07 - FIRST in Motion - Wide Web Project PDF

TUESDAY, MAY 8, 2018
FIRST in Motion -
Wide Web Project
NETWORKING CONTROL
COLOR
CUSTOMER
CULTURE INFORMATION
RESEARCH
TECHNOLOGY DESIGN
TROUBLESHOOTING
SOURCING
EDUCATION
SESSION PROCEEDINGS
FIRST in Motion – Wide Web Project
FIRST in Motion:
Wide Web Project
Session Chairs:
Dr. Malcolm Keif, Cal Poly
&
Mark Mazur, FTA Hall of Fame
Today’s Lineup
Indianapolis
FTA
Today’s Lineup
Indianapolis
FTA
Tuesday, May 8, 2018 1

Today’s Lineup
Indianapolis
FTA
Today’s Lineup
Indianapolis
FTA
Today’s Lineup
Indianapolis
FTA

Today’s Referee
Indianapolis
FTA
FIRST in Motion
Project: Scope & Plan
Bob Coomes
Plastic Packaging Technologies, LLC
Kansas City, KS USA
bcoomes@plaspack.com
FIRST in Motion
The Objective:
To demonstrate the FIRST Methodology in a wide-web

environment while producing a 4-color process printed
piece in flexography.

FIRST in Motion
The Players:
Ø The FIRST in Motion Team
Ø Creative design & development provided by
Ø Color & Pre-Press support provided by
Ø Printing and Converting provided by
FIRST in Motion
The Plan:
1) Perform the Fives Stages of the FIRST methodology
ü Optimization: Determine preferred operating
parameters
ü Fingerprinting: Benchmark the process under same
conditions as in Optimization
ü Process Control: Analyze, establish and maintain
specific operating conditions
FIRST in Motion
The Plan (continued):
The Fives Stages of FIRST (continued)

ü Characterization: Capture color data for calibration
within the prepress system
ü Process Improvement: Improve quality, efficiency
and productivity through on-going evaluation &
modification as needed.

FIRST in Motion
2) Use CxF/X4 for communication of color
3) Use SCTV for measurement of Spot Color Tone Values
4) Work within CRPC 6 printing conditions
FIRST in Motion
Scope Creep -
In project management; refers to
continuous growth or expansion
in the overall project’s range.
The NEW plan was to print one design which would feature
7/c EG on the front panel and 4/c + 2 Spot Colors on the
back panel.
FIRST in Motion
Scope Creep…
There were 3 different designs were developed by VENN49
Option 1: Combo run using all three designs in one pass!
Option 2: Run one design in 7/c EG. Run another in 4/c!
Option 3: Run two designs 7/c EG & another 4/c + Spot in one
pass!
Option 4: Run 3 designs in 7/c EG in one lane; the other lane to
print the same 3 designs in 4/c + Spot!
The production planning GR OWS…!

FIRST in Motion
Option #4 chosen!
Ø Plate type/technology
Ø 3 different images
Ø 175 lpi
Ø 2 separation methods
Ø 2 separate sets of files/plates
…All in ONE pass!
FIRST in Motion
The NEW Objective:
To demonstrate the FIRST Methodology in a flexographic

wide-web environment producing 3 different designs in 7/c
EG in one lane while printing the same 3 designs in
traditional 4/c+ 2 Spot in the other - ALL in one pass!
FIRST in Motion
Wide Web Project
Overview
Mark Samworth, Color Specialist

6
POUCHES
1
Press Run
21 10
Colors Press Decks
4c
+ 7c
Spot
4c
+ 7c
Spot

4c
+ 7c
Spot
Mission
• Optimize, fingerprint, and characterize
a new set of printing conditions using
FIRST methodology.
• Print a production job “to the numbers”
and analyze results.
FIRST
Flexographic
Flexo
Image
Reproduction
Specifications &
Tolerances

Steps of TR012 (and FIRST 6.0)

1. Optimize
2. Fingerprint (curves to hit spec)
3. Process Control
4. Characterize (create profiles)
5. Process Improvement
Optimization
tints solids
Optimization - Tints
Best
HD Screen
Normal
AM

Optimization
tints solids
Optimization – Solids
Best
1 pixel
lid 2nd Best

l So l+ 16 pixel
r ma Pi x
e
No

1. Optimize
3. Process Control

Fingerprinting = Curves
Characterization = Profiles

P2P51 Chart

P2P OGV Chart
Automated Measurement

Spot Color Elements

Pantone 185 C
Pantone Reflex Blue C
Manual Measurement
SCTV CxF
Curves for Color Data
Plate / Press for Proofing


1. Optimize
3. Process Control
?
What Are We Aiming to Achieve?
What Are We Aiming to Achieve?

Process Spot
FIRST Hue°
Solids ISO 15339 CRPC-6
Substrate Corrected Pantone C
Linear ∆E-P
Tints G7 Linear SCTV

Process Control
GRACoL2013_CRPC-6_L92.39_A-0.04_B1.94
Process Control – Solids

1. Optimize
3. Process Control

The TC1617x Patch Set

TC1617x
IT8.7-4
P2P 51
Black
= + Cyan Magenta Yellow
The TC1617x Patch Set

TC1617x
TC1617x Table Points

TC1617x in Esko 4x4 format

IT8.7-4 IT8.7-4
CMYK OMYK
IT8.7-4 IT8.7-4
CGYK CMVK


1. Optimize
3. Process Control

Process Improvement Example
Pinholing in Shadows
Pinholing in Shadows

Ink Transfer Screening in Dots
Pinholing on Production Run?
Pinholing on Production Run?


1. Optimize
3. Process Control
FIRST in Motion
Wide Web Project
Job
Overview
Design
Press Size / Job Size

41.5”
Item 1 – 4c + Spot Item 1 – 7c ECG

20.625”

Item 1
Item 2
Item 3

Total Spot Colors = 20

17
?

41.5”

20.625”

41.5”
Plate Stagger
Item 1 – 4c + Spot
Item 1 – 7c ECG
20.625”
Item 2 – 7c ECG
Item 3 – 7c ECG

7c Process
4c + Spot
FIRST in Motion –
Technology Overview
CRPC6, SCTV, and CxF/X
Steve Smiley
steve@smileycolor.com
ISO 15339 - Pt2 CRPC’s

Characterized Reference Print
Conditions
• ISO standard for aim cross platform
printing (packaging)
• Agnostic across printing platforms
• CRPC-6 Defines a dataset very close to
traditional narrow web flexo – and
modern wide web flexo

ISO 15339 Pt2 Series CRPC 1-7

CRPC1 – Small gamut ( coldset news_
CRPC 2 – Flexo Corrugated Uncoated OBA
CRPC 3 – Flexo Corrugated Uncoated +OBA’s
CRPC 4 – Flexo SC Substrate “Walmart”
CPRC 5 – Flexo Corrugated Coated
CPRC 6 – Flexo Narrow & Wide Format
CRPC 7 – Flexo with Modern Plate and Screening
Technology Large Gamut
CRPC 1-7
CRPC-1 CRPC-2 CRPC-3 CRPC-4 CRPC-5 CRPC-6 CRPC-7
ISO 15339-Pt2 CRPC-6

ISO I5339 is a standards that can be easily calibrated to.
Inks fit this dataset well – however the Magenta run with
too thick of an ink film or too much pigment will hook to
the red/yellow side!
CRPC-6 Should be the aim for primary packaging

CMYK Calibration is preformed to Near Neutral or G7.

Client Aim - Proofing to CRPC6

• Profile or Dataset can be downloaded from:
– Color.org/profileregistry/CGATS 21 CRPC6
– Build proofing match on any systems for
consistent results - globally
OR
Your Custom Press Profile – with caution!
G7 Calibration
• Renders a common aim for all printing
• Common Visual Appearance
• Operators can run the press the same for
every job! Same target! Same Process
Control Metrics
G7 Metrics
FTA 185FTA Rfx
FIRST Target
P2P 51

Global Brands
“Packages shall Print similar all over the planet.”
• They cannot allow printers to all print to their
own custom profiles! In many cases
enclosures, labels, cartons…… are printed by
different printers!
• We would have results like old laminate
proofing problems:
• Approval ≠ Waterproof ≠ Matchprint
SCTV
Spot Colour Tone Value
SCTV= (Solid-paper x) + Soli(d-paper y) + (Solid-paper z)

(Tint- paper x) + (Tint- paper y) + (Tint- paper y)
Currently in Xrite Exact

Techkon SpectroDens – exporting as ISO 18620
CGS CxF Toolbox
Chromix Curve
Testing of Saturated Colors

• Press Data Uncalibrated
• Press Data Murray Davies
• Press Calibrated to SCTV
Curve print linear 10%=10%, 50%=50%

SCTV
Why SCTV for calibration and profiling?
SCTV to ISO 18620
ISO 5.0 NB Spectral Density

ISO 5. Narrow Band Spectral Density with Murray Davies
SCTV Calibration

SCTV Calibration
ISO 17972 Colour Exchange

Format
• 4 Part standard
• CxF/X-1 Color Exchange Format - Core
Schema
• CxF/X-2 Scanner Targets
• CxF/X-3 Target positioning
• CxF/X-4 Spot Colour Characterization
(shall be spectral data)

ISO 17972 - Part 4

Spot colour characterization
• Provides data for creating .ase file Adobe Swatch
Exchange format - can be used by designer to use the
Lab/RGB data from printed aim
• Provided data for ink formulation
• Provides tint information for client aims
• Provides Process Control tools.
Should be embedded in PDF/X mixing hints for blind transfer
CxF/X-4 Printed Aim

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
0%
50%
100%
Spot Color Elements

PPT FTA Red
PPT FTA Blue

Manual Measurement
SCTV CxF
ISO 17972 -Part 4

CxF/X-4 Data for 'FTA Blue'
Characterization Report
Spectral Data Reflectance Spectrum 100 % on Substrate CIE a*b* CIE L*
On Substrate On Black 1.0 100 100
400 0.1321 0.0137
410 0.1987 0.0150 0.8
50
420 0.2483 0.0149
430 0.2886 0.0158 0.6
440 0.3333 0.0186 0 50
450 0.3538 0.0188 0.4
460 0.3404 0.0180
-50
470 0.3094 0.0182 0.2
480 0.2594 0.0167
490 0.1968 0.0151 0.0 -100 0
390 420 450 480 510 540 570 600 630 660 690 -100 -50 0 50 100
500 0.1417 0.0123
510 0.1007 0.0103
520 0.0695 0.0086 Spot Color on Substrate Tonal Value Increase (TVI) [ISO 20654]
530 0.0520 0.0073 Dot % L* a* b* C* h° Tone value 40%
540 0.0440 0.0067 0 91.13 -1.06 1.42 1.77 126.76 0% 35%
550 0.0366 0.0061 10 85.35 -0.65 -3.51 3.57 259.51 9% 30%
560 0.0283 0.0056 20 78.82 -0.13 -9.59 9.59 269.23 20% 25%
570 0.0229 0.0050 30 71.97 0.68 -14.97 14.98 272.62 31% 20%
580 0.0206 0.0046 40 66.08 1.21 -18.77 18.81 273.70 40% 15%
590 0.0197 0.0045 50 60.38 1.96 -23.83 23.91 274.71 49% 10%
600 0.0182 0.0043 60 55.55 2.58 -28.71 28.83 275.14 57% 5%
610 0.0163 0.0039 70 49.19 3.93 -34.32 34.54 276.54 67% 0%
620 0.0153 0.0038 80 42.14 6.12 -42.36 42.80 278.22 77% -5%
630 0.0154 0.0037 90 35.58 8.74 -49.60 50.37 280.00 87% -10%
640 0.0169 0.0038 0% 20% 40% 60% 80% 100%
100 26.61 14.77 -59.83 61.63 283.87 100%
650 0.0208 0.0043
660 0.0255 0.0046 Spot Color Measurement Ink Properties
670 0.0287 0.0049 Brand color FTA Blue Device X-Rite eXact Opacity 13%
680 0.0287 0.0051 Inventory ID Method M0 Incandescent Spectral density 1 82
New Tools for Better

Communication
• Print to known Standard- not custom profile
- G7 Calibration – Using ISO 15339 datasets
• Calibrate Spot Colors using SCTV
• Be able to utilize CxF data
These tools can help you better satisfy Clients!

FIRST in Motion- Project

CRPC-6, CxF/X-4, SCTV
Steve Smiley
www.smileycolor.com
FIRST in Motion
• Aim CRPC-6 Proof and Calibrated Press –
(G7 inside)
• CxF/X-4 Spot colour management
• .ase file created from CxF/X data
• SCTV – Calibration of Spot Colour derived
from instrument or from software.
• Verification can be done using CxF/X-4 for
color, metamerism and SCTV ramps
Spot Color Elements

Pantone 185 C

Manual Measurement
SCTV CxF
Spot Color Tone Value (SCTV)
G27
Spot Color Tone Value (SCTV)
Pantone 185 C
H20

SCTV Calculation
• SCTV was calculated using optimization
and Fingerprint Spot Color Ramps
CxF/X-4 Digital Creation

• Measure data into software
• Save CxF Library
Using CxF/X-4 to create .ase

files
• Using CxF/X-4 library create .ase file for
Adobe Apps

Adobe Workflow
• Use customer aim profile – do not discard
Adobe Workflow
• Using actual inks from CxF/X-4 .ase file as
ink swatches
Embed CxF/X-4 in PDF/X set

sequence

File Format PDF/X-4 (1.6)

Created for Blind Transfer
• Containing Images
• Containing Fonts
• Containing ICC profile
• Containing spectral data for inks
formulation and process control
Communicating all required data!
Ink Formulation with CxF

• Import CxF
• Measure your
substrate
• Define Ink
Thickness
• ( anilox volume)

• Select Pigments
• Calculate Recipes


• Examine
Recipes
• Smooth
Spectral
Curves
• Smart
Ingredients
Proofing CXF
• Modern Proofing systems have spectral
blending algorithms for managing spot
colors. You have to provide data!
• The days of saying spot color are not
accurate one ink jet have been replaced
by use of CxFX-4 and spectral blending
Accurate Soft Proofing

CxF/X-4 with 11 Steps

• Printing the 11 step target delivers data
for:
• Design
CxF/X-4 Data for 'FTA Red'
Spectral Data Reflectance Spectrum 100 % on Substrate CIE a*b* CIE L*

On Substrate On Black 1.0 100 100
400 0.0807 0.0103
410 0.0799 0.0095 0.8
• Ink Formulation
50
420 0.0747 0.0071
430 0.0721 0.0064 0.6
440 0.0711 0.0079 0 50
450 0.0692 0.0073 0.4
460 0.0627 0.0059
-50
470 0.0537 0.0061 0.2
480 0.0473 0.0058
• Proofing
490 0.0439 0.0062 0.0 -100 0
390 420 450 480 510 540 570 600 630 660 690 -100 -50 0 50 100
500 0.0370 0.0054
510 0.0307 0.0051
520 0.0293 0.0051 Spot Color on Substrate Tonal Value Increase (TVI) [ISO 20654]
530 0.0285 0.0050 Dot % L* a* b* C* h° Tone value 40%
540 0.0262 0.0047 0 90.96 -1.02 2.17 2.40 115.18 0% 35%
• Process Control
550 0.0257 0.0046 10 84.82 8.73 4.18 9.68 25.59 14% 30%
560 0.0355 0.0055 20 79.57 17.27 6.32 18.39 20.11 26% 25%
570 0.0624 0.0072 30 74.43 25.77 9.30 27.40 19.84 38% 20%
580 0.1328 0.0111 40 69.07 34.25 12.56 36.48 20.13 50% 15%
590 0.3118 0.0182 50 66.14 40.66 15.04 43.35 20.30 58% 10%
600 0.5431 0.0242 60 62.65 48.41 18.35 51.77 20.76 66% 5%
610 0.6966 0.0271 70 60.46 52.75 20.74 56.68 21.46 72% 0%
620 0.7637 0.0287 80 57.03 59.64 25.40 64.83 23.07 82% -5%
630 0.7836 0.0297 90 54.79 64.68 29.57 71.12 24.57 89% -10%
640 0.7875 0.0303 0% 20% 40% 60% 80% 100%
100 51.41 70.65 37.28 79.88 27.82 100%
650 0.7942 0.0315
660 0.7923 0.0318 Spot Color Measurement Ink Properties
670 0.7898 0.0324 Brand color FTA Red Device X-Rite eXact Opacity 6%
680 0.7870 0.0333 Inventory ID Method M0 Incandescent Spectral density 1.59
690 0.7849 0.0340 Brand owner FTA Geometry 0°/45° Dot gain at 50% 8%
700 0.7834 0.0345 Contact www.flexography.org Filter None Print contrast at 70% 44%
Substrate Clear Poly Aperture ---
Substrate type Plastic Illuminant D50
Print process Flexography Observer 2°
Surface finish Gloss Laminated Tolerance 2.50 dE2000
3.50 metameric
When was your last fingerprint?

• Should have been your last job.
• Measuring and documenting process
control targets aligns press, as well as
proof to customers aims.
G7 Calibration/ Verification
target
FTA 185FTA Rfx

Verification of SCTV and Ink

• Using CxF/X-4 loaded into measuring
device tools can easily verify
• Best Match
• SCTV
• DE using reference CxF/X data
Using CxF for Verification
Reporting to Client Aims Met

CRPC-6, CxF/X-4, SCTV

• Communicating expectations from buyers
• Throughout entire supply chain
• Standard PDF/X-4 format
• Standard Profiles - ISO 1533—6
• CxF/X-4 spot colors
• SCTV for calibration
Thank you! Steve Smiley

steve@smileycolor.com
www.smileycolor.com
469-309-2025
FIRST In Motion
Press Optimization
Sean Teufler
Harper Corporation of America
Technical Director

FIRST, What Does It Tell Us?
1 2 3 4
Communicate Pay Attention Evaluate Keep Within
Among Teams to Individual Steps by Stable
Steps Taken Measurement Parameters
Communication 1.4.2.3
Press, Ink, Management Teams
What Are the Goals?
What Has Been Done?
Are We Prepared?
Can We Sustain a Stable Print Condition?
FIRST Provides Guidelines
Builds the Foundation

FIRST, Not
a Day-of- Part of the Foundation is Practice!
Trial
Philosophy Learning to Measure During Trial? No…
Do You Only Study on Test Day?

FIRST ’s
Foundation: For Everything
Defined After….
Press Run
Optimization Characterization
Fingerprint Fingerprint
Optimization
Characterization
Every Press Run
On-Press Ink Control 20.2.6

• Measuring Temperature and Viscosity
• Ink Temperatures Measured 73.1-75.5°F
• Viscometer Set by Zahn Cup
• #2 Signature Zahn Used
• Viscometer Monitored During Run
• No Sump Contamination
On-Press
Ink Control
20.2.6
Ink Viscosity & Temperature
Stayed Stable During Run

Anilox Selection
20.4.2
• 300 l/s 6.1 BCM for Opaque White
• 800 l/s 2.9 BCM for 185 and Reflex
• 1000 l/s 2.25 BCM for Process Yellow
DECK SEQUENCE TO DRUM • 1200 l/s 1.9 BCM for CMK & EG Green, EG Violet,
10 1 EG Orange
9 2
8 3 • All Cleaned & Verified
7 4 • Document Deck Sequence
6 5
Anilox Selection
20.4.2
FIM PROJECT
Color Anilox ID Line Volume Visc 1 Visc 2
Deck 1 Pro Black HW6002370 1200 1.9 27 27.3
Deck 2 Reflex Blue HW6002360 800 2.84 32 31.5
Deck 3 Process Cyan HW60023?? 1200 1.87 27.8 27.5
Deck 4 EG Violet HW6002372 1200 1.95 29 28.7
Deck 5 EG Green HW6002373 1200 1.93 24 23.2
Deck 6 Pro Magenta HW6002367 1200 1.93 31 30.7
Deck 7 185 Red HW6002361 800 2.91 32 31.7
Deck 8 EG Orange HW6002369 1200 1.93 29.2 29
Deck 9 Pro Yellow HW6002365 1000 2.25 26 25.9
Deck 10 White HW6002351 300 6.15 24.8 24.9
Ink Metering
System 20.4
• Enclosed
Chambers
• Low Pressure
• No Leaking
• Kiss Impression
• Chambers &
Pumps Free of
Contamination

If You Find Conditions

Out of Control….
• Examine Mechanical Issues
• Examine Process Controls
• Look at Training Possibilities
• Seek Outside Help
• Do Not Proceed With a Bad
Foundation
Optimization
Press Run
• Same Specifications
Were Followed as
Characterization
• Deck Sequence
• Ink Order
• Anilox Selection
• Viscosity
Press Run
Characterization • No Outside Influences Like
Contamination
• Measured Results Were
Repeatable
Press Run

• Challenges/Uniqueness
to Ink Targets
• Written Communication
and Verbal Follow
Through
• How, When, Why
• Documenting Initial
Setup
What Could Have
Been Done Better?
Curves From the Fingerprint

Process Control – CMYK Tints
Actual
vs
Desired
Process Control – CMYK Gray Balance
Actual
vs
Desired

Press Compensation Curves
H33 H34 H23 H32
Cyan Magenta Yellow Black
Process Control – OGV Tints

Actual vs. Desired
Orange Green Violet
H30 F22 H29
Orange Green Violet


H33 H34 H23 H32
H30 F22 H29
Curves From the Characterization
Process Control – CMYK Tints
Actual
vs
Desired

Process Control – Grey Balance
Actual
vs
Desired

from Characterization Run
H31 H38 H22 H34
Cyan Magenta Yellow Black
Process Control – OGV Tints

Actual vs. Desired
Orange Green Violet


H37 F32 H36
Orange Green Violet
Curves From Both Press Runs

Cyan Magenta Yellow Black Orange Green Violet 185 C Reflex
Curves
Run H33 H34 H23 H32 H30 F22 H29 H20 G27
Profiles
Run H31 H38 H22 H34 H37 H32 H36 H27 G31
AVG H32 H36 H32 H33 H33 H27 H33 H33 G29
ur ves
ver age” c n!
he “a n ru
Use t ro ductio
for p
Characterization
Richard Black
All Printing Resources – APR
rblack@teamflexo.com

Characterization
Columbus, OH
noun
1. portrayal; description:
the actor's characterization of a politician.
2. the act of characterizing or describing the
individual quality of a person or thing.
3. the creation and convincing
representation of fictitious characters, as in a
literary work.

noun
1. portrayal; description:
the actor's characterization of a politician.
2. the act of characterizing or describing the
individual quality of a person or thing.
3. the creation and convincing
representation of fictitious characters, as in a
literary work.
Characterization
• In this case the thing is a Press
Characterization Do’s & Don’ts

• Characterizations need to be treated like a
job from you best customer
• This is a representation of your quality
• It’s not just a bunch of color squares

Characterization Question #1
• Why are we aiming at spec like CPRC-6?
– Same reason McDonalds & Starbucks prepare to a
spec (defined recipe and procedure)….consistency
Characterization Aim Point

• Our CMYK aim point was CRPC-6
• CRPC = Characterized Reference Print Conditions


CRPC 6
0 100 0 0 48 75 -4 MAGENTA NOTE: No Solid Ink
100 0 0 0 56 -37 -50 CYAN
Densities (SID) we are
0 0 100 0 89 -4 93 YELLOW
0 0 0 100 16 0 0 BLACK running to Delta E
Green 181º
Orange 54º
Violet 307º
FIRST 6.0
Fingerprint
• Initial try for the Characterization aim point
BLACK
Fingerprint

Fingerprint
Small Cyan patch
Large Cyan patch
Fingerprint - Characterization
• Fingerprint had both MC16P and MCWSI
• After analysis ALC chose MCWSI for
Characterization run
• What is the difference of running to a density
specification versus running to a Delta E and/or
colormetric specification?
– SID is a measurement of Lightness/Darkness
– Delta E is a measurement that represents color
differences
Density =

Characterization Press Run

• What are my options if we cannot hit the
colormetric spec like CRPC-6?
– It depends if you are required to meet the spec or
aiming at the spec
– If you are required to hit a spec you may need to
work with suppliers (ink, anilox, etc..)

New Reference Colors
Ref Magenta
L 48.00
a 75.00
b -4.00
New
Reference
L 51.00
a 66.04
b 2.32

• How many pulls should I have once we reached
our desired color?
– At a minimum I would suggest 3-4 pulls at different
press speeds
• How often should I do a characterization?
– More than once a year
– You can use it or a version of it as a quality control
tool.
– You can print and measure P2P target and compare
results.

FIRST in Motion
Wide Web Project
Prepress
!
Converting Spot Colors to
7c Process (Expanded Gamut)

Based on the
Press Profile!
Magenta Orange ∆E 2000

100% 100% 1.9
Colors > 3.0 ∆E 2000

Master Ink Book Dependent Aim Ink Book
!
Images: A Closer Look
Images

Image Gamut Expansion

?
What Settings Were Used
For the 4c Separations?
!
100% GCR with
Indiscriminate Dropouts
For CMYK Images
Grey Component Replacement (GCR)

Min GCR
Max GCR
Max GCR 4c
Max GCR 7c
!
Full Job Conversion
CMYK + Spot

!
Full Job Conversion
7c Process

!
Expanded Gamut Proofing
Contract
Quality
Proofing
!
Job Assembly Into
Press Layout


41.5”
Plate Stagger
20.625”
Item 2 – 7c ECG
Item 3 – 7c ECG
7c Process
4c + Spot
!
Screening

!
Plate Imaging

Plate
Imaging
FIRST in Motion
Wide Web Project
Printed Results
Goal: Match The Profile

?
Did We Print to Our Spec?
7c Process
4c + Spot
How Close are the Solids to the Profile?

Comparing
Colors dE: 0.7
7c Process
4c + Spot
Solid Lab Values
dE: 0.8 dE: 1.2 dE: 0.5
dE: 0.4 dE: 0.9 dE: 2.4
dE: 1.1 dE: 0.6

?
Did We Print to CMY and K Tints to G7?
7c Process
4c + Spot
G7 Black Tint Density (worst case)

G7 CMY Tint Density (worst case)
G7 CMY Tint Gray Balance (worst case)
?
Did We Print OGV Tints to Spec?

7c Process
4c + Spot
Orange ∆E-P (first measurement)

7c Process
4c + Spot

Green ∆E-P
7c Process
4c + Spot
Violet ∆E-P

?
Did We Match Spot Color Solids?
To Their Aim?
7c Process
4c + Spot
Solid Lab Values
dE: 2.1
dE: 0.7

?
Did We Match Spot Color Tints
to the Linear SCTV Aim?
7c Process
4c + Spot
PANTONE 185 C - SCTV
SCTV
53.4%

7c Process
4c + Spot
PANTONE Reflex Blue C - SCTV
SCTV
51.8%
?
How Accurate Are The Spot Colors
Printed With Expanded Gamut?

Actual vs Aims
Dependent Aim
Master Ink Book
Book
dE: 2.9
dE: 1.9
dE: 1.1

Match to the Dependent Aim
dE: 1.1
dE: 0.6

dE: 1.2

dE: 1.5
?
Did the Press Match the Proof?
Contract
Quality
Proofing

Proof to Press Match
Note: these real life side-by-side pictures are the most realistic color match
that can be displayed given lighting, glare, and camera metamerism.
Proof Press
Note: this real life side-by-side picture is the most realistic color match
Proof Press

Proof Press
?
What Looks Better
4c + Spot or 7c?
Comparison
4c
+ 7c
Spot

Comparison
4c
+ 7c
Spot
Comparison
4c
+ 7c
Spot
Mission
• Optimize, fingerprint, and characterize
a new set of printing conditions using
FIRST methodology.
• Print a production job “to the numbers”
and analyze results.

6
POUCHES
1
Press Run
21 10
Colors Press Decks
FIRST in Motion
Wide Web Project
Printed
ThankResults
You
FIRST in Motion
Printer’s Perspective
Bob Coomes
Plastic Packaging Technologies, LLC
Kansas City, KS USA
bcoomes@plaspack.com

FIRST in Motion
Objective: Achieved!:
Demonstrate the FIRST Methodology in a flexographic
wide-web environment producing 3 different designs in 7/c
EG in one lane while printing the same 3 designs in
traditional 4/c+ 2 Spot in the other - ALL in one pass!
FIRST in Motion
The Process Works!
Although different plate technology was used, the printer
is able to maintain standard procedures in the pressroom.
ü No tooling changes
ü No special set-up requirements
ü Quick make-ready
ü Trouble-Shooting is simplified
FIRST in Motion
The Process Works!
Two different separation methods were used and printed
at 175 lpi, side-by-side in one pass through the press.
ü Complex assignment
ü Process Control throughout the workflow
ü Pre-Press – accurate curve & profile application
ü Print Production – run to the numbers

FIRST in Motion
The Process Works!
For Our Customers…
ü Capable of matching the Proof to Print
ü Consistency in color & print quality
ü Repeatability from job to job
ü Lower costs with quick make-ready & less waste
ü Customer Satisfaction!
Questions
THANK YOU!
Bob Coomes Sean Teufler
bcoomes@plaspack.com steufler@harperimage.com
Richard Black
rblack@teamflexo.com
Mark Samworth Steve Smiley

Mark.Samworth@esko.com steve@smileycolor.com

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TUESDAY, MAY 8, 2018

Tuesday, May 8, 2018 1

Tuesday, May 8, 2018 2

To demonstrate the FIRST Methodology in a wide-web

Tuesday, May 8, 2018 3

Ø The FIRST in Motion Team

Ø Creative design & development provided by

Ø Color & Pre-Press support provided by

Ø Printing and Converting provided by

The Fives Stages of FIRST (continued)

Tuesday, May 8, 2018 4

2) Use CxF/X4 for communication of color

3) Use SCTV for measurement of Spot Color Tone Values

4) Work within CRPC 6 printing conditions

The production planning GR OWS…!

Tuesday, May 8, 2018 5

…All in ONE pass!

To demonstrate the FIRST Methodology in a flexographic

Tuesday, May 8, 2018 6

Tuesday, May 8, 2018 7

Tuesday, May 8, 2018 8

Steps of TR012 (and FIRST 6.0)

Tuesday, May 8, 2018 9

lid 2nd Best

Steps of TR012 (and FIRST 6.0)

Tuesday, May 8, 2018 10

Tuesday, May 8, 2018 11

Tuesday, May 8, 2018 12

P2P OGV Chart

Tuesday, May 8, 2018 13

Spot Color Elements

Pantone Reflex Blue C

Tuesday, May 8, 2018 14

Steps of TR012 (and FIRST 6.0)

What Are We Aiming to Achieve?

Tuesday, May 8, 2018 15

Process Control – Solids

Steps of TR012 (and FIRST 6.0)

Tuesday, May 8, 2018 16

The TC1617x Patch Set

= + Cyan Magenta Yellow

The TC1617x Patch Set

TC1617x Table Points

Tuesday, May 8, 2018 17

TC1617x in Esko 4x4 format

Tuesday, May 8, 2018 18

Steps of TR012 (and FIRST 6.0)

Tuesday, May 8, 2018 19

Process Improvement Example

Tuesday, May 8, 2018 20

Ink Transfer Screening in Dots

Pinholing on Production Run?

Pinholing on Production Run?

Tuesday, May 8, 2018 21

Steps of TR012 (and FIRST 6.0)

Press Size / Job Size

Item 1 – 4c + Spot Item 1 – 7c ECG

Item 2 – 4c + Spot Item 2 – 7c ECG

Item 3 – 4c + Spot Item 3 – 7c ECG

Tuesday, May 8, 2018 22

Tuesday, May 8, 2018 23

Total Spot Colors = 20

Spectral Data Reflectance Spectrum 100 % on Substrate CIE ab CIE L*