Madhusudan Adhikari, Resource Person Flatbed/offset Printing

Steps in the Printing

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Process:
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1. Photographing the
original (the copy).
2. Processing the
negative.
3. Making the plate.
4. Presswork.
 Map Reproduction
Madhusudan Adhikari, Resource Person
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Offset press
 Map Registration
• The basic problem of multi color map preparation
is register, i.e., making the colors print exactly
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where they should.

• To facilitate register, small crosses, called register
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marks, are placed on the four margins of every

plate (drawing) of the copy in exactly the same
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place on each.
• Alternate way is “Mechanical registration” which
involves using physical guides, pins, or notches or
punch holes and studs on the map sheets and
printing equipment. These guides help align and
position each sheet precisely during the
reproduction process.
• Sometimes T-bar with adjustable pins can be used
to align different map sheets precisely. The pins are
placed at key points on each sheet, and the T-bar
helps ensure that these points match across all
sheets.
 Quality of materials
• Dimensional stability of printing paper
• The larger the drawing and the reproduction the more important is the use of
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dimensionally stable materials.

• Plastics (Vinylite) are stable, and some drawing papers and tracing papers can be
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used in the smaller sizes. If drawing papers or tracing papers are used, care must
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be taken that the grain of the paper runs in the same direction on each overlay or
plate, so that if expansion or contraction does take place it will be more nearly
uniform on each.
• The quality of ink used
• Inks should exhibit consistent color throughout the print run
• Ink should have sufficient color density to achieve vibrant and rich colors
• Inks with appropriate drying times are essential for efficient offset printing
• Proper adhesion is essential for achieving sharp and durable prints
• Inks should be compatible with the printing plates used in the offset printing
process. They should transfer smoothly from the plate to the rubber blanket and
then onto the substrate without issues like plate scumming or ink buildup.
 Printing plate materials
• Printing plates can be made up of materials such as paper, plastic, and metal for different printing
processes.
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• 1. Paper Plates:
• Made from paper or paperboard materials.
• Used for short-run, cost-effective printing jobs.
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• Typically used for simple, one-color designs.

• Limited durability and not suitable for extended use.
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• Limited budget or one-time use applications.

• 2. Plastic Plates:
• Made from various plastic materials, including polyester and photopolymer.
• Photopolymer Plates: Light-sensitive plates used in flexography, letterpress, and some offset printing applications.
• Photopolymer plates offer high resolution and image detail.
• Polyester Plates: Used in lithography and screen printing.
• Polyester plates are durable and can withstand longer print runs.
• Suitable for various printing processes from short to medium print runs.
• 3. Metal Plates:
• Typically made from aluminum or steel.
• Aluminum Plates: Commonly used in offset printing.
• Aluminum plates are lightweight and cost-effective.
• Steel Plates: Used for gravure, letterpress, and some specialty printing applications.
• Steel plates offer durability and are suitable for longer print runs.
• Can be chemically treated for enhanced printing capabilities.
• High-quality and high-volume printing jobs.
 Choice of Printing plates
• The choice of printing plate material depends on the specific requirements of the
printing job
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• Print Run Length:

• Paper and plastic plates are often used for shorter print runs due to their cost-effectiveness.
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• Metal plates, especially aluminum, are preferred for longer print runs where durability and
consistency are essential.
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• Image Detail:
• Plastic plates, especially photopolymer plates, can offer high resolution and intricate image
detail.
• Metal plates, particularly aluminum, are capable of reproducing detailed images, making
them suitable for various applications.
• Cost:
• Paper and plastic plates are generally more economical, making them suitable for budget-
conscious or short-run projects.
• Metal plates, while often more expensive upfront, may offer cost savings over the long term for
high-volume jobs due to their durability.
• Plate Life and Reusability:
• Paper and some plastic plates are typically designed for single-use or limited reuse.
• Metal plates, particularly steel, can be more durable and may withstand multiple uses.
 Printing plate types
1. Intaglio Printing:
• Intaglio refers to printing methods where the image is incised into the printing plate, and the ink is held
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in the incised areas.

• Engraving: Image is incised into the plate using a tool called a burin.
• Etching: Plate is coated with an acid-resistant substance, and the image is drawn or etched into the
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coating. The plate is then etched with acid.

• Dry point: Image is incised into the plate without the use of acid.
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• Applications: Banknotes, stamps, fine art prints.

2. Surface (planar) Printing:
• Surface printing methods transfer the image from the printing plate's surface to the substrate.
• Image is drawn on a flat surface (stone or metal plate) with a grease-based substance.
• Water and ink are applied, and the ink adheres to the drawn image which is transferred to an
intermediate surface (rubber blanket) before being applied to the final substrate.
• Applications: Maps, Magazines, newspapers, packaging, posters.
3. Relief Printing:
• The raised areas of the printing plate carry the ink, which is then transferred to the substrate.
• Woodcut: Image is carved into a block of wood, and the raised areas hold the ink.
• Linocut: Similar to woodcut but uses linoleum instead of wood.
• Letterpress: Raised image areas on a plate or type are inked and pressed onto paper.
• Applications: Art prints, book printing (historically).
 Map Reproduction
Madhusudan Adhikari, Resource Person
Apex Educational Academy