, Specifications, Guidelines and Documents? 16.4 Standards, Specifications, Guidelines and Documents in Regards to Proofing 16.5 Spectrophotometer Guidelines 16.6 Viewing Artwork, Proofs & Printed Material 16.7 Proof Compliance Cover Sheet/Label 16.8 Proofing for Expanded Gamut Printing
ISO/PAS 15339-1 When producing printed color reproductions it is important that (yada yada yada) all working to a common set of parameters... (yada yada yada) Such an agreement enables the correct production of suitable input data and subsequent production of proofs from these data. The concept of reference printing conditions is simply the organization of characterization data sets into a minimum logical family that covers the full range of printable color gamut. http://www.npes.org/programs/standardsworkroom/toolsbestpractices.aspx
RPC 1 2 3 4 5 6 7 Reference Printing Conditions Name ColdsetNews HeatsetNewsBeta PremUnCoated SuperCal PubCoated PremCoated ExtraLarge US Reference SNAP2009 HeatsetNews BetaOffsetUncoated BetaSupercal SWOP2006_Coated GRACoL2013 Average of Digital Printers European Reference IFRA26 FOGRA42 FOGRA47 FOGRA40 FOGRA45 and 46 FOGRA39
Reference Printing Conditions SNAP2009 HeatsetNews BetaOffsetUncoated BetaSupercal SWOP2006_Coated GRACoL2013 Average of Digital Printers
Reference Printing Conditions CRPC6 Flexo Wide Web White Poly
CRPC6 is the same as GRACoL_2013 The difference between GRACoL 2006 and GRACoL 2013 is the white point. The target white point for GRACoL 2006 (95 L*, 0 a*, -2 b*) was based on the legacy ISO 12647-2 standard, which in turn was based on typical commercial printing stocks available in 1994. The white point of GRACoL 2013 (95, 1, -4) is slightly bluer, and is based on today s typical commercial stocks.
Two Approaches to Proofing 1. Characterize the printing conditions and make a specific proof for those printing conditions. 2. Use one of the standard datasets and make a proof to that standard (mostly CRPC6). Using Near Neutral Calibration procedures calibrate the press to match the same standard.
What is FIRST Certification? FIRST Certification is a process that provides companies the tools to comply with the FIRST Methodology through Employee Development Workflow Audit/Data Collection Workflow Compliance
Two Types of Certification 1. FIRST Individual Certifications - are focused on employee development in all areas of the production workflow. 2. FIRST Company Certification - is focused on companies that have provided the individual certification programs for their employees, but take it one step further by applying the practices through compliance with FIRST Methodology.
FIRST Individual Certifications These certifications are the Flexo industry s standard of excellence, and it's the absolute best way to communicate your proficiency in the flexographic print process. FIRST Individual Certification Programs are a curriculum composed of multi-level courses designed to deliver and assess specific flexographic skill sets and knowledge via online course study and examinations.
FIRST Individual Certifications Implementation Specialist FIRST Operator Certification Level I FIRST Implementation Certification Level II FIRST Implementation Certification Level III Press Operations FIRST Operator Certification Level I FIRST Press Operator Certification Level II FIRST Press Operator Certification Level III Prepress Operators FIRST Operator Certification Level I FIRST Prepress Operator Certification Level II FIRST Prepress Operator Certification Level III
Implementation Specialist Certification This certification program is designed for non-production personnel, including suppliers of flexographic products and services. At the completion of the three levels, students will have a solid understanding of FIRST methodology and be able to effectively communicate, analyze and apply FIRST design prepress/print specifications.
Press Operator Certification At the completion of the three levels, students will have a solid understanding of: FIRST specifications; the appropriate procedures for evaluating press conditions to achieve optimal results and reduce waste; how to communicate effectively with the entire supply chain; and the use of statistical process control to maintain press run consistency & color accuracy.
Prepress Operator Certification At the completion of the three levels, students will have a solid understanding of FIRST job assembly specifications, and the application of FIRST continuous tone color separation specifications, prepress calibration practices, and prepress output practices.
Serves as the Building Blocks. Same for all Three Programs. About the Industry. About the Process. Terminology Level I Course
Level II Courses The nuts and Bolts of the Individual Job Functions. Specific to the Application/Equipment. Basic Color Theory Essential Knowledge of Process Color Reproduction.
Applying the Science of FIRST to Individual Job Functions. Specific to FIRST Methodology. Running to the Numbers Process Control Level III Courses
FIRST Company Certification Workflow Mapping Device/Equipment Calibration Consumable Specification Verification Tonal Value Aim Points Workflow Tagging
What s In It For You? Jennye Scott, Berry Global
More Information To purchase a copy of FIRST or to learn more about FIRST Certification visit www.flexography.org For demonstrations, group pricing, membership and all other information contact Duane Woolbright at dwoolbright@flexography.org
Thank You! #Color2018 Joe Tuccitto jtuccitto@flexography.org (651) 319-5003 Mark R. Mazur mark.r.mazur@gmail.com (610) 574-6591 FIRST the Scoop