FOUR COLOR SPOT LABEL PRODUCTION 1

Four-Color Spot Label Production

Natalie G. Hinson

Clemson University

GC4061 – Package and Specialty Print Laboratory

Section 001

Michelle Fox

November 30, 2023

FOUR COLOR SPOT LABEL PRODUCTION 2

ABSTRACT

This paper studies the four-color flexographic press run done on the Nilpeter. The overall

objective of this project is to design labels using cyan, magenta, yellow, black, and foil, perform

prepress functions such as screening rules and trapping in ArtPro+, serve make-ready such as

plate making and mounting, and produce a 4-color plus foil. This project aims to identify areas of

concern or difficulty in design based on available production equipment, art limitations, and

reflection on the production of designed artwork. Beyond the press run, technical tests were done

based on printed substrates. These tests are commonly run on inks and substrates, including print

contrast, substrate whiteness/brightness, ink hue error, and grayness. The results of these tests

help analyze the overall print quality of the press run conducted.
FOUR COLOR SPOT LABEL PRODUCTION 3

Four-Color Spot Label Production

OVERVIEW/PURPOSE

The objective of the four-color spot label production was to design, perform prepress functions,

perform make-ready and production of a four-color plus foil, and reflect using the technical

production report. The purpose of the four-color spot label was to identify areas of concern or

difficulty in design based on production equipment available, art limitations, and reflection on

the production of designed artwork and cover all topics of production.

CONSTANTS

The press that was used was the Nilpeter. The plate material was DFR 067 Mils. The inks

used were FujiFilm LED/UV Flexo Ink in Cyan, Magenta, Yellow, and Black. The printing order

of the inks was Yellow, Cyan, Magenta, and Black. The substrate that was used was MacTac

Permanent. The die-cut used was 1.875 by 1.875 circles with .125 cavities in between and four

up/ six across.

ART CONSIDERATION/THEME

The art considerations for the four-color spot label differed from others because this project

allowed for CMYK color build. This meant that images could be used in the artwork. This led to

a much more comprehensive range of design options and a much different avenue of design for

these stickers. When considering what images to place on the stickers, analyzing photographs

used in the beauty cosmetics industry is essential to maintaining brand voice and feel.

THUMBNAILS

The thumbnail process uses only black and typically consists of a hand-drawn sketch. The

thumbnails for this project were done using GoodNotes 6 software on an iPad. There were four

sets of stickers for each thumbnail; typically, four to six sets of designs are done. Peers then
FOUR COLOR SPOT LABEL PRODUCTION 4

review these thumbnails to obtain feedback from group members designing labels for the same

industry: beauty and cosmetics. Below is an example of a thumbnail sketch completed for four-

color label production.

Image 1: Example of Thumbnail Sketch

PROOF

Once peers have reviewed the thumbnails, it is time to take the sketches and make them digital.

This is typically done using Adobe Illustrator. This process consists of pulling images and colors

to create designs to be critiqued by the professor or TA. These proofs are printed out using the

Konica-Minolta. Proofs are checked for correct color usage (using brand colors), image

resolution, making sure die-lines are right, and the overall design correlates to the proper brand

voice and feel.

Image 2.1: Signed-Off Solo Hard Proof

FOUR COLOR SPOT LABEL PRODUCTION 5

Image 3.2: Signed-Off Group Hard Proof

PREPRESS

The prepress process uses the ArtPro+ software. This software allows trapping and screening

rules to be implemented into the artwork. The first step in using ArtPro+ is saving the Adobe

Illustrator file as a PDF, making sure that only the colors Cyan, Magenta, Yellow, and Black are

used and a spot color to represent the foil layer. Then, open the PDF file into ArtPro+ and enter

the “screening rules” tab. This process allows for angles to be placed on each color. The yellow

angle is 82.5º, the magenta angle is 67.5º, the black angle is 37.5º, and the cyan angle is 7.5º. The

addition of foil also requires an angle which is also 37.5º. After determining the angles, set the

LPI (150 lpi), and the dot shape is Circular Euclidian. After the screening rules are complete,

select all artwork and apply the four-color screening rules to the painting. Once the is complete,

the trapping rules can be implemented. Trapping is creating overlaps where two colors meet. The

key when trapping is being able to keep the registration marks; therefore, it is essential that
FOUR COLOR SPOT LABEL PRODUCTION 6

before trapping is applied, you turn off the “running targets” layer of your artwork, which

consists of registration marks in the bearer bars.

PLATEMAKING

Platemaking Steps

The plate-making process for the Nilpeter requires the production of flexographic plates.

Flexographic plates are susceptible to light, and this process needs to be done considering that.

The DFR 067 Mils plates are located in a covered box and are required to stay protected when

not in use.

1. Back exposure

a. Machine Used: Cyrel Fast Exposure Unit

b. Time: 85 seconds

c. What does it do? Establishes plate relief.

Image 3.1: Cyrel Fast Exposure Unit

FOUR COLOR SPOT LABEL PRODUCTION 7

2. Imaging

a. Machine: ESKO CDI Spark 2530

b. Time: ~ 16 minutes

c. What does it do? It uses a laser to put an image onto the plate.

Image 3.2: ESKO CDI Spark 2530

3. Face exposure

a. Machine Used: Cyrel Fast Exposure Unit

b. Time: 6 minutes

c. Place face up into the machine.

d. Expose

4. Thermal development

a. Machine: Cyrel FAST 1000 TD

b. Time: 12 minutes

c. What does it do? Removes unused polymer.

FOUR COLOR SPOT LABEL PRODUCTION 8

Image3.3: Cyrel FAST 1000 TD

5. Final exposure

a. Machine Used: Cyrel Fast Exposure Unit

b. Time: 2 minutes/4 minutes

MAKEREADY PROCEDURES

Plate Mounting

Mounting plates to the makeready process requires using the Neovo machine. This

machine has a camera, two red lights, and a screen to help visually register and mount the plates.

Because cyan, magenta, yellow, black, and foil are being used, five plates must be mounted.

When mounting plates, a few things need to be considered: the plate's direction, the sticky back's

stickiness, and the registration. To mount the plates, large blue cylinders must be placed onto a

metal cylinder that allows the plate to be mounted to the Neovo. Once the plate is mounted in the

Neovo, the registration marks can be moved to be under the red lights, and once the plate is lined

up, roll the plate onto the plate cylinder using the rolling plate.
FOUR COLOR SPOT LABEL PRODUCTION 9

Image 4.1: Neovo Machine

Image 4.2: Mounted Plates

NILPETER SAFETY CONCERNS/BEST PRACTICES

There are various safety concerns when using the Nilpeter. UV ink can harm the skin, so

be careful when touching it. Another is ensuring that the operator has long pants and closed-toed

shoes and that longer hair is pulled back. It is best to handle one ink station at a time.
FOUR COLOR SPOT LABEL PRODUCTION 10

PARTS AND PIECES OF NILPETER

There are multiple ink stations on the Nilpeter. There is an adhesive station and one for

each color: cyan, magenta, yellow, and black, cylinders for the foil and a die-cut station. The

Nilpeter also requires ink stations and plate cylinders. The Nilpeter is controlled using an iPad,

which controls ink metering, registration, and starting and stopping stations. There is also a

monitor with a camera that takes pictures as printed items are coming through to check overall

registration.

Image 5: Overview of Nilpeter Stations

PROCEDURE AND PRESSWORK

Once plates have been mounted and checked over, printing on the Nilpeter can begin. To

load the plates onto the Nilpeter, stations must first be opened using the iPad. Once stations are

opened, the cylinders blow out air, which helps the plate slide onto the cylinder more efficiently.

Once all the plates have been mounted, the stations are then closed. Once the stations are closed,

the first color will begin printing. For this print job, yellow was printed first. The second color

can be registered once yellow’s ink coverage and registration look good. This process continues
FOUR COLOR SPOT LABEL PRODUCTION 11

until all four colors have been registered. After registration, the press is stopped, and the foil is

placed where it can adhere to the substrate. Once the foil is adhering to the substrate properly,

the press can be run until an adequate amount of product has been printed.

Image 6: Nilpeter Stations

Image 7: Closed View of Nilpeter Stations

FOUR COLOR SPOT LABEL PRODUCTION 12

Image 8: Black Ink Nilpeter Station

Image 9: Overview of Final Print

FOUR COLOR SPOT LABEL PRODUCTION 13

QUALITY CONTROL/ANALYSIS

Print Contrast – All Colors

Table 1: Print Contrast on All Colors

C M Y K

100 0.88 1.22 0.90 2.51

75 0.68 0.86 0.76 2.45

PC 22.73 29.51 15.56 2.39

Spectra Data of Each Color and Substrate

Table 2.1: Spectral Data (400-490) of Substrate

Substrate 400 410 420 430 440 450 460 470 480 490

Front 0.53 0.69 0.85 0.92 0.93 0.92 0.91 0.90 0.90 0.89
A
Back 0.59 0.66 0.72 0.76 0.78 0.79 0.80 0.81 0.82 0.83

Table 2.2: Spectral Data (500-600) of Substrate

Substrate 500 510 520 530 540 550 560 570 580 590 600

Front 0.88 0.88 0.87 0.87 0.86 0.86 0.86 0.86 0.86 0.87 0.87
A
Back 0.83 0.83 0.84 0.84 0.84 0.84 0.84 0.84 0.84 0.85 0.85

Table 2.3: Spectral Data (610-700) of Substrate

Substrate 610 620 630 640 650 660 670 680 690 700
 FOUR COLOR SPOT LABEL PRODUCTION 14

Front 0.87 0.87 0.88 0.88 0.89 0.89 0.89 0.89 0.89 0.89
A
Back 0.85 0.85 0.86 0.86 0.87 0.87 0.87 0.87 0.87 0.87

Table 2.4: Spectral Data (400-490) of Cyan

Table 2.5: Spectral Data (500-600) of Cyan

Sample 500 510 520 530 540 550 560 570 580 590 600

Cyan 0.71 0.66 0.60 0.52 0.43 0.34 0.26 0.19 0.15 0.13 0.12

Table 2.6: Spectral Data (610-700) of Cyan

Sample 610 620 630 640 650 660 670 680 690 700

Cyan 0.11 0.11 0.11 0.11 0.12 0.14 0.14 0.14 0.13 0.12

Table 2.7: Spectral Data (400-490) of Magenta

Sample 400 410 420 430 440 450 460 470 480 490

0.1
Magenta
3 0.17 0.22 0.24 0.25 0.24 0.22 0.18 0.15 0.12
FOUR COLOR SPOT LABEL PRODUCTION 15

Table 2.8: Spectral Data (500-600) of Magenta

Sample 500 510 520 530 540 550 560 570 580 590 600

Magenta 0.10 0.07 0.05 0.05 0.04 0.04 0.03 0.03 0.07 0.23 0.43

Table 2.9: Spectral Data (610-700) of Magenta

Sample 610 620 630 640 650 660 670 680 690 700

0.6
Magenta
1 0.72 0.78 0.81 0.83 0.84 0.84 0.84 0.84 0.84

Table 3: Spectral Data (400-490) of Yellow

Sample 400 410 420 430 440 450 460 470 480 490

Yellow 0.05 0.06 0.07 0.07 0.07 0.07 0.08 0.08 0.10 0.16

Table 3.1: Spectral Data (500-600) of Yellow

Sample 500 510 520 530 540 550 560 570 580 590 600

0.3 0.5 0.7 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8
Yellow
2 6 4 1 3 3 3 3 4 4 4

Table 3.2: Spectral Data (610-700) of Yellow

Sample 610 620 630 640 650 660 670 680 690 700

0.8
Yellow
0.85 0.85 0.85 0.86 0.87 7 0.87 0.87 0.87 0.86
FOUR COLOR SPOT LABEL PRODUCTION 16

Table 3.3: Spectral Data (400-490) of Black

Sample 400 410 420 430 440 450 460 470 480 490

0.0
Black
0.01 0.01 0.01 0.01 0.01 1 0.01 0.01 0.01 0.02

Table 3.4: Spectral Data (500-600) of Black

Sample 510 520 530 540 550 560 570 580 590 600

0.0
Black
0.03 0.02 0.02 0.02 0.02 1 0.01 0.02 0.02 0.02

Table 3.5: Spectral Data (610-700) of Black

Sample 610 620 630 640 650 660 670 680 690 700

0.0
Black
0.02 0.02 0.02 0.02 0.02 2 0.02 0.02 0.02 0.02

Substrate Opacity

Table 4.1: Substrate Opacity on White Backing

WHITE BACKING
x-Rite L* a* b* X Y Z

Substrate 94.3456 1.4137 -2.4534 0.898799 0.889703 0.883535

FOUR COLOR SPOT LABEL PRODUCTION 17

Table 4.2: Substrate Opacity on Black Backing

BLACK BACKING
x-Rite L* a* b* X Y Z

Substrate 91.7323 1.3855 -4.6938 0.864826 0.866571 0.86841

Substrate Whiteness

Table 5: Substrate Whiteness on White Backing

x-Rite L* a* b* X Y Z

1.324 -
Sample 1 94.5763 85.66082063 86.61880622 106.0603858
7 2.2381

Table 5.1: Substrate Whiteness on Black Backing

x-Rite L* a* b* X Y Z

78.9197472 79.8274849 101.49197

Sample 1 91.6074 1.2403 -4.5467
1 8 4

Table 5.2: Substrate Whiteness, Tint, and Opacity

x-Rite x y Whiteness Tint Opacity

96.8803921
Sample 1 0.307756042 0.311197824 -0.914196544 92.15953032
1

Substrate Brightness
FOUR COLOR SPOT LABEL PRODUCTION 18

Table 6: Substrate Brightness

Brightness

X-Rite

eXact
460 nm
(D50/2°,

M1)

Sample A 94.2

Substrate Fluorescence

Table 7: Substrate Brightness

Fluorescence

Are there
No
OBAs

present?

Ink Apparent Trap Tests

Table 8.1: Ink Apparent Trap Initial Data

C M Y

R 0.11 0.88 1.24

G 1.71 0.58 1.06

B 1.95 1.43 0.7

C 1.06 0.28 0.11

FOUR COLOR SPOT LABEL PRODUCTION 19

M 0.18 1.16 0.63

Y 0.01 0.04 0.92

Table 8.2: Ink Apparent Trap Red Data

Red (Y+M)

OP Second Down (MAGENTA) 0.88 72.16

First Down (Yellow) 0.043

Second Down (Magenta) 1.16

Table 8.3: Ink Apparent Trap Green Data

Green (Y+C)

OP Second Down (CYAN) 1.71 161.15

0.00

First Down (Yellow) 5

1.05

Second Down (Cyan) 8

Table 8.4: Ink Apparent Trap Blue Data

Blue (M+C)

1.95

OP Second Down (CYAN) 3 167.49

FOUR COLOR SPOT LABEL PRODUCTION 20

0.18

First down (Magenta) 1

1.05

Second down (cyan) 8

Ink Hue Error and Grayness

Table 9: Grayness

GRAYNES

S (l/h)*100

Cyan 11.95

Magenta 55.32

Yellow 1.33

Table 10: Hue Error

(m-1/h-

Hue Error 1)*100

Cyan 3.70

Magenta 31.90

Yellow 4.16

Ink Opacity
FOUR COLOR SPOT LABEL PRODUCTION 21

Table 11.1: Ink Opacity on White Backing

WHITE BACKING
x-Rite L* a* b* X Y Z

Cyan 63.96 -32.35 -40.04 23.90 32.75 83.21

Magenta 50.17 71.34 -3.01 35.57 18.56 23.73

Yellow 89.95 -5.54 87.76 72.04 76.20 12.64

Black 15.20 -2.42 6.13 1.81 1.95 1.60

Paper 94.49 1.29 -2.39 85.44 86.42 106.07

Table 11.2: Ink Opacity on Black Backing

BLACK BACKING
x-Rite L* a* b* X Y Z

Cyan 62.48 -30.79 -40.03 22.81 30.97 79.67

Magent
48.27 68.58 -5.01 32.39 17.01 22.96
a

Yellow 86.93 -6.88 83.57 65.38 69.86 12.23

Black 14.93 -3.96 5.51 1.70 1.90 1.62

Paper 91.73 0.58 -4.49 78.85 80.10 101.74

Table 11.3: Ink Whiteness, Tint, and Opacity

x-Rite x y Whitenes Tint Opacity

FOUR COLOR SPOT LABEL PRODUCTION 22

0.1708738 85.902483 94.549367

Cyan 0.2341739 283.460541
1 6 3

0.4568120 0.2384084 91.630803

Magenta 33.3200519 -197.28331
6 5 7

0.4478147 0.4736378 91.690224

Yellow -301.73806 -35.386858
5 9 3

0.3375797 0.3634806 3.2458895 97.426248

Black -100.5324
8 2 7 1

0.3074305 0.3109344 92.691745

Paper 97.3857913 -0.7599137
9 8 1

Overall, the press run went well. Little-to-no issues caused significant time loss when

running the four-color spot label production. For the most part, the execution of the artwork was

good. There were some issues when printing CMYK images and the quality of those images.
FOUR COLOR SPOT LABEL PRODUCTION 23

Image 10: Final Prints

As one can see from the image above, there is some patchiness in the text “R&R” and

“Rain and Rays Beauty Co.” There are apparent dots in that text, as well as the “R&D” in the

sticker with the side portrait of the woman’s face. In the sticker to the right of the side portrait of

the woman’s face, there are also apparent dots in that image. The overall quality of the stickers is

not bad, but there are glaring issues with the print quality. If changes could be made, the photos

might not be significant but more minor. Another change would be using vector art and more

simplicity in designs. The more complex a design is, the harder it is to replicate that quality on

press. The plans might have elevated print quality if larger text had also been used. The methods

of the stickers are not terrible, but changes would be made to increase the print quality.

Ink metering and impression have a ton of influence on a press run. The system controls

ink transfer, consistency, density, sharpness, build-up, and smudging. The metering system and

impression greatly impacted the press run because the stickers have excellent ink quality, texture,

and an excellent saturation of color. Two colors to notice are red and orange. These two colors
FOUR COLOR SPOT LABEL PRODUCTION 24

are very saturated and rich, meaning that the ink impression from the plate cylinder to the

substrate was good enough to create high color quality. The gradient in the “Prime Motors”

sticker is also produced in good quality, which can be difficult.

Image 11: Registration

One way to tell if a print run was executed well is the inks' registration quality. The

image above is an example of registration marks from the print run discussed in the technical

report. When analyzing these registration marks, they are on the right and left sides of the

substrate and are aligned well. There are no colors that are protruding from the registration

marks. Each color was registered well, which is a way to tell if a print run is executed well. Other

factors determining print recreation were done well: image sharpness, ink density, dot structure,

and overall consistency. The press run that was conducted lacked some image sharpness but had

strong ink density and overall consistency in print.